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DICKOW PUMPEN KG / Pump Data Sheet - Pump with Shaft Seal

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Order No.:
P.O. No.: 14EBE1736
PB14201782
Customer :
Buss-SMS-Canzler GmbH, Butzbach
Quantity :
Type :
1
NCL
s 32/210
Cust. Item No.:

Date :
P.O. Date :
Design :
Serial No.:

22.08.14 Week :
10.06.14
Dexd N13
PB14201782

34

Accessories
Motor manufacturer : ATB
Delivered by :
Type :
ISO-classif.:
Protection :
100L2
F
Output :
Voltage :
Frequency :
3,6 kW
440 V
Construction : B3
Thermistors : 3 pc.
VIK :
Frequency converter operation!
Coupling, Manuf./Type :
FLENDER ARPEX NAN 88-6/100
Base plate/frame :
5G

Assembled by :
Ex - classif.:
Terminal box :
Efficiency-class:

DICKOW
IP55
60 Hz
no

DICKOW
Exde II CT4
manufacturers standard
IE1

Guard material :
carb. st.
foundation bolts :

Thermosyphon vessel: acc. to 46.66

No. 50 1007

Name tag :

english

Execution
Pump flanges : Suct.: 2"
Impeller diam. :
Stages :
Ratg.: 300
198 mm
1
Impeller type : closed
Machined acc. to :
ASME RF
Circulation :
Bores, intermediate casing :
(1) no
Plan 53
(2) no
Casing mount :
Rotation :
foot
cw
Drain :
standard plug
Press. gauge conn.:
Nozzle orientation : standard
no
Self priming :
Painting : standard, RAL 9006
no
Heating jacket flange: Inlet DN/PN:
Outlet DN/PN:
Heating/Cooling : volute cas. :
intermed. cas.:
mech. seal :
Shaft seal :
Manufacturer : DICKOW
Double mech. seal
Inboard Type/Size :
Material :
N13
U3U3GG1G
Outboard Type/Size :
Material :
N13
U2U2GG1G

Disch.:

1,5"

Ratg.: 300

Materials
Wetted casing: GGG 40.3 / carb. st Side chan. impeller:
Diffuser :
Imp. wear ring :
Impeller :
Pump shaft :
1.4408
1.4021
Wear ring :
1.4571

bearing bracket: GG 25
Support column :
Dome cover :

Gasket :
Graphite
Shaft sleeve :
Mech. seal casing:

Operating Data
Liquid :
Oil
Solids :
Flow liquid :
Flow water :
Vapour pressure :
max. operating temp.:

Temperature :
Head liquid :
Head water :
Speed :
max. operating press.:

yes
5 m3/h

300C

265 C
20 mLC
1750 rpm
< 10 bar

Density :
0,79 kg/l
Viscosity :
1 mm2/s
Power cons. liquid :
1,0 kW
Power cons. water :
max. power cons.:
Perf. curve : 64. NC.202

Tests
Material
Certificate: yes
EN 10204 2.1

Witnessed:

Hydrostatic

Performance

NPSH

Certificate: yes Witnessed:


Test Press.: 15 bar

Certificate: yes Witnessed:


ISO 9906-3B 5 point

Certificate:

Balancing

Vibration

Certificate:
Witnessed:
DIN/ISO 1940 T1 6.3

Certificate:

Witnessed:

Sound power
Witnessed:

Certificate:
ISO 9614-2

Witnessed:

Drawings, Build sheets, Documentation


Build sheet :
Documentation : No.: 1 / mail
23.NCL.353
Mech. seal build sheet :
23.NC.246/I
Comments :

Language: german / engl

EU-Language IOM: not EU

# Soot; Particle size 50 m, max. 1 mm


I.O.M. manual of pump in spanish language!
Cold start @ 40C: 75,6 mm2/s => Power rating 1,8 kW

Rev.B vom 02.07.14 VK/Hu/we

ATEX - ExII2GcX Kat.: 2 Tempkl.: T1 (05 ATEX D 015)

63
64 Handled by Hu

Date 17.06.14

Techn. verified

Date

Weights : net
total
Motor No.:
546441001 H
ATEX:
08 ATEX 1087 X
Comm. verified

Date

Operating / Installation Instructions


NCL

Nr. 44.NCL.E4.12/10

Original Manual

DICKOW PUMPEN KG

Table of Contents

Table of Contents
Table of Contents ......................................................................................................................................... 2
1. General................................................................................................................................................. 4
2. Safety ................................................................................................................................................... 5
2.1 Designation of Warning Notices .................................................................................................. 5
2.2 Intended use.................................................................................................................................. 6
2.3 Avoidance of foreseeable operating errors................................................................................... 7
2.4 Qualification of personnel ............................................................................................................ 7
2.5 Additional safety regulations........................................................................................................ 7
2.6 Safety instructions for the operator / user..................................................................................... 7
2.7 Safety instructions for maintenance, inspection and assembly ................................................... 8
2.8 Non-observance of the instruction manual................................................................................... 8
2.9 Notices on explosion protection ................................................................................................... 8
3. Description......................................................................................................................................... 11
3.1 General discription ..................................................................................................................... 11
3.2 Design code ................................................................................................................................ 11
3.3 Classification pump size / frame size ......................................................................................... 11
3.4 Identification .............................................................................................................................. 12
3.5 Design......................................................................................................................................... 13
3.6 Scope of supply .......................................................................................................................... 13
3.7 Dimensions and Weights............................................................................................................ 14
4. Handling / Storage / Disposal ............................................................................................................ 15
4.1 Handling ..................................................................................................................................... 15
4.2 Storage / Preservation................................................................................................................. 16
4.3 Return of pump........................................................................................................................... 16
4.4 Disposal ...................................................................................................................................... 17
5. Installation / Mounting ...................................................................................................................... 18
5.1 Safety Instructions...................................................................................................................... 18
5.2 Foundation.................................................................................................................................. 18
5.3 Installation of pump unit ............................................................................................................ 18
5.4 Piping ......................................................................................................................................... 19
5.5 Insulation .................................................................................................................................... 22
5.6 Coupling alignment .................................................................................................................... 23
5.7 Alignment of pump and motor ................................................................................................... 24
5.8 Electrical connection of the pump unit....................................................................................... 25
6. Commissioning / Decommissioning.................................................................................................. 27
6.1 Commissioning........................................................................................................................... 27
6.2 Operating the pump .................................................................................................................... 31
6.3 Impeller trimming....................................................................................................................... 31
6.4
Operating limits......................................................................................................................... 32
6.5 Switching off the pump .............................................................................................................. 33
6.6 Decommissioning....................................................................................................................... 33
7. Maintenance / Servicing / Inspection ................................................................................................ 34
7.1 Safety regulations ....................................................................................................................... 34
7.2 Operating surveillance................................................................................................................ 35
7.3 Drainage and Disposal................................................................................................................ 37
7.4 Disassembly of pump unit.......................................................................................................... 37
7.5 Inspection ................................................................................................................................... 42
7.6 Assembly of pump unit .............................................................................................................. 43
7.7 Bolt torques ................................................................................................................................ 48

NCL E4.12.10

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Table of Contents
8.
9.

Troubleshooting................................................................................................................................. 49
Interchangeability .............................................................................................................................. 51
9.1 Frame size 0................................................................................................................................ 51
9.2 Frame size I ................................................................................................................................ 52
9.3 Frame size II............................................................................................................................... 53
9.4 Frame size III.............................................................................................................................. 54
9.5 Frame size IV ............................................................................................................................. 55
9.6 Frame size V............................................................................................................................... 56
10.
Sectional drawings ......................................................................................................................... 57
10.1 Pump........................................................................................................................................... 57
10.2 Mechanical seal .......................................................................................................................... 59
11.
Certificates ..................................................................................................................................... 61
11.1 EC-Declaration of Conformity...................................................................................................... 61
11.2 Document of Compliance........................................................................................................... 62

NCL E4.12.10

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1. General

1. General
This instruction manual describes the proper and safe usage of the pump during all operating phases.
The instruction manual does not consider local regulations. Adherence to those is the responsibility of the
owner.
The name tag states pump type and size, the most important operating data as well as the pump serial
number. The serial number is a precise description of the pump unit and serves as identification for all
following procedures.
In the event of damage the Customer Service of Dickow Pumpen must immediately be informed in order
to maintain guarantee claims.
For installation of supplied interchangeable units, the respective subchapters of "Maintenance, Servicing,
Inspection" must be observed.
Applicable documents:
-

Pump data sheet


Dimensional drawing
Sectional drawing
Parts lists
Sub-supplier documentation

NCL E4.12.10

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2. Safety

2. Safety
The manual includes basic instructions for installation, operation and maintenance. Only if these
instructions are strictly observed, a safe handling of pump or pump unit is guaranteed and personal injury
and material damage is avoided.
All the safety instructions in this manual must be considered.
This manual must be thoroughly reviewed and completely understood by the qualified personnel /
operator before attempting assembly and start-up.
The manual must consistently be available on site.
Indications and plates attached to the pump must be followed and kept in legible condition.

2.1

Designation of Warning Notices

Signal word

Explanation

DANGER

signifies an imminent danger.


If it will not be avoided, death or severe injury are the consequence.

WARNING

signifies a possibly dangerous situation.


If it will not be avoided, death or severe injury may be the consequence.

CAUTION

signifies a possibly dangerous situation.


If it will not be avoided, slight or minor injury may be the consequence.

ATTENTION

signifies a possibly harmful situation.


If it will not be avoided, danger for the pump and its function may be the
consequence.

Symbol

Explanation
General danger sign
Together with a signal word, it signifies dangers in connection with death
or injury.
Dangerous voltage
Together with a signal word, it signifies dangers in connection with
voltage.

NCL E4.12.10

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2. Safety

Warning from magnetic field


Together with a signal word, it signifies dangers in connection with
magnetic fields.

Hot surface
Together with a signal word, it signifies dangers in connection with hot
surfaces.
Explosion protection
Gives information on protection from explosion development in
hazardous area according to EC-Directive 94/9/EG.
Mechanical breakdown
Together with the signal word ATTENTION, it signifies dangers for the
pump and its function.
Notice
Provides recommendation and useful information for handling the
product.

2.2 Intended use


The pump / pump unit may only be operated in the application area which is described in the relevant
pump data sheet. This applies for instance to pumped liquid, flow, speed, pressure, temperature and motor
power. Further points to be observed:

Operate pump in technically faultless condition only.


Never operate pump if not completely assembled.
Never operate pump without liquid.
Observe the pump data sheet / operating manual regarding the minimum flow.
Observe the pump data sheet / operating manual regarding the maximum flow.
Never throttle pump on suction side.
Maximum speed is 2900 rpm (+10%) at 50 cycles and 3500 rpm (+10%) at 60 cycles.

NCL E4.12.10

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2. Safety

2.3

Avoidance of foreseeable operating errors

Never open shut-off valves in excess of the allowable range. This would cause exceedance of the
maximum flow and possible cavitation damage.
Never exceed the allowable application limits regarding pressure and temperature which are specified
in the pump data sheet.
Consider and adhere to all safety instructions and other notices mentioned in the operating manual.

2.4

Qualification of personnel

The personnel must possess the relevant qualification for assembly, operation, maintenance and
inspection of the pump unit.
Responsibility, competence and supervision must be strictly regulated by the owner.
Skill of the personnel shall be improved by training. Training course can be held by the technical staff of
Dickow Pumpen.

2.5

Additional safety regulations

Besides the safety instructions mentioned in this manual, the following additional regulations apply:

Accident prevention regulations


Explosion proof regulations
Safety regulations for handling hazardous materials
Applicable standards and laws

2.6

Safety instructions for the operator / user

Protection against contact with hot and cold components must be provided by customer.
Coupling guard and hand guard on the pump / pump unit must not be removed during operation.
Pump must always be earth connected / grounded.
Protective equipment for personnel must be provided and used.
Toxic liquid leakage must be drained off safely, without endangering individuals and environment.
Legal requirements must be observed.
Danger through electric energy must be excluded.

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2. Safety

2.7

Safety instructions for maintenance, inspection and


assembly

Alteration works or modifications on the pump are only allowed after consulting Dickow Pumpen.
Only original parts or parts approved by Dickow shall be used.
Repairs on the pump / pump unit may only be done during shutdown.
The pump casing must have cooled down to ambient temperature.
The pump must be depressurized and drained.
Consider the procedure for decommissioning according to chapter 6.6.
Pumps handling products dangerous to health must be decontaminated according to chapter 4.4
Coupling guard and hand guard must be mounted again after completion of the works.
Works on the pump unit may be done only with disconnected electricity.
Secure the pump unit against unintentional switch-on.

2.8

Non-observance of the instruction manual

Non-observance of this manual leads to loss of warranty and damage claims. Non-observance will
involve the following risks:

Endangering of individuals through electrical, thermal, mechanical and chemical impacts.


Danger through explosions.
Danger through breakdown of essential functions.
Endangering of environment through leakage of toxic liquids.

2.9

Notices on explosion protection

DANGER

Operation in explosive areas requires stringent attention to this


chapter.

NCL E4.12.10

Only pumps with Ex-identification are allowed to be used in


explosive areas.
Pumps must be designated for this service in the pump data sheet.
Intended use must be guaranteed.
Inadmissible operating conditions must be avoided in any case.
Special conditions apply for operation in compliance with ECDirective 94/9/EC (ATEX). The Ex-symbol shown here marks the
chapters in this manual which require special attention.

8 of 62

2. Safety
2.9.1

Surface temperature

The highest surface temperatures are to be expected at the pump casing, the atmospheric seal ring of the
mechanical seal and in the area of antifriction bearings. The surface temperature of the pump casing
complies with the temperature of the pumped liquid.
The surface in the bearing bracket must be open to the atmosphere. Insulation of the bearing bracket is not
allowed.
The expected temperature of atmospheric seal ring, respectively the allowable liquid temperature or
operating temperature of supply fluid for the DICKOW Metal bellows mechanical seals N6, N9, N10,
N11 and N13 can be determined with the formula below.
Temperature
class
T1
T2
T3
T4
T5
T6

Tmax Surface [C]


450 *
300
200
135
100
85

* max. operating temperature DICKOW-Metal bellows mechanical seal = 350C

-1

Speed [min ]
1450-1750
2900-3500
Class 1
Class 2
Class 3

=
=
=

Class 1
20
35

TMECH.SEAL [K]
Class 2
25
45

Class 3
40
60

water and watery liquids


other liquids
oil

Seal faces material code


SiC / SiC
U.U.
SiC / Carbon U.A.

Factor K
0,75
1,0

Temperature on the atmospheric seal component


TMECH.SEAL =

T + (K TMECH.SEAL)
T = Temperature pumped liquid respectively supply fluid

Allowable temperature of pumped liquid respectively supply fluid


Tallowable =

Tmax - (K TMECH.SEAL) - TS
TS = Safety reduction ; T-Classes T6-T3 = 5 C
T-Classes T2/T1 = 10 C

NCL E4.12.10

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2. Safety
NOTE
When using mechanical seals of other makes, the operating manuals of the
respective manufacturers must be considered.

2.9.2 Monitoring devices


The pump may only be operated within the limit values given in the pump data sheet and on the name tag.
In case the owner cannot guarantee for maintaining the operating limits, monitoring devices are required.
More information on monitoring devices can be inquired at DICKOW Pumpen.

NCL E4.12.10

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3. Description

3. Description
3.1

General discription

This pump is used especially for dangerous liquids handled in the chemical, petrochemical and general
industry.

3.2

Design code
Example: NCL b h 32/210 A Ge
NCL

pump type

special design ; e.g. b = heating jacket

material execution ; e.g. h = 1.4408 / 1.4571

32

nominal width discharge flange [mm]

210

nominal impeller diameter [mm]

scope of supply ; e.g. A = bare shaft pump

Ge

shaft sealing ; e.g. Ge = standard mechanical seal, balanced

3.3 Classification pump size / frame size


Frame size

Pump sizes

NCL E4.12.10

II

III

IV

26/170
26/210

32/165
32/210
40/165
40/210
50/165
50/210

32/250
40/250
40/320
50/250
50/330
65/165
65/210
65/250
80/165
80/210
80/250
100/210

65/320
80/320
100/250
100/320
100/400
125/250
125/320
125/400
150/250

150/320
150/400
150/500
200/260
200/320
200/400
200/500
250/320

250/400
250/500

11 of 62

3. Description

3.4

Identification

3.4.1

Name tag

Fig. 1: Name tag German and English

3.4.2

Identification acc. to EC-Explosion Proof Directive


Group II
Category 2
Application in atmospheres with gas / steam / fog
Protection through constructural safety EN 13464-5
see below

Reference number of technical documentation

Fig. 2: ATEX-Name tag


The surface temperature does not depend on the ignition source, but on the temperature of the pumped
liquid. There is no identification with a temperature class or a temperature. The symbol "X" is integrated
in the identification. Chapter 2.9.1 refers to the arising surface temperatures. (Consider the notes on the
pump data sheet)

NCL E4.12.10

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3. Description

3.5

Design

Design
volute casing pump
horizontal installation
single stage
compliance with requirements of ISO 5199
casing dimensions according to EN 22858
Pump casing
single volute / double volute (depending on pump size)
radially split
cast-on feet or centerline mounted
Impeller
closed or open
back vanes, injection slots and/or relief holes for thrust load balance
Bearing
motor end: paired angular ball bearing as fixed bearing
pump end: cylinder roller bearing
oil lubrication
optional: grease lubrication

Shaft sealing
stuffing box
single and double mechanical seal
cartridge seal

3.6

Scope of supply

Depending on the pump execution, the following items belong to the scope of supply:

Pump
Elastic coupling with or without spacer
Coupling guard
Casted base plate respectively welded base plate of stiff design
Drive motor
Special accessories if required

NCL E4.12.10

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3. Description

3.7

Dimensions and Weights

Dimensions and weights can be taken from the foundation plan / dimensional drawing.

NCL E4.12.10

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4. Handling / Storage / Disposal

4. Handling / Storage / Disposal


4.1

Handling

DANGER

Slipping of pump / pump unit from its suspension


Danger of life through components falling down !

Lift the pump / pump unit only in horizontal position.


Never hook up the pump on its bare shaft.
Never hang up the pump unit on the ring screw of the motor.
Do not stay underneath floating loads.
Consider weight indications in the dimensional drawing.
Observe the local accident prevention regulations.
Use suitable and approved lifting accessories.

Fig. 3: lifting the pump

Fig. 4: lifting the complete pump unit

Fig. 5: lifting the pump mounted on base plate

NCL E4.12.10

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4. Handling / Storage / Disposal

4.2

Storage / Preservation

ATTENTION

Damage during storage through moisture or dirt.


Corrosion and / or contamination of the pump !

ATTENTION

Outside storage requires a watertight cover over pump or over packed


pump and accessories.

Wetted, contaminated or damaged openings and joints.


Leakage or damage of the pump !

Plugged openings should be uncovered only during installation.

The following measures are recommended for storage of the pump / pump unit:

Store the pump in a sheltered dry place with constant air humidity.
Turn the shaft manually once a month.

New pumps of material GGG (ductile iron) and ferritic cast steel are covered inside with anti-corrosive
agent and dewatering-fluid. The maximum dry storage period is 12 months.
For storing a pump that has been in operation already, consider chapter 6.6.

4.3

Return of pump

Drain the pump properly considering chapter 7.3.


Rinse and clean the pump in general, especially when handling dangerous, explosive, hot or other
risky liquids.
A Document of Compliance completely filled in must always be attached to the pump. Refer to
chapter 11.2.

NOTE

If required, a Document of Compliance can be downloaded under


www.dickow.de.
http://www.dickow.de/unbedenk-en.pdf

NCL E4.12.10

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4. Handling / Storage / Disposal

4.4

Disposal

WARNING

Liquids dangerous to health


Danger for individuals and environment !

1.
2.
3.
4.

Collect and dispose rinsing water and residual liquid.


Wear protective clothing and face mask.
Consider the legal regulations for disposal of liquids dangerous to
health.

Disassemble pump / pump unit.


Collect grease and oil.
Separate pump materials
Dispose according to the local regulations.

NCL E4.12.10

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5. Installation / Mounting

5. Installation / Mounting
5.1

Safety Instructions

DANGER

Improper installation in explosive area


Danger of explosion !

Consider the local applicable explosion proof regulations.


Consider indications on the pump data sheet and on the name tag of
pump and motor.

5.2 Foundation
WARNING

Installation on weak and unstable foundations


Personal injury and material damage !

Consider sufficient concrete strength (minimum class XO) of the


foundation acc. to DIN 1045.
Place the pump unit on hardened foundation only.
Place the pump unit on level and even surfaces only.
Consider weight indications of dimensional drawing.

5.3

Installation of pump unit

5.3.1

Installation on foundation

1.

Place the pump unit on the foundation and align it with a water-level.
Allowable deviation: 0,2 mm/m
Insert shims for height compensation. Always insert them both-sided near the
foundation bolts between base plate and foundation.
If the space between the foundation bolts is > 600 mm, insert additional shims in the
middle between the foundation bolts.
All shims must seat solidly.
Hook the foundation bolts into the provided bore.
Concrete the foundation bolts.
Align the base plate after concrete has hardened.
Tighten the foundation bolts evenly.
Pour the base plate with vibration-free concrete of normal graining with a watercement-value (W/Z-value) 0,5. Provide a pourable consistency by using a mobile
solvent. Cure of concrete according to DIN 1045.

2.
3.
4.
5.
6.
7.
8.
9.

NCL E4.12.10

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5. Installation / Mounting
5.3.2

Installation without foundation

Installation without foundation requires a solid and even ground.


1.
2.
3.
4.

Place the pump unit on stilts and align it with a water-level.


For height compensation, loosen screws and counter nuts of stilts.
Adjust the nut until available height differences are compensated.
Fasten the counter nuts of the stilts.

5.4

Piping

DANGER

Exceedance of the allowable loads at the pump flanges


Danger to life from leaking hot, toxic, caustic or flammable liquids.

NCL E4.12.10

Do not use the pump as an anchor point for piping.


Support piping before the pump and connect it stress-free.
Consider allowable flange forces and moments according to chapter 5.4.2.
Compensate expansion of the piping in case of high temperatures.

19 of 62

5. Installation / Mounting
5.4.1

Suction pipe

Layout of suction pipe requires special attention. NPSH Available and NPSH Required must be clearly
defined. Pay attention to the following:

Mounting of elbows close to the pump suction must be avoided. Provide a straight pipe of
minimum two suction pipe diameters.
Never connect a larger suction pipe direct to the pump. Flow eddies reduce the free flow area of the
pump. Use an eccentric reducer, consider the figures below.

Fig. 6: Flow eddies

Fig. 7: Reducer connection

At suction lift conditions, the suction pipe must continuously slope upwards towards pump suction.
Eliminate air pockets.
At flooded suction conditions, the suction pipe must slope gradually downwards to the suction
flange. Avoid air pockets to ensure a complete venting.
Maximum flow speed of 2 m/s must not be exceeded.

ATTENTION

Welding beads, scale and other impurities in the piping.


Damage of the pump !

Piping must be thoroughly cleaned before connecting the pump.


Remove impurities from the pipes.
If required, insert a filter.

Use a filter with a mesh width of 0,5 mm.


Insert filter with a surface of minimum triple the pipe section.

NOTE

NCL E4.12.10

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5. Installation / Mounting
5.4.2

Allowable flange forces and moments

pump size
26/125 - 210
32/165 - 250
40/125 - 320
50/125 - 330
65/125 - 320
80/165 - 320
100/210 - 400
125/250 - 400
150/250 - 500
200/250 - 500
250/320 - 500

pump size
26/125 - 210
32/165 - 250
40/125 - 320
50/125 - 330
65/125 - 320
80/165 - 320
100/210 - 400
125/250 - 400
150/250 - 500
200/250 - 500
250/320 - 500

Suction flange
DN
40
1 "
50
2"
65
3"
80
3"
100
4"
125
6"
125
6"
150
6"
200
8"
250
10"
300
12"

Fx [N]
GGG GS

Fy [N]
GGG GS

Fz [N]
GGG GS

F [N]
GGG GS

Mx [Nm]
GGG GS

My [Nm]
GGG GS

Mz [Nm]
GGG GS

M [Nm]
GGG GS

556

875

490

770

445

700

860

1360

580

910

400

630

470

735

840

1330

735

1155

670

1050

600

945

1150

1820

625

1022

445

700

515

805

910

1430

935

1470

825

1295

760

1190

1460

2310

670

1050

490

770

535

840

970

1540

1115

1750

1000

1575

915

1435

1750

2760

715

1120

515

805

580

910

1040

1640

1490

2345

1335

2100

1200

1890

2330

3670

780

1225

560

875

645

1015 1150

1820

1760

2765

1580

2485

1425

2240

2750

4340

935

1470

670

1050

845

1330 1350

2130

1760

2765

1580

2485

1425

2240

2750

4340

935

1470

670

1050

845

1330 1350

2130

2225

3500

2000

3150

1800

2835

3480

5490

1115

1750

780

1225

915

1435 1620

2550

2980

4690

2670

4200

2400

3780

4640

7310

1445

2275

1025 1610 1180 1855 2130

3360

4245

5845

3785

5215

3430

4725

6620

9130

2260

3115

1600 2205 1855 2555 3320

4580

5080

7000

4550

6265

4090

5635

7950 10950 3075

4235

2185 3010 2515 3465 4520

6230

Discharge flange
DN
25
1"
32
1 "
40
1 "
50
2"
65
3"
80
3"
100
4"
125
6"
150
6"
200
8"
250
10"

NCL E4.12.10

Fx [N]
GGG GS

Fy [N]
GGG GS

Fz [N]
GGG
GS

F [N]
GGG
GS

Mx [Nm]
GGG
GS

My [Nm]
GGG GS

Mz [Nm]
GGG GS

M [Nm]
GGG
GS

335

525

315

490

380

595

570

910

400

630

270

420

315

490

570

910

400

630

380

595

470

735

730

1150

490

770

335

525

380

595

710

1120

490

770

445

700

560

875

860

1360

580

910

400

630

470

735

840

1330

670

1050

600

945

735

1155

1150

1820

625

980

445

700

515

805

910

1430

825

1295

755

1190

935

1470

1460

2310

670

1050

490

770

535

840

970

1540

1000 1575

915

1435

1111

1750

1750

2760

715

1120

515

805

580

910

1040

1640

1335 2100

1200

1890

1490

2345

2330

3670

780

1225

560

875

645

1015

1150

1820

1580 2485

1425

2240

1760

2765

2750

4340

935

1470

670

1050

845

1330

1350

2130

2000 3150

1800

2835

2225

3500

3480

5490

1115

1750

780

1225

915

1435

1620

2550

2670 4200

2400

3780

2980

4690

4640

7310

1445

2275

1025

1610

1180

1855

2130

3360

3790 5215

3430

4725

4245

5845

6620

9130

2260

3115

1600

2205

1855

2555

3320

4580

21 of 62

5. Installation / Mounting
Forces and moments are based on 20C. Temperature dependent correction values are given in figure 9.

Fig. 8: Temperature correction diagram


In case that not all acting loads reach the maximum allowable values, one of these loads may exceed the
limit value under the following provisions.

Exceedance is limited to 1,4 times the allowable value.


For the actual forces and moments acting on the flange shall apply:

/F/ actual

/F/
max. allowable

5.5

/M/ actual

/M/
max. allowable

Insulation

WARNING

Wetted casing parts adopt the temperature of the pumped liquid.


Risk of burns !

ATTENTION

Insulate casing parts


Attach protective device

Heat accumulation in the bearing bracket


Bearing damage !

NCL E4.12.10

Do not insulate the bearing bracket

22 of 62

5. Installation / Mounting

5.6

Coupling alignment

DANGER

Inadmissible temperatures on coupling or antifriction bearings due to


misalignment of the coupling
Danger of explosion !

WARNING

Proper alignment of coupling must anytime be ensured.

Unintentional switch-on of the pump unit


Risk of injury through moving components !

ATTENTION

Works on the pump unit may be done only with disconnected electricity.
Secure the pump unit against unintentional switch-on.

Offset of pump shaft and motor shaft


Damage of pump, motor and coupling !

Coupling check has always to be performed after pipe connection.


Coupling check has also to be performed at pump units supplied on common
base plate.

Fig. 9: Angular and radial misalignment of couplings

Fig. 10: Coupling alignment

NCL E4.12.10

23 of 62

5. Installation / Mounting
1.
2.
3.
4.

5.
6.
7.
8.

Dismantle coupling guard.


Loosen support foot.
Place a straight edge (1) axially across the coupling half.
Possible radial displacement Kr becomes visible as a light gap.
Better: Determine the radial misalignment by measuring the distances A and B at three points
staggered by 120.
The coupling is aligned correctly if the distance to the shaft is identical at all points.
Check the distance s1 circularly between the coupling halves. The coupling is aligned correctly if
the distance is circularly identical.
Concerning the allowable deviation s1 and Kr of both coupling halves, refer to the instruction
manual of the coupling manufacturer !
Mount the support foot.
Mount the coupling guard.

5.7

Alignment of pump and motor

WARNING

Exposed rotating coupling


Risk of injury through rotating shaft !

DANGER

Operate the pump unit only with coupling guard.


Select the coupling guard according to corresponding standards.

Ignition hazard through friction sparks


Danger of explosion !

Use non-sparking material for coupling guard only to exclude flying sparks in
case of contact.
Consider EN 13463-1.

After the pump unit is installed and piping is connected, check the coupling alignment and realign motor
if necessary.
Use shims for height compensation.
1.
2.
3.
4.
5.
6.
7.
8.

Dismantle coupling guard.


Check coupling alignment. Consider chapter 5.6.
Loosen hold down bolts of motor.
Place shims under the motor feet for height compensation.
Tighten hold down bolts of motor.
Check function of coupling / shaft. The coupling must easily be turnable by hand.
Mount the coupling guard.
Check the space between coupling and coupling guard.

NCL E4.12.10

24 of 62

5. Installation / Mounting

5.8

Electrical connection of the pump unit

DANGER

Improper electrical installation


Danger of explosion !

DANGER

Electrical installation requires additionally observance of IEC 60079-14.


Explosion proof motors shall be connected through motor protection switch
only

Working on the pump unit by unqualified personnel


Danger to life through electric shock !

WARNING

Electrical connection must be performed by qualified electrician only.


Regulations IEC 30364 and IEC 60079 must be considered.

Incorrect power connection


Short circuit !

Adhere to connection conditions of local energy supply companies.

Proceedings:
1.
2.
3.

Check for compliance of the available supply voltage with the indications on the motor name tag.
Select suitable connection method.
Check for identical rotating direction of motor and pump. Consider the rotating direction arrow of
the pump !

NOTE
Observe the instruction manual of the motor !

NCL E4.12.10

25 of 62

5. Installation / Mounting
5.8.1

Checking rotating direction

DANGER

Temperature rise through parts touching each other


Danger of explosion !

ATTENTION

Never check rotating direction with dry pump.


Disconnect the pump for checking rotating direction.

Wrong rotating direction of motor and pump


Damage of the pump !

1.
2.
3.

Consider the rotating direction arrow on the pump.

Start motor briefly. Note rotating direction of the motor.


Rotating direction of the motor must comply with the rotating direction arrow on the pump.
In case of wrong rotating direction, change the cables in the motor terminal box.

NCL E4.12.10

26 of 62

6. Commissioning / Decommissioning

6. Commissioning / Decommissioning
6.1

Commissioning

The following points must be checked prior to start-up;

The pump unit is correctly electronically connected to all relevant protective devices.
The pump is filled with liquid.
Rotating direction has been checked.
All additional connections are connected and fully functional.
Lubricants are checked.
After a longer standstill period, the measures mentioned in chapter 7
"Maintenance/Servicing/Inspection" must be considered and performed.

6.1.1

Filling of lubrication oil

ATTENTION

Lack of lube oil in the oil reservoir of constant level oiler


Damage of antifriction bearings !

ATTENTION

Check oil level regularly.


Oil reservoir must always be sufficiently filled.

Lack of lube oil in the bearing bracket


Damage of antifriction bearings !

NCL E4.12.10

The threaded hole of the constant level oiler must be in horizontal position.

27 of 62

6. Commissioning / Decommissioning
1.
2.
3.

Unscrew vent plug (1).


Fold down the constant level oiler (2) away from bearing bracket (3) and hold it tight.
Fill in the oil through the vent plug bore (1) until the filling level reaches the connection pipe of
the constant level oiler (2)
Fill up the oil reservoir to the maximum.
Fold back the constant level oiler (2) to its original position.
Screw in the vent plug (1).
Check the oil level in the oil reservoir of the constant level oiler (2) after a few minutes. Repeat
steps 4 to 6 until oil outflow from the oil reservoir has stopped.

4.
5.
6.
7.

NOTE
Exceeding oil level causes temperature increase or oil leakage.

For filling quantity and oil quality refer to chapter 7.2.2.


Executions with grase lubrication are not provided with constant level oiler and vent plug. Antifriction
bearings are permanent grease lubricated. Relubrication is not required.

6.1.2

Filling and venting the pump

DANGER

Formation of explosive atmosphere inside the pump


Danger of explosion !

1.
2.
3.

6.1.3

The pump must permanently be filled with liquid.


Appropriate monitoring measures must be provided.

Vent and fill up pump and suction pipe with liquid.


Pump is selfventing.
Open shut-off valve in suction pipe completely
Open all additional connections completely (e.g. external circulation, external flush)

Shaft sealing

The pump will be supplied with installed shaft sealing. If a fluid reservoir is foreseen, it must be filled
according to the reservoir manual.
If double mechanical seals are provided, a barrier pressure supply must be connected prior to starting the
pump, following the instruction manual of reservoir respectively mechanical seal.
In case of external flush, the pump must be flushed with the quantities and pressures as stated in the pump
data sheet respectively in the dimensional drawing.

NCL E4.12.10

28 of 62

6. Commissioning / Decommissioning
6.1.4

Design with heating jacket

Pump casing and intermediate casing with heating jacket.


Permissible heating agent:

Hot water
Steam
Heat transfer oil

Pressure- and temperature limits:

tmax = 200C
pmax = 25 bar

ATTENTION

Elevated surface temperature


Danger of explosion !

ATTENTION

Consider the allowable temperature class.

Lack of heating fluid


Damage of the pump !

ATTENTION

Provide sufficient amount of heating fluid.

Heating period too short


Damage of the pump !

ATTENTION

Consider a sufficient heating period of the pump (approx. 2 hours)


Check free rotation of the pump shaft.

Exceedance of the allowable heating fluid temperature


Leak of pumped liquid or heating agent !

NCL E4.12.10

Consider the application limits for pressure and temperature.

29 of 62

6. Commissioning / Decommissioning
6.1.5

Inspection of shaft sealing

A mechanical seal is a dynamical seal and due to physical and technical reasons never leakage free.
Design, tolerances, operating conditions, smoothness etc. determine the quantity of leakage.
Leakage may increase during normal running-in of the sliding faces but will return to normal value after
sufficient running time. If this should not be the case, the mechanical seal must be shut down, dismantled
and inspected.
A gland packing must slightly drip during operation.

DANGER

Elevated temperature at gland packings


Danger of explosion !

Gland packings are not suitable for use in explosive areas.

Leakage on the gland packing is adjusted as follows:


1.
2.
3.
4.
5.
6.
7.

Tighten the gland nuts only slightly by hand.


Check rectangular and centric seat by using a packing gauge.
After the pump is filled up, leakage must be available.
Tighten the gland nuts so far that the appearing leakage is reduced to 60-120 drops per minute.
Start the pump.
After a running time of 5 minutes, reduce the leakage by fastening the gland nuts for 1/6 turn.
Watch the leakage.

Leakage too high

Repeat step 6 and 7.

Leakage too low

Loosen the gland nuts slightly.

No leakage

Switch off the pump unit immediately!


Loosen the gland and repeat the procedure.

6.1.6

Starting the pump

DANGER

Exceedance of allowable pressure- and temperature limits


Danger of explosion ! !
Leakage of hot or toxic liquid

NCL E4.12.10

Never operate pump with closed shut-off valves in suction and/or


discharge pipe.
Start-up pump unit only against partially opened shut-off valve on
discharge side.

30 of 62

6. Commissioning / Decommissioning
DANGER

Elevated temperature through dry run


Danger of explosion !

1.
2.
3.
4.
5.

Never operate pump in empty condition.


Always fill up pump properly.
Operate pump only within the allowable operating range.

Open shut-off valve completely in suction pipe


Open shut-off valve partially in discharge pipe
Switch on the motor.
When the pressure gauge indicates pressure, open shut-off valve on discharge side until
the duty point is reached.
When the operating temperature is reached, check coupling alignment and realign if
necessary.

6.2

Operating the pump

WARNING

High surface temperatures through hot liquids


Risk of burns !

ATTENTION

Avoid touching the pump surface.


Wear protective clothing.

Abnormal noises, vibrations, temperatures or leakage


Damage of the pump !

6.3

Switch off the pump immediately.


Only restart the pump unit after cause of trouble has been eliminated.

Impeller trimming

The impellers are hydraulically balanced in order to reduce thrust load. Additional to the wear rings,
thrust load balance is done individually or in combination with

Back vanes
Balancing holes
Injection slots

Impeller diameter can be trimmed within the range that is shown in the performance sheet.

NCL E4.12.10

31 of 62

6. Commissioning / Decommissioning

6.4

Operating limits

DANGER

Exceedance of operating limits regarding pressure, temperature and speed


Danger of explosion !
Leaking hot or toxic liquid !

6.4.1

Maintain the allowable service conditions specified in the pump data sheet.
Avoid operation against closed shut-off valve.
Never operate pump at a temperature higher than specified in the pump data
sheet.

Flow rate

If not stated otherwise in the pump data sheet, the following applies:
Qmin

= 0,25 x Qopt

Qmax

= 1,2 x Qopt

6.4.2

Switching frequencies

DANGER

Elevated surface temperature of the motor


Danger of explosion !

When using explosion proof motors, consider the information in the motor
manual regarding switching frequencies.

The switching frequencies are defined by the maximum temperature rise of the motor and depend on the
power reserve of the motor during operation and on the starting conditions.

NOTE
Read instruction manual of motor manufacturer !

6.4.3

Abrasive liquids or solids

If products containing abrasives or solids are handled, increased wear is to be expected.


The inspection intervals in this regard must be shorter than the usual ones.

NCL E4.12.10

32 of 62

6. Commissioning / Decommissioning

6.5 Switching off the pump


1. Keep shut-off valve in suction pipe open.
2. Close shut-off valve in discharge pipe.
3. Switch off the motor and watch for steady run down.

NOTE
In case a non-return valve is installed in the discharge pipe, the shut-off valve can
remain open. A counter pressure must be available.

For a longer standstill period, the following must be observed:

Liquids which tend to polymerization, crystallization or solidification, must be drained completely.


If required, rinse the pump with a suitable liquid.
Close shut-off valve in the suction pipe.
Flush connections must be closed.

6.6 Decommissioning
The pump unit remains in the piping:

Provide sufficient amount of liquid for the test runs.


Switch on the pump unit regularly monthly or quarterly.

The pump unit will be dismantled and stored:

Empty the pump properly.


Observe the safety instructions acc. to chapter 7.1 / 7.3.
Spray the inside of the pump casing with preservation agent. Not required for stainless steel pumps.
Spray preservation agent through suction and discharge flange.
Plug suction and discharge flanges, e.g. with plastic caps.
Lubricate all unpainted outside surfaces of the pump with oil and grease free of silicone. Not required
for stainless steel pumps.
Pay attention to additional notes in chapter 4.2.

NCL E4.12.10

33 of 62

7. Maintenance / Servicing / Inspection

7. Maintenance / Servicing / Inspection


7.1

Safety regulations

DANGER

Improper maintained pump unit


Danger of explosion !

WARNING

Maintain the pump unit regularly


Establish a maintenance schedule

Unintentional switching-on of the pump unit


Risk of injury through moving components !

WARNING

Works on the pump unit may be done only at disconnected electricity.


Secure the pump unit against unintentional switch-on.

Hot liquids
Risk of injury!

WARNING

Let the pump unit cool down to ambient temperature.

Liquids dangerous to health


Risk of injury !

Consider legal requirements.


Take safety measures for individuals and environment when draining the
pumped liquid.
Decontaminate the pumps.

The user must assure that maintenance, inspection and assembly is performed by qualified personnel.
These persons must have studied this operating manual comprehensively.
A maintenance schedule needs a minimum of effort and may avoid expensive repairs.
Any use of force on the pump unit must be avoided.

NCL E4.12.10

34 of 62

7. Maintenance / Servicing / Inspection

7.2

Operating surveillance

DANGER

Elevated surface temperature through hot running antifriction bearings


Danger of explosion ! Fire hazard !

ATTENTION

Check antifriction bearings regularly for running noise.


Check the lubricant level regularly.

Wear caused by dry run


Damage of the pump !

ATTENTION

Never operate an empty pump unit.


Never close the shut-off valve in suction pipe during operation.

Exceedance of the allowable liquid temperature


Damage of the pump !

Operation against closed discharge valve is not allowed.


Consider the temperature indications in the pump data sheet.

The following requires regular checking during operation:

The pump must always run steady and vibration-free.


Check antifriction bearings for running noise. Vibrations, noises and increased power input are signs
of wear.
Check the elastic elements of the coupling.
Clean the filter in the suction pipe regularly.

7.2.1

Lubrication / Lifetime of antifriction bearings

DANGER

Elevated surface temperature through hot running antifriction bearings or


defective bearing seals
Danger of explosion ! Fire hazard !

Check lubricant condition regularly.


Check lubricant level regularly.

Lubrication of antifriction bearings is normally provided by mineral oil.


Lube oil CLP46 or 68 according to DIN 51517 or HD20W/20 with a kinematic viscosity of 46-68 mm2/s
at 40C can be used, e.g.

OMV lube EPX 46


Shell Morlina 46-68

NCL E4.12.10

35 of 62

7. Maintenance / Servicing / Inspection


The calculated lifetime of antifriction bearings is also at critical service conditions more than 25000
operating hours.
The oil filling shall be renewed the first time after 200 operating hours, then once a year.
Bearing frame
0/I
II
III
IV
V

Filling Qty [l]


0,75
1,0
1,25
2,7
3,5

NOTE
Executions with grease lubrication have permanent grease lubricated antifriction
bearings. Relubrication is not required.

NOTE
If the ambient temperature is < -20C DICKOW Pumpen should be consulted.
Observe the comments in the pump data sheet.

7.2.2
1.
2.
3.
4.

Oil change

Place a suitable bowl for the waste oil underneath the drain plug.
Unscrew the drain plug from the bearing bracket and drain the oil.
After emptying, screw in the drain plug again.
Fill up oil again considering chapter 6.1.1.

WARNING

Lubricating liquids dangerous to health


Danger for individuals and environment !

NCL E4.12.10

Draining requires safety measures for individuals and environment .


Consider legal requirements concerning disposal of liquids dangerous to
health.

36 of 62

7. Maintenance / Servicing / Inspection

7.3

Drainage and Disposal

WARNING

Pumped liquids dangerous to life


Endangering for individuals and environment !

Collect flushing liquid and possible residual liquid and dispose it.
Wear protective clothing and face masks.
Consider legal requirements concerning disposal of liquids.

Drainage of pumped liquids through the drain plugs at the casing, through a connected shut-off valve or
through a flange.
Mode of drainage and position can be taken from the dimensional drawing !

7.4

Disassembly of pump unit

7.4.1

General instructions

Pay attention to safety instructions of chapter 7.1.


Working on the motor requires observance of the documentation provided by the motor manufacturer.
Consider the sectional drawings when disassembling.
In case of damage, our service department can be contacted.

DANGER

Working on the pump unit without sufficient preparation


Risk of injury !

7.4.2
5.
6.
7.
8.

Switch off the pump unit properly.


Close shut-off valves on suction and discharge side.
Drain and depressurize the pump.
Flush connections must be closed.
Let the pump unit cool down to ambient temperature.

Removal of driver

Disconnect the motor.


Remove coupling guard.
Remove the hold down bolts of the motor from the baseplate.
Decouple pump and motor by displacing the motor.

WARNING

Tilting the motor


Squeezing of hands and feet !

NCL E4.12.10

Secure the motor by lifting or bracing.

37 of 62

7. Maintenance / Servicing / Inspection


NOTE
If pump units are equipped with spacer type couplings, the motor can remain
bolted to the baseplate while dismantling the interchangeable unit.

7.4.3

Disassembly of rotating unit

If spacer type couplings are used, the motor can remain bolted to the baseplate. Remove the spacer piece
according to the operating instructions of the coupling manufacturer.

Fig. 11: Disassembly of rotating unit


1.
2.
3.
4.
5.

Loosen hexagon nut 920.2.


Loosen hexagon head bolt (1) of support foot 183.
Press the complete interchangeable unit (2) out off the volute casing 102 by using jack screws.
Pull the unit out off the casing and place it beside.
Pull off the coupling hub (3) from the shaft end.

WARNING

Tilting the rotating unit


Squeezing of hands and feet !

7.4.4

Secure the rotating unit by lifting or bracing.

Disassembly of impeller

The works according to chapter 7.4.3 are completed.


1.
2.
3.
4.

Clamp the complete unit in vertical position in a jaw chuck.


Loosen impeller nut 922 respectively inner hexagon cap screw 914.12 (frame size 0) (right hand
thread).
Pull off the impeller from pump shaft.
Remove the key 940.1.

NCL E4.12.10

38 of 62

7. Maintenance / Servicing / Inspection


7.4.5

Disassembly of shaft sealing

The works according to chapter 7.4.4 are completed.


DICKOW-Mechanical seal N6 / N10 / N11
1. Pull off the mechanical seal 433 from pump shaft.
2. Remove the hexagon nut 920.1.
3. Press the intermediate casing 113 out off its centring and place it on the bench.
4. Remove hexagon nut 920.5, pull off the packing ring 457.
5. Slide the seal ring 475 carefully out off the intermediate casing.
DICKOW-Mechanical seal N9 / N13
1. Pull off the product side mechanical seal 433.1 from the pump shaft.
2. Remove the hexagon nut 920.5.
3. Slide the seal end plate 471, the pressure ring 474 and the stationary seal ring 475.2 towards the
shaft step.
4. Remove the hexagon nut 920.1.
5. Press the intermediate casing 113 out off its centring.
6. Pull off the atmospheric seal 433.2 and the distance sleeve 525 from the pump shaft.
7. Take out the seal end plate 471, the pressure ring 474 and the stationary seal ring 475.2 from the
bearing bracket.
8. Remove the rotating seal ring 475.1 from the intermediate casing 113.
Standard Mechanical seal according to EN 12756
1. If available, remove the inner hexagon cap screw 914.1 and press the packing ring 457 out off the
intermediate casing 113.
2. Pull off the shaft sleeve 524 together with the rotating seal unit from the pump shaft.
3. Remove the hexagon nut 920.1.
4. Press the intermediate casing 113 out off its centring.
5. Remove the hexagon nut 920.5.
6. Remove the seal end plate 471.
7. Dismantle seal ring 475 and O-ring.

NCL E4.12.10

39 of 62

7. Maintenance / Servicing / Inspection


Tandem-Standard Mechanical seal acc. to EN 12756 (API-Plan 52)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Remove the hexagon nut 920.5.


Slide the seal end plate 471 with the stationary seal ring 475.2 towards the shaft step.
Remove the hexagon nut 920.1.
Press the intermediate casing 113 out off its centring.
Pull off the shaft sleeve 524 with mechanical seal 433 and seal ring support 476 from pump shaft.
Loosen the grub screws in the mechanical seal 433.2 and pull off the seal from the shaft sleeve.
Remove seal ring support 476 with rotating seal ring 475.1.
Loosen grub screw in the mechanical seal 433.1 and pull the seal off.
Press the rotating seal ring 475.1 together with the O-ring out off the seal ring support 476.
Take the seal end plate 471 out off the bearing bracket.
Press the stationary seal ring 475.2 together with the O-ring out off the seal end plate.

Double Standard Mechanical seal acc. to EN 12756 (API-Plan 53)


1.
2.
3.
4.
5.
6.
7.
8.

Remove inner hexagon cap screw 914.1.


Remove seal ring support 476 and seal ring 475.
Press the stationary seal ring 475.2 together with the O-ring out off the seal ring support 476.
Pull off the shaft sleeve 524 with the mechanical seal 433.1/2 from pump shaft.
Remove the hexagon nut 920.1.
Press the intermediate casing 113 out off its centring and place it on the bench.
Remove the hexagon nut 920.5 and pull off the seal end plate 471.
Press the stationary seal ring 475.2 together with the O-ring out off the seal end plate 471.

Cartridge-Mechanical seal
1.
2.
3.
4.
5.
6.
7.

If available, remove the inner hexagon cap screw 914.1 and press the packing ring 457 out off the
intermediate casing 113.
Remove the hexagon nut 920.5.
Remove the hexagon nut 920.1.
Press the intermediate casing 113 out off its centring.
Pull off the intermediate ring 509 from the pump shaft.
Attach assembly gauges to the mechanical seal.
Loosen the grub screws and pull off the complete seal unit 433 from the pump shaft.

NCL E4.12.10

40 of 62

7. Maintenance / Servicing / Inspection


7.4.6

Disassembly of antifriction bearings

The works according to chapter 7.4.5 are completed.


1.
2.
3.
4.
5.
6.
7.
8.

Loosen grub screw 904.1 and pull off the deflector 507 from pump shaft.
Loosen hexagon head bolt 901.2 and pull off bearing cover 360 with radial seal ring 421.2.
Press the pump shaft 211 together with angular ball bearing 325 out off the bearing bracket seat.
Use a press- or drilling spindle.
Remove the inner hexagon cap screws 914.2 and take off the bearing bracket lantern 344.
Press the outer ring of the cylinder roller bearing 322 out off the bearing bracket 330.
Remove circlip 932.2 und disk 550.3 from pump shaft.
Pull off the angular ball bearing 325 from pump shaft.
Pull off the disk 550.3 from pump shaft.

The following procedure applies for frame size V:


1.
2.
3.
4.
5.
6.
7.

Loosen grub screw 904.1 and pull off the deflector 507 from pump shaft.
Loosen inner hexagon cap screw 914.6 and pull off bearing cover 360.2 together with radial seal
ring 421.1.
Loosen inner hexagon cap screw 914.5 and pull off bearing cover 360.1 together with radial seal
ring 421.2.
Press the pump shaft 211 together with angular ball bearing 325 out off the bearing bracket seat.
Use a press- or drilling spindle.
Press the outer ring of the cylinder roller bearing 322 out off the bearing bracket 330.
Loosen and remove shaft nut 921.
Pull off the angular ball bearing 325 from pump shaft.

7.4.7

Replacement of antifriction bearings

Frame size
0/I
II
III
IV
V

322
NU 306
NU 307
NU 409
NU 411
NU 313

325
2x 7306 BUA
2x 7307 BUA
2x 7311 BUA
2x 7313 BUA
2x 7314 BUA

Execution with permanent grease lubrication:


Frame size
0/I
II
III
IV

NCL E4.12.10

321
2x 6306.2RS
2x 6307.2RS
2x 6409.2RS
2x 6411.2RS

41 of 62

7. Maintenance / Servicing / Inspection

7.5

Inspection

7.5.1

Impeller / Wear ring

The surfaces in the wear ring area may not have any visible grooves. Diameters of surfaces have to be
measured. The total clearance in new condition is 0,6 mm. If the clearance exceeds 0,9 mm, the wear
rings must be replaced.

7.5.2

Bearing bracket

Measure the inner diameter of ball bearing seats. Replace the bearing bracket if following values are
exceeded:
Frame size 0 / I
Frame size II
Frame size III
Frame size IV
Frame size V

7.5.3

max. 72,009 mm
max. 80,009 mm
max. 120,010 mm
max. 140,012 mm
max. 140,026 mm + 150,026 mm

DICKOW - Mechanical seal

The metal bellows are stressed when installed, the spring load provides a sufficient closing force on the
sliding surfaces.
Measure the mechanical seal after disassembly and thorough cleaning.
Replace the mechanical seal if the length dimensions are below the following:

Fig. 12: Seal length


Mechanical seal
N6
N10
N11
N9
N13

NCL E4.12.10

product side
atmosphere side
product side
atmosphere side

Code
A
U1
U3
U3
A
U1
U3
U3
U2
U3
U2

0/I
46
49
54
48,5
86
86
81
48,5
45
53,5
48

L [mm] at frame size


II
III
58
58
58
58
65
65
60,5
56
105
105
113
60,5
56
53
59
65,5
65,5
58
64

IV
67
67
77
74
140
74
79
79
82

42 of 62

7. Maintenance / Servicing / Inspection

7.6

Assembly of pump unit

7.6.1

General instructions

Consider the safety instructions of chapter 7.1.


Consider sectional drawings for assembly.
Use new gaskets only.
Mount gaskets without lubricants.
Do not use assembling aid when mounting the gaskets. If necessary, use customary contact adhesive.
Never use superglue.
Lubricate fittings and screw joints with graphite or similar lubricant. Lubricants must be compatible
with the pumped liquid.
Tighten all screws properly. Consider chapter 7.7.
When mounting the shaft sleeve use new tolerance rings only.

ATTENTION

Unprofessional assembly
Damage of the pump !

Assemble pumps / pump units under consideration of the general rules of


engineering.
Only use original spare parts.

The following must be checked prior to assembly:

All dismantled parts are cleaned and checked for wear.


Damaged or worn out parts must be replaced by original spare parts.
All sealing surfaces are cleaned.

NCL E4.12.10

43 of 62

7. Maintenance / Servicing / Inspection


7.6.2
1.
2.
3.

Assembly of antifriction bearings

Slide the disk 550.3 onto the pump shaft.


Heat up the angular ball bearing 325 to 80-100C.
Push the angular ball bearing 325 onto the pump shaft until limit.

NOTE
Install the angular ball bearings in O-arrangement.
Angular ball bearings installed in pairs must be of the same manufacturer.

4.
5.
6.
7.
8.
9.

Slide disk 550.3 and circlip 932.2 onto the pump shaft.
Press the outer ring of the cylinder roller bearing 322 into the bearing bracket 330.
Fit the bearing bracket lantern 344 and fasten it with inner hexagon cap screws 914.2.
Press the pump shaft 211 together with the angular ball bearing 325 into the bearing bracket seat.
Use a press- or drilling spindle.
Fit the bearing cover 360 with the new radial seal ring 421.2 and tighten the hexagon cap screws
901.2.
Push the deflector 507 onto the pump shaft. Tighten the grub screw 904.1.

The following procedure applies for frame size V:


1.
2.
3.
4.
5.
6.
7.
8.

Heat up the angular ball bearing 325 to 80-100C.


Push the angular ball bearing 325 onto the pump shaft until limit. Consider the NOTE
Screw on the shaft nut 921 and tighten it.
Press the outer ring of the cylinder roller bearing 322 into the bearing bracket 330.
Fit the bearing cover 360.2 with the new radial seal ring 421.1 and tighten the inner hexagon cap
screws 914.6.
Press the pump shaft 211 together with the angular ball bearing 325 into the bearing bracket seat.
Use a press- or drilling spindle.
Fit the bearing cover 360.1 with the new radial seal ring 421.2 and tighten the inner hexagon cap
screws 914.5.
Push the deflector 507 onto the pump shaft. Tighten the grub screw 904.1.

NCL E4.12.10

44 of 62

7. Maintenance / Servicing / Inspection


7.6.3

Assembly of mechanical seal

The works according to chapter 7.6.2 are completed.


Installation requires attention of the following:

Consider the seal drawing.


Works must be performed proper and thoroughly.
Remove protective agent on sliding surfaces completely.
Never apply lubricants to sliding surfaces.
Never compress the metal bellows to a block.
Axial forces must always be applied to the bellows support when pushing on the metal bellows.
Check parallelism with the casing part after assembly.
Surface of shaft sleeve must be clean and smooth. The edge has a chamfer.

DICKOW-Mechanical seal N6 / N10 / N11


1.
2.
3.
4.

Insert the seal ring 475 carefully into the intermediate casing.
Insert the pressure ring 474 and fasten it with hexagon nuts 920.5
Press the intermediate casing 113 into the centring and fasten it with hexagon nuts 920.1.
Slide the mechanical seal 433 onto the pump shaft.

DICKOW-Mechanical seal N9 / N13


1.
2.
3.
4.
5.
6.

Insert the rotating seal ring 475.1 into the intermediate casing 113.
Push the seal end plate 471, pressure ring 474 and stationary seal ring 475.2 onto the pump shaft
until it rests on the shaft step.
Push distance sleeve 525 and atmospheric seal 433.2 onto the pump shaft.
Press the intermediate casing 113 into the centring and fasten it with hexagon nuts 920.1.
Fasten the seal casing by hexagon nuts 920.5.
Slide the product sided mechanical seal 433.1 onto the pump shaft.

Standard Mechanical seal acc. to EN 12756


1.
2.
3.
4.
5.

Install the seal ring 475 with O-ring in the seal end plate 471.
Screw the seal end plate 471 to the intermediate casing 113 by hexagon nuts 920.5.
Press the intermediate casing 113 into the centring and fasten it with hexagon nuts 920.1.
Push the shaft sleeve 524 and rotating seal unit onto the pump shaft.
If available, press the packing ring 457 into the intermediate casing 113 and fasten it with inner
hexagon cap screws 914.1.

NCL E4.12.10

45 of 62

7. Maintenance / Servicing / Inspection


Tandem-Standard Mechanical seal acc. to EN 12756 (API-Plan 52)
1.
2.
3.
4.
5.
6.
7.
8.
9.

Install the stationary seal ring 475.2 and O-ring in the seal end plate 471.
Push the seal end plate 471 onto the pump shaft until it rests on the shaft step.
Install the rotating seal ring 475.1 and O-ring in the seal ring support 476.
Push the mechanical seal 433.1 onto the shaft sleeve and fasten it with grub screw.
Push the seal ring support 476 onto the shaft sleeve.
Push the mechanical seal 433.2 onto the shaft sleeve and tighten the grub screw.
Slide the complete unit onto the pump shaft 211.
Press the intermediate casing 113 into the centring and fasten it with hexagon nuts 920.1.
Screw the seal end plate 471 to the intermediate casing by hexagon nuts 920.5.

Double Standard Mechanical seal acc. to EN 12756 (API-Plan 53)


1.

Install the rotating seal ring 475.1 and O-ring in the seal end plate 471 and push it onto the pump
shaft.
Screw the seal end plate 471 to the intermediate casing by hexagon nuts 920.5.
Press the intermediate casing 113 into the centring and fasten it with hexagon nuts 920.1.
Slide the shaft sleeve 524 with mechanical seal 433.1/2 onto the pump shaft.
Install stationary seal ring 475.2 and O-ring in seal ring support 476.
Screw the seal ring support 476 to the intermediate casing 113 by inner hexagon cap screws 914.1.

2.
3.
4.
5.
6.

Cartridge-Mechanical seal
1.
2.
3.
4.

Push the complete seal unit 433 onto the pump shaft.
Press the intermediate casing 113 into the centring and fasten it be hexagon nuts 920.1.
Screw the seal unit 433 to the intermediate casing 113 by hexagon nuts 920.5.
Tighten the grub screws and loosen the assembly gauges.

7.6.4
1.
2.

Assembly of impeller

Slide the impeller onto the pump shaft.


Tighten the impeller nut 922 respectively the inner hexagon cap screw 914.12
(frame 0) by a torque wrench (right hand thread).

ATTENTION

Missing Heli-Coil insert


Impeller will not be fixed !

NCL E4.12.10

Make sure that impeller nut respectively pump shaft (frame 0) are provided
with Heli-Coil insert.

46 of 62

7. Maintenance / Servicing / Inspection


7.6.5

Assembly of rotating unit

WARNING

Tilting the rotating unit


Squeezing of hands and feet !

Secure the rotating unit by lifting or bracing

NOTE
Consider Figure 15 !

1.
2.
3.
4.
5.
6.

Slide the rotating unit into the volute casing.


Use new gasket 400.5.
Tighten hexagon nut 920.2 by a torque wrench.
Mount the support foot 183 with hexagon cap screw 901.1 and washer 554.8.
Fasten the support foot with hexagon cap screw to the baseplate.
Slide the coupling hub onto the shaft end.

7.6.9

Motor assembly

NOTE
The first two steps do not apply for pumps with spacer type coupling.

1.
2.
3.
4.

Couple pump and motor by displacing the motor.


Fix the motor to the baseplate.
Align pump and motor. Consider chapter 5.7.
Align coupling. Consider chapter 5.6.

NCL E4.12.10

47 of 62

7. Maintenance / Servicing / Inspection

7.7

Bolt torques

standard bolts
5
9
22
45
80
195
370

M5
M6
M8
M10
M12
M16
M20

Bolt torque [Nm]


8.8
A4-70
expansion bolts
standard bolts
expansion bolts
4
6
16
30
55
55
40
145
135
100
280
260
195

Calculation basis:

80% Yield strength utilisation of screw material.

Friction coefficient = 0,14 ; use screw lubricant for threads and head / nut contact surface.
Recommended: Klber-paste HEL 46-450.

Torque controlled tightening by torque wrench.

NOTE
Deviating bolt torques are indicated in the pump data sheet.

Bolt torque for screwed plugs (independent of material):

G 1/4 = 25 Nm

G 3/8 = 45 Nm

G 1/2 = 75 Nm

Bolt torque for impeller nut 922 respectively inner hexagon cap screw 914.12 and shaft nut 921
(independent of material)
Frame size
0
I
II
III
IV
V

NCL E4.12.10

922 resp. 914.12


Bolt torque [Nm]
Wrench size
30
19
100
32
120
41
140
50
140
65
140
65

921
Bolt torque [Nm]
----------160

48 of 62

8. Troubleshooting

8. Troubleshooting
Failure
Pump delivers no or not enough liquid
Motor is overloaded
Bearing temperature too high
Pump is leaking
Increased noises and vibrations
Inadmissible temperature increase
Shaft seal leakage
Failure number
1 2 3 4 5

Number
1
2
3
4
5
6
7

Problem
Pump or piping not
completely vented or filled
Shut-off valve in suction line
not completely opened

X
X

Air pockets in piping system

Wrong rotating direction

Counter pressure of the pump


is higher than specified
Viscosity of pumped liquid is
higher than specified

Counter pressure of the pump


is lower than specified

Wrong speed
Pump unit is not aligned
correctly

Pump stressed by piping

Ball bearing damage


Unbalance of rotating parts,
e.g. impeller
Casing screws and screwed
plugs loose
Coupling gap not correct

X
X
X

NCL E4.12.10

NPSHA too low

Elimination
Venting respectively filling
Open shut-off valve
Correct piping layout
Install vent valve
Exchange 2 phases of power supply
Readjust the duty point by discharge
valve
Increase speed
Install a larger impeller
Consult the factory
Trim the impeller
Readjust the duty point by discharge
valve
Check liquid level in suction tank
Improve NPSHR by inducer
Reduce resistances in suction line
Open shut-off valve in suction line
completely
Check speed
Check coupling alignment and
correct if necessary
Check piping connections and pump
mounting
Renew antifriction bearings
Balance the parts
Tighten the screws and plugs
Renew gaskets
Correct coupling gap

49 of 62

8. Trouble shooting
Failure number
1 2 3 4 5

X
X

No cooling flow available


from motor to antifriction
bearing
Gland tightened too strong or
bevelled

Shaft sealing worn out

X
X

Shaft sleeve grooved or rough


Failure in circulation pipe
Damaged elastomeres on
mechanical seal
Boiling point of pumped
liquid at atmospheric pressure
is below the operating
temperature

X
X

NCL E4.12.10

Problem

Abrasive solids

Elimination
Check the plant
Install a cooling fan
Correct it
Renew shaft sealing
Check flushing/barrier fluid
Renew shaft sleeve
Enlarge the cross section
Replace elastomeres
Use double mechanical seal
Use seal with steam quench
Install wear resistant seal faces
Change seal flush (plan 31/32)
Install double mechanical seal
(plan 53)

50 of 62

9. Interchangeability

9. Interchangeability
9.1

Frame size 0

NCL E4.12.10

51 of 62

9. Interchangeability

9.2

Frame size I

NCL E4.12.10

52 of 62

9. Interchangeability

9.3

Frame size II

NCL E4.12.10

53 of 62

9. Interchangeability

9.4

Frame size III

NCL E4.12.10

54 of 62

9. Interchangeability

9.5

Frame size IV

NCL E4.12.10

55 of 62

9. Interchangeability

9.6

Frame size V

NCL E4.12.10

56 of 62

10. Sectional drawings

10. Sectional drawings


10.1 Pump

Fig. 13 : Sectional drawing Standard design NCL

914.12

Fig. 14 : Impeller bolting, frame size 0

NCL E4.12.10

57 of 62

10. Sectional drawings

Fig. 15: Bearing bracket, frame size V

Fig. 16: Execution with permanent lubricated antifriction bearings

NCL E4.12.10

58 of 62

10. Sectional drawings

10.2 Mechanical seal

Fig. 17:
single acting DICKOW-Mechanical seal

Fig. 18:
Tandem DICKOW-Mechanical seal

Fig. 19:
single acting DIN Standard-Mechanical seal

Fig. 20:
Tandem DIN Standard Mechanical seal

NCL E4.12.10

59 of 62

10. Sectional drawings

Fig. 21:
double acting DIN Standard-Mechanical seal

NCL E4.12.10

Fig. 22:
Cartridge-Mechanical seal

60 of 62

11. Certificates

11. Certificates
11.1 EC-Declaration of Conformity
EC-Declaration of Conformity
according to EC-Machinery Directive 2006/42/EG, Annex II, No. 1A
DICKOW PUMPEN KG
Siemensstrae 22
D-84478 Waldkraiburg

Herewith we declare that the pump unit described in the data sheet

Designation
Type:
Size
:
Design:
Serial No.:

Centrifugal pump
NCL

is in compliance with all relevant provisions of the EC-Machinery Directive 2006/42/EG.

Applied harmonized standards:


EN 809:1998
EN ISO 12100-1:2003
EN ISO 12100-2:2003
EN 12162:2001

EN ISO 12732-1:2008
EN ISO 12732-3:2008
EN ISO 14121-1:2007
EN ISO 20361:2009

Additionally applied standards and technical specifications:


EN ISO 5199:2002
EN ISO 9906:1999
EN 12723:2000
EN 22858:1993

VDMA 24276:2001

Waldkraiburg,
(Name, Position)

the responsible person is authorized to compile the technical documentation

NCL E4.12.10

61 of 62

11. Certificates

11.2 Document of Compliance


Document of Compliance
Please fill in this statement for health innocuousness completely and attach it to the pump to
be returned to the factory.
Pump data
Type:

Serial No.: PB

Reason for shipment

Contamination of the pump


Hazardous liquids were not handled
Hazardous liquids were handled
Pumped liquid:
The pump has been
cleaned

flushed

breamed

The following safety measures must be taken before opening/repairing the pump:

Customer data
Company:
Address:
Name:
(Block Letters)

Phone:
Fax:
E-Mail:
Position:

This is to certify that the above mentioned pump has been proper cleaned/flushed/breamed
and repair can be performed without risk.
Date:

NCL E4.12.10

Signature:

62 of 62

Instrucciones de servicio / montaje


NCL

N 44.NCL.ES4.04/14

Traduccin del manual de instrucciones original

DICKOW PUMPEN KG

ndice de contenido

ndice de contenido
ndice de contenido ...................................................................................................................................... 2
1. Generalidades ...................................................................................................................................... 4
2. Seguridad ............................................................................................................................................. 5
2.1 Identificacin de advertencias ...................................................................................................... 5
2.2 Uso conforme a lo previsto .......................................................................................................... 6
2.3 Prevencin de usos errneos previsibles ...................................................................................... 6
2.4 Cualificacin del personal ............................................................................................................ 7
2.5 Normas de seguridad adicionales ................................................................................................. 7
2.6 Indicaciones para la seguridad del usuario/operador .................................................................... 7
2.7 Indicaciones para la seguridad en trabajos de mantenimiento, inspeccin y montaje .................. 7
2.8 Incumplimiento del manual de instrucciones ............................................................................... 8
2.9 Indicaciones sobre la proteccin contra explosiones .................................................................... 8
3. Descripcin .........................................................................................................................................11
3.1 Descripcin general .....................................................................................................................11
3.2 Designacin .................................................................................................................................11
3.3 Asignacin tamao constructivo/soporte de rodamiento.............................................................11
3.4 Identificacin ...............................................................................................................................12
3.5 Estructura constructiva ................................................................................................................12
3.6 Volumen de suministro ...............................................................................................................13
3.7 Dimensiones y pesos ...................................................................................................................13
4. Transporte / almacenamiento intermedio / eliminacin .....................................................................14
4.1 Transporte....................................................................................................................................14
4.2 Almacenamiento / conservacin..................................................................................................15
4.3 Devolucin ..................................................................................................................................15
4.4 Eliminacin .................................................................................................................................16
5. Colocacin / instalacin......................................................................................................................17
5.1 Normas de seguridad ...................................................................................................................17
5.2 Cimientos ....................................................................................................................................17
5.3 Colocacin del grupo de bombas ................................................................................................17
5.4 Tuberas .......................................................................................................................................18
5.5 Aislamiento .................................................................................................................................21
5.6 Alineacin del acoplamiento .......................................................................................................21
5.7 Alineacin de la bomba y del motor............................................................................................22
5.8 Conexin elctrica del grupo de bombas.....................................................................................23
6. Puesta en servicio / puesta fuera de servicio.......................................................................................25
6.1
Puesta en servicio........................................................................................................................25
6.2 Uso de la bomba ..........................................................................................................................29
6.3 Correccin del rodete ..................................................................................................................29
6.4 Lmites del margen de trabajo .....................................................................................................30
6.5 Desconexin de la bomba............................................................................................................31
6.6 Puesta fuera de servicio ...............................................................................................................31
7. Mantenimiento/conservacin/ inspeccin ..........................................................................................32
7.1 Normas de seguridad ...................................................................................................................32
7.2 Supervisin del funcionamiento ..................................................................................................33
7.3 Vaciado y eliminacin .................................................................................................................35
7.4 Desmontaje del grupo de bombas................................................................................................35
7.5 Inspeccin de componentes .........................................................................................................39
7.6 Montaje del grupo de bombas .....................................................................................................41
7.7 Pares de apriete de los tornillos ...................................................................................................45

NCL ES4 04.14.doc

2 de 60

ndice de contenido
8.
9.

Correccin de averas .........................................................................................................................47


Intercambiabilidad de piezas ..............................................................................................................49
9.1 Soporte de rodamiento 0..............................................................................................................49
9.2 Soporte de rodamiento I ..............................................................................................................50
9.3 Soporte de rodamiento II .............................................................................................................51
9.4 Soporte de rodamiento III............................................................................................................52
9.5 Soporte de rodamiento IV ...........................................................................................................53
9.6 Soporte de rodamiento V .............................................................................................................54
10.
Dibujos seccionales .........................................................................................................................55
10.1 Bomba .........................................................................................................................................55
10.2 Cierre de anillo deslizante ...........................................................................................................57
11.
Certificaciones .................................................................................................................................59
11.1 Declaracin de conformidad CE .................................................................................................59
11.2 Certificado de no objecin ..........................................................................................................60

NCL ES4 04.14.doc

3 de 60

1. Generalidades

1. Generalidades
Este manual de instrucciones describe el uso correcto y seguro en todas las fases de operacin de la
bomba.
El manual de instrucciones no considera las normativas locales cuyo cumplimiento es responsabilidad del
usuario.
La placa de caractersticas indica la serie y el tamao constructivo, los datos de servicio importantes, as
como el nmero de serie. El nmero de serie describe claramente la bomba / el grupo de bombas de forma
y sirve para su identificacin en todos los procesos posteriores.
En caso de defecto se deber informar sin demora al Departamento de Servicio posventa de la empresa
Dickow Pumpen con el fin de conservar los derechos de garanta.
Para el montaje de las unidades de sustitucin suministradas se tienen que observar los subcaptulos
correspondientes de "Mantenimiento, conservacin, inspeccin".
Documentos de aplicacin paralela:
-

Hoja de datos de la bomba


Plano de instalacin u hoja de medidas
Dibujo seccional
Listas de piezas
Documentacin de subproveedores

NCL ES4 04.14.doc

4 de 60

2. Seguridad

2. Seguridad
El manual de instrucciones contiene indicaciones bsicas para la instalacin, el funcionamiento y el
mantenimiento. Solo el cumplimiento de las indicaciones garantiza el manejo seguro de la bomba o del
grupo de bombas y evita daos personales y materiales.
Se deben observar todas las indicaciones para la seguridad contenidas en este manual de instrucciones.
el personal cualificado competente / el usuario debe leerse y comprender el manual de instrucciones antes
del montaje y de la puesta en servicio.
El manual de instrucciones tiene que estar disponible en todo momento in situ.
Los avisos y rtulos colocados en la bomba se tienen que observar y mantener en estado legible.

2.1 Identificacin de advertencias


Palabra de
sealizacin

Explicacin

PELIGRO

Sealiza un peligro inminente.


Si no se evita, las consecuencias son la muerte o lesiones de mxima
gravedad.

ADVERTENCIA

Sealiza una situacin potencialmente peligrosa.


Si no se evita, las consecuencias pueden ser la muerte o lesiones de
mxima gravedad.

PRECAUCIN

ATENCIN

Smbolo

Sealiza una situacin potencialmente peligrosa.


Si no se evita, las consecuencias pueden lesiones leves o
insignificantes.
Sealiza una situacin potencialmente daina.
Si no se evita, las consecuencias pueden ser peligros para la bomba y
su funcionamiento.

Explicacin
Smbolo de peligro general
Sealiza en combinacin con una palabra de sealizacin
peligros que conllevan la muerte o lesiones.
Tensin elctrica peligrosa
Sealiza en combinacin con una palabra de sealizacin
peligros relacionados con la tensin elctrica.

NCL ES4 04.14.doc

5 de 60

2. Seguridad

Advertencia contra campos magnticos


Sealiza en combinacin con una palabra de sealizacin
peligros relacionados con campos magnticos.
Superficie caliente
Sealiza en combinacin con una palabra de sealizacin
peligros relacionados con superficies calientes.
Proteccin contra explosiones
Ofrece informacin para la proteccin contra explosiones en
atmsferas potencialmente explosivas segn la Directiva 94/9/CE.
Daos en la mquina
Sealiza en combinacin con la palabra de sealizacin ATENCIN
peligros para la bomba y su funcionamiento.
Nota
Ofrece recomendaciones e informacin til para el manejo del
producto.

2.2 Uso conforme a lo previsto


La bomba / el grupo de bombas solo se debe utilizar en el margen de trabajo descrito en la hoja de datos
de la bomba de aplicacin paralela. Esto rige, en particular, para el medio de bombeado, el caudal, la
velocidad de giro, la presin, la temperatura y la potencia del motor. Asimismo, se aplica lo siguiente:

La bomba solo se debe utilizar en estado tcnicamente impecable.


No se permite utilizar la bomba en estado parcialmente montado.
La bomba no se debe utilizar nunca sin medio de bombeado.
Observar las indicaciones sobre el caudal mnimo en la hoja de datos de la bomba o en el manual de
instrucciones.
Observar las indicaciones sobre el caudal mximo en la hoja de datos de la bomba o en el manual de
instrucciones.
No estrangular la bomba en el lado de aspiracin.
La velocidad de giro mxima es de 3500 rpm (+10 %).

2.3 Prevencin de usos errneos previsibles

Los rganos de cierre en el lado de impulsin no se deben abrir nunca ms all del margen admisible.
En este caso se superara el caudal mximo y existira un riesgo de daos por cavitacin.
No se deben superar nunca los lmites de uso admisibles indicados para la presin y la temperatura.
Observar y cumplir todas las indicaciones para la seguridad y dems instrucciones contenidas en el
manual de instrucciones.

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2. Seguridad

2.4 Cualificacin del personal


El personal debe mostrar la cualificacin correspondiente para el montaje, la operacin, el mantenimiento
y la inspeccin de la bomba / del grupo de bombas.
El mbito de responsabilidad, las competencias y la supervisin deben ser regulados detalladamente por
el usuario.
Eventuales lagunas de conocimiento del personal se tienen que eliminar mediante una formacin. La
formacin puede ser impartida por el personal cualificado de la empresa Dickow Pumpen.

2.5 Normas de seguridad adicionales


Adems de las indicaciones para la seguridad contenidas en este manual de instrucciones se aplican las
siguientes normas de seguridad adicionales:

Normas de prevencin de accidentes


Normas de proteccin contra explosiones
Normas de seguridad para la manipulacin de sustancias peligrosas
Normas y leyes aplicables

2.6 Indicaciones para la seguridad del usuario/operador

El usuario deber montar una proteccin contra el contacto con componentes calientes y fros.
No se permite retirar durante el funcionamiento la proteccin del acoplamiento y la proteccin contra
el contacto en la bomba / en el grupo de bombas.
Conectar siempre la puesta a tierra del grupo de bombas.
Facilitar el equipo de proteccin al personal e imponer su utilizacin.
Evacuar las fugas de medios de bombeado peligrosos de manera que no se produzca ningn riesgo
para las personas ni para el medio ambiente. Observar las disposiciones legales.
Excluir todo peligro por energa elctrica.

2.7 Indicaciones para la seguridad en trabajos de


mantenimiento, inspeccin y montaje

Solo se permite realizar trabajos de transformacin o modificaciones en la bomba previa consulta


a la empresa Dickow Pumpen.
Utilizar nicamente piezas originales o componentes aprobados por la empresa Dickow Pumpen.
Ejecutar los trabajos en la bomba / en el grupo de bombas nicamente en estado parado.
La caja de bomba debe haber alcanzado la temperatura ambiente.
La bomba debe estar sin presin y vaca.
Observar el procedimiento para la puesta fuera de servicio segn el captulo 6.6.
Descontaminar las bombas utilizadas con medios peligrosos para la salud. Observar el captulo 4.4.
Al finalizar los trabajos, volver a montar la proteccin del acoplamiento y la proteccin contra el
contacto.

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2. Seguridad

Los trabajos en el grupo de bombas solo se deben ejecutar con las conexiones elctricas
desembornadas.

Asegurar el grupo de bombas contra la conexin accidental.

2.8 Incumplimiento del manual de instrucciones


El incumplimiento de este manual de instrucciones causa la prdida de los derechos de garanta e
indemnizacin. El incumplimiento conlleva los siguientes riesgos:

Peligro para las personas por influencias elctricas, trmicas, mecnicas y qumicas.
Peligros por explosin.
Peligros por el fallo de funciones importantes.

Peligro para el medio ambiente en caso de fugas de sustancias peligrosas.

2.9 Indicaciones sobre la proteccin contra explosiones


PELIGRO

Las indicaciones contenidas en este captulo se tienen que observar


estrictamente para el funcionamiento en atmsferas potencialmente peligrosas

2.9.1

El uso de bombas en atmsferas potencialmente peligrosas solo se permite con


la identificacin correspondiente.
Las bombas deben estar declaradas para esta aplicacin segn la hoja de datos
de la bomba.
Garantizar el uso conforme a lo previsto.
Evitar estrictamente cualquier funcionamiento inadmisible.
Para el funcionamiento segn la Directiva 94/9/CE (ATEX) se aplican unas
condiciones especiales. El smbolo que se muestra junto a estas lneas identifica
los apartados de este manual de instrucciones que se debern observar
especialmente.

Temperatura de superficie

Las temperaturas de superficie ms altas se pueden esperar en la caja de bomba, en el contraanillo del
cierre de anillo deslizante en el lado de la atmsfera y en la zona de los rodamientos. La temperatura de
superficie en la caja de bomba corresponde a la temperatura del medio de bombeado.
En la zona del soporte de cojinete debe existir un contacto libre de la superficie con el entorno. No se
permite aislar el soporte de cojinete.
La temperatura a esperar en el contraanillo en el lado de la atmsfera y la determinacin de la temperatura
admisible del medio de bombeado o la temperatura de trabajo del lquido de obturacin para el cierre de
anillo deslizante (GLRD) con fuelle metlico DICKOW N6, N9, N10, N11 y N13 resulta de las siguientes
frmulas.

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2. Seguridad
Clase de
temperatura
T1
T2
T3
T4
T5
T6

Tmx superficie [C]


450 *
300
200
135
100
85

* Temperatura de trabajo mx. cierre de anillo deslizante con fuelle metlico DICKOW = 350C
Velocidad de
giro [rpm]
1450-1750
2900-3500
Clase 1
Clase 2
Clase 3

=
=
=

Clase 1

TGLRD [K]
Clase 2

Clase 3

20
35

25
45

40
60

Agua y medios similares


Otros medios
Aceites

Emparejamiento
de
anillos
deslizantes - abreviatura
SiC / SiC
U.U.
SiC / carbono U.A.

Factor K
0,75
1,0

Temperatura en el componente del lado de la atmsfera del cierre de anillo deslizante


TGLRD =

T + (K TGLRD)
T = temperatura del medio de bombeado o del lquido de
obturacin

Temperatura admisible del medio de bombeado o del lquido de obturacin


Tadm =

Tmx - (K TGLRD) - TS
TS = reduccin por seguridad ; clases T6-T3 = 5
Clases T2/T1 = 10 C

NOTA
En caso de utilizar cierres de anillo deslizante de otros fabricantes, observar el
manual de instrucciones del fabricante en cuestin.

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2. Seguridad
2.9.2

Dispositivo de vigilancia

La bomba solo se debe utilizar dentro de los valores lmite indicados en la hoja de datos de la bomba y en
la placa de caractersticas.
Si el usuario no puede garantizar el cumplimiento de los lmites de servicio, se deben prever dispositivos
de vigilancia.
Srvase consultar a la empresa Dickow Pumpen para obtener ms informacin sobre dispositivos de
vigilancia.

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3. Descripcin

3. Descripcin
3.1 Descripcin general
Esta bomba se utiliza en todas las aplicaciones de la industria qumica, petroqumica y general en las
cuales se tienen que bombear lquidos agresivos.

3.2

Designacin
Ejemplo: NCL b h 32/210 A Ge
NCL

3.3

Serie

Versin especial constructiva, p.ej. b = con calefaccin

Versin de material, p. ej. h = 1.4408 / 1.4571

32

Anchura nominal tubuladura de impulsin [mm]

210

Dimetro nominal rodete [mm]

Volumen de suministro, p. ej. A = extremo de eje libre

Ge

Junta de eje; p. ej. Ge = cierre de anillo deslizante normalizado, descargado

Asignacin tamao constructivo/soporte de


rodamiento

soporte de
rodamiento

tamao
constructivo

NCL ES4 04.14.doc

II

III

IV

26/170
26/210

32/165
32/210
40/165
40/210
50/165
50/210

32/250
40/250
40/320
50/250
50/330
65/165
65/210
65/250
80/165
80/210
80/250
100/210

65/320
80/320
100/250
100/320
100/400
125/250
125/320
125/400
150/250

150/320
150/400
150/500
200/260
200/320
200/400
200/500
250/320

250/400
250/500

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3. Descripcin

3.4 Identificacin
3.4.1

Placa de caractersticas

Fig. 1: Placa de caractersticas en alemn y en ingls

3.4.2

Identificacin segn la Directiva CE de proteccin contra explosiones


Grupo II
Categora 2
Uso en ambientes con gas/vapor/neblina
Proteccin a travs de la seguridad constructiva EN
13464-5
ver abajo

Nmero de referencia de la documentacin tcnica

Fig. 2: Placa de caractersticas ATEX

La temperatura de la superficie no depende de la fuente de ignicin, sino de la temperatura del medio de


bombeado. No se realiza ninguna identificacin con una clase de temperatura o una temperatura. En la
identificacin se incorpora el smbolo"X". En el captulo 2.9.1 se menciona la temperatura que se produce
en la superficie. Observar las indicaciones en la hoja de datos de la bomba.

3.5 Estructura constructiva


Tipo de construccin
Bomba de caja espiral
Instalacin horizontal
una etapa

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3. Descripcin

Se cumplen los requisitos segn ISO 5199


Dimensiones segn EN 22858

Caja de bomba
Espiral simple / espiral doble en funcin del tamao
Divisin radial
Pies o garras integrados por fundicin

Rodete
Cerrado o abierto
Los labes posteriores y los orificios de descarga y/o de inyector descargan el empuje axial

Cojinetes
En el lado del motor, rodamiento de bolas de contacto angular emparejado como cojinete fijo
En el lado de la bomba, rodamiento de rodillos cilndricos
Lubricacin por aceite
opcionalmente: lubricacin por grasa

Junta de eje
Empaquetadura para prensaestopas
Cierre de anillo deslizante simple o doble

Cierres de cartucho (cartridge)

3.6

Volumen de suministro

Segn la versin, el volumen de suministro comprende los siguientes elementos:

Bomba
Acoplamiento elstico con o sin elemento de desmontaje
Proteccin del acoplamiento
Placa base de fundicin o bastidor soldado en versin rgida a la torsin
Motor de accionamiento
En su caso, accesorios especiales adicionales

3.7

Dimensiones y pesos

Datos sobre las dimensiones y los pesos figuran en el plano de instalacin / la hoja de medidas.

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4. Transporte / almacenamiento intermedio / eliminacin

4. Transporte / almacenamiento
intermedio / eliminacin
4.1

Transporte

PELIGRO

Deslizamiento de la bomba / del grupo de bombas de la suspensin


Peligro de muerte en caso de cada de elementos!

Transportar la bomba / el grupo de bombas nicamente en posicin horizontal.


La bomba no se debe suspender nunca por el extremo del eje libre.
El grupo de bombas no se deben suspender nunca por la argolla del motor.
No se permite la estancia debajo de cargas suspendidas.
Observar las indicaciones de pesos en el plano de instalacin.
Observar las normas locales para la prevencin de accidentes.
Utilizar medios de fijacin apropiados y homologados.

Fig. 3: Transporte de la bomba

Fig. 4: Transporte del grupo de bombas


completo

NCL ES4 04.14.doc

Fig. 5: Transporte de la bomba en la placa base

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4. Transporte / almacenamiento intermedio / eliminacin

4.2

Almacenamiento / conservacin
Daos por humedad o suciedad durante el almacenamiento

ATENCIN

Corrosin y/o ensuciamiento de la bomba!

En caso de almacenamiento en el exterior, cubrir la bomba o la bomba


embalada y los accesorios para protegerlos del agua.

Orificios y puntos de conexin hmedos, sucios o daados

ATENCIN

Fugas o defectos en la bomba!

Los orificios cerrados solo se deben poner al descubierto durante la


instalacin.

Recomendamos tomar las siguientes medidas para el almacenamiento de la bomba o del grupo de
bombas:

Almacenar la bomba en un local seco y protegido con una humedad del aire constante.
Girar el rbol manualmente una vez al mes.

Las bombas nuevas fabricadas con los materiales GGG y fundicin de acero ferrtico estn sometidas a un
tratamiento previo interno con un producto anticorrosivo y Dewatering-Fluid. El perodo de
almacenamiento mximo en caso de almacenamiento seco es de mx. 12 meses.
Para el almacenamiento de una bomba que ya haya sido utilizada, observar el captulo 6.6.

4.3

Devolucin

Vaciar correctamente la bomba. Observar el captulo 7.3.


La bomba se debe aclarar y limpiar siempre, sobre todo si ha funcionado con medios nocivos,
explosivos, calientes o que conlleven otro tipo de riesgos.
La bomba se debe acompaar siempre con un certificado de inocuidad completamente rellenado. Ver
el captulo 11.2.

NOTA

Si es necesario, se puede descargar un certificado de inocuidad de


Internet en www.dickow.de.
http://www.dickow.de/unbedenk-en.pdf

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4. Transporte / almacenamiento intermedio / eliminacin

4.4

Eliminacin

ADVERTENCIA

Medios de bombeado peligrosos para la salud


Peligro para las personas y el medio ambiente!

Recoger y eliminar el lquido de aclarado y el lquido


restante.
Llevar ropa protectora y una mascarilla protectora.
Observar las disposiciones legales para la eliminacin de
lquidos peligrosos para la salud.

1.

Desmontar la bomba / el grupo de bombas.

2.

Recoger las grasas y los aceites.

3.

Clasificar los materiales de la bomba.

4.

Eliminar todo conforme a la normativa local.

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5. Colocacin / instalacin

5. Colocacin / instalacin
5.1 Normas de seguridad
PELIGRO

Colocacin incorrecta en atmsferas potencialmente explosivas


Peligro de explosin!

Observar las normas para la proteccin contra explosiones vigentes a nivel local.
Observar las indicaciones en la hoja de datos de la bomba y la placa de
caractersticas de la bomba / del motor.

5.2 Cimientos
ADVERTENCIA

Colocacin en cimientos sin afirmar y no portantes


Daos personales y materiales!

5.3
5.3.1

Es necesario asegurar una resistencia suficiente del hormign


(mn. clase XO) de los cimientos (DIN 1045).
Colocar el grupo de bombas nicamente en cimientos fraguados.
Colocar el grupo de bombas nicamente en una superficie
horizontal y plana.
Observar las indicaciones de pesos en el plano de instalacin.

Colocacin del grupo de bombas


Colocacin de los cimientos

1.

Colocar el grupo de bombas en los cimientos y alinearlos con un nivel de agua. Desviacin de
posicin admisible 0,2 mm/m.

2.

Insertar chapas niveladoras para la compensacin de la altura. Colocarlas siempre en ambos


lados en la proximidad inmediata de los tornillos de anclaje, entre el bastidor base y los
cimientos.
Con una distancia entre los tornillos de anclaje de > 600 mm, colocar adicionalmente chapas
niveladoras en el centro, entre los tornillos de anclaje.

3.
4.

Todas las chapas niveladoras deben estar aplicadas en posicin plana.

5.

Enganchar los tornillos de anclaje en los orificios previstos.

6.

Sellar los tornillos de anclaje con hormign.

7.

Alinear el bastidor base una vez que el hormign haya fraguado.

8.

Apretar los tornillos de anclaje firme y uniformemente.

9.

Sellar el bastidor base con hormign antivibratorio de granulacin normal con una relacin
agua/cemento (R A/C) de 0,5. Establecer la consistencia fluida por medio de un fluidificante.
Realizar un tratamiento posterior del hormign segn DIN 1045.

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5. Colocacin / instalacin
5.3.2

Colocacin sin cimientos

Para la colocacin sin cimientos, la base debe mostrar la resistencia y las caractersticas necesarias.
1.
2.
3.
4.

Colocar el grupo de bombas en los elementos de ajuste y nivelarlo con un nivel de agua.
Para la compensacin de la altura, aflojar el tornillo y la contratuerca en los elementos de ajuste.
Reajustar la tuerca de ajuste hasta que las eventuales diferencias de altura queden compensadas.
Apretar las contratuercas en los elementos de ajuste.

5.4

Tuberas

PELIGRO

Superacin de las cargas admisibles en las tubuladuras de bomba


Peligro de muerte en caso de escapes de medio de bombeado caliente, txico,
corrosivo o inflamable por falta de estanqueidad!

5.4.1

No se permite utilizar la bomba como punto fijo para la tubera.


Apoyar la tubera inmediatamente antes de la bomba y conectarla sin tensiones.
Observar las fuerzas y los pares admisibles en las tubuladuras. Ver el captulo
5.4.2.
Compensar la expansin de la tubera al aumentar la temperatura.

Tubera de aspiracin

La trayectoria de la tubera de aspiracin se tiene que ejecutar con un cuidado especial. Los valores NPSH
de la bomba y la instalacin deben estar definidos claramente. Se deber tener en cuenta lo siguiente:

Los codos no se deben conectar directamente a la tubuladura de aspiracin. Se deber prever un


tramo de entrada recto. Longitud mn. 2 veces el dimetro de la tubera de aspiracin.

No se debe conectar nunca una tubera de aspiracin con un dimetro nominal mayor directamente
a la bomba. Las turbulencias reducen la seccin de entrada libre. Utilizar una pieza de empalme
excntrica. Observar las figuras!

Fig. 6: Turbulencias

Fig. 7: Conexin excntrica

Para el funcionamiento de aspiracin, tender la tubera de aspiracin con un ascenso continuo hacia
la tubuladura de aspiracin. Evitar la formacin de bolsas de aire.
Para el funcionamiento de afluencia, tender la tubera de aspiracin con un descenso continuo hacia
la tubuladura de aspiracin. Evitar la formacin de bolsas de aire para asegurar una purga de aire
completa.

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5. Colocacin / instalacin

No se debe sobrepasar la velocidad de flujo mxima de 2 m/s.

ATENCIN

Perlas de soldadura, cascarilla y otras impurezas en la tubera


Daos en la bomba!

Limpiar a fondo la tubera antes de conectar la bomba.


Eliminar las impurezas de las tuberas.
Insertar un filtro si es necesario.

Utilizar filtros con una abertura de malla de 0,5 mm.


Insertar un filtro con la triple seccin transversal de la tubera.

NOTA

5.4.2

Fuerzas y pares admisibles en las tubuladuras

Tamao
constructivo
26/125 - 210
32/165 - 250
40/125 - 320
50/125 - 330
65/125 - 320
80/165 - 320
100/210 - 400
125/250 - 400
150/250 - 500
200/250 - 500
250/320 - 500

Tubuladura de aspiracin
DN
40
1 "
50
2"
65
3"
80
3"
100
4"
125
6"
125
6"
150
6"
200
8"
250
10"
300
12"

Fx [N]
GGG GS

Fy [N]
GGG GS

Fz [N]
GGG GS

F [N]
GGG GS

Mx [Nm]
GGG GS

My [Nm]
GGG GS

Mz [Nm]
GGG GS

M [Nm]
GGG GS

556

875

490

770

445

700

860

1360

580

910

400

630

470

735

840

1330

735

1155

670

1050

600

945

1150

1820

625

1022

445

700

515

805

910

1430

935

1470

825

1295

760

1190

1460

2310

670

1050

490

770

535

840

970

1540

1115

1750

1000

1575

915

1435

1750

2760

715

1120

515

805

580

910

1040

1640

1490

2345

1335

2100

1200

1890

2330

3670

780

1225

560

875

645

1015 1150

1820

1760

2765

1580

2485

1425

2240

2750

4340

935

1470

670

1050

845

1330 1350

2130

1760

2765

1580

2485

1425

2240

2750

4340

935

1470

670

1050

845

1330 1350

2130

2225

3500

2000

3150

1800

2835

3480

5490

1115

1750

780

1225

915

1435 1620

2550

2980

4690

2670

4200

2400

3780

4640

7310

1445

2275

1025 1610 1180 1855 2130

3360

4245

5845

3785

5215

3430

4725

6620

9130

2260

3115

1600 2205 1855 2555 3320

4580

5080

7000

4550

6265

4090

5635

7950 10950 3075

4235

2185 3010 2515 3465 4520

6230

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5. Colocacin / instalacin

Tamao
constructivo
26/125 - 210
32/165 - 250
40/125 - 320
50/125 - 330
65/125 - 320
80/165 - 320
100/210 - 400
125/250 - 400
150/250 - 500
200/250 - 500
250/320 - 500

Tubuladura de impulsin
DN
25
1"
32
1 "
40
1 "
50
2"
65
3"
80
3"
100
4"
125
6"
150
6"
200
8"
250
10"

Fx [N]
GGG GS

Fy [N]
GGG GS

Fz [N]
GGG
GS

F [N]
GGG
GS

Mx [Nm]
GGG
GS

My [Nm]
GGG GS

Mz [Nm]
GGG GS

M [Nm]
GGG
GS

335

525

315

490

380

595

570

910

400

630

270

420

315

490

570

910

400

630

380

595

470

735

730

1150

490

770

335

525

380

595

710

1120

490

770

445

700

560

875

860

1360

580

910

400

630

470

735

840

1330

670

1050

600

945

735

1155

1150

1820

625

980

445

700

515

805

910

1430

825

1295

755

1190

935

1470

1460

2310

670

1050

490

770

535

840

970

1540

1000

1575

915

1435

1111

1750

1750

2760

715

1120

515

805

580

910

1040

1640

1335

2100

1200

1890

1490

2345

2330

3670

780

1225

560

875

645

1015

1150

1820

1580

2485

1425

2240

1760

2765

2750

4340

935

1470

670

1050

845

1330

1350

2130

2000

3150

1800

2835

2225

3500

3480

5490

1115

1750

780

1225

915

1435

1620

2550

2670

4200

2400

3780

2980

4690

4640

7310

1445

2275

1025

1610

1180

1855

2130

3360

3790

5215

3430

4725

4245

5845

6620

9130

2260

3115

1600

2205

1855

2555

3320

4580

Las fuerzas y los pares se refieren a una temperatura de 20 C. Valores de correccin en funcin de la
temperatura: ver la figura.

Fig. 8: Diagrama de correccin de temperatura


Si no todas las cargas aplicadas alcanzan los valores mximas, una de estas cargas puede sobrepasar el
valor mximo en las siguientes condiciones:

La superacin est limitada al 140% del valor admisible.


Para las fuerzas y los pares efectivos que actan en cada brida se aplica lo siguiente:

/F/ actual

/F/ mx. admisible

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/M/ actual


/M/ mx. admisible

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5. Colocacin / instalacin

5.5

Aislamiento
Los elementos de la caja que se encuentran en contacto con el
producto toman la temperatura del medio de bombeado.

ADVERTENCIA

Peligro de quemaduras!

Aislar los elementos de la caja.


Montar un dispositivo de proteccin.

Acumulacin de calor en el soporte de cojinete

ATENCIN

Daos en el cojinete!

5.6

No se permite aislar los soportes de cojinete.

Alineacin del acoplamiento

PELIGRO

Temperaturas improcedentes en el acoplamiento o en los rodamientos en caso


de alineacin defectuosa del acoplamiento
Peligro de explosin!

ADVERTENCIA

Asegurar en todo momento la alineacin correcta del acoplamiento.


Conexin accidental del grupo de bombas
Peligro de lesiones por elementos mviles!

ATENCIN

Los trabajos en el grupo de bombas solo se deben ejecutar con las


conexiones elctricas desembornadas.
Asegurar el grupo de bombas contra la conexin accidental.

Decalaje de los rboles de la bomba y del motor


Daos en la bomba, en el motor y en el acoplamiento!

Controlar siempre el acoplamiento despus de conectar la tubera.


Realizar el control del acoplamiento tambin en grupos de bombas entregados
sobre una placa base comn.

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5. Colocacin / instalacin

Fig. 9: Decalaje angular y radial de acoplamientos

Fig. 10: Alineacin del acoplamiento


1.

Desmontar la proteccin del acoplamiento.

2.

Soltar el pie de apoyo.

3.

Colocar una regla de canto agudo (1) axialmente encima de la mitad de acoplamiento.

4.

Un eventual decalaje radial Kr queda visible por la rendija de luz.


Mejor: Medir el decalaje radial determinando las distancias A y B en tres puntos decalados en 120.
El acoplamiento est alineado correctamente si existe en todos los puntos la misma distancia frente
al rbol.

5.

Comprobar en toda la circunferencia la distancia s1 entre las mitades de acoplamiento. El


acoplamiento est alineado correctamente si existe en todos los puntos la misma distancia.

6.

Con respecto a la desviacin admisible s1 y Kr de las dos mitades de acoplamiento, observar


las indicaciones segn el manual de instrucciones del fabricante del acoplamiento!

7.

Atornillar el pie de apoyo.

8.

Montar la proteccin del acoplamiento.

5.7

Alineacin de la bomba y del motor

ADVERTENCIA

Acoplamiento rotatorio abierto


Peligro de lesiones por el rbol en rotacin!

NCL ES4 04.14.doc

Utilizar el grupo de bombas nicamente con la proteccin del


acoplamiento.
Elegir la proteccin del acoplamiento conforme a las directivas aplicables.

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5. Colocacin / instalacin
PELIGRO

Peligro de ignicin por chispas producidas por friccin


Peligro de explosin!

Elegir el material para la proteccin del acoplamiento de manera que no se


produzca ninguna proyeccin de chispas en caso de contacto.
Observar EN 13463-1.

Despus de la colocacin del grupo de bombas y la conexin de la tubera, controlar la alineacin del
acoplamiento y reajustarlo, en su caso, en el motor.
Compensar eventuales diferencias de altura con la ayuda de una chapa espaciadora.
1.

Desmontar la proteccin del acoplamiento.

2.

Controlar la alineacin del acoplamiento. Observar el procedimiento segn el captulo 5.6.

3.

Soltar la tuerca hexagonal en los pies del motor.

4.

Colocar chapas espaciadoras debajo de los pies del motor hasta que la diferencia de altura quede
compensada.
Apretar las tuercas hexagonales en los pies del motor.

5.
6.
7.

Comprobar el funcionamiento del acoplamiento / rbol. El acoplamiento se debe poder girar


fcilmente a mano.
Montar la proteccin del acoplamiento.

8.

Controlar la distancia entre el acoplamiento y la proteccin del acoplamiento.

5.8

Conexin elctrica del grupo de bombas

PELIGRO

Instalacin elctrica inadecuada


Peligro de explosin!

PELIGRO

Para la instalacin elctrica se tiene que observar adicionalmente IEC


60079-14.
Los motores protegidos contra explosiones se tienen que conectar
siempre a travs de un guardamotor.

Trabajos en el grupo de bombas por personal no cualificado


Peligro de muerte por electrocucin!

ADVERTENCIA

La conexin elctrica debe ser establecida nicamente por un


electricista cualificado.
Observar las normas IEC 30364 e IEC 60079.

Conexin de red incorrecta


Cortocircuito!

NCL ES4 04.14.doc

Observar las condiciones de conexin de las empresas de suministro


de energa locales.

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5. Colocacin / instalacin

Procedimiento:
1.

Comparar la tensin de red existente con los datos que figuran en la placa de caractersticas del
motor.
Elegir un conexionado apropiado.
Comparar el sentido de giro del motor con el sentido de giro de la bomba. Observar la flecha
indicadora del sentido de giro en la bomba!

2.
3.

NOTA
Observar las instrucciones de servicio adjuntas al motor!

5.8.1

Comprobar el sentido de giro

PELIGRO

Aumento de la temperatura en caso de contacto entre los elementos


Peligro de explosin!

ATENCIN

No se debe comprobar nunca el sentido de giro con la bomba en seco.


Desacoplar la bomba para comprobar el sentido de giro.

Sentido de giro equivocado del motor y la bomba


Daos en la bomba!

Observar la flecha indicadora del sentido de giro en la bomba.

1.

Arrancar brevemente el motor. Observar el sentido de giro del motor.

2.

El sentido de giro del motor debe coincidir con la flecha indicadora del sentido de giro en la
bomba.
Si el sentido de giro est equivocado, invertir el cable de alimentacin de red en la caja de
bornes del motor.

3.

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6. Puesta en servicio / puesta fuera de servicio

6. Puesta en servicio / puesta fuera de


servicio
6.1 Puesta en servicio
Antes de la puesta en servicio, comprobar los siguientes puntos:

Se ha establecido correctamente la conexin electrnica del grupo de bombas con todos los
dispositivos de proteccin.
La bomba se llena con medio de bombeado.
Se ha comprobado el sentido de giro.
Todas las conexiones adicionales han sido establecidas y estn operativas.
Se han comprobado los lubricantes.
Al cabo de una parada prolongada, observar y ejecutar las medidas descritas en el captulo 7
Mantenimiento/conservacin/inspeccin.

6.1.1

Carga de lubricante

ATENCIN

Demasiado poco aceite lubricante en el depsito de reserva del regulador de


nivel de aceite
Daos en los rodamientos!

ATENCIN

Controlar regularmente el nivel de aceite.


El depsito de reserva siempre debe estar llenado suficientemente.

Demasiado poco aceite lubricante en el soporte del rodamiento


Daos en los rodamientos!

El agujero roscado del regulador de nivel de aceite debe encontrarse en


posicin horizontal.

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6. Puesta en servicio / puesta fuera de servicio

1.
2.
3.

Desenroscar el tornillo de purga (1).


Abatir el regulador de nivel de aceite (2) apartndolo del soporte de rodamiento (3) y sujetarlo.
Introducir aceite a travs del orificio para el tornillo de purga (1) hasta que el aceite entre en el
ngulo de conexin del regulador de nivel de aceite (2).
Llenar el depsito de reserva hasta el mximo.
Volver a colocar el regulador de nivel de aceite (2) en su posicin bsica.
Enroscar el tornillo de purga (1).
Controlar al cabo de unos minutos el nivel de aceite en el depsito de reserva del regulador del
nivel de aceite (2). Repetir los pasos 4 - 6 las veces que haga falta hasta que ya no salga ms aceite
del depsito de reserva.

4.
5.
6.
7.

NOTA
Un nivel de aceite excesivo causa un aumento de la temperatura, falta de
estanqueidad o fugas de aceite.

Volumen de carga y calidad del aceite: ver el captulo 7.2.2.


En la versin con lubricacin por grasa se suprimen el regulador del nivel de aceite y el tornillo de
purga. Los rodamientos tienen lubricacin permanente por grasa. No requieren ningn reengrase.

6.1.2

Llenar y purgar la bomba

PELIGRO

Formacin de un ambiente explosivo en el interior de la bomba


Peligro de explosin!

1.
2.
3.

6.1.3

La bomba debe estar siempre llena de medio de bombeado.


Se deben prever unas medidas de vigilancia al efecto.

Purgar la bomba y la tubera de aspiracin y llenarla con medio de bombeado.


La bomba es autopurgante.
Abrir completamente el rgano de cierre en la tubera de aspiracin.
Abrir completamente todas las conexiones adicionales (p. ej., circulacin externa, alimentacin
externa).

Junta de eje

La bomba se suministra con una junta de eje montada. Llenar un depsito de alimentacin previsto segn
el manual de instrucciones del depsito.
En caso de cierres de anillo deslizante doble, antes de conectar la bomba conectar una aplicacin de
presin de bloqueo segn el manual de instrucciones del depsito o del cierre de anillo deslizante.
En caso de alimentacin externa de la bomba, alimentar la bomba con las cantidades y presiones que se
indican en la hoja de datos de la bomba o en el plano de instalacin.

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6. Puesta en servicio / puesta fuera de servicio


6.1.4

Versin con calefaccin

La caja de la bomba y las cajas intermedias pueden tener calefaccin en caso necesario.
Medios de transmisin de calor admisibles:

Agua caliente
Vapor de agua
Aceite portador de calor

Lmites de presin y temperatura:

tmx = 200 C
pmx = 25 bar

ATENCIN

Temperatura de superficie excesiva


Peligro de explosin!

ATENCIN

Observar la clase de temperatura admisible.

Falta de medio de transmisin de calor


Daos en la bomba!

ATENCIN

Preparar una cantidad suficiente de un medio de transmisin de calor


apropiado.

Tiempo de calentamiento demasiado corto


Daos en la bomba!

ATENCIN

Prestar atencin al calentamiento suficiente de la bomba (aprox. 2 horas).


Prestar atencin al movimiento libre del rbol de bomba.

Superacin de la temperatura admisible del medio de transmisin de calor


Escapes de medio de bombeado o de transmisin de calor!

6.1.5

Observar los lmites de empleo de presin y de temperatura.

Controlar la junta de eje

Un cierre de anillo deslizante es una junta dinmica que, por motivos fsicos y tcnicos, no puede estar
libre de fugas. La cantidad de la fuga est determinada por el diseo, las tolerancias, las condiciones de
funcionamiento, la suavidad de marcha, etc.

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6. Puesta en servicio / puesta fuera de servicio


Una fuga elevada durante el proceso normal de rodaje de las superficies deslizantes se reduce a una
cantidad normal con el transcurso del tiempo de funcionamiento. Si no fuera este el caso, el cierre de
anillo deslizante se deber detener, desmontar y comprobar.
Una empaquetadura para prensaestopas debe gotear ligeramente durante el funcionamiento.

PELIGRO

Formacin de
prensaestopas

sobretemperatura

en

las

empaquetaduras

para

Peligro de explosin!

Las empaquetaduras para prensaestopas no son apropiadas para ser


utilizadas en atmsferas potencialmente explosivas.

Para ajustar la fuga en el prensaestopas, proceder de la siguiente manera:


1.
2.
3.
4.
5.
6.
7.

Apretar solo ligeramente a mano las tuercas del casquete prensaestopas.


Controlar con ayuda de un calibre de empaquetadura el asiento en ngulo recto y centrado.
Despus de llenar la bomba, debe existir una fuga.
Apretar las tuercas del casquete prensaestopas de manera que la fuga se reduzca a 60-120
gotas por minuto.
Arrancar la bomba.
Al cabo de 5 minutos de funcionamiento, apretar 1/6 de vuelta las tuercas del casquete
prensaestopas para reducir la fuga.
Observar la fuga.

Fuga demasiado elevada

Repetir los pasos 6 y 7.

Fuga demasiado baja

Aflojar un poco las tuercas del casquete prensaestopas.

Ninguna fuga

Desconectar inmediatamente el grupo de bombas. Aflojar el


casquete prensaestopas y repetir el proceso.

6.1.6

Conectar la bomba

PELIGRO

Superacin de los lmites de presin y de temperatura admisibles


Peligro de explosin! Escapes de medio de bombeado caliente o txico!

PELIGRO

No se deben utilizar nunca la bomba con los rganos de cierre cerrados en


la tubera de aspiracin y/o de impulsin.
Arrancar el grupo de bombas nicamente contra un rgano de cierre
ligeramente abierto en el lado de impulsin.

Sobretemperatura en caso de funcionamiento en seco


Peligro de explosin!

NCL ES4 04.14.doc

La bomba no se debe utilizar nunca en estado sin llenar.


Llenar la bomba siempre correctamente.
Utilizar la bomba nicamente en el margen de trabajo admisible.

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6. Puesta en servicio / puesta fuera de servicio

1.

Abrir completamente el rgano de cierre en la tubera de afluencia/aspiracin.

2.

Abrir ligeramente el rgano de cierre en la tubera de impulsin.

3.
4.

Conectar el motor.
Si el manmetro indica presin, abrir el rgano de cierre en el lado de impulsin hasta que se
haya alcanzado el punto de trabajo.

5.

Cuando se alcanza la temperatura de servicio, controlar la alineacin del acoplamiento y


reajustarlo si es necesario.

6.2

Uso de la bomba

ADVERTENCIA

Temperaturas elevadas de la superficie al trabajar con medios de


bombeado calientes
Peligro de quemaduras!

ATENCIN

Evitar el contacto con la superficie de la bomba.


Llevar ropa protectora.

Ruidos, vibraciones o temperaturas anormales o fugas


Daos en la bomba!

Desconectar inmediatamente el grupo de bombas.


El grupo de bombas solo se debe volver a poner en servicio una vez que se
hayan eliminado las causas.

6.3 Correccin del rodete


Los rodetes estn descargados hidrulicamente para la compensacin del empuje. Adicionalmente al uso
de los anillos de desgaste, la compensacin se realiza individualmente o en combinacin con:

labes posteriores
orificios de descarga
orificios de inyector

Se puede realizar una correccin del dimetro del rodete dentro del intervalo indicado en la hoja de curvas
caractersticas.

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6. Puesta en servicio / puesta fuera de servicio

6.4 Lmites del margen de trabajo


PELIGRO

Superacin de los lmites de uso con respecto a presin, temperatura y


velocidad de giro
Peligro de explosin! Escapes de medio de bombeado caliente o txico!

6.4.1

Observar los datos de servicio admisibles indicados en la hoja de datos de la


bomba.
Evitar el funcionamiento con el rgano de cierre cerrado.
No utilizar la bomba nunca a una temperatura ms alta que la indicada en la
hoja de datos de la bomba.

Caudal

Salvo indicacin contraria en la hoja de datos de la bomba, se aplica lo siguiente:


Qmn
Qmx

=
=

6.4.2

0,25 x Qpt
1,2 x Qpt

Frecuencia de cambios

PELIGRO

Temperatura de superficie del motor demasiado alta


Peligro de explosin!

En motores protegidos contra explosiones, observar las indicaciones sobre la


frecuencia de cambios contenidas en el manual de instrucciones del motor.

La frecuencia de cambios queda determinada por el aumento de temperatura mximo admisible del motor
y depende de las reservas de potencia del motor durante el funcionamiento y de las condiciones de
arranque.

NOTA
Observar el manual de instrucciones del fabricante del motor!

6.4.3

Medios abrasivos o sustancias slidas

Si se bombean medios de bombeado con componentes abrasivos o sustancias slidas, se debe prever un
mayor desgaste. Los intervalos de inspeccin se deben reducir frente a los tiempos usuales.

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6. Puesta en servicio / puesta fuera de servicio

6.5 Desconexin de la bomba


1. El rgano de cierre en la tubera de aspiracin permanece abierto.
2. Cerrar el rgano de cierre en la tubera de impulsin.
3. Desconectar el motor y prestar atencin a su giro estable hasta la parada.

NOTA
Si est instalada una vlvula de retencin en la tubera de impulsin, el rgano de
cierre puede permanecer abierto. Debe existir una contrapresin.

En caso de parada prolongada, se deben observar los siguientes puntos:

Evacuar completamente los medios que tienden a la polimerizacin, cristalizacin o solidificacin.


En su caso, aclarar la bomba con un lquido apropiado.
Cerrar el rgano de cierre en la tubera de aspiracin.

Cerrar las conexiones adicionales.

6.6 Puesta fuera de servicio


El grupo de bombas permanece instalado en la tubera:

Prever un volumen de lquido suficiente para el ciclo de funcionamiento.


Conectar el grupo de bombas regularmente en intervalos mensuales a trimestrales.

El grupo de bombas se desmonta y almacena:

Vaciar correctamente la bomba.


Observar las indicaciones para la seguridad en el captulo 7.1 / 7.3.
Rociar el interior de la caja de bomba con agente anticorrosivo. Esto no es necesario en bombas de
acero inoxidable.
Pulverizar el agente anticorrosivo por las tubuladuras de aspiracin y de impulsin.
Cerrar las bridas de aspiracin y de impulsin.
Cubrir todas las superficies brillantes en el exterior de la bomba con aceite o grasa sin silicona.
Observar las indicaciones adicionales en el captulo 4.2.

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7. Mantenimiento / conservacin / inspeccin

7. Mantenimiento/conservacin/
inspeccin
7.1

Normas de seguridad

PELIGRO

Mantenimiento inadecuado del grupo de bombas


Peligro de explosin!

ADVERTENCIA

Efectuar regularmente el mantenimiento del grupo de bombas.


Crear un plan de mantenimiento.

Conexin accidental del grupo de bombas


Peligro de lesiones por elementos mviles!

ADVERTENCIA

Los trabajos en el grupo de bombas solo se deben ejecutar con las conexiones
elctricas desembornadas.
Asegurar el grupo de bombas contra la conexin accidental.

Medios de bombeado calientes


Peligro de lesiones!

ADVERTENCIA

Dejar que el grupo de bombas se enfre hasta la temperatura ambiente.

Medios de bombeado peligrosos para la salud


Peligro de lesiones!

Observar las disposiciones legales.


Al vaciar el medio de bombeado, tomar las medidas oportunas para la
proteccin de las personas y del medio ambiente.
Descontaminar las bombas.

El usuario debe asegurar que todos los trabajos de mantenimiento, inspeccin y montaje sean ejecutados
por personal tcnico cualificado. Este personal debe informarse suficientemente mediante el estudio de
las instrucciones de servicio.
Un plan de mantenimiento permite evitar reparaciones caras con un mnimo de trabajo.
Se debe evitar cualquier aplicacin de fuerza en el grupo de bombas.

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7. Mantenimiento / conservacin / inspeccin

7.2

Supervisin del funcionamiento

PELIGRO

Temperatura elevada de la superficie por el calentamiento de los rodamientos


Peligro de explosin! Peligro de incendio!

ATENCIN

Comprobar regularmente los ruidos de rodadura de los rodamientos.


Comprobar regularmente el nivel de lubricante.

Desgaste en caso de funcionamiento en seco


Daos en la bomba!

ATENCIN

El grupo de bombas no se debe utilizar nunca sin llenar.


Bajo ningn concepto se debe cerrar el rgano de cierre en la tubera de
aspiracin durante el funcionamiento.

Superacin de la temperatura admisible del medio de bombeado


Daos en la bomba!

No se permite el funcionamiento contra un rgano de cierre cerrado en el lado


de impulsin.
Observar los datos de temperatura en la hoja de datos de la bomba.

Durante el funcionamiento se deben comprobar regularmente los siguientes puntos:

La bomba debe funcionar siempre de forma estable y sin vibraciones.


Comprobar los ruidos de rodadura de los rodamientos. Vibraciones, ruidos, as como un consumo de
corriente aumentado son indicios de desgaste.
Controlar los elementos elsticos del acoplamiento.
Limpiar regularmente el filtro en la tubera de aspiracin.

7.2.1

Lubricacin/vida til rodamientos

PELIGRO

Temperatura elevada de la superficie debido al sobrecalentamiento de los


rodamientos o hermetizaciones de rodamientos defectuosas
Peligro de explosin! Peligro de incendio!

Comprobar regularmente el estado del lubricante.


Comprobar regularmente el nivel de lubricante.

La lubricacin de los rodamientos se realiza generalmente con aceite mineral.


Se pueden utilizar aceites lubricantes CLP46 o 68 segn DIN 51517 o HD20W/20 con una viscosidad
cinemtica de 46-68 mm2/s a 40 C, p. ej.:

OMV lube EPX 46


Shell Morlina 46-68

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7. Mantenimiento / conservacin / inspeccin


Incluso con condiciones de carga desfavorables, la vida til calculatoria de los rodamientos es de ms de
25 000 horas de funcionamiento.
El primer cambio de aceite se debe realizar al cabo de 200 horas de funcionamiento. A continuacin, la
carga de aceite se tiene que renovar una vez al ao.
Soporte de
rodamiento
0/I
II
III
IV
V

Volumen de
carga [l]
0,75
1,0
1,25
2,7
3,5

NOTA
En caso de ejecucin con lubricacin por grasa, los rodamientos disponen de una
lubricacin permanente por grasa. No requieren ningn reengrase.

NOTA
Para temperaturas ambientes de < -20 C, srvase consultar a la empresa Dickow
Pumpen. Observar las indicaciones en la hoja de datos de la bomba.

7.2.2
1.
2.
3.
4.

Cambio de aceite

Colocar un recipiente apropiado para el aceite usado debajo del tornillo de cierre.
Desenroscar el tornillo de cierre en el soporte de coijnete y vaciar el aceite.
Despus del vaciado, volver a enroscar el tornillo de cierre.
Volver a llenar con aceite. Observar el captulo 6.1.1.

ADVERTENCIA

Fluidos lubricantes peligrosos para la salud


Peligro para las personas y el medio ambiente!

NCL ES4 04.14.doc

Durante el vaciado, tomar las medidas de proteccin oportunas


para las personas y el medio ambiente.
Observar las disposiciones legales con respecto a la eliminacin de
lquidos peligrosos para la salud.

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7. Mantenimiento / conservacin / inspeccin

7.3 Vaciado y eliminacin


Medios de bombeado peligrosos para la salud

ADVERTENCIA

Peligro para las personas y el medio ambiente!

Recoger y eliminar el lquido de aclarado y el eventual lquido restante.


Llevar ropa protectora y una mascarilla protectora.
Observar las disposiciones legales con respecto a la eliminacin del
lquido.

El vaciado del medio a bombear tiene lugar a travs de los tornillos de purga en la caja, un rgano de
cierre conectado o una conexin abridada.
Ver el plano de instalacin con respecto al modo de vaciado y la situacin.

7.4

Desmontaje del grupo de bombas

7.4.1

Indicaciones generales

Observar las indicaciones para la seguridad en el captulo 7.1.


Al realizar trabajos en el motor, observar la documentacin del fabricante del motor en cuestin.
En el desmontaje, observar los dibujos seccionales.
En caso de defectos, nuestro Servicio tcnico se encuentra a su disposicin.

PELIGRO

Trabajos en el grupo de bombas sin preparacin suficiente


Peligro de lesiones!

7.4.2
1.
2.
3.
4.

Desconectar correctamente el grupo de bombas.


Cerrar los rganos de cierre en el lado de aspiracin y de impulsin.
Vaciar la bomba y descargar la presin.
Cerrar las eventuales conexiones adicionales.
Dejar que el grupo de bombas se enfre hasta la temperatura
ambiente.

Desmontaje del motor

Desembornar el motor.
Retirar la proteccin del acoplamiento.
Soltar los tornillos de fijacin del motor en la placa base.
Desacoplar la bomba y el motor desplazando el motor.

ADVERTENCIA

Vuelco del motor


Aplastamiento de manos y pies!

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Asegurar el motor suspendindolo o apoyndolo.

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7. Mantenimiento / conservacin / inspeccin


NOTA
En los grupos de bombas con acoplamiento de desmontaje, el motor puede
permanecer atornillado en la placa base para el desmontaje de la unidad de
sustitucin.

7.4.3

Desmontaje de la unidad de introduccin

En la versin con acoplamiento de desmontaje, el motor permanece atornillado en la placa base. Retirar la
pieza de desmontaje segn las instrucciones de servicio del fabricante del acoplamiento.

Fig. 11: Desmontaje unidad de introduccin


1.
2.
3.

Soltar la tuerca hexagonal 920.2.


Soltar el tornillo hexagonal (1) en el pie de apoyo 183.
Con la ayuda de unos tornillos extractores, expulsar la unidad de introduccin completa (2) de la
caja en espiral 102.

4.
5.

Retirar la unidad de introduccin de la caja y depositarla.


Retirar el cubo de acoplamiento (3) del extremo del rbol.

ADVERTENCIA

Vuelco de la unidad de introduccin


Aplastamiento de manos y pies!

7.4.4

Asegurar la unidad de introduccin suspendindola o apoyndola.

Desmontaje del rodete

Los trabajos segn el captulo 7.4.3 estn terminados.


1.
2.
3.
4.

Sujetar la unidad completa en posicin vertical en un mandril.


Soltar la tuerca del rodete 922 o el tornillo hexagonal 914.12 (Lt. 0) (rosca derecha).
Retirar el rodete del rbol de bomba.
Quitar la chaveta de ajuste 940.1.

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7. Mantenimiento / conservacin / inspeccin


7.4.5

Desmontaje de la junta de eje

Los trabajos segn el captulo 7.4.4 estn terminados.


Cierre de anillo deslizante DICKOW N6 / N10 / N11
1.
2.
3.
4.
5.

Retirar el cierre de anillo deslizante 433 del rbol de la bomba.


Quitar la tuerca hexagonal 920.1.
Expulsar la caja intermedia 113 del centraje y colocarla en el puesto de trabajo.
Quitar la tuerca hexagonal 920.5, retirar el anillo de presin 457.
Extraer el contraanillo 475 con cuidado de la caja intermedia.

Cierre de anillo deslizante DICKOW N9 / N13


1. Retirar el cierre de anillo deslizante 433.1 en el lado del producto del rbol de la bomba.
2. Quitar la tuerca hexagonal 920.5.
3. Tirar la caja del cierre de anillo deslizante 471, el anillo de presin 474 y el soporte de contraanillo
475.2 hasta el reborde del rbol.
4. Quitar la tuerca hexagonal 920.1.
5. Expulsar la caja intermedia 113 del centraje.
6. Retirar el cierre de anillo deslizante 433.2 en el lado de la atmsfera y el casquillo distanciador 525
del rbol de la bomba.
7. Retirar la caja del cierre de anillo deslizante 471, el anillo de presin 474 y el soporte de
contraanillo 475.2 del soporte de rodamiento.
8. Retirar el soporte de contraanillo 475.1 de la caja intermedia 113.
Cierre de anillo deslizante normalizada segn EN 12756
1. Si existe, retirar el tornillo de cabeza con hexgono interior 914.1 y expulsar el anillo base 457 de
la caja intermedia 113.
2. Retirar el casquillo protector del rbol 524 junto con la unidad de cierre de anillo deslizante
rotatoria del rbol de transmisin.
3. Quitar la tuerca hexagonal 920.1.
4. Expulsar la caja intermedia 113 del centraje.
5. Quitar la tuerca hexagonal 920.5.
6. Quitar la caja del cierre de anillo deslizante 471.
7. Desmontar el contraanillo 475 y el anillo trico.
Cierre de anillo deslizante normalizado tndem segn EN 12756 (API-Plan 52)
1.
2.
3.
4.
5.

Quitar la tuerca hexagonal 920.5.


Pasar la caja del cierre de anillo deslizante 471 con el contraanillo 475.2 hasta el reborde del rbol.
Quitar la tuerca hexagonal 920.1.
Expulsar la caja intermedia 113 del centraje.
Retirar el casquillo protector del rbol 524 con el cierre de anillo deslizante 433 y el soporte de
contraanillo 476 del rbol de la bomba.

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6. Soltar los tornillos prisioneros en el cierre de anillo deslizante 433.2 y retirar el cierre de anillo
deslizante del casquillo protector del rbol.
7. Retirar el soporte de contraanillo 476 con el contraanillo 475.1.
8. Soltar el tornillo prisionero en el cierre de anillo deslizante 433.1 y retirar el cierre de anillo
deslizante.
9. Expulsar el contraanillo 475.1 junto con el anillo trico del soporte de contraanillo 476.
10. Retirar la caja del cierre de anillo deslizante 471 del soporte de rodamiento.
11. Expulsar el contraanillo 475.2 junto con el anillo trico de la caja del cierre de anillo deslizante.
Cierre de anillo deslizante normalizado de doble efecto segn EN 12756 (API-Plan 53)
1.
2.
3.
4.
5.
6.
7.
8.

Quitar el tornillo de cabeza con hexgono interior 914.1.


Quitar el soporte de contraanillo 476 y el contraanillo 475.
Expulsar el contraanillo 475.2 junto con el anillo trico del soporte de contraanillo 476.
Retirar el casquillo protector del rbol 524 con el cierre de anillo deslizante 433.1/2 del rbol de la
bomba.
Quitar la tuerca hexagonal 920.1.
Expulsar la caja intermedia 113 del centraje y colocarla en el puesto de trabajo.
Quitar la tuerca hexagonal 920.5 y retirar la caja del cierre de anillo deslizante 471.
Expulsar el soporte de contraanillo 475.2 junto con el anillo trico de la caja del cierre de anillo
deslizante 471.

Cierre de anillo deslizante Cartridge


1. Si existe, retirar el tornillo de cabeza con hexgono interior 914.1 y expulsar el anillo base 457 de
la caja intermedia 113.
2. Quitar la tuerca hexagonal 920.5.
3. Quitar la tuerca hexagonal 920.1.
4. Expulsar la caja intermedia 113 del centraje.
5. Retirar el anillo intermedio 509 del rbol de la bomba.
6. Fijar calibres de montaje en el cierre de anillo deslizante.
7. Soltar los tornillos prisioneros y retirar la unidad de cierre 433 completa del rbol de la bomba.

7.4.6

Desmontaje del rodamiento

Los trabajos segn el captulo 7.4.5 estn terminados.


1.
2.
3.
4.
5.
6.
7.
8.

Soltar el tornillo prisionero 904.1 y retirar el anillo dispersor 507 del rbol de la bomba.
Soltar el tornillo hexagonal 901.2 y retirar la tapa del rodamiento 360 con la junta radial 421.2.
Expulsar el rbol de la bomba 211 junto con el rodamientos de bolas de contacto angular 325 del
asiento del soporte de rodamiento. Utilizar un husillo portabrocas o de prensa.
Soltar los tornillos de cabeza con hexgono interior 314.2 y quitar la linterna del soporte de
rodamiento 344.
Expulsar el aro exterior del rodamiento de rodillos cilndricos 322 del soporte de rodamiento 330.
Retirar la arandela de seguridad 932.2 y el disco de apoyo 550.3 del rbol de la bomba.
Retirar el rodamiento de bolas de contacto angular 325 del rbol de la bomba.
Retirar el disco de apoyo 550.3 del rbol de la bomba.

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7. Mantenimiento / conservacin / inspeccin


Procedimiento con el soporte de rodamiento V:
1.
2.

Soltar el tornillo prisionero 904.1 y retirar el anillo dispersor 507 del rbol de la bomba.
Soltar los tornillos de cabeza con hexgono interior 914.6 y retirar la tapa del rodamiento 360.2
con la junta radial 421.1.
Soltar los tornillos de cabeza con hexgono interior 914.5 y retirar la tapa del rodamiento 360.1
con la junta radial 421.2.
Expulsar el rbol de la bomba 211 junto con el rodamientos de bolas de contacto angular 325 del
asiento del soporte de rodamiento. Utilizar un husillo portabrocas o de prensa.
Expulsar el aro exterior del rodamiento de rodillos cilndricos 322 del soporte de rodamiento 330.
Soltar y quitar la tuerca del rbol 921.
Retirar el rodamiento de bolas de contacto angular 325 del rbol de la bomba.

3.
4.
5.
6.
7.

7.4.7

Cambio del rodamiento

Soporte de
rodamiento
0/I
II
III
IV
V

322

325

NU 306
NU 307
NU 409
NU 411
NU 313

2x 7306 BUA
2x 7307 BUA
2x 7311 BUA
2x 7313 BUA
2x 7314 BUA

Versin con lubricacin permanente:


Soporte de
rodamiento
0/I
II
III
IV

321
2x 6306.2RS
2x 6307.2RS
2x 6409.2RS
2x 6411.2RS

7.5

Inspeccin de componentes

7.5.1

Rodete/anillo de desgaste

Las superficies de rodadura en la zona del anillo de desgaste no deben mostrar surcos visibles. Medir los
dimetros de las superficies de rodadura. El juego total en estado nuevo es de 0,6 mm. Sustituir los anillos
de desgaste cuando el juego supera 0,9 mm.

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7.5.2

Soporte de rodamiento

Medir los dimetros interiores de los asientos de rodamiento de bolas. Sustituir el soporte de rodamiento
cuando se superan las siguientes medidas:

Soporte de rodamiento 0 / I
Soporte de rodamiento II
Soporte de rodamiento III
Soporte de rodamiento IV
Soporte de rodamiento V
7.5.3

max. 72,009 mm
max. 80,009 mm
max. 120,010 mm
max. 140,012 mm
max. 140,026 mm + 150,026 mm

Cierre de anillo deslizante DICKOW

Los fuelles de metal se tensan de tal modo en el estado de instalacin que mediante la fuerza de resorte se
obtiene una fuerza de cierre suficiente en las superficies deslizantes. Despus del desmontaje y una
limpieza minuciosa, medir el cierre de anillo deslizante. Sustituir el cierre de anillo deslizante cuando no
se alcancen las siguientes medidas longitudinales.

Fig. 12: Longitud cierre de anillo deslizante

Cierre de anillo deslizante


N6
N10
N11

N9

N13

NCL ES4 04.14.doc

en el lado del
producto
en el lado de la
atmsfera
en el lado del
producto
en el lado de la
atmsfera

Cdigo
A
U1
U3
U3
A
U1
U3
U3

L [mm] en soporte de rodamiento


0/I
II
III
IV
46
58
58
67
49
58
58
67
54
65
65
77
48,5
60,5
56
74
86
105
86
105
113
140
81
48,5
60,5
56
74

U2

45

53

59

79

U3

53,5

65,5

65,5

79

U2

48

58

64

82

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7. Mantenimiento / conservacin / inspeccin

7.6 Montaje del grupo de bombas


7.6.1

Indicaciones generales

Observar las indicaciones para la seguridad en el captulo 7.1.


En el montaje, observar los dibujos seccionales.
Utilizar fundamentalmente juntas planas nuevas.
Montar las juntas planas sin lubricantes.
Renunciar al uso de dispositivos auxiliares de montaje al montar juntas planas. Si es necesario,
utilizar adhesivos de contacto corrientes en el mercado. No utilizar nunca pegamentos rpidos.
Untar los puntos de ajuste, as como las uniones atornilladas con grafito o productos similares. El
lubricante debe ser compatible con el medio de bombeado.
Apretar todos los tornillos conforme a las prescripciones. Observar el captulo 7.7.
Montaje inadecuado

ATENCIN

Daos en la bomba!

Montar las bombas/el grupo de bombas conforme a las reglas vigentes en


la construccin de mquinas.
Utilizar siempre repuestos originales.

Antes del montaje se deben comprobar los siguientes puntos:

Todos los elementos desmontados han sido limpiados y examinados con respecto a su desgaste.
Los elementos defectuosos o desgastados deben ser sustituidos por repuestos originales.
Todas las superficies de hermetizacin han sido limpiadas.

7.6.2
1.
2.
3.

Montaje del rodamiento


Deslizar el disco de apoyo 550.3 sobre el rbol de la bomba.
Calentar el rodamiento de bolas de contacto angular 325 a 80-100C.
Deslizar el rodamiento de bolas de contacto angular 325 sobre el rbol de la bomba hasta el tope.

Montar rodamientos de bolas de contacto angular en disposicin en O.


Montar solamente rodamientos de bolas de contacto angular por pares de un solo
fabricante.

4.
5.
6.

Deslizar el disco de apoyo 550.3 y la arandela de seguridad 932.2 sobre el rbol de la bomba.
Presionar el aro exterior del rodamiento de rodillos cilndricos 322 dentro del soporte de
rodamiento 330.
Colocar la linterna del soporte de rodamiento 344 y fijarla con los tornillos de cabeza con
hexgono interior 914.2.

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7.

Presionar el rbol de la bomba 211 junto con el rodamientos de bolas de contacto angular 325 en el
asiento del soporte de rodamiento. Utilizar un husillo portabrocas o de prensa.
Colocar la tapa de rodamiento 360 con la nueva junta radial 421.2 y apretar los tornillos
hexagonales 901.2.
Deslizar el anillo dispersor 507 sobre el rbol de la bomba. Apretar el tornillo prisionero 904.1.

8.
9.

Procedimiento con el soporte de rodamiento V:


1.
2.

Calentar el rodamiento de bolas de contacto angular 325 a 80-100C.


Deslizar el rodamiento de bolas de contacto angular 325 sobre el rbol de la bomba hasta el tope.
Tener en cuenta las indicaciones.
Enroscar la tuerca del rbol 921 y apretarla.
Presionar el aro exterior del rodamiento de rodillos cilndricos 322 dentro del soporte de
rodamiento 330.
Colocar la tapa de rodamiento 360.2 con la nueva junta radial 421.1 y apretar el tornillo de cabeza
con hexgono interior 914.6.
Presionar el rbol de la bomba 211 junto con el rodamientos de bolas de contacto angular 325 en el
asiento del soporte de rodamiento. Utilizar un husillo portabrocas o de prensa.
Colocar la tapa de rodamiento 360.1 con la nueva junta radial 421.2 y apretar el tornillo de cabeza
con hexgono interior 914.5.
Deslizar el anillo dispersor 507 sobre el rbol de la bomba. Apretar el tornillo prisionero 904.1.

3.
4.
5.
6.
7.
8.

7.6.3

Montaje de la junta de eje

Los trabajos segn el captulo 7.6.2 estn terminados.


Durante el montaje se debe tener en cuenta fundamentalmente lo siguiente:

Tener en cuenta la designacin de la junta de eje.


Trabajar con limpieza y cuidado.
Retirar los protectores de las superficies deslizantes sin dejar residuos.
No aplicar nunca lubricante a las superficies deslizantes.
Nunca apretar a tope el fuelle metlico.
Las fuerzas axiales de montaje para colocar el fuelle metlico se deben ejercer siempre sobre el
portafuelle.
Despus de la insercin, comprobar el paralelismo ortogonal con el elemento de la caja.
La superficie del casquillo protector del rbol debe estar perfectamente limpia y lisa. El canto de
montaje est biselado.

Cierre de anillo deslizante DICKOW N6 / N10 / N11


1.
2.
3.
4.

Insertar con cuidado el contraanillo 475 en la caja intermedia.


Insertar el anillo de presin 474 y apretar con tuerca hexagonal 920.5.
Presionar la caja intermedia 113 en el centraje y apretar con tuercas hexagonales 920.1.
Deslizar el cierre de anillo deslizante 433 sobre el rbol de la bomba.

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7. Mantenimiento / conservacin / inspeccin

Cierre de anillo deslizante DICKOW N9 / N13


1.
2.
3.
4.
5.
6.

Insertar el soporte de contraanillo 475.1 en la caja intermedia 113.


Deslizar la caja del cierre de anillo deslizante 471, el anillo de presin 474 y el soporte de
contraanillo 475.2 sobre el rbol de la bomba hasta el reborde del rbol.
Deslizar sobre el rbol de la bomba el casquillo distanciador 525 y el cierre de anillo deslizante
433.2 del lado de la atmsfera.
Presionar la caja intermedia 113 en el centraje y apretar con tuercas hexagonales 920.1.
Apretar la caja del cierre de anillo deslizante con las tuercas hexagonales 920.5.
Deslizar el cierre de anillo deslizante 433.1 del lado del producto sobre el rbol de la bomba.

Cierre de anillo deslizante normalizado segn EN 12756


1.
2.
3.
4.
5.

Montar el contraanillo 475 con el anillo trico en la caja del cierre de anillo deslizante 471.
Atornillar la caja del cierre de anillo deslizante 471 a la caja intermedia 113 con las tuercas
hexagonales 920.5.
Presionar la caja intermedia 113 en el centraje y apretar con tuercas hexagonales 920.1.
Deslizar sobre el rbol de la bomba el casquillo protector del rbol 524 y la unidad de cierre de
anillo deslizante rotatoria.
En caso de que exista, presionar el anillo base 457 en la caja intermedia 113 y apretar con los
tornillos de cabeza con hexgono interior 914.1.

Cierre de anillo deslizante normalizado tndem segn EN 12756 (API-Plan 52)


1.
2.
3.
4.
5.
6.
7.
8.
9.

Montar el contraanillo 475.2 y el anillo trico en la caja del cierre de anillo deslizante 471.
Deslizar la caja del cierre de anillo deslizante 471 sobre el rbol de la bomba hasta el reborde del
rbol.
Montar el contraanillo 475.1 y el anillo trico en el soporte del contraanillo 476.
Deslizar el cierre de anillo deslizante 433.1 sobre el casquillo protector del rbol y apretar con el
tornillo prisionero.
Deslizar la unidad de soporte del contraanillo 476 sobre el casquillo protector del rbol.
Deslizar el cierre de anillo deslizante 433.2 sobre el casquillo protector del rbol y apretar el
tornillo prisionero.
Deslizar la unidad completa sobre el rbol de la bomba 211.
Presionar la caja intermedia 113 en el centraje y apretar con tuercas hexagonales 920.1.
Atornillar la caja del cierre de anillo deslizante 471 a la caja intermedia con tuercas hexagonales
920.5.

Cierre de anillo deslizante normalizado de doble efecto segn EN 12756 (API-Plan 53)
1.
2.
3.
4.
5.

Montar el soporte del contraanillo 475.1 y el anillo trico en la caja del cierre de anillo deslizante
471 y deslizarla sobre el rbol de la bomba.
Atornillar la caja del cierre de anillo deslizante 471 a la caja intermedia con tuercas hexagonales
920.5.
Presionar la caja intermedia 113 en el centraje y apretar con tuercas hexagonales 920.1.
Deslizar el casquillo protector del rbol 524 con el cierre de anillo deslizante 433.1/2 sobre el rbol
de la bomba.
Montar el contraanillo 475.2 y el anillo trico en el soporte del contraanillo 476.

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7. Mantenimiento / conservacin / inspeccin


6.

Atornillar a la caja intermedia 113 el soporte del contraanillo 476 con los tornillos de cabeza con
hexgono interior 914.1.

Cierre de anillo deslizante Cartridge


1.
2.
3.

Deslizar sobre el rbol de la bomba la unidad de cierre completa 433.


Presionar la caja intermedia 113 en el centraje y apretar con tuercas hexagonales 920.1.
Atornillar a la caja intermedia 113 la unidad de cierre 433 con los tornillos de cabeza con hexgono
interior 920.5.
Apretar los tornillos prisioneros y desprender los calibres de montaje.

4.

7.6.4
1.
2.

Montaje del rodete

Pasar el rodete sobre el rbol de bomba.


Soltar la tuerca del rodete 922 o la tuerca con hexgono interior 914.12 (Lt. 0) con una llave
dinamomtrica (rosca derecha).

ATENCIN

Falta el inserto Heli-Coil


Atornilladura del rodete floja!

7.6.5

Asegurarse de que la tuerca del rodete o el rbol de bomba (Lt. 0) est


dotado del inserto Heli-Coil.

Montaje de la unidad de introduccin

ADVERTENCIA

Vuelco de la unidad de introduccin


Aplastamiento de manos y pies!

Asegurar la unidad de introduccin suspendindola o apoyndola.

NOTA
Observar la figura 15!

1.
2.
3.
4.
5.
6.

Introducir la unidad de introduccin en la caja en espiral.


Utilizar una junta plana 400.5 nueva.
Apretar la tuerca hexagonal 920.2 con una llave dinamomtrica.
Montar el pie de apoyo 183 con el tornillo hexagonal 901.1 y la arandela 554.8.
Fijar el pie de apoyo con el tornillo hexagonal en la placa base.
Montar el cubo de acoplamiento en el extremo del rbol.

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7.6.6

Montaje del motor

NOTA
En la versin con acoplamiento de desmontaje se suprimen los dos primeros pasos.

1.

Acoplar la bomba y el motor desplazando el motor.

2.

Fijar el motor en la placa base.

3.

Alinear la bomba y el motor. Observar el captulo 5.7.

4.

Alinear el acoplamiento. Observar el captulo 5.6.

7.7 Pares de apriete de los tornillos

M5
M6
M8
M10
M12
M16
M20

Tornillo rgido
5
9
22
45
80
195
370

Par de apriete [Nm]


8.8
A4-70
Tornillo de dilatacin Tornillo rgido Tornillo de dilatacin
4
6
16
30
55
55
40
145
135
100
280
260
195

Base de clculo:

80% de aprovechamiento del lmite elstico del material del tornillo.

Coeficiente de friccin = 0,14 ; utilizar un lubricante para tornillos para la rosca y la superficie de
aplicacin de la cabeza/tuerca.
Recomendacin: Klberpaste HEL 46-450.

Apriete con par controlado mediante una llave dinamomtrica.

NOTA
Eventuales desviaciones de los pares de apriete de los tornillos se indican en la
hoja de datos de la bomba.

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7. Mantenimiento / conservacin / inspeccin


Par de apriete para tornillos de cierre (independiente del material):

G 1/4 = 25 Nm

G 3/8 = 45 Nm

G 1/2 = 75 Nm

Pares de apriete para la tuerca del rodete 922 o el tornillo del rodete 914.2 y la tuerca del rbol 921
(independiente del material):
Soporte de
rodamiento
0
I
II
III
IV
V

NCL ES4 04.14.doc

922 o 914.12
Par de apriete [Nm]
Ancho de llave
30
19
100
32
120
41
140
50
140
65
140
65

921 Par de apriete [Nm]


----------160

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8. Correccin de averas

8. Correccin de averas
Avera
La bomba no bombea, o bombea demasiado poco
Motor sobrecargado
Temperatura de rodamientos demasiado alta
Fuga en la bomba
Aumento de ruido y vibraciones
Aumento inadmisible de la temperatura
Elevada fuga en la junta del eje

Nmero de avera
2 3 4 5 6

Nmero
1
2
3
4
5
6
7

Causa

Correccin

La bomba o la tubera no est


completamente purgada o llenada

Purgar o llenar

El rgano de cierre en la tubera de


afluencia no est completamente
abierto

Abrir el rgano de cierre

Formacin de bolsas de aire en la


tubera

Modificar la conduccin de la
tubera, montar una vlvula de
purga

Sentido de giro incorrecto

Invertir 2 fases de la alimentacin


elctrica

La contrapresin de la bomba es
superior a lo indicado

Volver a regular el punto de


trabajo, aumentar la velocidad de
giro
Montar un rodete ms grande

La viscosidad del medio de


bombeado es superior a lo indicado

Consultar al fabricante

La contrapresin de la bomba es
inferior a lo indicado

Repasar el rodete
Volver a regular el punto de
trabajo

NPSHA demasiado bajo

Controlar el nivel de lquido


Mejorar NPSHR mediante un
inducer
Reducir las resistencias en la
tubera de afluencia
Abrir completamente el rgano
de cierre en la tubera de
afluencia

Velocidad de giro incorrecta

Comprobar la velocidad de giro

Grupo de bombas mal alineado

Controlar la alineacin del


acoplamiento y realinear si es
necesario

X
X

NCL ES4 04.14.doc

47 de 60

8. Correccin de averas

Nmero de avera
2 3 4 5 6

Causa

Correccin

Bomba en la tubera deformada

Comprobar las conexiones de


tubera y la fijacin de la bomba

Defecto de rodamiento

Cambiar rodamiento

Desequilibrio de componentes
rotatorios, p. ej. rodete

Reequilibrar el componente en
cuestin

Tornillos de la caja y tornillos de


cierre aflojados

Apretar los tornillos


Cambiar la junta plana

No se mantiene la distancia del


acoplamiento

Corregir distancia

No existe la corriente de
refrigeracin del motor al rodamiento

Comprobar la instalacin
Instalar rodete de ventilador

Casquete prensaestopas demasiado


apretado o torcido

Modificar

Junta de eje desgastada

Cambiar la junta de eje


Controlar el lquido de aclarado y
de bloqueo

Casquillo protector del rbol estriado


o demasiado rugoso

Cambiar el casquillo protector del


rbol

Error en tubera de circulacin

Aumentar la seccin

Elastmeros daados en el cierre de


anillo deslizante

Sustituir los elastmeros

Con la presin atmosfrica, el punto


de ebullicin del medio de bombeado
se mantiene por debajo de la
temperatura de trabajo

Usar cierre de anillo deslizante


doble
Reequipar enfriamiento de vapor

Partculas slidas abrasivas

Montar emparejamiento de
anillos deslizantes resistentes al
desgaste
Modificar la forma de marcha
(Plan 31/32)
Montar el cierre de anillo
deslizante
de doble efecto (Plan 53)

NCL ES4 04.14.doc

48 de 60

9. Intercambiabilidad de piezas

9. Intercambiabilidad de piezas
9.1

Soporte de rodamiento 0

NCL ES4 04.14.doc

49 de 60

9. Intercambiabilidad de piezas

9.2 Soporte de rodamiento I

NCL ES4 04.14.doc

50 de 60

9. Intercambiabilidad de piezas

9.3 Soporte de rodamiento II

NCL ES4 04.14.doc

51 de 60

9. Intercambiabilidad de piezas

9.4 Soporte de rodamiento III

NCL ES4 04.14.doc

52 de 60

9. Intercambiabilidad de piezas

9.5 Soporte de rodamiento IV

NCL ES4 04.14.doc

53 de 60

9. Intercambiabilidad de piezas

9.6 Soporte de rodamiento V

NCL ES4 04.14.doc

54 de 60

10. Dibujos seccionales

10. Dibujos seccionales


10.1 Bomba

Fig. 13: Plano global versin estndar NCL

914.12

Fig. 14: Atornilladura del rodete soporte de rodamiento 0

NCL ES4 04.14.doc

55 de 60

10. Dibujos seccionales

Fig. 15: Versin soporte de rodamiento V

Fig. 16: Versin rodamiento con lubricacin permanente con grasa

NCL ES4 04.14.doc

56 de 60

10. Dibujos seccionales

10.2 Cierre de anillo deslizante

Fig. 17: cierre de anillo deslizante de efecto simple


DICKOW

Fig. 18: cierre de anillo deslizante tndem


DICKOW

Fig. 19: cierre de anillo deslizante de efecto simple


normalizado

Fig. 20: Cierre de anillo deslizante normalizado


tndem

NCL ES4 04.14.doc

57 de 60

10. Dibujos seccionales

Fig. 21: cierre de anillo deslizante de efecto doble


normalizado

NCL ES4 04.14.doc

Fig. 22: Cierre de anillo deslizante Cartridge

58 de 60

11. Certificaciones

11. Certificaciones
11.1 Declaracin de conformidad CE
Declaracin de conformidad CE
segn la Directiva CE sobre mquinas 2006/42/CE, anexo II, n. 1A
DICKOW PUMPEN KG
Siemensstrae 22
D-84478 Waldkraiburg

Por la presente, declaramos que el grupo de bombas descrito en la hoja de datos de la bomba

Designacin:
Tipo:
Tamao constructivo:
Versin:
N. de serie.:

Bomba centrfuga
NCL

cumple todas las disposiciones pertinentes de la Directiva CE sobre mquinas


2006/42/CE

Se han aplicado las siguientes normas armonizadas


EN 809:1998
EN ISO 12100-1:2003
EN ISO 12100-2:2003
EN 12162:2001

EN ISO 12732-1:2008
EN ISO 12732-3:2008
EN ISO 14121-1:2007
EN ISO 20361:2009

Adems, se han aplicado las siguientes normas y especificaciones tcnicas


EN ISO 5199:2002
EN ISO 9906:1999
EN 12723:2000
EN 22858:1993

VDMA 24276:2001

Waldkraiburg, a
(Nombre, funcin)

El responsable dispone de plenos poderes para recopilar la documentacin tcnica

NCL ES4 04.14.doc

59 de 60

11. Certificaciones

11.2 Certificado de no objecin


Document of Compliance
Please fill in this statement for health innocuousness completely and attach it to the pump to
be returned to the factory.
Pump data
Type:

Serial No.: PB

Reason for shipment

Contamination of the pump


Hazardous liquids were not handled
Hazardous liquids were handled
Pumped liquid:
The pump has been
cleaned

flushed

breamed

The following safety measures must be taken before opening/repairing the pump:

Customer data
Company:
Address:
Name:
(Block Letters)

Phone:
Fax:
E-Mail:
Position:

This is to certify that the above mentioned pump has been proper cleaned/flushed/breamed
and repair can be performed without risk.
Date:

NCL ES4 04.14.doc

Signature:

60 de 60

EC Declaration of conformity of the explosion proof


as defined by EC-Explosion Proof Directive 94/9/EC, Annex X B
DICKOW PUMPEN KG
Siemensstrae 22
D-84478 Waldkraiburg

Herewith we declare that the pump unit, described in the pump data sheet

Type NCL
complies with the following provisions applying to EC-Explosion proof directive 94/9/EC

II 2 G cX

Product identification:
Safekeeping of technical documentation:

Physikalisch-Technische Bundesanstalt
Bundesallee 100
D-38116 Braunschweig

No. of Registration: 05 ATEX D 015

Applied harmonized European standards in particular


EN 1127-1 : 2011
EN ISO/IEC 80079-34:2011

EN 13463-1 : 2009
EN 13463-5 : 2011

Furthermore the following standards and technical Specifications have been applied
EN 12162 : 2001 + A1 : 2009

(Jrgen Konrad, Head of technical department DICKOW)

EN ISO 9906 : 2012


EN ISO 5199 : 2002

P24h6

27

Pumpe / pump

28k6

60

24

70

Motor / motor

31

130

385

DNd 1,5"

190

Wellenenden / shaft ends

490

22

440

DNs 2"

190

80

573

M12

426

P2

2x DIN 125-10,5-1.4571
DIN 939-M10-A4-70

2x DIN 934-M10-A4

140

M8 M10

740

1120

100

Erdungsanschluss
Earth connection

253

110

100
60
380

80
60

Plan53

Erdungsanschluss M10
Earth connection M10

6B
7B

180
160

Aufstellungsplan / Foundation plan

Rev.

~1236
160

Description

D
K
d1
DN

Flansche/flanges

13B

G1/4

G1
7B

Date

30.06.14

Loserth

Konrad
Signature Checked

Ablass lraum / drain oilroom;


plugged

Ablass Grundplatte/ drain baseplate

Ablass / drain; plugged

8xP19
92,1

G1/4

127

4xP22.2

73

6B

165

2"

114

Bezeichnung/designation

156

1.5"

d1
K
ASME B16.5 Class300

Flansche / flanges

Anschlsse/
connections

FLENDER ARPEX NAN


88-6/100

5G

100L2/3,6kW/B3/ExdeIICT4

Dexd N13

NCL s 32/210

PB14201782

Buss-SMS-Canzler GmbH,
Butzbach

14EBE1736

DN

Coupling:

Kupplung:

Base plate:

Rahmen:

Motor:

Design:

Ausfhrung:

Pump type:

Pumpentype:

Serial No.:

Pumpen Nr.:

Customer:

Kunde:

Item No.:

Pos. Nr.:

P.O. No.:

Best. Nr.:

Siemensstr. 22,
Postbox 1254,

D-84478 Waldkraiburg
D-84465 Waldkraiburg

Partslist
Pump type:
Design:
Sectional drawing:

NCLs 32/210
DEXD N13
54.NCL.90 / 14.NC.246/I

Buss Canzler
14EBE1736

Customer:
P.O.No.:
Item-No.:

54.VP.1
Part-N

Pcs Ident-No.

Parts name

1 14201782-M

Motor

1 00874031

Coupling guard

1 90440008

Base plate

Drawing/Stand.

Dimension/Size

04.50.1007

Material
ST

G5

GG25

1 01914755

Couplings

102

1 00741545

Volute casing 2"/1 1/2" Class300RF

01.15.288

113

1 00148226

Intermediate casing

02.23.1730

183

1 00690332

Support foot

03.60.229

211

1 00252671

Pump shaft

03.26.919

233

1 00011904

Impeller

02.12.338

12.129

1.4408

322

1 01016709

Cylindrical roller bearing

DIN 5412

NU306.TVP2

ST

325

2 01003379

Angular ball bearing

DIN 628

7306BUA

ST

330

1 00125349

Bearing bracket

01.18.88

18.88

GG 25

344

1 00231261

Bearing bracket lantern

02.24.38

24.38

GG 25

360

1 00577074

Bearing cover

04.35.297

35.68

GG 25

400.01

1 00598752

Gasket

04.39.292

VULKOLAN

400.02

1 00597927

Gasket

04.39.155

0,3

NOVATEC PREMIUM

400.05

1 00608621

Gasket

04.39.251

213*220*1,5

SIGRAFLEX HD-PRO

400.06

1 00597920

Gasket

04.39.154

22*32*1,5

GRAFIT/TITAN TGG

400.07

1 00598004

Gasket

04.39.168

22*32*1,5

GRAFIT/TITAN TGG

400.10

1 00599357

Gasket

04.39.396

53*60*0,5

GRAFIT/TITAN TGG

400.11

1 00598904

Gasket

04.39.318

51*58*0,5

GRAFIT/TITAN TGG

400.12

1 00599231

Gasket

04.39.375

48*54*0,5

GRAFIT/TITAN TGG

400.13

1 00599208

Gasket

04.39.371

22*25*0,3

NOVATEC PREMIUM

411.01

1 00599837

Joint ring

04.39.467

14*18,8*2

KUPFER

411.02

1 01907836

Joint ring

DIN 7603

A 14*18*1,5

TOP-CHEM 2000

411.15

2 01907841

Joint ring

DIN 7603

A 17*23*1,5

TOP-CHEM 2000

411.16

2 01907841

Joint ring

DIN 7603

A 17*23*1,5

TOP-CHEM 2000

411.17

1 01907846

Joint ring

DIN 7603

A 21*26*1,5

TOP-CHEM 2000

411.18

1 01907846

Joint ring

DIN 7603

A 21*26*1,5

TOP-CHEM 2000

411.19

2 01911498

Joint ring

EN 837-1

G1/2

PTFE

411.20

1 01907846

Joint ring

DIN 7603

A 21*26*1,5

TOP-CHEM 2000

411.21

1 01907846

Joint ring

DIN 7603

A 21*26*1,5

TOP-CHEM 2000

411.22

1 01907846

Joint ring

DIN 7603

A 21*26*1,5

TOP-CHEM 2000

411.23

1 01907846

Joint ring

DIN 7603

A 21*26*1,5

TOP-CHEM 2000

411.25

1 01907856

Joint ring

DIN 7603

A 33*39*2

TOP-CHEM 2000

411.26

1 01907846

Joint ring

DIN 7603

A 21*26*1,5

TOP-CHEM 2000

411.27

1 01907851

Joint ring

DIN 7603

A 27*32*2

NOVATEC PREMIUM

411.28

2 01907831

Joint ring

DIN 7603

A 10*13,5*1,5

TOP-CHEM 2000

Date

Rev.

1 handled by
approved

NAN 88-6/100

Signature

08.09.14
08.09.14

SCHARF
KONRAD

15.288

GGG 40.3
S355J2+N

60.229

GG 25
1.4021+QT 800

partslist

Side

PB14201782

Siemensstr. 22,
Postbox 1254,

D-84478 Waldkraiburg
D-84465 Waldkraiburg

Partslist
Part-N

Pcs Ident-No.

Parts name

412.24

1 01904614

O-ring

421.01

1 01016376

Shaft seal

421.02

1 01016376

Shaft seal

433.01

1 00654047

Mechanical seal

14.N25.354

1.4571/SIC/NOPR

433.02

1 00654055

Mechanical seal

14.N25.355

1.4571/SIC/NOPR

471

1 00027157

Mechanical seal casing

03.16.523

S355J2

474

1 00482931

Pressure ring

04.32.994

S355J2

475.01

1 00465508

Seal ring

04.30.439

1.4462/SIC/NOPR

475.02

1 00465212

Seal ring

04.30.402

507

1 00476086

Deflector

04.32.309

512.01

1 00610331

Wear ring

04.40.48

1.4571

512.02

1 00610331

Wear ring

04.40.48

1.4571

525

1 00362631

Distance sleeve

04.27.826

1.4571

550.01

1 01013110

Support disc

DIN 988

SS30*42*2,5

FST

550.02

1 01013124

Support disc

DIN 988

SS56*72*3

FST

550.03

2 01013110

Support disc

DIN 988

SS30*42*2,5

FST

554.01

8 01000739

Disc

DIN 125

A13

ST

554.03

2 01000736

Disc

DIN 125

A10,5

ST

554.16

4 01000740

Disc

DIN 125

A13

A4

591

1 00620262

Thermosiphon vessel

00.46.66

638

1 01900534

Constant level oiler with protection cage

ACL 7596 NPT 1/4" ST-VERZINKT/GLAS

655

1 01989802

Handpump

PFH-L/6

691

1 01989268

Manometer 233.30 + alarm sensor 831.1

100MM / 0-25BAR / G1/2


1.4571

692

1 01989502

Bimetal Thermometer

0-160 C, G1/2

695.01

1 01986251

Level switch typ 60-ARV

710.01

1 01036277

Pipe

EN 10305-4

12*1,5*500

1.4571

710.02

2 01036282

Pipe

EN 10305-4

12*1,5*1000

1.4571

710.03

1 01036007

Pipe

EN 10305-4

6*1*1000

1.4571

731.15

2 01914009

Screwing

SS-12MO-1-6 RS

1.4401

731.16

2 01914009

Screwing

SS-12MO-1-6 RS

1.4401

731.23

1 01914037

Screwing

SS-12MO-1-8 RS

1.4401

731.28

2 01914102

Screwing

SS-6MO-1-2 RS

1.4401

731.34

2 01914122

Screwing

SS-12MO-1-4

1.4401

732

1 00619127

Fastener

741.01

1 01986028

Ball valve

741.02

1 01905467

Pressure Gauge Valve

742

1 01905469

Non-return valve

901.01

2 01010038

Hexagon head bolt

DIN 933

901.02

4 01009816

Hexagon head bolt

901.16

2 01010153

Hexagon head bolt

902.01

8 01011329

902.02

8 01011341

902.04

2 01011257

1 handled by
approved

Dimension/Size

Material

63*2

FKM 80

DIN 3760

A30*40*7

VITON

DIN 3760

A30*40*7

VITON

1.4462/SIC/NOPR
32.309

1.4408

1.4571
1.4571
1.4571

2"-VS-L260/12-V52A-EX
1.4571

03.45.31

ST
2*NPT1/4" INNEN

1.4408

G1/2

1.4571

RHD 6-L

1.4571

M10*25

8.8

DIN 933

M6*10

8.8

DIN 933

M12*40

A4-70

Stud

DIN 939

M12*30

8.8

Stud

DIN 939

M12*45

8.8

Stud

DIN 939

M10*65

8.8

Date

Rev.

Drawing/Stand.

DIN 16270

Signature

08.09.14
08.09.14

SCHARF
KONRAD

partslist

Side

PB14201782

Siemensstr. 22,
Postbox 1254,

D-84478 Waldkraiburg
D-84465 Waldkraiburg

Partslist
Part-N

Pcs Ident-No.

Parts name

Drawing/Stand.

Dimension/Size

Material

903.01

1 01003427

Screwed plug

DIN 910

G1/4

ST

903.04

1 01003427

Screwed plug

DIN 910

G1/4

ST

903.17

1 01003436

Screwed plug

DIN 910

G1/2

A4

903.20

1 01003436

Screwed plug

DIN 910

G1/2

A4

903.21

1 01003436

Screwed plug

DIN 910

G1/2

A4

903.26

1 01003436

Screwed plug

DIN 910

G1/2

A4

903.27

1 01003440

Screwed plug

DIN 910

G3/4

A4

904.01

1 01006650

Grub screw

DIN 915

M5*8

A4

904.02

2 01006646

Grub screw

DIN 915

M5*6

A4

904.03

2 01006646

Grub screw

DIN 915

M5*6

A4

913

1 00452734

Vent plug

04.29.92

914.02

3 01017506

Inner hexagon cap screw

DIN 6912

M10*20

8.8

920.01

8 01001877

Hexagon nut

DIN 934

M12

920.02

8 01001877

Hexagon nut

DIN 934

M12

920.05

2 01001872

Hexagon nut

DIN 934

M10

920.16

2 01010981

Hexagon nut

DIN 934

M12

A4

922

1 00442512

Impeller nut

04.28.57

932.01

2 01013057

Circlip

DIN 984

J72*2,5K

FST

932.02

1 01001109

Circlip

DIN 471

A30*1,5

FST

932.04

1 01012997

Circlip

DIN 983

A30*1,5K

FST

940.01

1 00690119

Key

04.60.96

940.02

1 01022549

Key

DIN 6885

Date

Rev.

1 handled by
approved

Signature

08.09.14
08.09.14

SCHARF
KONRAD

ST

C45+C

1.4571
A8*7*36

1.4571

partslist

Side

PB14201782

Spriralgehusepumpe einflutig / Volute casing pump end suction

Baugre / Size 32/210


Drehzahl / Speed n = 1750 1/min
[m]
24,5
24

Frderhhe / Head

210

23,5
23

20%
30%

22,5
22
21,5
21

200

35%
38%
40%

20,5
20
19,5

42%

19
18,5

Eff.
43%

18
17,5

180

17
16,5
16
15,5
15
14,5
14

160

13,5
13
12,5
12

140

11,5
11
10,5
10
9,5

38%

9
8,5
8
7,5
7
6,5
[kW]
1,7

Wellenleistung /Shaft power P2

1,6

210

1,5
1,4
200

1,3
1,2
1,1
1

180

0,9
0,8

160

0,7
0,6

140

0,5
0,4
0,3
0,2
[m]
1,55 NPSH-Werte/values
1,5
1,45
1,4
1,35
1,3
1,25
1,2
1,15
1,1
1,05
1
0,95
0,9
0,85
0,8
0,75
0,7
0,65
0,6
0,55
0

0,5

1,5

2,5

3,5

4,5

5,5

6,5

7,5

8,5

9,5 10 10,5 11 11,5 12 12,5 13 13,5 14 14,5 15 15,5 16 16,5 [m/h]

Dichte / density = 1 kg/dm


kin. Zhigkeit / kin. v iscosity = 1 mm/s
Bei Magnetpumpen Kupplungsv erlustleistung addieren / f or magnetic pumps add. magnetic losses

64.NC.202
Stand / Issue: 22.10.2009

Operating- and Maintenance Instructions for


Shaft Sealing for DICKOW-Chemical Standard Pumps, Series NC

14.NC.246e
page 1/4

Double Metal Bellows Mechanical Seal


Brand DICKOW - Standard design "N13"

1. SECTIONAL DRAWING and PARTS LIST


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88;**
88;**

Issue 11/09
(Rev. 2)

Operating- and Maintenance Instructions for


Shaft Sealing for DICKOW-Chemical Standard Pumps, Series NC

14.NC.246e
page 2/4

2. TECHNICAL SPECIFICATION
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Operating- and Maintenance Instructions for


Shaft Sealing for DICKOW-Chemical Standard Pumps, Series NC

14.NC.246e
page 3/4

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Operating- and Maintenance Instructions for


Shaft Sealing for DICKOW-Chemical Standard Pumps, Series NC

14.NC.246e
page 4/4

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Operation / Installation Instructions


Thermosiphon Vessel

No. 44.TSB.E3.11/13

Original Manual

DICKOW PUMPEN KG

Table of Contents

Table of Contents
Table of Contents ......................................................................................................................................... 2
1. General................................................................................................................................................. 3
2. Safety ................................................................................................................................................... 4
2.1 Designation of Warning Notices .................................................................................................. 4
2.2 Intended use.................................................................................................................................. 5
2.3 Avoidance of foreseeable operating errors ................................................................................... 5
2.4 Qualification of personnel ............................................................................................................ 5
2.5 Additional safety regulations........................................................................................................ 5
2.6 Safety instructions for the operator / user..................................................................................... 6
2.7 Safety instructions for maintenance, inspection and assembly .................................................... 6
2.8 Non-observance of the instruction manual ................................................................................... 6
3. Description........................................................................................................................................... 7
3.1 General description....................................................................................................................... 7
3.2 Construction ................................................................................................................................. 7
3.3 Design Data .................................................................................................................................. 8
3.4 Identification ................................................................................................................................ 8
3.5 Scope of supply ............................................................................................................................ 8
3.6 Dimensions and Weights .............................................................................................................10
4. Handling / Storage / Disposal .............................................................................................................11
4.1 Handling ......................................................................................................................................11
4.2 Storage / Preservation ..................................................................................................................11
4.3 Return shipment ..........................................................................................................................11
4.4 Disposal .......................................................................................................................................12
5. Installation ..........................................................................................................................................13
6. Commissioning ...................................................................................................................................15
6.1Barrier fluid .................................................................................................................................15
6.2 Mechanical seal in Tandem arrangement ....................................................................................16
6.3 Double mechanical seal ...............................................................................................................17
7. Maintenance / Servicing / Inspection .................................................................................................18
7.1 Safety regulations ........................................................................................................................18
7.2 Operating surveillance .................................................................................................................18
8. Hazard analysis ...................................................................................................................................19
8.1 Pressure .......................................................................................................................................19
8.2 Temperature.................................................................................................................................19
8.3 Corrosion .....................................................................................................................................19
8.4 Protective measures .....................................................................................................................20
9. Documentation....................................................................................................................................21
10.Data sheet / Certificate........................................................................................................................22
10.1 Data sheet Thermosiphon Vessel ................................................................................................22
10.2 Type- and Pressure Test Certificate ............................................................................................23
10.3 Declaration of Conformity ..........................................................................................................24

TSB E3 11.13

2 of 24

1. General

1. General
This instruction manual describes the proper and safe usage of the thermosiphon vessel during all
operating phases.
The instruction manual does not consider local regulations. Adherence to those is the responsibility of the
owner.
The name tag states the most important operating data as well as the serial number. The serial number is a
precise description of the system and serves as identification for all following procedures.
In the event of damage the Customer Service of Dickow Pumpen must immediately be informed in order
to maintain guarantee claims.
Applicable documents:
-

Data sheet
Dimensional drawing
Piping plan
Parts list
Sub-supplier documentation

TSB E3 11.13

3 of 24

2. Safety

2. Safety
The manual includes basic instructions for installation, operation and maintenance. Only if these
instructions are strictly observed, a safe handling of the thermosiphon system is guaranteed and personal
injury and material damage is avoided.
All the safety instructions in this manual must be considered.
This manual must be thoroughly reviewed and completely understood by the qualified personnel /
operator before attempting assembly and start-up.
The manual must consistently be available on site.
Indications and plates attached to the thermosiphon vessel must be followed and kept in legible condition.

2.1

Designation of Warning Notices

Signal word

Explanation

DANGER

signifies an imminent danger.


If it will not be avoided, death or severe injury are the consequence.

WARNING

signifies a possibly dangerous situation.


If it will not be avoided, death or severe injury may be the consequence.

CAUTION

signifies a possibly dangerous situation.


If it will not be avoided, slight or minor injury may be the consequence.

ATTENTION

Symbol

signifies a possibly harmful situation.


If it will not be avoided, danger for the thermosiphon vessel and its function may
be the consequence.

Explanation
General danger sign
Together with a signal word, it signifies dangers in connection with death or
injury.
Dangerous voltage
Together with a signal word, it signifies dangers in connection with voltage.

Hot surface
Together with a signal word, it signifies dangers in connection with hot surfaces.

TSB E3 11.13

4 of 24

2. Safety
Explosion protection
Gives information on protection from explosion development in hazardous area
according to EC-Directive 94/9/EG.
System breakdown
Together with the signal word ATTENTION, it signifies dangers for the
thermosiphon vessel and its function.
Notice
Provides recommendation and useful information for handling the product.

2.2

Intended use

The thermosiphon system may only be used for the specified application Any other or additional use
does not constitute intended use.
Operation under conditions beyond the design date is not allowed.

2.3

Avoidance of foreseeable operating errors

Never exceed the allowable application limits regarding pressure and temperature which are specified
in the data sheet.

Consider and adhere to all safety instructions and other notices mentioned in the operating
manual.

Unauthorized rebuilding and alterations of the thermosiphon system are not permitted.

2.4

Qualification of personnel

The personnel must possess the relevant qualification for assembly, operation, maintenance and
inspection of the thermosiphon system.
Responsibility, competence and supervision must be strictly regulated by the owner.
Skill of the personnel shall be improved by training. Training course can be held by the technical staff of
Dickow Pumpen.

2.5

Additional safety regulations

Besides the safety instructions mentioned in this manual, the following additional regulations apply:

Accident prevention regulations


Explosion proof regulations
Safety regulations for handling hazardous materials
Applicable standards and laws

TSB E3 11.13

5 of 24

2. Safety

2.6

Protection against contact with hot and cold components must be provided by customer
Equipment must always be earthed / grounded.
Protectiv equipment for personnel must be provided and used.
Toxic liquid leakage must be drained off safely, without endangering individuals and environment.
Legal requirements must be observed.
Danger through electric energy must be excluded.
Hydrogen must not be used as process fluid.

2.7

Safety instructions for the operator / user

Safety instructions for maintenance, inspection and


assembly

Only original parts or parts approved by Dickow shall be used.


Repairs on the thermosiphon system may only be done during shutdown.
The vessel must have cooled down to ambient temperature.
The vessel must be depressurized and drained.
Works on the thermosiphon system may only be done with disconnected electricity.

2.8

Non-observance of the instruction manual

Non-observance of this manual leads to loss of warranty and damage claims. Non-observance will
involve the following risks:

Endangering of individuals through electrical, thermal, mechanical and chemical impacts.


Danger through explosions.
Danger through breakdown of essential functions.
Endangering of environment through leakage of toxic liquids.

TSB E3 11.13

6 of 24

3. Description

3. Description
3.1

General description

Thermosiphon vessels are used for supplying barrier fluid to double and tandem seal arrangements. They
are used for cooling and act as fluid reservoir. The fluid exchange is effected either through natural
circulation or forced circulation.
Natural circulation
The circulation will adjust itself according to the thermosiphon principle. This means, the heated, specific
lighter liquid rises from the sealing chamber through the piping into the thermosiphon vessel, will cool
down there and sink as the specific heavier liquid back to the sealing chamber.
Forced circulation
In case the natural circulation is insufficient, it can be supported by several circulation devices. This can
be done by a pumping thread or a pumping ring on seal side. If no satisfactorily performance is obtained
therewith, a circulation pump must be integrated into the circuit.
A thermosiphon system is not working independently, but is intended to be assembled with a machine.
According to the Pressure Vessel Guideline 97/23/EU, the thermosiphon vessel is suitable for hazardous
liquids of group 1 and is subject to the Conformity Valuation Procedure of category II. The modules B1
(EU-design test) and C1 (conformity of construction) are chosen.

3.2

Construction

The thermosiphon vessel in standard configuration is provided with all connections and fittings. In order
to increase the cooling effect, an internal cooling coil can be connected.
A large threaded plug in the vessel cover allows easy cleaning of the inside.
The different liquid levels are shown in the drawing.

NLL
LLL
HLL

TSB E3 11.13

=
=
=

Normal filling level


Minimum filling level
Maximum allowable filling level

7 of 24

3. Description

3.3

Design Data

Vessel volume
Max. allowable operating pressure
Max. allowable operating temperature
Min. allowable operating temperature
Test overpressure (20C)
Working volume MAX - MIN
Cooling capacity Natural circulation 1)
Cooling capacity Forced circulation 1)
Required cooling water quantity

3.4

Vessel
Cooling coil
8 litre
0,37 litre
25 bar
40 bar
200C
200C
-60C
-10C
43 bar
60 bar
ca. 1,6 litre
ca. 1,5 kW
ca. 4 kW
ca. 0,4 m3/h

1)

Guide value at barrier


fluid :
Water/60C
Cooling water/20C

Identification

Each thermosiphon vessel is provided with a name tag. The name tag indicates the design data, the serial
number, as well as the CE-marking with the identification number of the named authority (CE 0036).

3.5

Scope of supply

Depending on the design of the thermosiphon system, different monitoring devices and auxiliaries can be
connected.

TSB E3 11.13

8 of 24

3. Description
3.5.1

Gauges

For monitoring of the vessel pressure, a gauge (NG100) with a display range of 0-10 or 0-25 bar can be
used. Material: brass/fibre glass respectively 1.4571.
For constant monitoring, a tube-spring manometer (NG100) according to EN 837-1 with a measuring
range of 0-25 bar, material 1.4571, can be installed together with an inductive limit signal sensor. Details
about safety, installation and wiring are stated in the corresponding operating manual. The pressure
gauges with thread G shall be connected to the upside connection 2.

3.5.2

Thermometer

For monitoring of the operating temperature, a bimetal dial thermometer with connection at the rear and a
thermowell of 1.4571 can be used.
The thermometer with thermowell and thread G shall be connected to the downside connection 5.

3.5.3

Level switch

For constant monitoring of the filling level, a magnetic float switch with reed contact can be used.
Switching operation is performed contactless, wearfree and without auxiliary power.
L1
L2

= LSH = 140 mm =>


= LSL = 210 mm =>

upper switchpoint at rising liquid level


lower switchpoint at falling liquid level

Details about safety, installation and wiring are stated in the corresponding operating manual.
The level switch shall be screwed into the G2-thread
(connection 7) on top of the thermosiphon vessel.
As far as requirements on the functional safety up to SIL 2 acc. to
IEC 61508 / IEC 61511-1 must be met, a vibration limit switch
(Liquiphant) including a filling level evaluator should be applied
instead of a magnetic float switch.

TSB E3 11.13

9 of 24

3. Description
3.5.4

Optoelectronic limit indicator with switching amplifier

For monitoring the filling level in critical service conditions, an optoelectronic limit indicator can limit
the maximum filling level.
The switching amplifier included in scope of supply, must be installed in a safe area and operated
together with the limit indicator.
Details about safety, installation and wiring are stated in the corresponding operating manual.
The limit indicator is to be screwed with the thread G directly into the thermosiphon vessel (connection
10).

3.5.5

Refill unit

Manual refilling during operation in case of barrier fluid loss is possible with a refill unit. This consists of
a reservoir (volume approx. 1 litre) with filler plug and a handpump. The refill unit is mounted near the
thermosiphon vessel.
Pumping capacity is approx. 3,2 cm3/stroke. Discharge pressure depends on the manual force and is
approx. 10 bar. A pressure relief valve is not included.
The refill unit is protected by a check valve between vessel and unit.
The refill unit is not suitable for building up an appropriate barrier pressure for double mechanical seals.

3.5.6

Diaphragm accumulator

For pressurization of double mechanical seals a diaphragm accumulator can be used. This device is
delivered ready for operation. The filling pressure (po) is indicated on the accumulator casing. Prior to
start-up the notes in chapter 6.3 must be observed.
Details about safety, installation and wiring are stated in the corresponding operating manual.
The diaphragm accumulator with connection thread G shall be mounted to the upside connection 11.
When a diaphragm accumulator is used, a refill unit and a pressure gauge with limit switch is additionally
required.

3.6

Dimensions and Weights

Dimensions and weights can be taken from the foundation plan / dimensional drawing.

TSB E3 11.13

10 of 24

4. Handling / Storage / Disposal

4. Handling / Storage / Disposal


4.1

Handling

Use only suitable lifting devices for handling, e.g. hemp rope or coil loops. Do not use any chains or
steel ropes.
Systems mounted to the machine must be lifted in vertical position only.
Protect the thermosiphon system against vibrations.
Handling of gas-filled diaphragm accumulators must be carried out with reasonable care and caution
and in compliance with all safeety regulations.

WARNING

Damage of the diaphragm accumulator


Danger to life through bursting of the accumulator!

4.2

Do not operate with damaged bladder accumulators.

Storage / Preservation

Storage for some weeks or months needs to be on a dry place in a shed, protected against weather and
dust. The thermosiphon system must also here be covered to be protected against dust.

4.3

Return shipment

Drain the vessel properly..


Always attach a document of compliance completely filled in..

NOTE

If required, a Document of Compliance can be downloaded under


www.dickow.de
http://www.dickow.de/unbedenk-en.pdf

TSB E3 11.13

11 of 24

4. Handling / Storage / Disposal

4.4

Disposal

WARNING

Liquids dangerous to health


Danger for individuals and environment!

Collect and dispose rinsing water.


Wear protective clothing and face mask.
Consider the legal regulations for disposal of liquids dangerous to health.

1.

Disassemble themosiphon system.

2.

Collect any liquids.

3.

Separate materials.

4.

Dispose according to the local regulations.

TSB E3 11.13

12 of 24

5. Installation

5. Installation
DANGER

Improper installation in explosive area


Danger of explosion!

DANGER

Consider the local applicable explosion proof regulations.

Improper electrical installation


Danger of explosion!

DANGER

For electrical installation consider additionally IEC 60079.

Incorrect power connection


Danger to life through electric shock!
Electric shock!

ATTENTION

Adhere to connection conditions of local energy supply companies.


Electrical connection must be performed by qualified electrician only.
Consider regulations IEC 30364 und IEC 60079

Impurities in the piping


Damage of mechanical seal!

Piping must be thoroughly cleaned before connecting.

Installation of piping requires observance of the following instructions:

Use stainless steel pipes with large cross section for piping.
Avoid large choking resistances in the pipes (e.g. tight radii of curvature).
Pipes must be laid upwards or downwards as short as possible to prevent air pockets.
The mounting height of the thermosiphon vessel should be 1 to 2 m above shaft axis (at horizontal
arrangement) or above barrier fluid inlet at the mechanical seal casing (at vertical arrangement). If
circulation is effected with pump device, a smaller distance is allowable.
Pipes must be clean and free of scales.
Cooling water pipes leading to the thermosiphon vessel must be installed such that the maximum
operating pressure of the cooling coil will not be exceeded and the regulations applying on site are
maintained. The cooling water flow must be adjustable.
Drain connection is to be provided at the lowest point in the system.
Pipeline fixation with sound-proof pipe clamps spaced in intervals of max. 2 m.

TSB E3 11.13

13 of 24

5. Installation
If the system is working in connection with double mechanical seals, the nitrogen flushing must be
considered.
Withdrawing nitrogen from a gas grid
requires a check valve in the gas pipe leading to the thermosiphon vessel. If the pressure in the gas grid is
too high, a re-controllable pressure regulator is required. The thermosiphon system should be protected by
an additional safety valve.
Withdrawing nitrogen from a bottle
requires a re-controllable regulator.
If the system is working in connection with tandem mechanical seals, a bleeder pipe or overflow pipe
may additionally be required.

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6. Commissioning

6. Commissioning
Prior to start-up check the following::

The thermosiphon system is properly electronically connected with all the monitoring equipment.
The vessel is filled with barrier fluid.
All monitoring devices are functioning.

6.1

Barrier fluid

A proper selection of the barrier fluid is of great importance for a perfect function of the mechanical seal.
The fluid may not have any negative affects on the mechanical seal and the environment. The following
aspects should be considered:

The barrier fluid must be compatible with the product handled.

Do not use any customary antifreezers. The additives of such products will affect the function of
mechanical seals.
Mixtures of water and technically pure propylene glycol (1,2-propandiol) shall be used.
Ethylenglycol as antifreeze is classified as harmful and subject to the classification according to
EU-Hazardous Substances Ordinance.

Do not use any motor-, turbine-, gear- or compressor oil. These oils contain additives which in
fact improve the oil quality, but lead to sediments between the sliding faces of mechanical seals,
the so called plating and consequently cause increasing leakage.
Light lube oils of viscosity class ISO VG 5 should be preferred. Good experiences are available
with the following oils:
- Shell Morlina 5
- Aral Vitam AC
- Klber Paraliq 12, Summit or alfa
- OMV Sealfluid SH2

The autoignition temperature of the barrier fluid should be at least 50K above the maximum
operating temperature of the pump.

The temperature of the barrier fluid must be certain below the atmospheric boiling point (20K).

Water used as quench fluid is in many cases an appropriate supply medium.


This however should only be used if it is compatible with the product and adverse reactions are
excluded.
Demineralized or distilled water should be preferred. Though, problems may occur with
hard/hard-pairing and highly stressed mechanical seals due to poor lubrication properties. This
necessarily requires consultation of the factory.

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6. Commissioning

Following conditions must be maintained:


-The temperature at the seal outlet must not exceed 60C.
- The water may not contain any solids and not tend to sedimentation.
- Conductivity between 25-250 S/cm
- Water hardness 100 ppm CaCO3 (5,6dH)
- Chloride content < 250 ppm
- pH-value between 6,5 7,5

If ambient conditions are below the freezing point, low-temperature resistant barrier fluids shall
be used, preferably the alcohols ethanol or propanol. Both substances however are covered by
TA-Luft due to their high vapour pressure. Connection with air can easily form ignitable
mixtures. Alternatively, thermal oils suitable for low temperatures, e.g. Sylterm XLT, can be
used.

White oils are high quality lubricants. They are synthesized from paraffin oils and therefore
excellently suitable as barrier fluid. However, the maximum temperature is limited to 60C.

In general, we recommend to use the following barrier fluids:


Medium
Water/Propylene glycol
Light lube oil (OMV SH2 )
Propanol
Thermal oil, e.g. Syltherm XLT

6.2

Viscosity in cSt at
40C
12
5
1
5

Operating temperature C
Minimum
Maximum
-20
80
20
150
-40
20
-40
200

Mechanical seal in Tandem arrangement

Each start-up must be performed in following steps:

Filling of the thermosiphon vessel with clean barrier fluid up to the middle of sight glass (NLL).
Filling can be done through the filling hole provided on the vessel.
The filling level is mostly monitored by means of level switch with MIN-(LLL) and MAXContact (HLL). The MAX-contact is not aopplicable at the operating method with bleeder pipe or
overflow pipe.
Opening of the cooling water pipe respectively adjustment of the flow rate.

After initiation of the thermosiphon system, the respective mechanical seal may be loaded product side
and the pump can be started.

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6. Commissioning

6.3

Double mechanical seal

Each start-up must be performed in following steps:

Filling of the thermosiphon vessel with clean barrier fluid up to the middle of sight glass (NLL).
Filling can be done through the filling hole provided on the vessel or by a hand-refill pump.
The filling level is monitored by means of level switch with MIN-contact.
The barrier pressure is to be set in constant height approx. 10% but at least 2 bar above the
highest appearing operating pressure of the mechanical seal. At pressure variations, a sufficient
safety distance must be available.
Opening of the cooling water pipe respectively adjustment of the flow rate.

After initiation of the thermosiphon system, the respective mechanical seal may be loaded product side
and the pump can be started.

When using a diaphragm accumulator, proceed as follows:

The diaphragm accumulator is delivered with the filling pressure as stated on the name tag and is
mounted to the thermosiphon vessel.
Open one of the overhead screw connections on the vessel and fill in the barrier fluid slowly until
liquid emerges.
Plug the screw connection and continue the filling with the refill unit until the maximum barrier
pressure is reached.
Vent the thermosiphon system repeatedly during filling.
The maximum barrier pressure can be taken from documentation, data sheet or dimensional
drawing.

CAUTION

Leakage of barrier fluid


Danger for individuals and environment!

TSB E3 11.13

Retighten screw plugs on fluid and gas sides.

17 of 24

7. Maintenance / Servicing / Inspection

7. Maintenance / Servicing / Inspection


7.1

Safety regulations

DANGER

Improper stressrelief at double mechanical seals


Fire hazard! Risk of injury!

7.2

For stressrelief take safeguard measures for individuals and environment.

Operating surveillance

The thermosiphon system does not require routine maintenance. However, regular inspections in order to
control liquid level, pressure and temperature should take place.
The entire equipment shall be examined half-yearly on leaks, loosened piping anchorage or other
damages.

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8. Hazard analysis

8. Hazard analysis
8.1

Pressure

Allowable internal pressure:


Static pressure:

25 bar
yes

Hazards: The pressure can cause bursting of the pressure vessel if inadmissible operating conditions
occur. The fluid may be toxic, corrosive or otherwise harmful or hazardous. If the fluid escapes into the
environment, the physical state of the fluid may change if the evaporation point is exceeded. Depending
on the fluid, harmful or hazardous vapours may form in the ambient atmosphere. Inhaling the vapours or
contact with the fluid may result in injuries. Emerging fluid can cause fire hazard or explosion.

8.2

Temperature

Allowable temperature min.:

- 60C

Hazards: Contact with emerging fluid can cause burnlike injuries. If the fluid escapes into the
environment, the physical state of the fluid may change when the evaporation point is exceeded. Toxic,
corrosive or otherwise harmful or hazardous vapours may form. Due to the change in physical state from
liquid to gaseous, the volume of escaping fluid changes also. The fluid mixes with the atmosphere.
Inhaling the vapours or contact with the fluid can result in injuries.

Allowable temperature max.:

+ 200C

Hazards: Contact with the fluid will cause burns. If the fluid escapes into the environment, the physical
state of the fluid may change if the evaporation point is exceeded. Hot, toxic, corrosive or otherwise
harmful or hazardous vapours may form. Due to the change in physical state from liquid to gaseous, the
volume of escaping fluid changes also. The fluid mixes with the atmosphere. Inhaling the vapours or
contact with the fluid can result in injuries. Emerging fluid can cause fire hazard or explosion.

8.3

Corrosion

Outside:

Hazards: Aggressive fluids such as chlorides in the environment can lead to corrosion. Condensate may
occur on the surface and leads in conjunction with the fluids from environment to corrosion of the
surface.

Inside:

Hazards: Aggressiv buffer fluids in connection with adverse operating temperatures may attack the
material and lead to corrosion. The buffer fluid may also contain sealing fluid and therefore have a highly
corrosive effect.

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8. Hazard analysis

8.4

Protective measures

The following protective measures have been taken in order to eliminate or to exclude the hazards
mentioned before as far as possible.

8.4.1 Application of suitable materials

Basic materials according to the Pressure Vessel Guideline and the AD-2000 Legislation, suitable
for the service conditions.
Application of proof tested and admitted welding filler materials.
Sealing materials are suitable for pressure, temperature and medium.
Sight glasses are according to manufacturers statement suitable for pressure, temperature and
medium.

8.4.2 Design and construction

Applied legislations are the Pressure Vessel Guideline and the AD-2000 Legislation.
Extensive references on applications with proven design are available.
Use of CrNiMo-steel with austenitic structure is possible on customers request.
Information on pressure- and temperature limitation included in the instruction manual.

8.4.3 Manufacture and inspection

Welding procedure with auditing of procedures according to AD-2000 HP 2/1.


Manufacturer Qualification according to ISO 9001.
Welder and welder supervisors with qualification according to AD-2000 HP3.
Qualification of the staff for manufacture, assembly and testing according to Dickow-QMSystem, complying with ISO 9001.
Manufacturing tolerances according to AD-2000 HP1 and details hereof indicated in the shop
drawings.
Utilisation of the allowable stress in the welded joint 85%.
Final inspection on each vessel according to AD-2000 Legislation, series HP.

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9. Documentation

9. Documentation
The following papers are always part of the documentation for thermosiphon systems:
1.
2.
3.
4.
5.
6.

Operating manual for thermosiphon vessel


Operating manual for the installed monitoring and safety devices
Type- and pressure test certificate
Inspection certificate 3.1 according to DIN EN 10204 for the used materials
Data sheet for thermosiphon vessel
Declaration of conformity according to Pressure Vessel Guideline 97/23/EG

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10. Data Sheet / Certificate

10. Data sheet / Certificate


10.1 Data sheet Thermosiphon Vessel
Data sheet - THERMOSIPHON VESSEL
Design data:

Volume: 8 litre

Pressure: max. 25 bar

Temperature: max. 200C

P.O. No.:

Item No.:

Customer:

Pump serial No.:

Pump type:

Design:

without cooling coil

23.TSB.1

46.66

with cooling coil

23.TSB.1

46.70

St
1.4571
St
1.4571

Mark the required accessories and material

1
Plastic/Ms
1.4571
Plastic/Ms
1.4571

G 1/2

411.17; 903.17

G 1/2

411.18/19
691
741.2
903.18

1.4571

1.4571

TS003/03.20

G 1/2
G 1/2

G 1/2

G 1/2

G2

8
9
10
11

G 3/8
G 3/8
G 1/2
G 3/4

12

G 1/8

13
14

G 1/2
G 1/2

1.4571

--St/FKM
St
1.4571

3
4

411.20 / 903.20
411.21 / 903.21
411.22 / 903.22 692
411.23; 710.1 731.23; 731.34
741.1
412.24
695.1
903.24
54.VP.1
54.VP.1
411.26; 903.26; 695.3
411.27; 903.27; 595
411.28; 903.28 655 / 742
731.28 / 710.3

Pressure gas connection


Pressure gauge 0 10 bar, 100
Pressure gauge 0 25 bar, 100
Manometer Type 233.30 NG 100, 0-25 bar; chemical design; max. 100C;
EN-837-1 with inductive limit signal sensor Type 831.1
Universal connection
Filling
Thermometer Typ A5400; 0-160C; connection on reverse side;
with thermowell 10x63 lg.
Drain; valve
Float switch Typ 60-ARV2-VS-L260/12-V52A-Ex
L1 = LSH = 140mm; upper switchpoint at rising liquid level (plan 52)
L2 = LSH = 210mm; lower switchpoint at falling liquid level (plan 52/53)
Supply circulation
Return circulation
Optoelectronic level detector 720.211.30000.0660
Diaphragm accumulator Type 0,32-210 filling pressure p =
Refill unit including check valve
Cooling water outlet
Cooling water inlet

Documentation:

Inspection Certificate 3.1 acc. to EN 10204


Type- and Pressure Test Certificate for pressure vessels
I.O.M Manual for thermosiphon vessel and monitoring- resp. safety devices
Declaration of Conformity acc. to. Pressure Vessel Guideline

Comment:

According to Pressure Vessel Guideline 97/23/EG, the thermosiphon vessel is suitable for
hazardous liquids of group 1 and is subject to the Conformity Valuation Procedure of category
II. The modules B1 and C1 are chosen.
issued (date / signature)

TSB E3 11.13

techn.verified by (date / signature)

22 of 24

10. Data sheet / Certificate

10.2 Type- and Pressure Test Certificate


Bescheinigung ber die Bau- und Druckprfung von
Druckbehlter
Certificate on the inspection of construction and pressure testing of pressure vessel
Besteller:
Customer:

Best.-Nr.:
Order-No.:

Gegenstand:
Equipment:

Thermosiphonbehlter mit Khlschlange


Thermosiphon vessel with cooling coil

Hersteller:
Manufacturer:

Dickow Pumpen KG

Zeichnungs-Nr.:
Drawing-No.:
Anforderungen:
Requirements:

Best.-Datum:
Order Date:

Pumpen-Seriennr.:
Pump Serial No.:
Druckgerterichtlinie 97/23/EG Kategorie II
Pressure vessel guideline 97/23/EG Category II

Fabr.-Nr.:
Ser.-No.:

Modul / Module B1+C1


Baujahr:
Year of fabr.:

Raum, druckbeaufschlagt / Pressure vessel


Behlter / Vessel
Khlschlange / Cooling Coil

Auslegungsdaten
Design Data
Max. zulssiger Betriebsdruck
Max. Operating pressure [bar]

25

40

Inhalt
Volume [L]

0,37

Zulssige Betriebstemperatur [C]


Allowable Operating Temperature

200

200

Prfberdruck bei 20C


Test Pressure at 20C [bar]

43

60

Prfgrundlage:
Test conditions:

AD-Merkblatt 2000

Es wurde eine Wasserdruckprfung durchgefhrt: ohne Befund


Standzeit:
30 min
A hydrostatic pressure test was carried out: without failure
Test time:
Prfung der Kennzeichnung: ohne
Sichtprfung: ohne Beanstandungen
Makontrolle (Stichproben): ohne Beanstandung
Beanstandung
Visual inspection: without failure
Dimension check (random test): without failure
Inspection of marking: without failure
Ergebnis der Prfungen:
Die gestellten Anforderungen sind erfllt.
Prfstempel:
D1
Test results: o.k.
According to requirements.
Test stamp:

Der Druckbehlter stimmt hinsichtlich Werkstoffen, Abmessungen und Herstellung, insbesondere den Fgeverfahren mit den auf der
Zeichnung festgelegten Vorgaben berein. Fr die in der Zeichnung angegebenen Werkstoffe liegen Bescheinigungen ber
Werkstoffprfungen vor.
The pressure vessel corresponds to the requirements of the drawing in respect to materials, dimensions and manufacture, especially the
welding procedure. Material test certificates for the materials specified are available.

Waldkraiburg, den
___________________________
Abnahmebeauftragter
Authorised Inspection Representative

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10. Data sheet / Certificate

10.3 Declaration of Conformity


Declaration of Conformity
acc. to Directive 97/23/EG
for a pressure equipment

The manufacturer
Dickow Pumpen KG
Siemensstr. 22
84478 Waldkraiburg
herewith declares that thepressure equipment
Description:

Thermosiphon vessel 46.66 / 70

Serial No.:
max. allowable pressure PS:

25

bar

allowable min/max temperature TS:

-60 to +200

Volume V:

Year of manufacture:
Test pressure PT:
Test fluid:

bar
Water

corresponds with the Pressure Equipment Directive 97/23/EC


Applied conformity
assessment procedures:

Modul B1 + C1

Applied standards and technical


specifications

AD 2000, DIN EN 287-1

Other applied EC-Directives:

non

Engaged notified bodies:


Surveillance of the QS-System:
Examination / inspections / test
during manufacture
Certificates which are included:

./.
TV Industrie Service GmbH

EC-Design Examination Certificate No.:

P-IS-DD1-TRT-05-01-531-001-Z004666

EC-Declaration of Conformity No.:

P-IS-DD1-TRT-05-01-531-01

EC-Type Examination Certificate No.:

./.

Location, Date:
Waldkraiburg,
Signature

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Operating
instructions

GB

Pressure gauge model 2 NS 63


per directive 94/9/EC (ATEX)
II 2 GD c TX

Contents
1. Safety
2. Description
3. Specifications and intended use
4. Commissioning
5. Maintenance and cleaning
Appendix 1: Declaration of conformity
formodels 23x.50/53.063 and 23x.30.063

Declarations of conformity see www.wika.de.


2094366.05 01/2011 GB/D

Specifications: see data sheet on www.wika.de


Subject to technical modifications.
2010 WIKA Alexander Wiegand SE & Co. KG

WIKA Alexander Wiegand SE & Co. KG


Alexander-Wiegand-Strae 30
63911 Klingenberg Germany
Tel.
(+49) 9372/132-0
Fax
(+49) 9372/132-406
E-Mail info@wika.de
www.wika.de

1. Safety
WARNING!
Before installation, commissioning and operation, ensure that the appropriate
pressure gauge has been selected in terms of measuring range, design and
specific measuring conditions.
The compatibility of the materials under pressure with the medium must be checked!
In order to guarantee the measuring accuracy and long-term stability specified, the
corresponding load limits must be observed.
Serious injuries and/or damage can occur should these not be observed.
Only qualified persons authorised by the plant manager are permitted to install,
maintain and service the pressure gauges.

2. Description
Nominal size 63 mm
The gauges measure the pressure by means of resilient bourdon tube pressure
elements
The measuring characteristics are in accordance with EN 837-1 standard
In addition, the enclosing and the pressurised components of models 23x.30 also meet
the requirements of this standard, relating to safety pressure gauges with a solid baffle
wall (code S3).

3. Specifications and intended use


Pressure limitation
Model 23x.50/53:
Steady:
3/4 full scale value
Fluctuating: 2/3 full scale value
Short time: full scale value

Model 23x.30:
Steady:
full scale value
Fluctuating: 0.9 full scale value
Short time: 1.1 full scale value

Mechanical connection
In accordance with the general technical regulations for pressure gauges (i.e. EN 837-2
"Selection and installation recommendations for pressure gauges").
When screwing gauges in, the force
required for this must not be applied
through the case, but rather through the
spanner flats (using a suitable tool) provided for this purpose on the square shaft of
standard connections.

Installation with
spanner

Correct sealing of pressure gauge connections with parallel threads must be made
using suitable sealing rings, sealing washers or WIKA profile seals. The sealing of tapered
threads (e.g. NPT threads) is made by providing the thread , with additional sealing
material such as, for example, PTFE tape (EN 837-2).
Spanner flats
Sealing face

Sealing by
the thread

The torque depends on the seal used. Connecting the gauge using a clamp socket or a
union nut is recommended, so that it is easier to orientate the gauge correctly.
When a blow-out device is fitted to a pressure gauge, it must be protected against being
blocked by debris and dirt. With safety pressure gauges (see dial symbol k) it must be
ensured that the free space behind the blow-out back is at least 15 mm.
After mounting, set the compensating valve (if available) from
CLOSE to OPEN.
Temperature effect
When the temperature of the measuring system deviates from
the reference temperature (+20 C): max. 0.4 %/10 K of full scale value
IP Ingress protection
Enclosing case IP 65 (EN 60529 / IEC 529)
Operating temperature
Ambient: Model 232 -40 ... +60 C

Model 233 -20 ... +60 C
Medium: The permissible medium temperature does not only depend on the instrument
design, but also on the ignition temperature of the surrounding gases, vapours
or dust. Both aspects have to be taken into account. For permissible maximum
medium temperatures see table 1

Attention! In the case of gaseous substances, the temperature may increase due to
compression warming. In these cases it may be necessary to throttle the rate of change
of pressure or reduce the permissible medium temperature.
Table 1: Permissible medium temperature
Temperature class of the ambient
atmosphere (ignition temperature)

T6
T5
T4
T3
T2
T1

(85 C < T 100 C)


(100 C < T 135 C)
(135 C < T 200 C)
(200 C < T 300 C)
(300 C < T 450 C)
(T > 450 C)

Maximum permissible medium temperature (in


the measuring system)
Models 232
(dry gauges)
+70 C
+85 C
+120 C
+185 C
+200 C
+200 C

Models 233
(liquid-filled gauges)
+70 C
+85 C
+100 C
+100 C
+100 C
+100 C

The effective maximum surface temperature is not only dependant upon these instruments,
but mainly on the respective medium temperature!

Materials
Wetted parts:
Movement:
Dial and pointer:
Case, bezel ring:
Window:

Stainless steel
Stainless steel
Aluminium
Stainless steel (model 23x.30: with blow-out back)
Laminated safety glass

Installation
Nominal position per EN 837-1 / 9.6.7 figure 9: 90 ( )
Process connection lower mount (LM) or back mount (BM)
In order to avoid any additional heating, the instruments must not be exposed to direct
solar irradiation while in operation!
Pressure gauges must be earthed via the process connection!
Permissible ambient and operating temperatures
When mounting the pressure gauge it must be ensured that, taking into consideration the
influence of convection and heat radiation, no deviation above or below the permissible
ambient and medium temperatures can occur. The influence of temperature on the display
accuracy must be observed.

Permissible vibration load at the installation site


The instruments should always be installed in locations free from vibration.
If necessary, it is possible to isolate the instrument from the mounting point by installing a flexible connection line between the measuring point and the pressure gauge and
mounting the instrument on a suitable bracket.
If this is not possible, the following limit values must not be exceeded:
Dry gauges:
Frequency range < 150 Hz
(Model 232)
Acceleration < 0.7 g (7 m/s2)
Liquid-filled gauges: Frequency range < 150 Hz
(Model 233)
Acceleration < 4 g (40 m/s2)
The liquid filling must be checked on a regular basis.
The liquid level must not drop below 75 % of the gauge diameter.

4. Commissioning
During the commissioning process pressure surges must be avoided at all costs. Open the
shut-off valves slowly.

5. Maintenance and cleaning


The instruments are maintenance-free.
The indicator and switching function should be checked once or twice every year. The
gauge must be disconnected from the process to check with a pressure testing device.
Clean the pressure gauge with a moist cloth.
Repairs must only be carried out by the manufacturer or appropriately qualified skilled
personnel.
When dismounting, close the compensating valve (if available).
WARNING!
Residual media in dismounted pressure gauges can result in a risk to persons,
the environment and equipment.
Take sufficient precautionary measures.

Appendix 1: Declaration of conformity

Mechanical
temperature measurement

Bimetal thermometer
Model 54, industrial series
WIKA data sheet TM 54.01
for further approvals
see page 6

Applications
General process instrumentation in the chemical and

petrochemical industries, oil and gas industries, energy


and water/wastewater industries
Temperature measurement in harsh and aggressive
environments
With liquid damping also suitable for applications with high
vibrations

Special features
Application range from -70 ... +500 C
Case and stem from stainless steel

Bimetal with zero point adjustment at the back of the case


Individual stem length from 63 ... 1,000 mm
Germanischer Lloyd approval (option)

Description
The model 54 bimetal thermometer has been developed and
is manufactured in accordance with the EN13190 standard.
The thermometer meets the high requirements of the process
industries.
Especially in the chemical and petrochemical, oil and
gas, power engineering and shipbuilding industries, the
temperature measuring instrument manufactured from
stainless steel is used successfully. Through the high ingress
protection of the thermometer (IP65) and its liquid damping,
operation under high vibration conditions is possible.

Fig. left: bimetal thermometer model A5402


Fig. right: bimetal thermometer, adjustable stem and
dial version model S5412

The model 54 satisfies the high requirements for resistance


against aggressive media. As an option, the casing, the
stem and the process connection can be made from
316Ti(1.4571).
To allow optimum fitting to the process, individual insertion
lengths and different process connections can be selected.
WIKA data sheet TM 54.01 05/2014

Page 1 of 6

Standard version
Measuring element
Bimetal coil

Permissible operating pressure at the stem


max. 25 bar, static

Nominal size in mm
63, 80, 100, 160

Permissible ambient temperature at case


-20 ... +60 C (others on request)

Connection designs
S Standard (male thread connection) 1)
1 Plain stem (without thread)
2 Male nut
3 Union nut
4 Compression fitting (sliding on stem)
5 Union nut with fitting

Temperature limits for storage and transport


-20 ... +60 C (EN 13190)

1) Not for version adjustable stem and dial

Model overview
Model
A5400
A5401
A5402
A5403
R5440
R5441
R5442
R5443
S5410
S5411
S5412
S5413

NS

63
80
100
160
63
80
100
160
63
80
100
160

Design

Ingress protection
IP 65 per EN 60529 / IEC 529

Options
Scale range F, C/F (dual scale)
Liquid damping up to max. 250 C (at the sensor)

Back mount (axial)

GL approval in connection with liquid damping, not with

Lower mount (radial)

Back mount, adjustable stem and dial

Accuracy class
Class 1 per EN 13190

adjustable stem and dial design or NS160, vibration


loading 25 ... 200 Hz, 5 g (for further information see
certificate No. 40156-01 HH)
Laminated safety glass, polycarbonate
Stem diameter 6, 10 mm
Ingress protection IP 66
Thermometer with electrical output signal (data sheet
TV15.01)
Special measuring ranges or dial printing to customer
specifications (on request)
Version per ATEX Ex II 2 GD c TX, see marking on the
instrument

Working range
Normal (1 year):
Measuring range (EN 13190)
Short time (24 h max.): Scale range (EN 13190)
Case, ring
Stainless steel 1.4301 (304)
Stem, process connection
Stainless steel 1.4571 (316Ti)
Elbow behind the case
Aluminium, only with lower mount version
Dial
Aluminium, white, black lettering
Window
Instrument glass
Pointer
Aluminium, black, adjustable pointer
Insertion length L1
63 ... 1,000 mm
minimum/maximum length is dependent on the measuring
range and diameter

Page 2 of 6

WIKA data sheet TM 54.01 05/2014

Scale ranges, measuring ranges 1), error limits (EN 13190)


Scale graduation per WIKA standard
Measuring range 1)
in C

Scale range
in C

Scale spacing
in C

-20 ... +40


-10 ... +50
10 ... 50
10 ... 70
10 ... 90
10 ... 110
20 ... 140
20 ... 180
30 ... 220
30 ... 270
50 ... 350
50 ... 450

-30 ... +50


-20 ... +60
0 ... 60
0 ... 80
0 ... 100
0 ... 120
0 ... 160
0 ... 200
0 ... 250
0 ... 300
0 ... 400
0 ... 500

1
1
1
1
1
2
2
2
2
2
5
5

Error limit
C
1
1
1
1
1
2
2
2
2.5
5
5
5

1) The measuring range is indicated on the dial by two triangular marks. Only within this range is the stated error limit valid per EN 13190.

Connection designs
3073050.05

Design standard (male thread connection) 1)


Standard insertion length l1 = 100, 160, 200, 250 mm

Nominal size Process connection Dimensions in mm


NS

63, 80, 100, 160 G B


GB
NPT
NPT

SW

14
16
19
20

27
32
22
30

d4

26
32
-

8
8
8
8

1) Not for version adjustable stem and dial

Legend:
G
Male thread
i
Thread length
d4 Diameter of the sealing
collar

SW
d
l2

Spanner width
Stem diameter
active length

Legend:
a
Distance to the case/articulated joint
d1 Plain diameter

d
l2

Stem diameter
active length

Legend:
G
Male thread
i
Thread length incl. collar
SW Spanner width

d Stem diameter
l2
active length

3073050.05

Design 1, plain stem (without thread)


Standard insertion lengths I1 = 100, 140, 160, 200, 240, 290 mm
Basis for design 4, compression fitting
Nominal size Dimensions in mm
NS

d1

63, 80, 100, 160 18

d
8

a for
axial
15

a for
adjustable stem and dial
25

3073050.05

Design 2, male nut


Standard insertion length l1 = 140, 180, 230 mm

Nominal size Process connection Dimensions in mm


NS

63, 80, 100, 160 G B


M18 x 1.5

20
12

WIKA data sheet TM 54.01 05/2014

SW
27
24

d
8
8

Page 3 of 6

3073050.05

Design 3, union nut


Standard insertion length l1 = 126, 186, 226, 276 mm

Nominal size Process connection Dimensions in mm


NS

G1

63, 80, 100, 160 G


G
M20 x 1.5

8.5
10.5
13.5

SW

27
32
32

8
8
8

Legend:
G1 Female thread
i
Thread length
SW Spanner width

d Stem diameter
l2
active length

3073050.05

Design 4, compression fitting (sliding on stem)


Insertion length l1 = variable
Length L = l1 + 40 mm

Nominal size Process connection Dimensions in mm


NS

63, 80, 100, 160 G B


GB
NPT
NPT

14
16
19
20

SW
27
32
22
30

d4

26
32
-

d
8
8
8
8

Sealing ring

Legend:
G
Male thread
i
Thread length
d4 Diameter of the sealing
collar

SW Spanner width
d Stem diameter
l2
active length

Legend:
G
Male thread
i
Thread length
d4 Diameter of the sealing
collar

SW Spanner width
d Stem diameter
active length
l2

3073050.05

Design 5, union nut and fitting


Standard insertion length l1 = 100, 160, 200, 250 mm

Nominal size Process connection Dimensions in mm


NS

63, 80, 100, 160 G B


GB
NPT
NPT

Page 4 of 6

14
16
19
20

SW
27
32
22
30

d4

26
32
-

d
8
8
8
8

WIKA data sheet TM 54.01 05/2014

Dimensions in mm

NS
63
80
100
160

Dimensions in mm

20
20
22
25

b1 1)
35
35
37
40

b2
38
38
40
43

Lower mount (radial)

68
77
107
161

d4

8 2)
8 2)
8 2)
8 2)

F 1)

26
26
26
26

47
56
66
96

1) With scale ranges 0 ... 300 C the dimensions increase by 40 mm


2) Option: Stem 6, 10 mm

R
U

Dimensions in mm

63
80
100
160

20
20
22
25

b3

63
63
65
68

Weight in kg

0.20
0.25
0.35
0.50

0.30
0.35
0.45
0.60

Back mount (BM)


Lower mount (LM)

3280854.01

Adjustable stem and dial version

NS

3280919.01

3280897.01

Back mount (axial)

68
77
107
161

8 1)
8 1)
8 1)
8 1)

66
66
66
66

Weight
in kg
0.35
0.40
0.50
0.65

1) Option: Stem 6, 10 mm

WIKA data sheet TM 54.01 05/2014

Page 5 of 6

Thermowell

CE conformity

In principle, the operation of a mechanical thermometer


without a thermowell with low process-side loading (low
pressure, low viscosity and low flow velocities) is possible.

ATEX directive (option)


94/9/EC, II 2 GD c TX

However, in order to enable exchanging the thermometer


during operation (e.g. instrument replacement or calibration)
and to ensure a better protection of the instrument and
also the plant and the environment, it is advisable to use a
thermowell from the extensive WIKA thermowell portfolio.
For further information on the calculation for the thermowell,
see Technical information IN 00.15.

Approvals (option)
GOST-R, import certificate, Russia

GOST, metrology/measurement technology, Russia


GL, ships, shipbuilding (e.g. offshore), Germany

CRN, safety (e.g. electr. safety, overpressure, ...), Canada

Certificates (option)
2.2 test report

3.1 inspection certificate

DKD/DAkkS calibration certificate

Approvals and certificates, see website

Ordering information
Model / Nominal size / Scale range / Connection design / Connector size / Insertion length l1 / Options

Page 6 of 6

WIKA data sheet TM 54.01 05/2014

WIKA Alexander Wiegand SE & Co. KG


Alexander-Wiegand-Strae 30
63911 Klingenberg/Germany
Tel.
+49 9372 132-0
Fax
+49 9372 132-406
info@wika.de
www.wika.de

05/2014 GB

2008 WIKA Alexander Wiegand SE & Co. KG, all rights reserved.
The specifications given in this document represent the state of engineering at the time of publishing.
We reserve the right to make modifications to the specifications and materials.

Operating Instructions
Betriebsanleitung

Bimetal Thermometers

GB

Bimetall-Thermometer

also per directive


auch nach Richtlinie

94/9/EG (ATEX)

Examples

GB Operating instructions Bimetal thermometers Page 3-28

Seite 29-54

12968065 11/2008 GB/D

D Betriebsanleitung Bimetall-Thermometer

Contents

Contents
1.

General information

2.

Transport and storage

3.

Safety instructions

4.

Installation conditions and installation

5.

Troubleshooting Measures

6.

Indicator check

7.

Indicator correction

8.

Electrical alarm contacts

9.

Explosion protection

10.

Maintenance and servicing / cleaning

10

11.

Repairs

11

12.

Disposal

11

Enclosure 1: Declaration of conformity for Model 53 without contacts

12

Enclosure 2: Declaration of conformity for Model 54 without contacts

13

Enclosure 3: Declaration of conformity for Model 55 without contacts

14

Enclosure 4: Declaration of conformity for Model 55 without alarm


contacts Model 831

15

Enclosure 5: EC prototype test certificate (Ex certificate for gases)


for slot-type initiators of types SJ (WIKA Model 831)

16-18

Enclosure 6: EC prototype test certificate (Ex certificate for gases)


for SN sensors of types SJ (WIKA Model 831 SN / S1N)

19-22

Enclosure 7: EC prototype test certificate (Ex certificate for dusts) for


proximity sensors of types SJ (WIKA Model 831 and 831 SN / S1N)

23-27

12968065 11/2008 GB/D

Information
This symbol provides you with information, notes and tips.

Warning!
This symbol warns you against actions that can cause injury to
people or damage to the instrument.

WIKA Operating instructions Bimetal thermometers

GB

1. General information / ... / 4. Installation conditions and installation


1. General information
Please read these operating instructions before commissioning
the thermometer.

GB

These operating instructions contain information on mounting, commissioning and maintenance. Besides these operating instructions you
should also observe existing standards, supplementary technical data,
specifications on the type plate and, if necessary, additional certificates.
Designated use: The bimetal thermometer is used mostly in the process
industry to monitor and control the temperature of the process.

2. Transport and storage


The thermometers must be kept dry and clean during storage and transportation. Avoid shocks and vibrations. Protect the thermometers from direct sunlight,
dust, insects, humidity and other aggressive atmospheres. We recommend
that, for temperatures around the dew point (1 C around 0 C), you always
use liquid damping. The packaging material is transparent in order to prevent
any enclosed accessories getting lost.
Permissible storage temperature: -20 C +60 C

3. Safety instructions
The appropriate national safety regulations (i.e. VDE 0100 / EN 60
079-14 / 837-2) must be observed when installing, commissioning
and operating these devices.

4. Installation conditions and installation


Before installation ensure that all the necessary accessories needed for the
mounting method have been delivered. The accessories will be either on the
instrument or supplied in a separate bag, which in most cases will be attached
to the thermometer.

WIKA Operating instructions Bimetal thermometers

12968065 11/2008 GB/D

Do not work on gauges with alarm contacts unless the power has been
isolated.
Serious injury and/or damage can occur if the appropriate regulations are not
observed.
Only appropriately qualified personnel should work on these instruments.

4. Installation conditions and installation

GB

Installation using
a spanner

When mounting a rotatable and inclinable bimetal thermometer, specific


instructions must be followed. In order to set the indicator to the desired position, the following steps must be taken:
1. The lock nut or union nut must be loosened at the process connection.
2. The hexagon bolts and slotted screws at the swivel joint must be loosened.
loosen
Make sure to loosen the screws
on the opposite side as well!

3. Position the indicator as required, tighten the hexagon bolts and slotted
screws, and finally tighten the lock nut or union nut firmly.
If a thermowell is used, the stem must not be allowed to touch the bottom of
the thermowell.

12968065 11/2008 GB/D

Ambient conditions
Thermometers that do not meet with case ingress protection (IP 65) must be
protected from humidity and other aggressive atmospheres.
Observe the following points during sensor installation:
If possible, the whole length of the sensor should be exposed to the temperature to be measured.
In pipelines or other measuring points the temperature probe should be
directed as far towards the flow as possible.
When using thermowells they must be filled with a thermal contact medium
in order to reduce the heat transfer resistance between the outer wall of the
sensor and the inner wall of the thermowell. The working temperature of the
thermal compound is -40 C to +200 C.

WIKA Operating instructions Bimetal thermometers

4. Installation conditions and installation / ... / 6. Indicator check


For filled devices, ensure that the medium temperature remains below 250 C.
The reason: At temperatures over 250 C, the filling fluid in the stem can cloud
or change colour and, in some cases, catch fire.
Before installing the probe, check whether the probe material used (speciGB
fied in the delivery note) is chemically resistant/neutral to the medium being
measured. This also applies to thermowells.
Heat conduction errors occur when the size, volume or area of the medium
to be measured is very small, so that the temperature probe becomes
noticeable as a thermal mass. Heat conduction errors may also occur when
the insertion length is not sufficient, or when the instrument mounting fittings
are attached to a good heat conductor (e.g. metal plates) and the temperature difference between them and the medium to be measured is very high.
Attention!
Do not fill hot thermowells. There is a danger that the oil may spurt out!

5. Troubleshooting measures
Bimetal thermometers, both with and without contacts, are maintenance-free
instruments according to their basic design. As measuring instruments, their
measuring accuracy should be checked at application-specific intervals. The
wear condition of probes exposed to a permanent thermal stress (even if this
stress is very low), and of electro-mechanical contacts exposed to vibratory
stress, must be checked from time to time. If any visible damage is found, the
instrument must be replaced.

6. Indicator check
Indicator checks should only be carried out in comparison with a more accurate
instrument or, if possible, with a calibrated instrument. The temperature during
the check must remain constant.Fluctuating temperatures may lead to reading
errors caused by the different response times of the probes.

For thermometers with protective sleeves, a minimum waiting time of at least


15 minutes, for temperature equalisation, should be observed, provided the
appropriate immersion length is adhered to.

WIKA Operating instructions Bimetal thermometers

12968065 11/2008 GB/D

For thermometers without protective sleeves, a minimum waiting time of 10


minutes, for temperature equalisation, should be observed, provided the appropriate immersion length is adhered to.

7. Indicator correction / 8. Electrical alarm contacts


7. Indicator correction
Any interference with or modification to the instrument will invalidate
the warranty!
Indicator corrections on bimetal thermometers with contacts may only be
carried out by the manufacturer or in adequately equipped workshops by qualified persons.
The micro-adjustment mechanism built into the pointer should only be
operated using a screwdriver, and only if the thermometer has been
damaged due to improper handling, severe shocks, during transport, etc.
When correcting an indication error using the micro-adjustment mechanism,
a calibrated thermometer must be used for comparison. Subsequently, the
thermometer must be checked at several temperature points.

8. Electrical alarm contacts


Bimetal thermometers (only type 55) can be equipped with sliding, inductive or
electronic contacts. (see data sheet AC 08.01)
In most cases, bimetal thermometers with contacts are used as two-position controllers for on-off control or as three-position controllers for on-off-on
control with adjustable dead-band. In general thermometers contacts can only
carry the operating current of an interposing control relay.

12968065 11/2008 GB/D

The contact mechanism consists of the red set pointer and the measuredvalue pointer. The red set pointer can be adjusted using the supplied setting
tool. The measured-value pointer in a sliding contact mechanism consists of
a pair of drag pointers, which are held against the red set pointer by springs
and is opened and closed at the set value by means of an operating pin on the
measured-value pointer.

Electrical connection should only be carried out by qualified electricians.


The switches are terminated on screw terminals within the terminal box.
Conductor cross-section max. 1.5 mm2
The terminal assignment is stated on the connection plate of the thermometer

Adjusting the nominal-value pointer


The red set pointers for the alarm contacts are adjustable via the adjustment
lock on the window using an adjustment key (included in delivery; on standard
gauges this is found on the outside edge of the junction box.
WIKA Operating instructions Bimetal thermometers

GB

8. Electrical alarm contacts

red set pointers

GB
adjustment key
removable
adjustment lock

The red set pointers for the alarm contacts are adjustable over the full range
of the instrument. Switching points should be set in the range between 10 %
und 90 % of the full scale, to ensure switching accuracy and the long life of the
measuring mechanism.
8.1 Sliding contact Model 811
Sliding contacts are control switches which make or break connected electric
circuits as the contact arm, moved by the measured-value pointer, reaches the
appointed set-point.
Surface oxidation at the contact points may lead to malfunction, which can
result in contact-arcing, particularly in the case of intrinsically safe circuits (low
voltages and currents), and in the case of relatively high contact loads.
Since the indication must not be affected by the contact mechanism, actuating
forces, and therefore also the possible contact rating, are low.
Sliding contacts are not suitable for liquid-filled instruments!
The sliding contacts are not intrinsically safe and are, therefore, not suitable for
applications in hazardous areas!

8.2 Inductive alarm sensor Model 831


Inductive alarm sensors are non-contact inductive proximity sensors, which
make or break when a control flag, linked to the measured-value pointer, moves
adjacent to or disengages from the control head (slot-type initiator). Changes in
the signal level will then actuate a control unit (switch amplifier).
Details see data sheet AC 08.01.

WIKA Operating instructions Bimetal thermometers

12968065 11/2008 GB/D

Details see data sheet AC 08.01.

8. Electrical alarm contacts / 9. Explosion protection


8.3 Electronic contact Model 830 E
Direct switching of low-level signals, which are typically used in conjunction
with a PLC, is possible using these inductive alarm contacts, complete with
integrated amplifiers, factory-fitted within the instrument.
The usual advantages of inductive contacts are also valid for this system, such
as highly-secure contact operation, zero wear due to non-contact operation
and virtually no adverse effect on the measuring system, thus ensuring the
accuracy of the indication.
No additional control unit is required.
The Model 830 E electronic contact is not intrinsically safe and, therefore, not
suitable for use in hazardous areas!
Details see data sheet AC 08.01.
8.4 Electromagnetic compatibility
EMC according to EN 60947-5-2
The instruments should be protected against strong electromagnetic fields.
8.5 Contact functions
The contact function of the respective alarm contact is determined by the index
1 or 2 after the model number.
1 = Contact makes when pointer approaches the set point in clockwise direction
2 = Contact breaks when pointer approaches the set point in clockwise direction

9. Explosion protection
The devices indicate the temperature to be measured by means of a bimetal
coil and an indicator shaft. The passive indication instrument does not influence
actively the temperature rise.

12968065 11/2008 GB/D

9.1 Labelling of the devices for use in hazardous areas


If instruments without contacts (only type 53, 54 and 55) are used in hazardous
areas, they are marked as follows on the dial:
PO number (Production order number from WIKA; all product and production
related information is saved under this number)
ATEX marking
II 2 GD c TxC IP65

WIKA Operating instructions Bimetal thermometers

GB

9. Explosion protection / 10. Maintenance and servicing, cleaning


9.2 EC prototype test certificate for inductive contacts of type 831
Standard version, Model 831.XX
PTB 99 ATEX 2219 X (Enclosure 2) and ZELM 03 ATEX 0128 X (Enclosure 4)
Depending on the number of switches and on the case diameter, either
GB
Type SJ2-N ... or Type SJ3,5- ... -N ... is used.
Safety pattern version, Models 831.XX - SN or - S1N
PTB 00 ATEX 2049 X (Enclosure 3) and ZELM 03 ATEX 0128 X (Enclosure 4)
Depending on the number of switches and enclosure on the case diameter,
either Models SJ 2-SN..., SJ 2-S1N..., SJ 3,.5-SN ... or SJ 3,.5-S1N ... are used.
The permissible limits for Ui, li and Pi of intrinsically safe supply circuits depend
on the sensor type. They can be taken from the corresponding EC-type test
certificates (also see Data sheet AC 08.01).
Suitable switch amplifiers are, for example:
Circuit
(s. Ex-certific.)

Model 1
Model 2

Sensor type Model designation EC-type examination certificate


Pepperl & Fuchs

WIKA
model

Standard
Standard
Standard
Standard
SN Sensors
SN Sensors

904.31
904.32
904.28
904.29
904.33
904.30

KFD2-SR2-Ex1
KFD2-SR2-Ex2
KFA6-SR2-Ex1
KFA6-SR2-Ex2
KFD2-SH-Ex1
KFA6-SH-Ex1

PTB 00 ATEX 2080


PTB 00 ATEX 2080
PTB 00 ATEX 2081
PTB 00 ATEX 2081
PTB 00 ATEX 2042
PTB 00 ATEX 2043

For further information on explosion protection see manufacturers declaration


of conformity for the thermometer, EC-type examination certificate and operating instructions for the electrical alarm contacts (enclosed, where applicable,
for the respective instrument version).

10. Maintenance and servicing / Cleaning

The instruments should be cleaned with a damp cloth, moistened with soap
solution. When cleaning the inside of the terminal box, the mains power must
be disconnected. All parts must be dry before the power is reconnected.

10

WIKA Operating instructions Bimetal thermometers

12968065 11/2008 GB/D

The instruments require no maintenance or servicing. The indicator and


switching function should be checked once or twice every 12 months. For this
the instrument must be disconnected from the process and checked using a
temperature calibrator.

11. Repairs / 12. Disposal


11. Repairs
Repairs are only to be carried out by the manufacturer.

GB

12. Disposal

12968065 11/2008 GB/D

Disposal of instrument components and packaging materials should be in


accordance with the respective waste treatment and disposal regulations of the
region or country to which the instrument is supplied.

WIKA Operating instructions Bimetal thermometers

11

Enclosure 1:

12968065 11/2008 GB/D

GB

12

WIKA Operating instructions Bimetal thermometers

Enclosure 2:

12968065 11/2008 GB/D

GB

WIKA Operating instructions Bimetal thermometers

13

Enclosure 3:

12968065 11/2008 GB/D

GB

14

WIKA Operating instructions Bimetal thermometers

Enclosure 4:

12968065 11/2008 GB/D

GB

WIKA Operating instructions Bimetal thermometers

15

Enclosure 5:

12968065 11/2008 GB/D

GB

16

WIKA Operating instructions Bimetal thermometers

Enclosure 5:

12968065 11/2008 GB/D

GB

WIKA Operating instructions Bimetal thermometers

17

Enclosure 5:

12968065 11/2008 GB/D

GB

18

WIKA Operating instructions Bimetal thermometers

Enclosure 6:

12968065 11/2008 GB/D

GB

WIKA Operating instructions Bimetal thermometers

19

Enclosure 6:

12968065 11/2008 GB/D

GB

20

WIKA Operating instructions Bimetal thermometers

Enclosure 6:

12968065 11/2008 GB/D

GB

WIKA Operating instructions Bimetal thermometers

21

Enclosure 6:

12968065 11/2008 GB/D

GB

22

WIKA Operating instructions Bimetal thermometers

Enclosure 7:

12968065 11/2008 GB/D

GB

WIKA Operating instructions Bimetal thermometers

23

Enclosure 7:

12968065 11/2008 GB/D

GB

24

WIKA Operating instructions Bimetal thermometers

Enclosure 7:

12968065 11/2008 GB/D

GB

WIKA Operating instructions Bimetal thermometers

25

Enclosure 7:

12968065 11/2008 GB/D

GB

26

WIKA Operating instructions Bimetal thermometers

Enclosure 7:

12968065 11/2008 GB/D

GB

WIKA Operating instructions Bimetal thermometers

27

Operating instructions
Betriebsanleitung
Mode d'emploi
Manual de instrucciones
Inductive contact model 831
in pressure and temperature gauges

Induktivkontakt Typ 831


in Druck- und Temperaturmessgerten
Contact inductif type 831
des manomtres et thermomtres
Contacto inductivo, modelo 831
en manmetros o termmetros

Inductive contact
Model 831.112

Inductive contact model 831.1


in pressure gauge model 232.50.100

GB
D
F
E

GB Operating instructions model 831

Page 3 - 24

D Betriebsanleitung Typ 831

Seite 25 - 46

F Mode demploi type 831

Page 47 - 56

E Manual de instrucciones modelo 831

Pgina 57 - 66

2010 WIKA Alexander Wiegand SE & Co. KG


All rights reserved. / Alle Rechte vorbehalten.
WIKA is a registered trademark in various countries.
WIKA ist eine geschtzte Marke in verschiedenen Lndern.
Prior to starting any work, read the operating instructions!
Keep for later use!

Lire le mode demploi avant de commencer toute opration !


A conserver pour une utilisation ultrieure !
Leer el manual de instrucciones antes de comenzar cualquier trabajo!
Guardar el manual para una eventual consulta!

22

WIKA operating instructions inductive contact model 831

2371673.05 05/2014 GB/D/F/E

Vor Beginn aller Arbeiten Betriebsanleitung lesen!


Zum spteren Gebrauch aufbewahren!

Contents

Contents

GB

1.

General information

2.

Safety

3.

Specifications

4.

Design and function

5.

Transport, packaging and storage

6.

Commissioning, operation

10

7.

Maintenance and cleaning

12

8.

Dismounting and disposal

12
13 - 15

Appendix 2: EC-type examination certificate (Ex approval for


gases) for SN sensors models SJ
(WIKA model 831-SN/S1N)

16 - 19

Appendix 3: EC-type examination certificate (Ex approval


for dusts) for proximity sensors models SJ
(WIKA model 831 and 831-SN/S1N)

20 - 24

2371673.05 05/2014 GB/D/F/E

Appendix 1: EC-type examination certificate (Ex approval for


gases) for slot sensors models SJ
(WIKA model 831)

WIKA operating instructions inductive contact model 831

1. General information
1. General information
designed and manufactured using state-of-the-art technology.
All components are subject to stringent quality and environmental criteria
during production. Our management systems are certified to ISO 9001 and
ISO 14001.

These operating instructions contain important information on handling the

inductive contacts. Working safely requires that all safety instructions and work
instructions are observed.

Observe the relevant local accident prevention regulations and general safety

regulations for the inductive contacts' range of use.

The operating instructions are part of the product and must be kept in the im-

mediate vicinity of the instruments with inductive contacts and readily accessible to qualified personnel at any time.

Skilled personnel must have carefully read and understood the operating

instructions, prior to beginning any work.

The manufacturer's liability is void in the case of any damage caused by

using the product contrary to its intended use, non-compliance with these
operating instructions, assignment of insufficiently qualified skilled personnel
or unauthorised modifications to the inductive contact.

The general terms and conditions, contained in the sales documentation, shall

apply.

Subject to technical modifications.


Further information:

- Internet address:
- Relevant data sheet:

www.wika.de / www.wika.com
AC 08.01

2371673.05 05/2014 GB/D/F/E

GB

The inductive contacts described in the operating instructions have been

WIKA operating instructions inductive contact model 831

1. General information / 2. Safety


Explanation of symbols
WARNING!
... indicates a potentially dangerous situation that can result in
serious injury or death, if not avoided.

GB

Information
points out useful tips, recommendations and information for
efficient and trouble-free operation.
WARNING!
... indicates a potentially dangerous situation in a potentially
explosive atmosphere, resulting in serious injury or death, if not
avoided.

2. Safety
WARNING!
Before installation, commissioning and operation, ensure that
the appropriate inductive contact has been selected in terms of
design and specific measuring conditions.
Non-observance can result in serious injury and/or damage to
equipment.
Only work on the instrument with the voltage disconnected.
Further important safety instructions can be found in the individual chapters of these operating instructions.
2.1 Intended use

2371673.05 05/2014 GB/D/F/E

Inductive contacts are installed in pressure and temperature measuring


instruments. The instrument pointer of the measuring instrument moves the flag
of the inductive contact out of or into the slot sensor. The resulting change of the
current supply is used for triggering a switching amplifier.
The inductive contact has been designed and built solely for the intended use
described here and may only be used accordingly.
The manufacturer shall not be liable for claims of any type based on operation
contrary to the intended use.

WIKA operating instructions inductive contact model 831

2. Safety
2.2 Personnel qualification

WARNING!
Risk of injury should qualification be insufficient!
Improper handling can result in considerable injury and damage
to equipment.
The activities described in these operating instructions may
only be carried out by skilled personnel who have the qualifications described below.

GB

Skilled personnel
Skilled personnel are understood to be personnel who, based on their technical
training, knowledge of measurement and control technology and on their experience and knowledge of country-specific regulations, current standards and directives, are capable of carrying out the work described and independently recognising potential hazards.
2.3 Additional safety instructions for instruments per ATEX
WARNING!
Non-observance of these instructions and their contents may
result in the loss of explosion protection.
WARNING!
It is imperative that the application conditions and safety requirements of the EC-type examination certificate are followed.
Pressure gauges must be earthed via the process connection!
2.4 Special hazards

Dangerous pressure media such as oxygen, acetylene, flammable gases or


liquids, toxic gases or liquids as well as for refrigeration plants or compressors
require attention above the standard regulations. Here the specific safety codes or
regulations must be considered.
For additional important safety instructions see chapter "2.3 Safety instructions for
instruments per ATEX".
WARNING!
Residual media in dismounted measuring instruments can
result in a risk to persons, the environment and equipment. Take
sufficient precautionary measures.
6

WIKA operating instructions inductive contact model 831

2371673.05 05/2014 GB/D/F/E

WARNING!
Observe the information given in the applicable type examination
certificate and the relevant country-specific regulations for
installation and use in potentially explosive atmospheres (e.g.
IEC 60079-14, NEC, CEC). Non-observance can result in serious
injury and/or damage to equipment.

2. Safety
2.5 Labelling / safety marks
Product label

GB

Pin assignment

Date of manufacture

Explanation of symbols
Before mounting and commissioning the pressure gauge,
ensure you read the operating instructions!
CE, Communaut Europenne
Instruments bearing this mark comply with the relevant European
directives.

2371673.05 05/2014 GB/D/F/E

ATEX European Explosion Protection Directive


(Atmosphre = AT, explosible = Ex)
Instruments bearing this mark comply with the requirements of
the European Directive 94/9/EC (ATEX) on explosion protection.

WIKA operating instructions inductive contact model 831

3. Specifications / 4. Design and function


3. Specifications
IP Ingress protection

GB The ingress protection to EN 60529 against external influences depends on the


basic instrument and is found in the respective data sheet.
Admissible ambient temperatures
The inductive contacts can be used in the range from -25 to +70 C (SN sensors
up to +100 C). Where the permissible temperatures for the basic instrument (see
data sheet) deviate from this range, the lower value is valid.
When operating in potentially explosive atmospheres, please note the reduced
values (see respective EC-type examination certificate).
For the type of the integrated slot sensors, see the measuring instrument's
product label.

4. Design and function


Description
The built-in electrical switch contacts are non-contact slot-type inductive proximity
sensors, which are powered from switching amplifiers with certified intrinsically
safe circuits. When the adjustable set points are reached, their output circuits will
be opened or closed.
As standard model 831 slot sensors, to EC-type examination certificate

PTB 99 ATEX 2219 X (see appendix 1) and ZELM 03 ATEX 0128 X (see
appendix 3), are used

Model 831-SN and -S1N SN sensors, to PTB 00 ATEX 2049 X (see appendix

2) and ZELM 03 ATEX 0128 X (see appendix 3), are special designs with
safety features (that are not relevant to explosion protection) for special
applications

Suitable switching amplifiers for model 831 are:


With type 1 circuit: Control unit KFD2-SR2-Ex1 and

KFD2-SR2-Ex2
With type 2 circuit: Control unit KFA6-SR2-Ex1 and

KFA6-SR2-Ex2 - model 904.28/29
Suitable switching amplifiers for model 831-SN and 831-S1N are:
With type 2 circuit: Control unit KFD2-SH-Ex1 and

KHA6-SH-Ex1 - model 904.30
8

WIKA operating instructions inductive contact model 831

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The connected loads for the switches are in accordance with EN 60947-5-6
(NAMUR).

4. Design and function / 5. Transport, packaging ...


Scope of delivery
Cross-check scope of delivery with delivery note.

GB

5. Transport, packaging and storage


5.1 Transport
Check pressure gauge for any damage that may have been caused by transport.
Obvious damage must be reported immediately.
5.2 Packaging
Do not remove packaging until just before mounting.
Keep the packaging as it will provide optimum protection during transport (e.g.
change in installation site, sending for repair).
5.3 Storage

2371673.05 05/2014 GB/D/F/E

Permissible conditions at the place of storage:


Storage temperature: -20 ... +70 C

WIKA operating instructions inductive contact model 831

6. Commissioning, operation
6. Commissioning, operation
In accordance with the general technical regulations for pressure and

temperature measuring instruments (e.g. EN 837-2 or EN 13190).

When screwing gauges in, the force required for this must not be applied through
the case, but rather through the spanner flats (using a suitable tool) provided for
this purpose on the square shaft of standard connections.
Installation with
spanner

With safety pattern gauges (see dial symbol k) you need to pay attention to the
fact that the free space behind the blow-out back will be at least 15 mm.
Requirements for the installation point
To avoid, amongst other things, switch signal "chatter", it must be ensured that the
instruments are mounted free of vibration.
If the measuring point is not sufficiently stable a measuring instrument support
such as a bracket or flange should be used for fastening (possibly via a flexible
capillary). If the pressure gauge is exposed to vibration or pulsating pressure
or both, then a liquid filled pressure gauge may provide considerably better
performance and readability. Instruments should be protected against coarse dirt
and wide fluctuations in ambient temperature.
Electrical connection
Connection of the switches via screw terminals in the terminal box
Conductor cross section max. 1.5 mm2

The terminal assignment is stated on the product label of the pressure or tem-

perature measuring instrument

The gauges must be connected to the equipotential bonding of the plant

10

WIKA operating instructions inductive contact model 831

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GB

Mechanical connection

6. Commissioning, operation
The permissible limits of Ui, Ii and Pi for the intrinsically safe supply circuits
depend on the sensor type. They can be taken from the corresponding EC-type
examination certificates. (The sensor type is stated on the connection label of
the pressure or temperature measuring instrument.)
Suitable switching amplifiers are e.g.:
Circuit

Sensor type Model designation EC-type examination WIKA


Fa. Pepperl & Fuchs certificate
Model

Model 1

Model 2


standard
standard
standard
standard
SN-sensors
SN-sensors

(s. Ex certificate)

KFD2-SR2-Ex1
KFD2-SR2 Ex2
KFA6-SR2-Ex1
KFA6-SR2-Ex2
KFD2-SH-Ex1
KHA6-SH-Ex1

PTB 00 ATEX 2080


PTB 00 ATEX 2080
PTB 00 ATEX 2081
PTB 00 ATEX 2081
PTB 00 ATEX 2042
PTB 00 ATEX 2043

904.31
904.32
904.28
904.29
904.33
904.30

Electromagnetic compatibility
EMC to EN 60947-5-2.
The instruments are to be protected against strong electromagnetic fields.
Adjusting the set pointers
The setting of the set points is achieved using the adjustment lock in the window with the aid of the adjustment key (part of the scope of delivery; found in
standard instruments on the side of the terminal box).

Set pointer

2371673.05 05/2014 GB/D/F/E

Adjustment lock

removable
adjustment key

The set pointers for the limit switches are freely adjustable over the full scale
range. For reasons of switching accuracy and long life of the mechanical
measuring systems, the switch points should be between 10 % and 90 % of the
measuring span.
WIKA operating instructions inductive contact model 831

11

GB

7. Maintenance and cleaning / 8. Dismounting and disposal


7. Maintenance and cleaning

The indicator and switching function should be checked once or twice every
year. The instrument must be disconnected from the process to check with a
pressure or temperature testing device.
Repairs must only be carried out by the manufacturer or appropriately qualified
skilled personnel.
7.2 Cleaning
CAUTION!
Before cleaning, correctly disconnect the measuring
instrument from the pressure supply, switch it off and
disconnect it from the mains.
Clean the instrument with a moist cloth.
Electrical connections must not come into contact with

moisture.

It must be ensured that all the parts are dry before the power

isswitched on again.

Wash or clean the dismounted measuring instrument before

returning it, in order to protect personnel and the environment


from exposure to residual media.

8. Dismounting and disposal


WARNING!
Residual media in dismounted measuring instruments can result
in a risk to persons, the environment and equipment.
Take sufficient precautionary measures.
8.1 Dismounting
Only disconnect the measuring instrument once the system has been
depressurised!
8.2 Disposal
Incorrect disposal can put the environment at risk. Dispose of instrument
components and packaging materials in an environmentally compatible way and
in accordance with the country-specific waste disposal regulations.
12

WIKA operating instructions inductive contact model 831

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GB

7.1 Maintenance
The instruments are maintenance-free.

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Appendix 1:

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GB

WIKA operating instructions inductive contact model 831

13

Appendix 1:

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14

WIKA operating instructions inductive contact model 831

Appendix 1:

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WIKA operating instructions inductive contact model 831

15

Appendix 2:

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16

WIKA operating instructions inductive contact model 831

Appendix 2:

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WIKA operating instructions inductive contact model 831

17

Appendix 2:

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18

WIKA operating instructions inductive contact model 831

Appendix 2:

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WIKA operating instructions inductive contact model 831

19

Appendix 3:

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20

WIKA operating instructions inductive contact model 831

Appendix 3:

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WIKA operating instructions inductive contact model 831

21

Appendix 3:

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22

WIKA operating instructions inductive contact model 831

Appendix 3:

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WIKA operating instructions inductive contact model 831

23

Appendix 3:

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24

WIKA operating instructions inductive contact model 831

Montage- und Betriebsanleitung


Mounting and operating instruction
Montage et mode demploi
KEMA 01ATEX1053 X
Bitte zur knftigen Verwendung aufbewahren
Please retain for future usage
Veuillez conserver pour un usage futur

Schwimmer Magnetschalter
Magnetic float switches
Rgulateurs de Niveau Flotteur Sries 60 et 80

MB6080EX.doc

Rev. 5 31.03.2008

MB6080EX.doc.

English
Symbol legend
The following symbols are used in these operating instructions:

Warning
Instructions on correct installation and proper operation of the
Float Switch 60-80 . Failing to comply with these instructions
can lead to malfunction of or damage to the switch.

Precaution
Instructions which must be complied with to avoid injury or
property damage or loss of the type permit.

Information
Facts and information concerning proper operation of the Float
Switch 60-80

Instructions for electrical installation


Information on proper electrical installation.

Safety information
Read these instructions before installing the Float Switches 60-80 and putting
then into operation.
These instructions are intended for the specialists in charge of mounting, installation and setup.
Comply with the relevant safety regulations when using the equipment.
Unauthorized access and impermissible use of the equipment will result in the loss of guarantee
and liability protection.
Measures must be taken to prevent risks to persons and property in the event of a defect in the
Float Switches 60-80 .
Do not install in ferromagnetic surroundings or the immediate vicinity of strong electromagnetic fields.
(minimum distance: 1 m).
Float Switches 60-80 must not be exposed to heavy mechanical loads.
Comply with the maximum current and voltage values for intrinsically safe operation as specified in
the installation and operating instructions.

MB6080EX.doc

11 / 31

Danger!
There is a risk of poisoning or suffocation when working in containers. Relevant
personal protection measures (e.g. respiratory devices, protective clothing, etc.)
must be taken before work is carried out.
Danger, risk of explosion!
An explosive atmosphere may develop in a container. Measures must be taken to prevent
sparking. Work in such areas must be done by qualified personnel in accordance with the
relevant safety regulations and guidelines.

Application and field of use


An approval has been issued for the Float Switches 60-80 for use as explosion-protected
equipment within the scope of application defined by EU Guideline 94/9/EU in hazardous areas.
They comply with the specifications regulating use of electrical equipment in explosion risk areas.
The technical data in these operating instructions must be complied with.
Ignition protection type

II 1/2G EEx ia IIC T3...T6


II 2 D T 80 C IP6X
Float and Guide tube, zone 0

Structure and functional description


The Float Switches 60-80 are used to monitor filling levels in containers holding liquid
mediums. These mediums must not contain heavy soiling or coarse suspended matter must not
show a tendency to crystallize out.
KSR Magnetic Float Switches are used to control distinct levels of a liquid. They are based on the
float principle with individual contacts for every level to be monitored.
A float with a built-in magnetic system actuates a small reed contact through the wall of the guide
tube. Thus the switching operation is without direct contact to the liquid, free of wear and tear, and
does not require any power supply.
KSR Magnetic Float Switches are available with multiple switch points.

Removal of transport packaging and transport safety devices


Remove the Float Switch carefully from the transport packaging.
See the instructions on the shipping packaging; remove all transport safety devices before
removing the Float Switch.
Never forcibly remove the Float Switch from the packaging by taking hold of the guide tube!
Before installing the Float Switch, the float safety bands must be removed. Make sure all
packaging components have been removed and that the float moves freely on the guide tube.

12 / 31

MB6080EX.doc

Installation in the container


The Float Switches are installed in the container using flanges or mounting plugs. (See
the type designation on the product for the specific design of your Float Switch)
Prior to installation, make sure the installation opening in the container agrees in size and
dimensions with the installation option of the Float Switch.
Depending on the design of the Float Switches 60-80,
the guide tube is inserted into the container from the
outside. Installation should be vertical. To ensure proper
functioning, the angle of installation must not deviate
exceed 30 from the vertical position.

1
2
3
4

The guide tube of the Float Switches 60-80 is inserted


into the container from the outside through the installation
opening. It is then fixed by tightening the thread or the
screws for flanged versions.

In Float Switches featuring a mounting plug,


the thread must be screwed in for the entire
length of the thread.
Float Switches featuring flanges must be
installed using suitable bolts, washers and nuts.
Please comply with the maximum torque ratings of the
bolts / screws used when tightening them down.
Use suitable gaskets. Make sure the gasket material is
resistant to the medium and its vapours as well as to the
expected temperature and pressure loads.
Designs, where the floats diameter is lager then the core
opening must be installed with the float removed form the
guide tube.

max. 30

1
2
3
4
5
6
7
8

Terminal Box
Cable gland
Process Connection
Gasket
Guide tube
Float
Teflon washer
Set collar or Tension
clamp

Procedure:
Fig. Float Switch
1. Mark the upper side of the float (e.g. with "top")
2. Mark position of the set collar to be removed
3. Remove set collars and teflon washer
4. Remove floats
5. Install Float Switch 60-80
6. Position the floats, set collars and teflon washer from inside the container. Mind the marked
positions!

The purpose of the teflon washer is to avoid potential ignition sparking if the
float should fall against the set collar. Operating the equipment without teflon
washer is not permitted.

MB6080EX.doc

13 / 31

Maximum length of guide tubes


In containers in which turbulences can be expected, Float Switch over 3,000 mm long
must also be secured so as to prevent the Guide tube from bending.
This can be achieved, for instance, with a receiving sleeve at the bottom of the
container.

Electrical connection
Float Switches 60-80 must only be operated on certified intrinsically safe control
circuits of ignition protection type EEx ia.
Float Switches 60... - 80...

EEx ia

The electrical data on the type plate and the additional regulations governing intrinsically safe
circuits must be complied with. This work must be done by trained specialist personnel.
The electrical connection of the Float Switches 60-80 is realized with integrated terminals.
See the connection diagram inside the terminal box or included with the equipment, or the
information in catalogue 1003- for the applicable connection scheme.

Selecting the connection cable


The connection cable must be selected as suitable for the expected ambient
conditions (temperature, aggressive atmosphere, weathering, etc.).
The number of wires depends on the number of switching points.
wires
switching point
1
2
3
4

Closing /
Change over
Opening
3
4
5
7
7
10
9
13

See the relevant connection scheme in each case.


The connection is to be done with cable marked in light blue. The diameter of the connection cable
must be within the clamp range of the cable gland. If other cable diameters are used, moisture and
dust may penetrate into the equipment.
Use of single bunched conductors is not permissible!

Conduction capacity and inductance


When determining the required cable length, the maximum permissible inductances and
capacities of the connected intrinsically safe control device must be taken into account.
These values should not be exceeded by the connection cable.

14 / 31

MB6080EX.doc

Cable Connection

1. The connection cable must be laid in accordance with the applicable regulations applying to
installation of intrinsically safe circuits
2. Remove the lid of the terminal box
3. Insert the cable through the cable gland collet into the terminal box
4. Remove jacketing and expose strands
5. Attach terminal lugs to the strands
6. Insert the wires into the row terminals as per diagram and fasten them down
7. Replace and fasten down the terminal box lid
Use the appropriate connection scheme

Equipotential bonding and PE connection


There is at least one PE connection terminal for connection of a PE conductor in the
terminal box of the Float Switch 60-80.
In the case of Float Switches without external ground terminals, an electrical connection must be
established between the mounting plug and the container during installation. If there is a ground
terminal, the equipotential bonding or PE connection can be realized by this means.

Maintenance
Float Switches 60-80 function free of maintenance if used properly. However, they must be
subjected to a visual check within the framework of regular inspection, including a container
pressure test.

MB6080EX.doc

15 / 31

Functional test
The functional test serves to determine the proper function of the reed contacts.
Functional test prior to installation in the container
Before the Float Switch is installed, it can be checked with a continuity checker or an ohmmeter.
1. Connect the wires of the switch
point to be tested to the
continuity checker or ohmmeter.
2. Raise float and move it up to the
switch point position. Depending
on the switching function,
continuity or no continuity will be
indicated.
3. Move float back to initial
position. The switching function
must be reversed.
4. Repeat steps 1-3 for each
switching point.

L1

L2

Float raised

Float at initial
position

Important:
The switching point dimensions L
refer to the gasket area and the
distance to the middle of the float.
Functional test of installed Float Switch
1.
2.
3.
4.
5.
6.
7.

The functionality of installed Float Switches can only be tested from the inside of the container
It is recommended to de-install the Float Switch for the functional test
Disconnect electrical connections
De-install Float Switch
Functional test as per chapter "Prior to installation in container"
Install Float Switch in the container
Re-establish electrical connection as per the relevant connection scheme
Functional testing may trigger unintended reactions in subsequent control
circuits. Risk of property damage or personnel injuries.

16 / 31

MB6080EX.doc

Error search
The following table lists the most frequent causes of error and the necessary
countermeasures

Error

Cause

Countermeasure
Compare
with
False terminal connection
connection diagram
Insulation
Check terminals
Set
collars
out
of
position
No switching
or replaced incorrectly Control position of set
function or
after the guide tube is collar
undefined
removed
Reed contact defective
due
to
mechanical Return to factory
vibrations
Float installed incorrectly Turn float around
False switching
False
ordering Please contact the
point dimensions
information
factory
Reworking
of
Thread
or
flange
container
dimensions
of
Float
Reworking of Float
Float Switch cannot Switch do not agree
Switch at factory
be attached at the
Reworking of thread
intended position on Thread of mounting plug
or replacement of
the container
on container defective
mounting plug
Bolt threading on the
Send back to factory
Float Switch defective
Please give us a call in case of any difficulties. We will do everything we can to
provide you with the required advice and help.

Technical data
Summary electrical data on Float Switch variants with permit
Basic
type

Code1

Code2

60

..

G..

..

L...

/..

...

80

..

DN..PN..

..

L...

/..

...

MB6080EX.doc

Code3 Code4 Code5 Code6

Umax /
Imax

Tmax

36V /
100mA
36V /
100mA

180C
180C

Ignition
protection
type
EEx ia IIC
T3...T6
EEx ia IIC
T3...T6

17 / 31

Temperatures - Float Switch 60-80


Temperature
class

Maximum surface
temperature

T3
T4
T5
T6

200C
135C
100C
85C

Maximum
Maximum ambient
process temperature on
temperature
terminal box
180C
60C
130C
60C
95C
60C
80C
60C

Category 2D Dust maximum


surface temperature for use in
area Zone 21

T +80C*

*The maximum ambient temperature of the equipment is also dependant from the operating temperature of the fluid and
the ambient temperature and has to be below the ignition temperature.

Type Code Float Switch 60-80


Type Code Float
Code 1
V

Code 2 Code 3 Code 4


52
A
...
Code 4
Float ID in mm
38
*a Only for 120 Float with
Float ID 38mm
Code 3
magnet system
R = radial
A = Axial
Code 2
Float OD in mm

See type code material

Old float type code


Basic type
Material
Version
44
S
K
S
52
62
S
A
80
S
B23
83
S
B
98
S
C
105
S
D
120
S
F
120*a
S
F38
200
S
200
300
S
300
* all dimensions in mm
Code 1
Material
V
Stainless steel
T
Titanium
HC
Hastelloy HC
HB
Hastelloy HB

18 / 31

MB6080EX.doc

Type Code Float Switch


Basic type Code 1 Code 2

Code 3

Code 4

Code 5

Code 6

Code 7

60

W90/80

SU

L.../12

V52A...

F / V / .../....

Code 8

Code 8:

Zulassungen *2
EX ATEX Zulassung
EX DNV ATEX und DNV
EX GL ATEX und GL
Code 7:
Float
see Type Code Float
Code 6:
L.../...= Guide tube length max. / Guide tube - OD
Code 5:
Contact separation / NAMUR / * Optional code (The number of
letters in the code corresponds to the number of contacts)
S Closing
on rising level
Opening
on rising level
U Contact separation
on rising level
.../ N
acc. to NAMUR DIN EN 60947-5-6 *
*(only if Option available)
Code 4:
Guide tube material
V = Edelstahl ; HB = Hastelloy B ; HC = Hastelloy C ; T = Titan
Code 3
W.../... Winkelangabe/Winkelnge (nur wenn Option vorhanden)
Code 2
Process connection / Material / nominal size (pressure rating )/ Flange face

Code 1:
A
APL
AV
AV6
AV7
AV9

Flange

FV/.../.../..

Triclamp

FCV...

Dairy fitting
acc. to DIN
11851
Mounting
thread
Sanitary
nozzle
Material:
.../V/... =
.../HB/... =
.../HC/... =
.../T/... =

MRV...

RV...
ISV

F/ Material/ (numerical value nominal size.../ pressure rating...)/ Flange face


DN50 - DN250 or Ansi 1 6 / PN6 - PN64 or 150lbs - 600lbs
C/ Material / (numerical value nominal size.../ pressure rating...)
DN10 - DN100; 1-4 Zol
MR/ Material / (numerical value nominal size.../ pressure rating...)
DN10 - DN150
R/ Material / size
G1 " - G3 "
IS / Material (max. 4 bar)
(Sanitary nozzle / Ingold nozzle)

Stainless steel
Hastelloy B
Hastelloy C
Titanium

= Version with terminal box Aluminium


= Version with terminal box Polyester
= Version with terminal box Stainless steel
= Version with terminal box Stainless steel
= Version with terminal box Stainless steel
= Version with terminal box Stainless steel

Basic type

60

MB6080EX.doc

19 / 31

Float Switchnominal pressure


Process connection
Basic type 80

Basic type 60

Nominal pressure in bar

PN 6

6 bar

PN 16

16 bar

PN 40

40 bar

PN 64

64 bar

150 lbs

15 bar (at max 148C)

300 lbs

38 bar (at max 148C)

600 lbs

77 bar (at max 148C)

Mounting
Thread

G1 G3

Flange

Nominal pressure in bar

In cases of maximum bolt threading


length and suitable gaskets at the
process connection, the float
pressure specification applies.*
* When float ST/0.8 is used, special
mounting threads have to be used
in connection with a nominal
pressure of 64 bar.

If the pressure specifications for the process connection (e.g. flange) and float differ, the lowest
pressure figure is then the nominal pressure of the Float Switch.

KSR float
Type

Type
old

Max.
operating
pressure

Type

Type
old

[bar]
V44A

SVK

Max.
operating
pressure

Type

Type
old

[bar]

Max.
operating
pressure
[bar]

16

T83A

STB

25

HB44A

SHBK

16

V52A

SV

40

T80A

STB23

25

HB52A

SHB

40

V62A

SVA

32

T98A

STC

25

HB62A

SHBA

32

V83A

SVB

25

T105A

STD

25

HB83A

SHBB

25

V80A

SVB23

25

T120A

STF

25

HB80A

SHBB23

25

V98A

SVC

25

HC44A

SHCK

16

HB98A

SHBC

25

V105A

SVD

25

HC52A

SHC

40

HB105A

SHBD

25

V120A

SVF23

25

HC62A

SHCA

32

HB120A

SHBF23

25

V120A/38 SVF38

25

HC83A

SHCB

25

HB120A/38 SHBF38

25

V200A

SV200

16

HC80A

SHCB23

25

HB200A

16

V300A

SV300

16

HC98A

SHCC

25

T44A

STK

16

HC105A

SHCD

25

T52A

ST

25

HC120A

SHCF23

25

T52A/0,6

ST/0,6

40

HC120A/38 SHCF38

25

T52A/0,8

ST/0,8

40

HC200A

16

T62A

STA

25

20 / 31

SHC200

SHB200

MB6080EX.doc

Franais
Lgende
Les symboles suivants sont utiliss dans ce mode demploi:

Avertissement
Instructions pour un montage correct et une mise en service
conforme des rgulateurs de niveau type 60 resp. 80 Une
non-observation de ces instructions peut conduire des erreurs
de fonctionnement ou des dtriorations.

Danger - Prcautions
Instructions dont la non-observation peut conduire des dgts
corporels ou matriels.

Information
Indications et informations pour une utilisation approprie des
rgulateurs de niveau type 60 resp. 80

Instructions pour linstallation lectrique


Informations pour une installation lectrique approprie.

Instructions relatives la scurit


Veuillez lire ces instructions avant l'installation et la mise en service des rgulateurs
de niveau type 60 resp. 80
Ces instructions sont destines un personnel qualifi qui va raliser les travaux de montage et
d'installation.
Veuillez respecter les rgles de scurit approprie lors de linstallation.
Une intervention non autorise et une utilisation interdite entranent la perte de la garantie et de la
possibilit de recours des rclamations.
Veuillez prendre les mesures ncessaires, en cas de panne sur les rgulateurs de niveau type
60 resp. 80, pour viter des risques pour le personnel et le matriel.
Veuillez ne pas installer les rgulateurs de niveau type 60 resp. 80 proximit de puissants
champs lectro-magntiques (1 m de distance minimum).
Les rgulateurs de niveau type 60 resp. 80 ne doivent pas subir de contraintes mcaniques
importantes.
Les valeurs lectriques maxi indiques dans le mode demplo et appropries lutilisation en
scurit intrinsque doivent tre respectes.
MB6080EX.doc

21 / 31

Danger!
Lors de travaux dans un rservoir, il existe un danger d'empoisonnement ou de
suffoquement. Ces travaux ne peuvent tre entrepris qu'en application de
mesures de scurit adaptes aux personnes (par exemple port de masque
respiratoire, vtements de protection ou quivalent).
Attention, danger d'explosion!
Il peut exister un risque de formation d'atmosphre explosive dans un rservoir. Il faut alors
prendre les mesures ncessaires afin dviter la formation d'tincelle. Seulement un
personnel qualifi et form aux exigences relatives aux directives de scurit pourra
intervenir dans de telles zones.

Utilisation et domaine d'application


Les rgulateurs de niveau type 60 resp. 80 sont des appareils protgs contre les risques
dexplosions cconformment la directive europenne 94/9/CE et, ce titre, ils sont homologus
pour l'installation dans des zones explosives.
Ils rpondent aux exigences des appareils lectriques pour zones explosives.
Les caractristiques techniques donnes dans ce mode demploi doivent tre respectes.

Type de protection:

II 1/2G EEx ia IIC T3...T6


II 2 D T 80 C IP6X
Flotteur et tube de guidage zone 0

Principe et description de fonctionnement


Les rgulateurs de niveau type 60 resp. 80 servent contrler le niveau des liquides dans les
rservoirs. Ces liquides ne doivent pas contenir de particules solides et ne doivent pas tre enclins
la cristallisation.
Les rgulateurs de niveau travaillent selon le principe du flotteur avec transmission magntique. A
l'intrieur du tube de guidage, se trouvent un ou plusieurs interrupteurs lame souple (contacts
sous gaz inerte). Sur le tube de guidage sont monts un ou plusieurs flotteurs. Leur position est
fonction du niveau du liquide contrler. Un aimant permanent est mont l'intrieur de ces
flotteurs. Ds que le champ magntique atteint le domaine d'action de linterrupteur lame souple,
ce dernier est actionn. Le nombre et la position des flotteurs dpend du nombre de contacts, de
leur fonction ainsi que de leur position. Veuillez consulter la grille de code pour les diffrentes
variantes.

Enlvement des emballages et des accessoires de fixation ncessaires au transport


Les rgulateurs de niveau doivent tre dballs avec prcaution.
Veuillez tenir compte des instructions figurant sur l'emballage et enlever tous les accessoires de
fixation avant de sortir le rgulateur de son emballage.
Ne jamais forcer sur le tube de guidage pour extraire l'appareil de son emballage!
Avant le montage du rgulateur de niveau, veuillez ter les bandes de fixation des flotteurs.
Assurez-vous que toutes les fixations et emballages ncessaires au transport ont bien t enlevs
et que le flotteur coulisse librement sur le tube de guidage.

22 / 31

MB6080EX.doc

Installation dans le rservoir


Selon le modle, les rgulateurs de niveau sont monts dans le rservoir par
l'intermdiaire d'une bride ou d'un bouchon filet (veuillez vous rfrer la plaque
identificatrice du rgulateur de niveau).
Avant le montage, veuillez vous assurer que l'ouverture prvue pour le montage ainsi que le mode
de fixation correspondent bien l'encombrement et aux dimensions du rgulateur de niveau.
Le montage se fait, quel que soit le modle de rgulateur
de niveau type 60 resp. 80, partir de l'extrieur du
rservoir. Les rgulateurs doivent tre monts en position
verticale, + ou - 30 afin d'assurer un bon fonctionnement.

1
2
3
4

Le tube de guidage des rgulateurs de niveau type 60


resp. 80 doit tre introduit par l'ouverture prvue du
rservoir. La fixation se fait par serrage du bouchon filet,
le cas chant des vis pour les excutions avec bride.

Les rgulateurs de niveau avec bouchon filet


sont visser sur toute la hauteur du filetage.
Les rgulateurs de niveau avec bride sont
fixer avec les vis, rondelles et crous adapts.
Veuillez respecter la correcte force de serrage des
croux lors du vissage.
Veuillez utiliser des joints dtanchit adapts. Il est
ncessaire de s'assurer que ces joints rsistent
durablement au fluide et ses vapeurs, ainsi qu' la
temprature et la pression de service.
Pour les excutions dont le diamtre du flotteur est
suprieur celui de l'ouverture du rservoir, il est
ncessaire de dmonter le flotteur avant le montage de
l'appareil.

8 7

1
2
3
4
5
6
7
8

Botier de raccordement
max. 30
Presse toupe
Bouchon filet
Joint
Tube de guidage
Flotteur
Rondelle tflon
Bague d'arrt ou collier de
serrage

Abb. Schwimmer-Magnetschalter...

Procdure:
1. Marquer la partie suprieure du flotteur (par exemple "haut")
2. Marquer la position des bagues d'arrt
3. Dmonter les bagues d'arrt et rondelles de protection
4. Dmonter le flotteur
5. Monter le rgulateur de niveau type 60 resp. 80 dans louverture du rservoir
6. Remonter (par trou d'homme) le flotteur, les bagues d'arrt et rondelles en Tflon. Respecter le
marquage!
Les rondelles de protection servent viter de potentielles tincelles en cas de
heurt du flotteur contre la bague d'arrt. Un fonctionnement sans rondelles de
protection n'est pas autoris.

MB6080EX.doc

23 / 31

Longueur maximale des tubes de guidage


Dans les rservoirs avec risque de turbulences, et pour des rgulateurs de niveau de
longueur suprieure 3000 mm, il faudra prvoir une fixation au fond du rservoir afin
dviter une dformation du tube de guidage.

Raccordement lectrique
Les rgulateurs de niveau type 60 resp. 80 peuvent uniquement tre raccords
des circuits certifis en scurit intrinsque ayant un type de protection EEx ia.
Rgulateurs de niveau type 60 resp. 80

EEx ia

Veuillez respecter les caractristiques lectriques apposes sur la plaque identificatrice ainsi que
les instructions complmentaires concernant les circuits lectriques de scurit intrinsque. Ces
appareils pourront uniquement tre installs par un personnel qualifi.
Le raccordement lectrique des rgulateurs de niveau type 60 resp. 80 se fait par
l'intermdiaire des bornes de connexion intgres.
Le schma de connexion de l'appareil se trouve, soit dans le botier de raccordement, soit sur le
schma de raccordement joint l'appareil, soit dans le catalogue 1003-

Choix du cble de raccordement


Le choix du cble de raccordement doit tenir compte de l'environnement (temprature,
atmosphre agressive, conditions mtorologiques).
Le nombre de conducteurs dpend du nombre de contacts.
contacts

conducteurs
fermeture par niveau montant /
ouverture par niveau montant

1
2
3
4

3
5
7
9

nombre de lettres indique le


nombre de contacts

4
7
10
13

Veuillez respecter le schma de raccordement


Le raccordement doit se faire avec un cble de couleur bleu clair. Le diamtre du cble de
raccordement doit tre adapt la taille du presse-toupe afin d'viter tout risque de pntration
d'humidit et poussire lintrieur du botier.
L'utilisation de conducteurs simples est interdite.

Charges capacitive et inductive


La longueur du cble de raccordement doit tenir compte des charges inductives et
capacitives maxi du relais scurit intrinsque raccord au circuit. Ces valeurs ne
doivent en aucun cas tre dpasses.

24 / 31

MB6080EX.doc

Raccordement du cble

1. Utiliser un cble de raccordement conforme aux prescriptions en vigueur relatives l'installation


de circuits lectriques en scurit intrinsque.
2. Enlever le couvercle du botier de raccordement.
3. Introduire le cble de raccordement dans le botier par le presse-toupe.
4. Dnuder le cble et les conducteurs.
5. Apposer des terminaisons sur les conducteurs.
6. Insrer selon le schma de connexion les fils conducteurs dans les bornes et les fixer.
7. Remettre le couvercle du botier et le fixer.
Veuillez respecter les schmas de connexion

Echange quipotentiel et raccordement la terre


Dans le botier de raccordement des rgulateurs de niveau type 60 resp. 80, il y a
au moins une borne de raccordement la terre pour connexion du fils conducteur
"terre". Pour les rgulateurs de niveau sans borne extrieure de mise la terre, il faut,
lors de l'installation, raliser une connexion lectrique au rservoir par le bouchon filet. En cas
d'existence d'une borne de mise la terre, l'change quipotentiel pourra se faire par celle-ci.

Entretien
Les rgulateurs de niveau type 60 resp. 80, utiliss conformment aux instructions, ne
ncessitent pas d'entretien. Dans le cadre des rvisions de routine ou dun test de pression
hydrostatique du rservoir, ils devront toutefois tre soumis un contrle visuel.

MB6080EX.doc

25 / 31

Test de fonctionnement
Le test de fonctionnement sert constater le bon fonctionnement des interrupteurs
lame souple.
Test de fonctionnement avant installation dans le rservoir
On peut contrler le rgulateur de niveau avant son installation dans le rservoir l'aide d'un
appareil de test de continuit lectrique ou d'un ohmmtre.

1. Raccorder l'ohmmtre les fils


du contact contrler.
2. Soulever le flotteur jusqu' la
hauteur de ce contact qui
commutera ou non selon sa
fonction lectrique.
3. Remettre le flotteur dans sa
position initiale. La fonction du
contact doit alors s'inverser.
4. Rpter les points 1 3 pour
chaque contact.

L1

L2

flotteur au
travail

flotteur au repos

Remarque:
Les positions L des points de
contact se rfrent au plan du joint
dtanchit et au milieu du flotteur.

Test de fonctionnement aprs installation dans le rservoir.


1. Le test de fonctionnement sur un rgulateur de niveau dj mont ne peut s'effectuer que de
l'intrieur du rservoir.
2. Il est conseill de dmonter le rgulateur de niveau et d'effectuer le test sur l'appareil dmont.
3. Dconnecter les raccordements lectriques.
4. Dmonter le rgulateur de niveau.
5. Effectuer le test de fonctionnement selon le chapitre prcdent "Test de fonctionnement avant
l'installation dans le rservoir".
6. Remonter le rgulateur de niveau dans le rservoir.
7. Rtablir le raccordement lectrique selon le schma de raccordement.
Lors du test de fonctionnement, des ractions involontaires dans le sytme de
contrle peuvent survenir. Risque de dgts matriels ou corporels.

26 / 31

MB6080EX.doc

Recherche d'erreurs
Dans le tableau ci-dessous, se trouvent les causes d'erreurs les plus
frquentes et les mesures prendre.

Erreurs

Origine
Raccordement une
mauvaise borne
Fil non dnud
Pas de seuil de Bague d'arrt dplaces
contact ou seuil de ou mal remontes lors
contact mal dfini
d'un dmontage
Interrupteur

lame
souple dtrior suite
un choc mcanique
Flotteur mal mont
Position du contact
Erreur de donne lors de
incorrecte
la commande

Mesures
Voir
schma
de
raccordement
Contrler les bornes
Contrler la position
des bagues d'arrt
Retour l'usine
Retourner le flotteur
Consulter le fabricant

Modification
de
du
Dimensions du bouchon louverture
ou de la bride ne rservoir
Impossibilit
de correspondent pas
Modification
du
monter le rgulateur
rgulateur l'usine
de niveau dans le
Rusinage du filetage
Filetage du manchon du
rservoir
ou remplacement du
rservoir dfectueux
manchon
Filetage du rgulateur
Retour l'usine
dfectueux
Nous sommes votre entire disposition pour tout renseignement utile.
N'hsitez pas nous appeler.

Caractristiques techniques
Sommaire des caractristiques techniques des diffrentes variantes de
rgulateurs de niveau type 60 resp. 80
Type de
base
60

G..

Code
3
..

Code
4
L...

Code
5
/..

Code
6
...

DN..PN..

..

L...

/..

...

Code 1

Code 2

..
..

80

MB6080EX.doc

U max /
T max
I max
36V /
180C
100mA
36V /
180C
100mA

Type de
protection
EEx ia IIC
T3...T6
EEx ia IIC
T3...T6

27 / 31

Tempratures - Rgulateurs de niveau type 60 resp. 80


Classe de
temprature

Temp. maxi de
surface

Temp. maxi
du process

Temp. ambiente
maxi au niveau du
botier

T3
T4
T5
T6

200C
135C
100C
85C

180C
130C
95C
80C

60C
60C
60C
60C

Catgorie 2D Poussire
temprature maximale de
surface pour utilisation en
zone 21

T +80C*

*La temprature maximale de surface de l'appareil dpend aussi de la temprature de service du fluide et de la
temprature ambiante. Elle doit rester en de de la temprature d'auto-inflammation.

Grille de code des rgulateurs de niveau 60... - 80...


Grille de code des flotteurs
Code 1
V

Code 2 Code 3 Code 4


52
A
...
Code 4
Diamtre interne en mm
38
*a Only for 120 Float with
Diamtre interne du flotteur 38mm
Code 3
magnet system
R = radial
A = Axial
Code 2
Flotteur sphrique
Old float type code
Sans code
Matriau
K

44
S
S
52
62
S
80
S
83
S
98
S
105
S
120
S
120*a
S
200
S
300
S
* all dimensions in mm

See type code material

Type de base

A
B23
B
C
D
F
F38
200
300

Code 1
Matriau du flotteur
V
Flotteur en acier inoxydable
T
Flotteur en titane
HC
Flotteur en Hastelloy C
HB
Flotteur en Hastelloy D

28 / 31

MB6080EX.doc

Grille de code des rgulateurs de niveau type 60 resp. 80


Type de
base

Code 1

Code 2

Code 3

Code 4

Code 5

Code 6

Code 7

60

F / V / .../....

W90/80

SU

L.../12

V52A...

Code 8

Code 8:

Zulassungen *2
EX ATEX Zulassung
EX DNV ATEX und DNV
EX GL ATEX und GL
Code 7:
code des flotteurs
Voir grille de code des flotteurs
Code 6:
L.../...= Longueur du tube de guidage /
du tube en mm
Code 5:
Kontaktfunktion / Namurbeschaltung / *Zusatzcode (Le nombre de
lettres indique le nombre de contacts)
S fermeture par niveau montant
ouverture par niveau montant
U nombre de lettres indique le nombre de contacts
.../ N
acc. to NAMUR DIN EN 60947-5-6 *
*(only if Option available)
Code 4:
Matriau du tube de guidage
V = Acier inoxydable, HB = Hastelloy B, HC = Hastelloy C, T = Titane
Code 3
W.../... Winkelangabe/Winkelnge (nur wenn Option vorhanden)
Code 2
Prozessanschluss: Werkstoff / Gre/ Druck / Flansch Dichtflche

Code 1:
A
APL
AV
AV6
AV7
AV9

Flansche

FV/.../.../..

Triclamp

FCV...

Milchrohrverschraubung
Einschraubgewinde
INGOLD
Stutzen
Werkstoff:
.../V/... =
.../HB/... =
.../HC/... =
.../T/... =

MRV...
RV...
ISV

F/ Werkstoff/ (Zahlenwert Gre.../Druck...)/ Dichtflche


DN50 DN250 bzw. Ansi 1 6 / PN6 PN64 bzw. 150lbs
600lbs
FV130 = (KSR Ronde PN40)
FC/ Werkstoff/ (Zahlenwert Gre...)
DN10 DN100; 1-4 Zol
MR/ Werkstoff/ (Zahlenwert Gre...)
DN10 DN150
R/ Werkstoff/ (Zahlenwert Gre...)
G1 G3
IS / WERKSTOFF (max. 4 bar)

Edelstahl
Hastelloy B
Hastelloy C
Titan

= Ausfhrung mit Aluminiumgehuse


= Ausfhrung mit Polyestergehuse
= Ausfhrung mit Edelstahlgehuse
= Ausfhrung mit Edelstahlgehuse
= Ausfhrung mit Edelstahlgehuse
= Ausfhrung mit Edelstahlgehuse

Type de base:

60

MB6080EX.doc

29 / 31

Pression nominale des rgulateurs de niveau


Raccordement process
Type de base 80

Type de base 60

Bride

Pression nominale en bar

PN 6

6 bar

PN 16

16 bar

PN 40

40 bar

PN 64

64 bar

150 lbs

15 bar ( temp. max 148C)

300 lbs

38 bar ( temp. max 148C)

600 lbs

77 bar ( temp. max 148C)

Bouchon

G1 G3

Pression nominale en bar


Avec une longueur maxi de filetage
et un joint dtanchit adapt au
bouchon, la pression nominale du
flotteur est applicable.*
* En cas d'utilisation du flotteur
ST/0,8 une pression nominale de
64 bar, il faudra utiliser des
bouchons spciaux.

Si les indications de pression du raccordement process (par exemple de la bride) diffrent de celles du
flotteur, la valeur la plus basse est la pression nominale du rgulateur de niveau.

Flotteurs KSR
Type

V44A

Type Pression
vieux de service
maxi [bar]
SVK

Type

Type Pression
vieux de service
maxi [bar]

Type

16

T83A

STB

25

HB44A

Type Pression
vieux de service
maxi [bar]
SHBK

16

V52A

SV

40

T80A

STB23

25

HB52A

SHB

40

V62A

SVA

32

T98A

STC

25

HB62A

SHBA

32

V83A

SVB

25

T105A

STD

25

HB83A

SHBB

25

V80A

SVB23

25

T120A

STF

25

HB80A

SHBB23

25

V98A

SVC

25

HC44A

SHCK

16

HB98A

SHBC

25

V105A

SVD

25

HC52A

SHC

40

HB105A

SHBD

25

V120A

SVF23

25

HC62A

SHCA

32

HB120A

SHBF23

25

V120A/38 SVF38

25

HC83A

SHCB

25

HB120A/38 SHBF38

25

V200A

SV200

16

HC80A

SHCB23

25

HB200A

16

V300A

SV300

16

HC98A

SHCC

25

T44A

STK

16

HC105A

SHCD

25

T52A

ST

25

HC120A

SHCF23

25

T52A/0,6

ST/0,6

40

HC120A/38 SHCF38

25

T52A/0,8

ST/0,8

40

HC200A

16

T62A

STA

25

30 / 31

SHC200

SHB200

MB6080EX.doc

MB6080EX.doc

31 / 31

KSR KUEBLER AG Adressen

KSR KUEBLER Niveau-Messtechnik AG


Heinrich-Kbler-Platz 1
Tel:[+49] 06263 870
http://www.ksr-kuebler.com

DE-69439 Zwingenberg/Neckar
Fax:[+49] 06263/87-99
e-Mail:info@ksr-kuebler.com

KUBLER FRANCE S.A.


10, avenue dAlsace
Tel:[+33] 03 89 75 41 73
http://www.ksr-kuebler.com

FR-68700 Cernay
Fax: [+33] 03 89 75 53 14
e-Mail:ksr-fr@ksr-kuebler.com

KSR KUEBLER Level Measurement & Control Ltd.


Tan Capel, Betws Gwerfil Goch
Tel:[+44] 1490 460 584
http://www.ksr-kuebler.com

Corwen, Denbighshire LL21 9PU, GB


Fax:[+44] 1490 460 477
e-Mail:ksruk@ksr-kuebler.com

KSR H&H Measurement B.V.


Alphenseweg 4-h
Tel:[+31] 13 533 96 88
http://www.h-hm.com

NL-5133 Riel / Niederlande


Fax: [+31] 13 533 19 62
e-Mail: info@h-hm.com

KSR KUEBLER Level Control Products of America Inc.


8349-M Arrowridge Blvd
Tel:[+1] 704 522 7663
http://www.ksr-usa.com

Charlotte, NC 28273 USA


Fax: [+1] 704 522 7616
e-Mail:info@ksr-usa.com

SHANGHAI KSR KUEBLER Automation Instrument Co. LTD


No. 510 Yu Tang Road
Tel:[+86] 21 57745225
http://www.ksr-kuebler.com

Industrial Zone Songjiang Shanghai 201613, P.R. China


Fax: [+86] 21 67741420
e-Mail: china@ksr-kuebler.com

KSR KUEBLER (SINGAPORE) Level Measurement & Control PTE LTD


21 Toh Guan Road East,
Tel: [+65] 6316 7625 6
http://www.ksr-kuebler.com

#09-17 Toh Guan Centre Singapore 608609


Fax.: [+65] 6316 7627
e-Mail:ksr-asia@ksr-kuebler.com

MB6080EX.doc

KEMA Quality B.V.


Utrec hts eweg 310, 6812 AR Arnhem, Die Niederlande
Postfach 9035, 6800 ET Arnhem, Di e Niederl ande
Telefon +31 26 3 56 34 21, Tel efax +31 26 3 52 58 00

AKKREDITIERT DURCH
DEN NIEDERLNDISCHEN
AKKREDITIERUNGSRAT

Hand pump PFH-L

Application:
As delivery pump in central lubrication
systems.

Technical data:

- Subject to modifications -

Delivery capacity:
Delivery pressure at 70 N
1)
manual power :
Temperature range:
Viscosity range:
Weight:
Reservoir capacity:

3,2 cm/stroke
approx. 10 bar
-10 ... +80 C
6,3 ... 2700 cP
2,7 kg
1l

Material:
PTFE (Teflon)
- Sealing:
- Reservoir and
pump casing:
Alu hard coated
- Pump internals,
screwing and
return valve:
stainless steel 1.4571

1)

The delivery pressure depends on the


manual power applied. A pressure
control valve is not incorporated.

Remark on dimensional drawing:


1
2
3
4
5
6

Hand lever
Pressure connection for pipe outside
diameter 6 or 8
Filling sieve mesh width 300m
Filling cap
Reservoir
Discharge screw M10x1

Purchase-designation:
Hand pump
Type

PFH-L

Pressure connection
for:

Pipe-AD 6
Pipe-AD 8

Hand pump PFH-L


101.870

EUGEN WOERNER

GmbH & Co. KG


Postfach 1661
DE-97866 Wertheim
Hafenstrasse 2
DE-97877 Wertheim
Tel. +49 (0) 9342 803-0 info@woerner.de
Fax.+49 (0) 9342 803-202 www.woerner.de

Leaflet-No.
Replaces No.
Page 1 of 3

0369.09.10 EN
0369.03.10 EN

Spare parts:

- Subject to modifications -

22

Item Designation

Purch.-no.

Item Designation

Purch.-no.

Item Designation

800.912-06

10

Cover

101.603-35

19

Lock screw M10x1

800.908-23

11

Split washer 4

807.980-01

20

Suction valve

101.914-65

12

Cheese head M4x10

800.912-02

21

Sealing ring 36x42x1 T

915.100-86

13

Sieve B50

913.300-13

22

14

Tank cap D65

913.300-39

Pump body
with delivery piston

101.851-64

23

Lip ring I 16

915.402-01

24

Pressure spring
1,6x10x59 Niro

911.200-96

25

Bolt

101.909-45

27

Casing

151.005-35

Sealing set

101.862-64

Cheese head M4x20

Parallel straight pin


6x24

800.007-21

Cranked grip M8x27

922.200-01

Hand lever

151.011-45

Set screw M4x12

800.417-04

Washer 34x2

101.908-45

Return valve

952.800-62

Reservoir

101.853-25

Pipe

101.927-45

15

Opening plug PG9

972.205-02

16

Straight panel screwing


for PFH-L/8 Niro
101.871-65
101.871-66
for PFH-L/6 Niro

17

Sealing ring 15x20x2 T

915.100-87

18

Sealing ring 10x14x1 T

915.100-84

EUGEN WOERNER GmbH & Co. KG


Postfach 1661
DE-97866 Wertheim
Hafenstrasse 2
DE-97877 Wertheim
Tel. +49 (0) 9342 803-0 info@woerner.de
Fax.+49 (0) 9342 803-202 www.woerner.de

Leaflet-No.
Page 2 of 3

0369 EN

Purch.-no.

Important information on this publication


Reproduction, also in extracts, only permitted with the approval of the firm of EUGEN
WOERNER GmbH & Co. KG.
All the information in this publication has been examined for correctness with great care.
Nevertheless, WOERNER cannot assume any liability for losses or damage resulting
directly or indirectly from the application of the information contained in this publication.
All products from WOERNER may only be used as intended and corresponding to the
information in this publication.
For products supplied with operating instructions, the additional directives and information
contained in them are to be complied with.

- Subject to modifications -

Materials deviating from those mentioned in this publication and the technical documents
which further apply may only be poured into and processed in the appliances and systems
manufactured and supplied by WOERNER by following agreement with and written
approval by WOERNER.
The safety and danger information stated in the safety data sheets of the substances used
must be taken into account at all costs.
Transportation of gases, liquefied gases, gases under pressure, vapours and liquids, the
vapour pressure of which is more than 0,5 bar above normal atmospheric pressure
(1013 mbar) at the maximum admissible temperature, of easy inflammable or explosive
media as well as transportation of foodstuffs is forbidden.

Information on EU Directive 2002/95/EC (RoHS)


With Directive 2002/95/EC of January 27, 2003, for the limitation of the use of certain
hazardous substances in electrical and electronic devices (RoHS) material bans come into
effect from July 2006 for electrical and electronic devices newly placed on the market for
lead, cadmium, hexavalent chromium, mercury and brominated flame retardants.
In its controls and switching devices, WOERNER only uses materials which fulfil the criteria
of EU Directive 2002/95/EC.
To the extent that hexavalent chromium has been used as corrosion protection in the parts
which we produce ourselves, it has already been replaced by other environmentally
tolerable protective measures.
The mechanical devices supplied by WOERNER are not affected by EU Directive
2002/95/EC as they are appliances added or installed on "large-scale stationary industrial
tools" (cf. EU Directive 2002/96/EC, Annex IA).
But as WOERNER is conscious of its responsibility towards the environment, we shall also
use materials fulfilling the requirements of the Directive for devices not covered by EU
Directive 2002/95/EC as soon as they are generally available and their use is technically
possible.

EUGEN WOERNER

GmbH & Co. KG


Postfach 1661
DE-97866 Wertheim
Hafenstrasse 2
DE-97877 Wertheim
Tel. +49 (0) 9342 803-0 info@woerner.de
Fax.+49 (0) 9342 803-202 www.woerner.de

Leaflet-No.
Page 3 of 3

0369 EN

FLENDER ARPEX
all-steel couplings
ARS-6, ARP-6, ARH-8,
ARC-6/8/10, ARW-4/6, ARF-6 series
Operating instructions
BA 8704 en 04/2012

FLENDER couplings

FLENDER ARPEX
all-steel couplings
ARS-6, ARP-6, ARH-8,
ARC-6/8/10, ARW-4/6, ARF-6 series

Technical data

General notes

Safety instructions

Transport and
storage

Technical
description

Fitting

Startup

Operation

Faults, causes
and remedy

Maintenance
and repair

10

Spare parts,
customer service

11

Declarations

12

Operating instructions
Translation of the original operating instructions

BA 8704 en 04/2012
2 / 37

Notes and symbols in these operating instructions


Note: The term "operating instructions" will in the following also be shortened to "instructions" or "manual".

Legal notes
Warning-note concept
This manual comprises notes which must be observed for your personal safety and for preventing material damage.
Notes for your personal safety are marked with a warning triangle or an "Ex" symbol (when applying
Directive 94/9/EC), those only for preventing material damage with a "STOP" sign.
WARNING! Imminent explosion!
The notes indicated by this symbol are given to prevent explosion damage.
Disregarding these notes may result in serious injury or death.
WARNING! Imminent personal injury!
The notes indicated by this symbol are given to prevent personal injury.
Disregarding these notes may result in serious injury or death.
WARNING! Imminent damage to the product!
The notes indicated by this symbol are given to prevent damage to the product.
Disregarding these notes may result in material damage.
NOTE!
The notes indicated by this symbol must be treated as general operating information.
Disregarding these notes may result in undesirable results or conditions.
WARNING! Hot surfaces!
The notes indicated by this symbol are made to prevent risk of burns due to hot surfaces
and must always be observed.
Disregarding these notes may result in light or serious injury.
Where there is more than one hazard, the warning note for whichever hazard is the most serious is always used.
If in a warning note a warning triangle is used to warn of possible personal injury, a warning of material damage may
be added to the same warning note.

Qualified personnel
The product or system to which these instructions relate may be handled only by persons qualified for the work
concerned and in accordance with the instructions relating to the work concerned, particularly the safety and
warning notes contained in those instructions. Qualified personnel must be specially trained and have the
experience necessary to recognise risks associated with these products or systems and to avoid possible hazards.

BA 8704 en 04/2012
3 / 37

Intended use of Siemens products


Observe also the following:
Siemens products must be used only for the applications provided for in the catalogue and the relevant
technical documentation. If products and components of other makes are used, they must be
recommended or approved by Siemens. The faultfree, safe operation of the products calls for proper
transport, proper storage, erection, assembly, installation, startup, operation and maintenance. The
permissible ambient conditions must be adhered to. Notes in the relevant documentations must be
observed.

Trademarks
All designations indicated with the registered industrial property mark are registered trademarks of Siemens AG.
Other designations used in these instructions may be trademarks the use of which by third parties for their own
purposes may infringe holders rights.

Exclusion of liability
We have checked the content of the instructions for compliance with the hard and software described.
Nevertheless, variances may occur, and so we can offer no warranty for complete agreement. The information
given in these instructions is regularly checked, and any necessary corrections are included in subsequent editions.

Note on the EC Machinery Directive 2006/42/EC


Siemens couplings in the "FLENDER couplings" product range must be treated as "components" in the sense
of the EC Machinery Directive 2006/42/EC.
Therefore, Siemens needs not issue a declaration of incorporation.
Information on safe fitting, safe startup and safe operation can be found in this instructions manual; in addition
the "warningnote concept" therein must be observed.

BA 8704 en 04/2012
4 / 37

Contents
1.

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

View of the various types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.

General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1
2.2

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8
8

3.

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1

Obligations of the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.

Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

4.1
4.2
4.3

Scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage of the coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10
10
10

5.

Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

5.1
5.2
5.3

General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Marking of the coupling parts for use in potentially explosive zones . . . . . . . . . . . . . . . . . . . . . . . . .
Operating conditions in potentially explosive areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11
12
13

6.

Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

6.1
6.2
6.2.1
6.2.1.1
6.2.2
6.2.3
6.2.4
6.3
6.4
6.5
6.5.1
6.5.2
6.6
6.6.1
6.6.2
6.7
6.7.1
6.7.2
6.8
6.8.1
6.8.2
6.9
6.9.1
6.10
6.11
6.11.1
6.12

General information on fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Instructions for machining the finished bore, axial fastening, set screws and balancing . . . . . . . .
Finished bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parallel keyway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axial fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the coupling parts in case of shafthub connection with parallel key . . . . . . . . . . . . . . . . . . .
Demounting the shafthub connection with parallel key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shrink connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Demounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamping and slip hub connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Demounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Split clamping hubs with halfshell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Demounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Split spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting split spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting split spacers with creepcurrent insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
"C", "D" and "F" flange screw connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting of assemblybalanced couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pushing the units together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inserting spacer or intermediate unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the plate packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14
15
15
16
16
16
17
17
18
19
19
20
20
21
22
22
23
23
24
24
26
27
27
28
29
29
30

BA 8704 en 04/2012
5 / 37

7.

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

7.1

Procedure before startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

8.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

8.1

General operating data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

9.

Faults, causes and remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32

9.1
9.2
9.3
9.3.1
9.3.2
9.3.3

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible faults when selecting the coupling and/or coupling size . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible faults when installing the coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible faults in maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32
32
33
33
33
34

10.

Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34

10.1
10.2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing plate packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34
34

11.

Spare parts, customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

11.1
11.2

Spareparts stockage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Addresses for ordering spare parts and customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35
35

12.

Declarations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

12.1

EC declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

BA 8704 en 04/2012
6 / 37

1.

Technical data
Technical data, such as dimensions, weights, performance data, peak torques, operating life and
operating temperature ranges, etc., relating to the ARPEX couplings listed in these operating instructions
are documented in the product catalogues set out in table 1 and can be made available on request or
accessed on the Internet at any time (see back cover).
Where the coupling design deviates from that shown in the respective catalogue, an orderspecific
dimensioned drawing containing all the required technical data is enclosed with the delivery.
Table 1:

Assignment product catalogues

Series
Catalogue-No.

ARS6

ARP6

ARH8

ARC8/10

ARW4/6

ARF6

MD 10.1

MD 10.1

K430

MD 10.1

MD 10.1

MD 10.1

These data together with the contractual agreements on the coupling determine the limits of its proper use.
Limited temperature ranges apply to use in potentially explosive environments in
accordance with Directive 94/9/EC. The classification in temperature classes is shown
in item 5.3, "Conditions of use".
For sustained faultfree operation the coupling must be designed with an application
factor appropriate to the application. In the event of a change in operating conditions
(output, speed, changes to the prime mover and driven machine) the design must
always be checked.
1.1

View of the various types

ARP6

ARS6

ARC6/8/10

ARH8

ARW4/6
ARF6
Fig. 1:

View of the various types

BA 8704 en 04/2012
7 / 37

2.

General notes

2.1

Introduction
These instructions are an integral part of the delivery of the coupling and must be kept in its vicinity for
reference at all times.
All persons carrying out work on the coupling must have read and understood these
instructions and must adhere to them. Siemens accepts no responsibility for damage
or disruption caused by disregard of these instructions.
The "FLENDER coupling" described in these instructions has been developed for stationary use in
general engineering applications. The coupling serves to transmit power (torque and speed) between two
shafts or flanges connected by this coupling.
The coupling has been manufactured in accordance with the state of the art and is delivered in a condition
for safe and reliable use. Any changes on the part of the user which may affect safety and reliability are
prohibited. This applies equally to safety features designed to prevent accidental contact.
The coupling complies with the requirements in Directive 94/9/EC.
The coupling must be used and operated strictly in accordance with the conditions laid down in the contract
governing performance and supply.
The coupling is designed only for the application described on the orderspecific drawing of the coupling.
Other operating conditions are regarded as incorrect and must be contractually agreed.
For any damage resulting therefrom only the user or operator of the machine or plant is responsible.
The coupling described in these instructions reflects the state of technical development at the time these
instructions went to print.
In the interest of technical progress we reserve the right to make changes to the individual assemblies and
accessories which we regard as necessary to preserve their essential characteristics and improve their
efficiency and safety.

2.2

Copyright
The copyright to these instructions is held by Siemens AG.
These instructions must not be wholly or partly reproduced for competitive purposes, used in any
unauthorised way or made available to third parties without our agreement.
Technical enquiries should be addressed to the following factory or to one of our customer services:

Siemens AG
Schlavenhorst 100
46395 Bocholt
Tel.:
Fax:

+49 (0)2871 / 92-0


+49 (0)2871 / 92-2596

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3.

Safety instructions
Any changes on the part of the user are not permitted. This applies equally to safety
features designed to prevent accidental contact.

3.1

Obligations of the user

The operator must ensure that all persons involved in installation, operation, maintenance and repair
have read and understood these operating instructions and comply with them at all times in order to:
avoid injury or damage,
ensure the safety and reliability of the coupling,
avoid disruptions and environmental damage through incorrect use.

During transport, assembly, installation, demounting, operation and maintenance of the unit, the
relevant safety and environmental regulations must be complied with at all times.

The coupling may only be operated, maintained and/or repaired by persons qualified for the work
concerned (see "Qualified personnel" on page 3 of this manual).

All work must be carried out with great care and with due regard to safety.

All work on the coupling must be carried out only when it is at a standstill. The drive unit must be secured
against being switched on accidentally (e.g. by locking the key switch or removing the fuses from the
power supply). A notice should be attached to the ON switch stating clearly that work is in progress.

The coupling must be fitted with suitable safeguards to prevent accidental contact. The operation of the
coupling must not be impaired by the safeguard.
For the use in potentially explosive environments the protective equipment must
comply at least with type of protection IP2X.

The drive unit must be shut down as soon as changes to the coupling are detected during operation.

If the coupling is intended for installation in plant or equipment, the manufacturer of such plant or
equipment must ensure that the contents of the present operating instructions are incorporated in his
own instructions.

Spare parts must be obtained from Siemens (see section 11, "Spare parts, customer service").

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4.

Transport and storage


Observe the instructions in section 3, "Safety instructions".

4.1

Scope of supply
The products supplied are listed in the dispatch papers. Check on receipt to ensure that all the products
listed have actually been delivered. Parts damaged during transport or missing parts must be reported in
writing immediately. After consulting Siemens an expert is to be called in.
A damaged coupling becomes an explosion hazard. Operating the coupling with
damaged coupling parts is not permitted in potentially explosive environments in
accordance with Directive 94/9/EC.

4.2

Transport
When transporting the unit, use only lifting and handling equipment of sufficient
loadbearing capacity.
The coupling must be transported using suitable transport equipment only.
Different forms of packaging may be used depending on the size of the coupling and method of transport.
Unless otherwise agreed, the packaging complies with the HPE Packaging Guidelines.
The symbols marked on the packing must be observed at all times. These have the following meanings:

Top

Fig. 2:
4.3

Fragile

Keep dry

Keep cool

Centre of
gravity

Use no hand
hook

Attach
here

Transport symbols

Storage of the coupling


The coupling is delivered in a preserved condition and can be stored in a covered, dry place for up to
6 months. If the unit is to be stored for a longer period, it should be treated with a longterm preservative
agent (Siemens must be consulted).
Correctly stored couplings retain their properties unchanged. Unfavourable storage conditions and
improper treatment will negatively affect the physical properties of the coupling. Such negative effects may
be caused by e.g. the action of extreme temperatures or humidity.
The storage area must be dry and free from dust. The couplings must not be stored with aggressive
chemicals, acids, alkalis, etc.
Damp storage rooms (air humidity higher than 65 %) are not suitable. Ensure that no
condensation occurs.

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5.

Technical description

5.1

General description

Fig. 3:
1
2
3
4

Hexagonal plate pack and octagonal plate pack


Hub
Plate pack
Spacer
Plate pack

5
6
7
8

Hub
Hexagonal ring plate pack
Hexagonal tie plate pack
Octagonal tie plate pack

ARPEX couplings are allsteel couplings. The plate packs are arranged between the flanges of the
coupling parts and bolted to them alternately.
The individual plates are threaded onto bushes and clamped together with a clipped on, internally bevelled
retaining rings. The retaining rings are held on by the expanded bush ends, which lie against the angled
face.
So constructed, the plate pack in ring plate pack designs forms a complete unit. In tie plate packs the
individual tie plates are crimped together to form plate strands and then pushed together in the shape of
a ring to form the plate pack.
Through this arrangement of the plate packs the ARPEX coupling is torsionresistant and transmits the
torque without circumferential backlash. In axial and radial direction the coupling is however still flexible
and can absorb axial, radial and angular misalignment of the coupled units.
Depending on the series, collar bolts and nuts or conical screw connections join the plate packs to sleeve
and coupling part flanges.
The size designation of the coupling indicates the outside flange diameter (da) of the coupling in mm and
the configuration of the plate pack ("6" = hexagonal) This information is prefixed by a letter combination
specifying the component parts of the coupling.
Example:

ARS6 NHN 2556


Coupling with 2 hubs (N) and 1 "H" spacer (H) size 2556 with hexagonal plate pack in
the ARS6 series

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5.2

Marking of the coupling parts for use in potentially explosive zones


Couplings which are ordered in ATEX configuration, have the following marks on the outer circumference
of one of the coupling part (e.g. on the hub):

Complete mark:
Siemens AG

II 2G T2/T3/T4/T5/T6 -40CvTav230/150/85/50/35C

46395 Bocholt Germany


FLENDER couplings ARPEX <year built>

II 2D T 120 C -40CvTav70C
I M2

Abbreviated mark:
Siemens AG

II 2G TX

46395 Bocholt Germany


FLENDER couplings ARPEX <year built>

II 2D T 120 C -40CvTav70C
I M2

All component parts must also be marked


packaging only need be marked).

(in the case of small components, if necessary, the

If, in addition to the CE mark, the letter "U" together with the Siemens order number has been stamped
on, the coupling part has been delivered by Siemens un or prebored.
Siemens supplies unbored and prebored couplings with CE marking only under the
condition that the customer assumes the responsibility and liability for correct
refinishing in a declaration of exemption.

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5.3

Operating conditions in potentially explosive areas


The machines connected by the coupling must be earthed by an earth leakage
resistance < 106 .
If coated couplings are used in potentially explosive areas, the requirements made of
the conductivity of the coating and the limitation on the thickness of the coat applied
must be observed in accordance with standard "DIN EN 134631". Where coatings
have a thickness less than 200 m, no electrostatic charge is to be expected.
If they are to be used below ground in potentially explosive areas the couplings must
only be used with drive motors, which can be switched off on occurring of an
explosible atmosphere.

Equipment group I (underground applications, mining)


Category M2 (coupling is not approved for equipment category M1).

Equipment category II (use above ground, industry)


Categories 2 and 3 (coupling is not approved for equipment category 1).
Material group G (areas, in which there are explosible gas, vapour, mist, air mixtures),
zones 1 and 2 (coupling is not approved for use in zone 0).
Material group D (areas where dust can form explosible atmospheres),
Zones 21 and 22 (coupling is not approved for equipment category 20).
Explosion group IIC (Explosion groups IIA and IIB are included in IIC).
The permissible temperature classes and/or maximum surface temperatures are assigned as
a function of the maximum ambient temperature occurring in the immediate vicinity of the coupling
(see table 2).

Table 2:

Temperature classes

Ambient temperature

Temperature class

- 40 C up to max. + 230 C

T2

< 280 C

- 40 C up to max. + 150 C

T3

< 200 C

- 40 C up to max. + 85 C

T4

< 135 C

- 40 C up to max. + 50 C

T5

< 100 C

- 40 C up to max. + 35 C

T6

<

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Max. surface temperature

85 C

6.

Fitting
Observe the instructions in section 3, "Safety instructions"!

6.1

General information on fitting


Fitting work must be done with great care by qualified specialist personnel.
As early as during the planning phase it must be ensured that sufficient space is available for installation
and subsequent care and maintenance work.
Adequate lifting equipment must be available before beginning the fitting work.
The tightening torques specified in tabels 4, 5 and 6 must always be adhered to. Any
other tightening torques may result in accelerated wear and damage to the coupling.
Failure to observe the instructions in this section may result in breakage of the
coupling.
Danger to life from flying fragments.
A damaged coupling becomes an explosion hazard. Operating the coupling with
damaged coupling parts is not permitted in potentially explosive environments in
accordance with Directive 94/9/EC.
Under no circumstances must welding work be done on the coupling or coupling
components, as this will negatively affect the physical property of the coupling.
If coated couplings are used in potentially explosive areas, the requirements made of
the conductivity of the coating and the limitation on the thickness of the coat applied
must be observed in accordance with standard "DIN EN 134631".
Where coatings have a thickness < 200 m, no electrostatic charge is to be expected.
Where coatings are thicker than 200 m, an electrostatic charge, e.g. by cleaning the
coupling, must be avoided.
At the customers express request Siemens also supplies unbored or prebored coupling parts for
couplings which will not be operated in potentially explosive environments as set out in Directive 94/9/EU.
The necessary refinishing must then be carried out in strict compliance with the following specifications
and with particular care!
Responsibility for carrying out the refinishing is borne by the customer. Siemens will
accept no guarantee claims arising from unsatisfactory refinishing.

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6.2

Instructions for machining the finished bore, axial fastening, set screws and balancing

6.2.1

Finished bore
Remove preservative agent from coupling parts.
Observe the manufacturers instructions for handling the solvent.
When machining the finished bore the parts must be carefully aligned. For the permissible radial and axial
runouts, refer to DIN ISO 286 Basic Degree of Tolerance IT 7.
The parts must be fitted on the marked faces (
) (see figure 4).
IT 7 B

IT 7 A

B
C

Fig. 4:
1
2

D1

D1

D1

IT 7

IT 7

Finished bore to ISO tolerances


"N"-hub / "B"-hub
"M"-hub

"M"-hub

The maximum permissible bore diameters (see section 1, "Technical Data") are
designed for drivetype fastenings without taper action to DIN 6885/1 and must not
under any circumstances be exceeded. The finishmachined bores must be 100 %
checked with suitable measuring equipment.
If other shafthub connections (such as splined hub profiles, taper or stepped bores and drivetype
fastenings with taper action or other connections) are to be used instead of the drivetype fastenings
provided for, Siemens must be consulted.
For drive by means of parallel keys the following fit pairs are prescribed for the bores (see table 3):
Table 3:

Fit pairs
Type of fit

Shaft tolerance

Interference fit with parallel-key


connection

Shrink fit without parallel-key connection

Bore tolerances
Reversing operation

Setting-up operation

h6

P7

N7

k6

M7

H7

m6

K7

H7

n6

J7

H7

p6

H7

F7

to customer
specification

on request

on request

The assigned fits must be adhered to in order, on the one hand, to keep the play in the
shafthub connection as low as possible, depending on utilisation of the tolerance
zones, and, on the other, to keep the hub tension arising from the oversize within the
permissible load limit. Failure to adhere to the assigned fits may impair the shafthub
connection.

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6.2.1.1 Parallel keyway


The parallel keyways must be designed to suit the available parallel keys. For parallel keyways the
tolerance zone of the hub keyway width ISO P9 must be adhered to.
6.2.2

Axial fastening
A set screw or end plate must be provided to secure the coupling parts axially. If end plates are used,
Siemens must be consulted with regard to machining the recesses in the coupling parts.

6.2.3

Set screws
To prevent damage to the shafts, the setscrew hole should be arranged on the parallel
keyway.
In exceptional cases the set screw must be offset 180 to the parallel keyway, if
because of the diameter of the drilled hole and hub core too little material is left
between the parallel keyway and the hub core (e.g. series ARS6, size 786).
e

Fig. 5:

Setscrew bore

The following guidelines must be observed:


The set screw should be inserted in the centre of the hub core (see figure 5). If this option is not possible,
care must be taken that the distance (e) is at least M x 1.5.
Use a threaded stud with cup point to DIN 916 for set screws.
The length of the set screw must be selected so that it fills the threaded hole, but does
not project from the hub (Lmin. = M x 1.2).

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6.2.4

Balancing
Prebored couplings and/or prebored coupling parts are delivered unbalanced. It is recommended that
these parts are balanced to suit the application after finishboring (see DIN 740, DIN ISO 1940 part 1).
Balancing is normally done by drilling material away. To keep the amount of material to be removed to
a minimum, a largest possible balance radius must be selected (see figure 6).
Finishbored couplings and/or coupling parts are balanced according to the customers specifications.

Fig. 6:
6.3

Arrangement of the balancing bore with onelevel balancing (balanced after machining the
keyway)

Fitting the coupling parts in case of shafthub connection with parallel key
Before beginning assembly the fitting bores and contact surfaces for rings, bushes, nuts and closefitting
bolts or taper pins and bushes (see item 6.12, "Fitting the plate packs" and/or separate assembly
instructions) must be cleaned of any rustpreventer. Likewise, the shaft ends must be carefully cleaned.
Observe the manufacturers instructions for handling the solvent.
The coupling parts must be fitted with the aid of suitable equipment to avoid damaging
the shaft bearings through axial joining forces. Always use suitable lifting equipment.
The shaft ends should not project from the inner sides of the hub. If necessary, the hubs can be adjusted
to the length of the shaft by fitting spacers or spacer rings (see figure 7). Axial fastening can be effected
by means of a set screw or end plate.
L1

Fig. 7:
1

Spacer ring
Spacer ring
The set screws should be tightened only with a hexagon socket spanner to
DIN ISO 2936, without extension tube.

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In case of hubs with a parallelkey connection fitting may be aided by slightly heating the coupling hubs
(maximum 150 C).
Take precautions to avoid burns from hot parts.
Wear suitable protective gloves.
Hubs with transition fits and heated hubs can be pulled onto the slightly oiled shaft end with the aid of
a fitting device.
Screw threaded rod (the size of the thread depends on the shaft diameter) into the shaft end. Fit an
appropriately sized washer over the threaded rod. By screwing on and tightening a nut the hub is pushed
onto the shaft (see figure 8).

Fig. 8:
1
2
6.4

Fitting the hub with threaded rod


Threaded rod
Washer

Nut

Demounting the shafthub connection with parallel key


If a coupling hub with parallelkey connection is to be pulled off the shaft, the plate packs must first be
demounted. Then, if necessary, the end plate can be demounted or the set screw loosened. With the aid
of a detaching device (threearmed pullingoff device) or by inserting a pullingoff device into the pullingoff
holes provided if these are required in the order pull the hub off the shaft end (see fig. 9 and 10).
In case of an interference fit the hub must, if necessary, be evenly slightly heated with a burner and carefully
pulled off the shaft, using a detaching device.
Take precautions to avoid burns from hot parts.
Wear suitable protective gloves.
Check the demounted parts to see if they can be reused and, if necessary, return them to Siemens for
repair.

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Fig. 9:
1

Hub with tapped pullingoff holes


Pulling-off holes

Fig. 10: Threearmed pullingoff device (cannot be used for all hubs)
6.5

Shrink connections

6.5.1

Fitting
Cylindrical shrink fits are joined by heating the outer part. The correct joining temperature is calculated by
the manufacturer specifically for the order and is shown on the coupling drawing delivered with the unit.
To avoid premature locking the joining operation must be carried out quickly in a draughtfree area.
Care must be taken to keep transport distances short.
In the case of stepped shaft ends, when the hubs are pulled on, the locking bolts must
be removed from the threaded connections. When the hubs have been pulled on, the
locking screws must be screwed back in.
The surfaces to be joined must be absolutely clean and greasefree.
Observe the manufacturers instructions for handling the solvent.
Take precautions to avoid burns from hot parts.
Wear suitable protective gloves.

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6.5.2

Demounting
The coupling hubs must be provided with one or more oil channels, depending on length and design. The
oil must be injected into the join by way of the oil connections the number of which corresponds to the
number of oil pumps. Axial misalignment is achieved by means of a separate hydraulic press or
mechanical pullingoff device.
Secure hub axially. Risk of injury from falling coupling parts.

6.6

Clamping and slip hub connection


Forces are transmitted frictionally by the ARPEX clamping and slip hubs. The clamping or slip hubs are
delivered in an assembled condition (ready to fit) (see figs. 11 and 12).

Fig. 11: Clamping hub, type 124 (example: ARS6)


1
2
3
4

5
6
7

Tensioning bolt
Bevel surface "lubricated"
free of grease
Clamping hub

Clamping ring
Forcing-off bolt
Shaft

1
3
2
5
4

Fig. 12: Slip hub, type 125 (example: ARS6)


1
2
3
4

Forcing-off thread
Bronze bush
Bevel surface "lubricated"
free of grease

5
6
7
8

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Tensioning bolt
Clamping hub
Clamping ring
Shaft

6.6.1

Fitting
During fitting the following procedure must be observed:

Degrease the hub bore and shaft.


Hub bore and shaft must be absolutely clean and free of grease.
Observe the manufacturers instructions for handling the solvent.

Slightly loosen the tensioning bolts and pull the clamping ring off the hub slightly so that the clamping
ring sits loosely on it.

Push the hub onto the shaft.

Tighten the tensioning bolts evenly one after the other, going round several times until the clamping ring
lies evenly against the flange of the clamping or slip hub. The clamp connection is able to function when
the torque for tensioning bolts (quality 10.9) specified in table 5, "Tightening torques for connecting and
tensioning bolts" in item 6.8.1 has been reached and the clamping ring thus lies up against the hub
flange.
Failure to observe these instructions may impair the function of the clamping and/or
slip hub.

3
1

Fig. 13: Demounting with highpressure pump


1
2

Forcing-off bolt ISO 4017


G1/4"

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High-pressure pump

6.6.2

Demounting
Undo the tensioning bolts evenly one after the other. Each bolt must be loosened only half a turn per pass.
Unscrew all tensioning bolts 3 to 4 thread turns.
If the clamping ring does not come free off the clamping or slip hub by itself, forcingoff bolts to match the
number of available threads must be inserted in the ARPEX flange and evenly tightened until the clamping
ring comes free. Before once more pulling on the clamping ring, remove the bolts once more!
Clamping and slip hubs of type 124 (see Fig. 11) have, dependent on the size, already been equipped with
forcingoff bolts in the clamping ring. Before once more pulling on the clamping ring screw them back to
their original position!
If these actions do not work in case of larger clamping hubs, oil must be pumped by a highpressure pump
into the join between the clamping ring and the clamping hub to release the clamping ring. For this the
highpressure hose of the pump must be connected to the clamping ring via the G1/4" connecting thread
on the outer circumference (see Fig. 13).
Before reclamping remove the forcingoff bolts and reseal the G1/4" connecting thread, using the plug
supplied with the unit.
If the clamping ring is pulled off the clamping hub hydraulically, the bevel faces must be cleaned of
hydraulic oil and regreased with "Altemp Q NB 50" (Co. Klber).
Observe the manufacturers instructions for handling the solvent.
Released clampinghub connections do not have to be demounted and regreased before being
retensioned. If however the bevel faces still have to be regreased, the abovementioned lubricant must
be used.

6.7

Split clamping hubs with halfshell


The halfshells are loosely bolted to the hubs (see figure 14).

3
Fig. 14: Split clamping hub with halfshell
1
2

Marking by numbers
Gap dimension

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Marking by numbers

6.7.1

Fitting
Before fitting, the halfshells must be removed from the hubs and the holes carefully cleaned and
degreased using a suitable degreasing agent.
Observe the manufacturers instructions for handling the solvent.
Do not interchange halfshells.
Check that the number markings (markingpunch number) at the side of the hub core
are identical (see Fig. 14).
Place the clamping hubs on the shaft ends. The tension screws in the halfshell must first be evenly
screwed up only handtight.
Ensure the halfshells are evenly seated. Check the gap size is even and, if necessary,
adjust.
Then, using a torque wrench, tighten the tension screws alternately in at least 3 passes (see table 4).
First pass:

Tighten the clamping bolts to 30 % of the tightening torque (see table 4).

Second pass: Tighten the clamping bolts to 60 % of the tightening torque (see table 4).
Third pass:
Table 4:

Tighten the clamping bolts to 100 % of the tightening torque (see table 4).

Tightening torques for split clamping hubs with halfshell

Bolt
ISO 4762 (DIN 912)
Thread

Tightening torque
30%
60%
100%
[Nm]
[Nm]
[Nm]

M6

12

M8

18

30

18

36

60

30

60

100

M14

48

96

160

M16

75

150

250

M10
M12

6.7.2

Quality

10.9

Demounting
Demounting is done in reverse order of fitting. Here the tension screws must be undone alternately in at
least 2 to 3 passes.
Risk of injury from falling coupling parts.
Secure all coupling parts before undoing the clamping bolts.

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6.8

Split spacers
Split spacers are fitted together according to length and tightened handtight or delivered as single parts.

6.8.1

Fitting split spacers

Before assembly the fitting holes and the contact surfaces of the coupling parts must be degreased.
Fitting holes and contact surfaces of the coupling parts must be absolutely clean and
greasefree.
Observe the manufacturers instructions for handling the solvent.

The inner and outer "recess" (centering pin, figure 15) and the fitting bores as well as the contact faces
of the individual parts of the split spacer must be inspected for any damage and, if necessary, reworked.

Before fitting the connecting bolts note any balancing marks (see fig. 15 and fig. 16). If the spacers are
unmarked, the halves must be fitted so that the fitting holes of the outer flanges are correctly aligned
(see fig. 15 and fig. 16).

The connection of the "recess" or closefitting bolt must be joined accurately and carefully.

The connecting bolts must be tightened crosswise and evenly with the specified tightening torque
(see table 5, "Tightening torques for connecting and tensioning bolts").

Care must be taken that the "recess" connection is straight.


Failure to observe these instructions may result in impairing the proper function of the
coupling.

3
4
Fig. 15: Uspacer with "recess" (centering pin) (ARS6)
1
2

Marking on balanced spacer,


during fitting, the balance marks must be
one above the other
Fitting bore

3
4

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All-steel locking nut to DIN 980 Form "V"


Hexagon bolt to ISO 4017 - 8.8

3
4
Fig. 16: Uspacer with closefitting bolts (ARC8)
1

Marking on balanced spacer Spacer,


during fitting, the balance marks must be
one above the other

Table 5:

Thread

2
3
4

Fitting bore
Flanged nut
Close-fitting bolt - 10.9

Tightening torques for connecting and clamping bolts


Tightening torque TA

Tightening torque TA

Tightening torque TA

Standard screw
+ standard nut to DIN
and ISO

Standard screw
+ locking nut to DIN 980
See figure 15

Close-fitting bolt
+ collar nut
Tensioning bolt

Strength class 8.8

Strength class 8.8

Strength class 10.9

M5

5 Nm

6 Nm

7 Nm

M6

9 Nm

11 Nm

12 Nm

M8

20 Nm

25 Nm

30 Nm

M 10

41 Nm

50 Nm

60 Nm

M 12

70 Nm

80 Nm

100 Nm

M 14

110 Nm

125 Nm

160 Nm

M 16

170 Nm

195 Nm

250 Nm

M 18

235 Nm

260 Nm

350 Nm

M 20

330 Nm

370 Nm

480 Nm

M 22

450 Nm

500 Nm

660 Nm

M 24

570 Nm

640 Nm

850 Nm

M 27

840 Nm

920 Nm

1200 Nm

M 30

1140 Nm

1200 Nm

1700 Nm

M 36

2000 Nm

2100 Nm

3100 Nm

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6.8.2

Fitting split spacers with creepcurrent insulation


Here the apply the same assembly instructions as those in item 6.8.1, however in the case of "U"spacers
with integrated creepcurrent insulation (see Fig. 17) the tightening torques in table 6, "Tightening torques
for connecting bolts with creepcurrent insulation" must always be adhered to.

Fig. 17: Split spacer with creepcurrent insulation


1

Creep-current insulation

Table 6:

Fitting bore

Tightening torques for connecting bolts with creepcurrent insulation


Thread

Tightening torque TA

M6

10 Nm

M8

20 Nm

M 10

38 Nm

M 12

75 Nm

M 16

155 Nm

M 20

280 Nm

M 24

470 Nm

M 30

1000 Nm

M 36

1550 Nm

The tightening torques indicated in tables 5 and 6 apply only to untreated bolts which
are inserted (only lightly oiled) in the condition as delivered.
Other tightening values, which are additionally documented or must be enquired
about from the manufacturer, apply to coated or separately treated bolts.

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6.9

"C", "D" and "F" flange screw connection


"C", "D" and "F" flanges are delivered readyassembled as an individual part or with a spacer, as agreed.

6.9.1

Fitting

Before fitting the coupling parts must be carefully cleaned with a suitable cleaning agent.
Observe the manufacturers instructions for handling the solvent.

The "recess" (centering pin, Fig. 18) or fitting bores (Fig. 19) and the contact face of the "C", "D" and
"F" flange must be inspected for any damage and, if necessary, reworked.

The connection of the "recess" or closefitting bolt must be joined accurately and carefully.

The connecting bolts must be tightened crosswise and evenly with the specified tightening torque
(see table 5).

Care must be taken that the "recess" connection is straight.


Failure to observe these instructions may result in impairing the proper function of the
coupling.

6
3
4

Fig. 18: "C" and "F" flange screw connection (example ARS)
1
2
3
4

"C" flange
"F" flange
Connection provided by the customer
"Recess" connection

5
6
7

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Hexagon bolt to ISO 4017 - 8.8


Connection provided by the customer
Hexagon bolt to ISO 4017 - 8.8

1)

1)

Fig. 19: Fflange connection (example ARC)


1)

Detail "X"
1
2
3
4

Transport lock / mounting aid


Tensioning bolt
Fitting spacer

Fitting of assemblybalanced couplings

AAAA

AAAA

AAAA

On couplings which have been assemblybalanced each individual coupling component must be marked
on the outside diameter of the flange with a fourdigit number (Figure 20, "AAAA"). When assembling, care
must be taken that only coupling parts having the same numbers on the outside circumference of the flange
are bolted together. The coupling parts must be arranged so that the numbers are in line and can be read
from one direction (see figure 20). Only in this way will the balancing condition meet the requirements!

AAAA

6.10

5
6
7

"F" flange
Connection provided by the customer
Close-fitting bolt with collar nut
Connection provided by the customer

Fig. 20: Marking in case of assembly balancing


1
2

readable from here


Hub 1

3
4

BA 8704 en 04/2012
28 / 37

Spacer
Hub 2

6.11

Pushing the units together


Set the shafts of the machines to be connected exactly the required shaft distance apart and align the
machines precisely (see figure 21).

Fig. 21: Aligning the units


1

Distance "SX" between shafts

6.11.1 Inserting spacer or intermediate unit


If necessary, using suitable lifting gear, insert spacer or intermediate unit between the flanges.
Notice, Danger of squeezing. Wear safety gloves.
If intermediate units with prefitted plate packs are used, they should not be demounted. The plate packs
are secured with transport locks (they are also used to facilitate assembly; see Detail "X" figure 19).
After inserting the intermediate unit the transport locks must be removed, before the screw connections
of the flanges are tightened to the specified tightening torque.
Operation with the transport locks fitted is not permissible. Remove all transport
locks.

BA 8704 en 04/2012
29 / 37

6.12

Fitting the plate packs


ARPEX plate packs are packed individually, when delivered. The delivery includes instructions for fitting
ARPEX plate packs in German. Instructions in other languages must be ordered separately.
ARPEX fitting instructions include all the necessary data and instructions for correctly fitting the plate
packs.
The tightening torques for the plate pack bolting should exclusively be taken from the related
actual assembly instructions!
Furthermore all necessary details for alignment of the units to be connected are documented.
Matching of all existing sets of fitting instructions with their series is shown in table 7.
The sets of fitting instructions set out below can be ordered from Siemens or on the Internet (see back
cover).
Table 7:

Matching of the individual series with their fitting instructions

Series

ARS6
ARP6

ARP6

ARC6/8/10
ARF6
ARW4/6
ARH8

Type

Assembly instructions

with close-fitting screw connection

AN 4200

with conical bolting

AN 4243

3-part (e.g. "NAN") with close-fitting screw connection

AN 4224

3-part (e.g. "NAN") with conical bolting

AN 4256

5-part (e.g. "MCECM") with close-fitting screw


connection

AN 4228

5-part (e.g. "MCECM") with conical bolting

AN 4253

Standard version

AN 4241

Version with special conical bolting

AN 4244

Standard version

AN 4233

with close-fitting screw connection

AN 4239

with conical bolting

AN 4254

with close-fitting screw connection

AN 4213

with conical bolting

AN 4246

BA 8704 en 04/2012
30 / 37

7.

Startup
Observe the instructions in section 3, "Safety instructions"!

7.1

Procedure before startup


Before startup the screw connections must be checked and, if necessary, retightened. The alignment
and the distance dimension "S1" (see tables in seriesspecific assembly instructions) must also be
checked and, if necessary, adjusted.
Coupling types with prefitted plate packs must be checked before startup to ensure that the transport
locks (see detail "X" Figure 19) have been completely removed.
Then finally fit the coupling guard to prevent unintentional contact.
For the use in potentially explosive environments the protective equipment must
comply at least with type of protection IP2X.
Failure to observe these instructions may result in breakage of the coupling.
Danger to life from flying fragments.
A damaged coupling becomes an explosion hazard. Operating the coupling with
damaged coupling parts is not permitted in potentially explosive environments in
accordance with Directive 94/9/EC.

8.

Operation
Observe the instructions in section 3, "Safety instructions"!

8.1

General operating data


During operation of the coupling watch for:

Changes in running noise

Sudden vibrations
If any malfunctions are noticed during operation, the drive assembly must be switched
off at once. The cause of the fault must be determined, using the fault table in section 9.
The troubleshooting table contains a list of possible faults, their causes and
suggested remedies.
If the cause cannot be identified or the unit repaired with the facilities available, you
are advised to contact one of the Siemens customerservice offices for specialist
assistance (see section 2).

BA 8704 en 04/2012
31 / 37

9.

Faults, causes and remedy


Observe the instructions in section 3, "Safety instructions"!

9.1

General
The following irregularities can serve as a guide for fault tracing.
Where the system is a complex one, all component units must be included when tracing faults.
The coupling must run with little noise and vibration in all operating phases. Irregular behaviour must be
treated as a fault requiring immediate remedy.
Siemens will not be bound by the terms of the guarantee or warranty or otherwise be
responsible in cases of improper use of the coupling, modifications on the coupling
carried out without the agreement of Siemens, or use of spare parts not supplied by
Siemens.
When remedying faults and malfunctions, the coupling must always be taken out of
service. Secure the drive unit to prevent it from being started up unintentionally.
A notice should be attached to the ON switch stating clearly that work is in progress.
We also refer to the relevant accident prevention regulations at the place of
installation.

9.2

Possible faults
Table 8:

Faults, causes and remedy

Faults
Sudden changes in the noise
level and/or sudden
vibrations.

Causes
Change in alignment.

Remedy
Stop the installation.
If necessary, rectify any cause of the
changes in alignment (e.g. by fastening loose
foundation bolts).

Plate breakage, torque


transmission via close-fitting
bolts / conical bolting

Check wear; procedure as described in


section 10.
Stop the installation.
Demount coupling and remove remains of
pack.
Check and replace damaged coupling parts.
Check and, if necessary, adjust alignment
(see section 6).

Operating the coupling with broken ARPEX plate packs is not permitted under
Directive 94/9/EC. A correct torque transmission is no longer guaranteed in such case.
Perform a visual check of the ARPEX coupling as described in section 10.
A damaged coupling becomes an explosion hazard. Operating the coupling with
damaged coupling parts is not permitted in potentially explosive environments in
accordance with Directive 94/9/EC.

BA 8704 en 04/2012
32 / 37

9.3

Improper use
Experience has shown that the following faults can result in incorrect use of the ARPEX coupling. In
addition to observing the other instructions in this manual, care must therefore be taken to avoid these
faults.
Directive 94/9/EC requires the manufacturer and user to exercise especial care.
Failure to observe these instructions may result in breakage of the coupling.
Danger to life from flying fragments.
Through incorrect use the coupling may become an explosion hazard.
Incorrect use of the ARPEX coupling can result in damage to the coupling.
Coupling damage may result in stoppage of the drive and the entire plant.

9.3.1

9.3.2

Possible faults when selecting the coupling and/or coupling size

Important information for describing the drive and the environment are not communicated.

System torque too high.

System speed too high.

Application factor not correctly selected.

Chemically aggressive environment is not taken into consideration.

The temperature in the direct vicinity of the coupling is beyond the permissible range.

Machining of a finished bore with incorrect diameter or incorrect fit assignment (see section 6).

The transmission capacity of the shafthub connection is not appropriate to the operating conditions.

Possible faults when installing the coupling

Components with transport or other damage are being fitted.

When fitting coupling parts in a heated condition, these components are being excessively heated.

The shaft diameter is beyond the specified tolerance range.

Coupling parts are interchanged during fitting work.

Specified tightening torques and/or angles are not being adhered to.

Alignment and/or shaftmisalignment values do not match the specifications in the assembly and/or
operating instructions.

The coupled machines are not correctly fastened to the foundation, and as a result shifting of the
machines e.g. through loosening of the foundationscrew connection is causing excessive
displacement of the coupling parts.

ARPEX plate packes are not fitted correctly (see seriesspecific assembly instructions).

The coupling protection used is not suitable for operation within the meaning of the
explosionprotection requirements and/or in accordance with Directive 94/9/EC.

Operating conditions are being changed without authorisation.

BA 8704 en 04/2012
33 / 37

9.3.3

10.

Possible faults in maintenance

Maintenance intervals are not being adhered to.

No genuine ARPEX plate packs are being used.

Damaged ARPEX plate packs are being used.

ARPEX plate packs are being used which do not meet the technical specification for the application.

Leakage in the vicinity of the coupling is not being identified and as a result chemically aggressive
media are damaging the coupling.

Maintenance and repair


Observe the instructions in section 3, "Safety instructions"!
All work on the coupling must be carried out only when it is at a standstill.
The drive unit must be secured against being switched on accidentally (e.g. by locking
the key switch or removing the fuses from the power supply). A notice should be
attached to the ON switch stating clearly that work is in progress.
We also refer to the relevant accident prevention regulations at the place of
installation.

10.1

General
ARPEX couplings do not require maintenance; however, they should be visually inspected during
regular system maintenance inspections at least once a year. Especial attention should be given to the
condition of the plate packs. If individual plates or several plates are broken, the plate pack affected must
be replaced (see item 10.2).
No further maintenance work is necessary.
If the above specified maintenance instructions are not adhered to, a correct operation
of the coupling within the meaning of Directive 94/9/EC can no longer be guaranteed.

10.2

Replacing plate packs


Only original ARPEX plate packs must be used for replacement in order to guarantee troublefree torque
transmission and faultfree operation.
Normally, the plate packs can be replaced without moving the coupled machines. Exceptions
are combinations with socalled "B" hubs (hubs which for reasons of space are fitted the other
way round and so project into the spacer) and special solutions.
For refitting, the instructions in section 6, "Assembly", and section 7, "Startup", must be carefully
observed!

BA 8704 en 04/2012
34 / 37

11.

Spare parts, customer service

11.1

Spareparts stockage
By stocking the most important spare parts on site you can ensure that the coupling is ready for use.
To order spare parts, refer to the spareparts list.
We guarantee only the original spare parts supplied by us. Nongenuine spare parts
have not been tested or approved by us. They may alter technical characteristics of
the coupling, thereby posing an active and/or passive risk to safety. Siemens will
assume no liability or guarantee for damage caused by nongenuine spare parts not
supplied by Siemens. The same applies to any accessories not supplied by Siemens.
Please note that certain components often have special production and supply specifications and that we
supply you with spare parts which comply fully with the current state of technical development as well as
current legislation.
When ordering spare parts, always state the following:

Quantity
Designation
Size
Number of the coupling drawing
Position of the spare part in the spareparts list
11.2

Addresses for ordering spare parts and customer service


When ordering spare parts or requesting a service specialist, please contact Siemens first (see section 2,
"General notes").

BA 8704 en 04/2012
35 / 37

12.

Declarations

12.1

EC declaration of conformity

EC declaration of conformity
within the meaning of EC Directive 94/9/EC of 23.03.1994 and the legal requirements laid down for its
implementation
The manufacturer, Siemens AG, 46395 Bocholt, Germany, declares that the equipment described in these
assembly and operating instructions:

FLENDER ARPEX
all-steel couplings
ARS-6, ARP-6, ARH-8,
ARC-6/8/10, ARW-4/6, ARF-6 series
is in conformity with Article 1 and Article 8, Paragraph 1 b) ii) of Directive 94/9/EC and complies with the
requirements of Directive 94/9/EC and the following standards:
DIN EN 11271
DIN EN 134631
DIN EN 134635
DIN EN 1710

:
:
:
:

102011
072009
102011
082008

The technical documentation has been delivered to the body named below:
DEKRA EXAM GmbH, 44727 Bochum, Germany, code number: 0158.

Bocholt, 20120419
Andre Jansen
(Director Engineering KUE)

Bocholt, 20120419
Nicola Warning
(Director Business Subsegment KU)

BA 8704 en 04/2012
36 / 37

Further Information:
"FLENDER gear units" on the Internet
www.siemens.com/gearunits
"FLENDER couplings" on the Internet
www.siemens.com/couplings
Service & Support:
http://support.automation.siemens.com/WW/view/en/10803928/133300
Lubricants:
http://support.automation.siemens.com/WW/view/en/42961591/133000

Siemens AG
Industry Sector
Mechanical Drives
Alfred-Flender-Strae 77
46395 Bocholt
GERMANY

Subject to modifications
Siemens AG 2012

www.siemens.com/drive-technologies

Datenblatt fr Drehstrom-Kurzschlulufer-Motor
Data sheet for threephase induction motor
Toleranz IEC 60034
tolerance IEC 60034

Typ
Type
IEC Baugre
IEC size
Bauform
Mounting design
Umgebungstemperatur
Ambient temperature
Schutzart
Type of enclosure
Ex-Schutzart
Ex-Protection
Wrmeklasse
Thermal classification
Bemessungsleistung
Rated output
Betriebsart
Duty type
Bemessungsspannung
Rated voltage
Frequenz
Frequency
Drehzahl
Speed
Bemessungsstrom
Rated current
Anlaufstrom

CD 100 L2 - 4
100
B3
-20 ... 40
IP 55
II 2G Ex de IIC T4 Gb
F
3,6

kW

S1
D 440

60

Hz

1700
7,2
IA/IN

min-1
rpm
A

5,5

Starting current
Leistungsfaktor
Power factor
Wirkungsgrad
Efficiency
Bemessungsmoment
Rated torque
Anlaufmoment

MA/MN

2,3

Starting torque
Kippmoment

MK/MN

2,7

Breakdown torque
Gewicht
Weight
Bemerkung
Remarks

0,82
80,5

20,2

Nm

46
mit Kaltleiter als alleiniger Schutz
geeignet fr FU-Betrieb
nur grundiert
Motornr. 546441 001

ATV 1 Sabrina Solte 02.07.2014

kg

Mabild
Dimension drawing
nderungen vorbehalten
Rights of modification reserved

CD 100L2-4

L
LD
b
a

SP

BA

HA

BC

DB

HD

AC

AA

BB

AB

O1

O2

GA

Motormae / Motor dimensions


AC
201

L
415

LD
149

SP
230

H
100-0,5

E
60

GA
31

F
8

DB
M10

AB
200
HA
15

B
140
K
12 H17

BA
45

AA
45
C
63

BB
175

Mae Anschlussraum / Dimensions terminal box


a
145

b
145

c
88

d
53

Kabeleinfhrung / Cable gland


Gewindegre
Thread
Kabeldurchmesser
Cable diameter

IM B3/IM 1001

Anschlussraum / Terminal Box:

EAR 80

Kundenkennung / ITEM No.:

Fumae / Feet dimensions


A
160
BC
17,5

Bauform / Mounting:
HD
305

Wellenmae / Shaft dimensions


D
28 j6

Prinzipskizze Anschlussraum
Schematic Diagram Terminal Box

O1
M32x1,5

O2
M25x1,5

12-21

8-17,5

Kundenmotor-Nr. / Cust. motor No.:

Ex.-Schutz / Ex. protection:

Ex de

Zertifikat / Certificate:

08 ATEX 1087 X

Spannung / Voltage:
Frequenz / Frequency:
Leistung / Output:
Polzahl / Number of poles:
Syn. Drehzahl / Syn. speed:
Lager DS / Bearing d.e.:
Lager NS / Bearing n.d.e.:
Gewicht ca. / Weight approx.:
Fettsorte / Grease type:
Nachschmierfrist / Interval:
Fettmenge / Grease quantity:
Raumtemp. / Ambient temp.:
Kaltleiter / PTC-thermistor:

D 440 V
60 Hz
3,6 kW
4
1800 min-1
6206 2Z C3
6206 2Z C3
46 kg

-20 bis / up to +40 C


O2

Alle Mae in mm / All dimen. in mm


Nicht mastblich / Not to scale

Bemerkung / Notes:

Abt. / Dep.:

ATV

Datum / Date: 02.07.2014

Angebots-Nr. / Offer No.:


Motor-Nr. / Motor No.:
Rev. / Rev.:
Name / Name:
Seite / Page:
CD100L2-4 de B3 13.1100.0.00.00.1.2.1.1.0.0

546.441.001
00
S.Solte
1

Dieses Mabild wurde mit dem Mabildgenerator Version 1.6 erstellt. Alle Angaben sind nur nach Besttigung durch den Hersteller verbindlich.
This dim. drawing is generated with the dimension drawing generator version 1.6 All entries are only binding after confirmation of the producer.

Operating Manual

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Deutsch: Sollten Sie die Angaben in dieser Betriebsanleitung in der vorliegenden Sprache
nicht lesen knnen, so wenden Sie sich bitte an das Herstellerwerk.
Dansk: Hvis denne brugsanvisning ikke er skrevet p et sprog, som du forstr, s henvend
dig venligst til fabrikanten.
Suomi: Ellette pysty lukemaan tmn kyttohjeen tietoja olemassa olevalla kielell, ottakaa
yhteytt valmistajaan.
Franais: Si vous ne pouvez pas lire la langue dans laquelle sont crites les indications
contenues dans les prsentes instructions de service, veuillez vous adresser au fabricant.
Espaol: Si no puede leer las indicaciones en estas instrucciones de funcionamiento
editadas en el presente idioma, dirjase por favor a la empresa fabricante.
Elinika:
, .
English: If you cannot understand the operating instructions in the language provided please
contact the manufacturers.
Italiano: Se non potete leggere le informazioni contenute nelle istruzioni per luso nella lingua
in cui sono formulate, vi preghiamo di rivolgervi allo stabilimento di produzione.
Nederlands: Wanneer u op grond van de gebruikte taal de gegevens in deze
bedrijfshandleiding niet kunt lezen, verzoeken wij u om contact op te nemen met de fabrikant.
Portugs: Caso no lhe seja possvel compreender as indicaes neste manual de
instrues no presente idioma, queira contactar o fabricante, por favor.
Svenska: Om du inte frstr innehllet i instruktionsboken p det aktuella sprket, kontakta
tillverkaren.
etina: Pokud byste informace v tomto nvodu k obsluze nemohli st ve stvajcm jazyce,
obrate se prosm na vrobce.
Magyar: Ha a hasznlati tmutat adatai ezen a nyelven nem rthetek, akkor krjk,
forduljon a gyrthoz.
Slovenina: V primeru, da podatkov v priloenih navodilih za uporabo v danem jeziku ne
razumete, se obrnite na proizvajalca.
Slovenina: Pokia by ste daje v tomto nvode na pouitie v danom jazyku nevedeli
preta, obrte sa prosm na vrobn zvod.
Lietuvikai: Jei negalite perskaityti ioje naudojimo instrukcijoje tam tikra kalba pateikt
duomen, kreipkits gamintoj.
Latviski: Ja aj lietoanas pamcb informcija sniegta Jums nezinm valod, ldzam
Js vrsties raotjfirm.
Polski: Jeeli nie moecie Pastwo przeczyta instrukcji obsugi w tym jzyku, prosimy o
zwrcenie si z tym do zakadu produkcyjnego.
Eesti: Kui te ei suuda selle tegevusjuhendi andmeid antud keeles lugeda, siis palun
prduge tootjatehase poole.
:
, .
Romn: Dac nu nelegei instruciunile de exploatare n limba n care sunt furnizate, v
rugm s contactai productorul.

ATB NORDENHAM GmbH


Helgolnder Damm 75
26954 Nordenham, Deutschland
Tel. +49 4731 365 0
Fax: +49 4731 365 159
E-Mail: info@atb-nordenham.de
Web: www.atb-nordenham.de

BA 01.07-GB

Erklrung der EG-Konformitt


Declaration of EC-Conformity
Attestation de conformit CE
Wir erklren in alleiniger
Verantwortung, dass

We declare that it is our sole


responsibility that

Nous attestons sous notre


seule responsabilit

Drehstrommotoren

Three-Phase-Motors

Moteurs courant triphas

Typ CD

Type CD

Type CD

auf die sich diese Erklrung


bezieht, den Bestimmungen
der folgenden Richtlinie
entsprechen

to which this declaration


relates is in accordance with
the provision of the
following directives

se rfrant cette attestation


correspondent aux dispositions
des directives suivantes

94/9/EG

94/9/EEC

94/9/CEE

und mit folgenden


Normen bereinstimmen.

and is in conformity with the


following standards.

et sont conformes aux


normes.

EN 60079-0:2012
EN 60079-1:2007
EN 60079-7:2007
EN 60079-31:2009 (nur bei II 2D)
EN 60034-1,5,6,7,8,9,12,14

EN 60079-0:2012
EN 60079-1:2007
EN 60079-7:2007
EN 60079-31:2009 (only at II 2D)
EN 60034-1,5,6,7,8,9,12,14

EN 60079-0:2012
EN 60079-1:2007
EN 60079-7:2007
EN 60079-31:2009 (seulement II 2D)
EN 60034-1,5,6,7,8,9,12,14

Kennzeichnung

Marking

Marquage

0044

II 2G Ex d IIC T3...T6 Gb bzw. Ex de IIC T3...T6 Gb


PTB 08 ATEX 1087 X
oder wahlweise / or optional / ou au choix II 2D Ex tb IIIC T200 C T85 C Db

Das bezeichnete Produkt ist zum Einbau in


eine andere Maschine bestimmt. Die
Inbetriebnahme ist solange untersagt, bis
die Konformitt des Endproduktes mit der
Richtlinie 2006/42/EG festgestellt ist.

The indicated product is intended for


installation into a different machine.
Operation is prohibited until the final
product concurs with the 2006/42/EEC
regulations.

Diese Erklrung ist keine Zusicherung von This statement does not warrant any
Eigenschaften im Sinne der
characteristics regarding product liability.
Produkthaftung.
Die Sicherheitshinweise der
Produktdokumentation sind zu beachten.

Le produit indiqu est prvu pour tre


intgr dans une machine. La mise en
service nest autorise que lorsque la
conformit du produit final selon la
directive 2006/42/CEE a t vrifie.
Cette dclaration ne constitue pas une
assurance des proprits au sens de la
responsabilit produit.

Safety instructions stated in the production Les consignes de scurit rappeles dans la
records have to be adhered to.
documentation du produit doivent tre
respectes.
Mehrere der in der zugehrigen EGMore of the standards stated in the
Baumusterprfbescheinigung genannten
respective EC-Type-Examination
Plusieurs de ces normes appartenant
Normen wurden bereits durch neue
Certificate have already been replaced by
lattestation CE des certificats dessai de
Ausgaben ersetzt. Der Hersteller erklrt fr new editions. The manufacturer
type, ont fait lobjet de nouvelles ditions.
das Produkt die bereinstimmung auch
Le constructeur dclare la conformit du
declares that his product also complies
mit den Anforderungen der neuen
with the requirements of the new editions produit suivant les exigences des nouvelles
Normenausgaben, da entsprechende
normes. Des essais appropris ont t
since the tests has been done.
Prfungen durchgefhrt wurden.
effectus.

Nordenham, den 1. Mai 2013, Ausgabe 6

ATB NORDENHAM GMBH


HELGOLNDER DAMM 75
D-26954 NORDENHAM

Wolfgang Sobel
Leiter Konstruktion

Physikalisch-Technische Bundesanstalt
'V' 'T'-

Braunschweig und Berlin

Zertifizierungsstelle, Zertifizierungssektor Explosionsschutz


Physikalisch-TechnischeBundesanstalt,Postfadi33 45,38023 Braunschwei
Ihr Zeidien:
Ihre Nadvicht vom:
Mein Zeichen:

AT6 Motorentechnik GmbH


Herrn Sobel
Helgolnder Damm 75

Meine Nadiriditvom:

ATB2011-10-17.docx
Teleiaxdurchwahl:

Jrg Fltotto
05311592-3599
05311592-693599

E-Mai:

Joerg.floetotto@ptb.de

Bearbeitetvon:
Telefondurchwahl:

26954 Nordenham

EC-Type-Examination Certificate PTB 08 ATEX 1087 X / Three phase motor type CD 315

Dear Mr. Sobel,


we are pleased to confirm that the motor of type CD 315 within the above mentioned certificate
can be operated up to speeds of 5300 rpm.
An additional reference pressure test has been done according to EN 60079-1:2007, clause
15.1.3 with the motor in running (5300 rpm.) and in standstill. A pre compression factor of 1.34
has been applied for admissible ambient temperatures down to -55 "C. Furthermore a dynamic
overpressure test according to clause 15.1.3.2 has been done with Acetylene and Hydrogen.
The required pressures of 1.5 times reference pressure could be achieved for each gas. No
damage of the enclose and no transfer of internal ignition to the outside atmosphere could be
detected.

A static overpressure test according to clause 16.1 and PTB working instruction PL-Ex-1 / 3.5
AA-2.13is required as a routine for the flameproof motor enclosure. For this test a test pressure
of 20 bar has to be applied. In case of admissible motor ambient temperatures below -20 "C
and down to -55 "C this pressure shall be increased to 27 bar.
All the other details of test report PTB Ex 08-18277 and the certificate PTB 08 ATEX 1087X
remain unchanged.
We hope that we could help you with our short statement. In case of any further questions don't
hesitate to contact us.

=sS
Best regards,

Jrg Fltotto

o" Test protocol No.: 2011 / 00241.I


.0 / 2682
O
0
h.

",

Hausadresse, Lleferanschrift
Bundesallee 100
38116 Braunschwelg
DEUTSCHLAND

Telefon: +49 531 592-0


Telefax: +49 531 592-9292
E-Mail: poststelle@ptb.de
Intemet: http:liwww.ptb.de

Achtung neue Bankverblndung ab 25, M a n 2011:


Deutsche Bundesbank, Filiale Leipzig
PTB Berlin-Charlottenburg
BLZ 860 000 00
Abbestr. 2-12
Kto.-Nr.: 860 010 40
IBAN:DE38660000000088001040
10587 Beriin
DEUTSCHLAND
BIC: MARKDEFI860. VAT-Nr.: DE 81 1 240 952

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