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ALLWEILER

Operating and Maintenance Instructions


including Disassembly and Assembly Instructions
Hydraulic I

ID No.:

Keep
for future
use!
Order No.:

Series No.:

Contents
0.

Brief instructions

1.

General

2.

Safety

3.

Transportation and interim storage

4.

Description

5.

Design of system

6.

Installation of pump

7.

Start-up and switch-off

8.

Maintenance

9.

Servicing, disassembly and reassembly

!
These operating and maintenance instructions
contain information by the pump manufacturer. They may have to be supplemented by
instructions of the operating company.
Specific information for the operation and
maintenance of the technical system in which
the pump is integrated, is not included. This
can only be provided by the company responsible for the installation and design of the system (system manufacturer).
Such specific information for the operation
and maintenance of the technical system
in which the pump is integrated has priority over the information provided by the
pump manufacturer.
See operating instruction of system manufacturer!

10. Faults, causes and remedies


11. Ancillary documentation
12. Identification

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0.

Brief instructions for commissioning a supplied complete pump unit.

The pumped fluid may not have a tendency to crystallise and may not contain any solids, having an
abrasive effect (see Section 1.1. Use and areas of application).
Remove protective seals from connection pieces prior to connecting the pipes.
If the pump has been preserved, drain off preservation agent (dispose of correctly!) and clean
pump.
Align pump or pump unit on foundation and secure.
Clean pipe system.
Observe direction of flow and rotation (see arrows on pump).
Fill pump with pumping medium (pump must be fully ventilated).
All shut-off fittings in the suction and delivery pipe must be opened.
Check that the coupling protection is installed and that all safety devices are operational.
Install motor circuit breaker. Electrical connection must be provided by a qualified electrician! Check
voltage, speed and direction of rotation.
Turn pump manually and check for light, even movement.
Switch on motor.
Once the operating speed has been reached, check the operational pressure on the pressure gauge,
regulating the operating point by throttling on the delivery side, where necessary.
The delivery volume may not fall below a specified minimum.
The pump must always be supplied with fluid and may never run dry!
Generally do not touch pumps in operation as they might be hot.
The power required increases with an increase in lift height and a decreasing pumping volume!
The pump may never be started or operated with the suction and/or delivery side closed.
Neither during installation nor during operation may pipe runs transfer any stresses onto the pump.

The safety instructions specified under Section 2-ff must be observed!

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1.

General

1.1

Use and areas of application

Only correctly operating pumps, achieving the


agreed performances under the specified tolerances
leave our works. Provided the below operating instructions are observed, the fault-free operation and
full pumping performance is thus guaranteed.

The pump is a self-priming periphery pump. It is suitable for pumping clear and cloudy as well as gaseous fluids, not containing any abrasive constituents.
The pump is designed as a multi-stage sectional
case pump. The use of uniform components for several pump series and sizes allows economic stockkeeping and procurement of spare parts. The pump
is driven by an electrical motor.

Test pressure = 1.5 x pump operating pressure


1.3

Characteristic curve of the side channel pumps

The pump may only be used for operating conditions


specified by the client and confirmed by the supplier.
The correct use is stipulated in the datasheet enclosed in the Appendix.
Fig. 1.1

This pump may only be used for the purpose


stipulated in the datasheet as it may otherwise be
hazardous for people and the environment.
The pump may not be operated below or above
the density stated in the datasheet as otherwise
the pump may be damaged.

Systems in which the breakdown or failure could


lead to injury or damage must be equipped with
alarms and/or stand-bye units and their functioning must be regularly checked.

Fig. 1.2

Units directly or indirectly linked to drinking water systems must be freed from any impurities
prior to installation and commissioning.

Operational pumps should generally not be


touched as they may be hot.
Fig. 1.3

In general, the data relating to speed, pressure and


temperature specified in the datasheet are deemed
to be the values at which the correct function of the
pump is guaranteed. It is not permitted to deviate
from these values.

In case of a closed delivery pipe, the temperature


of the pumped medium in the pump rises. As a
result, overpressure that may be hazardous is
created. Special hazards are created by higher
temperatures in case of easily combustible or
flammable media. This may lead to an explosion.
These hazards are avoided by installing a bypass
system with a pressure control valve.
Specified supply pressures (system pressures) may
also not be exceeded. Where no pressures and/or
temperatures are stipulated in the order confirmation,
the pressure and temperature limits specified in the
brochure apply as long as these values are not further limited by the used shaft seals.

1.2

Testing

Requirements:
1. Start with opened slides.
2. Never operate with closed delivery pipe.
3. Only operate in the range Qmin to Qmax.
1.4

Guarantee
Our liability for deficiencies in supply is specified in
our terms of delivery. We do not accept any liability
for damage resulting from the non-compliance with
the operating instructions and conditions of use.
Where operating conditions change at a future point
in time (i.e. different pumped medium, speed, viscosity, temperature or supply conditions), it must be established in each case and, where necessary confirmed that the pump is suited for this changed condition. Unless otherwise agreed, pumps supplied by us
may only be opened or changed by ourselves or at
authorised customer service centres during the period of guarantee. Non-compliance cancels our liability for any deficiencies.

Prior to leaving our works, all pumps are thoroughly


tested on our test stand.

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1.5

Sound level

In case of safety information whose non-compliance


could be hazardous for the machine and its function,
the word

Depending on the pump size, the sound level of


our pump lies between 60 and 72 dB(a).

CAUTION

This noise is, however, not only caused by our


pumps. Noise can also be produced by:

drive units
incorrectly installed couplings
other appliances in the same room (i.e. heating)
water pipes, water taps or valves. Flowing water
always generates noise (i.e. water hammer). It is,
however, possible to reduce these noises by
suitable measures to an acceptable level.

has been added. Instructions given on the machine


itself, such as direction of rotation arrows, symbols
for fluid connections must be observed and maintained in a fully legible condition.
2.2

Personnel carrying out the operation, maintenance,


inspection and installation must be suitably qualified
for these tasks. The areas of responsibility, duties
and monitoring of the personnel must be precisely
specified by the user. Where the personnel does hot
have the required knowledge, employees must be
trained and instructed. Where required, this training
can be carried out by the manufacturer/supplier of
the machine on behalf of the user. The user must
also ensure that the contents of the operating
instructions are fully understood by his personnel.

The flow speeds of the water should be kept as low


as possible.
In order to reduce the flow speed, adequately dimensioned pipe runs, pressure reducers and devices are
particularly effective.
Where the pump generates most of the noise, the
noise level can be reduced by the following measures:

2.3

1. Install pump on rubber buffers.


2. Insert a rubber connection piece in the suction
and delivery pipe between the pump and the pipe
system.
3. Pipe runs should not be in direct contact with
walls, ceilings, and floors.
4. Where necessary, surround pumps (not motor)
with a soundproof housing.
2.

2.1

Identification of safety information in the operating instructions


Safety information contained in these Operating Instructions, which if not complied with can result in a
hazard for the personnel, are specially identified with
a general hazard symbol:

Hazard symbol acc. to ISO 3864-B.3.1


Safety information relating to electrical hazards are
specially identified with:

Hazards in case of non-compliance with safety


instructions
Non-compliance with safety instructions can endanger the personnel, the environment and the machine.
Non-compliance with safety instructions can also
void any liability claims.
Non-compliance with safety instructions could, for instance, result in the following hazards:
Failure of important machine/plant functions
Failure of stipulated maintenance and servicing
methods
Endangering of personnel due to mechanical and
chemical effects
Endangering of the environment as a result of the
leaking of hazardous substances

Safety
These operating instructions contain basic information that must be observed for the installation, operation and maintenance. The operating instructions
must, therefore, be read by the fitter and the respective trained personal / user prior to the installation
and start-up and must be kept with the machine/system at all times.
In addition to the general safety instructions specified
in this main section, also special safety instructions
listed under other main sections - such as for private
use - must be complied with. These Operating Instructions do not replace local safety regulations.

Qualifications and training of personnel

2.4

Safe working procedures


The safety instructions contained in these Operating
Instructions, all existing national accident prevention
regulations as well as all internal work, operating and
safety instructions issued by the user, must be complied with.

2.5

Safety information for users/operators


Where hot or cold machine parts may cause hazards, these parts must be protected by a guard.
Guards shielding moving parts (i.e. coupling
protection) may not be removed whilst the
machine is running.
Leaks (i.e. in the shaft seal) of hazardous
pumped substances (i.e. explosive, toxic, hot)
must be disposed off in such a way that neither
the personnel nor the environment are endangered. Legal regulations must be complied with.
Any electrical hazards must be prevented (for details see VDE regulations and information from
your energy supply company).

Hazard symbol acc. to ISO 3864-B.3.6

ALLWEILER
2.6

Safety information for maintenance, inspection


and installation work
The user must ensure that all maintenance, servicing
and installation work is carried out by authorised and
qualified trained staff who have gained the necessary
information by studying the operating instructions.
In general, any work on the machine must only be
carried out once the machine has been shut down.
The procedures for shutting down the machine,
stipulated in the Operating Instructions, must be
complied with.
Pumps or pump assemblies, pumping potentially
harmful substances, must be decontaminated.
Pumps forwarded to us for repair, must be cleaned in
such a way that our employees are not exposed to
any health hazards. Immediately after completion of
the work, all safety equipment and guards must be
re-installed and/or started.
Prior to starting up the machine again, , sections 7.1,
7.3 and 7.4 must be observed.

2.7

Reconstruction and manufacture of spare parts


by the user

3.3

Unpacking
Prior to unpacking, the packaging should be visually
inspected. Any noted transportation damage should
be listed on the receipt or delivery note. Any claims
should be immediately forwarded to the shipping
agent and/or the transport insurance company.

3.4

Interim storage
If the pump or the unit are not installed immediately
after delivery, the machine must be stored in a dry
room free from vibrations.

3.5

Transportation
The pump must be correctly transported. Figs. 3.13.3 show the correct handling.

Where the pump unit is transported by a crane,


the crane and the sling gear must be sufficiently
dimensioned. The sling gear may not be connected to the suspension eyes of the motor!

Reconstruction or changes to the machine are only


permitted with the prior approval of the manufacturer.
Original spare parts and accessories authorised by
the manufacturer ensure the safe operation of the
machine. The use of other parts may void the liability
of the manufacturer for any resulting consequences.
2.8

Unauthorised operation
The safe operation of the machine can only be guaranteed, if the machine is operated as stipulated in
section 1 of these operating instructions. The limits
specified in that datasheet may not be exceeded at
any time.

3.

Transportation and interim storage

3.1

Safety measures

Never stand under loads moved by cranes.


Always keep a safe distance to transported
loads.

Fig. 3.1
Pump and motor on base plate

Fig. 3.2
Pump in block design

Only use permissible and correctly working lifting gear.


Match the length of the lifting gear elements so
that the pump or the unit is suspended straight.
Do not remove any information or documents attached to the pump.
Handle the pump carefully.
3.2

Packaging
The symbols contained on the packaging must be
observed. The inlet and delivery sides of the pump
must be closed with plugs during transportation and
storage. The flanged connections must be removed
during installation of the pump unit.
5

ALLWEILER
According to the specifications by the conservation
agent manufacturer, the preservation agent offers a
protection of 6 months. The active ingredients contained in this preservation agent also offer adequate
anti-corrosion protection in case of high humidity
(sea, tropical climate).
3.6.2

Removal of preservation agent and disposal


Prior to start-up, the applied preservation agent must
be removed. Any internal preservation must be
drained off.

The pump must be completely cleaned. This applies,


in particular, for pumps used in the food or drinking
water supply sector.

Fig. 3.3
Pump with vertical design
3.6

A suitable solvent, compatible with the pumped medium (foodstuff) can be used as a cleaning agent for
removing the internal and external preservation
agent.

Preservation
If the pump has been preserved by our works, this is
shown by:
1. The sign attached to the pump.

3.7

3.6.1

4.

Description

4.1

Constructive design

Preservation agents

Self-priming, sectional case pump operating according to the periphery pump principle. The performance
of the peripheral pump depends a. o. on the gap between the impeller and the stepped housing (0.15 to
0.17 mm)

The below specified preservation agent can be used


for external and internal preservation.
Preservation agent:
SHELL FLUID BD22, Deutsche Shell AG, Frankfurt.
In case of an external preservation, all air and uncoated parts such as shaft ends, flanged surfaces,
etc. are preserved. The preservation agent is painted
or sprayed with a spray gun. In case of internal preservation, the housing, shafts, impellers and the shaft
seal are preserved. The preservation agent is applied by filling the pump. During filling, the shaft
should be slowly turned in the normal direction of rotation. The pump should be filled until the preservation agent has reached the sealing strips of the delivery and suction flange without any air inclusions.
The delivery side and suction side must then be
closed with a blank flange.
NOTE: The specified preservation agent is the
recommend agent. Preservation agents with
other preservation characteristics from other
mineral oil manufacturers may also be used.

Storage and monitoring preservation


In case of longer storage, the operator must check
the conservation of the pump in regular intervals.
The filling level of the pump must be checked every
six months. Where required, preservation agent must
be replenished up to sealing strip level at the delivery
flange.

2. The respective information on the delivery note


and invoice.
CAUTION The preservation protection will last for six
months. Please observe that all pumps produced
from grey cast iron and nodular iron that have been
operated (even for just a trial run), must be protected
against corrosion when placed out of service. External and internal preservation measures have to be
carried out and instructions 3.6.1 + 3.6.2 apply.

Preservation agent must be disposed off correctly!

Due to the narrow gap widths, the pump is not suitable


for pumping media containing solid particles (in special
cases, a filter must be installed on the suction side).
4.2

Housing
The suction and delivery housing as well as the suction and delivery sides are laterally divided. Flat
packings are used as seals between the housing and
housing components.

4.3

Position of connection pieces / flanges / dimensions


see datasheet

4.4

Additional connections
The delivery housing of the pump contains:
1 screw-in stopper for connecting a pressure
gauge.
1 screw-in stopper for draining the fluid.
6

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The suction housing of the pump contains:
1 screw-in stopper for connecting a manovacuummeter.
1 screw-in stopper for draining the fluid (complete
drainage is not possible).
4.5

5.

Design of system

5.1

Pipe system
CAUTION The arrows indicating the direction of
flow on the pipe connection of the pump must be
observed. The nominal width of the pipes must
correspond with the nominal width of the pump
connection section (see datasheet).

Impellers
Open, star-shaped impellers with relief holes providing axial-thrust compensation.

4.6

4.7

Shaft

Ensure that the pipes have been cleaned prior to


pump installation.

The pump is equipped with a special deflectionresistant shaft, ensuring a smooth operation during
all load phases.

Support the pipework to ensure that no stresses


are transferred to the pump (pump parts may
break).

Storage and preservation

Avoid large cross-sectional


changes of direction.

see datasheet
4.8

Coupling and shock protection

Prior to the connection piece of the pump a


smoothing section with the diameter of the
nominal width of the suction section and a
length, ten times the diameter of the suction
connection should be installed. This will prevent
cavitation.

A flexible coupling by Flender, type N-Eupex, series


B, is used for our pumps.

The flow speed in the suction and/or feed line


should not exceed 1 m/s.

Important note for installing the coupling:

5.1.1

Only use couplings, where the coupling half on the


pump side can be secured in axial direction with the
nut on the shaft end. Turn or rework hole in hub on
pump-sided coupling half in such a way that the coupling half can be easily slid onto the shaft end. Do
not use hammer!

!
4.10

and

A different nominal width can be compensated


for by eccentric transition sections. This prevents the formation of any air inclusions in the
pipe system.

Drive
The pumps are driven by an electric motor. In most
cases, totally enclosed fan-cooled A.C. cage motors,
series B3 or B14, protection type IP44/54 acc. to IEC
standard, insulation class B, motor winding for 380 V
or 660 V, 50 or 60 Hz are used. Explosion-proof motors and other types can also be provided.

4.9

transitions

For accident prevention, the pump must be


shock protected acc. to DIN 31001. Where explosive substances are pumped, the protection must
be made from a material that cannot produce
sparks (i.e. brass).

The pipes must be dimensioned in such a way that a


correct supply flow to the pump is guaranteed and
the function of the pump is thus not impaired. The
suction and delivery side should have a flow speed
of approx. 1 m/s.
Special attention should be paid to the air-tightness
of the suction pipe and compliance with NPSH values.
5.1.2

If you wish to install other accessory on the pump or


pump unit, please inform the manufacturer about the
accessory to be installed.

Changes in cross-section and direction


The direction of flow through the pump body is indicated by arrows on the pump housing.

Accessory
The supplied accessory is specified in the datasheet.
The respective Operating and Installation Instructions for the accessory are also enclosed in the Appendix.

Nominal width

Sudden changes in cross-section and direction as


well as sharp bends must be avoided.
5.1.3

Support and flange connections


The pipes must be connected free from stress,
should be supported close to the pumps and should
be easy to secure to avoid any distortion. Once the
bolts are released, the flanges should still rest
against each other, should not bounce off each other
or press against each other. The pump must be protected against thermal stresses in the pipe system by
suitable measures, i.e. the installation of compensators. Hydraulic forces must also be absorbed by suitable pipe fixings before and after the pump.

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5.1.4

Cleaning of pipe system prior to installation


CAUTION It must be observed that the pipe runs
are completely clean prior to start-up. They may
not contain any welding beads, burrs, rust, etc.
None of the flange seals may protrude internally.
The correct seal of the connections must be
checked. (See Section 3.6 Preservation).

!
5.2

Do not drain-off
wastewater!

anti-corrosion

agent

Return valve

with

Suction pipe
In order to guarantee a cavity-free operation, Section
5.4 Supply conditions must be observed. The suction
line can be installed in any suitable manner. It can
run through the pump as the pump can also suck up
media uphill. The cross-section of the suction pipe
may not be smaller than the suction pipe connection
of the pump. A flow speed of 1 m/s should be ensured in the suction pipe. In case of difficult suctionside conditions, a smoothing section, having a length
of ten times the pipe diameter before entry into the
pump, must be installed. In the suction operation, the
suction basket must be at least 0.2 m below the lowest fluid level (see Fig. 5.1).

Fig. 5.2
5.3

Delivery pipe
The pipes on the delivery side should also have a
constant cross-section. In case of higher pumping
lifts and longer pressure pipes it is sensible, to provide a soft-closing return valve (see Fig.5.1 + 5.2).

5.4

Supply conditions (NPSH)


In order to guarantee a fault-free continuous operation, the supply and/or suction conditions of the plant
must be adapted to the pump requirements (NPSH).

Return valve

The operating conditions are fulfilled if the NPSH


value of the plant (NPSHexist) is higher than the
pump NPSH normal value (NPSHact).
NPSHexist > NPSHact

Suction basket
(Return valve)

The (NPSHexist) is specified in the characteristic diagrams for each pump type.
On request, we can provide forms for calculating the
NPSH normal values.
In the suction operation it must be observed that the
geodetic lift of 7 m (for water at 20C is not exceeded). Please observe, in case of pumping agents
with low evaporation pressures or water with temperatures of above 20C that the lift of the pump will
decrease accordingly.

Fig. 5.1
CAUTION In order to maintain its self-priming
state, the pump must constantly be filled with
pumping media.
The peripheral pump is able to supply air or gas with
the pumped media and to evacuate a suction pipe.
The pumps must first be filled or have been filled with
liquid. The suction ability is limited a vacuumetric lift
of approx. 7 m (for water 20) and reduces with increasing wear. The suction time is limited from one to
max. two minutes as the suction stagnates due to the
medium warming in the pump. In order to prevent
drainage of the pump after switch-off, a return valve
must be provided on the suction side (see Fig. 5.1).
For the supply operation, the fluid level must be kept
at at least 0.5 m above the pipe connection. In case
of the medium being supplied from a container and a
vacuum, an equalising pipe (AL) should be installed
(see Fig. 5.2).

CAUTION Where media close to the boiling point


is pumped, the supply height and/or the NPSH
value must be observed as a cavitation will otherwise be created in the pump and this could
lead to the destruction of the hydraulic system.
5.5

Information relating to the design and construction of boiler plants


1. Design supply pump with a respective reserve
according to TRD 401.
2. In case of two possible pump types the pump
with the better NPSH value should always be
chosen.
3. The length of the suction and delivery pipe of the
boiler supply pump should be kept as short as
8

ALLWEILER
possible and should include as few as possible
bends and elbows.

5.6

Speed, pressure and temperature


Suitable safety measures must be provided on the
plant side to ensure that the limits for speed, pressure and temperature, specified in the datasheet, are
guaranteed not to be exceeded (see DIN 24295,
Section 3.4).

4. The suction pipe should be one nominal width


larger than the connection at the suction housing.
There should be no abrupt reductions in the
pipes.
5. In case of the parallel operation of two pumps,
each pump is assigned to its own suction pipe
(see Fig. 5.3).

Stoppers, flushing, cooling


Suitable regulating and control options must be provided for any existing flushing or blocking systems.
For the required quantities and pressures, see description of shaft seals (see Section 8. Maintenance).
In case of hazardous pumping media or high temperatures, it must be ensured that the pump is put
out of action in case of a failure of the blocking or
flushing system. The blocking and flushing system
must be in operation prior to the start of the pump.
The systems may only be taken out of order during
stand-still of the pump, if at all, based on the type of
operation (see Section 7. Start-up and switch-off).

6. The connection of the suction pipe to the supply


container should never be vertical but always
horizontal. This prevents the creation of any turbulence (see Fi. 5.3).

Incorrect!

Minimum volumes, operating range


The operating range specified in the specification
sheets must be complied with and may neither be
fallen short of or exceeded. The left characteristic
limit represents the minimum volume for the pump.

Correct!

Fig. 5.3
7. Ensure that the feed pump never runs dry

The minimum volume for the pump must be ensured


under all operating conditions by using suitable
measures on the plant side, such as free-running return valves or a bypass. Ensure that the transmission
rate is not exceeded. On request, we will be happy to
assist you with the design of the free-running return
valves or bypass.

8. In case of over-dimension pumps, install a throttle


unit in the delivery pipe.
9. Compensators should be installed in the suction
and delivery pipes. Also, a filter should be installed in the suction pipe and a return valve in
the delivery pipe (see Fig. 5.3).

The suction and delivery side of the pump must be


equipped with a manometer/vacuum or pressure
gauge. In order to accurately maintain the lifting
height (see rating plate), a throttle must be provided
on the delivery side. In case of higher lifts (<20 m),
long pipe runs, parallel operation and plannedspecific counterpressures (system pressure), a return
valve (R) must be installed to prevent the medium
from flowing back through the pump once the unit is
switched off (see Fig. 5.1 + 5.2).

10. Do not install any volume-dependent control


valves in the delivery pipe of the pump.
11. When dimensioning the system, the worst NPSH
value with the smallest possible pumping pressure of the pump must be taken into consideration.
12. Pressure-sensing equipment should be provided
on the suction and delivery side.

5.7 Electrical connections

13. The sliders on the suction and delivery pipes


should be designed in such a way that they are
not inadvertently closed.
14. In case of a smaller than intended differential
pressure, the feed pump operates in a worse
NPSH range. In order to prevent any damage,
the pump should consequently be respectively
throttled (see Fig. 5.4).

Pressure decreases!
NPSH increases!

Safety devices

The mains cable of the coupled drive motor must


be connected by a qualified electrician according
to the circuit diagram provided by the motor
manufacturer. For this purpose, the valid VDE
regulations and the regulations of the local utility
company must be observed. Any electrical hazard must be prevented.
5.8

Inspection
After completion of the installation, the imperviousness of all pipe runs and connections must be
checked. It must also be checked that the unit does
not contain any blockage (it must be possible to turn
the shafting manually).

Fig. 5.4

ALLWEILER

!
5.9

Based on the valid accident prevention regulations, the operational safety of the plant must be
checked (electrical connections, coupling protection etc).

6.3.3

The dimensions for the required installation area of


the pump unit are shown in the dimensional table. It
must be ensured that the switch-off and control
equipment as well as the measuring devices can be
easily accessed.

Hydrostatic compression test


If a hydrostatic pressure test is carried out on the
pipe system, the pump should not be included in the
test.

CAUTION Sufficient room must be provided for


maintenance and servicing, in particular for
changing the drive motor or the complete pump
unit.

If the pipe system cannot be pressurised without the


pump, it must be ensured that no foreign bodies enter the pump.
The pump may only be pressurised with 1.3 x the
nominal pressure of the pump. The nominal pressure
is specified in the datasheet.

6.3.4

6.

Installation of pump

6.1

Safety measures

Is the electrical connection for the drive motor


free from any voltage?
Are the suction or supply pipe and delivery pipes
empty and are they respective valves closed?
Can the pump be easily turned manually (turning
the ventilator of the motor)?
Have all existing internal regulations been observed?
6.3.5

1. Tighten the flange connection. Remove protective


caps of pipe sections prior to connection of the
pipe runs.
2. Secure the pump and motor feed. The motor and
pump feed should only be tightened by hand.

Ensure that the suction and/or supply pipes as


well as the delivery pipe are valved off.

6.2

Installation tools
No special tools are required for assembly and installation.

6.3

First installation

6.3.1

Permissible ambient conditions

Installation of pump and mounting in pipe system


The pump must be aligned with the pipe runs. The
pipe runs must be supported in such a way that no
distortion occurs once the pump is connected. When
tightening the bolts, the following sequence must be
observed:

The pipe runs must be carefully connected as


otherwise pumping media would exit during the
operation of the pump and cause a hazard for the
operating personnel.

Ensure that all electrical connections are not


under voltage. Otherwise there is a danger of
electrocution.

Checking the installation


Prior to installing the pump in the plant, the following
points should be checked:

For pumps with a stuffing box, the packing must be


replaced after the pressure test (as incorrectly compressed no longer suitable for operation). Where
the pipe is emptied after the pressure test, the pump
must be correctly preserved (otherwise rusting and
problems with start-up). The connection of the pipe
to the pump must ensure that the arising reaction
forces of the pipe do not exceed the maximum permissible suction forces and suction moments under
any operation.
Prior to start-up, the pipe system and installed fittings, devices, etc. must be cleaned from any impurities such as welding beads, forging scale, etc.

Required installation area

6.3.6

Checking the flexible coupling


After connection of the pipe run, the direction of the
coupling must be checked and adjusted where necessary.

Ruler

The ambient temperature may lie between 20C


and plus 40C. The humidity should be as slow as
possible, to prevent corrosion.
6.3.2

Floor, foundation

Fig. 6.1
Alignment, using fine ruler

The pump must be installed on an even, vibrationfree floor or foundation. Vibrations reducing feet must
be used, where necessary.
10

ALLWEILER

Radial offset
Fig. 6.5

Fig. 6.2
Alignment, using dial gauge

Angled offset
Fig. 6.6

Fig. 6.3
Alignment, using dial gauge
Permissible offset for flexible couplings (only applies for supplied original couplings):
radial
Kr

1(58)
2(68)
3(80)
4(95)
5(110)
6(125)
7(140)
8(160)

mm
0.10
0.11
0.13
0.15
0.18
0.21
0.24
0.27

N-EUPEX size

Size

Permissible shaft offset


angled
axial
Kw
Ks
Smax Smin Smin up to Smax
mm
mm
0.10
24
0.11
24
0.13
24
0.15
24
0.18
24
0.21
24
0.24
24
0.27
25

Speed factor
Sn max = 1.5

Axial offset
Fig. 6.7

!
6.4

The coupling must be protected against contact


with a protection device acc. to DIN 31001 in
order to prevent any accidents.
Protection and control devices
The existing protection and control devices must be
installed and connected in accordance with the respective instructions.

!
6.5

A protective motor switch must be supplied. In


case of any work being carried out on components carrying voltage, the mains plug must be
pulled out or the mains switch must be switched
off and the fuse must be removed. Ensure that
nobody is able to restart the unit whilst work is
carried out on the motor.
Final checks
The following final checks must be carried out:
1. Check that connecting flanges are properly sealing.

Speed n [1/min.]

Fig. 6.4

2. Check that the pump is running easily.

Kr and Kw are valid for shock-free operation


and ambient temperatures of -30C to 80C.
Permissible offset Kr x Sn or Kw x Sn.
Sn = speed factor
Kr and Kw can occur simultaneously. The total
of both offsets may not exceed Kr or Kw .
11

ALLWEILER
7.

Start-up and switch-off

7.1

Safety measures

7.2.4

The direction of rotation of the motor must correspond with the directional arrows on the pump. Respective arrows are shown on the pump. To check
the direction of rotation, the motor can be briefly
switched on. An incorrect direction of rotation can
damage the pump.

Electrical connections must be designed to comply with the regulations of the local utility company as well as the stipulations of ElexV. In addition the ElexV guidelines of BG-Chemie must
also be complied with. This work may only be
carried out by respectively authorised personnel.

CAUTION Never run pump against specified direction of rotation! Only check direction of rotation on filled pump!

The pump must be correctly filled as otherwise


the pump may be damaged.
When using hot pumping media, the pump
should be filled slowly to prevent any distortion
or thermal shock.

7.3

Start-up

7.3.1

Start
Switch on motor!

In case of explosive, toxic, hot or corrosive media it must be ensured that no hazard occurs for
persons or the environment.

CAUTION Never start or operate pump (even


briefly!) against a closed delivery side! Switch on
pump with shut-off unit open. Also, all sliders
contained in the suction pipe must be opened.

The pumped volume should only be regulated on


the delivery side during constant speed. The control fittings on the suction and/or feed side must
be fully opened during operation.
7.2

Start-up preparations

7.2.1

Filling the pump


The pump must be fully filled with pumping media.
The system must be vented via the auxiliary connections at the flanges. This only occurs once and can
possibly be carried out prior to the connection of the
pipe. During subsequent start-ups the pump is selfpriming.
Easy operation of the pump shaft must be checked.
The readiness of all auxiliary connections must be
checked. All shut-off fittings in the suction and delivery pipe must be opened. Where media with temperatures of <100C is pumped, the pump (pump
body) must be heated prior to start-up. This is best
done by using hot media to fill and flow through the
pump body until it has approximately reached the
temperature of the media at least 10 min.

Any existing bypasses must be closed in the suction


operation. The bypass can remain open during supply operation. Once the unit has reached the nominal
speed (see rating plate) the lift should be adjusted by
slowly closing the fitting on the delivery side.
The suction time depends on the length of the suction pipe and will be several seconds for the first
time. In case of the use of a foot or return valve in
the suction pipe, pumping starts immediately upon
the pump being switched on again.
7.3.2

CAUTION In case of the pressure in the exit


cross-section of the pump showing an impermissible increase due to operational malfunction,
suitable safety measures (i.e. installation of relief
valve) should be implemented on the plant side.

Drive motor
The electrical connection must be carried out by
a qualified electrician, observing VDE and local
regulations, in particular, with regards to protective measures. Check operating voltage and
speed of motor. Speed at 50 Hz: 1450 1/min. or at
60 Hz: 1750 1/min. A protective motor switch
must be provided!

7.2.3

Storage
The bearings are filled with sufficient grease by the
manufacturer and are thus operational.

Adjusting pumping output


The pumping volume can only be adjusted once the
correct pumping speed is attained. The operating
data of the pump is specified on the rating plate and
in the datasheet. The produced lift should be controlled, using the pressure gauge and should be adjusted on the delivery side in case of any deviation.
Even during operation, never operate against closed
delivery side!

CAUTION The pumps may not run dry under any


circumstances! Heating-up can destroy pump
components.
7.2.2

Checking direction of rotation

7.3.3

Maintaining a minimum flow volume


In order to prevent any damage to the pump, any
operation against the closed shut-off slider of the delivery pipe must be avoided.
Safety measures on the plant side (i.e. overflow
valve) must be used to ensure that the operational
pressure of the pump is not exceeded as a result of
malfunctioning during the operation.
CAUTION The minimum pumped volume is
shown in the performance diagram of the pump
(smallest shown Q value).
12

ALLWEILER
7.3.4

Temperature
7.4.2
Any sudden temperature changes (temperature
shocks must be avoided).

7.3.5

7.3.6

It must be checked whether the pump shaft is standing still. In case of a leaking return valve in the delivery pipe, it may occur that the pump shaft is turned
backwards by reflowing pump media. The pump may
not be switched on whilst the pump shaft is turning
backwards as this may damage the pump.

Higher density of pumped media


Where the density of the pumped media is higher
than that stated in the order information (i.e. larger
than the value on which the design of the pump was
based), the performance data of the pump is reduced
whilst the performance requirement is increased. It
must be observed that the motor is not being overloaded.

7.5

Measures in case of longer standstill


Where pumps are stored for a longer period prior to
installation, pumps must be protected against humidity and moisture, (i.e. by packing in oil paper and
plastic foil!). For other measures see Section 3.7
Storage and monitoring preservation.

Increased pumping volume


CAUTION Where a higher pumping volume is
produced than specified in the order and design
data, it must be observed that the existing feed
height still suffices (condition: NPSHexist. <
NPSHact.) as other cavitation and other adverse
effects may occur.

In case of the pump being stored, the suction and


delivery section and all other feed and drain sections
must be closed with blank flanges or stoppers. During storage, the pump must be at least turned once a
month (do not switch on, to prevent dry running). The
rotational position of parts such as shafts and ball
bearings should be changed at the same time.
Where necessary, unblock by slightly tapping the
shaft in actual direction. After a maximum of four
years, replace bearing as the grease will be unusable due to ageing.

Where the pump is used as a boiler feed pump, it


must be observed that the pump is not used for a
smaller operating pressure than the intended one.
Where the feed boiler is periodically operated at a
lower operating pressure, the pump must be throttled
to the standard operating pressure of the boiler, using the manual shut-off valve and a pressure gauge
installed on the delivery section of the pump housing.
7.3.7

Restart

CAUTION In case of longer standstill periods, the


pump must be filled with suitable preservation
agent. In case of a possible exposure to frost, the
pump, the shut-off circuit, etc. must be protected
against freezing or drained and preserved.

Switching frequency
The pump may be switched on and off up to ten
times per hour.

7.4

Switch-off and restart

7.4.1

Switch-off
Prior to the standstill of the pump no shut-off units
may be closed on the delivery and suction side.
Switch off motor.
Check that pump drains off evenly. In case of an installed return valve, shut-off units do not have to be
closed.

8.

Maintenance

8.1

Safety measures

!
8.2

For any maintenance and servicing, the information provided in Section 2. Safety must be observed. Regularly implemented inspection and
maintenance work carried out on the pump and
the drive machine will prolong the life of the
units.
General control

In case of longer standstill and excess pressure on


the suction side (feed) the shut-off fitting on the suction side must be closed. Any auxiliary equipment
(sealing liquid, etc.) must be switched off.

The pump may never be operated without pumping media or with the flow of the pumping media
being disrupted. Check the fluid level in the suction and/or feed container.

For pumps where the pumping media is under vacuum, it must be checked that still sufficient operating
media is in the pump prior to restarting. Fill pump if
necessary.

The minimum supply volume must be maintained.


Control speed and lift.
The drive motor may not be overloaded.

Where the pump remains under pressure and temperature even when in standstill mode, all existing
shut-off pipes must remain activated. Shut-off devices must remain activated, if there is a danger of
air being sucked in (in case of feed from vacuum systems or in case of parallel operation with mutual suction pipe). In case of possible frost, fully drain pump
and pipes.

The pumps and units should always run quietly


and free from vibration. All suction-sided shut-off
units, filters must be kept fully opened.
Pressure and temperature monitoring equipment
as well as flow equipment must be monitored.

13

ALLWEILER
Installed stand-by pumps should be switched on
and off again once a week.
8.3

Maintenance of components

8.3.1

Storage and lubrication

8.3.2

Axial face seals are maintenance-free but are only


free from leakage to a certain extent. During operation it must be observed that the axial face seals
never run dry and that the conditions of use are
within the application limits of the selected axial face
seals. A leakage of approx. 2.5 cm3 per hour is acceptable.

9.

Servicing, disassembly and reassembly

Flexible coupling

9.1

Safety regulations

In case of a leaking axial face seal, this cannot be retightened; it is therefore recommended to remove
and check the axial face seal and shaft as well as
any ancillary elements. As the life of the axial face
seals can normally not be estimated, we recommend
to store replacement seals.

Drive

In case of pumps operated with hazardous materials


and/or media dangerous to the environment, the customer/operator must, on his own accord, inform our
own or the installation personnel on site or our works
or repair shop. In this case, a certificate for the
pumped media, for instance in form of a DIN safety
sheet, must be provided upon requesting a customer
service fitter.

Stuffing box packing


Stuffing box packing is constantly serviced. In order
to increase the life of the stuffing box packing, the
packing must be accurately monitored and adjusted
during the first operating hours. The stuffing box
packing should drip slightly during operation. In order
to prevent the unit from running dry, the plant and/or
nut should be loosened where necessary.

In case of any on site work, the users and/or our


service personnel must be made aware of any hazards that may arise in connection with the repairs.
These instructions contain a description of the main
disassembly and assembly steps. The assembly
steps described in the individual sections must be
adhered to.

Stuffing boxes should only be tightened to such an


extent that a small leak of approx. 60 drops per minute can still escape (stuffing box lubrication!).
9.2
Dry-running packaging hardens, overheats and destroys the shaft. In case of longer operating periods
and frequent retightening of the stuffing box rings, an
additional stuffing ring can be inserted. After an operating time of approx. 4,000 to 5,000 hours and a
deformation of the packing rings by more than 25%,
the entire shaft seal should be repackaged.

Due to the resulting injury hazard, pumps may


under no circumstance be repackaged during
operation.

As repairs are carried out by our own personnel


or by specialised installers, it must be ensured
that the pump is completely emptied and clean.
This applies, in particular, for pumps that are
sent to our works or a contractual agent for repair.
For the protection of our employees and for environmental reasons, we are not able to accept pumps
filled with pumping media for repair. Customers/operators must otherwise pay for the cost of the
correct disposal.

See Operating Instructions of the drive motor manufacturer.


8.3.4

Axial face seals

External rolling bearing are permanently filled with


grease. These closed bearings cannot and do not
have to be lubricated. The temperature of the bearings may not exceed 80C. In case of the correct operation of the pump, bearings only have to be
changed for the first time after approx. 10,000 operating hours. Also, internal carbon sliding bearings
must be changed after this operating period. Where
any access temperature is being detected, this indicates a damaged bearing and the deep groove ball
bearing should be replaced as soon as possible (see
Section 9. Servicing).

The condition of the flexible element in the coupling


should be regularly checked. Note: Used flexible
elements should be replaced. After approx. 1,000
operating hours, the distance between the two coupling halves should be checked for the first time (see
Section 6.3.6 Checking the flexible coupling). The
rubber coupling packages used in the claw couplings
must be checked. In case of heavy wear, it must be
assumed that the motor is not aligned with the pump
or that the distance between the coupling sections
has changed. In most cases this will cause bearing
damage in the pump.
8.3.3

8.3.5

Dismantling information
During the guarantee period, the pump may only
be disassembled by ourselves or by an authorised workshop.
Outside of the guarantee period, the pump may
only be dismantled and installed by experienced
personnel.
Prior to the start of the assembly, the unit must
be secured in such a way that it cannot be
switched on.

14

ALLWEILER

The pump housing must be depressurised and


empty.

All shut-off units in the suction, feed and delivery


pipes must be closed.

All parts must have attained ambient temperature.

Remove pump from motor, base plate and pipes


prior to repair.

9.3

Motor repairs
Electrical repairs may only be carried out by a
qualified electrician.

9.4

Disassembly
CAUTION The position of the individual housing
parts must be marked prior to the disassembly to
ensure that they can be reassembled in the correct order (i.e. by chalk markings).
Detailed disassembly and reassembly instructions can be provided on request.
Please contact: see last page

15

ALLWEILER
10.

Faults, causes and remedies

10.1

Safety regulations

!
10.2

Faults may only be remedied by trained personnel. In case of faults, pump must be switched off as soon as
possible!
Faults and remedy
Faults
Pumping volume too low

Cause
Counter pressure too high
Lift too high or feed height too low

Blocked filter
NPSH not observed
Sealing gap too large due to wear
Incorrect direction of rotation or
speed
Housing or suction pipe leaking

Pump not sucking

Leaking pump
Temperature increase in pump

Suction pipe or suction-side shaft


seal leaking
Lift too high
Gap between impeller and stage too
large
Incorrect direction of rotation
Liquid volume in pump too low
Suction or pressure slider closed
Incorrect pipe connection
Incorrect electrical connection
NPSH not observed

Closing stopper not removed


Housing fixing leaking
Defective seals
Pump or pipe not fully filled

Suction lift too high and/or delivery


lift too low
Pump is running dry
Pump runs unevenly or noisily

Pump or pipe not completely filled


Suction lift too high and/or delivery
lift too low (cavitation)
Q-min. is not reached

Motor protection switch cuts


out

Pump is not installed level on floor


or is twisted
Foreign bodies in pump
Foreign bodies in pump
Closed slider in pressure pipe
The permitted pumping conditions
were not complied with
Power take-up greater than set
upper limit
Increased friction in pump

Remedy
Readjust operating point
Check fluid level, open suction-side
shut-off units
Clean filters and dirt pans installed on
the suction side
Replace worn pump components
Reconnect motor
Replace housing seals. Check flange
connections
Replace housing seals. Check flange
connections
Check fluid levels
Replace worn pump components
Reconnect motor
Refill pump!
Open all shut-off units!
Reconnect pump
Reconnect motor
Clean filters and dirt pans installed on
the suction side
Remove closing stoppers
Check securing torque of housing bolts
Replace seals
Vent and fill pump as well as suction/supply line
Check fluid levels, open suction-sided
closing units
Clean the filters and dirt pans installed
on the suction side
Vent and fill pump as well as suction
and/or feed pipe
Check fluid levels, open suction-sided
shut-off units
Clean filter and dirt pans installed on
suction site
Check installation of pumps
Disassemble and clean pump
Disassemble pump and replace damaged parts
Open shut-off units
Observe the pumping conditions specified in the datasheet
Check the motor protection switches
and the electrical connections
Check:
whether the pump is blocked by
foreign bodies
stuffing box is tightened too much
shaft seal is OK

16

ALLWEILER
11.

Ancillary documentation

11.1

Impeller gap dimensions


Pump material types 10, 12, 22 with flat seals (tmax. = 120C).
Depth of presThickness of
Pump series
Impeller widths
sure side
seal
100/110
10 0.02
9.98 + 0.02
0.15 + 0.02
210/220/330
10 0.02
9.98 + 0.02
0.15 + 0.02
440
14 0.02
13.98 + 0.02
0.17 + 0.02
550
19 0.04
19.01 + 0.04
0.17 + 0.02
660
22 0.04
22.01 + 0.04
0.17 + 0.05
Pump material type 32 with PTFE round seals (tmax. = 120C).
Depth of presPump series
Impeller widths
Thickness of seal
sure side
100/110
10 0.02
10.15 + 0.02
0.03
210/220/330
10 0.02
10.15 + 0.02
0.03
440
14 0.02
14.18 + 0.02
0.03
550
19 0.04
19.18 + 0.04
0.03
660
22 0.04
22.18 + 0.04
0.03
Pump material type 10, 12, 22 with PTFE T-type flat seals (tmax. = 140C).
Depth of presPump series
Impeller widths
Thickness of seal
sure side
100/110
10 0.02
10.04 + 0.02
0.15 + 0.02
210/220/330
10 0.02
10.07 + 0.02
0.15 + 0.02
440
14 0.02
14.07 + 0.02
0.17 + 0.02
550
19 0.04
19.14 + 0.04
0.17 + 0.02
660
22 0.04
22.16 + 0.04
0.17 + 0.05
Pump material type 32 with PTFE, T-type round seals (tmax. = 140C).
Depth of presPump series
Impeller widths
Thickness of seal
sure side
100/110
10 0.02
10.21 + 0.02
0.03
210/220/330
10 0.02
10.24 + 0.02
0.03
440
14 0.02
14.25 + 0.02
0.03
550
19 0.04
19.31 + 0.04
0.03
660
22 0.04
22.33 + 0.04
0.03

Total gap
0.13 + 0.06
0.13 + 0.06
0.15 + 0.06
0.18 + 0.10
0.18 + 0.13

Total gap
0.18 + 0.04
0.18 + 0.04
0.19 + 0.04
0.21 + 0.08
0.21 + 0.08

Total gap
0.19 + 0.06
0.22 + 0.06
0.24 + 0.06
0.31 + 0.01
0.33 + 0.13

Total gap
0.24 + 0.04
0.27+ 0.04
0.28 + 0.04
0.34 + 0.08
0.36 + 0.08

Gap on each
side
0.065 + 0.03
0.065 + 0.03
0.075 + 0.03
0.09 + 0.05
0.09 + 0.065
Gap on each
side
0.09 + 0.02
0.09 + 0.02
0.095 + 0.02
0.105 + 0.04
0.105 + 0.04
Gap on each
side
0.095 + 0.03
0.11 + 0.03
0.12 + 0.03
0.155 + 0.05
0.165 + 0.065
Gap on each
side
0.12 + 0.02
0.135 + 0.02
0.14 + 0.02
0.17 + 0.04
0.18 + 0.04

Contents of Appendix:
11.2

Sectional diagram of pump

11.3

Sectional diagram of shaft seal

11.4

Datasheet
The technical specifications of the pump are contained in the datasheet. The dimensions are contained in the dimensional table which can be supplied on request.

12.

Identification
The pumps contain a nameplate according to DIN 24299 as shown in Fig. 12.1.

Fig. 12.1
17

ALLWEILER
11.2

Cross-section of pump

SONWW

SONW

SRNWW

18

ALLWEILER
SOBW

SRBWW

SOVW/SRVW single stage

SOBW/SRVW multi-stage

19

ALLWEILER
11.3

Sectional drawing of shaft seal

Sliding ring type

Stuffing box type

Part no.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
17
18
21
22
23
24

Designation
delivery housing
suction housing
suction section
delivery side
suction side
impeller
shaft
double footstand
foot lantern
bearing support
rolling bearing
bearing lid
end bearing lid
spacer ring
bearing bushing, long
bearing bushing, short
cheese-head screw
splash ring
sealing ring, white
sealing ring, narrow
packing ring

Part no.
26
27
28
29
30
31
33
34
35
36
41
42
43
51
52
53
61
62
63
64
65

Designation
stuffing box
union nut
curved washer
washer
shaft nut
stopper
connecting bolt with nut
bypass
pipe fixing
locking ring
coupling half, pump side
coupling half, motor side
coupling packages
counter flange
flange seal
hexagonal screw
axial face seal
counter ring
flat backing
circlip ring
set collar

20

ALLWEILER

Subject to technical alterations

ALLWEILER
Radolfzell Works
Postfach 1140
D78301 Radolfzell
Allweilerstrasse 1
D78315 Radolfzell
Germany
Phone (07732) 86 0
Fax (07732) 86 436
E-mail: service@allweiler.de
internet: http://www.allweiler.de