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Operation Manual
for
Centrifugal Pumps Type
SLM NV
Execution acc. to Directive 94/9/EC
01/2005
BAE-21900-Coversheet-05.doc
KLAUS UNION D-44795 BOCHUM BLUMENFELDSTRASSE 18 +49 (0) 234 45 95 - 0 TELEFAX +49 (0) 234 43 23 87 www.klaus-union.de
Contents of Operation Manual
1.
General
BA/E -21900-01/..
2.
Safety
BA/E -21900-02/..
3.
Transport, Preservation
and Intermediate Storage
BA/E -21900-03/..
4.
Constructional Description
BA/E -21900-04/..
5.
Installation and Assembly
BA/E -21900-05/..
6.
Commissioning and Shutdown
BA/E -21900-06/..
7.
Maintenance
BA/E -21900-07/..
8.
Malfunctions,Causes and Elimination
BA/E -21900-08/..
BAE-21900-Contents 04/2003
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BA/E-21900-01/1
General
Page 1 of 1
11/2003
This operation manual describes the following pump types:
Single-stage centrifugal pump with magnet drive
•
of bearing-support construction with grease-lubricated anti-friction bearings
•
•
•
•
of bearing-support construction with oil-lubricated anti-friction bearings
•
•
•
SLM NVN
SLM NVS
SLM NVE
SLM NVO
SLM NVEO
of close-coupled construction
•
•
SLM NVB
SLM NVEB
Prior to commissioning, this operation manual must be read thoroughly and fully
understood by the operational staff (erecting and qualified staff). The manual contains
important instructions for the safe operation and designated use of the pump. Observing
these instructions helps to achieve a high level of availability and a long working life of
the pump while ensuring a safe operation.
Further operation manuals regarding components of the pump unit, e. g. electric motors,
monitoring equipment, etc. shall equally be observed.
Pictorial representations and information given in this operation manual are subject to
technical modifications resulting in the improvement of KLAUS UNION products.
This operation manual is a copyright of KLAUS UNION.
This operation manual includes technical instructions and drawings, which must not be
reproduced (neither in total nor in part), distributed or exploited without authority for the
purpose of competition or transmitted to third parties
KLAUS UNION GmbH & Co. KG
P.O. Box 10 13 49
D-44713 Bochum
Phone
Telefax
Internet
:
:
:
+49 (0) 234 45 95 - 0
+49 (0) 234 43 23 87
www.klaus-union.de
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BA/E-21900-02/1
Safety
Page 1 of 7
10/2004
1.
General
This operation manual contains fundamental instructions to be observed during
installation, operation and maintenance. By all means, this operation manual must be
read by the installation personnel and the responsible qualified staff prior to installation
and commissioning. The manual is always to be held available on site.
In addition to the general safety instructions given in this section, the special safety
instructions mentioned in the following sections are to be observed.
KLAUS UNION will not assume any responsibility for damage incurred due to nonobservance of this operation manual.
2.
Marking of Safety Instructions
The safety instructions given in this operation manual are specially marked:
Dangerous situation.
Possible consequences: Damage to health and life of persons.
Electrical hazard.
Possible consequences: Severe or even lethal injuries.
Important instructions regarding explosion protection.
Danger to health of persons with a pacemaker resulting from
strong magnetic field.
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Safety
Page 2 of 7
10/2004
In case of dangers to the machine and its functions the word
ATTENTION
has been inserted.
References made on the machine itself, such as
•
•
•
direction-of-rotation arrow
dry-running warning
marks for fluid connections
must by all means be observed and kept completely legible.
3.
Qualification and Training of Staff
The staff responsible for the operation, maintenance, inspection and assembly must
have the appropriate qualifications to perform these duties. Scope of responsibility,
purview and supervision of staff must be clearly organized by the operating company. If
the staff do not possess of the necessary expertise they must be trained to acquire the
necessary knowledge. Furthermore, the operating company is to ensure that the
contents of the operation manual is fully understood by the staff.
4.
Dangers of Non-Compliance with Safety Instructions
The pump units described in the present operation manual are usually used in industrial
plants for the transport of partly hazardous products. Non-compliance with safety
instructions can therefore cause danger to persons as well as to the environment. Noncompliance will result in the loss of any claim for damages.
In detail, non-compliance with the operation manual can result in the following dangers,
e.g.:
•
•
•
Danger to persons by electrical, mechanical and chemical influences
Danger to the environment by leakage of dangerous substances
Failure of important functions of the machine or plant
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Safety
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10/2004
5.
Safety-Conscious Work
Safety instructions mentioned in this operation manual, existing national regulations for
prevention of accidents as well as any internal working, operating and safety
instructions of the operating company have to be observed.
When operating the pump in hazardous locations, articles
marked with the
–sign are to be given special attention and
observance.
6.
Safety Instructions for the Operating Company/Operator
In case hot (temperature exceeding 50°C) or cold (temperature
lower than 0°C) surfaces cause danger, they must be protected
against accidental contact.
Protection against accidental contact for rotating parts (e.g.
coupling guard) must not be removed during operation of the
machine.
Electrical hazard may be given. The corresponding instructions
are to be observed.
Magnet drives cause strong magnetic fields. Persons with a
pacemaker should not stay close to the magnet drive or come
into close bodily contact with parts of it.
For processing dangerous products, evacuation lines or drains must be installed in a
way to prevent any danger to people or environment. Local government regulations are
to be observed.
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Safety
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10/2004
7.
Safety Instructions for Maintenance, Inspection and Assembly
The operating company has to ensure that any maintenance, inspection and assembly
works are performed by authorized and qualified staff. The staff must have read and
fully understood the operation manual.
As a matter of principle, any works on the pump unit must be carried out during
standstill. The pump casing must be depressurized and fully drained. Instructions given
in the section "Commissioning and Shutdown" of this operation manual must be
observed.
Pumps processing noxious liquids must be decontaminated.
Immediately upon termination of the works, any safety and protection devices must be
reinstalled and put into operation. During re-commissioning, the instructions given in the
section "Commissioning and Shutdown" of this operation manual must be observed.
The lifting capacity of lifting gear and tackle must be designed to
correspond at least with the own weight of the complete pump
unit.
8.
Unauthorized Modification and Manufacture of Spare Parts
Modification of or changes to the pump may only be carried out upon agreement with
the manufacturer. Original spare parts and accessories authorized by the manufacturer
contribute to your safety. KLAUS UNION will refuse to accept any responsibility for
damage resulting from the use of other parts.
If the pump is modified or changed without authority and / or other
than original spare parts are used for repair works, the explosion
protection will be forfeited.
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Safety
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10/2004
9.
Designated Use
Operational reliability of the pump is only granted for its designated use. The limiting
values indicated in the data sheet, particularly those regarding temperature of the
pumped liquid and pumping capacity must not be exceeded.
In case of pumps for which no datasheet is available (e. g. pool
pumps), it must be checked prior to their commissioning,
whether the allowable surface temperatures are not exceeded
(refer to article „Temperature Limits“)
Driving motor and flexible coupling (in case of pumps of bearingsupport construction) must have an approval for the use in areas
subject to explosion hazards.
10.
Temperature Limits
When being operated to its designated use, the pump's maximum
surface temperature must not exceed the temperature category of
the explosion protection zone.
The ignition temperature of the liquid must be at least by 50°C
higher than the maximum surface temperature of the pump.
The plant operator must ensure that the maximum allowable temperature of the
hazardous area is not exceeded when hot liquids are processed. Refer to the following
table for the maximum allowable temperature of the pumped liquid in accordance with
the applicable temperature category:
Temperature Category
T1
T2
T3
T4
Maximum Temperature of the Pumped Liquid [°C]
400
270
175
110
In case of temperature categories T5 or T6, contact KLAUS UNION for further
information.
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Safety
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The pump is designed for use in ambient temperatures of 40°C
max. For ambient temperatures exceeding 40 °C, explosion
protection is no longer granted.
11.
Speed Limits
It is possible to operate the pump with a frequency converter. Lubrication of the journal
bearing and cooling of the magnet drive are sufficient even at a slower speed.
The maximum allowable speed is mentioned on the rating plate
and in the data sheet. If the pump is operated at a speed
exceeding the maximum speed indicated, explosion protection is
no longer granted.
Prior to operating the pump unit with a frequency converter it
must be checked, whether the driving motor is appropriate for
that purpose.
12.
Sound Pressure Level
The sound pressure level LPA and the sound power level LWA of the pump measured to
DIN 45635 are mentioned in the following diagramme dependent on the pump power
and speed.
When assessing the total sound pressure level of the pump with motor, the motor data
as indicated by the motor supplier are to be considered.
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Safety
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pump power Pp [kW]
Centrifugal pump with magnet drive (without motor), sound power level LWA and sound
pressure level LPA, speed n = 1450 1/min
pump power Pp [kW]
Centrifugal pump with magnet drive (without motor), sound power level LWA and sound
pressure level LPA, speed n = 2900 1/min
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Transport, Preservation and
Intermediate Storage
1.
BA/E-21900-03/1
Page 1 of 3
10/2004
Scope of Delivery
The contents of the individual packing units is listed in the packing list. Upon delivery, it
is to be checked whether the consignment as mentioned on the packing list is complete.
The supplier is to be given written notice immediately of any damage to the goods
incurred during transport and / or missing parts.
2.
Degree of Disaggregation
The degree of disaggregation depends on mode and conditions of transport, local
conditions and lifting equipment available. On principle, it is possible to disassemble the
pump into several sub-assemblies. However, the pump is to be transported in as
complete a unit as possible. However, if the pump is delivered in sub-assemblies, refer
to the drawing enclosed with the packing list for the contractual degree of
disaggregation.
3.
Packing
The transport route is decisive for the kind and material of packaging. If not particularly
stipulated in the contract, the packing corresponds with the packaging regulations HPE
laid down by the Bundesverband Holzmittel, Paletten, Exportverpackung e.V (Federal
Association Wood for Packaging, Pallets, Export Packaging Inc.). The graphical
symbols attached to the packing are to be observed:
Top
Fragile
Use no hooks
4.
Keep dry
Gravity center
Store away from heat
Post here
Transport
Transport of the pumps must be carried out expertly. During transport, the pump must
remain in a horizontal position and it must be ensured that it does not slip out of the
transport suspension (ref. to drawing). Shocks and impacts are to be avoided.
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Transport, Preservation and
Intermediate Storage
BA/E-21900-03/1
Page 2 of 3
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Suspended loads must not be transported over the heads of
persons.
The lifting capacity of lifting gear and tackle must be designed to
correspond at least with the own weight of the complete pump
unit.
The pump unit (close-coupled and bearing-support construction) has to be transported
as shown below.
ATTENTION
If necessary, use available securing devices for
transport.
Never fasten the transport straps to the eye bolts of motor or pump lantern.
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Transport, Preservation and
Intermediate Storage
5.
BA/E-21900-03/1
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Preservation and Intermediate Storage of the Pump
The centrifugal pump type SLM NV has been provided with a preservative either
according to the customer's specification or as detailed in the operation manual. For a
longer-term storage of the centrifugal pump, special preservative measures are to be
taken.
Prior to delivery, shaft ends have been equipped with protection caps for protection
against dirt and damage. The connecting flanges of the pump casing are provided with
flange covers for protection against dirt. Protection caps and flange covers must not be
removed during intermediate storage.
Having been packed into seaworthy cases for their transport, the pumps can be stored
for a period of up to one year in their packing without special measures having to be
taken. Nevertheless, to avoid damage to the anti-friction bearings in the pumps owing to
vibrations, e. g. due to machines operated in close vicinity, the pumps should be stored
in rooms free of vibrations.
For intermediate storage, parts of the following low-alloy components must be treated
with a preservative:
•
•
bare shaft ends of drive shafts
surfaces of the pump casing made of cast steel GP240GH (1.0619) that are in
contact with the pumped liquid
Concerning the anti-friction bearings it is understood that the lubricant in them will not
be adversely affected during a one-year storage period provided the pumps are stored
appropriately. If possible, the pumps should be turned by hand once a month during the
storage period.
Commercially available preservatives can be used. For application and removal of the
preservative, specific instructions given by the respective manufacturer must be
observed. Preservation will protect the material for about 1 year. In case of a longer
storage period, preservation must be renewed.
The storage area must be dry and free of dust.
Any plain metal parts must be oil- or grease-lubricated for protection against corrosion.
When storing pumps equipped with their driving motors, equally observe the instructions
concerning preservation and storage given in the operation manual covering the driving
motor.
ATTENTION
For outdoor storage, the pump unit must be provided
with a water-proof cover.
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Constructional Description
Page 1 of 4
10/2004
1.
General Description
The sealless centrifugal pump type SLM NV is a standard chemical pump with magnet
drive. The pump is appropriate for the processing of aggressive, toxic, explosive,
valuable, inflammable, malodorous or noxious liquids in the industry. The main
dimensions and capacities of standard chemical pumps are standardized to DIN EN
22858. Moreover, the centrifugal pump type SLM NV conforms to DIN ISO 5199 and
VDMA (Association of German Engineering Shops) standard VDMA 24279.
2.
Pump Identification Marking
SLM NVS 050-032-160-09E03 W
Line of Products
Type of Bearing Support
Nom. Dia. Suction Nozzle
Nom. Dia. Discharge Nozzle
Nom. Dia. Impeller
Size of Magnet Drive
Material of Magnets
Length of Magnets
Additional Constructions
Legend of identification letters for additional constructions:
H1
H2
S
W
F
Z, C
E1
E2
RT
OT
D
heated casing
heated intermediate lantern
thermal barrier without secondary sealing
thermal barrier with secondary sealing
internal filter
ceramics isolation shell of zirconium oxide (Z);
plastic isolation shell of CFRP (C)
external feeding connection:
- one external connection
- internal flush bores with closed back
external flushing / vent:
- one external connection
- internal flush bores open
pump with reduced flush flow
pump without flush flow:
- two external connections for feeding / venting
- throttle bush on impeller side
double isolation shell
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Constructional Description
Page 2 of 4
10/2004
Marking of the types of bearing support:
Bearing Support
Type
Comments
SLM NVN / NVE
DIN standard
SLM NVS
standard
Grease lubrication of
standard constructional length
Grease lubrication with
larger anti-friction bearing spacing
Oil lubrication with
larger anti-friction bearing spacing
SLM NVO / NVEO standard
Marking of the types of bearing support:
Type
SLM NVB / NVEB close-coupled pump
3.
Comments
Motor lantern
Constructive Design
The centrifugal pump type SLM NV is a single-stage, single-entry, horizontal radial flow
centrifugal pump with magnet drive. Its outer dimensions are identical to the usual
standard chemical pump with stuffing box packing or mechanical seal. In the case of the
magnet-drive pump, the pump power is transmitted from the driving motor via the
magnet drive to the impeller. The magnet drive transmits the torque without slip and
hermetically seals the product chamber from the atmosphere. The isolation shell
between the two magnet rotors forms the static sealing.
3.1
Hydraulic Component
Essentially, the hydraulic component comprises the impeller and the pump casing.
Within the hydraulic component, the mechanical shaft output is transformed into
hydraulic power. The pump shaft runs in journal bearings, which are made of ceramics
and lubricated by the pumped liquid. The product-side magnet rotor is mounted on the
shaft that it drives.
3.2
Magnet Drive
The magnet drive hermetically seals the hydraulic component from the driving
component on the atmosphere. The magnet drive comprises the inner and outer
magnet rotors and the isolation shell. The isolation located between the two rotors seals
the system. The power transfer is effected without slip.
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Constructional Description
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10/2004
3.3
Driving Component
3.3.1
Close-Coupled Pump Type SLM NVB / SLM NVEB
With the close-coupled pump type, the outer magnet rotor is mounted direct on the
motor shaft. The motor is bolted via a motor lantern directly onto the intermediate
lantern of the pump.
3.3.2
Bearing-Support Pump Type SLM NVN / NVS / NVE / NVO / NVEO
With the bearing-support pump type, the outer magnet rotor is fastened to the drive
shaft. The shaft runs in anti-friction bearings. The bearing support is screwed on the
intermediate lantern, the pump comes with a bare shaft end. Construction types SLM
NVN / NVS / NVE feature grease-lubricated anti-friction bearings whereas pump types
SLM NVO / NVEO are supplied with oil-lubricated anti-friction bearings.
4.
Construction Variants
4.1
Heated Pump H1 and/or H2
The pumps are equipped with a heating jacket on the pump casing (H1) and / or with a
heating jacket in the intermediate lantern (H2). Both heating jackets can be connected
with a bypass-line or designed as separate heatings.
In the standard construction, the heating jackets are designed for a working pressure of
16 bar at 200°C (vapour) or 6 bar at 350°C (heat transfer oil).
The heating jackets may also be used for cooling purposes (a maximum of 6 bar at
170°C).
4.2
Thermal Barrier and Secondary Sealing S or W
Being located between the bearing support (with bearing-support construction) or the
driving motor (with close-coupled construction) and the hydraulic component, the
thermal barrier helps to dissipate the product heat. Thus, the anti-friction bearing
temperature is reduced when warm liquids are processed.
In addition, the thermal barrier can be equipped with a radial shaft seal ring, sealing the
area to the outer magnet carrier. By way of a secondary sealing, the gasket prevents
the liquid from immediately leaking to the atmosphere in case of a leakage of the
isolation shell. A precondition for the use of the secondary sealing is the monitoring of
the outer magnet carrier's area in order to detect any leakage in time.
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Constructional Description
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4.3
Internal Filter F
When processing liquids containing solids, the internal filter ensures that no particles of
solid matter exceeding a defined size enter the flush flow channels and thus reach the
magnet drive and the journal bearings respectively.
4.4
External Feeding and Flushing Connections E1 and E2
The external connections permit the external flushing, feeding or venting of the pump.
Connection E1 is used when the constant external feeding of the magnet drive is
required. Connection E2 is suitable for short-time flushing or external venting of the
magnet drive.
4.5
Pump with Reduced Flush Flow Type RT
The pump construction with reduced flush flow is used, when a medium solids content
in the pumped liquid is to be expected and it is no longer sufficient, to filter the flow with
an internal filter alone.
4.6
Pump without Internal Flush Flow Type OT
This pump type is used when liquids with a high percentage of solids are processed.
The isolation shell chamber is equipped with two external connections for filling and
venting of the magnet drive.
4.7
Double Isolation Shell D
When a high level of safety is required, the pump can be equipped with a double-skin
isolation shell. The isolation shell actually consists of two isolation shells with one of
them put into the other. Each of the two isolation shells is designed to meet the
requirements of the specified operation conditions. If one of them should fail, the system
still remains sealed. The space between the two shells can be monitored.
4.8
Inducer
When NPHS values prevailing in the plant are very low, inducers are used in many
cases. They considerably reduce the pump’s NPSH throughout the pump’s entire
operation range without modifying the pump’s characteristics. In most cases, it will be
possible to retrofit pumps in the plant with an inducer without requiring major
modification works.
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Installation and Assembly
Page 1 of 9
10/2004
1.
General Instructions
Prior to installation, the pump should be checked for any damage it might have suffered
during transport. The flange covers may only be removed right before installation.
When turning the pump shaft by hand, abradant noises may be heard from within the
pump. These noises result from the grease-free assembly of the journal bearings.
Having filled the pump with the pumped liquid, these noises will disappear.
KLAUS UNION cannot be held responsible for any damage resulting from inexpert
installation.
The pictorial representations have been simplified.
Prior to installing the pump with the pertaining driving motor in
areas subject to explosion hazards, ensure that the entire
equipment has been approved for the prevailing explosion
protection zone.
Instructions given in the operation manuals of the driving motor
and the flexible coupling are to be observed.
The installation of electrical equipment is exclusively to be
performed by qualified staff. Any regulations valid at the time are
to be observed.
Magnet drives cause strong magnetic fields. Persons with a
pacemaker should not stay close to the magnet drive or come
into close bodily contact with parts of it.
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Installation and Assembly
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2.
Installation Conditions
Arrange pipework and equipment pertaining to the pump in a way to have enough
space available for assembly and maintenance works. For dimensions of the pump refer
to the attached installation plan.
The concrete foundation must have set before the pump is placed on it. The surface of
the foundation must be plane and level.
3.
Installation of Bearing-Support Pump Types
SLM NVN / SLM NVS / SLM NVO / SLM NVE / SLM NVEO
3.1
Installation of the Completely Assembled Unit
The complete unit mounted on the base plate comprises pump, motor and flexible
coupling. The coupling guard covering the flexible coupling serves as a protection
against accidental contact.
Install the unit according to the installation plan and align it using a spirit level. Insert the
foundation bolts in the foundation and grout them with a fast setting grout-mixture. Once
the grout mixture has set, tighten the foundation bolts fast always applying the same
tightening moment.
3.2
Installation of the Partially Assembled Unit
In case the pump unit is not supplied as a complete unit but in sub-assemblies such as
pump, coupling, motor and base plate, the installation is effected as described
hereafter:
Insert the key into the key groove of the motor-side shaft end. Fit the motor-side
coupling half on the shaft by means of a standard draw-on device. The same procedure
is to be followed for the pump-side coupling half.
Align the axial distance between motor- and pump-side coupling halves according to the
dimensions given in the installation plan. Compensate vertical shaft displacements by
using plane-parallel shims.
Eliminate any misalignment of both coupling halves. Put a straight-edge on approx. 4
opposite points on the circumference of the coupling and observe the u. m. drawings.
The radial and axial variance between the two coupling halves must not exceed a
maximum of 0.1 mm.
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Installation and Assembly
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straight-edge
misalignment
radial misalignment
straight-edge
straight-edge
correctly aligned
Align couplings with a diameter exceeding 120 mm with the help of a dial gauge.
Compensate a vertical displacement by placing underneath or removing plan-parallel
shims. Fix pump and motor on the base plate with the bolts provided for that purpose.
Install the completely assembled and aligned unit according to the installation plan and
align it using a spirit level. Insert the foundation bolts in the foundation and grout them
with a fast setting grout-mixture. Once the grout mixture has set, tighten the foundation
bolts fast always applying the same tightening moment.
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Installation and Assembly
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3.3
Installation of Pumps Designed for Higher Liquid Temperatures
With pumps processing liquids at a working temperature exceeding 100°C, a
misalignment can occur in the flexible coupling due to the different thermal expansion of
motor and pump. The excessive misalignment can result in vibrations and higher wear
on the flexible coupling and the anti-friction bearings.
For the correct installation of the unit, the pump must be operated in the plant to achieve
its working temperature. Having shut down the unit, check the axial and radial shaft
misalignment of both coupling halves. Prior to measuring the shaft misalignment,
release the bolts of the support (part no. 901.6). If any shaft misalignment is assessed,
it must be compensated by putting plane-parallel shims underneath motor and/or
support.
4.
Installation of the Close-Coupled Pump Types SLM NVB
and SLM NVEB
The complete unit comprises motor and pump being supplied by KLAUS UNION
completely mounted on a base plate.
Install the unit according to the installation plan and align it using a spirit level. Insert the
foundation bolts in the foundation and grout them with a fast setting grout-mixture. Once
the grout mixture has set, tighten the foundation bolts fast always applying the same
tightening moment.
5.
Pipework
Any pipework being connected should be state of the art and designed for the
respective operating conditions. Ensure that the forces and moments transmitted by the
pipework do not exceed the admissible values. (Admissible pipework forces and
moments will be indicated in the following).
The pipework must be free of any impurities such as weld slag or scale. Avoid
disturbance of the pump flow by variable velocity or irrational flow to the pump inlet.
Such disturbances will adversely affect the pump capacity, the smooth operation and
the NPSH characteristics of the pump.
When connecting the pipework make sure that as little tension as possible occurs. Refer
to instructions such as given in VDMA standard VDMA 24277 „Spannungsarmer
Rohrleitungsanschluß“ (Low-tension connection of pipework).
Exceeding the admissible pipework forces and moments as well
as tensions on the connections can result in escapes and
leakages. In such a case, toxic and hot liquids will pose danger
to life.
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Installation and Assembly
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10/2004
5.1
Suction-Side Pipework
The construction of the suction-side pipework shall have as few baffles (bends, valves,
etc.) as possible because these elements are often responsible for variable velocity and
eddying. Avoid disturbances by asymmetric feed stream. When modifying nominal
diameters use conical sections. If a shut-off valve is used, it must always be completely
open during operation and it must never be used to control the rate of flow.
Always install the suction pipe ascending to the pump. When dimensioning the suction
pipe, ensure that the flow velocity does not exceed 2 m/s.
Feed pipes must be installed descending to the pump. The flow velocity must not
exceed 2.5 m/s.
For liquids being processed close to their boiling point, the flow velocity shall not exceed
0.8 m/s.
5.2
Pressure Pipework
Right behind the pump, a control valve must be available to control the rate of flow. A
check valve must be provided between pump and shut-off valve when long pressure
pipework or static delivery heads exceeding 10 m are given. The check valve protects
the pump against liquid reflux and runback at shutdown. The flow velocity shall not
exceed 5 m/s.
When modifying nominal diameters use conical sections.
6.
Admissible Forces and Moments
The forces and moments the pipework transmits on the pump flanges must not exceed
the values indicated. The values have been determined on the basis of DIN ISO 5199
„Centrifugal pumps, technical requirements, class II“ (Edition December 2003).
The values indicated apply to pump casings PN16 and higher made of cast steel,
stainless steel and Hastelloy up to a temperature of 120°C. For temperatures up to
250°C the values indicated shall be multiplied by 0.95 and for temperatures up to 350°C
the values shall be multiplied by 0.9.
In case other materials or temperatures are involved, please contact KLAUS UNION.
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Installation and Assembly
Page 6 of 9
10/2004
Table 1: Admissible forces and moments acting on the suction flange
Diameter
DN
025
032
040
050
065
080
100
125
150
200
250
300
350
400
Fx
Force
[N]
Fy
595
735
875
1155
1470
1750
2345
2765
3500
4690
5845
7000
8155
9310
490
595
700
945
1190
1435
1890
2240
2835
3780
4725
5635
6580
7525
Fz
Diameter
DN
525
630
770
1050
1295
1575
2100
2485
3150
4200
5215
6265
7315
8365
025
032
040
050
065
080
100
125
150
200
250
300
350
400
Mx
Moment
[Nm]
My
Mz
630
770
910
980
1050
1120
1225
1470
1750
2275
3115
4235
5425
6790
490
595
735
805
840
910
1015
1330
1435
1855
2555
3465
4445
5565
420
525
630
700
770
805
875
1050
1225
1610
2205
3010
3850
4830
Table 2: Admissible forces and moments acting on the discharge flange
Diameter
DN
025
032
040
050
065
080
100
125
150
200
250
300
350
400
Fx
Force
[N]
Fy
525
630
770
1050
1295
1575
2100
2485
3150
4200
5215
6265
7315
8365
595
735
875
1155
1470
1750
2345
2765
3500
4690
5845
7000
8155
9310
Fz
Diameter
DN
490
595
700
945
1190
1435
1890
2240
2835
3780
4725
5635
6580
7525
025
032
040
050
065
080
100
125
150
200
250
300
350
400
Mx
Moment
[Nm]
My
Mz
630
770
910
980
1050
1120
1225
1470
1750
2275
3115
4235
5425
6790
490
595
735
805
840
910
1015
1330
1435
1855
2555
3465
4445
5565
420
525
630
700
770
805
875
1050
1225
1610
2205
3010
3850
4830
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Installation and Assembly
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10/2004
If not all of the loads acting on the flanges reach the maximum admissible values, one
of these loads may exceed the usual limiting value provided the following additional
equations of condition are fulfilled:
•
Any components of a force or moment must be limited to the maximum
admissible value multiplied by 1.4.
•
The forces and moments actually acting on each flange must fulfil the following
equation of condition:
⎛ ∑ | F | existing
⎜⎜
⎝ ∑ | F | max
⎞ ⎛ ∑ | M | existing
⎟⎟ + ⎜⎜
⎠ ⎝ ∑ | M | max
2
2
⎞
⎟⎟ ≤ 2
⎠
The equation of condition must be verified for each flange.
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Installation and Assembly
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7.
Auxiliary Connections
Depending on the construction type, the pump can be equipped with connections for
heating, draining and monitoring. Refer to the installation plan attached to the pump for
the exact location of those connections.
If the pump is fitted with a heating jacket, the temperature of the
heating medium must not exceed the maximum allowable surface
temperature of the pump.
The ignition temperature of the heating liquid must be at least by
50°C higher than the maximum surface temperature of the pump.
The instruments for the monitoring of the pump such as
temperature sensors, pressure sensors, etc. must have the
corresponding approval for use in areas subject to explosion
hazards.
8.
Insulation
Exclusively insulate the pump in the area shown below.
It is to be made sure that the areas of the anti-friction bearings
and the thermal barrier (in case the pump is fitted with one) are
not insulated.
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Installation and Assembly
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10/2004
9.
Electrical Connection
The electrical connection of the driving motor must be performed
by a skilled person. The relevant regulations on that subject are
to be observed.
An earthing cable is to be provided between pump unit and
foundation for equipotential bonding.
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Commissioning and
Shutdown
1.
BA/E-21900-06/3
Page 1 of 6
01/2005
Preparations for Commissioning
The correct functioning of the journal bearings is a precondition
to prevent the outer magnet carrier from running into the
intermediate lantern and thus to prevent the occurrence of
unacceptably high temperatures.
If the pump was not explicitly ordered free from oil and grease,
there will be residues of anti-seize paste on wetted components.
Prior to commissioning, compatibility of the anti-seize paste with
the pumped liquid shall be checked.
In case of uncertainty, please contact KLAUS UNION.
1.1
Bearing Support with Grease-Lubricated Anti-Friction Bearings
Pumps of bearing-support construction with grease-lubricated anti-friction bearings are
supplied fully greased.
Shortly after commissioning and as a precaution, the bearings should be relubricated
with the pump running by means of a relubricating device (lubrication nipple part no.
630.2). (For further details regarding type and quantity of the lubricants to be used and
the appropriate relubricating intervals refer to section "Maintenance" of this operation
manual.)
By all means, observe the prescribed quantity of grease. In case
the quantity of grease filled in is either too low or too high, failure
of the anti-friction bearings will occur.
1.2
Bearing Support with Oil-Lubricated Anti-Friction Bearings
In case of pumps of bearing-support construction equipped with
oil-lubricated anti-friction bearings, the bearing support must be
filled with lubricating oil prior to initial commissioning.
Always observe the prescribed oil level. The oil level being either
too high or too low will result in failure of the anti-friction
bearings.
For recommended types of oil refer to section "Maintenance" of this operation manual.
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Commissioning and
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1.2.1
BA/E-21900-06/3
Page 2 of 6
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Construction with Gauge
To fill the bearing support with lubricating oil, remove vent plug (part no. 672) and fill the
bearing support with oil until half of the gauge (part no. 642) is covered with oil.
1.2.2
Construction with Constant-Level-Oiler
To fill with oil, remove vent plug (part no. 672). Fill oil into the bearing support (part no.
330) until the oil becomes visible in the screwed socket with the oil reservoir folded
back. Then fill the oil reservoir through the chamfered drain pipe and fold it back. Now
the oil level adjusts to the required level. As long as there is oil in the oil reservoir, the
Constant-Level-Oiler will ensure that the oil level is always correct.
672
642
330
Right
1.3
Wrong
Checking the Direction of Rotation
The motor's direction of rotation must correspond with the direction-of-rotation arrow on
the intermediate lantern.
Only check the direction of rotation with the pump filled (closecoupled construction) or with the motor uncoupled (bearingsupport construction).
1.4
Filling and Venting
Filling and venting of pump and plant are carried out simultaneously. Prior to filling the
pump, fully open any valves in suction and pressure pipes. During the filling process
turn the pump shaft by hand. For that purpose, the current feed to the motor must be
interrupted and the coupling guard removed. No air pockets must remain in the system.
Air and gas pockets will result in the immediate failure of the pump.
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Commissioning and
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BA/E-21900-06/3
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When a pump is operated which has not been completely filled,
an ignition source can develop due to excessive heat input. When
being operated in areas subject to explosion hazards, the pump
must be completely filled. If the operating company cannot
ensure the complete filling of the pump, appropriate monitoring
measures must be taken.
If it is not possible to vent the pump via the pressure pipe, e. g. because a check valve
is installed in the pipe, the pump must be vented via a separate ventilating valve on the
discharge side.
1.4.1
Pump of Special Construction without Flush Flow OT
Prior to commissioning, the isolation shell chamber must be filled via flange AF and
vented via flange BF (ref. to drawing). Upon complete filling and venting, the
connections must be closed.
During operation of the pump, the pressure in the isolation shell
chamber is equal to the delivery pressure. Therefore, keep the
connecting flanges tightly closed and do not open them during
operation.
2.
Monitoring Equipment
When the pump is operated in areas subject to explosion hazards,
it may be necessary for the operating company to install
monitoring devices to ensure that the pump does not become an
ignition source. Essentially, ignition sources are hot surfaces and
sparks (when rotating components contact). If required, KLAUS
UNION can offer advice and support concerning the choice and
purchase of monitoring equipment.
For installation, commissioning and operation of the monitoring equipment observe the
corresponding operation manuals supplied with the instruments.
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Commissioning and
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3.
BA/E-21900-06/3
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Commissioning
Completely open all suction-side shut-off valves and slightly open the control valve in
the pressure pipe.
To prevent the pump from excessively heating up, never operate
it against closed control valve on the discharge side. For start-up,
the discharge-side control valve must be sufficiently open for the
minimum rate of flow Qmin.
If for operating reasons it is only possible to commission the pump against closed
discharge-side control valve, it is to be checked with the help of the following equation,
whether the resulting heating of the pump during operation against closed gate valve is
allowable:
∆T
P
=
[K/s] Heating of the pump per second
t
ρ ⋅V ⋅ c p
P
Pumping capacity with the gate valve closed in [kW]
ρ
Density of the product in [kg/dm³]
V
Filling quantity of the hydraulic system in [Litre], refer to u. m. table
cp
Specific thermal capacity of the product in [kJ/kg/K]
Pump Size
040-025-125
040-025-160
040-025-200
050-032-125
050-032-160
050-032-200
050-032-250
065-040-125
065-040-160
065-040-200
065-040-250
065-040-315
080-050-125
080-050-160
080-050-200
080-050-250
080-050-315
100-065-125
100-065-160
100-065-200
100-065-250
Filling Quantity
[Litres]
0.5
0.7
1,0
0.7
0.9
1.3
2,0
0.9
1.2
1.8
2.6
3.7
1.3
1.7
2.3
3.5
4.8
1.9
2.4
3.2
4.7
Pump Size
100-065-315
125-080-160
125-080-200
125-080-250
125-080-315
125-080-400
125-100-200
125-100-250
125-100-315
125-100-400
150-125-250
150-125-315
150-125-400
200-150-250
200-150-315
200-150-400
200-150-500
250-200-250
250-200-315
250-200-400
300-250-315
Filling Quantity
[Litres]
6.4
3.5
4.6
6.3
8.4
13.1
5.7
7.9
10.6
16.5
10.9
14.1
21.6
15.4
19.4
28.5
40.5
24.3
29.8
42.2
40.5
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Commissioning and
Shutdown
BA/E-21900-06/3
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At the most, the pump can be operated against closed gate valve on the discharge side
until the allowable pump temperature is reached.
Switch on the motor.
If the delivery pressure does not increase despite rising speed, the pump has to be
switched off immediately and vented again carefully.
When the pressure gauge indicates delivery pressure, slowly open the control valve in
the pressure pipe until the duty point is reached. The rate of flow can be increased in
accordance with the characteristic curve until a point is reached where the motor would
be overloaded.
In case either the operation parameters are modified or they no longer correspond with
the ones stipulated in the order (delivery head, rate of flow Qmin and Qmax, viscosity,
density, liquid temperature), it is to be checked whether:
•
•
•
•
•
the magnet drive is still sufficient,
the motor is not overloaded,
on suction condition the suction head to be overcome does not get too high,
on feed condition the available feed head is still sufficient,
The maximum allowable temperature is not exceeded.
With liquid temperatures exceeding 100 °C it must be observed
that during commissioning or in case of varying operating
conditions the maximum speed in temperature changing does
not exceed 25 °C per minute.
On initial start-up, operate the pump for at least 3 hours under
operation conditions while checking for unusual noises and high
temperatures on the pump surface. Measure the surface
temperature with commercially available surface temperature
meters.
In rare cases it may happen during acceleration of the pump that
the magnet drive desynchronises ("breakaway of magnet drive").
This condition can be detected by monitoring the delivery head,
capacity and pump power output. Operation of the pump with a
desynchronised magnet drive can cause excessive temperatures.
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Commissioning and
Shutdown
4.
BA/E-21900-06/3
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Minimum and Maximum Rate of Flow
Unless otherwise indicated in the pump’s data sheet, the following limiting values should
be observed:
Continuous operation:
Minimum rate of flow
Maximum rate of flow
Qmin = 0.3 x Qopt
Qmax = 1.1 x Qopt
Short-time operation:
Minimum rate of flow
Maximum rate of flow
5.
Qmin = 0.1 x Qopt
Qmax = 1.2 x Qopt
Shutdown
Switch off the motor and close the shut-off valves. Drain the pump completely if it is
switched off for dismantling purposes.
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Maintenance
Page 1 of 27
01/2005
1.
General
Please observe the instructions given in the section "Safety" of this operation manual
when carrying out any maintenance works.
During the guarantee period, any maintenance works are either to be performed by
KLAUS UNION staff or with KLAUS UNION's authorisation. Dismantling and Reassembly of the centrifugal pump type SLM NV have to be carried out by qualified staff.
Magnet drives cause strong magnetic fields. Persons with a
pacemaker should not stay close to the magnet drive or come into
close bodily contact with parts of it.
Pumps processing dangerous liquids are to be decontaminated.
When draining the pump, any danger to persons and environment
must be precluded.
On principle, the driving motor must have been de-energized prior
to effecting any works on pumps. Unintentional energizing of the
pump must be precluded.
2.
Lubrication of Bearings
2.1
Journal Bearings
The journal bearings are lubricated by the pumped liquid. When the pump is operated to
its designated use, the journal bearings will be provided with a sufficient quantity of
lubricant and they will be resistant to wear and maintenance-free. Concerning
monitoring of operation to designated use, refer to instructions given in sub-section
“Inspection and Maintenance”.
If the pump has run dry unintentionally, the pump must be allowed
to cool down for a longer time. If the pump is filled with cold liquid
immediately upon its dry-running, the journal bearings may be
destroyed.
After longer periods of dry-running, the pump must be dismantled
and the journal bearings must be checked for any damage.
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Maintenance
Page 2 of 27
01/2005
2.2
Anti-Friction Bearings
To avoid the anti-friction bearings becoming an ignition source,
the anti-friction bearings must be maintained according to the
instructions given in the operation manual.
The anti-friction bearings are designed for a rated working life of 25000 hours at a
bearing temperature of 90°C. Replace the anti-friction bearings after 90 % of their
service life at the latest. However, the working life of the bearings can reduce due to
higher bearing temperatures and unfavourable operating conditions (strong vibrations,
aggressive environmental conditions, etc.).
2.2.1
Grease-Lubrication of Bearing-Support Construction SLM NVN, SLM NVS,
SLM NVE
For lubrication, use a high-quality anti-friction grease on lithium soap basis to
DIN 51825 of the following properties:
•
•
•
Basic oil:
Basic oil viscosity at 40°C:
Consistency (NLGI grade):
Mineral oil
abt. 90 mm²/s
2 to 3
When mixing various types of lubricants it may happen that the
consistency is changed in a way that sufficient lubrication of the
bearings is no longer guaranteed. If it is not clear whether the
lubricants can be mixed, the previously used lubricant has to be
removed from the bearing completely.
2.2.1.1 First Filling
If the pump has not been used for long periods (more than 1 year) the grease has to be
replaced. Refer to the table for the exact quantities of grease required.
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Maintenance
Page 3 of 27
01/2005
InletØ
SF
[mm]
040
040
040
050
050
050
050
065
065
065
065
065
080
080
080
080
080
100
100
100
100
100
Pump Size
OutletØ
ImDF
pellerØ
[mm]
[mm]
025
125
025
160
025
200
032
125
032
160
032
200
032
250
040
125
040
160
040
200
040
250
040
315
050
125
050
160
050
200
050
250
050
315
065
125
065
160
065
200
065
250
065
315
Quantity of
Grease
[cm³]
NVE
NVN NVS
70
100
70
100
100
70
100
100
100
200
70
100
100
70
100
200
100
100
100
InletØ
SF
[mm]
125
125
125
125
125
125
125
125
125
150
150
150
200
200
200
200
250
250
250
300
Pump Size
OutletØ
ImDF
pellerØ
[mm]
[mm]
080
160
080
200
080
250
080
315
080
400
100
200
100
250
100
315
100
400
125
250
125
315
125
400
150
250
150
315
150
400
150
500
200
250
200
315
200
400
250
315
Quantity of
Grease
[cm³]
NVE
NVN NVS
100
100 200
200
100
100
100
200
200
100
200
200
100
-
200
-
100
-
200
-
200
200
2.2.1.2 Regreasing During Operation
Depending on the temperature of the anti-friction bearings and the pump speed,
different relubricating intervals are to be observed:
Temperature of AntiFriction Bearings
Up to 100°C
More than 100°C
Pump Speed
1450 / 1750
2900 / 3500
1450 / 1750
2900 / 3500
1/min
1/min
1/min
1/min
Regreasing Intervals
5000 h
3500 h
1800 h
650 h
Regreasing of the bearings can be carried out either during operation or standstill.
When regreasing the anti-friction bearings during operation mind
the danger due to rotating shafts.
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Maintenance
Page 4 of 27
01/2005
Lubricate the ball bearings (part no. 321) with 10 g of grease. Regreasing is effected by
means of a grease gun via the lubricating nipple (part no. 630.2) located in the bearing
support (part no. 330).
2.2.2
Oil-Lubrication of Bearing-Support Construction SLM NVO, SLM NVEO
The oil has to be changed at least once a year or after a certain number of operating
hours depending on the temperature of the anti-friction bearings.
Anti-friction-bearing
temperature
Operating hours
Up to 80 °C
8000
More than 80°C
5000
Shut the pump down for the oil change.
Refer to the following table for the oil quantities required for the respective pump size.
Pump Size
(Impeller Diameter)
SLM NVO 125/ 160/ 200
SLM NVO 250
SLM NVO 315/ 400
SLM NVO 500
Quantity of Oil
abt. 450 ml
abt. 540 ml
abt. 1300 ml
abt. 1800 ml
When using a Constant-Level-Oiler, the additional quantity of oil amounts to 110 ml.
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Maintenance
Page 5 of 27
01/2005
For normal applications (pump temperature < 250°C, ambient temperature between
-10°C and 40°C) a lubricating oil on the basis of mineral oil with viscosity grade
ISO-VG 68 to DIN 51519 can be used. For special applications at higher temperatures
(temperature of the pumped liquid exceeding 250°C), lower temperatures (temperature
up to –60°C) or when a wide temperature range needs to be covered, a synthetic
lubricating oil with viscosity grade ISO-VG 100 is recommended.
3.
Inspection and Maintenance
3.1
Inspection during Operation
To prevent the occurrence of ignition sources, which can be
caused by failures and result in an explosion, the operating
company has to take measures for monitoring the pump.
Failures occurring during operation can cause the occurrence of an ignition source on
the pump that can lead to an explosion when an explosive atmosphere is given.
Examples for ignition sources: hot surfaces, sparks and discharge by electrostatic
charging. The following table lists possible malfunctions and measures to prevent that
these malfunctions result in the occurrence of an ignition source:
Malfunction
Possible Consequences
Operation with wrong
direction of rotation
Overheating of the isolation Monitoring of
shell
• Delivery head or
• Capacity or
• Pump output or
• Isolation shell
temperature
Overheating of the isolation Monitoring of
shell
• Delivery head or
• Capacity or
• Pump output or
• Isolation shell
temperature
Overheating of the isolation Monitoring of
shell caused by
• Delivery head or
vaporization in the pumped
• Capacity or
liquid or by cavitation within
• Pump output or
the pump
• Isolation shell
temperature
Dry-running as a result of
incorrect commissioning
(pump not filled and
vented)
Throttling of the suction
side shut-off valve or
clogging of a filter in the
suction pipework
Measures
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Malfunction
Possible Consequences
Measures
Pumping of non-specified
liquid (liquid temperature
too high)
The allowable surface
temperature is exceeded
Pumping of non-specified
liquid (liquid density too
high)
Breakaway of magnet drive
due to exceeding of the
allowable transmission
capacity
Monitoring of
• Liquid temperature or
• Isolation shell
temperature
Monitoring of
• Delivery head or
• Capacity or
• Pump output or
• Isolation shell
temperature
Monitoring of
• Delivery head or
• Capacity or
• Pump output or
• Isolation shell
temperature
Breakaway of magnet drive
due to exceeding of the
allowable transmission
capacity.
Overheating of the isolation
shell due to flush flow being
too low
Vaporization of liquid in the Monitoring of
Pumping of non-specified
pump
liquid (thermal capacity of
• Delivery head or
the liquid too low)
• Capacity or
• Pump output or
• Isolation shell
temperature
Pumping less than the
Vaporization of liquid in the Monitoring of
specified minimum flow
pump
• Capacity or
• Pump output or
• Isolation shell
temperature
Breakaway of magnet drive Overheating of the isolation Monitoring of
shell
on commissioning or by
• Delivery head or
overload of the magnet
• Capacity or
drive
• Pump output or
• Isolation shell
temperature
Damage to the anti-friction Overheating of anti-friction Monitoring of
bearings, heat caused by
bearings due to non• Anti-friction-bearing
observance of maintenance friction between rotating
temperature or
and stationary components
instructions
• Anti-friction-bearing
vibration
NPSH of the plant is lower Vaporization of liquid in the Monitoring of
than NPSH of the pump
pump
• Delivery head or
• Capacity or
• Pump output or
• Isolation shell
temperature
Pumping of non-specified
liquid (liquid viscosity too
high)
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For monitoring of the driving motor and the flexible coupling, observe the instructions
given in the respective operation manuals.
3.1.1
Monitoring of the Pump Output
The pump power input indicates whether the pump is operated to its designated use.
Moreover, any malfunctions or damage to the pump can be inferred from the pump
output. KLAUS UNION recommend the use of appropriate monitoring instruments in
areas subject to explosion hazards as well as in non-hazardous locations and offer such
devices on request. The instruments will be installed in the control cabinet and thus do
not have to be approved for hazardous areas.
3.1.2
Monitoring the Isolation Shell Temperature
Many malfunctions have a direct effect on the temperature of the isolation shell. As the
surface temperature on the outside of the isolation shell can be a direct ignition source
in hazardous areas, it is recommended to use an instrument to monitor the isolation
shell temperature particularly when the pump is used in hazardous areas.
KLAUS UNION can offer suitable instruments for that purpose.
3.1.3
Vibration Monitoring
The measuring of vibrations is particularly suitable to monitor the anti-friction bearings.
Refer to the table for the allowable rate of vibrations. The rate of vibrations has to be
measured horizontally and vertically to the shaft axis on the coupling-side end of the
bearing support. If the rates of vibrations thus determined exceed the maximum
allowable values, the cause has to be found.
Speed n
[min-1]
n ≤ 1800
1800 < n ≤ 4500
Maximum effective Rate of Vibrations veff (mm/s)
depending on the Shaft Height h1 of the Pump
h1 > 225 mm
h1 ≤ 225 mm
[mm/s]
[mm/s]
2.8
4.5
4.5
7.1
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3.2
Maintenance
The following descriptions of maintenance works to be executed require that the pump
has already been partially dismantled. Check the parts for their re-usability and replace
damaged components using new original spare parts.
If the clearance between rotating and stationary components is
too narrow, it may happen that these components contact and the
resulting frictional heat entails excessive temperatures.
3.2.1
Journal Bearings
Replace the journal bearing or parts of it using new original spare parts when the slide
faces show visible signs of wear (e. g. traces of grooves from running). Refer to the
following table for dimensions of bearing sleeves and bearing bushes as well as for the
axial clearance of the journal bearing.
Bearing
Inner Diameter
Bearing Bush
∅A
Outer Diameter
Bearing Sleeve
∅B
Thrust Bearing
Clearance
C
07 S
40 +0.025
39.97 –0.01
0.1 ±0.05
09 E
40
+0.025
39.98 –0.01
0.3 ±0.1
09 S
50 +0.025
49.97 –0.02
0.07 ±0.01
13 E / 16 E
53 +0.03
52.98 –0.01
0.5 ±0.1
19 E / 25 E / 31E
80 +0.035
79.98 –0.01
0.5 ±0.1
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3.2.2
Wear Ring Allowance
Replace wear rings (part no. 512, part no. 512.1) using new original spare parts when
the following maximum radial allowances are exceeded:
Choke-Gap
Diameter
[mm]
50
76
90
140
210
4.
to 75
to 89
to 139
to 209
to 270
> 270
Maximum Radial
Allowance
[mm]
s1
s2
0.20
0.25
0.25
0.35
0.50
0.50
0.25
0.30
0.40
0.50
Dismantling
For assembly and dismantling, the following KU-special tools are available:
Designation
Clamping Aid for Magnet Carrier Size 67/07S
Clamping Aid for Magnet Carrier Size 90/09E
Clamping Aid for Magnet Carrier Size 130/13E
Clamping Aid for Magnet Carrier Size 160/16E
Clamping Aid for Magnet Carrier Size 190/19E
Clamping Aid for Magnet Carrier Size 250/25E
Assembly Aid Shaft Nut Drive Shaft KM 9
Assembly Aid Shaft Nut Drive Shaft KM11
Assembly Aid for Bearing Bush Magnet Drive Size 09E
Assembly Aid for Bearing Bush Magnet Drive Size 09E .. Z
Id.-No.
P00001043
P00001044
P00001045
P00001046
P00001047
P00020945
P00548891
P00107749
P00969926
P00969925
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4.1
Preparations
•
•
•
•
•
Isolate the current feed to the motor.
Close the valves in suction and pressure pipework.
Dispose of the remaining residual liquid in the pump.
Remove the coupling guard.
When using a flexible coupling with cartridge unit: dismantle the cartridge unit. The
motor can remain installed on the base plate. When using a flexible coupling without
cartridge unit, remove the motor from coupling and base plate.
• Remove the pump-side coupling half from the pump's drive shaft.
ATTENTION
Use an offset cam for dismantling of the coupling.
• Disconnect suction and pressure nozzles of the pump from the pipework.
4.2
Dismantling of the Pump
ATTENTION
For assembly and dismantling of the pump, refer to
the pertaining sectional drawing.
It is recommended to use the specified KU-special tools.
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4.2.1
Pumps of Close-Coupled Construction Type SLM NVB and SLM NVEB
To dismantle the close-coupled pump, first remove the motor lantern (part no. 146.2)
together with the motor from the intermediate lantern (part no. 146.1). The pump is then
placed vertically on the intermediate lantern. Further dismantling of the close-coupled
pump as described for construction type with bearing support.
4.2.2
Pumps of Bearing-Support Construction Type SLM NVN, SLM NVS and
SLM NVO
With pumps of construction type with oil-lubricated anti-friction bearings, prior to
dismantling the lubricating grease must be drained from the bearing support (part no.
330) via the oil drain plug (part no. 903.8).
For dismantling, the pump should be positioned as indicated in the following drawing.
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•
•
•
•
Release and remove assembly stud nuts (part no. 920.1) and dismantle the
volute casing (part no. 102).
Pull the complete assembly comprising impeller (part no. 230) / casing cover
(part no. 161) / isolation shell (part no. 817) with a suitable lifting device from the
intermediate lantern (part no. 146.1).
Unscrew the cap screws (part no. 901.1) at the isolation shell flange and
dismantle the isolation shell. Use the forcing threads in the isolation shell flange
provided for that purpose.
With plastic or ceramics isolation shell:
Unscrew the cap screws (part no. 901.1) at the straining ring (part no. 515),
dismantle straining ring and isolation shell.
Plastic Isolation Shell
Ceramics Isolation Shell
•
For further dismantling, firmly secure the outer magnet carrier.
[Use of KU-special tool (clamping aid) is recommended]
• Release the impeller screwing (part no. 901.19 / part no. 922) and pull the
impeller off the shaft.
•
For pump construction with inducer, the screwing (part no. 901.19 / part no. 922)
is be released and removed. Turn the inducer (part no. 236) off the impeller
screwing (part no. 922). Release the impeller screwing (part no. 922) and pull the
impeller off the shaft.
•
Remove the thrust bearing (part no. 314) on the impeller side together with the
holder (part no. 386).
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Magnet Drive Size 09E:
•
•
•
•
•
•
Pull the casing cover (part no. 161) together with the bearing bush (part no.
545.1) off the pump shaft.
Carefully clamp the casing cover and unscrew the bearing bush from the casing
cover. (Size of the jaw SW80, use of KU-special tool is recommended)
Carefully pull bearing sleeves (part no. 529.1) and distance sleeve (part no. 525)
off the shaft.
Remove the inner magnet carrier from the clamping aid and pull the pump shaft
out of the inner magnet carrier.
Unscrew cap screws (part no. 901.18) and pull the intermediate lantern (part
no. 146.1) off the bearing support (part no. 330). Use the forcing threads in the
bearing support provided for that purpose.
Remove the lock washer (part no. 931) and release the shaft nut (part no. 921)
(use of KU-special tool is recommended). Pull the complete outer magnet carrier
(part no. 861 and 818.1) off the drive shaft (part no. 213).
Magnet Drive Sizes 13E, 16E, 19E, 25E, 31E:
•
•
•
•
•
•
Pull the casing cover (part no. 161) together with the bearing bush (part
no. 545.1) off the pump shaft.
Unscrew the cap screws (part no. 901.3) at the casing cover (part no. 161) and
remove the wear ring (part no. 512.1). Pull the casing cover off the bearing bush
(part no. 545.1) and the bearing bush off the shaft (part no. 211).
Carefully pull bearing sleeves (part no. 529.1) and distance sleeve (part no. 525)
off the shaft.
Remove the inner magnet carrier from the clamping aid and pull the pump shaft
out of the inner magnet carrier.
Unscrew the cap screws (part no. 901.18) and pull the intermediate lantern (part
no. 146.1) off the bearing support (part no. 330). Use the forcing threads in the
bearing support provided for that purpose.
Remove the lock washer (part no. 931) and release the shaft nut (part no. 921)
(use of KU-special tool is recommended). Pull the complete outer magnet carrier
(part no. 861 und 818.1) off the drive shaft (part no. 213).
All Magnet Drive Sizes:
•
•
•
Remove the bearing support from the assembly aid and position it horizontally on
a stable support.
Unscrew cap screws (part no. 901.17) and remove the bearing cover (part
no. 360). Use the forcing threads provided for that purpose.
For Grease-Lubricated Construction without Thermal Barrier:
o Remove the snap ring (part no. 932).
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•
For Grease-Lubricated Construction with Thermal Barrier:
o Dismantle thermal barrier (part no. 152) with / without shaft seal ring (part
no. 421.3) and shaft sleeve (part no. 525.1).
o Remove the snap ring (part no. 932).
•
For Oil-Lubricated Construction:
o Dismantle thermal barrier (part no. 152) with
(part no. 421.3) and shaft sleeve (part no. 525.1).
o Remove the snap ring (part no. 932).
shaft
seal
ring
•
For Oil-Lubricated Construction with Labyrinth Sealing:
o Remove the snap ring (part no. 932.2).
o Dismantle thermal barrier (part no. 152) with bearing cover (part no.
360.2) and shaft sleeve (part no. 525.1).
o Remove the snap ring (part no. 932).
•
Remove the bearing unit [drive shaft (part no. 213), ball bearing (part no. 321)],
bearing insert (part no. 381 with grease-lubricated construction) from the bearing
support.
Dismantle the ball bearings with standard offset cams.
•
4.2.3
Pumps with Bearing Support SLM NVE, SLM NVEO
In case of pump construction type with oil-lubricated anti-friction bearings, prior to
dismantling the lubricating oil must be drained from the bearing support (part no. 330)
via the oil drain plug (part no. 903.8).
For dismantling purposes, the pump should be positioned as shown in sub-section
"Pumps with bearing support SLM NVN, SLM NVS and SLM NVO".
•
•
•
•
•
•
•
Release the assembly stud nuts (part no. 920.1) and remove the volute casing
(part no. 102).
Unscrew the cap screws (part no. 901.1) and remove the assembly comprising
impeller (part no. 230) / bearing bush (part no. 545.1) / inner magnet carrier (part
no. 818) with a suitable lifting device.
Lift the isolation shell (part no. 817) out of the centring of the intermediate lantern
(part no. 146.1).
Firmly secure inner magnet carrier with impeller and bearing bush.
[Use of KU-special tool (clamping aid) is recommended]
Unscrew impeller screwing (part no. 906) and impeller from the inner magnet
carrier shaft.
Pull thrust bearings (part no. 314), bearing sleeve (part no. 529.1) and bearing
bush (part no. 545.1) off the inner magnet carrier shaft.
Unscrew cap screws (part no. 901.18) and pull the intermediate lantern (part
no. 146.1) off the bearing support (part no. 330). Use the forcing threads in the
bearing support provided for that purpose.
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•
•
•
Release the lock washer (part no. 931) and the shaft nut (part no. 921) (use of
KU-special tool is recommended). Pull the complete outer magnet carrier (part
no. 861 und 818.1) off the drive shaft (part no. 213).
Remove the bearing support from the assembly aid and position it horizontally on
a stable support.
Unscrew cap screws (part no. 901.17) and remove bearing cover (part no. 360).
Use the forcing threads provided for that purpose.
•
For Grease-Lubricated Construction without Thermal Barrier:
o Remove the snap ring (part no. 932).
•
For Oil-Lubricated Construction:
o Dismantle thermal barrier (part no. 152) with shaft seal ring (part
no. 421.3) and shaft sleeve (part no. 525.1).
o Remove the snap ring (part no. 932).
•
Remove the bearing unit [drive shaft (part no. 213), ball bearing (part no. 321)],
bearing insert (part no. 381 with grease-lubricated construction) from the bearing
support.
Remove the ball bearings with standard offset cams.
•
5.
Re-Assembly
Prior to re-assembly, check the usability of all pump components. During assembly, the
anti-friction bearings must be protected from dirt and moisture. Any sealing surfaces are
to be cleaned carefully, used static gaskets are to be replaced by new ones. Check the
clearances and the journal bearing for wear as indicated above.
Fitting surfaces and screwed connections have to be coated with graphite or a similar
agent. Where components in contact with the liquid are concerned, make sure that the
antiseize agent used is compatible with the pumped liquid.
When replacing the outer magnet carrier tube and/or outer
magnet carrier hub by original spare parts, this unit must be
assembled prior to balancing. (Balancing quality class G 6.3 to
DIN ISO 1940).
5.1
Magnet Drive
5.1.1
Bearing-Support Construction SLM NVN, SLM NVS, SLM NVO
•
Heat the ball bearing (part no. 321) to abt. 80°C and push it on the drive shaft
(part no. 213).
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•
For Grease-Lubricated Construction without Thermal Barrier:
o Push the bearing insert (part no. 381) on the shaft.
o Heat the second ball bearing to abt. 80°C and mount it on the shaft.
o Insert the snap ring (part no. 932) into the bearing support (part no. 330).
o Heat the bearing support to abt. 80 °C in the bearing seat area, push the
shaft equipped with anti-friction bearings into the bearing seat.
o Insert the radial shaft seal ring (part no. 421.2) into the bearing cover (part
no. 360), mount the bearing cover to the bearing support by means of cap
screws (part no. 901.17).
ATTENTION
•
During installation of the radial shaft seal ring (part
no. 421.2) into the bearing cover (part no. 360) takes
care to observe the correct assembly direction.
For Grease-Lubricated Construction with Thermal Barrier:
o Push the bearing insert (part no. 381) on the shaft.
o Heat the second ball bearing to abt. 80°C and mount it on the shaft.
o Insert the snap ring (part no. 932) into the bearing support (part no. 330).
o Heat the bearing support to abt. 80 °C in the bearing seat area, push the
shaft equipped with the anti-friction bearings into the bearing seat.
ATTENTION
When installing a new secondary sealing, this must be
pushed on the shaft sleeve about 3 minutes prior to its
installation in the thermal barrier. Thus, the sealing lip
is predeformed prior to final installation.
o Then the shaft sleeve (part no. 525.1) is pushed on the drive shaft.
o Insert the secondary sealing (part no. 421.3) into the thermal barrier (part
no. 152), push the thermal barrier in front of the bearing support
ATTENTION
When fitting the secondary sealing (part no. 421.3) in
the thermal barrier (part no. 152) take care to observe
the correct assembly direction. The sealing lip of the
secondary sealing must face the outer magnet carrier.
o Insert radial shaft seal ring (part no. 421.2) into the bearing cover (part no.
360), mount the bearing cover with cap screws (part no. 901.17) to the
bearing support.
ATTENTION
During installation of the radial shaft seal ring (part
no. 421.2) into the bearing cover (part no. 360) takes
care to observe the correct assembly direction.
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•
For Oil-Lubricated Construction:
o Push the splash ring (part no. 508) on the shaft via the knurled surface.
o Heat the second ball bearing to abt. 80°C and mount it on the shaft.
o Insert the snap ring (part no. 932) into the bearing support (part no. 330).
o Heat the bearing support in the bearing seat area to abt. 80 °C, push the
shaft equipped with anti-friction bearings into the bearing seat.
ATTENTION
When installing a new secondary sealing, this must be
pushed on the shaft sleeve about 3 minutes prior to its
installation in the thermal barrier. Thus, the sealing lip
is predeformed prior to final installation.
o Then the shaft sleeve (part no. 525.1) is pushed on the drive shaft.
o Insert the secondary sealing (part no. 421.3) into the thermal barrier (part
no. 152), push the thermal barrier in front of the bearing support
ATTENTION
When fitting the secondary sealing (part no. 421.3) in
the thermal barrier (part no. 152) take care to observe
the correct assembly direction. The sealing lip of the
secondary sealing must face the outer magnet carrier.
o Insert radial shaft seal ring (part no. 421.2) into the bearing cover (part
no. 360), mount the bearing cover with cap screws (part no. 901.17) to the
bearing support.
ATTENTION
During installation of the radial shaft seal ring (part
no. 421.2) into the bearing cover (part no. 360) takes
care to observe the correct assembly direction.
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•
For Oil-Lubricated Construction with Labyrinth Sealing:
o Push the splash ring (part no. 508) on the shaft via the knurled surface.
o Heat the second ball bearing to abt. 80°C and mount it on the shaft.
o Insert the snap ring (part no. 932) into the bearing support (part no. 330).
o Heat the bearing support in the bearing seat area to abt. 80 °C, push the
shaft equipped with anti-friction bearings into the bearing seat.
o Push shaft sleeve (part no. 525.1) on the drive shaft.
o Insert the bearing cover (part no. 360.2) into the thermal barrier (part
no. 152) and secure it with snap ring (part no. 932.2).
o Mount the thermal barrier in front of the bearing support.
o Mount the bearing cover (part no. 360) with cap screws (part no. 901.17)
to the bearing support.
o Push the splash ring (part no. 423.1) on the drive shaft (part no. 213).
•
Secure drive shaft (part no. 213) against turning and insert the key (part
no. 940.1) into the key groove.
Push the outer magnet carrier with the outer magnet carrier hub on the shaft end
and fasten and secure the outer magnet carrier with the lock washer (part
no. 931) and the shaft nut (part no. 921). (Use of KU-special tool is
recommended)
•
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5.1.2
Bearing-Support Construction SLM NVE, SLM NVEO
•
Heat the ball bearing (part no. 321) to abt. 80°C and push it on the drive shaft
(part no. 213).
•
For Grease-Lubricated Construction without Thermal Barrier:
o Push the bearing insert (part no. 381) on the shaft.
o Heat the second ball bearing to abt. 80°C and mount it on the shaft.
o Insert the snap ring (part no. 932) into the bearing support (part no. 330).
o Heat the bearing support in the bearing seat area to abt. 80 °C, push the
shaft equipped with anti-friction bearings into the bearing seat.
o Insert the radial shaft seal ring (part no. 421.2) into the bearing cover (part
no. 360), mount the bearing cover with cap screws (part no. 901.17) to the
bearing support.
ATTENTION
•
During installation of the radial shaft seal ring (part
no. 421.2) into the bearing cover (part no. 360) takes
care to observe the correct assembly direction.
For Oil-Lubricated Construction:
o Push the splash ring (part no. 508) on the shaft via the knurled surface.
o Heat the second ball bearing to abt. 80°C and mount it on the shaft.
o Insert the snap ring (part no. 932) in the bearing support (part no. 330).
o Heat the bearing support in the bearing seat area to abt. 80 °C, push the
shaft equipped with anti-friction bearings into the bearing seat.
ATTENTION
When installing a new secondary sealing, this must be
pushed on the shaft sleeve about 3 minutes prior to its
installation in the thermal barrier. Thus, the sealing lip
is predeformed prior to final installation.
o Then the shaft sleeve (part no. 525.1) is pushed on the drive shaft.
o Insert the radial shaft seal ring (part no. 421.3) into the thermal barrier
(part no. 152), push the thermal barrier in front of the bearing support.
ATTENTION
When fitting the secondary sealing (part no. 421.3) in
the thermal barrier (part no. 152) take care to observe
the correct assembly direction. The sealing lip of the
secondary sealing must face the outer magnet carrier.
o Insert the radial shaft seal ring (part no. 421.2) into the bearing cover (part
no. 360), mount the bearing cover to the bearing support by means of cap
screws (part no. 901.17).
ATTENTION
During installation of the radial shaft seal ring (part
no. 421.2) into the bearing cover (part no. 360) takes
care to observe the correct assembly direction.
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Maintenance
Page 20 of 27
01/2005
Grease-Lubricated Anti-Friction Bearings
•
•
5.1.3
Oil-Lubricated Anti-Friction Bearings
Secure drive shaft (part no. 213) against turning and insert the key (part no.
940.1) into the key groove.
Push the outer magnet carrier with the outer magnet carrier hub on the drive
shaft and fasten and secure the outer magnet carrier with the lock washer (part
no. 931) and the shaft nut (part no. 921). (Use of KU-special tool is
recommended)
Close-Coupled Construction SLM NVB, SLM NVEB
Construction with Thermal Barrier and Secondary Sealing:
ATTENTION
•
When installing a new secondary sealing, this must be
pushed on the outer magnet carrier hub about
3 minutes prior to its installation in the thermal barrier.
Thus, the sealing lip is predeformed prior to final
installation.
Insert the secondary sealing (part no. 421.3) into the thermal barrier (part
no. 152).
ATTENTION
When fitting the secondary sealing (part no. 421.3) in
the thermal barrier (part no. 152) take care to observe
the correct assembly direction. The sealing lip of the
secondary sealing must face the outer magnet carrier.
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Maintenance
Page 21 of 27
01/2005
•
•
Push the motor lantern (part no. 146.2) with the thermal barrier fitted to it or the
motor lantern (part no. 146.2) and the thermal barrier (part no. 152) in front of the
motor and fasten the components to the motor by means of cap screws (part
no. 901.12).
Push the complete outer magnet carrier (part no. 818.1 / part no. 861) onto the
motor shaft and fasten and secure it by means of cap screws (part no. 901.11
and 914.11) and lock washer (part no. 554.4).
Construction without Thermal Barrier and Secondary Sealing
•
•
Push the motor lantern (part no. 146.2) in front of the motor and fasten it to the
motor by means cap screws (part no. 901.12).
Push the complete outer magnet carrier (part no. 818.1 / part no. 861) onto the
motor shaft and fasten and secure it by means of cap screws (part no. 901.11
and 914.11) and lock washer (part no. 554.4).
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Maintenance
Page 22 of 27
01/2005
5.2
Hydraulic Component
5.2.1
SLM NVN, SLM NVS, SLM NVB, SLM NVO
5.2.1.1 Magnet Drive 09E
•
•
•
•
•
•
•
•
Screw bearing bush (part no. 545.1) into the casing cover (part no. 161). (Size of
the jaw SW 80, use of KU-special tool is recommended)
Push the inner magnet carrier (part no. 818.2) on the pump shaft (part no. 211)
and fix it in a clamping aid. [Use of KU-special tool (clamping aid) is
recommended]
Insert the elastomer washer (part no. 504.2) and the thrust bearing (part no. 314)
into the inner magnet carrier.
Carefully assemble SiC-bearing sleeves (part no. 529.1) and distance sleeve
(part no. 525) and push the resulting assembly over the pump shaft.
Carefully push the assembly comprising casing cover / bearing bush over the
bearing sleeves on the pump shaft.
Put the elastomer washer (part no. 504.2) and thrust bearing (part no. 314) in the
holder (part no. 386) and push it on the pump shaft.
Install the key (part no. 940.4) in the key groove of the pump shaft and push the
impeller (part no. 230) on the pump shaft.
Fasten and secure the impeller with the impeller screwing (part no. 901.19 / part
no. 922). (For tightening moments of the screwing refer to the corresponding
table)
•
For construction with inducer, fasten and secure the impeller with the impeller
screwing (part no. 922). (For tightening moments of the screwing refer to the
corresponding table) Screw the inducer (part no. 236) on the impeller screwing
(part no. 922) and fasten and secure it by means of the screwing (part no. 901.19
/ 931.3).
•
Remove the assembled unit from the clamping aid and position the assembly
with the impeller facing the ground on a stable support to proceed with the
assembly of the isolation shell.
•
For Construction with Metal Isolation Shell:
Insert the gasket (part no. 400.3) into the lining groove of the casing cover. Place
the isolation shell (part no. 817) in the centring and fasten it on the casing cover
by means of cap screws (part no. 901.1).
•
For Construction with Plastic Isolation Shell:
The inner isolation shell made of PTFE functions like a static gasket at the casing
cover. Fit the isolation shell (part no. 817, outer and inner isolation shells) in the
lining groove of the casing cover. Pull the straining ring (part no. 515) over the
isolation shell and screw it with cap screws (part no. 901.1) on the casing cover.
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Maintenance
Page 23 of 27
01/2005
•
For Construction with Ceramics Isolation Shell:
Fit the O-ring (part no. 412.1) in the lining groove of the casing cover. Pull the
straining ring (part no. 515) over the isolation shell (part no. 817), position it
together with the isolation shell in the centring and screw it with cap screws (part
no. 901.1) on the casing cover.
ATTENTION
In case of pump construction with ceramics isolation
shell, make sure the isolation shell does not jam in the
straining ring. You must be able to turn the isolation
shell freely in the straining ring.
5.2.1.2 Magnet Drive 13E, 16E, 19E, 25E, 31E
•
•
•
•
•
•
•
•
Screw the bearing bush (part no. 545.1) together with the wear ring (part
no. 512.1) with cap screws (part no. 901.3) on the casing cover (part no. 161).
Push the inner magnet carrier (part no. 818.2) on the pump shaft (part no. 211)
and fix it in a clamping aid. [KU-special tool (clamping aid) is recommended.]
Insert the elastomer washer (part no. 504.2) and the thrust bearing (part no. 314)
in the inner magnet carrier.
Carefully assemble SiC-bearing sleeves (part no. 529.1) and distance sleeve
(part no. 525) and push the resulting assembly over the pump shaft.
Carefully push the assembly comprising casing cover / bearing bush over the
bearing sleeves on the pump shaft.
Put the elastomer washer (part no. 504.2) and thrust bearing (part no. 314) in the
holder (part no. 386) and push it on the pump shaft.
Install the key (part no. 940.4) in the key groove of the pump shaft and push the
impeller (part no. 230) on the pump shaft.
Fasten and secure the impeller with the impeller screwing (part no. 901.19 / part
no. 922). (For tightening moments of the screwing refer to the corresponding
table)
•
For construction with inducer, fasten and secure the impeller with the impeller
screwing (part no. 922). (For tightening moments of the screwing refer to the
corresponding table). Screw the inducer (part no. 236) on the impeller screwing
(part no. 922) and fasten and secure it by means of the screwing (part no. 901.19
/ 931.3).
•
Remove the assembled unit from the clamping aid and position the assembly
with the impeller facing the ground on a stable support to proceed with the
assembly of the isolation shell.
•
For Construction with Metal Isolation Shell:
Insert the gasket (part no. 400.3) into the lining groove of the casing cover. Place
the isolation shell (part no. 817) in the centring and fasten it on the casing cover
by means of cap screws (part no. 901.1).
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Maintenance
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01/2005
•
For Construction with Plastic Isolation Shell:
The inner isolation shell made of PTFE functions like a static gasket at the casing
cover. Fit the isolation shell (part no. 817, outer and inner isolation shells) in the
lining groove of the casing cover. Pull the straining ring (part no. 515) over the
isolation shell and screw it with cap screws (part no. 901.1) on the casing cover.
•
For Construction with Ceramics Isolation Shell:
Fit the O-ring (part no. 412.1) in the lining groove of the casing cover. Pull the
straining ring (part no. 515) over the isolation shell (part no. 817), position it
together with the isolation shell in the centring and screw it with cap screws (part
no. 901.1) on the casing cover.
ATTENTION
5.2.2
In case of pump construction with ceramics isolation
shell, make sure the isolation shell does not jam in the
straining ring. You must be able to turn the isolation
shell freely in the straining ring.
SLM NVE, SLM NVEB, SLM NVEO
5.2.2.1 Magnet Drive 07S
•
Firmly fix inner magnet carrier shaft (part no. 818) in a clamping aid.
[Use of KU-special tool (clamping aid) is recommended]
• Push thrust bearing (part no. 314), bearing sleeve (part no. 529.1), bearing bush
(part no. 545.1), thrust bearing (part no. 314) on the inner magnet carrier shaft.
• Screw the impeller (part no. 230) on the shaft end and fasten it by means of
washer (part no. 554.6), circlip (part no. 931.2) and cap screw (part no. 906).
5.2.2.2 Magnet Drive 09S
•
•
•
•
•
•
Firmly fix inner magnet carrier shaft (part no. 818) in a clamping aid.
[Use of KU-special tool (clamping aid) is recommended.]
Push the thrust bearing (part no. 314) over the shaft.
Fit the tolerance ring (part no. 511) in the groove of the inner magnet carrier shaft
and push bearing sleeve (part no. 529.1) over the shaft.
Screw the bearing bush (part no. 545.1) on the bearing flange (part no. 350) by
means of cap screws (part no. 901.1) and push the resulting assembly over the
bearing sleeve.
Push the spacer (part no. 504) and the thrust bearing (part no. 314) on the inner
magnet carrier shaft.
Fit the spacer (part no. 504.2) in the impeller, screw the impeller (part no. 230)
on the shaft end and fasten it by means of washer (part no. 554.6), circlip (part
no. 931.2) and cap screw (part no. 906).
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Maintenance
Page 25 of 27
01/2005
5.3
Final Assembly
5.3.1
SLM NVN, SLM NVS, SLM NVB, SLM NVO
•
Bearing-Support Construction:
o Fix the completely assembled bearing support vertically in the assembly
aid as described in the corresponding dismantling procedure.
o Screw the intermediate lantern (part no. 146.1) on the bearing support by
means of screws (part no. 901.18 / part no. 902.3).
•
Close-Coupled Construction:
o Position the motor with flanged-on motor lantern (part no. 146.2) and the
completely assembled outer magnet carrier vertically on a stable support
with the outer magnet carrier facing upward. Secure the assembly against
overturning.
o Screw the intermediate lantern (part no. 146.1) on the motor lantern by
means of screws (part no. 901.18 / part no. 902.3).
•
Position the assembled unit comprising impeller/casing cover/isolation shell in
the centring of the intermediate lantern.
ATTENTION
The position of the casing cover in the intermediate
lantern is determined by a set screw in the
intermediate lantern.
•
•
Fit the gasket (part no. 400.1) in the centring of the casing cover.
Screw the assembly studs (part no. 902) in the threaded bores of the volute
casing (part no. 102).
• Put the volute casing in the centring of the casing cover and fasten it by means of
the assembly stud nuts (part no. 920.1) (the nuts to be tightened only slightly!).
• Put the pump in a horizontal position, align volute casing and intermediate
lantern and tightly fasten the assembly stud nuts (part no. 920.1).
(For tightening moments of the screwing refer to the corresponding table.)
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Maintenance
Page 26 of 27
01/2005
5.3.2
SLM NVE, SLM NVEB, SLM NVEO
•
Bearing-Support Construction:
o Fix the completely assembled bearing support vertically in the assembly
aid as described in the corresponding dismantling procedure.
o Screw the intermediate lantern (part no. 146.1) on the bearing support
by means of screws (part no. 901.18 / part no. 902.3).
•
Close-Coupled Construction:
o Position the motor with assembled outer magnet carrier vertically on a
stable support with the outer magnet carrier facing upward. Secure the
assembly against overturning.
o Screw the intermediate lantern (part no. 146.1) on the motor lantern
by means of screws (part no. 901.18).
•
•
Fit the isolation shell (part no. 817) in the centring of the intermediate lantern.
Position the assembly comprising impeller/journal bearing/inner magnet carrier in
the centring of the isolation shell and use cap screws (part no. 901.1) to screw
the unit on.
ATTENTION
•
•
Mind the correct position of the bearing cover in the
isolation shell. Observe the alignment pin between
bearing cover and isolation shell flange.
Insert the gasket (part no. 400.1) in the isolation shell flange.
Screw the assembly studs (part no. 902) in the volute casing (part no. 102) and
mount the volute casing on the isolation shell flange. Screw the volute casing on
applying the indicated tightening moment (refer to the corresponding table).
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Maintenance
Page 27 of 27
01/2005
5.4
Tightening Moments for Screws
In case materials of screws are not indicated here, please contact KLAUS UNION.
Part No.
901.1
901.1
901.1
901.19
902/
920.1
922
Position
Isolation Shell
Flange
Straining Ring
(Isolation Shell
made of
Zirconium)
Straining Ring
(Isolation Shell
made of CFRP)
Impeller Bolt
Volute Casing
Impeller Nut
Screw
Material
A4 - 70
1.7258
1.7709
Tightening
Moment [Nm]
Thread
M 8 / M 10/
M 12 / M 16
20 / 40 / 65 / 90
A4 - 70
M 8
M 10
M 12
25 / 45 / 75 / 100
15
25
35
A4 - 70
M 8
M 10
20
25
A4 - 70
M 8 / M10
2.4602
5.6 galvanized
+chromized
A4 - 70
M 12/ M 16 / M 20
1.7258
1.7709
M 16x1
M 20x1
1.4571/
M 24x1,5
2.4602
M 27x1,5
M 35x1,5
20 / 40
35 / 80 / 110
55 / 80 / 110
65 / 90 / 140
75 / 75
110 / 110
180 / 180
250 / 250
350 / 350
Materials of screws are mentioned in the parts list.
6.
Spare Parts
The attached spare parts list enumerates the recommended spare parts.
Exclusively use original spare parts for repairs and replacements.
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Malfunctions
Causes and Elimination
1.
BA/E-21900-08/1
Page 1 of 4
08/2003
Malfunctions and Causes
When contacting KLAUS UNION for further information
please advise our ref.-no. and / or the serial no.
Malfunctions
Reference-Number for Cause and
Elimination
Rate of flow is too low
1, 8, 9, 12, 14, 15
Rate of flow is too high
2, 16
Delivery head is too low
2, 3, 8, 9, 10, 12, 15
Delivery head is too high
1, 16, 29, 33
Pump does not suck or only to a
limited extent
3, 5, 8, 15
Pump does not feed
3, 4, 5, 6, 8, 15
Pump processes by fits and starts
3, 5, 8
Pump operates noisily
3, 5, 6, 7, 12, 13
Power input is too high
2, 6, 7, 10, 11, 13, 16
Power input is too low
9, 15, 29, 32, 33
Pump runs backwards
12, 18
Pump runs unsteadily
7, 13, 17, 19, 20, 21, 22, 23, 24, 25, 26,
27, 28, 29
Pump casing leaks
28, 30, 31
Pump runs hot
4, 15, 17
Pump stalled
6, 7, 13
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Malfunctions
Causes and Elimination
2.
BA/E-21900-08/1
Page 2 of 4
08/2003
Causes and Proceedings for Elimination of Malfunctions
Ref.-No.:
Cause
1
Resistance in pressure
pipework is too high.
2
Pressure-side pipework
resistance is too low.
Inlet pressure is too low,
geodetic suction height is too
high.
Shut-off valve in the pressure
or suction-side pipework
respectively is closed.
The suction-side pipework
still contains gas bubbles.
3
4
5
6
Foreign bodies in the pump.
7
8
Wear of journal bearings.
Suction pipework leaks.
9
Speed is too low.
10
Viscosity of the pumped
liquid is too high.
Density of the pumped liquid
is too high.
Wrong direction of rotation.
11
12
13
Anti-friction bearings are
damaged.
14
Inadmissible reduction of
area of cross section in the
suction pipework.
Elimination
Clean or replace pipework and valves.
Check the dimensions of the pipework
nominal diameters.
Throttle using control valve on pump
discharge.
Increase inlet pressure on the suction
side.
Open the shut-off valve. If necessary,
check swing-check valves.
Vent the unit. Check suction-side
pipework (refer to instructions given in
section "Installation and Assembly").
Dismantle and clean the pump. Replace
damaged components using new
original spare parts.
Check the bearing clearance.
Check the connections of the suctionside pipework (tightening moments and
gaskets). Check tightening moments of
screws and gaskets at the volute
casing. Replace damaged gaskets
using new original spare parts.
Check frequency and voltage of the
motor.
Contact KLAUS UNION.
Contact KLAUS UNION.
Check the motor's direction of rotation
(observe direction-of-rotation arrow on
the pump).
Replace the anti-friction bearings and
clean the oil chamber. Check whether
the lubricant is appropriate for field of
application.
Clean suction pipework and its baffles
(filter, valves, etc.). If necessary,
replace suction pipework.
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Malfunctions
Causes and Elimination
BA/E-21900-08/1
Page 3 of 4
08/2003
Ref.-No.:
Cause
Elimination
15
Breakaway of magnet drive.
16
Speed is too high.
17
Flush flow is too low.
18
Swing check valve jammed.
19
Impeller is clogged or
damaged.
Precipitation of crystals
from the pumped liquid.
Switch off the motor. As soon as the
motor comes to rest, switch it on again.
In case of a repeated breakaway of the
magnet drive, contact KLAUS UNION.
Check the frequency and the voltage of
the motor.
Check the flushing system. Clean the
components if necessary.
Check Qmin.
Check for correct operation of the swing
check valve.
Clean the impeller and replace it using a
new original spare part if necessary.
Increase the temperature of the pumped
liquid, e. g. by heating the pump. Contact
KLAUS UNION.
Check the anti-friction bearings and
replace them using new original spare
parts if necessary. Increase the quantity
of the lubricant according to the
specification.
Check the anti-friction bearings and
replace them using new original spare
parts if necessary. Check whether the
lubricant is suitable for your field of
application.
Check the anti-friction bearings and
replace them using new original spare
parts if necessary. Assemble the antifriction bearings properly.
Check the coupling for any misalignment.
If necessary, observe the instructions
given in the operation manual of the
flexible coupling.
Replace the flexible coupling by a new
one. If necessary, observe the
instructions given in the operation
manual of the flexible coupling.
Check and correct the construction of the
foundation.
Contact KLAUS UNION.
20
21
Specified quantity of
lubricant was not observed.
22
Unsuitable lubricant.
23
Inexpert assembly of antifriction bearings.
24
Misaligned or loose
coupling.
25
Flexible coupling is worn.
26
Poor workmanship of the
foundation.
Base plate is not rigid
enough with foundationless
execution.
27
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Malfunctions
Causes and Elimination
Ref.-No.:
Cause
28
29
30
Pump casing is distorted.
Pump design is incorrect.
Unsuitable casing gasket.
31
Casing screws have been
tightened insufficiently.
Density of the pumped
liquid is too low.
Viscosity of the pumped
liquid is too low.
32
33
BA/E-21900-08/1
Page 4 of 4
08/2003
Elimination
Check and correct pipework lengths.
Contact KLAUS UNION.
Replace the casing gasket using a new
original spare part.
Tighten the casing screws according to
the specified tightening moments.
Contact KLAUS UNION.
Contact KLAUS UNION.
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