Xylem LOWARA VOGEL Series Manual

en Model:Pa Installation, Operation and Maintenance Instruction
Translation of the Original Operation Manual
en Keep for further use !
Pay attention to this operating instruction before the delivery, installation, start-up a.s.o.!
VOGEL SERIES

Xylem Service Austria GmbH
Ernst Vogel-Straße 2
A-2000 Stockerau
Telefon:
+43 (0) 2266 / 604
Fax:
+43 (0) 2266 / 65311
E-Mail:
[e-mail]
Internet:
www.xylemaustria.com

Operating instructions
Table of Contents
Data Sheet
1. General ............................................................................................
1.1 Foreword
1.2 Guarantee
1.3 Safety regulations
1.4 Safety instructions
Dangers of not following safety instructions
Safety instructions for the operator
Speed, pressure, temperature
Permitted forces on flanges
NPSH
Sealing, flushing, cooling
Minimum flows
Protection against running dry
Back flow
2. Description ......................................................................................
2.1 Model
2.2 Shaft sealing
2.3 Bearings and lubrication
Oil lubrication
Bearing sizes and oil quantities
Grease lubrication
3. Transport, Handling and Storage ................................................
3.1 Transport, Handling
3.2 Storage
4. Installation, Operation ...................................................................
4.1 Assembly and connection of pump
4.2 Installation and alignment of coupling
Installation
Alignment
Permitted displacement for flexible couplings
4.3 Connecting the pipes to the pump
Suction and discharge pipe
Auxiliary pipes
4.4 Electrical connection
4.5 Starting up
Starting up for the first time
Restarting
4.6 Operation and monitoring
Permitted number of starts
4.7 Shutting down
4.8 Dismantling
5. Maintenance, Servicing ..................................................................
Stuffing boxes
page 3
page 7
page 8
page 9
page 16
Pa 100/3-en 1

Operating instructions
Mechanical seals
Oil changing
Grease lubrication
Couplings
Cleaning the pump
6. Longer periods of non-operation ..................................................
6.1 Drained pumps
6.2 Filled pumps
7. Faults - Causes and Solutions
........................................................
8. Repairs .............................................................................................
9. Spare Parts, Spare Pumps .............................................................
9.1 Spare parts
Ordering spare parts
9.2 Stand-by pumps
10. Plant Manager List ......................................................................
11. Log Book .......................................................................................
Appendix
page 17
page 18
page 21
page 22
page 23
page 24
Pa 100/3-en 2

Operating instructions
1. General
1.1 Foreword
This product complies with the safety requirements of EC Machinery Directive 2006/42/EC.
The staff employed on installation, operation, inspection and maintenance must be
able to prove that they know about the relevant accident prevention regulations and
that they are suitably qualified for this work. If staff do not have the relevant
knowledge, they should be provided with suitable instruction.
The operating safety of the pumps or units (i.e. pump plus motor) supplied is only guaranteed if
these are used in accordance with the provisions given in the attached Data Sheet and/or Point 4 in
„Installation and Operation“.
The operator is responsible for following the instructions and complying with the safety
requirements given in these Operating Instructions.
Smooth operation of the pump or pump unit can only be achieved if installation and maintenance
are carried out carefully in accordance with the rules generally applied in the field of engineering
and electrical engineering.
If not all the information can be found in these Operating Instructions, please contact us.
The manufacturer takes no responsibility for the pump or pump unit if the Operating Instructions
are not followed.
These Operating Instructions should be kept in a safe place for future use.
If this pump or pump unit is handed on to any third party, it is essential that these Operating
Instructions and the operating conditions and working limits given in the Confirmation of Order
are also passed on in full.
These Operating Instructions do not take into account all design details and variants nor all the
possible chance occurrences and events which might happen during installation, operation and
maintenance.
Alterations or changes to the machine are only permitted by agreement with the manufacturer.
Original spare parts and accessories authorised by the manufacturer should be used for greater
safety. We bear no responsibility for the consequences of using other parts.
We retain all copyright in these Operating Instructions; they are intended only for personal use by
the owner of the pump or the pump unit. The Operating Instructions contain technical instructions
and drawings which may not, as a whole or in part, be reproduced, distributed or used in any
unauthorised way for competitive purposes or passed on to others.
1.2 Guarantee
The guarantee is given in accordance with our Conditions of Delivery and/or the confirmation of
order.
Repair work during the guarantee period may only be carried out by us, or subject to our written
approval. Otherwise the guarantee ceases to apply.
Longer-term guarantees basically only cover correct handling and use of the specified material.
The guarantee shall not cover natural wear and tear and all parts subject to wear, such as
impellers, shaft sealings, shafts, shaft sleeves, bearings, wear rings etc., or damage caused by
transport or improper handling.
Pa 100/3-en 3

Operating instructions
In order for the guarantee to apply, it is essential that the pump or pump unit is used in accordance
with the operating conditions given on the type plate, confirmation of order and in the Data Sheet.
This applies particularly for the endurance of the materials and smooth running of the pump and
shaft sealing.
If one or more aspects of the actual operating conditions are different, we should be asked to
confirm in writing that the pump is suitable.
1.3 Safety regulations
These Operating Instructions contain important instructions which must be followed when the
pump is assembled and commissioned and during operating and maintenance. For this reason,
these Operating Instructions must be read by the skilled staff responsible and/or by the operator of
the plant before it is installed and commissioned, and they must be left permanently ready to hand
at the place where the pump or pump unit is in use. The operator must ensure that the contents of
the Operating Instructions are fully understood by the staff. The operator must confirm this by
signing the „Plant Manager List“ (see Point 10). These Operating Instructions do not refer to the
General Regulations on Accident Prevention or local safety and/or operating regulations. The
operator is responsible for complying with these (if necessary by calling in additional installation
staff).
The safety instructions contained in these Operating Instructions have the following special safety
markings as specified in DIN 4844:
Warning against personal accidents which could occur if the safety instructions
given in this part of the Operating Instructions are not followed.
Warning against dangerous electrical voltage.
Warning against possible damage to property or the environment.
It is absolutely essential that safety information affixed directly to the pump or pump unit is
followed and maintained so that it is always easily legible.
1.4 Safety instructions
Dangers of not following safety instructions
Failure to follow the safety instructions can result in the following, for example:
•People being at risk because of electrical, mechanical and chemical factors.
•Important functions of the pump or pump unit failing.
•Dangers to the environment as a result of dangerous substances leaking out.
Please
note
Pa 100/3-en 4

Operating instructions
Safety instructions for the operator
•Depending on the operating conditions, wear and tear, corrosion or age will limit the working
life of the pump/pump unit, and its specified characteristics. The operator must ensure that
regular inspection and maintenance are carried out so that all parts are replaced in good time
which would otherwise endanger the safe operation of the system. If abnormal operation or any
damage are observed, the pump must cease operation immediately.
•If the breakdown or failure of any system or unit could lead to people being hurt or property
being damaged, such system or unit must be provided with alarm devices and/or spare modules,
and they should be tested regularly to ensure that they function properly.
•If there is any risk of injury from hot or cold machine parts, these parts must be protected against
contact by the user, or suitable warning signs must be affixed.
•Contact protection on moving parts (e.g. coupling guards) must not be removed from systems
that are in operation.
•If dangerous media (e.g. explosive, toxic, hot) leak out (e.g. from shaft seals), these must be
directed away so that there is no danger to people or the environment. The provisions of the law
must be observed.
•Measures should be taken to exclude any danger from electricity (e.g. by complying with the
local regulations on electrical equipment). If work is carried out on live electrical components,
they should be unplugged from the mains or the main switch turned off and fuse unscrewed. A
motor protection switch is to be provided.
•Basically, all work on the pump or pump unit should only be carried out when the pump is
stationary and not under pressure. All parts must be allowed to return to ambient temperature.
Make sure that no-one can start the motor during such work. It is essential that the procedure for
stopping the system described in the Operating Instructions is observed. Pumps or pump systems
that carry media that are dangerous to health must be decontaminated before being taken apart.
Safety Data Sheets for the various liquids handled. Immediately the work has been completed,
all safety and protective devices must be replaced or restarted.
•Under EC Machinery Directives, every machine must be fitted with one or more emergency
command devices by which situations which represent an immediate danger or which could later
be dangerous can be avoided. This does not include machines in which the emergency switches
cannot reduce the danger, either because they do not reduce the time required to stop the
machine or because the do not allow the measures required by the danger to be taken. This
emergency switch must:
have controls that are clearly marked, easy to see and within easy reach;
stop the dangerous movement as quickly as possible without causing any additional danger;
trigger any specified safety movements or allow these to be started up.
If the emergency command device is no longer operated after an emergency „off“ switch has
been triggered, this must be maintained by blocking the emergency command device until it is
released again. It should not be possible to block the device without this triggering an emergency
„off“ switch. It should only be possible to release the device through an appropriate action; this
release should not start the machine up again - it should only make it possible to start it up again.
•If the power supply is interrupted or restored after being interrupted or if it is changed in any
other way, this should not cause any danger (e.g. pressure surges).
Pa 100/3-en 5

Operating instructions
Speed, Pressure, Temperature
Suitable safety measures must be taken at the plant to ensure that the speed, pressure and
temperature of the pump and the shaft sealing do not exceed the limit values given in the Data
Sheet. The given admission pressures (system pressures) must also be sufficiently high.
In addition, the pump must be protected against pressure surges such as can be caused by
switching off the plant quickly (e.g. by non-return valve on the pressure side, flywheel, air vessel).
Permitted forces on flanges
Basically, the suction and pressure lines should be such that the forces on the pump are kept to a
minimum. If this is not feasible, the figures given in the Appendix „Permitted forces and
moments“ should not under any circumstances be exceeded.
NPSH
When entering the impeller, the liquid being handled must have a minimum pressure NPSH to
prevent cavitation or breaking off of flow. This requirement is met if the unit NPSH value
(NPSHA) is well above the pump NPSH value (NPSHR) under all operating conditions.
Attention must be paid to the NPSH value in particular when liquids close to boiling point are
being handled. If the value falls below the pump NPSH value, this can lead to damage resulting
from cavitation or serious damage from overheating.
The NPSHR for each pump type is given in the sheets of characteristic curves. We can supply
leaflets for calculation of NPSH values on request.
Sealing, Flushing, Cooling
Suitable facilities for the regulation and monitoring of sealing, flushing or cooling are to be
provided.
When handling dangerous liquids or if temperatures are high, care should be taken to ensure that
the pump ceases operating if the sealing, flushing or cooling system fails.
Sealing, flushing and cooling systems must always be operational before the pump is started up.
They should not be taken out of operation until the pump has stopped, provided that the nature of
the operation allows this at all.
Minimum flows
If the pump is started against a closed pressure line valve, it should be noted that the power taken
up by the pump is transmitted to the liquid handled in the form of heat. This can cause the liquid
to heat up excessively within a relatively short time, which will then cause damage to the pump's
internal fittings. After the pump has reached operating speed, the discharge valve should therefore
be opened as quickly as possible. If operating conditions mean that Q = Ø is unavoidable, or if hot
water is circulating, a free flow non-return valve, or, on smaller systems, a by-pass pipe, should be
provided. We should be pleased to advise on determining the minimum flow or designing the by-
pass line.
Protection against running dry
The pumps must not run dry under any circumstances, since overheating can damage pump
components (e.g. mechanical seals).
Pa 100/3-en 6

Operating instructions
Back flow
In systems where pumps are operating in closed circuits under pressure (gas cushions, steam
pressure), the pressure of the gas cushion must not be reduced via the pump, since the back flow
speed may be much higher than the operating speed, which would destroy the unit.
2. Description
2.1 Model
Model Pa: horizontal shaft with external bearing on both sides, pressure side drive normal design,
rotating clockwise (seen from the drive side) with suction branch on left and discharge branch
radially above. Grease lubrication (oil lubrication on 123 Pa).
Special versions: suction branch on right or radially above, oil lubrication, drive on suction side
(anti-clockwise)
Please see the Data sheet and Appendices for the sectional drawings and index of parts for each
pump, and the detail drawings of the shaft sealing.
2.2 Shaft Sealing
There are basically two methods of shaft sealing: the stuffing box and the mechanical seal. You
will find the type of shaft sealing on your pump under the „Notes on construction“.
Instructions on packing a stuffing box and on installing and operating mechanical seals are given
in the relevant detail drawings in the Appendix.
See Appendix, „Operations“, for when the stuffing boxes and mechanical seals should be used.
You will find more information on stuffing boxes and mechanical seals, and the
risks of accidents that these may involve, under Point 4.6 „Operation and
Monitoring“ and in Point 5 „Maintenance and Repairs“.
2.3 Bearings and Lubrication
The pump shaft is guided in oversized roller bearings. Your Data Sheet will tell you whether your
pump is designed for grease lubrication or oil lubrication.
•Grease lubrication: standard design, except for 123 Pa
•Oil lubrication: standard design with 123 Pa, special design with 43 Pa up to 103 Pa
Oil lubrication
See Table of Lubricants T 011-007 in the Appendix for choice of oil and oil quality.
If the type of oil is changed, check that the new oil is compatible with the left-over oil.
Method of measurement
Level
Dip stick
between the minimum and maximum mark
(make sure that dip stick is inserted correctly)
Oil sight glass
to middle
Oil level pipe
to marking
Please
note
Pa 100/3-en 7

Operating instructions
Bearing sizes and oil quantities
Pump size
Grease lubrication
Bearing type
intake discharge
Oil lubrication
Bearing type
intake discharge
Qty.of oil
in litres
33 Pa
6305-2Z-C3
6305-2Z-C3
-
-
-
43 Pa *)
6306-2Z-C3
6306-2Z-C3
6306-C3
6306-C3
ca. 0.12
51 Pa *)
6307-2Z-C3
2x 7307 BG
6307-C3
2x 7307 BG
ca. 0.14
53 Pa *)
6307-2Z-C3
2x 7307 BG
6307-C3
2x 7307 BG
ca. 0.14
63 Pa *)
6307-2Z-C3
2x 7307 BG
6307-C3
2x 7307 BG
ca. 0.14
83 Pa *)
6308-2Z-C3
2x 7308 BG
6308-C3
2x 7308 BG
ca. 0.18
103 Pa *)
6308-2Z-C3
2x 7308 BG
6308-C3
2x 7308 BG
ca. 0.18
123 Pa
-
-
NU 310
2x 7310 BG
ca. 1.8
*)
Standard design: grease lubrication
Special design: oil lubrication
The quantity of oil give applies for both bearing casings together.
Grease lubrication
Grease lubricants to be chosen from Table T 011-007 in Appendix.
The bearings are already filled with grease and are thus ready for use.
If the type of grease is changed, check that it is compatible with the left-over oil.
3. Transport, Handling, Storage
3.1 Transport, Handling
•Check the pump/pump unit immediately upon delivery/receipt of despatch for damage or
missing parts.
•The pump/pump unit must be transported carefully and by competent personnel. Avoid serious
impacts.
•Keep the pump/pump unit in the same position in which it was supplied from the factory. Take
note of the instructions on the packaging.
•The intake and discharge side of the pump must be closed with plugs during transport and
storage.
Dispose of all packing materials in accordance with local regulations.
•Lifting devices (e.g. fork-lift truck, crane, crane device, pulleys, sling ropes, etc.) must be
sufficiently strong. The weight of the pump/pump unit is given in the Data Sheet.
•The pump/pump unit may only be lifted by solid points such as the casing, flanges or frame. The
following illustration shows the correct method of carrying by crane.
Please
note
Pa 100/3-en 8

Operating instructions
Sling ropes must not be fixed to ends of shafts or the ring loops of the motor.
Do not stand underneath suspended loads; take note of the general regulations on
prevention of accidents.
The pump/pump unit must be secured against tipping over and slipping until it has
been fixed in its final location.
3.2 Storage
Pumps or pump units that are stored for a long time before use must be protected against moisture,
vibrations and dirt (e.g. by wrapping in oil paper or plastic sheeting). Pumps must basically be
stored in a place where they are protected from the weather, e.g. under cover. During this time, all
suction and discharge branches and all other intakes and outlets must be closed with dummy
flanges or plugs (see also chapter 6 – Longer periods of non operation).
4. Installation, Operation
4.1 Assembly and connection of pump
The pump and motor (= pump unit) must be provided with a shared foundation base made in steel
or cast iron or a welded steel profile frame where this does not exist already or if it is not included
in the delivery. This foundation base must be placed on a foundation which can withstand all loads
that arise during operation.
The size of the foundation and the location and size of the recesses for the foundation anchors are
given in the dimension drawing, which is binding.
Sufficient space must be provided for maintenance and repair work, especially for
replacing the drive motor or the complete pump unit.
The motor fan must be able to take in enough cool air, and the intake grille must
therefore be at least 10 cm away from any wall, etc.
Please
note
Please
note
Please
note
Pa 100/3-en 9

Operating instructions
To prevent vibrations being transmitted to adjoining components, the foundation should be laid on
a suitable insulating base (panels providing insulation against structure-borne sound or vibration
panels).
The size of these insulating panels will vary, depending on circumstances, and
should therefore be determined by an experienced specialist..
Concrete foundations must be completely set before the pump unit is installed. Place the pump
unit on the foundation and level with a spirit level (on shaft or flange). Cast the joint between the
foundation base and anchors and the foundation.
Note:
•Use jointing compounds that will not shrink and with sufficient resistance.
•Avoid air bubbles.
•Check that the compound has properly set and hardened.
After setting, tighten the foundation anchor evenly and firmly. Check alignment of pump unit and
adjust if necessary; check that all screws between the pump/motor and the foundation base fit
snugly.
4.2 Installation and Alignment of Coupling
Make sure that nobody can start the motor during work on the coupling.
According to Accident Prevention Regulations, the pump unit may only be operated
when the coupling guard is mounted.
Installation
If the pump unit is not completely assembled until it reaches its place of use and no separate
operating instructions have been supplied by the manufacturer, you should proceed according to
the following points:
•Before starting installation, carefully clean shaft ends and coupling components.
•Pull coupling onto shaft end, do not hit. The coupling may be heated beforehand in an oil bath to
approx. 100 °C (pulling on is then easier). Remove rubber packs from coupling section first.
•The coupling sections must be flush with the shaft end surfaces.
•Secure coupling hubs against axial sliding using a pin screw.
Alignment
The following procedure should also be followed for pump units mounted complete on frames:
check coupling again after installation on the foundation plate.
Please
note
Pa 100/3-en 10

Operating instructions
Adjustment using dial gauge:
Adjustment using precision ruler:
Normal coupling Expansion coupling
•Check/measure the alignment at several points using a precision ruler and sensor. If a dial gauge
is used, one coupling side is to be turned.
•When aligning, keep the parallel and angular displacement of the shaft ends to a minimum. The
alignment can be more precise if a dial gauge is used. The permitted displacement for your
coupling is given in the following table (this only applies for couplings supplied originally by
us). You will find the exact designation for your coupling on the Data Sheet.
Permitted displacement for flexible couplings
Design ..GK, A..FK, B..FK, H..FK
Pa 100/3-en 11

Operating instructions
Design NAN.. and NHN..
•Align the coupling again after pump has reached normal operating temperature and system
pressure (if applicable), check once again and if necessary adjust. Read Point 4.5 „Starting up“
first.
•It must be possible to turn the unit by hand smoothly and easily.
•Mount coupling guard as shown in drawing no. 6396-312 (appendix).
The installation and alignment of the coupling must be carried out with the utmost
care and attention, and the motor will then run more reliably and last longer. Badly
aligned couplings cause noise, vibration and increased wear on bearings, couplings
and shaft seals.
4.3 Connecting the pipes to the pump
Suction and discharge pipe
•The pipes must be of a size and design that liquid can flow freely into the pump and that the
pump functions without problems. Particular attention is to be paid to ensuring that suction pipes
are airtight and that the NPSH values are observed. Lay the suction pipe in the horizontal section
towards the pump so that it is slightly inclined upwards so that no air pockets occur. In most
cases, it is recommended that a non-return valve is installed in the discharge pipe shortly after
the pump.
•When laying the pipes, make sure that the pump is accessible for maintenance and installation.
•Please note 1.4: „Permitted Forces on Flanges“.
Please
note
Pa 100/3-en 12

Operating instructions
•Before connecting up to pump: remove protective coverings from suction and discharge
branches.
•To protect the shaft sealing (especially mechanical seals) against foreign bodies, it is
recommended that a sieve, 800 micron, is installed in the suction/intake pipe when the motor is
being started up.
•Before starting up, the pipe system, fittings and equipment must be cleaned to remove weld
spatter, scale etc.. Any pollutants are to be completely removed from pump units that are directly
or indirectly connected to drinking water systems before being installed and taken into use.
•If the pipe system is tested with the pump installed,
do not exceed the maximum permitted casing pressure of the pump and/or shaft sealing (see
Data Sheet).
•When emptying the pipe after the pressure test, make sure that the pump is treated properly
(danger of rust and problems when starting up).
•In the case of pumps with stuffing boxes, replace packing after pressure test (packing may be
over-compressed and thus no longer suitable for use).
Auxiliary pipes
Any sealing, flushing or cooling pipe connections must be installed. Please consult the Data Sheet
to see which pipes, pressures and quantities are necessary. The position and size of connections to
the pump are given in the Appendix, „Summary of Screwed Connections“.
The relevant detail drawing of the shaft sealing contains a diagrammatic proposal for the pipework
and fittings. This proposal does not take into account the safety requirements for each specific
pump unit.
Point 1.4, „Sealing, flushing, cooling“ must be observed as regards regulation and
monitoring.
It is recommended that a pipeline is installed to take off any leakage from the shaft seal. For
connection, see Appendix, „Summary of Screwed Connections“.
4.4 Electrical connection
Electrical connection work may only be carried out by an authorised professional.
The rules and regulations valid for electrical technology, especially those concerned
with safety measures, must be observed. The regulations of the national power
supply companies operating in that area must also be observed.
Before starting work, check that the information on the motor rating plate is the same as the local
mains network. The power supply cable of the coupled drive motor must be connected up in
accordance with the wiring diagram produced by the motor manufacturer.
A protective motor switch is to be provided.
The direction of rotation should only be checked when the pump is full. Dry
running will cause damage to the pump.
Please
note
Please
note
Pa 100/3-en 13

Operating instructions
4.5 Starting up
The plant may only be started up by people who are familiar with the local safety
regulations and with these Operating Instructions (especially with the safety
regulations and safety instructions given here).
In order to be able to observe and monitor the shaft sealing, no protective covering
is provided in this area. If the pump is running, particular care should therefore be
taken (watch out for long hair, loose pieces of clothing etc.).
Starting up for the first time
•If a pump is oil-lubricated,first open both oil drains „AS“ and drain off any liquid that may have
collected (e.g. condensation). Close oil drains „AS“ and fill oil as described in Point 2.3 (for
position of all secondary connections, see Summary of Screwed Connections in Appendix). Fill
to level described in Point 2.3.
•For pumps with grease lubrication, no further lubrication is needed before initial start-up.
•Pump and suction pipe must be filled with liquid when starting up. When filling, open vent
screw „LV“ on the first step casing (seen from the suction side).
•Turn pump unit once again by hand and check that it moves smoothly and evenly.
•Check that coupling guard is installed and that all safety devices are operational.
•Switch on any sealing, flushing or cooling devices that are provided. See Data Sheet for quantity
and pressure.
•Open slide valve in suction /intake pipe.
•Set discharge side slide valve to approx. 25% of rated flow quantity. With pumps with a
discharge branch rated width less than 200, the slide valve can remain closed when starting up
(see also Point 1.4 „Minimum quantities“).
•Check direction of rotation by switching on and off briefly. It must be the same as the directional
arrow on the bearing frame.
•Start drive device.
•As soon as it reaches normal operating speed, open discharge valve immediately and adjust the
required operating point.
•Packing:
Packings need leakage to operate perfectly (liquid being handled to drip out).
To start with, set the leakage rate fairly high. During the first few hours of operation, slowly
reduce the leakage rate as the pump is running by gradually tightening the packing gland (see
item „69“ and „M2“ in the sectional drawing). The guideline value is around 10 drops/minute.
Packings that run dry will harden and then destroy the shaft sleeve and/or the
shaft.
Restarting
Basically, the same procedure should be followed as for starting up for the first time. However,
there is no need to check the direction of rotation and the accessibility of the pump unit.
The pump should only be automatically restarted if it has been made sure that the pump has
remained filled whilst lying idle.
Please
note
Pa 100/3-en 14

Operating instructions
4.6 Operation and Monitoring
Be particularly careful not to touch hot machine parts and when working in the
unprotected shaft seal area. Remember that automatically controlled systems may
switch themselves on suddenly at any time.
Suitable warning signs should be affixed.
Regular monitoring and maintenance will extend the life of your pump or pump
system.
•You must observe the area of application given on the Data Sheet.
•Do not exceed the output given on the motor rating plate.
•Avoid dry running, running against closed discharge valves or operation whilst the liquid
handled is in the vapour phase.
•Avoid sudden changes in temperature (temperature shocks).
•The pump and motor should run evenly and without vibrations; check at least once a week.
•The bearing temperature (measured on the bearing frame) should be max. 50 °C above ambient
temperature and should not exceed 90 °C; check at least once a week.
•Check oil level at least once a week and top up if necessary.
•Check leakage rate from packings at least once a week (see Point 4.5 „Packings“).
•Check the regulating and monitoring facilities of any sealing, flushing or cooling systems once a
week to ensure that they function properly. Outgoing cool water should be body temperature.
•Pumps which are exposed to corrosive chemicals or to wear through abrasion must be inspected
periodically for corrosion or wear and tear. The first inspection should be carried out after six
months. All further inspection intervals should be determined on the basis of the state of the
pump.
Permitted number of starts
Do not exceed the pump's permitted number of starts - see diagram.
With electric motors, the permitted number of starts is given in the attached motor operating
instructions.
If two different figures are given, the lower figure is valid.
motor power P [kW]
Please
note
Pa 100/3-en 15

Operating instructions
4.7 Shutting down
•Close slide valve in discharge pipe. This is not necessary if there is a spring-loaded non-return
valve.
•Switch of motor (make sure it runs down quietly).
•Close slide valve on suction side.
•Close auxiliary systems. Do not shut down cooling system until pump has cooled down.
•If there is any risk of freezing, empty pump, cooling areas and pipes completely.
If the pump also remains under operating conditions (pressure and temperature) when stationary:
leave all sealing, flushing and cooling systems switched on.
The shaft sealing must remain sealed if there is a risk of air being sucked in (in the event of supply
from vacuum systems or parallel operation with shared suction pipe).
4.8 Dismantling
The operator's or manufacturer's fitters should be informed as to the nature of the
liquid handled. In the case of pumps handling dangerous liquids, the liquid
handled should be disposed of by environmentally acceptable means before the
pump is dismantled.
•Before starting to disassemble the pump unit make sure that it cannot be switched on again.
•The pump casing must be depressurised and empty.
•All valves in the suction, intake and discharge pipes must be closed.
•All components must have cooled down to ambient temperature.
5. Maintenance, Servicing
Work should only be carried out on the pump or pump unit when it is not in
operation. You must observe Point 1.4 „Safety instructions“.
Maintenance and servicing work must only be carried out by trained, experienced
staff who are familiar with the contents of these Operating Instructions, or by the
Manufacturer's own service staff. The work carried out must be duly entered in the
„Log Book“ (see Point 11) and confirmed by being signed.
Stuffing boxes
Stuffing boxes require constant maintenance (see also Point 4.5, „Starting up for the first time“). If
the leakage rate can no longer be set correctly, the packing is worn out and must be replaced in
good time (increased wear on shaft sleeve and/or shaft).
Because of the risk of accidents, addition of packing to pumps during operation or
at operating pressure or temperature is strictly forbidden.
Please
note
Pa 100/3-en 16

Operating instructions
Mechanical seals
If the liquid being handled drips out at the mechanical seal, it is damaged and must be replaced.
Before opening the pump, it is essential that you note Point 1.4 „Safety
Instructions“, Point 4.8 „Dismantling“ and Point 8 „Repairs“.
Oil changing
(only with oil-lubricated pumps)
•After the first 200 operating hours, drain off the oil (oil drains „AS“) and rinse with fresh oil.
Close oil drains „AS“ again and fill in oil at connections „FS“ (for all connections, see
„Summary of Screwed Connections“ in Appendix) in accordance with Point 2.3. Fill to level
described in Point 2.3.
•After this, change oil every six months or every year (depends on air humidity).
•If the pump is left idle for any length of time, the oil should be changed after two years.
•For choice and quantity of oil, see Point 2.3 „Bearings and Lubrication“.
Old oil should be disposed of in accordance with the valid national environmental
regulations.
Grease lubrication
•Bearings on pumps that are lubricated for life require no maintenance.
•If the pump is left non-operational for any length of time, the grease in the bearings should be
changed after four years.
Couplings
Check the play in the coupling components regularly approx. every 1000 operating hours.
If wear is heavy, it must be assumed that the motor is not properly aligned with the
pump or that the distance between the coupling sections has changed.
Replace worn elements and re-install or adjust coupling, as described in Point 4.2.
Cleaning the pump
Dirt on the outside of the pump has an adverse effect on transmission of heat. The pump should
therefore be cleaned with water at regular intervals (depending on the degree of dirt).
The pump should not be cleaned with pressurised water - water will get into the
bearings
6. Longer periods of non-operation
After long stationary periods, packings may have hardened; these must be replaced
before start-up.
When starting up, follow the instructions for starting up for the first time (see Point
4.5)!
Please
note
Please
note
Please
note
Please
note
Pa 100/3-en 17

Operating instructions
6.1 Drained pumps
•Turn by hand at least 1x week (do not switch on because of dry running).
•If necessary, unblock by tapping gently on the shaft in axial direction.
•Replace bearing oil after 2 years or grease after 4 years.
6.2 Filled pumps
•Switch stand-by pumps on and immediately off again once a week.
•If the stand-by pump is at operating pressure and temperature:
leave all sealing, flushing and cooling systems switched on.
•Replace bearing oil after 2 years or grease after 4 years.
•Do not tighten the stuffing box until there are no leaks.
7. Faults - Causes and Solutions
The following notes on causes of faults and how to repair them are intended as an aid to
recognising the problem. The manufacturer's Customer Service Department is available to help
repair faults that the operator cannot or does not want to repair. If the operator repairs or changes
the pump, the design data on the Data Sheet and Points 1.2-1.4 of these Operating Instructions
should be particularly taken into account. If necessary, the written agreement of the manufacturer
must be obtained.
Faults
Code no. for cause and method of repair
Discharge too low
1, 4, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 17
Discharge stops after a time
8, 10, 11, 12, 30
Head too low
2, 4, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 30, 34
Head too high
3, 5, 34
Drive mechanism overloaded
2, 3, 5, 15, 16, 25, 27
Pump not running quietly
7, 10, 14, 22, 23, 24, 25, 29, 30, 33
Temperature in the pump too high
7, 10, 30
Temperature in the shaft sealing too high
17, 18, 19, 20, 21
Temperature at the bearing too high
2, 14, 23, 24, 25, 26, 29, 31, 32
Pump leaking
25, 28
Leakage rate at shaft sealing too high
16, 19, 20, 21, 22, 23, 25
Meaning of code number for cause and method of repair
1. Back-pressure too high
•open discharge valve further
•reduce resistance in discharge pipe (e.g. clean filter if necessary)
•use larger impeller (note available motor power)
2. Back-pressure too low, discharge too low
•
throttle discharge valve
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