2. Operating Instruction.pdf

SIHISuperNova Programme Range: ZLND Volute casing pump complying with EN 733 / DIN 24255 * PUMP DESCRIPTION: ____________________________ ______________________________ __ SERIAL NUMBER: ____________________ ____________________

Operating instructions Translation of the original instructions Safety issues

Chapter 1

Intended application

Chapter 2

Planning the installation

Chapter 3

Unpacking, storage, handling

Chapter 4

Installing the pump

Chapter 5

Start up and shut down

Chapter 6

Maintenance, dismantling and assembly

Chapter 7

Troubleshooting

Chapter 8

Technical data

Chapter 9

Connections, dimensions, sectional drawing

Chapter 10

Additional instructions: M1S

Annex I

Additional instructions: N1S, NFS

Annex II

Declaration of conformity. Example

Annex III

ATEX information

Annex IV

Regulation EU 547/2012

Annex V

*

With certain exceptions – see Technical Catalogue

Attention: Both the pump and/or the pump set must be installed and commissioned by qualified technical

personnel only and these installation, commissioning and operating instructions must be strictly observed. Failure to do so could result in: • danger to you and your colleagues, • the pump or the pump unit may be damaged, Note that the manufacturer is not liable for damages resulting from failure to observe these instructions. Please be aware of your responsibility to your colleagues when working on the pump or the pump set! Safety instructions marked with included in this Operating Instructions and in the Supplementary Operating Instructions, which must be attached to this Operating Instruction, have to be considered in particular when operating this pump in potentially explosive atmospheres! For local contact details: www.sterlingsihi.com

In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice.

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Fluid Systems BV) 2012

Safety issues

Page 1 of 3

1. Safety This operating manual gives basic instructions, which must be observed during installation, operation and maintenance of the pump. It is therefore imperative that this manual is read by the responsible personnel / operator(s) prior to assembly and commissioning. It must always be kept available at the site of pump installation. It is not only the general safety instructions contained in this chapter “Safety” which must be observed, but also the specific information provided in the other chapters. 1.1

Identification of safety symbols in the operating instructions Safety symbols are given in these operating instructions. Non compliance with these would affect safety and are identified by the following symbol

Danger symbol as per DIN 4844-W9 (ISO 3864 - B.3.1) Or in case of danger of electric current with:

Danger symbol as per DIN 4844 W-8 (ISO 3864 - B.3.6) The word ATTENTION

identifies those safety regulations where noncompliance may pose a danger to the pump and its function. It is imperative that the appropriate safety information is attached to the pump/pump set, for example: • an arrow indicating the direction of of rotation • symbols indicating fluid connections • the identification plate and that these are kept legible. For local contact details: www.sterlingsihi.com

Chapter 1

1.2

Qualification and training of personnel The personnel responsible for operation, maintenance, inspection and assembly must be adequately qualified. The scope of responsibility and supervision of the personnel must be exactly defined by plant management. If the staff do not have the necessary knowledge, they must be trained and instructed. This task may be performed by the machine manufacturer or supplier on behalf of the plant management. Moreover, plant management must ensure that the contents of the operation instructions are fully understood by plant operators and other relevant personnel such as maintenance staff. 1.3

Hazards in case of non compliance with safety instructions Non compliance with the safety instructions may result in risk to personnel as well as to the environment and the pump/pump set and result in the loss of any right to claim damages. For example, non-compliance may result from, or lead to, the following: • failure of important functions of the pump/pump set/plant • failure of specified procedures of maintenance and repair • exposure of people to electrical, mechanical and chemical hazards • danger to the environment owing to hazardous substances being released. 1.4

Compliance with regulations relating to safety at work When operating the pump the safety instructions contained in this manual, the relevant national accident prevention regulations and any other service and safety instructions issued by plant management must be observed.


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Safety issues

Page 2 of 3

1.5 •

•

•

•

Safety instructions relating to operation If high or low temperature pump/pump set components involve hazards, steps must be taken to avoid accidental contact. Guards for moving parts (e.g. couplings) must not be removed from the pump/pump set while in operation. Any leakage of of hazardous (e.g. explosive, toxic, hot) fluids (e.g. from the shaft seal) must be drained safely so as to prevent any risk to persons or the environment. Statutory regulations are to be complied with. Hazards from electricity are to be avoided by the user (see for example the VDEspecifications and the bye-laws of the local power supply utilities).

1.7

Chapter 1

Safety instructions for the use in areas with explosion hazard

In this section information is given for operation in areas where an explosion hazard exists.

1.7.1 Complete pump sets If the pump is combined with other mechanical or electrical components in one set, the category of the complete unit will correspond, based upon the Directive 94/9/EC, only to that category with which all of its components comply. Note:

1.6

Safety instructions relevant for maintenance, inspection and assembly work It is the plant manegement’s responsibility to ensure that all maintenance, inspection and assembly work is performed by authorized personnel who have adequately familiarised themselves with the subject matter by studying this manual in detail. Any work on the machine must only be performed when it is at a standstill. It is imperative that the procedure for shutting down the machine described in this manual is followed. Pumps and pump sets, which convey hazardous media, must be decontaminated. On completion of the work all safety and protective guards must be re-installed and made operative again. Prior to re-starting the machine, the instructions listed under “first commissioning” are to be observed.

For local contact details: www.sterlingsihi.com

These comments are of particular importance when pumps, which conform to a given category of Directive 94/9/EC, are powered by a driver which is not in the same category. Although the pump may bear the Ex sign, the set should not be used in areas with an explosion hazard when the motor is not classified for this application. This means that plant management personnel should always check that all elements of the set comply with the Directive 94/9/EC.

1.7.2 Execution of coupling guards Coupling guards that are to be used in areas with an explosion hazard, have to fulfil one of the following criteria: • consist of non-sparking material, e.g. brass. • if they consist of sparking material, e.g. steel sheet, they must be designed in such a way that the rotating parts will not come in contact with any part of the guard if errors, that could be foreseen, are committed by the user, e.g if a person steps on the guard.


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Safety issues

Page 3 of 3

1.7.3 Monitoring technical parameters When using pumps in areas with an explosion risk, the operator must check the following parameters regularly: • leakage of shaft seals • bearing temperature • that the pump is always filled with liquid during operation • that the pump does not operate against a closed valve for any length of time. The operator must ensure that pumps, which show evidence of abnormal operation, are switched off and not started again until the cause of the abnormal operation has been eliminated.

•

Chapter 1

modifications are only undertaken with Sterling Fluid Systems’ written agreement.

1.7.4 Avoiding external damage In areas with a risk of explosion the operator must ensure that the pumps and or pump set is not subjected to external impacts e.g by heavy objects. 1.8

Unauthorized alterations and production of spare parts Modifications may be made to the pump/pump set only after consultation with,and written approval from, the manufacturer. Using spare parts and accessories authorized by the manufacturer are in the interests of safety. Use of other parts may exempt the manufacturer from any liability. 1.9 Unauthorized mode of operation The reliability of the pump/pump set can only be guaranteed if it is used in the manner intended and in accordance with the instructions of this manual. The specified limit values must under no circumstances be exceeded. 1.10 Warranty / guarantee Sterling Fluid Systems guarantee satisfactory operation if: • the pump is installed and operated in compliance with these instructions and in operating conditions approved by Sterling Fluid Systems For local contact details: www.sterlingsihi.com


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Page 1 of 3

2. Application The pump is to be used only for the operating conditions stated by the customer and confirmed by the supplier. Guarantee is assumed within the scope of the Sterling Fluid Systems conditions of sale. Appropriate application and operating conditions are contained in the attached data sheets.

2.1

•

Warning of misuse

Chapter 2

2.3

Construction and mode of operation ZLND pumps are horizontal, single-stage volute casing pumps with nominal outputs and flange dimensions meeting EN 733 / DIN 24255. Their back pull out construction allows the disassembly of the complete bearing unit towards the drive side without removing the pump casing from the pipework. ZLND pumps are preferably used when pure or turbid liquids, not containing solid particles, are to be handled. Impurities up to a grain size of 3 mm can be handled, but shorten the service life.

The pump may only be used for the application(s) stated. Otherwise hazards for people and environment may arise.

ATTENTION •

•

Do not exceed fluid density stated. Otherwise, there is a the danger of motor overload. The pump must not be operated beyond its characteristic curve – otherwise there is a danger of cavitation and motor damage.

2.2 Accessories The accessories included in the scope of supply are indicated in the delivery note or in the order confirmation. The corresponding operating and installation instructions are also indicated in the Annex relating to accessories. If it is intended to mount other accessories on the pump or on the pump set, please inform the manufacturer in advance in order that appropriate technical advice can be given.



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2.4

Page 2 of 3

Chapter 2

Description

Type size

Hydraulic + Bearing A• First hydraulic B• Second hydraulic D• Double volute

032125 to 300500

Material design 0B: Cast iron GG25

052: Uncooled packing rings, external seal liquid

0C: Cast iron GG25, Bronze G-CuSn10 impeller

B27:WC/Carbon, EPDM

0E: Cast iron GG25, Stainless steel 1.4408 BJ3,C23,AF3,AX3,AY3,A93:SiC/Carbon, EPDM impeller

•B

ZLND

Shaft seal 041: Self-sealed, uncooled packing rings

Two ball bearings greased for life (2Z) • C Two ball bearings oil lubricated • S One double row angular

BJS,C2S,AFS, AXS,AYS,A9S: SiC/ SiC, Viton

contact bearing plus one ball bearing, grease lubricated • T One double row ball bearing plus ball bearing, oil lubricated

M1S,N1S,NFS: SiC/ SiC, Viton

Casing gasket 2: confined flat gasket of EWP 210 material 4: confined flat gasket of PTFE

1B: Ductile cast iron GGG40.3, cast iron GG25 BJJ,C2J,AFK,AXK,AYK,A9K: SiC/Carbon, Viton impeller

Alternatively A or B 032160, 032200 A 032125 to 200315, 250315 041, 052, B27, BJ3, C23, AF3, AX3, AY3, A93, D 200400 to 300500 BJS, C2S, AFS, AXS, AYS, A9S, BJJ, C2J, AFK, AXK, AYK, A9K, M1S, N1S, NFS Alternatively B, C, S or T

4B: Stainless steel 1.4408

Alternatively

Alternatively

0B, 0C, 0E, 1B, 4B

2, 4

Codes AX3, AXS, AXK: are equivalent to AF3, AFS, AFK respectively plus quench Codes AY3, AYS, AYK: are equivalent to AF3, AFS, AFK respectively plus heating Codes A93, A9S, A9K: are equivalent to AF3, AFS, AFK respectively plus external flushing Code B27: this execution is only valid for water up to 140 degrees.



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Example of a pump designation: 1-3 4

5-7 8-10 11 12 13-15 16-17 18

ZLND 125 250 A C 041 0B 2 Casing gasket Construction Shaft sealing Bearings:B,C,S, or T Hydraulic: A/B/D Impeller size Nominal discharge

Pump series

Chapter 2

2.5 Shaft sealing Depending on the application, different shaft sealing executions are offered (see 2.4) • a stuffing box with lantern ring (executions 041, 052, and optionally 051) or mechanical seals according to EN12756 are utilised in the following cases: • if the pump draws from a suction line, • if the pump is fed by a feed line with a pressure of less than 0.5 bar or • if the pumped liquid is at or near its boiling point. Provision of the sealing liquid is as follows: • 041: Internal self sealing ISO 5199 plan 01 • 052: External self sealing ISO 5199 plan 08 • 051: External self sealing ISO 5199 plan 09 • Mechanical seal: ISO 5199 plan 02. API plan 11 • Mechanical seal execution plus external flushing: ISO 5199 plan 08, API plan 32. • Mechanical seal execution plus quench: ISO 5199 plan 09. API plan 62.

ATTENTION Section 2.4 does not contain the codes for all

variations of mechanical seals. Where the code is not included or replaced by QQQ, consult the relevant data sheet of the mechanical seal supplier (e.g. special execution of the mechanical sealing in a back to back position).



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3.0


3.1

Piping system

Page 1 of 2

Ensure that air pockets cannot be created. Unequal nominal widths of the suction branch and suction line must be compensated by eccentric transition pieces.

ATTENTION

• •

• • •

• •

•

•

Chapter 3

Note the arrows on the pump branches indicating the direction of flow. Choose nominal widths of the pipelines according to the nominal widths of the pump branches or larger ones with the corresponding reductions. Flange sealing must not protrude on the inside. Ensure that the pipework is clean before installing of the pump. Support the pipework in order to avoid distortions at the pump components (risk of damage to pump components) Avoid abrupt changes of cross section and direction. Where different diameter pipework is to be used, connection should be by eccentric transition pieces. This will avoid the formation of air pockets in the pipework. For difficult pumping on the suction side, to stabilise the flow, a pipe length 15 times the diameter of the suction branch should be installed before the suction branch. The flow rate in the suction line or inflow line, must not exceed 2 - 3 m/s.

Flow straightener

Connection of eccentric pipe transitions It is recommended that a filter is installed in front of the pump with a filter surface of at least 3 times the pipe cross section (approx. 100 meshes/cm²). The suction opening of the suction line should be well below the liquid level, and a strainer should be used. The strainer must be far enough from the bottom to avoid excessive inlet losses, which could impair pumping performance. It is advisable to check that there is no leakage. 7 4

3

1

6

2

4

3.1.1 Suction line / inflow line See the sketches below for the optimum layout of pump installation for flow and suction lift operation.

1 Eccentric reducer ( suction line ) or 5

concentric reducer ( feed line ) 2 Shut-off valve 3 Suction line 4 Bend

Pump installation

5 Foot valve with suction strainer 6 Check valve 7 Regulating valve

positive suction head operation For local contact details: www.sterlingsihi.com

suction lift operation In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice.

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Page 2 of 2

Chapter 3

A shut-off valve should be installed in the feed line. It must be closed for maintenance work. It should be installed in order to avoid air pockets forming in the spindle cap, i.e. with the spindle in a horizontal position or pointing vertically downward.

3.1.2 Discharge line For flow regulation, a valve must be installed behind the pump. If non-return valves are used, they should close smoothly. Pressure shocks must be avoided. 3.1.3 Inlet and outlet connections The various connecting points are shows in the drawings. (See Annex, Chapter 10, point 10.1). 3.1.4 Pressure control For consistent control of pressure, it is advisable to install in the pipework a measuring point in front of, and behind the pump. 3.2 Electrical connections For the drive motor a mains connection is required which complies with the European Regulations and Directives for the Standards in Industry and with the instructions of the local power supply utilities of the country concerned.



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4.


4.1

Safety measures

• • • •

•

• •

Page 1 of 2

4.4 Handling The pump or pump set must be lifted and handled as shown in the following sketches.

Never stay below the suspended load. Keep a safe distance while the load is being transported. Use only approved lifting appliances, which are in good condition. Adjust the length of the lifting appliances in such a way that the pump and/ or the pump set, is suspended horizontally. Do not use the eyebolts on the pump components for lifting the assembled pump or the complete set. Do not remove documents, which are attached to the pump. Do not remove the protection covers from the pump suction/discharge. Otherwise, there may be a risk of contamination.

4.2 Unpacking Before unpacking, a visual check of the packing is recommended. If transport damage is visible, the extent should be noted on the receipt or on the delivery note. Potential claims must be lodged immediately with the carriers or the insurance company. 4.3 Interim storage If the pump or the pump unit is not installed immediately after delivery, it must be stored free from vibration in a dry room.


Chapter 4

Pump without motor

Pump set

4.5 Protection against corrosion In general, a protective coating is only applied to the following executions: OB, OC and OE. 4.5.1 Removal of protective coating To remove the protective coating, the pump should be filled and drained several times using appropriate agents, e.g. solvent naphtha, diesel oil or alkaline detergent. Flush with water, if necessary. The pump must be installed and started up immediately afterwards.

In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice

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Page 2 of 2

Chapter 4

4.5.2 Renewing corrosion protection If the pump has been supplied with a protective coating and has to be stored, a new protective coating should be applied after six months. For suitable protective coatings, contact Sterling Fluid Systems.



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Installing the pump

5.

Page 1 of 3

Chapter 5

Installing the pump 5.4.3

5.1 Requirements The pump and the pump set, must have been unpacked and handled as described in Chapter 4. 5.2 Use of trained staff Only appropriately trained staff must undertake the work described in this chapter. 5.3

•

• •

• •

Safety measures

Connect the pipework carefully to prevent the pumped liquid escaping during operation and endangering operating personnel. Ensure that the suction or inflow line, and the discharge line are closed by valves. Ensure that all electrical connections are “dead”. Otherwise, there is a risk of electric shock. Pay attention to relevant internal plant regulations. Avoid accidental contacts with hot components.

Remove the protective coating by following the instructions of Chapter 4. Otherwise there is a danger of contamination .

5.4

General information

5.4.1

Assembly tools

Special tools are not required for assembly and installation. 5.4.2

The pump must be installed on a flat floor or foundation free from vibration. In case of doubt use vibration dampening feet. The pump set must be correctly mounted on the foundations. To avoid distortion of the pump set and/or the foundation, parallel shims must be used between the base plate and foundation. Prior to installing, checks should be made with regard to:

ATTENTION •

Base, foundation

- Possible damage to the pump or the pump set that may occur in transit. - Ease of running ( check that the shaft is free to rotate by hand ). - The foundation dimensions. The following preparatory work must be carried out before to placing the pump: - Roughen and clean foundation surface. - Remove shuttering/cores from the anchor holes. - Blow the anchor holes clean. - Check the position and dimensions of the anchor holes against the arrangement drawing. 5.4.4 Installation of the set

The complete set mounted on the base plate must be placed on the foundation with its foundation (rag) bolts hanging below the baseplate. 5.4.5

Space required

The space required for the pump set is set out in the foundation plan or installation drawing. Ensure easy access to the shut-off and regulation valves as well as to any measuring instruments.

Permissible ambient conditions

The ambient temperature can be from -20 °C to +60 °C. The atmospheric humidity should be as low as possible in order to avoid corrosion. For local contact details: www.sterlingsihi.com


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Installing the pump

Page 2 of 3

5.4.6 Position

In principle the ZLND pumps are installed horizontally.

5.5 Motor Before assembly check the direction of rotation of the motor (indicated by an arrow on the pump casing). If this is not possible the direction of rotation of the complete unit can only be checked only if the pump is filled. In any event, the operating instructions of the motor manufacturer must be followed, since the motor is generally incorporated by STERLING FLUID SYSTEMS into the pump set. 5.6 Alignment of the set Place shims under the base plate on both sides of the foundation bolts, 10 mm from the base plate edge. Use a spirit level to align the set. If necessary, place shims between the foundation bolts to prevent the base plate from sagging. Care should be taken to minimize distortion of the base plate during installation. The location of the driver must not be higher than that of the pump. The max. deviation from the shaft centre line is ± 0.1 mm. The foundation bolts should be embedded in concrete using quick-setting grout. 5.7 Coupling Install the coupling avoiding hard blows, if necessary in warm condition. Arrange the pump and motor on a level base. The shaft ends must be aligned exactly. The distance between each half of the N-EUPEX B ( FLENDER ) coupling must be 2 - 3 mm (see fig.). For local contact details: www.sterlingsihi.com

Chapter 5

If other manufacturer’s couplings are used, follow the manufacturer’s instructions. After installation on the foundation and connecting the pipework, the coupling alignment must be checked and realigned, if necessary. Moreover, after reaching the operating temperature the alignment of the coupling must be checked again. The coupling requires a guard that meets DIN 31001 in order to avoid accidental contact during operation. In any event, the operating instructions of the coupling manufacturer must be followed, since the coupling is a component incorporated by Sterling Fluid Systems. ruler

The following is required a = a1 and b = b1

5.8 Checking before installation Before installing the pump on the plant, the following points must be checked: 1. Is the electrical current to the drive motor switched off? 2. Are suction and discharge lines emptied and closed by valves? 3. Is it possible to rotate the pump easily by hand (for this purpose turn the fan of the motor or the coupling)? 4. Have the latest internal/plant instructions been observed?.


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Installing the pump

Page 3 of 3

Chapter 5

5.9

Mounting the pump and installation into pipework The following instructions must be carried out: 1. Remove the protective covers from the pump flanges and the auxiliary pipework connections. 2. Correctly insert the flange seals. 3. Connect the suction or feed line. 4. Connect the discharge line. The pump must be aligned with the pipework. The pipework must be supported so that distortion cannot occur when connecting the pump.

5.10 Final work The following final steps must be undertaken: 1. Check the tightness of the connecting flanges. 2. Check for easy running of the pump (for that purpose turn the motor fan or the coupling). 3. Check the coupling alignment. 4. Install the coupling guard.

5.11 Hydrostatic pressure test When subjecting the piping system to a hydrostatic pressure test, exclude the pump from the pressure test. If it is not possible to test the pipework without the pump, ensure that foreign material cannot enter the pump.

•

•

The max. permissible pressure for a pressure test is 1,3 times the nominal pump pressure. The nominal pump pressure is indicated in the technical data sheet.



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Start-up and shut-down

Page 1 of 3

Chapter 6

6. Start-up and shut-down operations 6.1 Requirements The pump or the pump set, must be installed acc. to the instructions of Chapter 5.

•

•

6.2 Use of trained staff Only appropriately trained staff must carry out the work described in this chapter. 6.3

Safety measures

•

• •

•

Electrical connections must be made according to the European Regulations and Directives for the Standards in Industry and in compliance with the instructions of the local power supply utilities of the country concerned. Only appropriately authorized personnel may carry out this work. ATTENTION

• • • •

•

•

Fill the pump correctly; otherwise the shaft seal could be destroyed. Fill the supply lines correctly. Check the direction of rotation only when the pump is filled. Fill the pump slowly if hot media are being pumped in order to avoid distortions or heat shock. When handling explosive, toxic, hot, crystalline or corrosive media, ensure that there is no risk to people or the environment. Control the output at constant speed at the discharge side only. The valve at the suction side must always be completely open during operation to avoid the risk of cavitation.


If there is no bypass line, do not run the pump with the control valve closed for any length of time. Safety measures should be taken by the end user to ensure (for example by means of a relief valve) that the permissible pump casing pressure is not exceeded during operation If water up to 140°C is being pumped end user must ensure that pressure is at least 0,5bar above the vapour pressure of the hot water. Water quality see chapter 9 Repeat the alignment of the coupling at operating temperature. Re-align the pump or the motor, if necessary.

6.4 Electrical connection The motor must be connected at set out in the circuit diagram in the terminal box. 6.5 Checks before switching-on Before switching on the pump unit, the following points should be checked: 1. is all pipework connected and are the unions tight? 2. is the pump including the pipework filled properly? 3. is the shut-off valve in the discharge line closed? 4. is the shut-off valve in the suction line completely opened? 5. is the motor ready for operation? 6. is the direction of rotation of the motor correct? (check by running the motor for a short time) 7. is the coupling aligned exactly? 8. has the shaft seal been installed? 9. are the supply lines, if any, to the shaft seal open? 10. in the case of oil lubrication - has the bearing housing been correctly filled with oil?


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Fluid Systems) 2012


Page 2 of 3

11. is the gland finger slightly tight?.

Chapter 6

6.7

Switching frequency

Size

Fasten gland nuts

6.6 Start-up operation For starting proceed as follows: 1. open fully the valve on the suction side 2. close the valve on the discharge side 3. switch on the motor 4. check the pressure gauges at the pressure measuring points If the pumping pressure does not increase consistently with increasing speed, switch off the motor again and vent the pump one more. 5. After reaching operating speed, regulate the operating point of the pump by adjusting the valve in the discharge line (see technical data for permissible range of operation). 6. For “running in” the packing, the gland should be tightened only slightly (even in the case of considerable leakage initially). After approx. 30 minutes tighten the gland to such an extent that it leaks only slightly. Check it several times, until leakage from the packing is about 20 to 40 drops a minute. In extreme operating conditions and high temperatures this rate may be higher.

Permissible number of starts equally spaced per hour

032125,032160, 032200, 032250, 040125, 040160, 040200, 040250, 050125, 050160, 050200, 065125, 065160, 065200, 065250, 080160, 080200, 080250,100160, 100200, 100250, 100315, 125200, 150200, 150250 040315, 050250, 050315, 065315, 080315, 080400, 100400, 125250, 125315, 125400, 150315, 150400, 150500, 200250, 200315, 200400, 200500, 250300, 250315, 250400, 250500, 300400, 300500

15

8

6.8 Special instructions During operation the following points must be observed: - control the speed and the delivery head - ensure that the pump runs without vibration - control the liquid level in the suction line and/or inflow tank - control the bearing temperature (max. temperature 100 °C) - control the pressure in the supply lines according to the following limits: External flushing: • • •

Impeller size 125 Buffer pressure = pW + 0,5 bar Rest of impeller sizes: Buffer pressure = pW + H + 2,5 bar Flow = 0,1 – 0,2 m3 /h pW = suction pressure, in bar H = differential pressure of pump, in bar

Quench

Maximum pressure = 4 bar Pumping against a closed valve in the discharge line is permitted only if a minimum output via a bypass line is guaranteed.


Heating

Maximum pressure = 4 bar, with water steam to 140 ˚C


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Fluid Systems) 2012


Page 3 of 3

seal Executions with stuffing box: For correct operation of the shaft seal a slight leakage (20 - 40 drops per minute) is essential. If the leakage is reduced too much by retightening the packing, it will be destroyed. If the pump is equipped with code 052 or code 051, the supply lines to the stuffing box have to be open before the pump is started. Executions with mechanical seal: During running-in slight leakage may occur. If the pump is equipped with an external flush, quench or heating, the flush, quench or heating supply has to be switched on before the pump is started. The mechanical seal must be allowed to cool before the next re-start.

Chapter 6

- shaft

When handling explosive, toxic, hot, crystalline or corrosive media, ensure that people and the environment are not endangered. Even if the pump has been drained using the threaded plug 90.30, residues can remain in the pump. For transport, the pump must be free from any dangerous material. In case of extended periods out of service, protect the pump against corrosion.

ATTENTION

For executions with stuffing box: If the leakage increases considerably and cannot be adjusted by retightening the gland, the packing is worn and must be replaced by a new one. For executions with mechanical seal: If the initial leakage does not disappear within 5 minutes of operation, stop the pump, dismantle the seal and check for damage of the seal faces and auxiliary sealing.

6.9 Shutting-down Before shutting down close the valve on the discharge side. After shutting down, all valves may be closed. The valves of the auxiliary pipework connections, (quench, heating, external flush, code 052, code 051), have to be closed in the last place. If there is a risk of very low ambient temperatures, remove the pump and then drain it using the threaded plug 90.30.



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Fluid Systems) 2012


Page 1 of 10

7. Maintenance, dismantling and assembly

Chapter 7

grease nipple

7.1 Requirements The pump or the pump set must have been shut down in the manner described in Chapter 6. 7.2 Use of trained staff Only appropriately trained and skilled staff should undertake the work described in this chapter.

Grease lubrication:

Only authorised personnel must undertake electrical work associated with maintenance of the pump/pump set.

Grease amount per ball bearing:

7.3

Safety measures

The bearings receive their first engreasing at the supplier plant.

bearing housing 55: (shaft end diameter at the driving side 50 mm) 30 gramme bearing housing 65: (shaft end diameter at the driving side 60 mm) 40 gramme lubrication

low activity

middle and high

intervals

•

• • •

For explosive, toxic, hot, crystalline as well as different pumping media ensure that people and the environment are not endangered. Flush the pump with clean liquid before dismantling. The working place for disassembly or assembly must be clean. Before reinstallation, the pump must be free of any dangerous material.

7.4 Maintenance and inspection The pump requires only limited maintenance. 7.4.1

Bearing with grease lubrication

The pumps with bearing brackets 25, 35 and 45 use an antifriction bearing, lubricated for service life, on the drive side and on the pump side. The pumps with bearing brackets 55 and 65 must be greased through grease nipples 63.60.


activity

for grease

n ≤ 1500 1/min

1500 < n ≤ 3000 1/min

lubrication

every 5000 hours

every 2500 hours

at the latest after 12 months

After about 10000 hours of activity or the latest after two years, the bearings have to be disassembled, washed and refilled with grease. Under extremely unfavourable circumstances (wet or dusty environment or high temperatures of the environment) the lubrication intervals have to be chosen considerably shorter. For renewing or adding lubrication grease, only lithium soap bearing grease have to be utilised (e.g. Mobilux 2, Shell Aero Grease 16, Esso Unirex N3). 7.4.2

Bearing with oil lubrication

The pump is supplied empty (no oil). Before the initial start up, pour oil into the oil inlet hole until the oil level reaches the mark on the dipstick.


 (Sterling



Page 2 of 10

Chapter 7

and/or if there is danger of contamination, the oil should be renewed about every six months.

Oil filling

Oil properties: Operating temp. of bearing up to 80ºC n>1500 n≤1500 rpm rpm

Oil drainage

Ambient temp. < 0ºC

Type of lubrication DIN 51517

CL68

CL46

CL22

Kinematic viscocity at 50ºC in mm2 /s

61.2 to 74.8

41.8 to 50.8

19.8 to 24.2

Neutralisation figure

Maximum 0.15 mg KOH/g Maximum 0.02% weight Maximum 0.1% weight

Suitable motor oil

SAE 20 and 20W

Constant level oiler

As an additional accessory, it is possible to connect a constant level oiler. In this case, the bearing support must be filled with oil through the oil inlet hole, until the oil is visible in the screw-in elbow, the oil reservoir having been removed. Subsequently the oil reservoir should be filled with oil and put into its correct position. The bearing housing will be supplied with oil from the constant level oiler with the correct amount as long as there is oil in the reservoir. See sketch of oiling system below 1. Oil reservoir 2. Screw-in elbow 3. Fill in oil here 4. Never fill with oil here, always use the oil inlet hole.

Oil change intervals If the bearings are new, change the oil after about 200 hours and subsequently annually. These intervals only apply if the bearing temperature does not exceed 50 ºC. If the bearing temperature during operation is above 50 ºC but below 80 ºC For local contact details: www.sterlingsihi.com

( as Ash Oxide ) t Ash Water content

SAE 10W

Oil quantities: Bearing Bracket

25 35 45 55 65

Oil ( litre )

0.22 0.38 0.57 1.50 2.00 ATTENTION

The lubricating oil must be extremely pure, resistant to ageing, must have good viscositytemperature behaviour, good water separating properties and corrosion protection.

7.4.3 Stuffing box If leakage makes it necessary, the packing rings should be retightened. After extended periods and frequent retightening, the packing rings gradually lose their shape and elasticity. We therefore recommend replacing the packing material at regular intervals. As a typical indication, after an operating time of approx. 2500 hours or when the gland has been retightened by approximately half the width of a packing ring. Repacking When repacking, the stuffing box rings used up,


 (Sterling



as well as, the lantern ring are to be removed carefully from the shaft seal chamber. The shaft and shaft protection sleeve must not be damaged. Otherwise perfect sealing cannot be guaranteed and the shaft sleeve would then need replacing. If the pump is installed, cut soft packing rings diagonally, bend them in a spiral shape, position them on the pump shaft and bend them carefully into a ring form. Push the packing rings as well as the lantern ring by means of the gland into the shaft seal chamber. The cut joints should be staggered by 180°. Tighten the nuts at the gland steadily until resistance is felt when rotating the pump shaft by hand. Remove the gland again and fasten the nuts slightly. If the pump is removed in order to carry out repacking, it is useful to push the packing rings in the delivered condition, that means closed over the shaft sleeve. Lantern ring

Packing rings

7.4.4 Mechanical seal The mechanical seal should have little or no visible leakage. Where there is considerable leakage, check the mechanical seal. To do this, it is necessary to dismantle the rotating part(s). 43.30

16.10

Page 3 of 10

Chapter 7

7.4.5 Drive motor The drive motor must be maintained according to the instructions of the manufacturer.

7.5

Dismantling

7.5.1 Preparation for the dismantling Proceed as follows: • disconnect power to the motor • drain the plant, at least within the pump area, i.e. between the valves on the suction- and discharge side • if necessary, disconnect any measuring probes or control devices and remove them • drain liquid from the pump by means of the drain plug • dismantle shaft seal supply lines, if any. If oil lubricated bearings are used, drain the oil from the bearing housing. • the pump casing must not be detached from the pipe union • remove motor mounting bolts and move the motor so that there is sufficient space to remove the back pull out unit. When using a spacer coupling repositioning of the motor is not necessary. • dismantle guard coupling, pump feet and coupling.

7.5.2 Replacement parts The item numbers necessary for ordering spare parts are provided in the component parts list in the Annex. 7.5.3 Dismantling the pump •

50.40


For executions with bearing housings 25,35 and 45.

21.10


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Maintenance, dismantling and assembly 10.20

40.00

Page 4 of 10 90.10

16.10 40. 05

46.10

Chapter 7 45. 10

45.80

90.23

45.70

92.01 45.20 90.21

52.40

91.40

92.01

55.40

Design with a mechanical seal

90.30

1. Mark the position of the parts in relation to each other by a coloured pencil or a scribing tool. 2. Remove the hexagonal screws 90.10. 3. Remove the back pull out unit from the volute casing 10.20. 90.13 68.10

92.20

1. Detach the distance ring 50.40. 2. Remove the rotating part of the mechanical seal 43.30. 3. Remove the Allen head screws 91.40 and detach the casing cover 16.10. 0.40

43.30

16.10

91.40

23.00 94.01

68.10 90.13

4. Remove flat gasket 40.00. 5. Remove hexagonal screws 90.13 and remove protective screen 68.10. 6. Loosen impeller nut 92.20. 7. Remove impeller 23.00 and key 94.01.

Design with quench (AX3, AXS, AXK) Detach the cover 16.50, O-ring 41.23 and lip seals 42.11. 16.10

.

.

.

Design with stuffing box

1. Remove the Allen head screws 91.40 and detach the casing cover 16.10. 1. Detach hexagonal nuts 92.01 and studs 90.21. 2. Loosen hexagonal screws 90.23 and detach packing housing 45.10 and gland 45.20 with the pressure ring 45.70. 3. Detach packing ring 46.10 and lantern ring 45.80. 4. Detach the shaft sleeve 52.40.


Design with heating (AY3, AYS, AYK) Detach the cover 16.50, O-rings 41.22 and 41.23.


 (Sterling



16.10

41.22

Page 5 of 10

5. Pull out complete shaft 21.00 with both ball bearings 32.10 and support washers for ball bearing 50.50 if any. 6. Remove ball bearings 32.10 and support washers for ball bearing 50.50.

16. 50

41.23

2.10

4. Remove the static part of the mechanical seal 43.30 and pin 56.10. • .

16.10

Chapter 7

56.10

50.50

21.00

90.30

1. Release hexagonal screws 90.11, remove V-seal 42.20 in case of grease lubrication, dismantle bearing cover 36.00 and flat gasket 40.02. Remove the lip seal 42.10 if pump is oil lubricated. 2. Release the thrower 50.70 3. Undo hexagonal screws 90.12, remove washer 93.01 and dismantle the pump foot 18.30. 4. For oil lubricated pumps, remove the oil dip stick 91.60 and remove the constant level oiler (CLO) 63.80 if any. 50.70

42.20

42.10

33.00

91.60

18.30

40.02

93.01


90.12

42.10

36.00

90.11

42.20

32.10

For executions with bearing housings 55 and 65: 90.80 10.20

Bearing design B, C or 2:

50.50

50.20

40.00

90.20

92.00 92.06

56.00

1. Mark the position of all parts with a colour pen or scribing tool in order to be able to reassemble the pump correctly. 2. Unscrew hexagonal nuts 92.00. 3. Withdraw pull out assembly from the volute casing 10.20. Withdraw the flat gasket 40.00. The wear ring 50.20, if it is necessary can be removed. 92.20 93.00 40.03

23.00

94.01

16.10

90.22

92.02

94.00

4. Loosen impeller nut 92.20 and helicoil 93.00. 5. Remove impeller 23.00, key 94.01 and flat gasket 40.03. Unscrew hexagonal nuts 92.02 and detach the casing cover 16.10. In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice.

 (Sterling



Page 6 of 10

Chapter 7

Design with a stuffing box: Bearing design S or T:

1. Remove hexagonal nuts 92.01 and studs 90.21. 2. Detach the gland 45.20, the packing ring 46.10 and the lantern ring 45.80. 3. Detach shaft sleeve 52.40 and flat gasket 40.01. 4. Detach the pin 56.00 and then, the wear ring 50.21 16.10 90.22 46.10 45.80

45.20 40.01 52.40

1. Release the thrower 50.70 2. Release hexagonal screws 90.11 and 90.14, dismantle bearing covers 36.00, 36.01 and flat gaskets 40.02. Remove the lip seals 42.10. 3. Release hexagonal screws 90.12, remove washer 93.01 and dismantle the pump foot 18.30. 4. For oil lubricated pumps, remove the plug 67.20 and the constant level oiler (CLO) 63.80 if any. 0.14 36.01 63.60

42.10 40.02

50.70 33.00

18.30 93.01

56.00

50.21

90.21

55.40

92.01

93.21

40.02

42.10 36.00 63.60 94.00 90.11

90.12

5. Pull out complete shaft with both ball bearings 32.10 and 32.11 and circlip 93.21.

Design with a mechanical seal:

1. Loosen hexagonal screws 90.24 and withdraw the mechanical seal cover 47.10 with the flat gasket 40.06, static part of the mechanical seal 43.30 with pin 56.10. 2. Remove the shaft sleeve 52.30 with the distance ring 50.40, the rotating part of the mechanical seal 43.30 and the flat gasket 40.01. 3. Loosen grub screw 56.00. 4. Detach the pin 56.00 and then, the wear ring 50.21. 40.01

52.30 50.40 43.30 16.10 90.22 40.06 47.10

32.11

7.6

21.00

93.21

32.10

Post dismantling activities

7.6.1 Hints on cleaning. • Clean all parts. • Clean the clearances and sealing surfaces with an appropriate liquid. 7.6.2 Points to be checked The following pump components, if installed, must be checked: • Mechanical seal : If the running faces are damaged or worn, replace the mechanical seal.

56.00 50.21 For local contact details: www.sterlingsihi.com

56.10 90.24 In the search to improve continuously its products, Sterling Fluid Systems reserves the right to modify its products at any time without prior notice.

 (Sterling



•

•

•

Page 7 of 10 32.10

Shaft and shaft sleeve : Check the shaft

within the stuffing box. If the shaft has worn badly and is grooved, a new shaft or shaft sleeve should be used. Clearances : The difference in diameter between impeller clearance area and casing or cover clearance area should be 0.3 mm to 0.5 mm. In the case of excessive wear in the clearance area, wear rings must be installed. Radial seal ring : If the radial seal ring is damaged, it must be replaced.

7.7

Assembly

7.7.1 Tightening torque When tightening the bolts the following torques must be used:

Thread

M8

M10

M12

M16

M20

M24

M30

50.50

25

40

90

175

300

500

700

Nm

Nm

Nm

Nm

Nm

Nm

Nm

Nm

42.20

42.10

33.00

91.60

18.30

7.7.2 Pump assembly Proceed as follows: Bearing design B, C or 2 :

For executions with bearing housings 25,35 and 45: 1. Prior to installing bearings, the support washer for ball bearing 50.50 must be replaced, (only bearing housing 25). Install ball bearings (use new ball bearings, if necessary). Before installation, the ball bearings must be heated to 80ºC in an oil bath. (Only bearing design C or 2). 2. For a pump with oil lubrication, using a tool, press lip seal 42.10 in the bearing housing 33.00. When lip seals are used, the lip should point towards the drive end.


50.50

32.10

M36

12

•

21.00

3. Insert the shaft assembly into the bearing housing from the drive end towards non-drive end. 4. Attach the bearing cover 36.00, with its radial seal inserted, if it is oil lubricated, and the flat gasket 40.02;( the lip of the radial seal ring should point towards the non drive end). Then fasten hexagonal screws 90.11. In case of grease lubrication, mount the V- seals 42.20 in the shaft and lean one against the bearing housing 33.00. Insert the key 94.00. 5. Insert the oil dip stick 91.60 and the CLO 63.80 if any. 50.70

Torque

Chapter 7

40.02

93.01

42.10

36.00

90.11

42.20

90.12

6. Fasten pump foot 18.30 and insert the thrower 50.70. •

For executions with stuffing box:

7. Position the shaft sleeve 52.40 on the shaft. 8. Insert the packing housing 45.10 with the gasket 40.05 in the casing cover 16.10. 9. Install one of the packing rings 46.10 in the packing housing, the lantern ring 45.80 and then, the remaining packing rings. 10. Fasten hexagonal screws 90.23 , fix the studs 90.21 and hexagonal nuts 92.01.


 (Sterling


94.00


40.05 45.10

90.23 45.70

Page 8 of 10

Chapter 7

52.40

16.10

46.10

45.80

92.01

45.20

42.11

16 .50

90.21 55.40 92.01

11. Finally, install the pressure ring 45.70 and the gland 45.20. Fix the washer 55.40 and the following hexagonal nuts 92.01. 12. Adjust the stuffing box as described in Chapter 7.4.3. •

41.23

Attach the cover 16.50 and casing cover 16.10. .

.

For executions with mechanical seal:

7. Insert the static part of the mechanical seal 43.30, with the pin 56.10 if any, in the casing cover 16.10. .

16.10

56.10

Design with heating (AY3, AYS, AYK) Insert the O-rings 41.22 and 41.23 in the cover 16.50. 16.10

41.22

41.23

16. 50

Design with quench (AX3, AXS, AXK) Insert the lip seals 42.11 and the O-ring 41.23 in the cover 16.50. Attach the cover 16.50 and casing cover 16.10.



 (Sterling



Page 9 of 10

16.50

Chapter 7

Bearing design S or T :

For executions with bearing housings 55 and 65: Carry out the following steps: 1. Fit the shaft unit. 2. If the shaft is to be fitted with new bearings, they should be heated in an oil bath to a temperature of 80º C before assembling. First, install the ball bearing 32.11, then the circlip 93.21 and finally ball bearing 32.10. Make sure that the bearing is pressed home against the shoulders of the shaft. 3. If the lip seals have been removed, they must be exchanged. The lip seals should be fitted into the bearing cover with a bush, pressing on the external ring of the oil seals. The lips should point towards the bearing after installation. Pay attention to the bearing covers to avoid fitting them incorrectly. •

8. Attach the bearing housing 33.00 and the casing cover 16.10. 9. Insert the rotating part of the mechanical seal 43.30 and the distance ring 50.40. 10. Insert the key 94.01, impeller 23.00 and tighten the impeller nut 92.20. Attach the protective screens 68.10 with the hexagonal screws 90.13. 90.13 68.10

9 2. 20

2 3. 00

94.01 50.40

43.30

16.10

33.00

2.11

21.00

93.21

32.10

91.40

68.10 90.13

11. Insert the gasket 40.00 between the pull out unit and volute casing. Tighten hexagonal screws 90.10. .

.

90.30


.

4. Install the bearing cover of the pump side with the flat gasket 40.02 and the grease nipple 63.60 if any. 5. When fitting the rotating unit in the bearing housing 33.00, the circlip 93.21 must be inserted in the groove in the bearing housing. 6. Insert the bearing cover 36.01 with the flat gasket 40.02 and the grease nipple 63.60 if any. 7. Mount the plug 67.20, the oil level sight glass 64.20 and the constant level oiler ( CLO ) 63.80, where oil lubrication is used. 8. Fasten pump foot 18.30 and insert the thrower 50.70.


 (Sterling


Maintenance, dismantling and assembly 0.14 36.01 63.60

42.10 40.02

50.70 33.00

93.21

18.30 93.01

•

40.02

42.10 36.00 63.60 94.00 90.11

40.01

Chapter 7 52.30 50.40 43.30 16.10 90.22 40.06 47.10

90.12

For executions with stuffing box:

9. Mount the shaft sleeve 52.40 on to the shaft unit. 10. In the casing cover, insert one of the packing rings 46.10, the lantern ring 45.80, the remaining packing rings and finally the gland 45.20. 11. Fix the studs 90.21, the washers 55.40 and the nuts 92.01. Adjust the stuffing box as described in Chapter 7.4.3. 12. Mount the wear rings 50.21 with grub screws 56.00. 16.10 90.22 46.10 45.80

56.00

Page 10 of 10

50.21

90.21

55.40


56.10 90.24

12. Join the casing cover 16.10, the bearing housing 33.00 and fasten hexagonal nuts 92.02. 92.20 93.00 40.03

23.00

94.01

16.10

90.22

92.02

45.20 40.01 52.40

92.01

For executions with mechanical seal: 9. Install the mechanical seal cover 47.10 with the mechanical seal stationary part 43.30 and its pin 56.10 if any, then place the flat gasket 40.06 and hexagonal screws 90.24. 10. Insert the shaft sleeve 52.30 with the rotating part of the mechanical seal 43.30 and the distance ring 50.40. 11. In the casing cover 16.10, insert the wear ring 50.21 with grub screws 56.00 and the studs 90.22. •

56.00 50.21

Finally: 13. Insert the flat gasket 40.01, keys 94.01, impeller 23.00 and flat gasket 40.03. 14. Tighten the impeller nut 92.20 with the helicoil 93.00. 15. Insert the wear ring 50.20 with grub screws 56.00 and then, insert studs 90.20. 16. Insert flat gasket 40.00 between the unit and the volute casing 10.20. Tighten hexagonal nuts 92.00.


 (Sterling


Troubleshooting

8.

Page 1 of 1

Chapter 8

Help in case of trouble

8.1 Use of trained staff Trouble shooting must be undertaken only by appropriately trained personnel. 8.2

Symptoms, causes and remedies

Symptom Output too low

Cause - Back pressure too high. - Pump or pipework, resp., not completely filled. - Suction lift too high or positive suction head too low. - Sealing gap too large because of wear. - Wrong direction of rotation. - Casing or suction line leaks.

Pump does not prime or only intermittently

- Pump casing, shaft seal, foot valve or suction line leaks. - Suction lift too high or positive suction head too low.

Pump leaks

- Loose or jammed parts in the pump. - Casing bolts not correctly tightened. - Mechanical seal leaks. - Stuffing box leaks.

Temperature of the pump increases

- Seals defective. - Pump or pipework not completely filled. - Suction lift too high or positive suction head too low.

Pump runs noisily

- Stuffing box overtightened. - Pump is run against closed valve. - Pump or pipework not completely filled. - Suction lift too high or positive suction head too low.

Motor protection switch switches off.

- Pump is not properly levelled or is distorted. - Foreign material in the pump. - Pump is not properly levelled or is distorted. - Operating conditions outside of performance range of pump. - Loose or jammed parts in the pump.



Remedy Check the plant for contamination. Regulate anew the operating point. Vent and fill the pump as well as the suction or inflow line. Check the liquid levels, open the shut-off valves on the suction side. Clean the filters and dirt traps installed on the suction side. Replace worn parts. Change the motor connection. Replace the casing seal. Check the flange connections. Replace the casing seal. Check the shaft seal. Check the flange connections.. Check the liquid levels, open the shut-off valves on the suction side. Clean the filters and dirt traps installed on the suction side. Open and clean the pump. Check the tightening torque of the casing bolts. Check the seal surfaces and elastomere of the mechanical seal. In case of damages exchange mechanical seal. Check the condition of the stuffing box. If possible, retighten the stuffing box, if not, replace it. Replace the seals. Vent and fill the pump as well as the suction line or inflow line. Check the liquid levels, open the shut-off valves on the suction side. Clean the filters and dirt traps installed on the suction side. Loosen the stuffing box. Open the shut-off valve on discharge side. Vent and fill the pump as well as the suction line or inflow line. Check the liquid levels, open the shut-off valves on the suction side. Clean the filters and dirt traps installed on the suction side. Check the pump installation Dismantle and clean the pump. Check the pump installation. Refer to pump operating conditions stated in technical data. Open and clean the pump.

 (Sterling


Technical data

Page 1 of 3

9. Technical Data For technical information about the pump or pump set, which is not described in this chapter, see the specific data sheet. Note that data relating to a specific order may conflict with information provided here. In any such case, the order specific information will override data provided in the general technical documentation. Pressure component operating limits: Material 4B

Temperature -40ºC to 120ºC

Pressure Sizes 16 bar All

120ºC to 170ºC 14 bar 16 bar -20ºC to 120ºC 10 bar 0B/0C/0E/1B 14 bar bar 120ºC to 170ºC 14 9 bar 8 bar

All 032125 to 150400 200250 to 300500 150500 032125 to 080315 80400 to 300500 150500

Shaft sealing operating limits: Shaft sealing execution

Temperature

041, 052 B27 BJ3, BJS, BJJ AF3, AX3, AY3, A93, AFS,AXS,AYS,A9S, AFK,AXK,AYK,A9K M1S C23, C2S, C2J N1S, NFS

range -40°C to + 110°C -20°C to + 140°C -20°C to + 120°C -30°C to +150°C -20°C to + 180°C -20°C to + 180°C -40ºC to + 150ºC -50ºC to + 180ºC

Chapter 9

Flanges: Material design 4B: Complies with DIN 2543 PN16. Material design 0B, 0C, 0E, 1B: DIN 2533 PN16 / 2532 PN101) Flanges drilled according to ANSI 150 can be supplied. 1) 200250 Direction of rotation: Clockwise seen from the drive end of the pump. Materials of construction, and of shaft seals: See Chapter 2.4. Vibrations: ZLND range pumps comply with VDI 2056 and ISO 5199 Class K for pumps with a driving power of up to 15 kW and Class M with a driving power of more than 15 kW Noise levels: The noise levels of the pump comply with the Directive 001/30 - 1992 of the EUROPUMP Commission. The following table provides approximate values:

LWA (dB)

ATTENTION •

•

All indicated operating limits are not valid for all liquids which can be pumped. See technical data or delivery note. Shaft sealing execution B27 only configuration valid for water up to 140°C, water quality has to be in accordance to VdTÜV 1466; additional requirement: O2 (oxygene) < 0,02 mg/l.

P (kW)

pump without motor

Note that additional noise can be generated by: • the driver. • a possible misalignment of the coupling. • pipework (note: the larger the pipe diameter, the lower the pipe noise).

Flange locations: Axial suction flange, discharge flange radially upwards. For local contact details: www.sterlingsihi.com


 (Sterling


Technical data

Page 2 of 3

Chapter 9

Permissible branch forces and moments:

Values according to ISO/DIN 5199 – Class II (1997) – Annex B, Family Nº 2 for mounting on sheet metal baseplates and frames without grouting for pumping temperatures up to 110 ºC and up to 120 ºC for grouted baseplates / frames.

•

s i x A z h c n a r b p o T

s i x A x h c n a r b d n E

Material execution 0B / 0C / 0E: DN flanges 32 40 50 65 80 100 125 150 200 250 300 50 65 80 100 125 150 200 250 300 350

Fy (N) 400 400 540 820 820 1080 16 20 16 20 2160 2700 3220 600 900 900 1200 18 00 18 00 2400 2980 3580 4180

Fz (N) 500 500 660 1000 1000 1340 2000 2000 2680 3340 4000 540 8 20 8 20 1080 1620 1620 2160 2700 3220 3760

Fx (N) 440 440 600 900 900 1200 1800 1800 2400 2980 3580 660 1000 1000 1340 2000 2000 2680 3340 4000 4660

∑F

(N) 780 780 1040 1580 1580 2100 3140 3140 4180 5220 6260 1040 1580 1580 2100 3140 3140 4180 5220 6260 7300

My (Nm) 360 360 400 460 460 500 700 700 92 0 1260 1720 400 460 460 500 700 700 92 0 1260 1720 2200

Mz (Nm) 420 420 460 520 520 580 820 820 1060 1460 1980 460 520 520 580 820 820 1060 1460 1980 2540

Mx (Nm) 520 520 560 640 640 700 1000 1000 1300 1780 2420 560 640 640 700 1000 1000 1300 1780 2420 3100

∑M (Nm) 760 760 8 20 940 940 1040 1460 1460 1920 2620 3560 8 20 940 940 1040 1460 1460 1920 2620 3560 4560

Material execution 1B: Multiply by ƒ = 1,296; which is the relationship of E – modules between GGG-40.3 and GG-25 • Material execution 4B: Multiply by ƒ = 1,536; which is the relationship of E – modules between 1.4408 and GG-25. •



 (Sterling


Techical Data

Page 3 of 3

Chapter 9

Maximum permissible speeds at 50 Hz: Size 032125 032160 032200 040125 040160 040200 050125 050160 050200 065125 065160 0652001) 0801601) 080200 100160 100200

Max. speed rpm 3600

Size 032250 040250 050250 065250 080250 1002502) 1252002)

Max. speed rpm 3000

Max. speed rpm

Size 4) 040315 0503154) 0653154) 0803154) 080400 100315 100400 125250 125315 125400 150200 1502503) 150315 150400 200250

For material specification 4B:the max. speed changes to : 1) 3000 rpm 4) In material specification 0E and 4B max. speed 3000 rpm

2)

1800 rpm

1800

Size 150500 200315 200400 200500 250300 250315 250400 250500 300400 300500

Max speed rpm 1500

3)

1500 rpm

Operating range:

(Continuous operation) Sizes

032125 to 080400 0,3 Qopt < Q < 1,1 Qopt

100315 to100400 125315 to 125400 150250 to 150500 100160 to 100250

0,5 Qopt < Q < 1,1 Qopt

125200 to 125250 150200 200500 to 300500

0,7 Qopt < Q < 1,2 Qopt

200250 to 200400

This operating range is applicable if waterlike liquids are pumped. If liquids having distinctly different physical properties are handled, it may be necessary to narrow the permissible operating range. See the specific performance curve for more details.



 (Sterling



Page 1 of 15

10.


10.1

Connections

Connections for bearing brackets 25, 35 and 45.

um1 : Pressure gauge. Only available on request um2 : Pressure gauge. Only available on request ue : Drainage ueo : Oil drainage ufo : Oil filling uAL : Drainage for leakage. Threaded hole only available on request us : Sensor 9A : Quench liquid outlet (tandem arrangement) 9E : Quench liquid inlet (tandem arrangement) Size 1)

032125 032160 032200 032250 0401251) 040160 040200 040250 040315 0501251) 050160 050200 050250 050315 0651251) 065160 065200 065250 065315 080160 080200 080250 080315 080400 100160 100200 100250 100315 100400 125200 125250 125315 125400 150200 150250 150315 150400 200250

um1

um2 ue

ueo

ufo

uAL us

Chapter 10

1)

Only for Impellers ∅125

uk1 : Quench Inlet uk2 : Heating Inlet uk3 : 051 Inlet (Stuffing box) uk4 : 052 External sealing (Stuffing box) uk5 : External Flushing uk6 : Quench Outlet uk7 : Heating Outlet uk8 : 051 Outlet (Stuffing box) 11A : Sealing liquid outlet (back to back arrangement) 11E : Sealing liquid inlet (back to back arrangement)

uk1 uk2 uk3 uk4

uk5 uk6 uk7 uk8 9A

9E

11A

11E

G 1/8

G 1/4

G 1/4

G 1/8

G 1/4

G 1/4 ∅15.65

∅13

M8

G 1/4

G 1/4 G 3/8

G 1/8 G 1/4 G 1/8 G 1/4 G 1/8 G 1/4

Drawings are indicative only. For local contact details: www.sterlingsihi.com


© (Sterling Fluid Systems BV) 2012


Page 2 of 15

Chapter 10

Connections for bearing brackets 55 and 65

um1 um2 ue ueo ufo uAL

: Self sealing connection : Pressure/vacuum gauge. Only available on request : Drainage : Oil drainage : Oil filling : Drainage for leakage

Size 150500 200315 200400 200500 250300 250315 250400 250500 300400 300500

um1

G1/4

um2 ue

G1/2


ueo

G1/2

G1/4

ufo

∅20

uAL

G1/2

um3 : uk3 : uk4 : uk8 : umo : uk9 :

um3

G1/2

uk3

G1/4

uk4

G1/4


Pressure gauge connection 051 Inlet (Stuffing box) 052 External sealing (Stuffing box) 051 Outlet (Stuffing box) Oil level control 041 inlet (Stuffing box)

uk8

umo

G1/4

G3/4

uk9

G1/4



10.2

Page 3 of 15

Chapter 10

Table of Dimensions

All dimensions in mm Size

BB

032125 032160 032200 0322501) 040125 040160 040200 040250 0403151 050125 050160 050200 050250 0503151 065125 065160 065200 065250 065315 080160 080200 080250 080315 0804001) 1001601 100200 100250 100315 100400 1252001 125250 125315 125400 1502001) 1502501 150315 150400 2002501

25 25 25 25 25 25 25 25 35 25 25 25 25 35 25 25 25 35 35 25 35 35 35 45 35 35 35 35 45 35 35 45 45 35 35 45 45 45

DN2 32 32 32 32 40 40 40 40 40 50 50 50 50 50 65 65 65 65 65 80 80 80 80 80 100 100 100 100 100 125 125 125 125 150 150 150 150 200

Pump dimensions DN1 a f h1 50 80 360 112 50 80 360 132 50 80 360 160 50 100 360 180 65 80 360 112 65 80 360 132 65 100 360 160 65 100 360 180 65 125 470 225 65 100 360 132 65 100 360 160 65 100 360 160 65 100 360 180 65 125 470 225 80 100 360 160 80 100 360 160 80 100 360 180 80 100 470 200 80 125 470 225 100 125 360 180 100 125 470 180 100 125 470 200 100 125 470 250 125 125 530 280 125 125 470 200 125 125 470 200 125 140 470 225 125 140 470 250 125 140 530 280 150 140 470 250 150 140 470 250 150 140 530 280 150 140 530 315 200 160 470 280 200 160 470 280 200 160 530 280 200 160 530 315 200 160 590 280

h2 140 160 180 225 140 160 180 225 250 160 180 200 225 280 180 200 225 250 280 225 250 280 315 355 280 280 280 315 355 315 355 355 400 400 400 400 450 400

b 50 50 50 65 50 50 50 65 65 50 50 50 65 65 65 65 65 80 80 65 65 80 80 80 80 80 80 80 100 80 80 100 100 100 100 100 100 100

c 15 15 15 15 15 15 15 15 18 15 15 15 15 17 15 15 15 15 18 15 15 18 18 18 18 18 18 18 18 18 18 18 18 20 20 18 18 22

m1 100 100 100 125 100 100 100 125 125 100 100 100 125 125 125 125 125 160 160 125 125 160 160 160 160 160 160 160 200 160 160 200 200 200 200 200 200 200

Foot dimensions m2 n1 n2 70 190 140 70 240 190 70 240 190 95 320 250 70 210 160 70 240 190 70 265 212 95 320 250 95 345 280 70 240 190 70 265 212 70 265 212 95 320 250 95 345 280 95 280 212 95 280 212 95 320 250 120 360 280 120 400 315 95 320 250 95 345 280 120 400 315 120 400 315 120 435 355 120 360 280 120 360 280 120 400 315 120 400 315 150 500 400 120 400 315 120 400 315 150 500 400 150 500 400 150 550 450 150 500 400 150 550 450 150 550 450 150 500 400

s1* M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M16 M16 M12 M12 M16 M16 M16 M16 M16 M16 M16 M20 M16 M16 M20 M20 M20 M20 M20 M20 M20

s2* M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12 M12

w 260 260 260 260 260 260 260 260 340 260 260 260 260 340 260 260 260 340 340 260 340 340 340 370 340 340 340 340 370 340 340 370 370 3 40 3 40 370 370 430

x 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 140 180

d1 24 24 24 24 24 24 24 24 32 24 24 24 24 32 24 24 24 32 32 24 32 32 32 42 32 32 32 32 42 32 32 42 42 32 32 42 42 42

End shaft l 50 50 50 50 50 50 50 50 80 50 50 50 50 80 50 50 50 80 80 50 80 80 80 110 80 80 80 80 110 80 80 110 110 80 80 110 110 110

t 27 27 27 27 27 27 27 27 35 27 27 27 27 35 27 27 27 35 35 27 35 35 35 45 35 35 35 35 45 35 35 45 45 35 35 45 45 45

1)

Transnorm pump sizes, not included in DIN 24255 / EN 733. Flanges drilled according to ANSI 150 on request. *Holes for bolts of the dimensions indicated. For local contact details: www.sterlingsihi.com



u 8 8 8 8 8 8 8 8 10 8 8 8 8 10 8 8 8 10 10 8 10 10 10 12 10 10 10 10 12 10 10 12 12 10 10 12 12 12


Page 4 of 15

Chapter 10

Table of Dimensions

All dimensions in mm Size

BB

1505001 2003151 2004001) 2005001 2503001) 2503151) 2504001 2505001) 3004001 3005001)

55 55 55 55 55 55 65 65 65 65

DN2 150 200 200 200 250 250 250 250 300 300

Pump dimensions DN1 a f h1 200 180 670 400 250 200 670 355 250 180 670 355 250 200 670 425 300 305 655 425 300 250 670 375 300 250 720 400 300 250 720 450 350 300 720 425 350 300 720 480

h2 500 450 500 560 550 560 600 670 670 670

b 100 100 100 100 120 120 120 120 120 140

c 22 22 22 22 28 28 29 32 30 32

m1 200 200 200 200 240 240 240 240 250 250

Foot dimensions m2 n1 n2 150 640 540 150 550 450 150 550 450 150 660 560 190 700 600 190 620 520 190 700 600 190 750 650 190 760 660 190 840 720

s1* M20 M20 M20 M20 M20 M20 M20 M20 M24 M24

s2* M16 M16 M16 M16 M16 M16 M16 M16 M16 M16

w 489 489 489 489 474 489 508 508 508 508

x 180 180 180 180 180 180 180 180 180 180

d1 50 50 50 50 50 50 60 602) 60 602)

End shaft l t 115 53.5 115 53.5 115 53.5 115 53.5 115 53.5 115 53.5 145 64 145 64 145 64 145 64

u 14 14 14 14 14 14 18 18 18 18

1)

Transnorm pump sizes, not included in DIN 24255 / EN 733. Flanges drilled according to ANSI 150 on request. For these sizes the clearance corresponds to M6. 3) Discharge flange 12 x threaded drillings/M20 (only for PN 16 flanges). *Holes for bolts of the dimensions indicated. 2)

Flange connections to DIN 2501 PN 16

DIN 2501 PN 10

DN2 /DN1

32

40

50

65

80

100

125

150

200

250

D k d2 x number

140 100 18x4

150 110 18x4

165 125 18x4

185 145 18x4

200 160 18x8

220 180 18x8

250 210 18x8

285 240 22x8

340 295 22x12

405 355 26x12


300

400

460 520 580 410 470 525 26x12 26x16 30x16


350

100

125

150

200

220 180 18x8

250 210 18x8

285 240 22x8

340 295 22x8



10.3

Page 5 of 15

Chapter 10

Parts list

When ordering spare parts give the following information: position number, the complete pump designation and the serial number, which can be found on the nameplate fixed to the pump. Pos. Nr.

Description

Pos. Nr.

10.20 Volute casing 10.200 Casing plug 10.201 Hexagonal screw 10.202* O-ring 16.10 Casing cover 16.50 Cover 18.30 Pump foot 21.00* Shaft 23.00* Impeller 32.10* Ball bearing 32.11* Ball bearing 33.00 Bearing housing 36.00 Bearing cover 36.01 Bearing cover 40.00* Flat gasket 40.01* Flat gasket 40.02* Flat gasket 40.03* Flat gasket 40.05* Flat gasket 40.06* Flat gasket 40.07* Flat gasket 40.08* Flat gasket 41.10* Flat gasket 41.11* Flat gasket 41.22* O-ring 41.23* O-ring 41.24* O-ring 42.10* Lip seal 42.11* Lip seal 42.20* V – seal 43.30* Mechanical seal 43.31* Mechanical seal 43.32* Mechanical seal 45.10 Packing housing 45.20 Gland 45.70* Pressure ring 45.80* Lantern ring 46.10* Packing ring 47.10* Mechanical seal cover 47.11* Mechanical seal cover 50.20* Wear ring 50.21* Wear ring 50.40* Distance ring 50.50* Support washer for ball bearing 50.70* Thrower 52.30* Shaft sleeve 52.40* Shaft sleeve 55.40 Washer 56.00 Grub screw


56.10 63.60 63.80 64.20 67.20 68.10 70.30 73.10 73.11 90.10 90.11 90.12 90.13 90.14 90.20 90.21 90.22 90.23 90.24 90.25 90.30 90.31 90.32 90.33 90.34 90.41 90.80 91.40 91.41. 91.60 92.00 92.01 92.02 92.06 92.20* 93.00* 93.01 93.21* 94.00* 94.01* 94.02* 99.99

Description

Pin Grease nipple Constant level oiler Oil level sight glass Plug Protection screen Pipe Compression nut Screw connection Hexagonal screw Hexagonal screw Hexagonal screw Hexagonal screw Hexagonal screw Stud Stud Stud Hexagonal screw Hexagonal screw Stud Threaded plug Threaded plug Threaded plug Threaded plug Threaded plug Grub screw Hexagonal screw Allen head screw Allen head screw Dip stick Hexagonal nut Hexagonal nut Hexagonal nut Hexagonal nut Impeller nut Helicoil Washer Circlip Key Key Key Plastic plug

* Recommended spare parts




Page 6 of 15

Chapter 10

ZLND 032125 to 200250 AB MECHANICAL SEALS, 0B 2 10.20

23.00

50.40

40.00

43.30 16.10

68.10 90.13

32.10

50.50

33.00

36.00

42.20

21.00

Mechanical seal code B271) /BJ3/BJS/BJJ

92.20

94.01

90.30

90.10

91.40

Mechanical Seal code AF3/AFS/AFK 10.20 23.00 50.40 43.30 40.00 16.10 56.10

Mechanical Seal code AX3/AXS/AXK 10.20 23.00 50.40 43.30 40.00 16.10 99.99 41.23 56.10 42.11 16.50

50.70

18.30

93.01

90.12

90.11

94.00

Mechanical Seal code C23/C2S/C2J 10. 20 23. 00 50. 40 43.30 40. 00 16. 10

Mechanical Seal code AY3/AYS/AYK 10.20 23.00 50.40 43.30 40.00 16.10 99.99 41.23 41.22 56.10 16.50

Mechanical Seal code A93/A9S/A9K 10.20 23.00 50.40 43.30 40.00 16.10 99.99 56.10

1)

Not available for size 080400, 100400, 125315, 125400, 150315, 150400, 200250.





Page 7 of 15

Chapter 10

ZLND 032125 to 200250 AC/A2 MECHANICAL SEALS, 0B 2 10.20

23.00

50.40

68.10 40.00 16.10 90.13

43.30

42.10

32.10

50.50

63.80

91.60

40.02

36.00 21.00

Mechanical seal code B271) /BJ3/BJS/BJJ

92.20

94.01

90.30

90.10

91.40

50.70

Mechanical Seal code AF3/AFS/AFK 10. 20 23. 00 50. 40 43. 30 40. 00 16. 10 56. 10

63.81 90.31

18.30

93.01 90.12 90.11 94.00

Mechanical Seal code C23/C2S/C2J 10.20 23.00 50.40 43.30 40.00 16.10

Mechanical Seal code AX3/AXS/AXK 10.20 23.00 50.40 43.30 40.00 16.10 99.99 41.23 56.10 42.11 16.50

10.20 23.00 50.40

33.00

Mechanical Seal code AY3/AYS/AYK 10.20 23.00 50.40 43.30 40.00 16.10 99.99 41.23 41.22 56.10 16.50

Mechanical Seal code A93/A9S/A9K 43.30 40.00 16.10 99.99 56.10

1)

Not available for size 080400, 100400, 125315, 125400, 150315, 150400, 200250.





Page 8 of 15

Chapter 10

ZLND 032125 to 200250 AB STUFFING BOX, 0B 2 10.20

23.00

68.10 40.00 16.10 40.05 90.23 45.70 45.20 90.13

52.40

32.10 50.50

33.00 36.00

42.20

21.00

Stuffing box code 041

2.20 94.01 90.30 45.10 46.10 45.80 92.01 90.10 91.40 55.40 90.21

50.70 18.30

93.01 90.12 90.11 94.00

Stuffing box code 052 10.20

52.40 23.00


45.80 45.10

40.00 16.10

99.99 40.05

92.01 45.70 55.40 46.10 45.20

90.21




Page 9 of 15

Chapter 10

ZLND 032125 to 200250 AC/A2 STUFFING BOX, 0B 2 . 10.20 23.00

52.40

40.00

16.10

40.05

. 45.70

68.10 90.13

. 42.10

. 50.50

91.60 40.02

36.00 21.00


92.20 94.01 45.10 46.10 45.80 92.01 91.40 90.21 33.00 63.81 90.31 18.30 93.01 90.12 90.11 94.00 90.30 90.10 55.40 50.70

Stuffing box code 052 10.20

52.40 23.00


45.80 45.10

40.00 99.99 16.10

92.01 45.70 55.40

40.05 46.10 45.20


90.21



Page 10 of 15

Chapter 10

ZLND 200315 to 300500 and 150500 AS MECHANICAL SEALS, 0B 2 4 . 10.20 50.40

.

16.10

4 .

90.80 90.34 40.00 92.06

73.10 41.10

. . 90.22 73.11 70.30 92.02 41.11 47.10 36.01

93.21

.

63.60

.

21.00

4.

Mechanical seal code BJ3/BJS/BJJ

92.20 94.01 50.20 93.00 56.00

40.01

90.30

50.21 56.00

52.30

90.20 92.00

50.40 23.00 40.00 73.11 47.10 56.10 10.20 43.30 16.10 40.06 41.11 90.24 52.30

www.sterlingsihi.com

90.24

90.14 18.30 90.12 90.11 32.11 93.01 42.10 40.02

Shaft seal Code C23/C2S/C2J

Shaft seal Code AF3/AFS/AFK

For local contact details:

40.06

50.40 23.00 40.00 52.30 73.11 47.10 10.20 43.30 16.10 40.06 41.11 90.24




Page 11 of 15

Chapter 10

ZLND 200315 to 300500 and 150500 AT/A2 MECHANICAL SEALS, 0B 2

10.20

40.03

50.40

23.00 73.11 90.80 16.10 41.11 90.34 40.00 92.06

73.10 41.10

90.22 70.30 92.02

50.70 67.20 93.21 90.11 94.00 47.10 90.14 32.11 33.00 32.10 21.00

Mechanical seal code BJ3/BJS/BJJ

92.20 94.01 50.20 93.00 56.00

40.01

90.30

50.21 56.00

52.30

43.30

90.20 92.00

40.06

90.24 36.01

50.40 23.00 40.00 73.11 47.10 56.10 43.30 16.10 40.06 41.11 90.24 52.30


64.20 18.30 90.12 36.00 63.80 93.01 40.02 42.10

Shaft seal Code C23/C2S/C2J

Shaft seal Code AF3/AFS/AFK 10.20

90.31

10.20

50.40 23.00 40.00 52.30 73.11 47.10 43.30 16.10 40.06 41.11 90.24




Page 12 of 15

Chapter 10

ZLND 200315 to 300500 and 150500 AS STUFFING BOX, 0B 2

10.20

40.03 23.00 90.80 73.11 45.80 16.10 41.11 90.34 40.00 92.06

73.10 41.10

90.22 70.30 92.02

45.20

50.70 33.00 32.10 36.00 94.00 36.01 93.21 63.60 21.00


92.20 93.00

94.01 50.20 56.00

40.01

90.30

50.21 56.00

46.10 90.20 52.40 92.00

55.40 90.21 92.01

90.14 18.30 90.12 90.11 32.11 93.01 40.02 42.10

Shaft seal Code 052 45.80 23.00 40.00 10.20 46.10 16.10 90.33


45.20

55.40 90.21 92.01


52.40



Page 13 of 15

Chapter 10

ZLND 200315 to 300500 and 150500 AT/A2 STUFFING BOX, 0B 2

10.20

40.03

45.80

23.00 50.70 67.20 93.21 90.11 94.0 73.11 90.80 73.10 90.22 16.10 41.11 90.34 40.00 92.06 41.10 70.30 92.02 45.20 90.14 32.11 33.00 32.10 21.00


92.20 94.01 50.20 93.00 56.00

40.01

90.30

50.21 56.00

46.10 90.20 52.40 92.00

55.40 90.21 92.01

36.01

90.31

64.20 18.30 90.12 36.00 63.80 93.01 40.02 42.10

Shaft seal Code 052 45.80 23.00 40.00 10.20 46.10 16.10 90.33


55.40 90.21 45.20 92.01


52.40



Page 14 of 15

Chapter 10

ZLND 032125 to 200250 AB MECHANICAL SEALS 0B 4 Shaft seal M1S

Shaft seal N1S





Page 15 of 15

Chapter 10

ZLND 032125 to 200250 AB DOUBLE MECHANICAL SEAL 0B 4 Shaft seal NFS





Multiple mechanical seal in tandem arrangement 1 Description The shaft is sealed by two balanced single-acting reversible mechanical seals acc. to EN 12750 (old DIN 24960) in tandem arrangement, (see general drawing). 2 Seal size / materials mechanical seal inboard, 43.31 Bearing bracket seal material size 25 KU024S Q12Q1VGG GNZ 35 KU032S Q12Q1VGG GNZ 45 KU045S Q12Q1VGG GNZ

mechanical seal outboard, 43.32 seal material size KU024S Q12Q1VGG GNZ KU032S Q12Q1VGG GNZ KU045S Q12Q1VGG GNZ

3 Disassembly 1. Dismantling the pump as described in the operating instructions, section 7.5.3. 2. Unscrew impeller nut 92.20 and remove impeller. 3. Detach the distance ring 50.40. 4. Remove the rotating part of the mechanical seal 43.31 (inboard). 5. Remove the Allen head screws 91.40 and 91.41, detach the casing cover 16.10. 6. Push mechanical seal cover 47.10 towards bearing bracket. 7. Detach the casing cover 16.10. 8. Remove the rotating part of the mechanical seal 43.32 (outboard). 9. Remove mechanical seal cover 47.10 from the shaft.

4 Assembly Reassembly the pump as described in the operating instructions, section 7.7.


Page 1 of 2

Annex I

The following rules should be observed when mounting the mechanical seal: Extreme care and cleanliness. Take care not to damage the seal faces and the Orings. Clean the shaft and the seat ring seat in the discharge casing and carefully remove any deposits. 1. Insert the static part of the mechanical seal 43.32, with the pin 56.10 , in the mechanical seal cover, insert gasket 40.08. 2. Push mechanical seal cover towards bearing bracket 3. The rotating part of the mechanical seal 43.32 must be fixed to the shaft. 4. Insert the O-ring 41.24 in the mechanical seal cover 47.11. 5. Insert the mechanical seal cover 47.11 in the casing cover 16.10. 6. Insert the static part of the mechanical seal 43.31, with the pin 56.10 , in the mechanical seal cover. 7. Mount casing cover 16.10 on the bearing bracket, fasten Allen head screws 91.40. 8. Mount mechanical seal cover 47.10 in the casing cover, fasten Allen head screws 91.41. 9. Insert rotating part of the mechanical seal 43.31 and the distance ring 50.40 10 Proceed with pump assembly as described in the operating instructions, section 7.7.2.

5 Liquid quench If the pump is equipped with a double-acting mechanical seal in tandem arrangement, the shaft seal chamber needs to be flushed with liquid from an external source. The flushing liquid must be free of solid particles, it should not crystallise and must it be compatible with liquid handled. This system must also remove the heat generated al the mechanical seal.


 (Sterling



Page 2 of 2

Annex I

6 General drawing and list of components

Fig. 6-1 Mechanical seal in tandem arrangement

Part nº 16.10 40.08 41.24 43.31 43.32 47.10 47.11 50.40 56.10 91.40 91.41

Part designation Casing cover Flat gasket O-ring Mechanical seal (inboard) Mechanical seal (outboard) Mechanical seal cover Mechanical seal cover Distance ring Pin Allen head screw Allen head screw

9A

Quench liquid outlet

G 1/4

9E

Quench liquid inlet

G 1/4



 (Sterling



Multiple mechanical seal in tandem arrangement 1 Description The shaft is sealed by two unbalanced single-acting reversible mechanical seals acc. to EN 12750 (old DIN 24960) in tandem arrangement, (see general drawing). 2 Seal size / materials mechanical seal inboard, 43.31 Bearing bracket seal material size 25 KU024S Q1Q1VGG M7N 35 KU032S Q1Q1VGG M7N 45 KU045S Q1Q1VGG M7N

mechanical seal outboard, 43.32 seal material size KU024S Q1Q1VGG M7N KU032S Q1Q1VGG M7N KU045S Q1Q1VGG M7N

3 Disassembly 1. Dismantling the pump as described in the operating instructions, section 7.5.3. 2. Unscrew impeller nut 92.20 and remove impeller. 3. Detach the distance ring 50.40. 4. Remove the rotating part of the mechanical seal 43.31 (inboard). 5. Remove the Allen head screws 91.40 and 91.41, detach the casing cover 16.10. 6. Push mechanical seal cover 47.10 towards bearing bracket. 7. Detach the casing cover 16.10. 8. Remove the rotating part of the mechanical seal 43.32 (outboard). 9. Remove mechanical seal cover 47.10 from the shaft.

4 Assembly Reassembly the pump as described in the operating instructions, section 7.7.


Page 1 of 4

Annex II

The following rules should be observed when mounting the mechanical seal: Extreme care and cleanliness. Take care not to damage the seal faces and the Orings. Clean the shaft and the seat ring seat in the discharge casing and carefully remove any deposits. 1. Insert the static part of the mechanical seal 43.32, with the pin 56.10 , in the mechanical seal cover, insert gasket 40.08. 2. Push mechanical seal cover towards bearing bracket 3. The rotating part of the mechanical seal 43.32 must be fixed to the shaft. 4. Insert the O-ring 41.24 in the mechanical seal cover 47.11. 5. Insert the mechanical seal cover 47.11 in the casing cover 16.10. 6. Insert the static part of the mechanical seal 43.31, with the pin 56.10 , in the mechanical seal cover. 7. Mount casing cover 16.10 on the bearing bracket, fasten Allen head screws 91.40. 8. Mount mechanical seal cover 47.10 in the casing cover, fasten Allen head screws 91.41. 9. Insert rotating part of the mechanical seal 43.31 and the distance ring 50.40 10 Proceed with pump assembly as described in the operating instructions, section 7.7.2.

5 Liquid quench If the pump is equipped with a double-acting mechanical seal in tandem arrangement, the shaft seal chamber needs to be flushed with liquid from an external source. The flushing liquid must be free of solid particles, it should not crystallise and must it be compatible with liquid handled. This system must also remove the heat generated al the mechanical seal.


 (Sterling



Page 2 of 4

Annex II


Fig. 6-1 Mechanical seal in tandem arrangement

Part nº 16.10 40.08 41.24 43.31 43.32 47.10 47.11 50.40 56.10 91.40 91.41

Part designation Casing cover Flat gasket O-ring Mechanical seal (inboard) Mechanical seal (outboard) Mechanical seal cover Mechanical seal cover Distance ring Pin Allen head screw Allen head screw

9A

Quench liquid outlet

G 1/4

9E

Quench liquid inlet

G 1/4



 (Sterling



Multiple mechanical seal in back to back arrangement 1 Description The shaft is sealed by two unbalanced single-acting reversible mechanical seals acc. to EN 12750 (old DIN 24960) in back to back arrangement, (see general drawing).

2 Seal size / materials mechanical seal inboard, 43.31 Bearing bracket seal material size 25 KU024S Q1Q1VGG M7N 35 KU032S Q1Q1VGG M7N 45 KU045S Q1Q1VGG M7N

mechanical seal outboard, 43.32 seal material size KU024S Q1Q1VGG M7N KU032S Q1Q1VGG M7N KU045S Q1Q1VGG M7N

3 Disassembly 1. Dismantling the pump as described in the operating instructions, section 7.5.3. 2. Unscrew impeller nut 92.20 and remove impeller. 3. Detach the distance ring 50.40. 4. Loosen the Allen head screws 91.40 and 91.41. 5 Push mechanical seal cover 47.10 towards bearing bracket. 6 Detach the casing cover 16.10. 7. Remove the rotating part of the mechanical seal 43.31 (inboard). 8. Remove the rotating part of the mechanical seal 43.32 (outboard). 9. Remove mechanical seal cover 47.10 from the shaft. 4 Assembly

Page 3 of 4

Annex II

The following rules should be observed when mounting the mechanical seal: Extreme care and cleanliness. Take care not to damage the seal faces and the Orings. Clean the shaft and the seat ring seat in the discharge casing and carefully remove any deposits. 1. Insert the static part of the mechanical seal 43.32, with the pin 56.10 , in the mechanical seal cover, insert gasket 40.08. 2. Push mechanical seal cover towards bearing bracket 3. The rotating parts of the mechanical seal 43.32 and 43.31 must be fixed to the shaft. 4. Insert the mechanical seal cover 47.11 with the gasket 40.07 and O-ring 41.24 in the casing cover 16.10. 5. Insert the static part of the mechanical seal 43.31, with the pin 56.10 , in the mechanical seal cover. 6. Fasten hexagonal screws 90.23. 7. Mount casing cover 16.10 on the bearing bracket, fasten Allen head screws 91.40. 8. Mount mechanical seal cover 47.10 in the casing cover, fasten Allen head screws 91.41. 9. Insert the distance ring 50.40 10. Proceed with pump assembly as described in the operating instructions, section 7.7.2.

5 Sealing liquid If the pump is equipped with a double-acting mechanical seal in back to back arrangement, the shaft seal chamber needs to be sealed with liquid from an external source. The sealing liquid must be free of solid particles, it should not crystallise and must it be compatible with liquid handled. This system must also remove the heat generated al the mechanical seal.

Reassembly the pump as described in the operating instructions, section 7.7.



 (Sterling



Page 4 of 4

Annex II


Fig. 6-2 Mechanical seal in back to back arrangement

Part nº 16.10 40.07 40.08 41.24 43.31 43.32 47.10 47.11 50.40 56.10 90.23 91.41

Part designation Casing cover Flat gasket Flat gasket O-ring Mechanical seal (inboard) Mechanical seal (outboard) Mechanical seal cover Mechanical seal cover Distance ring Pin Hexagonal screw Allen head screw

11A

Sealing liquid outlet

G 1/8

11E

Sealing liquid inlet

G 1/4



 (Sterling


Declaration of conformity. Example


Page 1 of 1


Annex III

 (Sterling


ATEX information

Page 1 de 11

Annex IV

Supplementary operating instructions in accordance to EC directive 94/9/CE (ATEX) for the use in potentially explosive atmospheres of the following pumps types, manufactured by Sterling Fluid Systems (Spain), S.A. type: ZLN, ZLK and ZLI (Industrial pumps) ULN (Self Priming Pumps) ZTN, ZTK and ZTI (Thermal Oil Pumps) ZHN, ZDN, ZEN and ZLI (Hot Water Pumps)

These supplementary operating instructions give only general instructions for the use of pumps in conditions that need explosion protection. The operating instructions of the specific pump must be taken into consideration as well.

Contents

Page

1

General objective

2

2

Safety issues

2.1 2.2 2.3 2.4

Identification of safety symbols in these operating instructions Compliance with regulations Qualification and training of personnel Safety instructions for maintenance, inspection and installation work

2 2 2 3 3

3

Instructions concerning pump and accessories

3.1 3.2 3.3 3.4

General Pump pressure containment components Coupling and coupling guard Belt drive

4

Instructions concerning installation and start-up of pump sets

4.1 4.2 4.3 4.4

Coupling Connection to power supply Earthing Belt drive

5

Instructions concerning operation and maintenance

5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9

Unauthorized modes of operation Explosion protection Pump filled and vented Marking Fluid pumped Checking of direction of rotation (see also pump specific operating manual) Pump operating mode Temperature limits Maintenance

6

Additional instructions for couplings in ATEX pump sets

6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9

Limitations Storage Installation Mounting coupling parts Alignment Fixing the coupling on the shaft Operation Maintenance Figures



3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 5 5 5 5 7 7 7 7 7 8 8 9 9 9 10

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Annex IV

General Objective

Pumping systems can be operated in hazardous areas. It is the obligation of the operator to define the zone and to select the pump with the correct category for this zone. The pump installation and operation must take into account the Operating Instructions that are described in these supplementary operating instructions. They contain important information for safe and reliable pump operation in hazardous areas. This information plus all information given for all components of the system (e.g. the operating instructions for the pump) are of vital importance to avoid risks. These supplementary operating instructions do not take into account national or local regulations; the operator must ensure that such regulations are strictly observed by all, including the personnel in charge of the installation. For any further information or instructions exceeding the scope of this manual or in case of damage, please contact Sterling Fluid Systems nearest customer service.

2

Safety issues

These supplementary operating instructions contain fundamental information concerning all actions with pumping systems, when operated in hazardous areas like: installation, inspection, operation, monitoring and maintenance. Therefore these and all other instructions related to safety must be known and available with easy access to all personnel involved in the above stated actions. Not only must the general safety instructions established in this chapter on “Safety issues” be complied with, but also the safety instructions outlined under specific headings as well as the safety instructions contained in the specific operating manual of the specific pump. 2.1 Identification of safety symbols in these instructions

In these supplementary operating instructions, the safety instructions related to explosion protection are marked with:

The sign

is used to highlight safety instructions where non-compliance may pose a damage to the pump and its functions. 2.2 Compliance with regulations

It is imperative to comply with the safety instructions contained in these supplementary operating instructions, the operating instructions of the pump type concerned, the relevant national and international explosion protection regulations, health and safety regulations and the operator’s own internal work, operation and safety regulations. Ex symbol relates to additional requirements, which must be complied with when the pump is operated in hazardous areas. In addition the following must be observed: If pumps / units are located in hazardous areas, it is imperative to make sure that the correct category of pump and equipment is selected and that unauthorised modes of operation are prevented. Noncompliance may result in first: increased risk of explosion and second: the specified temperature limits might be exceeded. Non-compliance with these safety instructions may also result in the loss of any rights to claim damages. Non-compliance may also result in hazards to persons by explosion. For local contact details: www.sterlingsihi.com


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Annex IV

2.3 Qualification and training of personnel

The personnel responsible for or involved in the installation, the operation, maintenance and inspection of the pump and the unit must be adequately qualified to carry out these works in hazardous areas. The scope of responsibility and supervision of the personnel must be exactly defined by plant management. If the staff does not have the necessary knowledge, they must be trained and instructed. The pump manufacturer or supplier on behalf of the plant management may perform this task. Moreover, plant management must ensure that the contents of the operation instructions are fully understood by plant operators and other relevant personnel such as maintenance staff. 2.4 Safety instructions for maintenance, inspection and installation work

The operator is responsible to assure that all installation work, inspection, operation and maintenance must be carried out by authorized and qualified specialist personnel, which is thoroughly familiarized with the pump operating instructions and these supplementary operating instructions. If necessary, additional explosion protection regulations must be considered.

3

Instructions concerning pump and accesories

3.1 General

Pumps and accessories for installations in hazardous areas must comply with the relevant category of mechanical and electrical equipment. Some details are pointed out below: 3.2 Pump pressure containment components

For handling inflammable fluids, the pump pressure containment components must be made of ductile material. 3.3 Coupling and coupling guard

The accident prevention regulations require, that pump drive must not be operated without a coupling guard. If a customer specifically decides, not to include a coupling guard in our delivery, then the operator must provide such coupling guard himself. The coupling must be selected and sized in accordance with the instructions of the coupling manufacturer. It is important to make sure that the materials selected for coupling and coupling guard are non-sparking in the event of mechanical contact. Sterling Fluid Systems scope of supply meets this requirement. In hazardous areas coupling guards must be of non-sparking material, whereby the coupling material must be considered. 3.4 Belt drive

Belts must include some electrically conductive material.

4

Instructions concerning installation and start-up of pump sets

In addition to the normal installation instructions, the specific criteria for explosion protection are listed below: 4.1 Coupling

The coupling must be installed, started-up and operated in accordance with the operating instructions of the coupling manufacturer. Misalignment of the coupling may result in inadmissible temperatures at the coupling and motor bearings. It has to be ensured that the coupling halves are correctly aligned at all times. 4.2 Connection to power supply

Only a properly trained electrician must effect connection to the power supply. The available main voltage must be checked against the data on the motor rating plate and an appropriate start-up method must be selected. For local contact details: www.sterlingsihi.com


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Annex IV

Sterling Fluid Systems strongly recommends using a motor protection device (motor protection switch) In hazardous areas, compliance with national and local regulations form and additional requirement for electrical connections. 4.3 Earthing

To eliminate risks due to electrostatic charging, pump set must be earthed directly or through an earthing line. 4.4 Belt drive

Belt-driven pump sets must always be earthed. The condition of the belts must be checked regularly.

5

Instructions concerning operation and maintenance

5.1 Unauthorized modes of operation

The warranty related to the operating reliability and safety of the unit supplied is only valid if the equipment is used in accordance to its designated use as described in the following sections of this supplementary operating manual and the specific pump operating manual. The limits stated in the data sheet must not be exceeded under any circumstances. Any operation of the pump outside the permissible operating range and any unauthorized modes of operation may result in the specific temperature limits being exceeded (see section 5.8). 5.2 Explosion protection

If pumps / units are installed in hazardous areas where compliance with EC directive 94/9/EC is required, the measures and instructions given in the following sections 5.3 to 5.9 must be carried out with no excuse, to ensure explosion protection. 5.3 Pump filled and vented

Especially dry running of a pump results in friction and non-allowed temperature rise. Therefore precautions have to be taken to prevent dry running. It is necessary that the system of suction and discharge lines and thus the wetted pump parts including seal chamber and auxiliary systems are completely filled with fluid to be handled at all time during pump operation, so that and explosive atmosphere is prevented. If the operator cannot warrant this condition, appropriate monitoring devices must be used. Improper installation (e.g. vertical installation) may impair the self-venting properties of the seal chamber, so that gas bubbles may be collected in the pump and cause the mechanical seal to run dry. High negative pressure on the suction side (e.g. due to clogged suction-side strainers or low system pressure) may result in air intake at the shaft seal forming gas bubbles in the pump. This may also cause the mechanical seal to run dry. Suitable monitoring facilities shall be installed, if necessary. For design inherent reasons, however, it is not always possible to exclude the existence of a certain residual volume not filled with liquid after the pump has been filled prior to start of operation. However, once the motor is started up the pumping effect will immediately fill this volume with pumped fluid. It is imperative to make sure that seal chambers and auxiliary seal systems are properly vented from air and filled with liquid. 5.4 Marking

The Ex marking on the pump only refers to the pump part, i.e. the coupling and motor must be considered separately. The coupling must have an EC Declaration of Conformity and the EC marking. The driver must be treated separately For local contact details: www.sterlingsihi.com


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Example of marking on the pump part: CE Ex II 2 G c T1 - T5 The safety instructions published in section 5.8 must be complied with. 5.5 Fluid pumped

Abrasive particles in the fluid handled may erode the casing walls to such and extent that fluid may escape. When handling inflammable media, it has to be ensured that the fluid does not contain any abrasive particles, or that the pump is regularly checked with respect to erosion. 5.6 Checking of direction of rotation (see also pump specific operating manual)

If the explosion hazard also exists during the installation phase, the direction of rotation must never be checked by starting up the unfilled pump unit, even for a short period, to prevent temperature increases resulting form contact between rotating and stationary components. If it is possible to fill the pump, the direction of rotation must be checked with the pump / motor coupling removed. 5.7 Pump operating mode

Make sure that the pump is always started up with the suction-side shut-off valve fully open and the discharge-side shut-off valve slightly open. However, the pump can also be started up against a closed swing check valve. Only after the pump has reached full rotational speed shall the discharge-side shut-off valve be adjusted to comply with the duty point.

Pump operation with closed shut-off valves in the suction and / or discharge pipes is not permitted. In this case, there is a risk of the pump casing reaching a high surface temperature after a very short time, due to a rapid temperature rise in the pumped fluid inside the pump. Additionally, the resulting rapid pressure build-up inside the pump may cause excessive stresses on the pump materials and even cause it to burst. The minimum flows indicated in the relevant pump operating manuals refer to water and water-like liquids. Longer operation periods with these liquids and at the flow rates indicated will not cause and additional increase in the temperature on the pump surface. However, if the physical properties of the fluids handled are different from water, it is essential to check if and additional heat build-up may occur and if the minimum flow rate must therefore be increased. The calculation formula below can be used to check if an additional heat build-up may lead to a dangerous temperature increase at the pump surface. To = Tf + ∆ϑ ∆ϑ = ((g * H) / (c * η))*(1 - η)

c g H Tf To η ∆ϑ

Specific heat of liquid [J / kg K] Acceleration due to gravity [m2/s] Pump head [m] Temperature of pumped fluid [º C] Temperature of casing surface [º C] Pump efficiency [-] Temperature difference [º C]

5.8 Temperature limits

In normal pump operation, the highest temperature is to be expected on the surface of the pump casing, at the shaft seal, at the bearing areas and at the pump shaft end in close coupled executions. Unless the pump is equipped with an additional heating facility, the surface temperature at the pump casing will correspond to the temperature of the fluid handled, assuming that the pump surface is freely exposed to the atmosphere.



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Annex IV

In any case, responsibility for compliance with the specified fluid temperature (operating temperature) lies with the plan operator. The maximum permissible fluid temperature depends on the temperature class to be complied with. The following limits for the maximum permissible temperature must be observed for the individual temperature classes as per EN 13463-1 given below (temperature increase in the shaft seal area, if any, has been taken into consideration): Temperature class as per EN 13463-1:

Permissible surface temperature

T5 T4 T3 T2 T1

100 º C 135 º C 200 º C 300 º C 450 º C

Max. Permissible fluid temperature for compliance with temperature class 80 º C 115 º C 180 º C 280 º C Temperature limit of the pump

The permissible operating temperature of the pump in question is indicated in the technical data. If the pump is to be operated at a higher temperature, the technical data are missing or if the pump is part of a pool of pumps, the maximum permissible operating temperature must be requested from the pump manufacturer.

Because of the very close contact between pumps and motors in close coupled design (ZLK and ZLI Industrial pumps; ZTK and ZTI, Thermal Oil Pumps; and ZLI, Hot Water Pumps), there is a thermal influence between pump and motor. Especially for motors with protection type EExe (increased safety) the possibility that the declaration of conformity losses its validity exits, as for the EC type examination an ambient temperature of 40 ºC is taken as a basis. This admissible ambient temperature could be exceeded in the area of the motor flange when pumping hot liquids. In the event of fluid temperature above 80 ºC, the temperature category of the unit / set is determined by the pump not by the motor. The motor is usually rated for continuous operation at the data indicated in the technical data. Frequent motor start-ups may result in increased surface temperature at the motor. Contact motor manufacturer, if necessary. Based on ambient temperature of max. 40 ºC and assuming that the pump unit is properly serviced and operated and that the surfaces in the bearing area are freely exposed to the atmosphere, compliance with temperature class T4 is warranted for surfaces in the area of rolling element bearings. If temperature class T5 (100 ºC) and T6 (85 ºC) have to be compliance with, special measures may have to be taken with regard to bearing temperature. In such cases and if ambient temperatures are higher, contact the manufacturer. Operator’s errors or malfunctions may result in substantially higher temperatures. Please refer to section 5.1 in this context. Mechanical seals may exceed the specified temperature limits if run dry. Dry running may not only result from an inadequately filled seal chamber, but also from excessive gas content in the fluid pumped. Pump operation outside the specified operating range may also result in dry running. Shaft seals shall be regularly checked for leakage. The above stated and also stated in other paragraphs related to the mechanical seal, is also applicable for any shaft sealing execution (i.e. packing rings, lip seal rings,…) It has to be verified, that V-rings are properly fitted to the shaft. Only proper contact should exist between the sealing lip and the shaft.



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Annex IV

5.9 Maintenance

Only a pump set, which is properly operated and maintained in perfect technical conditions, will give safe and reliable operation. This also applies to the reliable function of the rolling element bearings whose actual lifetime largely depends on the operating mode and operating conditions. Regular checks of the lubricant and the running noises will prevent the risk of excessive temperatures as a result of bearings running hot or defective bearing seals. The correct function of the shat seal must be checked regularly. Any auxiliary systems installed must be monitored, if necessary, to make sure they function correctly. Static sealing elements shall be regularly checked for leakage. The coupling guard and any other guards of fast rotating components must be regularly checked for deformation and sufficient distance from rotating elements. Regularly verify the correct position and the status of plastic components exposed to the atmosphere. It is strongly recommended to draw up a maintenance schedule, which includes the above-mentioned points. In case of repair, only original Sterling Fluid Systems spare parts must be used, which comply with the corresponding EC Directives.

6

Additional instructions for couplings in ATEX pump sets

The following instructions for couplings need especially to be followed for pump sets which are manufactured in conformity with Directive 94/9/EC for operations as category 2G equipment in hazardous areas. 6.1 Limitations

Only the coupling type BDS and HDS are released for pump sets in conformity with 94/9/EC. These couplings are designed to be operated according to the following parameters: - Max. 25 starts per hour. - Daily operating cycle up to 24 h. - Operation within the specified alignment. - Temperature range -30ºC a +80ºC in the immediate vicinity of the coupling. 6.2 Storage

If coupling parts are stored as spare parts, the storage area must be dry and free from dust. The flexible elements must not be stored with chemicals, solvents, motor fuels, acids, etc… Furthermore they should be protected against light, in particular sunlight and bright artificial light with high ultraviolet content.

The storage area must not contain any ozone-generating equipment, e.g. fluorescent light sources, mercury vapour lamps, high voltage electrical equipment. Damp storage areas are unsuitable. Ensure that no condensation occurs. The most favourable atmospheric humidity is below 65%. 6.3 Installation

Type B and H couplings shall never be operated in pump sets category 2G. The flexible elements are delivered in different materials and are then differently coloured or marked with stripes in different colours. Only elements of one type must be used in one coupling.

When assembling a pump set with a coupling, the fits of the bores and shafts must be checked. See table 6.C.1



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Annex IV

Table 6.C.1 Tolerances for coupling fit

Fit Shaft tolerance according to DIN 748/1

Nominal Shaft diamenter tolerance 50 mm

k6

> 50 mm

m6

≤

Coupling bore tolerante H7

Failure to observe these instructions may result in breakage of the coupling. Danger from flying fragments! The coupling then becomes and explosion hazard. 6.4 Mounting coupling parts

Before beginning installation, shaft ends and coupling part must be carefully cleaned. Before cleaning the coupling parts with solvent the flexible elements must be removed. If necessary, heating the coupling parts (to max 150 ºC) will facilitate fitting. With temperatures over 80 ºC the flexible elements must be removed form the coupling parts before heating.

Coupling parts must be fitted with the aid of suitable equipment to avoid damaging the shaft bearings through axial joining forces. Always use suitable lifting equipment. Shaft ends must not project from the inner sides of the hub. Axial security is effected by means of the set screw.

Tighten the set screws with a tightening torque in accordance with the table 6.C.3. Failure to observe these instructions may result in breakage of the coupling. Danger from flying fragments! The coupling then becomes and explosion hazard. After fitting the coupling parts onto the shafts the flexible elements, if previously removed must be fitted. Previously heated coupling parts must make cooled down again to a temperature below +80 ºC. It must be ensured that the flexible elements are of identical size and colour or have identical marking. Move together the pump set components to be coupled.

Danger of squeezing! 6.5 Alignment

Couplings connect shaft ends of the driver and the pump. The alignment of shaft ends needs to be adjusted within the following tolerances. The errors of alignment are differentiated into: - Axial misalignment: the allowable difference between maximum and minimum axial gap S between maximum and minimum axial gap S between the two coupling halves is given Table 6.C.2. - Angular misalignment: this can usefully be measured as the difference in the gap dimensions ∆S = Smax – Smin. The allowable values are given in Table 6.C.2, depending on coupling size and speed. For local contact details: www.sterlingsihi.com


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- Radial misalignment is the radial offset between the shaft centres. The allowable values are the same ∆S values like for the angular misalignment given in Table 6.C.2. The method to adjust the alignment is: - First correct the angular misalignment. - Then correct the axial gap. - Then correct the radial misalignment. The useful tools are a feeler gauge and a ruler as shown in figure 6.C.2. Table 6.C.2 Alignment dimensions

Coup. Axial type gap BDS S 76 88 103 118 135 152 172 194 218 245

mm 2–4 2–4 2–4 2–4 2–4 2–4 2–6 2–6 2–6 2–6

Angular and radial misalignment ∆S max. in mm at speed 750 1000 1500 2000 3000 1/min 1/min 1/min 1/min 1/min 0,25 0,2 0,2 0,15 0,15 0,25 0,2 0,2 0,15 0,15 0,25 0,25 0,2 0,2 0,15 0,3 0,25 0,2 0,2 0,15 0,3 0,25 0,25 0,2 0,15 0,35 0,3 0,25 0,2 0,2 0,4 0,35 0,3 0,25 0,2 0,4 0,35 0,3 0,25 0,2 0,45 0,4 0,3 0,3 0,2 0,5 0,4 0,35 0,3 0,25

6.6 Fixing the coupling on the shaft

For fixing the coupling parts on the shaft there are set screws, which need to be locked with the following torque depending on coupling size: Table 6.C.3 Torque for set screws

Size Torque Nm Size Torque Nm

76 88 103 4 4 4 172 194 218 15 25 25

118 4 245 25

135 152 8 8

6.7 Operation

If any irregularities are registered during operation (vibrations of noise) the pump set is to be switched off immediately. Determine the cause of the fault using the fault list in Chapter 8. This list contains possible faults, their reasons and successful actions. If the analysis is not possible then contact the Sterling Service. 6.8 Maintenance

Regular control of the torsional backlash is necessary to prevent. For local contact details: www.sterlingsihi.com


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The torsional backlash has to be measured in the following way: One coupling part is rotated against the other with no torque to a stop. Then this position of the two coupling halves is marked (se figure 6.C.3). Then the coupling parts are rotated into the other direction as far as possible without torque. The distance between both marks is the backlash measure ∆Sb. The maximum values for this measure are given in Table 6.C.4 by coupling size. If this measure is exceeded, then the flexible elements need to be exchanged.

The flexible elements must be replaced in sets (all elements of one coupling at once, independent of the individual wear). Only identically marked flexible elements must be used. Only spare parts from the original equipment manufacturer are allowed for replacement Table 6.C.4 Torsional backlash measure

Size ∆Sb

mm Size ∆Sb

mm

76

88

103 118 135 152 172

7,0

5,0

7,0

9,0 10,5 11,5 9,0

194 218 245 8,0

7,0

6,5

6.9 Figures: Figure 6.C.1

Measures for checking alignment

Smax

Smax

∆S

Smin

Figure 6.C.2

Smin ∆S = Smax - Smin Checking of alignment

Ruler

S For local contact details: www.sterlingsihi.com


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Figure 6.C.3

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Annex IV

Measurement of torsional backlash

∆Sb



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Annex V

Supplementary operating instructions in accordance to regulation EU 547/2012 in order to implement Directive 2009/125/EC, regarding eco-design requirements for water pumps:

ZLN, ZLK and ZLI

Contents

Page

1

Introduction

2

2

MEI

2.1 2.2 2.3 2.4

Definition Calculation Pump values Requirements

3

Efficiency

2 2 3 3

3.1 3.2

General overview Curves

4 4

4

Efficient operation

4

5

End of life

4

6

Web side information

4



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Page 2 of 4

Annex V

Introduction

For energy saving reasons all rotodynamic water pumps from types ZLND, ZLKD and ZLIC in future have to fulfil eco-design requirements with respect to pump efficiency. The measure for the quality of a pump in respect to efficiency is the “Minimum Efficiency Index” (MEI). EU 547/2012 implement Directive 2009/125/EC regarding eco-design requirements for the placing on the market of rotodynamic water pumps for pumping clean water, including where integrated in other products. Annex contains all relevant documentation about mentioned pumps related to information requirements include in ErP standard.

2

MEI

2.1.

Definition

“Minimum Efficiency Index” (MEI) could be defined as the measure for the quality of a pump in respect to efficiency. It is a dimensionless scale and related to best efficiency point (BEP), part load (PL) and overload (OL) conditions (0,75 x QBEP and 1,1 x QBEP). It is only valid for full impeller diameter at rated speed. The higher this value is, the better is pump in respect to efficiency and as lower is its energy consumption and CO2 emission.

2.2.

Calculation

The MEI-value for a particular pump size is calculated considering four parameters: a) Flow rate at BEP (QBEP). b) Specific speed (ns), which refers to the specific impeller shape (from radial type at the lowest values to axial at the highest ones)

ns = n ∗

Q BEP H BEP

3 / 4

[rpm]

where QBEP [m³/s], HBEP [m] and n [rpm].

c) A constant (C), which quantifies the differences in efficiency for different pump types (end suction, in-line,…) and speed. d) Required minimum efficiency at best efficiency point “ (η BEP )min requ ”. The formula is as follows:



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Annex V

(η BEP )min requ = 88,59 x + 13,46 y − 11,48 x 2 − 0,85 y 2 − 0,38 x y − C Pump Type, rpm Where, x = ln (ns) y = ln (Q) ln = natural logarithm Q = flow (m 3 /h) ns = specific speed (rpm) C = constant which depends on the pump type, nominal speed and MEI value. It could be found below table.

2.3.

Pump values

MEI-value of each pump is indicated in the nameplate as follows:

MEI ≥ [ x, xx ] It should be mentioned that the benchmark for highest efficiency water pump is MEI ≥ 0,7

2.4.

Requirements

MEI requirements for next years will be the following ones: a) Starting point in 2013: MEI ≥ 0,1 b) Updated value in 2015: MEI ≥ 0,4



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3

Efficiency

3.1.

General overview

Page 4 of 4

Annex V

a) The minimum required pump efficiency has to be at least equal or higher than that one indicated by the specific MEI value. b) Hydraulic pump efficiency is indicated in the nameplate in the format: % [--,-] c) The efficiency of a pump with a trimmed impeller is usually lower than one of a pump with the full impeller diameter. The trimming of the impeller will adapt the pump to a fixed duty point, leading to reduced energy consumption. The minimum efficiency index (MEI) is based on the full impeller diameter.

3.2.

Curves

Pump efficiency has a maximum at ns values in the range between 40 … 50. It decreases for higher and lower ns values, especially leading to very low values at n s ≤ 10 rpm. Requirements for pumps grow with increasing MEI, i.e. pumps have to reach higher efficiencies with increasing MEI-values. Benchmark efficiency graphs are permanently available under www.europump.org/efficencycharts

4

Efficient operation

The operation of this water pump with variable duty points may be more efficient and economic when controlled, for example, by the use of a variable speed drive that matches the pump duty to the system.

5

End of life

“End of life” pump treatment is a very important issue to fulfil eco-design requirements. The procedure to dismantle the pump is described in chapter 7 of the Instruction Manual document. In general, once pump has been dismantled, metallic parts come back to the foundry and for the rest of components, the recycling process follow the recommendation of our suppliers.

6

Web side information

This information is also available at www.sterlingsihi.com



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2. Operating Instruction.pdf

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