Operating Instructions BE2700 Brinkmann Immersions pumps of the series TA/STA/TAL/SAL901... 1303 Contents 1 General...1 2 Safety...2 3 Transport and storage...2 4 Description of product and accessories...2 5 Installation...2 6 Start up / Shut down...3 7 Servicing and Maintenance...3 8 Trouble shooter s guide...3 9 Spare parts...4 1 General These operating instructions apply to the pumps of the series TA/STA/TAL/SAL901... 1303 with different depths of immersion and specifications. The immersion pumps are suitable for handling contaminated coolants, (and extremely inflated fluids TAL/SAL construction). These operating instructions contain basic information and instructions which must be observed when the pump is being installed, operated or repaired. Therefore it is important that these operating instructions are read by the fitter, the operator and relevant technical personnel before installation and start-up, and they are available at all times at the place where the unit/system is being operated. Specifications Type TA/STA901 / 200 / 300 / 430 / 550 / 750 / 980 TA/STA902 / 270 / 370 / 500 / 620 / 820 /1050 TA/STA903 / 340 / 440 / 570 / 690 / 890 TA/STA904 / 410 / 510 / 760 / 960 TA/STA1301 / 210 / 310 / 440 / 560 / 760 / 990 TA/STA1302 / 290 / 390 / 520 / 840 /1070 TA/STA1303 / 370 / 470 / 600 / 720 / 920 Type TAL/SAL901 / 220 / 320 / 450 / 570 / 770 /1000 TAL/SAL902 / 290 / 390 / 520 / 840 /1070 TAL/SAL903 / 360 / 460 / 590 / 710 / 910 TAL/SAL904 / 430 / 530 / 660 / 780 / 980 TAL/SAL1301 / 230 / 330 / 460 / 580 / 780 /1010 TAL/SAL1302 / 310 / 410 / 540 / 660 / 860 /1090 TAL/SAL1303 / 390 / 490 / 620 / 740 / 940 Max. del. pressure bar / spec. weight 1 Max. del. volume l/min Depth of immersion TA TAL mm 2,2 930 200 220 300 320 430 450 550 570 750 770 980 1000 4,3 980 270 290 370 390 500 520 620 640 820 840 1050 1070 6,4 1050 340 360 440 460 570 590 690 710 890 910 8,6 1100 410 430 510 530 640 660 760 780 960 980 2,4 1400 210 230 310 330 440 460 560 580 760 780 990 1010 4,7 1600 290 310 390 410 520 540 640 660 840 860 1070 1090 6,8 1680 370 390 470 490 600 620 720 740 920 940 Weight STA = TA + 5 kg Weight SAL = TAL + 5 kg The STA/SAL series with SAE flange can be connected to either vertical or horizontal pipes. Weight TA TAL kg 41 42 43 44 45 46 48 49 53 54 60 61 60 61 63 64 67 68 71 72 76 77 86 87 90 91 94 95 99 100 100 101 103 104 107 108 111 112 116 117 46 47 48 49 50 51 53 54 58 59 65 66 76 77 79 80 87 88 92 93 99 100 94 95 97 98 103 104 105 106 110 111 Power Brinkmann Pumpen Edition 11/03 Page 1 kw 2,6 5,5 7,5 10 4,0 7,5 10
Mediums 2 Safety See appendix A. Kinetic viscosity of the medium... 90 mm 2 /s Water, cooling emulsions, cooling- and cutting-oils Temperature of medium 0... 80 C...200 C as special make Noise level / 50 Hz TA/STA901 66 dba TA/STA902, TA/STA1301 71 dba TA/STA903...904 74 dba TA/STA1302...1303 74 dba Measuring of noise level to DIN 45635 at distance of 1 m. 3 Transport and storage Protect the pump against damage when transporting. Store pump in dry and protected areas and protect it against penetration of foreign bodies. 4 Description of product and accessories Pumps of the series TA/STA/TAL/SAL901... 1303 are multi-stage rotary pumps. The impellers are fixed on the driving shaft extension. Pump and motor form a compact and space-saving unit. Pumps of this type are fitted out with semiopen impellers, (and a suction screw TAL/SAL construction). The motor is surface cooled and complies with the DIN IEC 34 resp. EN 60034 (IP 55). Tension voltage and frequency must correspond with the shown specification on the nameplate. The terminal links of the motor are delivered in star connection from the plant. A circuit breaker or overload trip must be provided and the tripping current adjusted to correspond with the motor rated current. Special electrical or mechanical versions are described in appendix B! Check the terminal links according to the following wiring diagram. Motors from 7,5 kw on are prepared for U/D start, 3 x 400V, 50Hz. Star connection 3 x 400 V, 50 Hz resp. 380-420 V, 50 Hz Delta connection 3 x 230 V, 50 Hz resp. 220-240 V, 50 Hz Work on the electrical equipment must only be carried out by a qualified electrician. The motor must be isolated before any work is carried out. 5 Installation The pumps are mounted on the top of the coolant tank with the pump body being immersed in the coolant. Pumps must be mounted securely. The pipework must be installed so that no distortion of the pump can occur. According to the drawing shown on the right, the maximum liquid level must stay about 30 mm below the mounting flange, also ensure that the minimal liquid level for the TA/STA pump is 60 mm before starting up the motor, for the TAL/SAL pump the suction hole of the pump body must be covered with liquid. The inlet is at the bottom of the immersed pump body. The distance between the inlet and the tank bottom must be so large that the inlet can not be blocked by deposits during longer shutdowns. To obtain the full flow rate it is recommended to choose for the pipework the nominal bore diameter of the pumps cross section for connection. Therfore pipe bends should be used, not pipe angles! The pipework must be qualified for occuring hydraulic pressure! The pump must be mounted in that way that rotating parts under the cover of the coolant tank can not be touched! Brinkmann Pumpen 2
6 Start up / Shut down Start up Switch off at the mains. After connection of the terminals close the terminal box. Briefly start the motor and check the rotation according to the arrow on the top of the motor. Looking through the fan cover of motor, the fan has to turn clockwise. If the direction is incorrect change over two of the power leads. Shut down Switch off at the mains. Open terminal box and disconnect the power leads Empty out the pump. ATTENTION The temperature of the medium is not allowed to be higher than 80 C or 200 C as special make! The pumps are for continuous running against a closed sliding valve not suitable ( plan bypass ). The particle-size in the medium is not allowed to be bigger than 10 mm for TA/STA/TAL/SAL901...904 and 15 mm for TA/STA/TAL/SAL1301...1303! Switching-on frequency: Motors less 3 kw max. 200 times per hour. Motors from 3 kw to 5,5 kw max. 40 times per hour. Motors greater 5,5 kw max. 20 times per hour. 7 Servicing and Maintenance The surface of the motor must be kept free of dirt. The motorshaft runs in permanent greased ball bearings and does not need any special service. 8 Trouble shooter s guide Fault Cause Remedy Motor does not start, no motor noise Motor does not start, humming noise. Pump does not pump Insufficient flow and pressure Power consumption is too high At least two of the power supply leads have failed One of the supply leads has failed Impeller faulty Motor bearing faulty liquid level too low Pump mechanism faulty Pipe blocked Wrong direction of rotation of impeller Pump mechanism silted up Worn pump mechanism Wrong direction of rotation of impeller Lime or other deposits mechanical friction Check fuses, terminals and supply leads Replace impeller Replace bearing Fill up liquid replace pump mechanism Clean pipe Change over two power supply leads Clean pump mechanism Replace pump mechanism repair pump Spare parts are available from the supplier. Standard commercially available parts are to be purchased in accordance with the model type. The ordering of spare parts should contain the following details: 1. Pumptype e.g. TA902 / 370 2. Pump No. e.g. 03022700 The date of the construction year is a component of the pumps type number. 3. Voltage, Frequency and Power Take item 1, 2 and 3 from the nameplate 4. Spare part with item No. e.g. Intake cover item No. 52 Brinkmann Pumpen 3
9 Spare part list for the immersion pumps of the series TA/STA/TAL/SAL901... 1303 Item Description 1 Stator with terminal board 2 Motor flange 3 End shield 4 Terminal box up to 5,5 kw 5 Terminal box frame up 7,5 kw 6 Terminal box cover up 7,5 kw 7 Fan 8 Fan cover 9 Ball bearing up to 5,5 kw DIN 625 9 Ball bearing up 7,5 kw DIN 628 10 Ball bearing DIN 625 11 Gasket 12 Gasket up 7,5 kw 13 Retaining ring 14 Thread rolling screw DIN 7500 15 Slotted cheese head screw DIN 84 16 Socket head cap screw DIN 912 17 Socket head cap screw DIN 912 19 Parallel pin DIN 7 20 Shaft seal TAL/SAL 50 Pump body 51 Shaft with rotor 52 Inlet cover for TA/STA 52 Intake cover for TAL /SAL 53 Pump plate up TA/STA/TAL/SAL902, 1302 55 Impeller 57 Suction screw only for TAL/SAL 58 Extension pump body 59 Distance liner 60 Distance liner 61 Running sleeve 62 Bearing bush 63 Distance plate 64 Woodruff key DIN 6888 66 O-Ring 67 O-ring 68 Splash ring 69 Splash ring 72 Socket head cap screw DIN 912 74 Stud bolt TA/STA/TAL/SAL1302...1303 75 Hexagon domed cap nut DIN 1587 TA/STA/TAL/SAL1302...1303 77 Hexagon thin nut TA/STA 78 Socket head cap screw DIN 912 82 Joining socket STA/SAL 83 Socket head cap screw STA/SAL 84 Spring washer STA/SAL 85 O-ring STA/SAL Brinkmann Pumpen 4 Tightening torques for screwed connections Thread - M5 M8 M16 M16 Strength classes 4.8 8.8 Tightening torque 3 Nm 15 Nm (Nm) (4,5 Nm for Item. 3) 30 Nm Item. 83 60 Nm Item. 77
Appendix A Safety instructions 2.0 General This operating manual gives basic instructions which are to be observed during installation, operation and maintenance of the pump. It is therefore imperative that this manual be read by the responsible personnel and operator prior to assembly and commissioning. It is always to be kept available at the installation site. It is only the general safety instructions contained under this main heading safety that are to be observed but also the specific information provided under the other main headings. 2.1 Identification of safety instructions in the operating manual Safety instructions given in this manual non-compliance with which would affect safety are identified by the following symbol: Safety sign according with ISO 3864 -B.3.1 or where electrical safety is involved, with: Safety sign according with ISO 3864 -B.3.6 Where non-compliance with the safety instructions may cause a risk to the machine and it s function the word ATTENTION is inserted. It is imperative that signs affixed to the machine, e.g.: arrow indicating the direction of rotation symbols indicating fluid connections be observed and kept legible. 2.2 Qualification and training of operating personnel The personnel responsible for operation, maintenance, inspection and assembly must be adequately qualified. Scope of responsibility and supervision of the personnel must be exactly defined by the plant operator. If the staff does not have the necessary knowledge, they must be trained and instructed, which may be performed by the machine manufacturer or supplier on behalf of the plant operator. Moreover, the plant operator is to make sure that the contents of the operating manual are fully understood by the personnel. 2.3 Hazards in the event of non-compliance with the safety instructions Non-compliance with the safety instructions may produce a risk to the personnel as well as to the environment and the machine and results in a loss of any right to claim damages. For example, non-compliance may involve the following hazards:- Failure of important functions of the machines/plant Failure of specified procedures of maintenance and repair Exposure of people to electrical, mechanical and chemical hazards Endangering the environment owing to hazardous substances being released. 2.4 Compliance with regulations pertaining to safety at work When operating the pump, the safety instructions contained in this manual, the relevant national accident prevention regulations and any other service and safety instructions issued by the plant operator are to be observed. 2.5 Safety instructions relevant for operation If hot or cold machine components involve hazards, they must be guarded against accidental contact. Guards for moving parts (e.g. coupling) must not be removed from the machine while in operation. Any leakage of hazardous (e.g. explosive, toxic, hot) fluids (e.g. from the shaft seal) must be drained away so as to prevent any risk to persons or the environment. Statutory regulations are to be complied with. Hazards resulting from electricity are to be prevented (see for example, the VDE Specifications and the bye-laws of the local power supply utilities). 2.6 Safety instructions relevant for maintenance, inspection and assembly work It shall be the plant operator s responsibility to ensure that all maintenance, inspection and assembly work is performed by authorised and qualified personnel who have adequately familiarised themselves with the subject matter by studying this manual in detail. Any work on the machine shall only be performed when it is at a standstill, it being imperative that the procedure for shutting down the machine described in this manual be followed. Pumps and pump units which convey hazardous media must be decontaminated. On completion of work all safety and protective facilities must be re-installed and made operative again. Prior to restarting the machine, the instructions listed under Start up are to be observed. 2.7 Unauthorised alterations and production of spare parts Any modification may be made to the machine only after consultation with the manufacturer. Using spare parts and accessories authorised by the manufacturer is in the interest of safety. Use of other parts may exempt the manufacturer from any liability. 2.8 Unauthorised modes of operation The reliability of the machine delivered will be only guaranteed if it is used in the manner intended, in accordance with clause 1 of this manual. The limit values specified in the data sheet must under no circumstances be exceeded. Brinkmann Pumpen