allheat operating manual

Centrifugal Pump withVolute CasingOriginal Operating Manual ALLHEAT Series®

N..WH, C..WH

Version BA-2010.03Print-No. 550 407VM-No. 460.0028 GB

ALLWEILER AG • Werk RadolfzellPostfach 1140Allweilerstr. 178301 RadolfzellGermanyPhone: +49 (0) 7732-86-0Fax: +49 (0) 7732-86-436E-mail: [email protected]: http://www.allweiler.com

We reserve the right to make technical changes.

Table of contents

Table of contents

1 About this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.1 Target groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.2 Other applicable documents . . . . . . . . . . . . . . . . 6

1.3 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . 7

1.4 Technical terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.2 General safety instructions . . . . . . . . . . . . . . . . . . 82.2.1 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.2.2 Obligations of the operating company . . . . . . 92.2.3 Obligations of personnel . . . . . . . . . . . . . . . . . . . . . 9

2.3 Specific hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.3.1 Explosion hazard area . . . . . . . . . . . . . . . . . . . . . . . 92.3.2 Hazardous pumped media . . . . . . . . . . . . . . . . . . 9

3 Layout and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.1 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.1.1 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.1.2 ATEX plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.1.3 Pump type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.2 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113.2.1 NTWH and CTWH series . . . . . . . . . . . . . . . . . . . . 113.2.2 NBWH and CBWH series . . . . . . . . . . . . . . . . . . . 123.2.3 NIWH and CIWH series . . . . . . . . . . . . . . . . . . . . . 13

3.3 Shaft seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.3.1 Mechanical seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.4 Auxiliary systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.4.1 Sealing systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4 Transport, storage and disposal . . . . . . . . . . . . . . . . . . 15

4.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154.1.1 Unpacking and inspection on delivery . . . . . . 154.1.2 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.2 Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.4 Removing the preservative . . . . . . . . . . . . . . . . . . 16

4.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5 Setup and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.1 Preparing the setup . . . . . . . . . . . . . . . . . . . . . . . . . . 185.1.1 Checking the ambient conditions . . . . . . . . . . . 185.1.2 Preparing the installation site . . . . . . . . . . . . . . . 185.1.3 Preparing the foundation and surface . . . . . . 185.1.4 Removing the preservative . . . . . . . . . . . . . . . . . . 185.1.5 Installing the heat insulation (optional) . . . . . 185.1.6 Defining the installation position (NBWH,

CBWH, NIWH and CIWH series) . . . . . . . . . . . 18

5.2 Installation on a foundation . . . . . . . . . . . . . . . . . . 195.2.1 Setting the pump aggregate on the

foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195.2.2 Fastening the pump aggregate . . . . . . . . . . . . . 19

5.3 Installation without foundation . . . . . . . . . . . . . . . 20

5.4 Installing in the pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.5 Installing the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 205.5.1 Version with coupling (NTWH and CTWH

series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205.5.2 Installation with stub shaft (NBWH, CBWH,

NIWH and CIWH series) . . . . . . . . . . . . . . . . . . . . . 21

5.6 Planning the pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . 215.6.1 Specifying supports and flange

connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215.6.2 Specifying nominal diameters . . . . . . . . . . . . . . . 215.6.3 Specifying pipe lengths . . . . . . . . . . . . . . . . . . . . . . 225.6.4 Optimizing cross-section and direction

changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225.6.5 Discharging leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225.6.6 Providing safety and control devices

(recommended) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.7 Connecting the pipes . . . . . . . . . . . . . . . . . . . . . . . . 225.7.1 Keeping the piping clean . . . . . . . . . . . . . . . . . . . . 225.7.2 Installing auxiliary piping . . . . . . . . . . . . . . . . . . . . . 225.7.3 Installing the suction pipe . . . . . . . . . . . . . . . . . . . . 225.7.4 Installing the pressure pipe . . . . . . . . . . . . . . . . . . 235.7.5 Inspection for stress-free pipe

connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235.7.6 Inspecting the support foot for

distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5.8 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . 235.8.1 Connecting the motor . . . . . . . . . . . . . . . . . . . . . . . . 235.8.2 Checking the direction of rotation . . . . . . . . . . . 23

5.9 Aligning the coupling precisely . . . . . . . . . . . . . . 24

5.10 Aligning the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255.10.1 Aligning the motor with sets of shims . . . . . . . 255.10.2 Aligning the motor with adjusting

screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.11 Installing the coupling guard . . . . . . . . . . . . . . . . 25

6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6.1 Putting the pump into service for the firsttime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6.1.1 Removing the preservative . . . . . . . . . . . . . . . . . . 266.1.2 Preparing auxiliary systems (if

available) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266.1.3 Filling and bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 266.1.4 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276.1.5 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6.2 Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286.2.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286.2.2 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6.3 Shutting down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6.4 Start-up following a shutdown period . . . . . . . 29

6.5 Operating the stand-by pump . . . . . . . . . . . . . . . 29

7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7.1 Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2 ALLHEAT Series® N..WH, C..WH BA-2010.03 460.0028 GB – 550 407

Table of contents

7.2.1 Antifriction bearings lubricated withgrease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7.2.2 Mechanical seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317.2.3 Carbon sleeve bearing . . . . . . . . . . . . . . . . . . . . . . 317.2.4 Sealing medium .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317.2.5 Cleaning the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7.3 Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327.3.1 Returning the pump to the

manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327.3.2 Preparations for dismounting . . . . . . . . . . . . . . . . 337.3.3 Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

7.4 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

7.5 Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . 34

8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

9.1 Sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . 389.1.1 Auxiliary connections . . . . . . . . . . . . . . . . . . . . . . . . 389.1.2 Part numbers and designations . . . . . . . . . . . . . 389.1.3 NTWH and CTWH series . . . . . . . . . . . . . . . . . . . . 409.1.4 NBWH and CBWH series . . . . . . . . . . . . . . . . . . . 429.1.5 NIWH and CIWH series . . . . . . . . . . . . . . . . . . . . . 449.1.6 CTWH 200-250/81 series . . . . . . . . . . . . . . . . . . . 469.1.7 Coupling guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

9.2 Exploded drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . 489.2.1 NTWH and CTWH series . . . . . . . . . . . . . . . . . . . 489.2.2 NBWH and CBWH series . . . . . . . . . . . . . . . . . . . 499.2.3 NIWH and CIWH series . . . . . . . . . . . . . . . . . . . . . 509.2.4 CTWH 200-250/81 series . . . . . . . . . . . . . . . . . . . 51

9.3 Technical specifications . . . . . . . . . . . . . . . . . . . . . . 529.3.1 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 529.3.2 Sound pressure levels . . . . . . . . . . . . . . . . . . . . . . . 529.3.3 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . 539.3.4 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539.3.5 Preservatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549.3.6 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549.3.7 Height offset for motor alignment with

adjusting screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559.3.8 Flange loads according to ISO 5199 . . . . . . . 56

9.4 Spare parts for two years of continuousoperation according to DIN 24296 . . . . . . . . . . 58

9.5 Safety certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

9.6 Declaration of conformity according to ECmachine directives . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

460.0028 GB – 550 407 BA-2010.03 ALLHEAT Series® N..WH, C..WH 3

Table of contents

List of figures

Fig. 1 Type plate (example) . . . . . . . . . . . . . . . . . . . . . . . . 10

Fig. 2 ATEX plate (example) . . . . . . . . . . . . . . . . . . . . . . . . 10

Fig. 3 Pump type code (example) . . . . . . . . . . . . . . . . . . 10

Fig. 4 NTWH and CTWH series . . . . . . . . . . . . . . . . . . . . 11

Fig. 5 NBWH and CBWH layout . . . . . . . . . . . . . . . . . . . 12

Fig. 6 NIWH and CIWH layout . . . . . . . . . . . . . . . . . . . . . 13

Fig. 7 Single mechanical seal with quenching(sketch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Fig. 8 Fastening the lifting gear to the pump unit(NTWH/CTWH series) . . . . . . . . . . . . . . . . . . . . . . . 15

Fig. 9 Fastening the lifting gear to the pump unit(NBWH/CBWH series) . . . . . . . . . . . . . . . . . . . . . . . 15

Fig. 10 Fastening the lifting gear to the pump unit(NIWH/CIWH series) . . . . . . . . . . . . . . . . . . . . . . . . . 15

Fig. 11 Fastening the lifting gear to the pump . . . . . . 15

Fig. 14 Installation without a foundation . . . . . . . . . . . . 20

Fig. 15 Widening the stub shaft . . . . . . . . . . . . . . . . . . . . . . 21

Fig. 16 Straight pipe lengths upstreamand downstream of the pump(recommended) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Fig. 20 Aligning the motor with adjustingscrews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Fig. 21 Widening the stub shaft . . . . . . . . . . . . . . . . . . . . . . 33

Fig. 22 U2.11A-S1 series overview sectionaldrawing, balanced mechanical seal and SiCbearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Fig. 23 Version with intermediate ring . . . . . . . . . . . . . . . 41

Fig. 24 Version for bearing bracket size 3and 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Fig. 25 U3.3A-K1 version, unbalanced mechanicalseal and carbon bearing . . . . . . . . . . . . . . . . . . . . . 41

Fig. 26 NTWH, CTWH version, lubrication and radialshaft seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41







Fig. 33 CTWH 200-250/81 series, U2.12A . . . . . . . . . 46

Fig. 34 Coupling guard on base plate versions . . . . . 47

Fig. 35 Coupling guard on flange versions . . . . . . . . . 47

Fig. 36 U2.11A-S1 series – balanced mechanicalseal and SiC bearing . . . . . . . . . . . . . . . . . . . . . . . . . 48

Fig. 37 U3.3A-K1 version – unbalanced mechanicalseal and carbon bearing . . . . . . . . . . . . . . . . . . . . . 48





Fig. 42 CTWH 200-250/81 series, U2.13A-K2 . . . . . 51

Fig. 43 Flange loads at the pump . . . . . . . . . . . . . . . . . . . 56

Fig. 44 Correction factor M and operatingtemperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57


Table of contents

List of tables

Tab. 1 Target groups and their duties . . . . . . . . . . . . . . 6

Tab. 2 Other applicable documents and theirpurpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Tab. 3 Warnings and consequences of disregardingthem .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Tab. 4 Symbols and their meaning . . . . . . . . . . . . . . . . . 7

Tab. 5 Technical terms and their meaning . . . . . . . . . 7

Tab. 6 Pump type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Tab. 7 Measures to be taken if the pump is shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Tab. 8 Measures depending on the behavior of thepumped medium .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Tab. 9 Measures to be taken after prolongedshutdown periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Tab. 10 Employed antifriction bearings . . . . . . . . . . . . . . 31

Tab. 11 Measures for return . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Tab. 12 Fault number assignment . . . . . . . . . . . . . . . . . . . 35

Tab. 13 Troubleshooting list . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Tab. 14 Abbreviations of the connectiondesignations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Tab. 15 Designations of components according topart numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Tab. 16 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Tab. 17 Sound pressure levels . . . . . . . . . . . . . . . . . . . . . . . 52

Tab. 18 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Tab. 19 Properties of lubrication grease . . . . . . . . . . . . . 53

Tab. 20 Minimum amounts for greaselubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Tab. 21 Relubrication intervals for the antifrictionbearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Tab. 22 Valvoline preservatives . . . . . . . . . . . . . . . . . . . . . . 54

Tab. 23 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Tab. 24 Height setting at the adjusting screw . . . . . . . 55

Tab. 25 Flange loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Tab. 26 Spare parts for two years of continuousoperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Tab. 27 Safety certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Tab. 28 Declaration of conformity according to ECmachine directives . . . . . . . . . . . . . . . . . . . . . . . . . . . 60


About this document

1 About this document

This manual• Is part of the pump

• Applies to the afore-mentioned pump series

• Describes safe and appropriate operation during alloperating phases

1.1 Target groups

Target group Duty

Operating company Keep this manual available at the site of operation of the system,including for later use.Ensure that personnel read and follow the instructions in thismanual and the other applicable documents, especially all safetyinstructions and warnings.Observe any additional rules and regulations referring to thesystem.

Qualified personnel, fitter Read, observe and follow this manual and the other applicabledocuments, especially all safety instructions and warnings.

Tab. 1 Target groups and their duties

1.2 Other applicable documents

Document Purpose

ATEX additional instructions Operation in explosion hazard areas

Order data sheet Technical specifications, conditions of operation

Setup drawing Setup dimensions, connection dimensions etc.

Technical description Technical specifications, operating limits

Sectional drawing Sectional drawing, part numbers, component designations

Supplier documentation Technical documentation for parts supplied by subcontractors

Spare parts list Ordering spare parts

Declaration of conformity Conformity with standardsContents of the declaration of conformity (→ 9.6 Declaration ofconformity according to EC machine directives, 0).

Tab. 2 Other applicable documents and their purpose


About this document

1.3 Warnings and symbols

Warning Risk level Consequences of disregard

DANGERImmediate acute risk Death, serious bodily harm

WARNINGPotentially acute risk Death, serious bodily harm

CAUTIONPotentially hazardous situation Minor bodily harm

NOTEPotentially hazardous situation Material damage

Tab. 3 Warnings and consequences of disregarding them

Symbol Meaning

Safety warning signTake note of all information highlighted by the safety warning signand follow the instructions to avoid injury or death.

Instruction

1. , 2. , ... Multiple-step instructions

Precondition

→ Cross reference

Information, advice

Tab. 4 Symbols and their meaning

1.4 Technical terms

Term Meaning

Sealing medium Medium for blocking or quenching shaft seals

Auxiliary systems Systems for operating the pump

Tab. 5 Technical terms and their meaning


Safety

2 Safety

The manufacturer does not accept any liability caused bydisregarding the entire documentation.

2.1 Intended use• Only use the pump for pumping the agreed pumped media

(→ order data sheet).

• Adhere to the operating limits and size-dependentminimum flow rate.

• Avoid dry running:Initial damage, such as destruction of the mechanical sealand plastic parts, will occur within only a few seconds.– Make sure the pump is only operated with, and never

without, a pumped medium.

• Avoid cavitation:– Fully open the suction-side armature and do not use it

to adjust the flow rate.– Do not open the pressure-side armature beyond the

agreed operating point.

• Avoid overheating:– Do not operate the pump while the pressure-side

armature is closed.– Observe the minimum flow rate (→ order data sheet).

• Avoid damage to the motor:– Do not open the pressure-side armature beyond the

agreed operating point.– Note the maximum permissible number of times the

motor can be switched on per hour (→ manufacturer'sspecifications).

• Consult the manufacturer about any other use of the pump.

• When a pump is delivered without a motor, the pump unitmust be completed in accordance with the stipulations ofmachine directive 2006/42/EC.

Prevention of obvious misuse (examples)• Note the operating limits of the pump concerning

temperature, pressure, flow rate andmotor speed (→ orderdata sheet).

• The power consumed by the pump increases withincreasing density of the pumped medium. To avoidoverloading the pump, coupling or motor, stay within theagreed density (→ order data sheet).Lower densities are allowed. Adapt the auxiliary systemsaccordingly.

• When pumping liquids containing solids, ensure thelimits for the proportion of solids and the grain size aremaintained (→ order data sheet, technical description).

• When using auxiliary systems, ensure there is a continuoussupply of the appropriate operating medium.

• Pumps used with water as the pumped liquid must not beused for foodstuffs or drinking water. Use of the pump forfoodstuffs or drinking water must be specified in the orderdata sheet.

• Only select the setup type according to this operatingmanual. For example, the following are not allowed:– Hanging base plate pumps in the pipe– Overhead installation– Installation in the immediate vicinity of extreme heat or

cold sources– Installation too close to the wall

2.2 General safety instructionsTake note of the following regulations before carrying outany work.

2.2.1 Product safety

The pump has been constructed according to thelatest technology and recognized technical safety rules.Nevertheless, operation of the pump can involve risks to lifeand health of the user or third parties and risk of damage tothe pump and other property.

• Only operate the pump if it is in perfect technical conditionand only use it as intended, staying aware of safety andrisks, and in adherence to the instructions in this manual.

• Keep this manual and all other applicable documentscomplete, legible and accessible to personnel at all times.

• Refrain from any procedures and actions that wouldexpose personnel or third parties to any risk.

• In the event of any safety-relevant faults, shut downthe pump immediately and have the fault corrected byappropriate personnel.

• In addition to the entire documentation for the product,comply with statutory or other safety and accident-prevention regulations and the applicable standards andguidelines in the country where the pump is operated.


Safety

2.2.2 Obligations of the operating company

Safety-conscious operation• Only operate the pump if it is in perfect technical condition

and only use it as intended, staying aware of safety andrisks, and in adherence to the instructions in this manual.

• Ensure that the following safety aspects are observed andmonitored:– Adherence to intended use– Statutory or other safety and accident-prevention

regulations– Safety regulations governing the handling of

hazardous substances– Applicable standards and guidelines in the country

where the pump is operated

• Make protective equipment available.

Qualified personnel

• Make sure all personnel tasked with work on the pumphave read and understood this manual and all otherapplicable documents, especially the safety, maintenanceand repair information, before they start any work.

• Organize responsibilities, areas of competence and thesupervision of personnel.

• Ensure that all work is carried out by specialist techniciansonly:– Fitting, repair and maintenance work– Work on the electrical system

• Make sure trainee personnel only work on the pump undersupervision of specialist technicians.

Safety equipment

• Provide the following safety equipment and verify itsfunctionality:– For hot, cold and moving parts: safety guarding

provided by the customer– For possible build up of electrostatic charge: ensure

appropriate grounding

Warranty

• Obtain the manufacturer's approval prior to carrying outanymodifications, repairs or alterations during the warrantyperiod.

• Only use genuine parts or parts that have been approvedby the manufacturer.

2.2.3 Obligations of personnel

• All directions given on the pumpmust be followed (and keptlegible), e.g. the arrow indicating the direction of rotationand the markings for fluid connections.

• Pump, coupling guard and components:– Do not step on them or use as a climbing aid– Do not use them to support boards, ramps or beams– Do not use them as a fixing point for winches or

supports– Do not use them for storing paper or similar materials– Do not use hot pump or motor components as a heating

point– Do not de-ice using gas burners or similar tools

• Do not remove the safety guarding for hot, cold or movingparts during operation.

• Use protective equipment if necessary.

• Only carry out work on the pump while it is not running.

• Isolate the motor from its supply voltage and keep it lockedin that state when carrying out any fitting or maintenancework.

• Reinstall the safety equipment on the pump as required byregulations after any work on the pump.

2.3 Specific hazards

2.3.1 Explosion hazard area• (→ ATEX additional instructions).

2.3.2 Hazardous pumped media• Follow the safety regulations for handling hazardous

substances when pumping hazardous(e.g. hot, flammable, poisonous or potentially harmful)media.

• Use protective equipment when carrying out any work onthe pump.


Layout and function

3 Layout and function

3.1 Labels

3.1.1 Type plate

NPSHkW1/min P mnm3/h H mQ

Nr Jahr

Typ

mm2/skg/dm 3

D - 78315 Radolfzell / Germany

Typ und Nr.

1

234

6

7

10

98

angebenBei Ersatzteilbestellung

5

Fig. 1 Type plate (example)

1 Pump type2 Year of manufacture3 Differential head4 Pump NPSH value5 Kinematic viscosity6 Power consumption7 Density8 Motor speed9 Flow rate10 Pump number

3.1.2 ATEX plate

Fig. 2 ATEX plate (example)

1 Explosion protection mark2 Reference to ATEX additional instructions

3.1.3 Pump type code

12

34

NBWH 32 - 200 / 01 / 180 U3.3A - K1 W128 - 38 / 300

5

6

7

8

9

Fig. 3 Pump type code (example)

Position Meaning

1 Series

2 Size

• Outlet flange standard nominal diameter [mm](outlet flange acutal diameter on CIWHseries)

• Nominal impeller diameter [mm]

3 Hydraulic number

4 Actual impeller diameter [mm]

5 Shaft seal

6 Bearing type

7 Material key

8 Stub shaft bore hole diameter [mm] (only onNBWH, NIWH, CBWH and CIWH series)

9 Motor bell housing external diameter [mm]

Tab. 6 Pump type code


Layout and function

3.2 Layout

3.2.1 NTWH and CTWH series

4cm

4cm

1 2 3 4 5

6789

Fig. 4 NTWH and CTWH series

1 Impeller2 Safety stuffing box3 Limit for heat insulation4 Shaft5 Antifriction bearing6 Bearing bracket7 Shaft seal8 Sleeve bearing9 Volute casing


Layout and function

3.2.2 NBWH and CBWH series

1 2 4 5

678910

4cm

4cm

3

Fig. 5 NBWH and CBWH layout

1 Impeller2 Safety stuffing box3 Limit for heat insulation4 Stub shaft5 Safety guarding6 Motor (fixed bearing on drive side)7 Fan8 Shaft seal9 Sleeve bearing10 Volute casing


Layout and function

3.2.3 NIWH and CIWH series

1

2

3

4

5

6

7

8

9

4cm

4cm

Fig. 6 NIWH and CIWH layout

1 Volute casing2 Safety stuffing box3 Fan4 Motor (fixed bearing on drive side)5 Safety guarding6 Stub shaft7 Shaft seal8 Sleeve bearing9 Impeller


Layout and function

3.3 Shaft sealsOnly one of the following shaft seals can be used.

3.3.1 Mechanical seals

Mechanical seals have functional leaks.

• Single mechanical seal

• Single mechanical seal with quenching

3.4 Auxiliary systems

3.4.1 Sealing systemsOnly one of the following sealing systems can be used.

Quenching

1

2 3

Fig. 7 Single mechanical seal with quenching(sketch)

1 Pumped medium2 Single mechanical seal3 Sealing medium (unpressurized)

The pressure of the pumped medium is higher than thepressure of the sealing medium during quenching. The sealsurfaces are lubricated by the pumped medium.

Application examples:• Pumped liquids that produce a chemical reaction with air

• Prevention of offensive odors

• Cooling of seals

• Protection from icing up.


Transport, storage and disposal

4 Transport, storage and disposal

4.1 TransportFor weight specifications (→ documents for the particularorder).

4.1.1 Unpacking and inspection on delivery1. Unpack the pump/aggregate on delivery and inspect it for

transport damage.2. Report any transport damage to the manufacturer

immediately.3. Dispose of packaging material according to local

regulations.

4.1.2 Lifting

DANGERDeath or crushing of limbs caused by falling loads!

Use lifting gear appropriate for the total weight to betransported.Fasten the lifting gear as illustrated in the followingillustrations.Never fasten the lifting gear onto the motor eyebolt (unlessused as a safety device against tipping over for units witha high center of gravity).Do not stand under suspended loads.

Fig. 8 Fastening the lifting gear to the pump unit(NTWH/CTWH series)

Fig. 9 Fastening the lifting gear to the pump unit(NBWH/CBWH series)

Fig. 10 Fastening the lifting gear to the pump unit(NIWH/CIWH series)

Fig. 11 Fastening the lifting gear to the pump

Lift the pump/unit properly.



4.2 PreservationNot necessary for non-rusting materials

NOTEMaterial damage due to inappropriate treatment forstorage!

Treat the pump properly, inside and outside, for storage.

1. Choose a preservative appropriate for the type andduration of storage (→ 9.3.5 Preservatives, Page 54).

2. Use the preservative specified by the manufacturer.3. All bare metal parts should be treated, inside and outside.

4.3 Storage

NOTEMaterial damage due to inappropriate storage!

Treat and store the pump properly.

1. Seal all openings with blind flanges, blind plugs or plasticcovers.

2. Make sure the storage room meets the followingconditions:– Dry– Frost-free– Vibration-free

3. Turn the shaft once a month.4. Make sure the shaft and bearing change their rotational

position in the process.

4.4 Removing the preservativeOnly necessary for pumps treated with preservative

WARNINGRisk of poisoning from preservatives and cleaning agentsin the foodstuffs and drinking water sector!

Only use cleaning agents which are compatible with thepumped liquid (→ 9.3.6 Cleaning agents, Page 54).Completely remove all preservative.

NOTEHigh water pressure or spray water can damage bearings!

Do not clean bearing areas with a water or steam jet.

NOTEDamage to seals due to wrong cleaning agents!

Ensure the cleaning agent does not corrode the seals.

1. Choose the cleaning agent according to the application.(→ 9.3.6 Cleaning agents, Page 54).

With Tectyl 506 EH: allow benzine to soak in for 10 minutes(recommended).

2. Dispose of preservatives according to local regulations.3. For storage times in excess of 6 months:

– Replace the elastomer parts made of EP rubber(EPDM).

– Check all elastomer parts (O-rings, shaft seals) forproper elasticity and replace them if necessary.



4.5 DisposalPlastic parts can be contaminated by poisonous orradioactive pumped media to such an extent that cleaningis insufficient.

WARNINGRisk of poisoning and environmental damage by thepumped medium or oil!

Use protective equipment when carrying out any work onthe pump.Prior to the disposal of the pump:– Catch and dispose of any escaping pumped medium

or oil in accordance with local regulations.– Neutralize residues of pumped medium in the pump.– Remove any preservative (→ 4.4 Removing the

preservative, Page 16).Remove any plastic parts and dispose of them inaccordance with local regulations.

Dispose of the pump in accordance with local regulations.


Setup and connection

5 Setup and connection

For pumps in explosion hazard areas (→ ATEX additionalinstructions).

NOTEMaterial damage due to distortion or passage of electricalcurrent in the bearing!

Do not make any structural modifications to the pump unitor pump casing.Do not carry out any welding work on the pump unit orpump casing.

NOTEMaterial damage caused by dirt!

Do not remove the transport seals until immediately beforesetting up the pump.Do not remove any covers or transport and sealing coversuntil immediately before connecting the pipes to the pump.

5.1 Preparing the setup

5.1.1 Checking the ambient conditionsMake sure the required ambient conditions are fulfilled(→ 9.3.1 Ambient conditions, Page 52).

5.1.2 Preparing the installation siteEnsure the installation site meets the following conditions:– Pump is freely accessible from all sides– Sufficient space for installation/removal of the pipes

and for maintenance and repair work, especially for theremoval and installation of the pump and the motor

– Pump not exposed to external vibrations (damage tobearings)

– Frost protection

5.1.3 Preparing the foundation and surfaceSetup options:– With concrete foundation– With steel foundation frame– Without foundation

Make sure the foundation and surface meet the followingconditions:– Level– Clean (no oil, dust or other impurities)– Foundation and surface can support the weight of the

pump aggregate and all operating forces– Ensure the pump is stable and cannot tip over– With concrete foundation: standard concrete of

strength class B 25

5.1.4 Removing the preservativeIf the pump is to be put into operation immediately aftersetup and connection: remove the preservative prior tosetup (→ 4.4 Removing the preservative, Page 16).

5.1.5 Installing the heat insulation (optional)Only necessary to maintain the temperature of the pumpedmedium

NOTEMaterial damage on the bearing or shaft seal due tooverheating!

Only install the heat insulation on the volute casing(→ Figure NTWH and CTWH series, Page 11).

Install the heat insulation properly.

5.1.6 Defining the installation position (NBWH,CBWH, NIWH and CIWH series)

1. Only install the pump horizontally or vertically with themotor facing upwards.

2. Ensure that the air discharge port is positioned at thehighest point:– If installed horizontally, rotate the housing cover 161.01

around the volute casing102.01.In doing so, make sure you do not damage the seal400.01.



5.2 Installation on a foundation

NOTEMaterial damage due to distortion of the base plate!

Place the base plate on the foundation and secure it asdescribed in the following.

5.2.1 Setting the pump aggregate on the foundation

✔ Implements, tools and materials:– Foundation bolts (→ setup drawing)– Steel washers– Non-shrinking mortar/concrete– Spirit level

1. Lift the pump aggregate (→ 4.1 Transport, Page 15).2. Attach the foundation bolts from below into the base plate

fixing holes.

Follow the manufacturer's instructions when usingadhesive anchors.

3. Set the pump aggregate down on the foundation. Whendoing so, sink the foundation bolts into the preparedanchoring holes.

32 1 2

Fig. 12 Installation with foundation

4. Use steel washers to align the pump unit to the height andsystem dimensions as described in the following:– Place a steel washer (2) to the left and right-hand side

of each foundation bolt (1).– If the distance between the anchoring holes is greater

than 750 mm, place additional steel washers (3) in themiddle, on each side of the base plate.

5. Make sure the steel washers lie flat against the base plate,in full contact.

6. Use the integrated spirit level to check whether the pump islevel end to end and side to side with a maximum allowabletilt of 1 mm/m.

7. Repeat the procedure until the base plate is correctlyaligned.

5.2.2 Fastening the pump aggregate

The damping behavior is improved by filling the base platewith mortar grout.

1. Fill the anchoring holes with mortar grout.2. When the mortar grout has set, screw down the base plate

at three points with the specified torque.3. Before tightening the remaining bolts, compensate for any

unevenness in the surface using metal spacing shims nextto each bolt.

4. Check the pump unit for any distortion with a straightedge:

1

Fig. 13 Checking for distortion

– Measure in two planes at an angle of 90° on thecircumference of the coupling.

– Check the light gap at the outer diameter using astraightedge (1):Position the straightedge across both halves of thecoupling.If there is significant deviation, undo the fixing to thebase plate and correct the distortion by inserting moreshims.

– Fill the inside of the base plate with concrete, ifintended. Knock on the base plate to ensure that nocavities are created in the process.

Couplings with a spacer piece (dismountable coupling) canalso be checked with a dial gauge.



5.3 Installation without foundation✔ Implements, tools and materials:

– Wrench– Spirit level

1

1

1

12

3

4

Fig. 14 Installation without a foundation

1. Lift the pump unit (→ 4.1.2 Lifting, Page 15).2. Install four leveling feet (1) as shown.3. Set the pump aggregate down on the surface.4. Use the adjustable feet (1) to adjust the height of the base

plate as shown above:– Use a wrench to hold the hex nut steady on the leveling

foot (4).– Loosen the hex nut (2).– Adjust the height by turning the hex nut (3).– Tighten the hexagon nut (2) (→ 9.3.3 Tightening

torques, Page 53).– Use the integrated spirit level to check whether the

pump is level end to end and side to side with amaximum allowable tilt of 1 mm/m.

– Repeat the procedure until the base plate is correctlyaligned.

5.4 Installing in the pipeNIWH and CIWH series only.

NOTEMaterial damage due to excessive forces!

Make sure the pipe is able to bear the weight of the pumpaggregate and all operating forces which occur.

1. Lift the pump aggregate (→ 4.1 Transport, Page 15).2. Raise the pump aggregate between the pipe ends.

Observe the pumping direction in the process.3. Screw the suction flange and pressure flange to the pipe

(→ 5.7 Connecting the pipes, Page 22).

5.5 Installing the motorOnly necessary if the pump unit is assembled on site.

NOTEMaterial damage caused by knocks and bumps!

Do not knock or hit any components of the pump.

5.5.1 Version with coupling (NTWH and CTWH series)Only necessary if the pump unit is assembled on site.

NOTEMaterial damage caused by knocks and bumps!

Keep the coupling halves properly aligned when slippingthem on.

1. Smear a very thin coat of molybdenum disulfide (e.g.Molykote) on the shaft ends of the pump and motor.

2. Insert shaft keys.3. Slip on the pump-side and motor-side coupling halves in

line.– Without a mounting rig: remove the rubber buffers and

heat the coupling halves up to approximately 100 °C.4. Tighten the grub screws on both coupling halves.5. Raise the motor and position it on the bell housing/

connection piece.6. Check the distance between the coupling halves with a

feeler gauge:– Permissible gap (→ setup drawing)– Use the feeler gauge to measure the gap (A) between

the coupling halves.– Align the coupling halves if the gap is too wide.

7. Tighten the motor fixing screws.



5.5.2 Installation with stub shaft (NBWH, CBWH,NIWH and CIWH series)

✔ Stub shaft, free from oil and grease

1

2

3

Fig. 15 Widening the stub shaft

1 Socket head cap screw2 Stub shaft3 Shaft key groove of motor shaft

WARNINGRisk of injury due to overturning motor!

Secure themotor to prevent overturning before workingon the stub shaft.

1. Remove retaining clamp:– To do so, unscrew the hexagon head bolts 901.10 from

the motor bell housing 341.012. Remove the guard sheet 686.01 from the motor bell

housing 341.01.3. Remove the socket head cap screw 914.06 from the stub

shaft 220.01.– For this, insert a Allen key into the cast-in recess in the

motor bracket.

Tighten the jack screw with a screwdriver without applyingany excessive force.The motor must be mounted on the pump bracket beforethe pump unit is installed in the container.

4. Widen the stub shaft:– Screw the cheese head screw (M10 x 40 or M12 x 40

ISO 1207, not included in the scope of delivery) intothe stub shaft.

5. Install the flanged motor, while ensuring:– The slot of the stub shaft is opposite to the shaft key

groove of the motor shaft– No shaft key is fitted– The stub shaft is up against the collar of the motor shaft

6. Screw in the motor bolts and tighten them.7. Undo and unscrew the jack screw. Screw in the socket

head cap screw 914.06 and tighten it with a torque wrench(→ 9.3.3 Tightening torques, Page 53).

8. Turn the pump by hand:– Ensure the pump can be turned without pressure

points.9. Install the safety guarding.

5.6 Planning the pipes

5.6.1 Specifying supports and flange connections

NOTEMaterial damage due to excessive forces and torquesexerted by the piping on the pump!

Do not exceed the permissible limits (→ 9.3.8 Flange loadsaccording to ISO 5199, Page 56).

1. Calculate the pipe forces, taking every possible operatingcondition into account:– Cold/warm– Empty/full– Unpressurized/pressurized– Shift in position of flanges

2. Ensure the pipe supports have permanent low-frictionproperties and do not seize up due to corrosion.

5.6.2 Specifying nominal diametersKeep the flow resistance in the pipes as low as possible.

1. Make sure the nominal suction pipe diameter is not smallerthan the nominal suction flange diameter.

2. Make sure the nominal pressure pipe diameter is notsmaller than the nominal pressure flange diameter.



5.6.3 Specifying pipe lengths

CD

B

A

Fig. 16 Straight pipe lengths upstream and downstreamof the pump (recommended)

A > 5 x nominal suction pipe diameterB Nominal suction pipe diameterC Nominal pressure pipe diameterD > 5 x nominal pressure pipe diameter

Maintain the recommended minimum values wheninstalling the pump.

Suction side: shorter pipes are possible but may restrictthe hydraulic performance.Pressure side: shorter pipes are possible but can result inincreased operating noise.

5.6.4 Optimizing cross-section and directionchanges

1. Avoid radii of curvature of less than 1.5 times the nominalpipe diameter.

2. Avoid abrupt changes of cross-section along the piping.

5.6.5 Discharging leaks

WARNINGRisk of injury and poisoning due to hazardous pumpedliquids!

Safely collect any leaking pumped liquid, then dischargeand dispose of it in accordance with environmentalregulations.

1. Provide equipment for collecting and discharging leakingliquids.

2. Ensure the free discharge of leaking liquids.

5.6.6 Providing safety and control devices(recommended)

Avoid impurities

1. Integrate a filter in the suction pipe.2. To monitor impurities, install a differential pressure gauge

with a contact manometer.

Avoid reverse running

Install a non-return valve between the pressure flange andthe gate valve to ensure the medium does not flow backwhen the pump is switched off.

Make provisions for isolating and shutting off the pipes

For maintenance and repair work.

Provide shut-off devices in the suction and pressure pipes.

Allow measurements of the operating conditions

1. Provide manometers for pressure measurements in thesuction and pressure pipes.

2. Provide load monitors (overload and underload) on themotor side.

3. Provide for pump-side temperature measurements.

5.7 Connecting the pipes

5.7.1 Keeping the piping clean

NOTEMaterial damage due to impurities in the pump!

Make sure no impurities can enter the pump.

1. Clean all piping parts and armatures prior to assembly.2. Ensure no flange seals protrude inwards.3. Remove any blind flanges, plugs, protective foils and/or

protective paint from flanges.

5.7.2 Installing auxiliary pipingFollow the manufacturers' specifications for any availableauxiliary systems.

1. Connect the auxiliary pipes to the auxiliary connections sothat they are stress-free and do not leak (→ setup drawing).

2. To avoid air pockets, run the pipes with a continuous slopeup to the pump.

5.7.3 Installing the suction pipe1. Remove the transport and sealing covers from the pump.2. To avoid air pockets, run the pipes with a continuous slope

up to the pump.3. Ensure no seals protrude inwards.4. For suction operation: install a foot valve in the suction pipe

to prevent the pump and suction pipe from running emptyduring downtimes.



5.7.4 Installing the pressure pipe

1. Remove the transport and sealing covers from the pump.2. Install the pressure pipe.3. Ensure no seals protrude inwards.

5.7.5 Inspection for stress-free pipe connections✔ Piping installed and cooled down

NOTEMaterial damage due to distorted pump casing

Ensure that all pipes are stress relieved when connectedto the pump.

1. Disconnect the pipe connecting flanges from the pump.2. Check whether the pipes can be moved freely in all

directions within the expected range of expansion:– Nominal diameter < 150 mm: by hand– Nominal diameter > 150 mm: with a small lever

3. Make sure the flange surfaces are parallel.4. Reconnect the pipe connecting flanges to the pump.

5.7.6 Inspecting the support foot for distortion

1. Loosen the bolts connecting the support foot to the baseplate.

2. If the support foot moves, compensate for distortion:– Lateral shift: by means of slotted holes– Height shift: by means of metal shims

3. Screw the support foot back onto the base plate, makingsure that the bearing bracket is not distorted in the process.

5.8 Electrical connection

DANGERRisk of death due to electric shock!

Have all electrical work carried out by qualified electriciansonly.

DANGERRisk of death due to rotating parts!

Isolate the motor from its supply voltage and keep it lockedin that state when carrying out any fitting or maintenancework.

5.8.1 Connecting the motor

Follow the instructions of the motor manufacturer.

1. Connect the motor according to the connection diagram.2. Make sure no danger arises due to electric power.3. Install an EMERGENCY STOP switch.

5.8.2 Checking the direction of rotation


Use protective equipment when carrying out any work onthe pump.Secure the shaft key from being thrown out when checkingthe sense of rotation.Keep an adequate distance to rotating parts.

NOTEMaterial damage caused by dry running or wrong directionof rotation!

Uncouple the motor from the pump.

1. Switch the motor on and immediately off again.2. Check whether the direction of rotation of the motor

corresponds to the arrow indicating the direction ofrotation on the pump.

3. If the direction of rotation is different: swap two phases.4. Couple the motor to the pump again.



5.9 Aligning the coupling preciselyOnly required on version with coupling (NTWH and CTWHseries)


Isolate the motor from its supply voltage and keep it lockedin that state when carrying out any fitting or maintenancework.

NOTEMaterial damage due to incorrect alignment of thecoupling!

Align the motor exactly to the pump if there is any vertical,lateral or angular misalignment.For detailed information and special couplings:(→ manufacturer's specifications)

Checking the alignment of the coupling✔ Implements, tools and materials:

– Feeler gauge– Straightedge– Dial gauge (for couplings with spacer piece)– Other suitable tools, e.g. laser alignment instrument

1

2

A

Fig. 17 Checking the alignment of the coupling

1. Measure in two planes at an angle of 90° on thecircumference of the coupling.

2. Check the light gap towards the outer diameter with astraightedge (1):– Position the straightedge across both halves of the

coupling.– Align the motor if there is a visible gap at the outer

diameter (→ 5.10 Aligning the motor, Page 25).

3. Measure the gap with a feeler gauge (2):– Permissible gap (→ setup drawing)– Use the feeler gauge to measure the gap (A) between

the coupling halves.– Align the motor if the gap is too wide (→ 5.10 Aligning

the motor, Page 25).

Fig. 18 Checking for lateral and vertical misalignment

4. Check for any lateral or vertical misalignment using the dialgauge:– Carry out the measurement as illustrated.– Align the motor if there is any lateral or vertical

misalignment (→ 5.10 Aligning the motor, Page 25).Permissible axial or radial deviation, measured on thecoupling front or circumference, respectively: < 0.05mm

Fig. 19 Checking for angular displacement

5. Check the angular displacement with a dial gauge:– Carry out the measurement as illustrated.– If there is any angular displacement: align the motor.



5.10 Aligning the motorAlignment options:– With sets of shims– With adjusting screws

5.10.1 Aligning the motor with sets of shims

1. Align the motor so that the coupling halves are exactly inline and fit shims if necessary.

2. Check the alignment.3. Repeat the alignment procedure if there is still any vertical

misalignment.4. Then tighten the motor fixing screws.

5.10.2 Aligning the motor with adjusting screws

1

43

2

Fig. 20 Aligning the motor with adjusting screws

Observe the angle of rotation of the spindle when adjustingthe adjusting screws (→ 9.3.7 Height offset for motoralignment with adjusting screw, Page 55).

1. Determine the necessary angle of rotation of the wrenchfor the height offset measured (→ 9.3.7 Height offset formotor alignment with adjusting screw, Page 55).

2. Loosen the hexagon head bolts (1).3. Carry out the following steps on all adjusting screws (3):

– Hold the adjusting screw (3) firmly on the hexagonhead (2) and loosen the lock nut (4).

– Turn the adjusting screw (3) to the selected angle.– Hold the adjusting screw (3) firmly on the hexagon

head (2) and tighten the lock nut (4).4. Tighten the hexagon head bolts (1).5. Check the alignment.6. Repeat the alignment procedure if there is still any vertical

misalignment.7. Then tighten the motor fixing screws.

5.11 Installing the coupling guardDo not unscrew the non-loseable nuts (902.101) from thethreaded rod.

Base plate version1. Installing the coupling guard

– Gap between coupling guard and pump < 8 mm– Gap between coupling guard and motor < 8 mm (set

the equalizing pipe (681.102) accordingly)

Flanged drive2. If available ,install the coupling guard (two plates) on the

bell housing (→ Figure Coupling guard on flange versions,Page 47).


Operation

6 Operation


6.1 Putting the pump into servicefor the first time

6.1.1 Removing the preservative

Only necessary for pumps treated with preservative

(→ 4.4 Removing the preservative, Page 16).

6.1.2 Preparing auxiliary systems (if available)

The manufacturer does not accept any liability for damagearising from the installation or use of a third-party orunapproved auxiliary system.

Sealing systems

1. Verify that the sealing medium is suitable to mix (i.e.compatible) with the pumped medium.

2. Identify the sealing system (→ order data sheet)(→ 3.4.1 Sealing systems, Page 14).

3. Install the sealing system (→ manufacturer'sspecifications).

4. Make sure the parameters required for the installed sealingsystem are met

5. Ensure that the permissible container pressureis not exceeded on blocking pressure systems(→ manufacturer's specifications).

6.1.3 Filling and bleeding✔ Auxiliary systems ready for operation

WARNINGRisk of injury and poisoning due to hazardous pumpedmedia!

Safely collect any leaking pumped medium and disposeof it in accordance with environmental rules andrequirements.

NOTEMaterial damage caused by dry running!

Make sure the pump is filled properly.

1. If necessary, fill the seal chamber with pumped liquid:– Bleed the pump using connection FF2/FV1.– If the pump is set up in a vertical position, also bleed

air using connection FF4/FV4.– Fill the pump with pumped liquid using connection

FF2/FV1.– If possible, turn the pump shaft by hand.

2. Fill the pump and the suction pipe with pumped medium.3. Open the suction-side armature.4. Open the pressure-side armature.5. If present: open the auxiliary systems and check the flow

rate.6. Verify that no pipe connections are leaking.


Operation

6.1.4 Switching on

✔ Pump set up and connected properly✔ Motor set up and connected properly✔ Motor exactly aligned with the pump✔ All connections stress-free and sealed✔ Any available auxiliary systems are ready for operation✔ All safety equipment installed and tested for functionality✔ Pump prepared, filled and bled properly

Pumped liquids with a high viscosity can cause increasedpower consumption. We recommend using a minimumamount of pumping liquid until the operating temperaturehas been reached.

DANGERRisk of injury due to running pump!

Do not touch the running pump.Ensure that the coupling guard is attached.Do not carry out any work on the running pump.Allow the pump to cool down completely before starting anywork.

DANGERRisk of injury and poisoning due to pumped liquidspraying out!

Use protective equipment when carrying out any work onthe pump.



NOTERisk of cavitation when throttling down the suction flowrate!

Fully open the suction-side armature and do not use it toadjust the flow rate.Do not open the pressure-side fitting beyond the operatingpoint.

NOTEMaterial damage caused by overheating!

Do not operate the pump for long periods with the pressure-side fitting closed.Observe the minimum flow rate (→ order data sheet).

1. Open the suction-side fitting.2. Close the pressure-side fitting.3. Switch on the motor and make sure it is running smoothly.4. Once the motor has reached its nominal speed, open

the pressure-side fitting slowly until the operating point isreached.

5. For pumps with hot pumped liquids, make sure anytemperature changes do not exceed 5 K/min.

6. Observe the following for use in high temperature systems:– Heat the pump to 100–130 °C– Bleed the pump using connection FF2/FV1 or FF4/FV4

7. After the first load under pressure and at operatingtemperature, check that the pump is not leaking.

8. If the pumped liquid is hot, switch off the pump briefly atoperating temperature, check the alignment of the couplingand realign the motor if necessary. (→ 5.9 Aligning thecoupling precisely, Page 24).

6.1.5 Switching off✔ Pressure-side fitting closed (recommended)

WARNINGRisk of injury due to hot pump parts!


1. Switch off the motor.2. Check all connecting bolts and tighten them if necessary.3. On pump unit with flange bearing housing, align the support

foot:– Unscrew all the screws of the support foot 183.01– Secure the support foot to the foundation– Make sure that the fastening screws 901.13 can be

inserted into slots of the motor bell housing– If necessary, adjust the support foot by placing metal

spacing shims underneath it– Put the washers 554.13 on the fastening screws

901.13– Secure the fastening screws 901.13 with hexagon nuts

920.13


Operation

6.2 Operating

6.2.1 Switching on✔ Pump set up and connected properly✔ Motor set up and connected properly✔ Motor exactly aligned with the pump✔ All connections stress-free and sealed✔ Any available auxiliary systems are ready for operation✔ All safety equipment installed and tested for functionality✔ Pump prepared, filled and bled properly


Do not touch the running pump.Ensure that the coupling guard is attached.Do not carry out any work on the running pump.Allow the pump to cool down completely before starting anywork.

DANGERRisk of injury and poisoning due to pumped liquidspraying out!




NOTERisk of cavitation when throttling down the suction flowrate!

Fully open the suction-side armature and do not use it toadjust the flow rate.Do not open the pressure-side fitting beyond the operatingpoint.

NOTEMaterial damage caused by overheating!

Do not operate the pump for long periods with the pressure-side fitting closed.Observe the minimum flow rate (→ order data sheet).

1. Open the suction-side fitting.2. Close the pressure-side fitting.3. Switch on the motor and make sure it is running smoothly.4. Once the motor has reached its nominal speed, open

the pressure-side fitting slowly until the operating point isreached.

5. For pumps with hot pumped liquids, make sure anytemperature changes do not exceed 5 K/min.

6. After the first load under pressure and at operatingtemperature, check that the pump is not leaking.

7. If the pumped liquid is hot, switch off the pump briefly atoperating temperature, check the alignment of the couplingand realign the motor if necessary (→ 5.9 Aligning thecoupling precisely, Page 24).

6.2.2 Switching off✔ Pressure-side fitting closed (recommended)

WARNINGRisk of injury due to hot pump parts!


Switch off the motor.

6.3 Shutting down


Safely collect any leaking pumped medium and disposeof it in accordance with environmental rules andrequirements.


Operation

Take the following measures whenever the pump is shutdown:

Pump is Measure

...shut downfor a prolongedperiod

Take measures according tothe pumped liquid (→ Table8 Measures depending onthe behavior of the pumpedmedium, ).

...emptied Close the suction-side andpressure-side armatures.

...dismounted Isolate the motor from its powersupply and secure it againstunauthorized switch-on.

...put intostorage

Follow the storage instructions(→ 4.3 Storage, Page 16).

Tab. 7 Measures to be taken if the pump is shut down

Duration of shutdown (dependingon process)

Behaviorof pumpedmedium Short Long

Solids sediment Flush thepump.

Flush thepump.

Solidifying/freezing,non-corrosive

Heat up orempty thepump andcontainers.

Empty thepump andcontainers.

Solidifying/freezing,corrosive

Heat up orempty thepump andcontainers.

Empty thepump andcontainers.Treat thepump andcontainerswithpreservative.

Remains liquid,non-corrosive

– –

Remains liquid,corrosive

– Empty thepump andcontainers.Treat thepump andcontainerswithpreservative.

Tab. 8 Measures depending on the behaviorof the pumped medium

6.4 Start-up following a shutdown period1. If the pump is shut down for over 1 year, take the following

measures before starting it up again:

Shutdown period Measure

> 1 year For versions with rollerbearings without lifetimelubrication: relubricate

> 2 years Replace elastomer seals(O-rings, shaft sealing rings).Replace antifriction bearings.

Tab. 9 Measures to be taken after prolongedshutdown periods

2. Carry out all steps as for the initial start-up (→ 6.1 Puttingthe pump into service for the first time, Page 26).

6.5 Operating the stand-by pump✔ Stand-by pump filled and bled

Operate the stand-by pump at least once a week.

1. Completely open the suction-side armature.2. Open the pressure-side fitting to the extent that the

stand-by pump reaches its operating temperature and isheated through evenly (→ 6.2.1 Switching on, Page 28).


Maintenance

7 Maintenance


Trained service technicians are available for fitting andrepair jobs. Present a pumped medium certificate (DINsafety data sheet or safety certificate) when requestingservice.

7.1 InspectionsThe inspection intervals depend on the operational strainon the pump.


Do not touch the running pump.Do not carry out any work on the running pump.



1. Check at appropriate intervals:– Maintenance of minimum flow rate– Temperature of antifriction bearings < 120 °C– Normal operating conditions unchanged– Top up oil if necessary– Coupling alignment and condition of elastic parts

2. For trouble-free operation, always ensure the following:– No dry running– No leaks– No cavitation– Suction-side gate valves open– Unclogged and clean filters– Sufficient supply pressure– No unusual running noises or vibrations– No overloading of the system– No excessive leakage at the shaft seal– Proper functioning of auxiliary systems

7.2 MaintenanceService life of the antifriction bearings for operation withinthe permissible operating range: > 2 yearsIntermittent operation, high temperatures, low viscositiesand aggressive ambient and process conditions reduce theservice life of antifriction bearings.

Mechanical seals are subject to natural wear, whichstrongly depends on the actual operating conditions.Therefore, general statements regarding their service lifecannot be made.


Do not touch the running pump.Do not carry out any work on the running pump.Isolate the motor from its supply voltage and keep it lockedin that state when carrying out any fitting or maintenancework.



WARNINGRisk of injury and poisoning due to hazardous or hotpumped media!

Use protective equipment when carrying out any work onthe pump.Allow the pump to cool down completely beforecommencing any work.Make sure the pump is unpressurized.Empty the pump, safely collect the pumped medium anddispose of it in accordance with environmental rules andrequirements.


Maintenance

7.2.1 Antifriction bearings lubricated with grease

1. As a precaution, replace antifriction bearings with lifetimelubrication every 2 years (recommended).The following antifriction bearings have been installed:

Bearing bracketsize

Antifriction bearing

1, 2 • Closed antifriction bearingwith guard discs

• Lifetime lubrication ex factory

3, 4 • Open antifriction bearingsNilos rings

• Greased ex factory

• Must be greased regularly(→ Table 21 Relubricationintervals for the antifrictionbearings, Page 53).

Tab. 10 Employed antifriction bearings

2. Make sure you use the correct type and minimum amountof grease when filling the bearing (→ 9.3.4 Lubricants,Page 53).

3. Fill the cavities between the rolling elements up to 40 %with grease.

4. Wipe off any excess grease with a soft object.

7.2.2 Mechanical sealsMechanical seals have functional leaks (→ manufacturer'sspecifications).Single mechanical seals with quenching: any drastic risein the level of the quenching system indicates a major leakat the product-side mechanical seal.Double mechanical seals: any drastic pressure drop in theblocking system (loss of blocking fluid) indicates a majorleak at the product-side mechanical seal.

1. In the event of a larger leak: replace the mechanical sealand its auxiliary seals and check the integrity of the auxiliarysystems.

2. Recommended: Empty out the bearing bracket regularly inorder to replace old pumping liquid:– Take the pump out of operation (→ 6.3 Shutting down,

Page 28).– Open connection FD2 of bearing bracket and safely

collect the pumping liquid.– Fill and bleed the pump (→ 6.1.3 Filling and bleeding,

Page 26).

7.2.3 Carbon sleeve bearing

Carbon sleeve bearings are wear parts.

As a precautionary measure, replace carbon sleevebearings every 2 years (recommended).

7.2.4 Sealing mediumOnly on versions with quenching.

1. Check the filling level of the sealing medium.2. After 4000 operating hours or when the maximum filling

level has been reached, replace the sealing medium:– Empty the sealing chamber and safely collect the

sealing medium.– Fill the seal chamber with sealing medium.

7.2.5 Cleaning the pump

NOTEHigh water pressure or spray water can damage bearings!

Do not clean bearing areas with a water or steam jet.

Clean large-scale grime from the pump.


Maintenance

7.3 Dismounting


Do not touch the running pump.Do not carry out any work on the running pump.Isolate the motor from its supply voltage and keep it lockedin that state when carrying out any fitting or maintenancework.



WARNINGRisk of injury and poisoning due to hazardous or hotpumped media!

Use protective equipment when carrying out any work onthe pump.Allow the pump to cool down completely beforecommencing any work.Make sure the pump is unpressurized.Empty the pump, safely collect the pumped medium anddispose of it in accordance with environmental rules andrequirements.

WARNINGRisk of injury due to heavy components!

Pay attention to the component weight. Lift and transportheavy components using suitable lifting gear.Set down components safely and secure them againstoverturning or rolling away.

WARNINGRisk of injury during disassembly!

Secure the pressure-side gate valve against accidentalopening.Depressurize the blocking pressure system, if available.Wear protective gloves as components can become verysharp through wear or damage.Remove spring-loaded components carefully (e.g.mechanical seal, tensioned bearing, valves etc.), ascomponents can be ejected by the spring tension.Observe the manufacturer's specifications (e.g. for themotor, coupling, mechanical seal, blocking pressuresystem, cardan shaft, drives, belt drive etc.).

7.3.1 Returning the pump to the manufacturer✔ Pump unpressurized✔ Pump completely empty✔ Electrical connections isolated and motor secured against

switch-on✔ Pump cooled down✔ Coupling guard dismounted✔ With coupling with spacer piece: spacer piece removed✔ Auxiliary systems shut down, depressurized and emptied✔ Manometer lines, manometer and holdings dismounted1. Enclose a truthfully and fully completed document of

compliance when returning pumps or components to themanufacturer (→ 9.5 Safety certificate, Page 59).

2. Take necessary measures, depending on the requiredrepair work, as listed in the table below when returning thepump to the manufacturer.

Repair carried out Measure for return

...at the customer'spremises

Return the defectivecomponent to themanufacturer.

...at themanufacturer'spremises

Flush the pump anddecontaminate it if it wasused to pump hazardousmedia.Return the complete pump(not disassembled) to themanufacturer.

...at themanufacturer'spremises forwarranty repairs

Only in the event ofhazardous pumped media:flush and decontaminate thepump.Return the complete pump(not disassembled) to themanufacturer.

Tab. 11 Measures for return


Maintenance

7.3.2 Preparations for dismounting

✔ Pump unpressurized✔ Pump completely empty, flushed and decontaminated✔ Electrical connections isolated and motor secured against

switch-on✔ Pump cooled down✔ Coupling guard dismounted✔ With coupling with spacer piece: spacer piece removed✔ Auxiliary systems shut down, depressurized and emptied✔ Manometer lines, manometer and holdings dismounted

In production, the pumps are constructed to a standardprocess. The slide-in unit can be removed withoutremoving the volute casing and piping.If a coupling with spacer piece is used, the motor canremain mounted on the base plate.

When dismounting, observe the following:– Mark the precise orientation and position of all

components before dismounting.– Dismantle components concentrically without canting.– Dismount the pump (→ sectional drawing).

7.3.3 Dismounting

Installation with stub shaft (NBWH, CBWH,NIWH and CIWH series)

1

2

3

Fig. 21 Widening the stub shaft

1 Socket head cap screw2 Stub shaft3 Shaft key groove of motor shaft

WARNINGRisk of injury due to overturning motor!

Secure themotor to prevent overturning before workingon the stub shaft.

1. Remove retaining clamp:– To do so, unscrew the hexagon head bolts 901.10 from

the motor bell housing 341.012. Widen the stub shaft:

– Unscrew the socket head cap screw 914.06 and screwa socket head cap screw M10 x 40 or M12 x 40 ISO1207 (not included in the delivery) into the stub shaft.


Maintenance

7.4 InstallingReinstall the components concentrically, without canting,in accordance with the markings made.

WARNINGRisk of injury due to heavy components!

Pay attention to the component weight. Lift and transportheavy components using suitable lifting gear.Set down components safely and secure them againstoverturning or rolling away.

WARNINGRisk of injury during assembly!

Install spring-loaded components carefully (e.g.mechanical seal, tensioned bearing, valves etc.), ascomponents can be ejected by the spring tension.Observe the manufacturer's specifications (e.g. for themotor, coupling, mechanical seal, blocking pressuresystem, cardan shaft, drives, belt drive etc.).

NOTEMaterial damage due to unsuitable components!

Always replace lost or damaged screws with screws of thesame strength (→ 9.3.3 Tightening torques, Page 53).Only replace seals with seals of the same material.

1. Observe the following during the installation:– Replace worn parts with genuine spare parts.– Replace seals, inserting them so that they cannot

rotate.– Maintain the specified tightening torques

(→ 9.3.3 Tightening torques, Page 53).2. Clean all parts (→ 9.3.6 Cleaning agents, Page 54). Do

not remove any prepared markings.3. On version with a fan and stub shaft (NBWH, CBWH, NIWH

and CIWH series):– Install the stub shaft (→ 5.5.2 Installation with stub

shaft (NBWH, CBWH, NIWH and CIWH series),Page 21).

– Push the fan 831.01with the tolerance ring 517.03 ontothe stub shaft 220.01 to the stop position.

4. On NTWH and CTWH series:– Fill the space in front of and behind the shaft seal

ring 421.01 with lubricant (→ Figure NTWH, CTWHversion, lubrication and radial shaft seal ring, Page 41).

5. Replace the antifriction bearings.6. Fill any open antifriction bearings without guard discs with

grease:– Make sure you use the correct type and minimum

amount of grease when filling the bearing(→ 9.3.4 Lubricants, Page 53).

– Fill the cavities between the rolling elements up to 40%with grease.

– Wipe off any excess grease with a soft object.

7. Observe the following when fitting the sleeve bearing bushwith lube oil:– Position the centering peg 562.06 as shown in the

illustration.8. Install the pump (→ sectional drawing).9. Install the pump in the system (→ 5 Setup and connection,

Page 18).

7.5 Ordering spare partsFor trouble-free replacement in the event of faults, werecommend keeping entire slide-in units or spare pumpsavailable on site.The application guidelines conforming to DIN 24296recommend provisioning for two years of continuous use(→ 9.4 Spare parts for two years of continuous operationaccording to DIN 24296, Page 58).

Have the following information ready to hand whenordering spare parts (→ type plate):– Short designation of the pump– Pump number– Year of manufacture– Part number– Designation– Quantity


Troubleshooting

8 Troubleshooting

For faults which are not specified in the following table orcannot be traced back to the specified causes, please consultthe manufacturer.Possible faults are identified by a fault number in the tablebelow. This number identifies the respective cause and remedyin the troubleshooting list.

Fault Number

Pump not pumping 1

Pumping rate insufficient 2

Pumping rate excessive 3

Pumping pressure insufficient 4

Pumping pressure excessive 5

Pump running roughly 6

Antifriction bearing temperatures too high 7

Pump leaking 8

Motor power uptake excessive 9

Tab. 12 Fault number assignment

Fault number

1 2 3 4 5 6 7 8 9

Cause Remedy

X – – – – – – – – Supply/suction pipe and/or pressure pipeclosed by armature

Open the armature.

X – – – – – – – – Transport and sealing cover still in place Remove the transport and sealingcover.Dismount the pump and inspect it fordry-running damage.

X – – – – X – – – Supply/suction pipe not bled properly ornot filled up completely

Fill up the pump and/or pipingcompletely and bleed them.

X – – – – X – – – Supply/suction pipe contains air pockets Install the armature for bleeding.Correct the piping layout.

X X – X – X – – – Supply/suction pipe, pump or suctionstrainer blocked or encrusted

Clean the supply/suction pipe, pump orsuction strainer.

X X – X – X – – – Pump running in the wrong direction Swap any two phases on the motor.

X X – X – – – – – Motor speed too low Compare the required motor speed withthe specifications on the pump typeplate. Replace the motor if necessary.Increase the motor speed if speedcontrol is available.

X X – X – X – – – Impeller out of balance or blocked Dismount the pump and inspect it fordry-running damage.Clean the impeller.

X X – X – X – – – Air is sucked in Seal the source of malfunction.

X X – X – X – – – Excessive amount of gas: pump iscavitating

Consult the manufacturer.

X X – – X X – – – Pressure pipe blocked Clean the pressure pipe.


Troubleshooting

Fault number

1 2 3 4 5 6 7 8 9

Cause Remedy

– X – X – – – – – Geodetic differential head and/or pipe flowresistances too high

Remove sediments from the pumpand/or pressure pipe.Install a larger impeller and consult themanufacturer.

– X – X – – – – – Supply/suction pipe not fully opened Open the armature.

– X – X – X – – – Supply/suction pipe cross-section toonarrow

Increase the cross-section.Remove any encrustations from thesuction pipe.Open the armature completely.

– X – X – X – – – Differential head excessive: NPSHpumplarger than NPSHsystem

Increase the supply pressure.Consult the manufacturer.

– X – X – X – – – Pumped medium temperature too high:pump is cavitating

Increase the supply pressure.Lower the temperature.Consult the manufacturer.

– X – X – X X – – Pump parts worn Replace the worn pump parts.

– X – X – X – – X Motor running on 2 phases Check the fuse and replace it ifnecessary.Check the cable connections andinsulation.

– X – X – X – – – Hydraulic parts of the pump dirty, clottedor encrusted

Dismount the pump.Clean the parts.

– X – X – – – – X Viscosity or specific gravity of the pumpedmedium outside the range specified forthe pump

Consult the manufacturer.

– X – – X X – – – Pressure-side armature not opened wideenough

Open the pressure-side armature.

– – X X – X – – X Pressure-side armature opened too wide Throttle down at the pressure-sidearmature.Machine the impeller down. Consult themanufacturer and adjust the impellerdiameter.

– – X – – X – – X Geodetic differential head, pipe flowresistances and/or other resistances lowerthan specified

Throttle down the flow rate at thepressure-side armature. Observe theminimum flow rate.Machine the impeller down. Consult themanufacturer and adjust the impellerdiameter.

– – X – X – – – – Viscosity lower than expected Machine the impeller down. Consult themanufacturer and adjust the impellerdiameter.

– – X – X X X – X Motor speed too high Compare the required motor speed withthe specifications on the pump typeplate. Replace the motor if necessary.Reduce the motor speed if speedcontrol is available.


Troubleshooting

Fault number

1 2 3 4 5 6 7 8 9

Cause Remedy

– – X – X X – – X Impeller diameter too large Throttle down the flow rate at thepressure-side armature. Observe theminimum flow rate.Machine the impeller down. Consult themanufacturer and adjust the impellerdiameter.

– – – – – X X – X Defective antifriction bearing in bearingbracket

Replace the antifriction bearing.

– – – – – X X – – Coupling not aligned properly Align the coupling.

– – – – – – X – X Defective antifriction bearing in motor Replace the antifriction bearing(→ manufacturer's specifications).

– – – – – – X – – Lubricant: too much, not enough orunsuitable

Reduce, top up or replace the lubricant.

– – – – – – X – – Excessive axial load Clean the relief bore in the impeller.

– – – – – – – X – Connecting bolts not tightened properly Tighten the connecting bolts.

– – – – – – – X – Mechanical seal worn Replace the mechanical seal.

– – – – – – – X – Mechanical seal worn by pumped liquid Check the pumped liquid.Replace the mechanical seal.

– – – – – – – X – Housing seal defective Replace the housing seal.

– – – – – – – X – Shaft sleeve is infiltrated Replace the shaft sleeve and/or O-ring.

– – – – – X X X X Pump distorted Check the pipe connections and pumpattachment.Check the coupling alignment.Check the attachment of the supportfoot.

– – – – – X – – – Coupling elements worn Replace the coupling units and realignthem.

– – – – – X – – – Flow quantity is below the minimum Increase the flow quantity to theminimum flow quantity.

Tab. 13 Troubleshooting list


Appendix

9 Appendix

9.1 Sectional drawings

9.1.1 Auxiliary connections

Abbreviation Connection

FD1 Pumped liquid / emptying

FD2 Pumped liquid / emptying

FF2/FV1 Filling / bleeding

FF4/FV4 Filling / bleeding

LO1 Leak / egress

Tab. 14 Abbreviations of the connection designations

9.1.2 Part numbers and designations

Part no. Designation

10 Lubricating chamber disc/covering plate

102.01 Volute casing

161.01 Housing cover

183.01 Support foot

201 Hexagon head bolt



210.01 Shaft

220.01 Stub shaft

230.01 Impeller

231 disc

321.02 Groove ball bearings

330.01 Bearing bracket

341.01 Motor bell housing

360.02 Bearing cover

400.01 Gasket

400.02 Gasket

400.03 Gasket

411.02 Seal ring

411.06 Seal ring

411.07 Seal ring

411.08 Seal ring

412.071) O-ring

421.01 Shaft seal ring

433.01 Mechanical seal

461.01 Gland packing


509.01 Intermediate ring

511.01 1) Centering ring

511.02 1) Centering ring

516.01 Nilos ring

516.02 Nilos ring

517.01 Tolerance ring

517.02 1) Tolerance ring

517.03 Tolerance ring

524.01 1) Shaft protection sleeve

529.01 1) Bearing sleeve

545.01 Bearing bush

550.01 1) Disc

550.02 1) Disc

550.106 Slotted disc

550.107 Disc

551.01 Spacing washer

551.02 2) Spacing washer





554.08 Washer

554.09 Washer

554.13 Washer

562.06 Spring dowel

562.08 Cylindrical pin

565.01 Rivet

681.101 Coupling guard

681.102 Equalizing pipe

686.01 Guard sheet

686.02 Guard sheet

710.01 Pipe

801.01 Flanged motor

831.01 Fan (push on to stop position)

901.01 Hexagon head bolt




Appendix






902.01 3) 4) Stud bolt

902.02 4) Stud bolt

902.102 Stud bolt

903.02 Screw plug

903.06 Screw plug

903.07 Screw plug

903.08 Screw plug

904.01 Grub screw


914.06 Socket head cap screw



920.01 3) 4) Nut

920.02 4) Nut

920.106 Hexagon nut

920.107 Hexagon nut

920.13 Nut

922.01 Impeller nut

923.01 1) Impeller nut

932.01 Circlip

932.02 2) Circlip

932.03 Circlip

932.05 Circlip

932.06 1) Circlip

932.07 Circlip

934.01 Spring washer

936.01 Spring ring

940.01 Shaft key

940.02 Shaft key

971.01 Name plate

Tab. 15 Designations of components accordingto part numbers

1) Only on version with SiC bearing2) Only on versions with carbon bearing.3) Only on NTWH series with bearing bracket size 44) Only on CTWH series


Appendix


210.01321.02

411.06433.01551.02551.07529.01545.01 551.05551.04

903.06400.03923.01932.03517.01

550.01 550.02 932.02 411.08 183.01 360.02 940.02

932.05901.13330.01903.08511.02

551.06

517.02511.01932.06

102.01

400.01

161.01

230.01

551.01

936.01934.01

922.01

940.01

932.01

461.01

903.02

411.02

421.01

902.01920.01

914.08901.06

901.01 411.07 903.07

971.01

710.01

565.01

Fig. 22 U2.11A-S1 series overview sectional drawing, balanced mechanical seal and SiC bearing


Appendix

509.01 901.01901.02400.01 400.02

902.02920.02

902.01920.01

Fig. 23 Version with intermediate ring

516.02516.01

Fig. 24 Version for bearing bracket size 3 and 4

210.01545.01 433.01

Fig. 25 U3.3A-K1 version, unbalanced mechanicalseal and carbon bearing

1

Fig. 26 NTWH, CTWH version, lubrication andradial shaft seal ring

1 Fill with lubrication grease completely


Appendix




Appendix

220.01433.01551.02932.02545.01


400.01400.02

509.01901.02

901.01



Appendix



* Only if it is set up in a vertical position


Appendix

220.01

545.01

433.01

932.02

551.02


400.01

400.02

509.01

901.02

901.01



Appendix

9.1.6 CTWH 200-250/81 series

A

Fig. 33 CTWH 200-250/81 series, U2.12A

A Fill this space completely withspecial grease (ASONIC GHY 72)


Appendix

9.1.7 Coupling guard

max. 8 mm max. 8 mm

Fig. 34 Coupling guard on base plate versions

Fig. 35 Coupling guard on flange versions


Appendix

9.2 Exploded drawings


Fig. 36 U2.11A-S1 series – balanced mechanical seal and SiC bearing

Fig. 37 U3.3A-K1 version – unbalanced mechanical seal and carbon bearing


Appendix





Appendix

9.2.4 CTWH 200-250/81 series

Fig. 42 CTWH 200-250/81 series, U2.13A-K2


Appendix

9.3 Technical specificationsMore technical specifications (→ order data sheet).

9.3.1 Ambient conditions

Operation under other ambient conditions should beagreed with the manufacturer

Relative humidity [%]Temperature[°C] Long-term Short-term

Setupheightabove sealevel [m]

–20 to +40 ≤ 85 ≤ 100 ≤ 1000

Tab. 16 Ambient conditions

9.3.2 Sound pressure levelsMeasuring conditions:

• Distance to the pump: 1 m

• Operation: cavitation-free

• Motor: IEC standard motor

• Tolerance ±3 dB

Lower-noise versions of the motors are available if theexpected noise levels exceed the permissible limits.

Sound pressure level [dB] for pumpwith motor at speed [rpm]

Nominal motorpower PM [kW]

1450 1750 2900 3500

1.5 58 58.5 63 64

2.2 60 60.5 66 67

3.0 62 62.5 68 69

4.0 63 63.5 69 70

5.5 65 65.5 71 72

7.5 66 66.5 72 73

11.0 68 68.5 74 75

15.0 69 69.5 75 76

18.5 70 70.5 76 77

22.0 71 71.5 77 78

30.0 72 72.5 78 79

37.0 73 73.5 79 80

45.0 74 74.5 80 81

55.0 75 75.5 80 81

75.0 76 76.5 81 82

90.0 76 76.5 82 83

110.0 77 77.5 82 83

132.0 78 78.5 83 84

160.0 79 79.5 84 85

200.0 80 80.5 85 86

250.0 83 83 83 84

315.0 84 84 85 85

355 85 85 86 86

Tab. 17 Sound pressure levels


Appendix

9.3.3 Tightening torques

Part no. Thread size Quality Tighteningtorque [Nm]

901.01 M10M12 GA-T2 35

60

901.02 M10M12 GA-T2 67

901.06 M12 8.8 60

901.08 M6 8.8 9

901.10M10M12M16

8.83050100

901.13 M12M16 8.8 60

146

902.01M10M12M16

GA-T23560146

902.02 M12M16 GA-T2 60

146

903.02903.06903.07903.08

G ¼G ⅜G ½

St101530

914.06 M8 12.9 25

914.08M6M8M10

8.892235

M20 x 1.5M24 x 1.5M30 x 1.5

17H112188340922.01

M36 x 1.5 8 700

923.01

KM 7-LHKM 9-LHKM 11-LHKM 14-LH

11H

65110200400

Tab. 18 Tightening torques1) not valid for pumps with packing stuffing box

9.3.4 Lubricants

Property of lubricationgrease

Value

Non-resinous and acid-free –

Anti-rust –

Worked penetration 250–280 mm/10

Dropping point > 250 °C

Temperature range forapplication

-40 to 180 °C

Manufacturer KLÜBER LUBRICATION

Name ASONIC GHY 72

Tab. 19 Properties of lubrication grease

Bearing bracketsize

Bearingabbreviation

Approx.amount ofgrease [g]

3 6410 J C4 35

4 6413 J C4 65

5 6413 J C4 65

Tab. 20 Minimum amounts for grease lubrication

Bearing bracketsize

Motor speed[rpm]

Relubricationintervals [h]1)

1450 114003

1750 10100

1450 105004

1750 9300

1450 10500

1750 9300

5

2900 8000

Tab. 21 Relubrication intervals for the antifriction bearings1) At temperatures > 70 °C, every further temperature

increase of 15 °C requires the relubrication interval behalved.


Appendix

9.3.5 PreservativesUse Valvoline preservatives or similar (recommended).

Type of storage Storageduration[months]

Preservativeinside/outside

Renew[months]inside/outside

6–12 Tectyl 511 M –In closed, dry anddust-free room

> 12 Tectyl 506 EH 48/48

6–12 Tectyl 542 –In open air, centralEuropean climate > 12 Tectyl 506 EH 48/18

6–12 Tectyl 542/Tectyl 506 EH

–In open air,tropical climate,aggressiveindustrialatmosphere orclose to sea

> 12 Tectyl 506 EH 48/12

Tab. 22 Valvoline preservatives

9.3.6 Cleaning agents

Application area Cleaning agents

Foodstuffs and drinkingwater sector

E.g. spirit, Ritzol 155, strongalkaline soapy solution,steam jet (for individualparts only)

Other Benzine, wax solvents,diesel, paraffin, alkalinecleaners

Tab. 23 Cleaning agents


Appendix

9.3.7 Height offset for motor alignment withadjusting screw

Heightadjustment[mm]

Rotationangle ofspindle [°]

Setting aid

0.02 5 –

0.04 10 –

0.06 15 –

0.08 20 –

0.10 25 –

0.13 30 Shaft key surface to point ofhexagon

0.15 35 –

0.17 40 –

0.19 45 –

0.21 50 –

0.23 55 –

0.25 60 Shaft key surface to shaftkey surface

0.27 65 –

0.29 70 –

0.31 75 –

0.33 80 –

0.35 85 –

0.38 90 1/4 turn

0.40 95 –

0.42 100 –

0.44 105 –

0.46 110 –

0.48 115 –

0.50 120 –

0.52 125 –

0.54 130 –

0.56 135 –

0.58 140 –

0.60 145 –

0.63 150 –

0.65 155 –

0.67 160 –

0.69 165 –

0.71 170 –

0.73 175 –

Heightadjustment[mm]

Rotationangle ofspindle [°]

Setting aid

0.75 180 1/2 turn

0.77 185 –

0.79 190 –

0.81 195 –

0.83 200 –

0.85 205 –

0.88 210 –

0.90 215 –

0.92 220 –

0.94 225 –

0.96 230 –

0.98 235 –

1.00 240 –

1.02 245 –

1.04 250 –

1.06 255 –

1.08 260 –

1.10 265 –

1.13 270 3/4 turn

1.15 275 –

1.17 280 –

1.19 285 –

1.21 290 –

1.23 295 –

1.25 300 –

1.27 305 –

1.29 310 –

1.31 315 –

1.33 320 –

1.35 325 –

1.38 330 –

1.40 335 –

1.42 340 –

1.44 345 –

1.46 350 –

1.48 355 –

1.50 360 1 turn

Tab. 24 Height setting at the adjusting screw


Appendix

9.3.8 Flange loads according to ISO 5199

Values for base plate

Not filled withconcrete

Filled with concrete

Pumpsize

Fv max(z)[N]

Fh max(x, y)[N]

Mt max[Nm]

Fv max(z)[N]

Fh max(x, y)[N]

Mt max[Nm]

20–160 1300 1000 200 3000 1400 270

25–160 2000 1400 400 4500 3100 850

25–200 1900 1400 350 4400 2900 800

32–160 2300 1600 500 4600 3200 1000

32–200 2100 1500 450 4500 3100 900

32–250 2500 1700 550 4800 3450 1100

40–160 2700 1800 650 5000 3600 1250

40–200 2400 1700 550 4800 3400 1100

40–250 2800 1900 700 5200 3800 1350

40–315 2900 2000 700 5300 3850 1400

50–160 3200 2100 800 5500 4100 1650

50–200 2800 1900 700 5200 3800 1350

50–250 3200 2200 850 5600 4250 1650

50–315 3300 2200 850 5700 4300 1700

65–160 4200 2800 1200 6700 5200 2400

65–200 4500 2900 1300 7000 5500 2600

65–250 4000 2600 1100 6400 5000 2250

65–315 4700 3100 1400 7300 5800 2850

65–400 3200 2200 850 5600 4100 1600

80–160 5300 3400 1650 8000 6400 3350

80–200 5600 3600 1700 8300 6700 3600

80–250 4900 3200 1400 7500 5900 3000

80–315 5900 3800 1850 8800 7100 3900

80–400 5400 3500 1650 8100 6500 3400

100–160 5000 3200 1500 7600 6000 3050

100–200 7000 4400 2300 10300 8700 5000

100–250 7900 5000 2700 11600 10300 6000

100–315 7200 4600 2400 10600 9100 5250

100–400 7200 4600 2350 10500 9000 5200

125–200 7300 4600 2400 10900 9500 5200

125–250 9700 6100 3450 14000 12800 7300

125–315 8500 5400 2950 12500 11400 6700

125–400 8600 5400 2950 12700 11600 6850

150–200 12600 8000 4800 17700 16600 9600

Values for base plate

Not filled withconcrete

Filled with concrete

Pumpsize

Fv max(z)[N]

Fh max(x, y)[N]

Mt max[Nm]

Fv max(z)[N]

Fh max(x, y)[N]

Mt max[Nm]

150–250 12800 8000 4850 17800 16700 9700

150–315 13200 8300 5050 18400 17300 10100

150–400 11400 7200 4200 16200 15000 8700

150–500 12100 7600 4550 17000 15900 9200

200–250 16600 10600 6600 22400 21400 12600

200–315 17500 11200 7000 23400 22400 13200

200–400 16000 10100 6300 21700 20700 12200

200–500 16700 10700 6650 22500 21500 12700

250–315 19900 13100 7350 25500 24500 13900

250–400 19800 13100 7400 25400 24400 14000

Tab. 25 Flange loads

z

yx

yx

z

2

1

Fig. 43 Flange loads at the pump

1 Outlet flange2 Suction pipe


Appendix

1

1,0

0,9

0,8

0,7

0,6

0,5

0,4

0,3

0,2

0,1

0 50 100 150 200 250 300 350 400 450[°C]

23

4

M

Fig. 44 Correction factor M and operating temperature

1 Non-alloyed steel cast2 Austenitic steel cast3 Spheroidal iron EN-GJS4004 Gray cast iron EN-GJL250


Appendix

9.4 Spare parts for two years ofcontinuous operation accordingto DIN 24296

Number of identical pumps (including stand-by pumps)

2 3 4 5 6 or 7 8 or 9 > 9

Part no. Part designation

Set/quantity of spare parts

210.11) Shaft complete 1 1 1 2 2 3 30 %

220.011) Stub shaft complete 1 1 2 2 2 3 30 %

230.01 Impeller 1 1 1 2 2 3 30 %

321.021) Groove ball bearing complete 1 1 2 2 3 4 50 %

400.02 Gasket (for version withintermediate ring) 4 6 8 8 9 12 150 %

412.07 O-ring 4 6 8 8 9 12 150 %

421.01 Shaft seal ring 2 3 4 5 6 7 90 %

433.01 Mechanical seal 2 3 4 5 6 7 90 %

461.01 Gland packing rings (set) 2 3 4 5 6 7 90 %

524.01 Shaft protection sleeve forpacking 1 1 2 2 2 3 30 %

529.011)SiC/SiC carbon sleevebearingcomplete

1 1 2 2 2 3 30 %

545.011) Steel/carbon bearing bushcomplete 1 1 2 2 2 3 30 %

Slide-in unit or drive unit 1 1 2 2 2 3 30 %Various1) Seals for pump housing (set)

Other seals (set) 4 6 8 8 9 12 150 %

Tab. 26 Spare parts for two years of continuous operation1) Can be purchased as a mechanical unit (BG) or as a sales unit (VG).


Appendix

9.5 Safety certificatePlease copy this document and send it together with thepump.

The pump and accessories submitted for inspection / repairs together with the safety certificate by us, the signatory,

Type: Delivery date:

Part no.: Order no.:

Reason for inspection / repair:

Was not used with liquids that are hazardous to health or the environment.

Used for the following application:

and came into contact with liquids that must be labeled for safety or are considered to be polluting.

Last pumped liquid:

The pump has been carefully emptied and cleaned on the outside and inside prior to delivery or provision.

Special safety precautions are not necessary for subsequent handling.

The following safety precautions regarding rinsing liquids, liquid residue and disposal are necessary:

If the pump was used with critical liquids, please make sure you enclose a safety data sheet in thepackage.

We hereby declare that the information given is correct and complete, and that the pump is being shipped in accordance withlegal requirements.

Company /address:

Phone:

Fax:

Customer no.: ____ ____ ____ ____ ____ ____ ____

Issuer name:(capital letters) Position:

Date: Company stamp / signature:Tab. 27 Safety certificate


Appendix

9.6 Declaration of conformity accordingto EC machine directives

The following declaration does not contain serial numbersor signatures. The original declaration is delivered with therespective pump.

EC declaration of conformity according tomachine directive, appendix II AWe,Allweiler AG, Postfach 1140, 78301 Radolfzell, Germany; Tel. +49 (0)7732 86-0, Fax. +49 (0)7732 86-436,hereby declare that the following machine adheres to the relevant EC directives detailed below:

ID no.

Designation ALLHEAT®

Equipment no.

Order no.

EC directives:

• Machine directive (2006/42/EC)

• Low-voltage directive (2006/95/EC)

• EMC directive (2004/108/EC)

Applicable harmonized norms:

• EN 809:1998

• EN ISO 12100-1:2003

• EN ISO 12100-2:2003

• EN 14121-1:2007

Person authorized to compile thetechnical file

Allweiler AGAllweilerstr. 178315 Radolfzell

Date: 11.26.2008 Company stamp / signature:

Head of Development/Construction

Company stamp / signature:

Head of Quality

Tab. 28 Declaration of conformity according to EC machine directives


allheat operating manual

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