Instruction manual. CombiBloc. Horizontal centrifugal monobloc pump

Transcription

1 Instruction manual CombiBloc Horizontal centrifugal monobloc pump CB/EN (0402) 4.0

2 EC Declaration of conformity (Directive 98/37/EC, appendix II-A) Manufacturer Johnson Pump Water B.V. Dr. A.F. Philipsweg 51 P.O. Box AA Assen Netherlands hereby declares that the pump, in case it is delivered as an assembly with drive (last position of serial number = A), is in conformity with the provisions of Directive 98/37/EC (as altered most recently) and the following directives and standards: EC directive 73/23/EEC, "Electric equipment for use within certain voltage limits" standards EN 292 part 1 & 2, EN 809 The pump to which this declaration refers may only be put into operation after it has been installed in the way prescribed by the manufacturer, and, as the case may be, after the complete system of which this pump forms part, has been made to fulfil the requirements of Directive 98/37/EC (as altered most recently). Manufacturer s declaration (Directive 98/37/EC, appendix II-B) Manufacturer Johnson Pump Water B.V. Dr. A.F. Philipsweg 51 P.O. Box AA Assen Netherlands hereby declares that the pump, in case it is delivered without drive (last position of serial number = B), is in conformity with the following standards: EN 292 parts 1 & 2, EN 809 and that this pump is meant to be incorporated in or combined with another machine (electric motor, combustion engine) and may only be put into use after the complete machine of which the pump under consideration forms part has been made and declared to comply with that directive. Assen, Janary 1st 2004 P. Ressenaar Director II-A / II-B (EN)

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4 CombiBloc Instruction manual CombiBloc All technical and technological information in this manual as well as possible drawings made available by us remain our property and shall not be used (otherwise than for the operation of this CombiBloc pump), copied, duplicated, made available to or brought to the notice of third parties without our prior written consent. Johnson Pump Water BV (hereafter called Johnson Pump) is part of Johnson Pump International AB. The core activities of Johnson Pump International AB are the development, production, sale and maintenance of pumps and pump units. Johnson Pump Water BV P.O. Box AA Assen The Netherlands Tel. +31 (0) Fax. +31 (0) Johnson Pump Water BV CB/EN (0402) 4.0 Instruction manual CombiBloc 1

5 2 Instruction manual CombiBloc

6 CombiBloc Table of contents 1 Introduction Preface Safety Guarantee Service and support Ordering spare parts Pump number Inspection of delivered items Forwarding instructions Dimensions and weight Use of pallets Lifting Storage 9 2 General Pump description Type code Applications Construction Design Materials Shaft sealing Bearing construction Application area Re-use Scrapping 13 3 Installation 15 Table of contents 3

7 3.1 Safety Preservation Environment Installation of the set Piping Mounting accessories Connection of the electric motor Voltage data Connection 220/380V and 230/400V Connection 380/660V and 400/695V 17 4 Commissioning Control pump Control electric motor Preparing the unit for commissioning Checking the sense of rotation Starting the pump Control Noise 20 5 Maintenance Daily maintenance Mechanical seal Lubrication of the bearings Environmental influences Noise Faults 22 6 Cause of failures 23 7 Disassembly and assembly Precautionary measures Tools Liquid draining Disassembly Back Pull Out system Disassembly Back Pull Out unit Assembly Back Pull Out unit Replacement of impeller and casing wear ring Disassembly of the impeller 27 4 Table of contents

8 CombiBloc Assembly of the impeller Disassembly of the casing wear ring Assembly of the casing wear ring Mechanical seal Instructions for mounting a mechanical seal Disassembly of the mechanical seal Assembly of the mechanical seal Replacing the stub shaft and the motor Disassembly of the stub shaft and the motor Assembly of stub shaft and the motor 32 8 Dimensions and weights Foot dimensions Dimensions CombiBloc G1, G2 en B2 (cast iron or bronze) Dimensions CombiBloc R6 (stainless steel) Weights 40 9 Parts Ordering parts and spare parts Order form Pump number Recommended spare parts Sectional drawing Parts list Sectional drawing shaft sealing CB Technical data Recommended locking liquids Tightening moments Tightening moments for bolts and nuts Tightening moments for impeller nut Maximum allowable speed Survey curves Cast iron/bronze pump Stainless steel pump Noise data Noise as a function of pump power Noise level 52 Index 53 Table of contents 5

9 Order form for spare parts 55 6 Table of contents

10 CombiBloc 1 Introduction 1.1 Preface This manual contains important and useful information for the proper functioning and maintenance of this pump. It also contains important instructions to prevent possible accidents and serious damage and to ensure the safe and smooth functioning of this pump.! Read this manual carefully before commissioning the pump. Familiarize yourself with the operation of the pump and strictly obey the instructions! The data published here comply with the most recent information at the time of going to press. However they may be subject to later modifications. Johnson Pump reserves the right to change the construction and design of the products at any time without being obliged to change earlier deliveries accordingly. 1.2 Safety The manual contains instructions for the safe operation of the pump. Operators and maintenance staff shall be familiarized with these instructions. A list of the symbols used in the aforementioned instructions as well as their meaning is stated below: Personal danger for the user. Strict and prompt observance of the corresponding instruction is imperative!! Risk of damage to or bad functioning of the pump. Obey the corresponding instruction to avoid this risk. Useful direction or tip for the user. Subjects that require extra attention are printed in bold typeface. This manual has been compiled by Johnson Pump with the utmost care. Nevertheless Johnson Pump cannot guarantee the completeness of this information and therefore assumes no liability for possible deficiencies in this manual. The buyer/user shall at all times be responsible for testing the information and for taking possible additional and/or deviating safety measures. Johnson Pump reserves the right to change the safety instructions at any time. Introduction 7

11 1.3 Guarantee Johnson Pump shall not be bound to any guarantee other than the guarantee accepted by Johnson Pump. In particular, Johnson Pump will not assume any liability for explicit and/or implicit guarantees such as but not limited to the marketability and/or suitability of the articles supplied. The guarantee shall forthwith and legally defunct in case: Service and/or maintenance has not been carried out strictly in accordance with the instructions. Necessary repairs have not been carried out by our personnel or have been carried out without our prior written consent. The articles supplied have been changed without our prior written consent. The spare parts used are not original Johnson Pump parts. Additives or lubricants used are other than those prescribed. The articles supplied are not used according to their nature and/or destination. The articles supplied are used amateurishly, carelessly, improperly and/or negligently. The articles supplied become defective due to outside circumstances beyond our control. All wearing parts shall be excluded from guarantee. Furthermore, all deliveries are subject to our "General conditions of delivery and payment", which will be forwarded to you free of charge on request. 1.4 Service and support This manual is intended for technicians and maintenance staff and for those who are in charge of ordering spare parts Ordering spare parts This manual contains the spare - and replacement parts recommended by Johnson Pump. A fax-order form is included in this manual. If you have questions or require further information about specific items, please don t hesitate to contact Johnson Pump Pump number The pump number is stated on the pumps type plate. Please refer to this number and the other data mentioned on the type plate when corresponding or ordering parts. These pump data are also stated on the label in the beginning of this manual. 1.5 Inspection of delivered items Check the consignment immediately on arrival for damage and conformity with the advice note. In case of damage and/or missing parts, have a report drawn up by the carrier at once. 8 Introduction

12 CombiBloc 1.6 Forwarding instructions Dimensions and weight The larger pump types of the CombiBloc family are too heavy to move them by hand. So use proper forwarding and lifting equipment. Dimensions and weight of the pump are stated on the label in the beginning of this manual Use of pallets In most cases the pump is packed on a pallet. In that case leave the pump on the pallet as long as possible in order to avoid damages and facilitate possible further transport in case the pump has to be moved elsewhere.! When using a forklift: Always place the shovels of the forklift as far apart as possible and lift the box with both levels to prevent it from toppling over Lifting If a pump or a complete pump unit has to be lifted, the slings should be fixed as shown in figure 1. Never stand underneath a load that is being lifted! figure 1 Lifting instructions pump. 1.7 Storage In case the pump is not immediately being used, the pump shaft has to be rotated manually twice a week. Introduction 9

13 10 Introduction

14 CombiBloc 2 General 2.1 Pump description The CombiBloc is a range of horizontal non-self-priming centrifugal pumps. The pump and the standard IEC flange motor are assembled by means of a lantern and a stub shaft to one complete unit. The CombiBloc is available in cast iron, bronze and stainless steel. The cast iron and bronze pump casings comply with DIN 24255, the stainless steel pump casings comply with ISO 2858 respectively DIN Type code Pumps of the CombiBloc family are available in various designs. The main characteristics of the pump are shown in the type code. Example: CB G2 90S Pump family: CB=CombiBloc Pump size: diameter discharge connection [mm] - nominal impeller diameter [ mm] pump casing/pump cover and impeller material G1 pump casing/pump cover: cast iron impeller: cast iron G2 pump casing/pump cover: cast iron impeller: bronze B2 pump casing/pump cover: bronze impeller: bronze R6 pump casing/pump cover: stainless steel impeller: stainless steel IEC size electric motor 80 90S 90L 100L 112M 132S 132M 160M 160L 180M 200L 225M 250M 280S 280M General 11

15 2.3 Applications In general, the CombiBloc pumps can be used for thin, clean or slightly polluted liquids. These liquids should not affect the pump materials. Further details about the application possibilities of your specific pump are mentioned in the order confirmation and/or in the data sheet enclosed with the delivery. Please do not use the pump for purposes other than those for which it is delivered without prior consultation with your supplier. Using a pump in a system or under system conditions (liquid, working pressure, temperature, etc.) for which it has not been designed may hazard the user! 2.4 Construction Design The design is characterized by a compact construction. The pump is combined, by means of a lantern and stub shaft, with a standard IEC electric motor. type B5 for electric motors upto and including size 112M, type B3/B5 for bigger types, in vertical position type V1 for all types. The pump cover is clamped between the pump casing and the lantern piece Materials This concerns the parts that are exposed to the pumped liquid. For each individual pump type there is only one construction of pump casing and impeller. These parts are available in 3 different types of material: cast iron, bronze and stainless steel. The stub shaft is made of stainless steel Shaft sealing The CombiBloc is provided with a mechanical shaft seal with mounting dimensions according to DIN (L1K). Only 3 diameters are used for the whole CombiBloc range: d1 = 30 mm, 40 mm or 50 mm Bearing construction The bearing of the CombiBloc is provided by the motor bearings. The choice of the motor-pump is such that the bearings of the applied electric motors can absorb the axial and radial forces without the bearing life being affected. The electric motors must be provided with a fixed bearing. 12 General

16 CombiBloc 2.5 Application area The application area globally looks as follows: Maximum value Capacity 850 m 3 /h Delivery head 105 m System pressure 10 bar Temperature 110 C 2.6 Re-use The pump may only be used for other applications after prior consultation with Johnson Pump or your supplier. Since the lastly pumped medium is not always known, the following instructions should be observed: Flush the pump properly Make sure the flushing liquid is discharged safely (environment!) Take adequate precautions and use the appropriate personal protection means (rubber gloves, spectacles)! 2.7 Scrapping If it has been decided to scrap a pump, the same procedure as for Re-use (2.6) should be followed. General 13

17 14 General

18 CombiBloc 3 Installation 3.1 Safety Read this manual carefully before installing and commissioning the pump. Non-observance of these instructions may cause serious damage to the pump that is not covered by our guarantee terms. Follow the instructions step by step. Make sure the motor cannot be started when work is done to the pump- motor combination and running parts are insufficiently shielded. The pumps are suitable for liquids with a temperature up to 110 C. As from 70 C the user, when installing the pump unit, should take appropriate protection and warning measures to prevent contact with hot pump parts. If danger arises in case of static electricity, the entire pump unit should be earthed properly. If there is a danger that the pumped liquid might be harmful to men or the environment, the user should take appropriate measures for safe drainage. Also possible leakage fluid from the shaft seal should be safely discharged. 3.2 Preservation To prevent corrosion, the pump is flushed with a preserving agent before leaving the works. Before putting the pump into operation, drain off any preservative agent and flush the pump thoroughly with hot water. 3.3 Environment The foundation must be hard, level and flat. The area in which the pump unit is to be placed should be adequately ventilated. A too high ambient temperature and air humidity, as well as a dusty environment may have a negative effect on the functioning of the motor. Around the pump unit there should be enough space to operate and if necessary repair the pump. Behind the cooling air inlet of the motor there should be a free area of at least 1/4 of the electric motor diameter, to ensure unobstructed air supply. 3.4 Installation of the set If the unit is delivered as a complete set, pump and motor are assembled in the works. In that case the impeller has already been properly adjusted axially. In case of permanent arrangement, level the pump on the foundation by means of shims and carefully tighten the nuts of the foundation bolts. Installation 15

19 3.5 Piping The piping to the suction and delivery connections must fit exactly and must not be subject to stress during operation. The passage of the suction pipe must be amply dimensioned. This pipe should be as short as possible and run towards the pump in such a way that no air pockets can arise. If this is not possible, a venting facility should be provided at the highest point of the pipe. If the inside diameter of the suction pipe is larger than the suction connection of the pump, an excentric reducer should be applied to prevent air pockets and whirls. See figure 2. figure 2 Excentric reducer to suction flange. The maximum allowable system pressure is stated in 2.5. If there is a risk that this pressure might be exceeded, for instance because of an excessive inlet pressure, appropriate measures should be taken by mounting a safety valve in the piping. Sudden changes in the rate of flow can lead to high pressure impulses in the pump and the piping (water shock). Therefore, don t use quick-acting closing devices, valves etc. 3.6 Mounting accessories Mount any parts that may have been supplied separately. If the liquid does not flow towards the pump, mount a foot valve at the bottom of the suction pipe. If necessary, combine this foot valve with a suction strainer to prevent impurities from being drawn in. When mounting, place temporarily (for the first 24 operating hours) a fine gauze between suction flange and suction pipe so as to prevent internal pump parts from being damaged by foreign matter. If the risk of damage continues to exist, mount a permanent filter. 3.7 Connection of the electric motor Regulations The electric motor must be connected to the mains by an approved electrician, according to the locally prevailing regulations of the electricity company. Always use a thermal motor safety switch. If possible, mount a working switch as close as possible to the pump. It is recommended to mount an earth leakage circuit breaker. 16 Installation

20 CombiBloc Voltage data On the type plate of the electric motors you will find one of the following voltage data: 220/380V 50Hz upto and incl. 1,5 kw. 380/660V 50Hz from 2,2 kw upward. or, if designed for Euro voltage: 230/400V 50Hz (277/480V 60Hz) upto and incl. 1,5 kw. 400/695V 50Hz (480/830V 60Hz) from 2,2 kw upward. Consult your supplier in case of deviating voltages and mains frequencies Connection 220/380V and 230/400V These motors can be connected in star to a mains of 380V cq. 400V between the phases. See figure 3 for correct connection. figure 3 Star connection Connection 380/660V and 400/695V These motors must be connected in delta to a mains of 380V cq. 400V between the phases. See figure 4 for the correct connection. figure 4 Delta connection. Installation 17

21 Motors with a power of 2,2 kw and more usually should not be connected in delta directly (the starting current will raise too much immediately after the motor has been started). So, the motor is first connected in star and after a few seconds when it has reached the required speed, it is converted to delta by means of a star-delta switch. See figure 5. figure 5 Star-delta switch. 18 Installation

22 CombiBloc 4 Commissioning 4.1 Control pump Check whether the shaft turns freely. Do this by turning the stub shaft a few times. 4.2 Control electric motor Check whether the fuses have been mounted. 4.3 Preparing the unit for commissioning Proceed as follows, both when the unit is put into operation for the first time and after the pump has been overhauled: 1 Fully open the stop valve in the suction pipe. Close the delivery stop valve. 2 Fill the pump and the suction pipe with the liquid to be pumped. 3 Turn the pump shaft a few times by hand and add more liquid, if necessary. 4.4 Checking the sense of rotation Beware of possible non-screened rotating parts when checking the sense of rotation! 1 The sense of rotation of the pump is indicated by an arrow. Check whether the sense of rotation of the motor corresponds with that of the pump. 2 Let the motor run for only a short time and check the sense of rotation. 3 If the sense of rotation is not correct, change connecting wire L1 and L2, see figures 3 and 4. 4 Mount the protective cap. 4.5 Starting the pump 1 Start the pump. 2 As soon as the pump is under pressure, slowly open the delivery stop valve until the working pressure is attained. Make sure that when a pump is running, rotating parts are always properly screened off by the protective cap! Commissioning 19

23 4.6 Control If a pump is in operation pay attention to the following: The pump should never run dry. Never use a stop valve in the suction pipe to control pump capacity. The stop valve should always be fully opened during operation Check whether the absolute inlet pressure is sufficient, so that no vapour can be formed. Check whether the pressure difference between suction and delivery pressure corresponds with the specifications for the duty point of the pump. The mechanical seal may never show visible leakage. 4.7 Noise The noise production of a CombiBloc pump depends to a great extent on the operating conditions. The values stated in chapter 10 are based on normal operation of the pump, driven by an electric motor. In case the pump is used outside the normal operation area, as well as in case of cavitation, the noise level may exceed 85 db(a). In that case precautions should be taken, like building a noise-barrier around the unit or wearing hearing protection. 20 Commissioning

24 CombiBloc 5 Maintenance 5.1 Daily maintenance Regularly check the outlet pressure. No water should get into the terminal box of the electric motor when the pump room is sprayed clean! Never spray water on hot pump parts! The sudden cooling down may cause them to burst and hot water may flow out! 5.2 Mechanical seal A mechanical seal generally requires no maintenance, however, it should never be allowed to run dry. If there are no problems it is not advisable to dismantle the seal. As the facing surfaces are running in on one another. Dismantling always means replacement of the mechanical seal. When the shaft seal is leaking it has to be replaced. 5.3 Lubrication of the bearings For maintenance of the motor bearings we refer to the instructions of the motor supplier concerned. 5.4 Environmental influences Regularly clean the filter in the suction pipe or the suction strainer at the bottom of the suction pipe, as the inlet pressure may become too low if the filter or the suction strainer is fouled. If there is a risk that the pumped liquid expands during solidification or freezing, the pump has to be drained and, if necessary, flushed after it has been put out of service. If the pump is out of service for a long time, it has to be preserved. 5.5 Noise If, after some time, the pump starts making noise this may indicate that something is wrong with the pump unit. For instance, a crackling noise can indicate cavitation or an excessively noise motor can indicate deterioration of the bearings. Maintenance 21

25 5.6 Faults The pump, of which you want to determine the fault, may be hot or under pressure. Take the appropriate precautions first and protect yourself with the proper safety devices (safety goggles, gloves, protective clothing)! To determine the source of the malfunctioning of the pump, proceed as follows: 1 Switch off the current supply to the pump unit. Block the working switch with a lock or remove the fuse. 2 Close the stop valves. 3 Determine the nature of the fault. 4 Try to determine the cause of the fault (see chapter 6) and take the appropriate measures, or: Contact your installer! 22 Maintenance

26 CombiBloc 6 Cause of failures Most frequently occurring failures In general, failures in a pump unit are attributable to the following causes: 1 Failures in the pump. 2 Failures or faults in the piping system. 3 Failures due to wrong installation or commissioning. 4 Failures due to a wrong pump selection. A number of the most frequently occurring failures as well as their possible causes are set forth in the table below: Possible causes Pump doesn t deliver any liquid The volume flow of the pump is insufficient The discharge head of the pump is insufficient Pump stalls after it has been put into operation The power consumption of the pump is higher than normal The power consumption of the pump is lower than normal Mechanical seal has to be replaced too often Pump vibrates or makes noise Bearings wear too soon or get hot Pump runs with difficulty, gets hot or gets stuck Cause of failures 23

27 Possible causes 1 Pump or suction pipe not sufficiently filled or de-aerated 2 Gas or air coming from the liquid 3 Air lock in the suction pipe 4 Suction pipe leaks air 8 The manometric suction head is too high. 9 Suction pipe or suction strainer is blocked. 10 Insuffiecient immersion of foot valve or suction pipe during operation of the pump. 11 NPSH available too low. 12 Speed too high. 13 Speed too low. 14 Wrong sense of rotation. 15 Pump doesn t work at the right duty point. 16 Liquid density differs from the calculated liquid density. 17 Liquid viscosity differs from the calculated liquid viscosity. 18 Pump works when the liquid flow is too low. 19 Wrong pump selection. 20 Obstruction in impeller or pump housing. 21 Obstruction in the piping. 22 Wrong installation of the pump unit. 23 Pump and motor not well aligned. 24 Rotating part running out of true. 25 Imbalance in rotating parts (for instance impeller, stub shaft) 26 Pump shaft is running out of true. 27 Bearings faulty or worn out. 28 Sealing ring faulty or worn out. 29 Damaged impeller. 30 Running surfaces of the mechanical seal are worn out or damaged. 32 Bad mounting of the mechanical seal. 33 Mechanical seal not suitable for the operation liquid or operation circumstances. 36 The flushing liquid to the mechanical seal is polluted. 37 Axial retaining of impeller or pump shaft is defective. 38 The bearings have been mounted wrongly. 39 Too much or too little bearing lubrication. 40 Wrong or polluted lubricant. 42 Too high axial force because of worn dorsal blades or excessive inlet pressure. 24 Cause of failures

28 CombiBloc 7 Disassembly and assembly 7.1 Precautionary measures Take adequate measures to avoid that the motor is started while you are working on the pump. This is especially important for electric motors with remote control: Switch the operating switch near the pump (if available) to "off". Switch off the pump switch on the switchboard. If necessary remove the fuses. Hang a danger board near the switchboard cabinet. 7.2 Tools For assembly and disassembly no special tools are required. However: special tools can make certain jobs easier, like replacing a mechanical seal. When this is the case it will be stated in the instructions. 7.3 Liquid draining! Make sure no liquid gets into the environment! Before starting any disassembly the pump should be drained by removing the drain plug (0310). If necessary, close the valves in the suction and delivery pipe. Take the following precautions if harmful liquids are pumped: 1 Wear protective gloves, shoes, glasses, etc. 2 Flush the pump properly. 3 Then put the draining plug back. (CB/EN #B) Disassembly and assembly 25

29 7.4 Disassembly Back Pull Out system CombiBloc pumps have a Back Pull Out system. The entire rotating part can be removed together with the motor. This means that almost the whole pump can be demounted without having to detach the suction and delivery piping Disassembly Back Pull Out unit figure 6 Disassembly of Back Pull Out unit. 1 Open the terminal box and loosen the wires. 2 If the electric motor has been mounted on a separate foundation, loosen the electric motor. 3 Remove the allen screws (0800).! NEVER start dismantling by loosening the motor bolts (0850) and nuts (0900). This may result in irrepairable damage to the shaft seal and the impeller! 4 Pull the motor together with the entire lantern out of the pump casing. The Back Pull Out unit of big pumps is heavy. Support it for instance with a beam, or use a pulley Assembly Back Pull Out unit 1 Mount a new pump casing packing (0300). 2 Mount the complete lantern with motor back into the pump casing. Tighten the allen screws (0800) crosswise. 26 Disassembly and assembly

30 CombiBloc 7.5 Replacement of impeller and casing wear ring The play between the impeller and the casing wear ring is 0,3 mm to the diameter at delivery. In case the play has increased to 0,5-0,7 mm due to wearing, the impeller and the casing wear ring should be replaced. figure 7 Disassembly of impeller Disassembly of the impeller The item numbers used are referring to figure 7 1 Disassemble the Back Pull Out unit. 2 Remove the impeller cap nut (1820), washer (1830) and spring washer (1825). Sometimes the nut has to be heated to break the Loctite-contact. 3 Remove the impeller (0120) with a pulley puller (or by inserting for instance 2 big screwdrivers between the impeller and the pump cover (0110). 4 Remove the impeller key (1860) Assembly of the impeller 1 Place the impeller key in the key way of the pump shaft. 2 Push the impeller onto the pump shaft against the spacer (1100)(CB : against the shaft shoulder). 3 Degrease the thread on the pump shaft and the thread in the impeller nut. 4 Put a drop of Loctite 242 Nutlock on the thread and mount the impeller nut with washer and spring washer. For the tightening moment of the nut please refer to the table in chapter Mount the Back Pull Out unit. (CB/EN #B) Disassembly and assembly 27

31 7.5.3 Disassembly of the casing wear ring This concerns / / / / / and all R6 (=stainless steel) versions b d A B C D figure 8 Disassembly of casing wear ring. After removing the Back Pull Out unit the casing wear ring can be removed. In most cases this ring is fixed so tightly that it cannot be removed undamaged. 1 Measure the thickness (d) and the width (b) of the ring, see figure 8A. 2 Make a centre hole in the middle of the edge of the ring at two opposite points, see figure 8B. 3 Use a drill with a diameter just a little bit smaller than the thickness (d) of the ring and drill two holes in the ring, see figure 8C. Don t drill deeper than the width (d) of the ring. Take care not to damage the fitting edge of the pump casing. 4 Use a chisel to cut the remaining part of the ring thickness. Now you can remove the ring in two parts from the pump casing, see figure 8D. 5 Clean the pump casing and carefully remove all bore dust and metal splinters Assembly of the casing wear ring 1 Clean and degrease the fitting edge of the pump casing where the casing wear ring is to be mounted. 2 Degrease the outer edge of the casing wear ring and put a few drops of Loctite 242 Nutlock on it. 3 Mount the casing wear ring in the pump casing. Take care it is not pushed out of alignment! 28 Disassembly and assembly

32 CombiBloc 7.6 Mechanical seal Instructions for mounting a mechanical seal First read the following instructions regarding the mounting of a mechanical seal. Follow these instructions closely when mounting a mechanical seal. Leave the assembly of a mechanical seal with PTFE (Teflon) covered O-rings to a specialist. These rings are easily damaged during assembly. A mechanical seal is a fragile precision instrument. Leave the seal in its original packing until you are ready to mount it! Clean all receiving parts properly. Make sure your hands and working environment are clean! Never touch the sliding surfaces with ones fingers! Take care not to damage the seal during assembly. Never put the rings down on their sliding surfaces! Special tools: Mounting the shaft seal unit is easier when you use a special tapered mounting bush. That way, the sharp shaft edges are covered so that the risk of damaging the seal during assembly is reduced. See figure 9. figure 9 Assembly of mechanical seal by means of a special mounting sleeve. (CB/EN #B) Disassembly and assembly 29

33 7.6.2 Disassembly of the mechanical seal The item numbers used are referring to figure 10 and figure 11. figure 10 Disassembly of mechanical seal. 1 Remove the impeller, see (Only for CB : Loosen the set screw (1260), see figure 11). 3 Pull the distance sleeve (1100) (CB : spacer sleeve (1200)) and the rotating part of the shaft seal (1220) off the shaft. 4 Mark the position of the pump cover (0110) in relation to the lantern (0250). Knock the pump cover loose and remove it. 5 Push the counter-ring of the shaft seal out of the pump cover. 30 Disassembly and assembly

34 CombiBloc Assembly of the mechanical seal 1 Make sure the stub shaft (2200) is not damaged. If it is, replace it. 2 Place the electric motor with the shaft upright. 3 Put the pump cover down flat and press the counter-ring of the seal straight into it. If necessary, use a plastic pressure piece. Never hammer it inside! The maximum axial turn of the counter-ring is 0,1 mm. 4 Mount the pump cover in the right position in the collar of the lantern. Check whether the pump cover is at right angles to the pump shaft. 5 Push the rotating part of the shaft seal and the distance sleeve (1100) (CB : spacer sleeve (1200)) onto the stub shaft. Put some glycerine or silicon spray on the bellows to prevent it from rolling on the shaft sleeve. 6 CB : Set the distance between the spacer sleeve and the shaft shoulder at 44 mm. Then fix the spacer sleeve by means of set screw (1260). See figure Mount the impeller and the other parts, see figure 11 Adjusting the mechanical seal of CB (CB/EN #B) Disassembly and assembly 31

35 7.7 Replacing the stub shaft and the motor figure 12 Assembly of stub shaft. The item numbers used are referring to figure Disassembly of the stub shaft and the motor 1 Remove the impeller and the shaft seal, see and Loosen the bolts (0850) and nuts (0900) and remove the lantern (0250) from the motor. 3 Remove both the protective caps (0270). 4 Loosen the set screws (2280) and pull the stub shaft (2200) from the motor shaft Assembly of stub shaft and the motor 1 For electric motors with IEC-size 80 upto and including 112M: remove the key from the motor shaft. 2 Put the motor in vertical position, shaft end up. Slide the stub shaft (2200) over the motor shaft. Don t fix the stub shaft yet. 3 For electric motors with IEC size 80 upto and including 112M: make sure the set screws (2280) are positioned over the key way in the motor shaft. 4 Mount the lantern (0250) on the electric motor, placing 0,5 mm shims between the lantern and the motor flange. 5 Then mount the pump cover (0110), the shaft seal (1200) and the impeller (0120). 6 Push the impeller over the motor shaft until the back blades lie against the pump cover. 7 Secure the stub shaft on the motor shaft with the set screws (2280). 8 Slightly loosen the fastening bolts (0900) of the electric motor and remove the shims. 9 Secure the electric motor. The distance between the back blades of the impeller and the pump cover should now be 0,5 mm. 10 Mount the pump casing and the protective caps (0270). 32 Disassembly and assembly

36 CombiBloc 8 Dimensions and weights figure 13 Dimensions. 8.1 Foot dimensions IEC dc IEC dc vm vn vo vp vr vs S S M L M L L M M L L S M M S M Dimensions and weights 33

37 8.2 Dimensions CombiBloc G1, G2 en B2 (cast iron or bronze) CB aa* ab* db tu va vb vc vd ve vf vj zb zh * ISO 7005 PN 16 DIN 2533 * ISO 7005 PN 10 DIN Dimensions and weights

38 CombiBloc IEC electric motor CB 80 90S 90L 100L 112M 132S 132M 160M 160L 180M 180L 200L 225S 225M 250M 280S 280M ta Dimensions and weights 35

39 IEC electric motor CB 132S 132M 160M 160L 180M 180L 200L 225S 225M 250M 280S 280M vt Dimensions and weights

40 CombiBloc 8.3 Dimensions CombiBloc R6 (stainless steel) CB aa* ab* db tu va vb vc vd ve vf vj zb zh * ISO 7005 PN 16 DIN 2543 Dimensions and weights 37

41 IEC electric motor CB 80 90S 90L 100L 112M 132S 132M 160M 160L 180M 180L 200L 225S 225M 250M 280S 280M ta Dimensions and weights

42 CombiBloc IEC electric motor CB 132S 132M 160M 160L 180M 180L 200L 225S 225M 250M 280S 280M vt Dimensions and weights 39

43 8.4 Weights Weight [kg] without electric motor CB IEC electric motor 80/90S/90L 100L/112M 132S/M 160M/L 180M/L 200L 225S/M 250M 280S/M ,5 27, , , , ,5 54,5 55,5 57,5 57,5 62, , ,5 36, , , ,5 55,5 56,5 58,5 58,5 63, , ,5 34,5 35,5 38, ,5 41, ,5 45, ,5 53,5 54,5 56,5 56,5 61,5 62, , ,5 38, , , , ,5 46,5 47,5 50,5 50, , ,5 63, , ,5 70,5 70,5 75,5 76,5 82,5 82, ,5 52, , ,5 72, ,5 76, , ,5 80,5 87,5 87, ,5 87,5 88,5 90,5 90,5 95,5 96,5 102,5 102, ,5 62, , ,5 111,5 111,5 116, , ,5 87, ,5 91, , , Dimensions and weights

44 CombiBloc 9 Parts 9.1 Ordering parts and spare parts Order form You can use the order form included in this manual for ordering parts. You must always state the following on the order: 1 Your address information. 2 The quantity, the item number and the description of the part. 3 The pump number. 4 In the event of different voltages for the electric motor you should state the correct voltage Pump number When ordering parts for a pump, please quote the pump reference number on your order. You can find the pump number on the type plate on the pump and on the label on the first page of these operating instructions Recommended spare parts Parts marked with a * are recommended spare parts. Parts 41

45 9.2 Sectional drawing figure 14 Sectional drawing pump. 42 Parts

46 CombiBloc 9.3 Parts list Item Number Description Materials G1 G2 B2 R pump casing cast iron bronze st.st pump cover cast iron bronze st.st. 0120* 1 impeller cast iron bronze bronze st.st. 0130* 1 casing wear ring cast iron bronze bronze st.st lantern piece cast iron protecting guard aluminium 0300* 1 gasket plug steel plug steel 0800 ** Allen screw steel washer steel bolt steel nut steel distance sleeve stainless steel spacer sleeve stainless steel 1220* 1 mechanical seal set screw stainless steel O-ring rubber 1820* 1 impeller nut stainless steel 1825* 1 spring washer stainless steel 1830* 1 washer stainless steel 1860* 1 impeller key stainless steel 2200* 1 stub shaft stainless steel coupling key steel 2280* 2 set screw stainless steel nameplate stainless steel arrow plate aluminium st.st. = stainless steel ** Number dependent on pump type 4, 8, or 12 Item 0130: not for pumps in cast iron and bronze (G1, G2 and B2), except CB , CB , CB , CB , CB , CB , CB , CB , CB , CB and CB Item 0810: only for CB Items 1200 and 1260: only for CB Parts 43

47 9.4 Sectional drawing shaft sealing CB figure 15 Sectional drawing mechanical seal CB Parts

48 CombiBloc 10 Technical data 10.1 Recommended locking liquids Part Impeller nut Casing wear ring Locking liquid Loctite 242 Nutlock Loctite 242 Nutlock 10.2 Tightening moments Tightening moments for bolts and nuts Thread Tightening moment [Nm] Material 8.8 A2, A4 M6 8,3 5,8 M ,09 M M12 68,8 43 M16 167,3 104, Tightening moments for impeller nut Size Tightening moment [Nm] M12 (bearing bracket 1) 43 M16 (bearing bracket 2) 104 M24 (bearing bracket 3) 220 Technical data 45

49 10.3 Maximum allowable speed CB G1 G2 B2 (cast iron/bronze pump) Max. speed [min -1 ] R6 (stainless steel pump) Technical data

50 CombiBloc 10.4 Survey curves Cast iron/bronze pump figure 16 Survey curve 3000 min -1 (G1, G2, B2). figure 17 Survey curve 1500 min -1 (G1, G2, B2). Technical data 47

51 figure 18 Survey curve 3600 min -1 (G1, G2, B2). figure 19 Survey curve 1800 min -1 (G1, G2, B2). 48 Technical data

52 CombiBloc Stainless steel pump figure 20 Survey curve 3000 min -1 (R6). figure 21 Survey curve 1500 min -1 (R6). Technical data 49

53 figure 22 Survey curve 3600 min -1 (R6). figure 23 Survey curve 1800 min -1 (R6). 50 Technical data

54 CombiBloc 10.5 Noise data Noise as a function of pump power figure 24 Noise level as function of pump power [kw] at 1450 min -1. figure 25 Noise level as function of pump power [kw] at 2900 min -1. Technical data 51

55 Noise level L [db] 4102 L1 - L2 [db] figure 26 Noise level entire pump unit. To determine the noise level of the entire set the noise level of the motor must be added to the noise level of the pump. This can simply be done by means of the graph printed above. 1 Determine the noise level of the pump (L1, see graph) and the motor (L2). 2 Calculate the absolute difference between both levels L1 - L2. 3 Find this value on the X-axis. 4 Go straight up to the curve. 5 Go left to the Y-axis. 6 Read the value on this Y-axis. 7 Add this value to the highest noise level (L1 or L2). Example: 1. Pump 75 db; motor 78 db = 3 db 3. 3 db on X-axis = 1,75 db on Y-axis 4. Highest noise level + 1,75 db = ,75 = 79,75 db 52 Technical data

56 CombiBloc Index A Application area 13 Applications 12 Assembly Back Pull Out unit 26 casing wear ring 28 impeller 27 mechanical seal 31 motor 32 stub shaft 32 B Back Pull Out system 26 C Commissioning 19, 20 Construction Bearing 12 Design 12 Materials 12 Shaft sealing 12 Control 20 electric motor 19 pump 19 D delta connection 17 Dimensions 9 cast iron or bronze pump 34 foot 33 stainless steel pump 37 Disassembly Back Pull Out unit 26 casing wear ring 28 impeller 27 mechanical seal 30 motor 32 stub shaft 32 F Failures causes 23, 24 Faults 22 G Guarantee 8 I Inspection delivered items 8 Installation 15, 16, 17, 18 pump set 15 L Lifting 9 Liquid draining 25 M Mechanical seal 29 instructions for mounting 29 Mounting accessories 16 N Noise 20, 21 as a function of pump power 51 Noise data 51 Noise level 52 P pallets 9 Preservation 15 Pump description 11 Index 53

57 R Re-use 13 Recommended locking liquids 45 Replacement casing wear ring 27 impeller 27 Replacing motor 32 stub shaft 32 S Safety 15 Scrapping 13 Sense of rotation 19 Special tools 29 star connection 17 star-delta switch 18 Starting the pump 19 Storage 9 Survey curves 47 T Tightening moments for bolts and nuts 45 for impeller nut 45 Tools 25 Type code 11 V Voltage data 17 W weight 9 Weights Index

58 FAX: ADDRESS: Order form for spare parts Your order will only be dealt with if this order form has been correctly completed and signed. Order date: Your order number: Pumptype: Execution: Quantity Pos.Nr Part Article number pump Delivery address: Invoicing address: Ordered by: Signature: Telephone: BESTFORM/004-EN 55

59 56 BESTFORM/004-EN