Zuwa UNISTAR 2000-A User manual

UNISTAR • COMBISTAR • NIROSTAR
Operating Instructions
Flexible Impeller Pumps
-Zumpe GmbH
Pumps and Sprayers
UNISTAR • COMBISTAR
NIROSTAR • ACOSTAR
Operating Instructions
Flexible Impeller Pumps

ZUWA Impeller Pumps
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ZUWA Impeller Pumps
Operating Instructions (Translation)
Contents
1. Introduction .......................................................................................................3
1.1 Further applicable documents .......................................................................3
1.2 Machine Specifications..................................................................................3
2. Declaration of conformity ..................................................................................4
3. Safety .......................................................................................................6
3.1 Intended use..................................................................................................6
3.2 Important safety instructions..........................................................................6
3.3 Legend ..........................................................................................................7
4. Technical data...................................................................................................8
4.1 Type plate......................................................................................................9
4.2 Impeller materials ........................................................................................10
5. Transportation and unpacking.........................................................................10
6. Mounting .....................................................................................................10
6.1 Connection of hoses or pipes ......................................................................11
6.2 Electrical connection....................................................................................11
6.3 Operation with hand drill or cordless screwdriver ........................................13
6.4 Using other drive systems ...........................................................................14
7. Commissioning and operation.........................................................................14
8. Storage .....................................................................................................15
9. Maintenance ...................................................................................................16
9.1 Routine inspection .......................................................................................16
9.2 Cleaning ......................................................................................................16
9.3 Disassembling the pump .............................................................................16
9.3.1 Series 2000-A, 2000-B and 2000-C directly flanged ............................17
9.3.2 Series 2000-A, 2000-B and 2000-C with pump adapter .......................18
9.3.3 Series synthetic pump ACOSTAR 2000-A ...........................................19
9.3.4 Series 2001-A, 2001-B and 2001-C .....................................................20
9.4 Replacing components ................................................................................21
9.5 Assembling the pump ..................................................................................22
9.6 Mounting and dismounting of transmission for V-belt drive .........................22
10. Accessories ................................................................................................... 23
10.1 Dry run protection ....................................................................................23
10.2 Flow control..............................................................................................23
10.3 Mechanical pressure switch.....................................................................24
10.4 Tool for changing the impeller..................................................................24
11. Troubleshooting ..............................................................................................25
12. Environmentally compatible disposal .............................................................. 25
13. Performance curves........................................................................................26

ZUWA Impeller Pumps
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1. Introduction
These operating instructions apply for the following pump types:
with motor
without motor
UNISTAR 2000-A
UNISTAR 2001-A
UNISTAR 2000-B
UNISTAR 2001-B
UNISTAR 2000-C
UNISTAR 2001-C
COMBISTAR 2000-A
COMBISTAR 2001-A
COMBISTAR 2000-B
COMBISTAR 2001-B
NIROSTAR 2000-A
NIROSTAR 2001-A
NIROSTAR 2000-B
NIROSTAR 2001-B
ACOSTAR 2000-A
The manual is intended for all users of the ZUWA impeller pumps which are listed
here.
1.1 Further applicable documents
Parts list with exploded drawings
1.2 Machine Specifications
All of the pumps are available in the following designs:
as a complete unit with electric motor, coupling and coupling protection
(series 2000)
without motor and with bare shaft (series 2001)
with electric motor
without motor
housing with impeller
wheel
The pumps are dry self-priming down to a depth of 3 metres.

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2. Declaration of conformity
Declaration of conformity
according to machinery directive 2006/42/EC annex II A
The manufacturer
ZUWA-Zumpe GmbH
Franz-Fuchs-Straße 13-17
D-83410 Laufen
hereby declares that the following products
product name: Impeller Pumps
types: UNISTAR 2000-A; UNISTAR 2000-B; UNISTAR 2000-C
COMBISTAR 2000-A; COMBISTAR 2000-B
NIROSTAR 2000-A; NIROSTAR 2000-B; ACOSTAR 2000-A
series: Impeller Pumps with motor
comply with the provisions of the above-mentioned CE Directive(s) including the amendments
valid at the time of declaration.
The following harmonised standards have been applied:
EN 1005-1:2001-10 Safety of machinery - Human physical performance -
Part 1: Terms and definitions
EN 1005-2:2003-04
Safety of machinery - Human physical performance -
Part 2: Manual handling of machinery and component parts of
machinery
EN 809:1998-07 Pumps and pump units for liquids - Common safety
requirements
The following harmonised and national standards and technical specifications have been
applied:
EMV directive 2004/108/EG
Low Voltage Directive 2006/95/EG
RoHs directive 2011/65/EU
Person authorized for the compilation of the technical
documentation:
Jürgen Huber
ZUWA-Zumpe GmbH
Franz-Fuchs-Straße 13-17
D-83410 Laufen

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Declaration of conformity
according to machinery directive 2006/42/EC annex II A
The manufacturer
ZUWA-Zumpe GmbH
Franz-Fuchs-Straße 13-17
D-83410 Laufen
hereby declares that the following products
product name: Impeller Pumps
types: UNISTAR 2001-A; UNISTAR 2001-B; UNISTAR 2001-C
COMBISTAR 2001-A; COMBISTAR 2001-B
NIROSTAR 2001-A; NIROSTAR 2001-B
series: Impeller Pumps without motor
comply with the provisions of the above-mentioned CE Directive(s) including the amendments
valid at the time of declaration.
The following harmonised standards have been applied:
EN 1005-1:2001-10 Safety of machinery - Human physical performance -
Part 1: Terms and definitions
EN 1005-2:2003-04
Safety of machinery - Human physical performance - Part 2:
Manual handling of machinery and component parts of
machinery
EN 809:1998-07 Pumps and pump units for liquids - Common safety
requirements
The following harmonised and national standards and technical specifications have been
applied:
RoHs directive 2011/65/EU
Person authorized for the compilation of the technical
documentation:
Jürgen Huber
ZUWA-Zumpe GmbH
Franz-Fuchs-Straße 13-17
D-83410 Laufen

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3. Safety
3.1 Intended use
The pumps are designed for dry-well installation. Make sure that the motor remains
dry (protection class IP 55).
Pump types
UNISTAR
Multi-purpose pump with aluminium casing designed for
transporting clean or contaminated fluids not containing
abrasive substances. Not suitable for handling foods and
abrasive or corrosive fluids.
COMBISTAR
Pump made from stainless steel (all parts which come into
contact with the liquid) and aluminium (cover), also suitable
for abrasive or slightly corrosive liquids.
Not suitable for foods.
NIROSTAR
Stainless steel pump that is particularly suitable for corrosive
and abrasive liquids, as well as for food and drinks.
ACOSTAR
Synthetic pump perfect for fluids with various viscosities plus
agressive acids, bases and solvents.
3.2 Important safety instructions
Store these instructions in such a way that they are accessible at all times for
pump operating personnel. Urge employees to read and follow these instructions.
Do not remove adhesive labels showing technical information.
Observe plant-related specifications and provisions.
Have work carried out by specialist personnel or personnel briefed according to
the VDE standard.
Only carry out work on the pump when the pump is not in operation and the drive
has been disconnected from the mains power supply.
In case of dangerous (e.g. hot, poisonous, explosive) pumped media, use
protective equipment.
Do not pump any liquids that are corrosive to the pump material.
Do not pump any liquids containing particles of diameter greater than 2 mm.
Do not use pumps under water.
Do not allow pumps to run without liquid for longer than one minute.
Only use genuine replacement parts, otherwise the warranty shall cease to be valid.
Impeller and seals are wear parts and wear out over time.
The manufacturer shall not be held liable for damage resulting from non-
adherence to the operating instructions.

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3.3 Legend
Danger of death and severe injury
Danger of death and severe injury due to electric shock
Danger of light bodily injuries and material damage
Information, note

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4. Technical data
UNISTAR 2000-A UNISTAR 2001-A UNISTAR 2000-B UNISTAR 2001-B UNISTAR 2000-C UNISTAR 2001-C COMBISTAR 2000-A COMBISTAR 2001-A COMBISTAR 2000-B COMBISTAR 2001-B NIROSTAR 2000-A NIROSTAR 2001-A NIROSTAR 2000-B NIROSTAR 2001-B ACOSTAR 2000-A
max. flow rate
in L/min
30 30 60 60 90 90 30 30 60 60 30 30 60 60 30
max. pressure in
bar (with
Perbunan
impeller)
5 4 5 4 5 4 5 4 5 4 5 4 5 4 3
connections
In/Out external
thread (inches
and nominal
width in mm)
¾“
19
¾“
19
1“
25
1“
25
1¼“
32
1¼“
32
¾“
19
¾“
19
1“
25
1“
25
¾“
19
¾“
19
1“
25
1“
25
¾“
19
max. speed
12 or 24-Volt motors: 3000 rpm
230- or 400-Volt motors: 2800 rpm
230-
400V
motor protection
class
IP 55
max.
temperature
90°C (with plastic impeller 60°C) 60°C
max. suction
height
7 metres (dry 3 metres)
maximum
viscosity of the
fluid
20.000 mPas
sound pressure
level
74 dB(A)

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4.1 Type plate
Type plate, example:
Drive:
00 no motor, open shaft
01 double bearing for belt drive
02 hydraulic drive
03 air motor
13 gear motor DC 12 V
14 DC 12 V-Creusen
15 DC 12 V-KEB
24 DC 24 V-Creusen
25 DC 24 V-KEB
34 DC 48 V
53 el. Motor 230 V special shaft
55 el. Motor 230 V L/R special shaft “C”
61 el. Motor 110 V / 50 Hz special shaft
62 el. Motor 110 V / 60 Hz special shaft
63 el. Motor 230 V special shaft
64 el. Motor 230 V standard shaft
65 el. Motor 230 V L/R special shaft
66 el. Motor 230 V L/R standard shaft
67 el. Motor 230 V / 60Hz special shaft
68 el. Motor 220 V / 60Hz special shaft
71 el. Motor 400 V special shaft “C”
73 el. Motor 400 V special shaft
74 el. Motor 400 V standard shaft
75 el. Motor 400 V L/R special shaft
76 el. Motor 400 V / 60Hz special shaft
77 el. Motor 480 V / 60Hz special shaft
80 Liveranimotor 230 V
82 Liveranimotor 400 V
86 gear motor 400 V
98 combustion motor 2stroke
99 combustion motor 4stroke
Seal type
(1st. digit)
1shaft seal
2mechanical seal
Seal material
(2nd digit)
shaft seal:
1 NBR
2 EPDM
3 FKM
4 CR
5 VQM
6 Eco-PE
mechanical seal:
1 ss-graphite-NBR
2 tungsten-carbide-NBR
3 tungsten-carbide-Viton
4 EPDM
5

Carbon-Ceramik-FKM
Bush
(2nd digit)
1 Polyamide
2 
3 green/Ploy
4 green/ss
5 
6 Alu
7 brass
8 ss
9 ss-spec.
Impeller
(1st. digit)
1 NBR
2 EPDM
3 FKM
4 CR
5 NR
6 Alu
7 brass
8 stainless
9 plastic

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4.2 Impeller materials
Impeller pumps are equipped with NBR impellers as standard.
Material designation
Suitable for:
Properties
NBR
Acrylonitrile butadiene rubber
(Perbunan®, Buna-N®)
water, antifreeze, heat
transfer fluid, vegetable
oil and grease
high impact elasticity and
good mechanical strength
good for applications
involving high pressures up
to max. 5 bar
EPDM
Ethylene propylene diene
rubber (Keltan®, Buna EP®)
high temperatures,
acids and alkalis
high elasticity and very
good mechanical stability
FKM or FPM
Fluorocarbon rubber (Viton®,
Fluorel®)
oil, diesel, fuel oil, palm
oil, soy bean oil and
oleaginous wood
preservatives
very good chemical
resistance, low mechanical
strength
CR
Chloroprene rubber
(Neoprene®, Bayprene®)
food, drinks
flame resistant, tearproof,
durable
plastic
water, mineral and
vegetable oils, diesel,
heat transfer fluid,
antifreeze
extremely tear resistant
and good mechanical
stability
max. fluid temperature
60°C
5. Transportation and unpacking
>After unpacking, immediately check the pump for completeness and damage.
>Immediately report any transit damage to the supplying company.
>Dispose of packaging material according to the respective local regulations.
6. Mounting
Danger
Danger of death due to electric shock
>Work on the electrics may only be carried out by specialist
personnel.
Danger
Danger of injury from rotating components
>Cover drive and pump shaft.

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Caution
Material damage due to overheating of engine
>Ensure sufficient space and air supply for the motor.
6.1 Connection of hoses or pipes
Observe correct direction of rotation of pump,
indicated by an arrow on the type plate and the lettering
In –Out.
Affix hoses as follows:
1. Screw suction line onto the side marked “In”.
2. Screw pressure line onto the side marked “Out”.
3. Verify that the connections are leaktight.
6.2 Electrical connection
6.2.1 Series 2000-A, 2000-B und 2000-C
Danger
Danger of death due to electric shock
>Fit the pump’s electric circuit with a ground fault circuit interrupter.
>Fit a motor overload switch.
230 Volt motors:
Thermal protection is fitted. Fitting of a motor overload switch is advisable.
400 Volt motors:
No thermal protection is fitted. Fitting of a motor overload switch is required (available
as accessory)
Direct current motors:
Protection against overcurrent by means of safety fuses:
12 Volt motors: 80-A
24 Volt motors: 50-A
The pump can be fitted vertically or horizontally. In case of vertical fitting, it
is advantageous to direct the pump head downwards, so that in case of
leaking the motor is protected against escaping liquid.
Hoses or lines must be suitable for the respective pumped medium.
Avoid long suction lines.
In the case of a suction height of more than 3 metres, fit foot valve in the
suction line in order to prevent drainage of the pump and suction line.

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Caution
Motor damage can arise due to unsuitable extension cable
>For extension cables of length up to 20 metres: Use cables with at
least the same cross section as the pump cable.
>For extension cables with a length of more than 20 metres: Use
cables with a larger cross section than the pump cable.
6.2.2 Series 2001-A, 2001-B und 2001-C
The pumps can, for example, be driven with the following drive systems:
power drill
V-belt drive
gear motor
hydraulic motor
pneumatic motor
Ensure correct speed and output of the drive system:
Max. speed 3000 rpm
Minimum output of the drive system:
- 370 Watt for types of series 2001-A
- 550 Watt for types of series 2001-B
- 1100 Watt for types of series 2001-C
When using external drive systems, observe the manufacturer’s
instructions.
Impeller pumps require an increased
starting torque.
For pumps with three-phase motor,
observe the direction of rotation of the
motor. The direction of rotation is indicated
by an arrow on the type plate.

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6.3 Operation with hand drill or cordless screwdriver
The pump needs to be fixed when it is used with a hand drill or any other electric drill
to avoid turning.
Fixation can be done in two ways:
A) with drill adapter
The adapter either comes with the pump or can be ordered separately from the
manufacturer. The adapter is suitable for any standard drills and screwdrivers. Article
No. adapter: 11012300
>Fix adapter on pump (see below).
>Insert pump shaft into chuck and tighten.
>Insert depth stop into upper aperture and tighten fixing screw.
B) with mounting feet and regraded support
Mounting feet and support can be ordered directly from the manufacturer.
Article No. mounting feet: 110 127 10
Article No. regraded support: 110 123 10
The support needs to be suitable for the drill. The
grading has to be high enough to provide for a
precisely horizontal alignment of drill and pump
>Fix mounting feet on top of the support.
>Insert pump shaft into chuck. Pump and drill
must be precisely aligned. Tighten chuck.
Caution
Material damage due to pressure on the shaft
>Do not affix the drill to the support, but allow it to lie loosely in such a
way that it has some play.

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6.4 Using other drive systems
If an external drive is being used, a claw coupling with adapter for the connection of
the pump with the motor (optional accessories, see parts list from item 200) is
necessary.
Caution
Material damage due to incorrect alignment of the pump
>If the claw coupling is being used, ensure precise alignment of the
pump and motor, to prevent the shaft from breaking. The claw
coupling can only compensate a degree of play of 0.1 mm.
7. Commissioning and operation
Danger
Danger of death due to explosion
>Do not pump any liquids with a flash point of less than 55 ° C.
>Do not pump petrol or solvents.
Danger
Danger of death and injury due to rotating parts
>Do not touch pump while it is in operation.
Danger
Danger of injury due to items of clothing and hair being caught in
the running drive
>Do not wear loose items of clothing such as ties, scarves and
shawls.
>Tie back long hair and protect using a head covering or hood.
Warning
Danger of injury and poisoning due to dangerous pumped media
>Safely collect escaping pumped media and dispose of in an
environmentally-friendly manner.
Caution
Material damage due to high temperatures of the pumped medium
>Do not pump liquids with a temperature of more than 90 °C,
otherwise the impeller material will become attacked.
ZUWA impeller pumps are dry self-priming. It is not necessary to fill the
pumps prior to commissioning except when the suction depth is more than
3 metres.

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Caution
Material damage due to dry running
>In case of a suction depth of more than 3 metres, fill prior to
commissioning.
>Never allow the pump to run dry for more than one minute.
>Open pressure line.
>To start the pump, switch on drive.
>Service interruption: wait 3 - 4 seconds before restarting
Caution
Material damage due to overpressure in the pump
>Do not block pressure side for more than a minute while the drive is
running.
All ZUWA impeller pumps are suitable for continuous operation.
UNISTAR 2000-C
This pump is equipped with a rotary switch to change
operating direction.
>Prior to changing the rotating direction turn off
pump and wait for 3 - 4 seconds. Then turn switch
into the new direction.
8. Storage
>Empty pump completely
>Clean pump in order to avoid adhesions and damage to the impeller
>Store pump under frost-protected conditions
After extended periods of pump
down time prior to commissioning, check that
the impeller wheel runs freely and that the pump starts. See also chapter 11:
“Troubleshooting”.
rotary switch

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9. Maintenance
Danger
Danger of death due to electric shock
>Prior to work on the pump, always disconnect the drive from the power
supply.
9.1 Routine inspection
>Regularly check the line connections for leak-tightness.
>The pump is supposed to be turned on in intervals of 2-3 seconds to keep the
Impeller from getting glued to the pump body.
9.2 Cleaning
Caution
Material damage due to aggressive cleaning agents
>Do not use cleaning agents that affect the materials of pump or
impeller wheel.
9.3 Disassembling the pump
The pumps of the NIROSTAR series are not fitted with lateral discs.
In addition to the disassembling as described on
the following pages the lateral connection flanges
can be dismantled from pumps of the 2000-C and
2001-C series.
lateral connection flange

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9.3.1 Series 2000-A, 2000-B and 2000-C directly flanged
1. Disconnect hose connections.
2. Release screws, remove cover.
3. Remove lateral disc (without hole) and
O-ring.
4. Remove housing with impeller.
5. Remove O-ring, lateral disc (with hole)
and rear cover. Detach locking ring
and press out shaft seal.
6. Press Impeller out of housing.
7. Housing with small rim on top, turn
impeller counter-clockwise into
housing. Push Impeller as far up as
possible.
small rim
Out
In

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9.3.2 Series 2000-A, 2000-B and 2000-C with pump adapter
1. Disconnect hose connections.
8. Release bolts and nuts, remove pump
head from pump carrier.
9. Release bolts, remove cover, O-rings
and lateral disc (with hole).
10. Remove housing with impeller, O-
rings and lateral disc (with hole).
11. Detach locking ring and press out
shaft.
12. Release safety rings and press out
bearing respectively shaft seal ring.
13. Push impeller out of housing.
14. Housing with small rim on top, turn
impeller counter-clockwise into
housing. Push Impeller as far up as
possible.
Out
In
small
rim
9.3.2 Series type 2000-A and 2000-B with pump carrier
Flexible impeller pump UNISTAR 2000-A/PT
Loosen the hexagon screws and
disassemble the pump head.
Dismantle pump head to
replace the defective part
Remove socket head screws and
remove the pump carrier.

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9.3.3 Series synthetic pump ACOSTAR 2000-A
1. Disconnect line connections.
15. Loose the star knobs and remove lid.
16. Remove lateral disc (without hole)
and O-ring.
17. Remove pump/impeller from shaft.
Squeeze impeller out of the pump
body.
18. Remove O-ring, lateral disc (with
hole) and PTFE ring .
19. Loose safety rings, squeeze off rod
and shaft seal.
20. Remove Ceramic sleeve and O-
rings.
Assembly of the pump to be completed
vice versa.
9.3.3 Series type PTFE pump ACOSTAR 2000-A
1. Disconnect the cable connections. 2. Loosen star knobs and remove cover.
3. Remove wear plate without hole and
O-ring. 4. Remove the housing with the impeller,
push the impeller out of the housing.
5. Remove O-ring, wear plate with hole,
and PTFE ring.
6. . Remove the retaining ring, push out
rod seal and shaft seal.
7. Remove socket head screws, pull off
the pump carrier, remove retaining ring,
press out shaft with bearings.
Reassemble the pump in reverse order.

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9.3.4 Series 2001-A, 2001-B and 2001-C
with mounting feet
with drill adapter
1. Disconnect line connections.
2. Release bolts, remove mounting feet or adapter and cover.
3. Remove lateral disc (without hole) and
housing with Impeller.
4. Remove O-rings and lateral disc (with
whole).
5. Detach locking ring and press out
shaft.
6. Release locking rings and press out
bearing respectively shaft seal ring.
with mounting feet
with drill adapter