p j z i OInstallation-, Operation-, Servicing-lnstructions Volute Casing Pumps Type: VOGEL-ICB ICB 50-32-160 S1VV2-222 Ex VOGEL-order no.: 8,581.512 Customer: EJK SP.Z.O.O: Pos. no. / Item no.: Your order no.: SJ/CH/85/03 ITT Industries Engineered for life Compliance Declaration as defined in EC Machinery Directive 89/392/EEC, Appendix II A We herewith declare that the pump units in model series as supplied by us, comply with the following relevant requirements: EC Machinery Directive, 93/44/EEC the relevant harmonized standards, especially EN 809 EN 292 Teil 1 EN 292 Teil 2 EN 60204 Teil 1 the relevant national technical standards and specifications, especially DIN 31001 ICB (Signature) Pumpenfabrik ERNST VOGEL GmbH A-2000 Stockerau, Ernst Vogel-Str. 2 Stockerau, 30.04.03 Engineered for life ITT Industries Data Sheet Type: ICB 50-32-160 S1VV2-222 Ex VOGEL-order no.: 8,581.512 Your order no.: SJ / CH/ 85/ 03 Pos. no. / Item no.: Customer: EJ K SP.Z.O.O: Handled liquid: Hydrocarbons Temperature: °C 15 Density (rho): kg/d m3 0,840 Viscosity: cP 1.400 Capacity: m3/h 75 Discharge: mFLS 24 Power consumption at rho: kW 1,66 Motor power requiered: kW 2,2 Speed: min-1 2873 Impeller diameter: mm 142 Suction flange: DN 50, PN 16 Direction: axial Discharge flange: DN 32, PN 16 Direction: upwards Max. test pressure: bar 24 Max. casing- operation-pressure: bar 16 Lubrication: Grease lubrication - the pump shaft is guided in the ball bearings of the motor. Shaft sealing: Single mech. seal without shaft sleeve - for single mechanical seals with installation dimensions acc. to DIN 24960 / EN 12756, Design K. API Plan 02 / ISO Plan 00. Additional data Crane 2 100, Gr.33, KBS, BQ1VGG, Carbon/ SiC/ Viton, unbalanced Materials: Motor: Nominal power: Voltage: Frequency: Speed: Model: Isolation class: Protection class: Additional data: Impeller Casing Casing cover Shaft 1.4408 1.4408 1.4408 1.4462 kW V Hz min-1 Manufacturer: Sound pressure level pump with motor: Weight unit: dB(A) kg M2J A 90 L2 2,2 3x380 V Y 50 2873 VI F IP55 Ex-protection EEx Dll BT4, incl. Certificat LCIE99 ATEX 6022, with 3 PTC-thermistors, suitable for operating with frequency converter, without cable gland ABB 67±3 -68 ITT Industries Engineered for life Data Sheet A Deviations from the above design data may lead to overloading. This could subsequently cause accidents where people could be hurt and property damaged. For this reason, our written agreement is required for any changes. Documentation: Cover Manufacturer's- or Compliance- Declaration Data Sheet Operating Instructions pump Mounting Instructions shaft sealing Performance curve Dimension drawing Sectional drawing Table of connections Permissible loads and torques on pump flanges Recommendation of lubrication Branch offices and service centres Operating Instructions motor QS-Documentation Quantity of Documentation(s) Date X X ICB 100/ 3-deutsch/ englisch X X 7200.1A610 7200.1A 700 L 7124-400 T 701-400 T 011-810 X ABB 6 (3000Ex) + ATEX Zertifikat X 1 30.04.2003 ITT Industries Engineered for life ICB Table of Contents PUMP NAME PLATE 3 1. GENERAL 4 1.1 For ewor d 4 1.2 Guar ant ee 4 1.3 Saf et y r egul at ions 4 1.4 Saf et y inst r uct ions 5 Dan g er s o f no t f o l l o w in g saf et y inst r uct io n s 5 Speed, Pr essu r e, Temper at ur e 6 Per mit t ed f o r ces o n f l anges 6 NPSH 6 Seal in g , Fl u shin g, Co o l in g 6 Minimum f l o w s 7 Pr o t ect io n ag ain st r unning dr y 7 Ba c k f l o w 7 2. DESCRIPTION 7 2.1 Mo del 7 2.2 Shaf t seal ing 7 2.3 Bear ing and Lubr icat ion 8 2.4 Per missibl e pr essur es and t emper at ur es 8 2.5 Wat er of co ndensat io n 9 3. TRANSPORT. HANDLING. STORAGE 9 3.1 Tr anspor t , Handl ing 9 3.2 St or age 10 4. in st a l l a t io n , o per at io n 10 4.1 ASSEMBLY OF PUMP UNIT 10 4.2 Co nnect ing t he pipes t o t he pump 10 Suct io n an d dischar ge pipe 10 4.3 El ect r ical co nnect io n 11 4.4 St ar t ing up 11 St ar t in g up f o r t he f ir st t ime 11 Rest ar t ing 12 4.5 Oper at ion and Monit or ing 12 Per mit t ed number o f st ar t s 12 4.6 Shut t ing down 12 5. ma in t en a n c e, ser v ic in g 13 ICB 100-en Artikel Nr. 1999991 1 Operating Instructions Mechan ical seal s 13 Mo t o r bear ing 13 Cl ean in g t he pump 13 6. LONGER PERIODS OF NON-OPERATION 13 6.1 Dr ained pumps 13 6.2 Fil l ed pumps 13 7. FAULTS - CAUSES AND SOLUTIONS 13 8. DISASSEMBLING THE PUMP AND REPAIR 15 8.1 Saf et y inst r uct ions 15 8.2. Gener al 16 8.3 Dismant l ing and mount ing of scr een of t he mot or l ant er n 16 8.4 Dismount ing of t he Back Pul l Out Assembl y 17 8.5 Impel l er r emoval 17 8.6 Remo val of t he Shaf t Seal ing 18 8.7 Dismant l ing of st ub shaf t 18 8.8 Recondit ioning 18 8.8.1 Cl ear an ce at impel l er 18 8.9 Inst al l at ion 19 8.9.1 Gener at e 19 8.9.2 New mo t o r 19 8.9.3 Mo unt ing o f st ub shaf t 19 9. SPARE PARTS. SPARE PUMPS 21 9.1 Spar e par ts 21 Or der ing spar e par t s 21 9.2 St an d-by pumps 21 10. PLANT MANAGER LIST 22 11. LOG BOOK 23 2 Artikel Nr. 1999991 ICB 100-en Pump Name Plate Pumpenfabrik Ernst Vogel GmbH A-2000 Stockerau/Austria ITT Industries Tvoel I ^ S/NI ] Year£ ---------- ---I $ G H Z Z V / h P| □kW O HI nC ZJ min 1 Pallw cQ ^]bar tnax a)l[^ rc 2 MatC ifp^C . i 1™" M Type *) Type of the pump S/N *) Serial number Year Year of construction Q Rated capacity at the operating point P Rated power at the operating point H Head (Energy head) at the operating point n Speed Pall wC Max. permitted casing-operation-pressure (=highest discharge pressure at the rated op erating temperature to which the pump casing can be used). fmaxall Highest permitted permanent temperature Mat Material of the pump casing (volute casing) Imp0 Outer diameter of the impeller *) Required information when ordering spare parts. ICB 100-en Artikel Nr. 1999991 3 Operating Instructions 1. General 1.1 Foreword This product complies with the safety requirements of EC Machinery Directive 89/392/EEC, 91/368/EEC, 93/44 EEC and the Austrian Machine Safety Order (MSO) of 27 April 1994. A The staff employed on installation, operation, inspection and maintenance must be able to / | \ prove that they know about the relevant accident prevention regulations and that they are / • \ suitably qualified for this work. I f the staff does not have the relevant knowledge, they should be provided with suitable instruction. The operating safety of the pumps or units (i.e. pump plus motor) supplied is only guaranteed if these are used in accordance with the provisions given in the attached Data Sheet and/or Point 4 in "Installa tion and Operation". The operator is responsible for following the instructions and complying with the safety requirements given in these Operating Instructions. Smooth operation of the pump or pump unit can only be achieved if installation and maintenance are carried out carefully in accordance with the rules generally applied in the field of engineering and elec trical engineering. If not all the information can be found in these Operating Instructions, please contact us. The manufacturer takes no responsibility for the pump or pump unit if the Operating Instructions are not followed. These Operating Instructions should be kept in a safe place for future use. If this pump or pump unit is handed on to any third party, it is essential that these Operating Instruc tions and the operating conditions and working limits given in the Confirmation of Order are also passed on in full. These Operating Instructions do not take into account all design details and variants nor all the possi ble chance occurrences and events which might happen during installation, operation and mainte nance. Alterations or changes to the machine are only permitted by agreement with the manufacturer. Origi nal spare parts and accessories authorised by the manufacturer should be used for greater safety. We bear no responsibility for the consequences of using other parts. We retain all copyright in these Operating Instructions; they are intended only for personal use by the owner of the pump or the pump unit. The Operating Instructions contain technical instructions and drawings which may not, as a whole or in part, be reproduced, distributed or used in any unauthorised way for competitive purposes or passed on to others. 1.2 Guarantee The guarantee is given in accordance with our Conditions of Delivery and/or the confirmation of order. Repair work during the guarantee period may only be carried out by us, or subject to our written ap proval. Otherwise the guarantee ceases to apply. Longer-term guarantees basically only cover correct handling and use of the specified material. The guarantee shall not cover natural wear and tear and all parts subject to wear, such as impellers, shaft sealings, shafts, shaft sleeves, bearings, wear rings etc., or damage caused by transport or improper handling. In order for the guarantee to apply, it is essential that the pump or pump unit is used in accordance with the operating conditions given on the type plate, confirmation of order and in the Data Sheet. This applies particularly for the endurance of the materials and smooth running of the pump and shaft sealing. If one or more aspects of the actual operating conditions are different, we should be asked to confirm in writing that the pump is suitable. 1.3 Safety regulations These Operating Instructions contain important instructions which must be followed when the pump is assembled and commissioned and during operating and maintenance. For this reason, these Operating Instructions must be read by the skilled staff responsible and/or by the operator of the plant before it is 4 Artikel Nr. 1999991 ICB 100-en ICB installed and commissioned, and they must be left permanently available at the place where the pump or pump unit is in use. The operator must ensure that the contents of the Operating Instructions are fully understood by the staff. The operator must confirm this by signing the "Plant Manager List" (see Point 10). These Operating Instructions do not refer to the General Regulations on Accident Prevention or local safety and/ or operating regulations. The operator is responsible for complying with these (if necessary by calling in additional installation staff). Equally, instructions and safety devices regarding handling and disposal of the pumped media and/or auxiliary media for flushing, lubrication &c, especially if they are explosive, toxic, hot &c, are not part of this operating instruction. For the competent and prescribed handling only the operator is responsible. The safety instructions contained in these Operating Instructions have the following special safety markings as specified in DIN 4844: A Warning against personal accidents which could occur if the safety instructions given in this part of the Operating Instructions are not followed. A Warning against dangerous electrical voltage. Attention Warning against possible damage to property or the environment. It is absolutely essential that safety information affixed directly to the pump or pump unit is followed and maintained so that it is always easily legible. All operation instructions of accessories (e.g. for motors) possibly enclosed must be followed and held available in the same way as this operation instruction. 1.4 Safety instructions Dangers of not following safety instructions If you don't follow the safety instructions it can result in the following, for example: • People being at risk because of electrical, mechanical, thermionic and chemical factors. • Important functions of the pump or pump unit failing. • Dangers to the environment as a result of dangerous substances leaking out. Safety instructions for the operator • Depending on the operating conditions, wear and tear, corrosion or age will limit the working life of the pump/ pump unit, and its specified characteristics. The operator must ensure that regular inspec tion and maintenance are carried out so that all parts are replaced in good time, which would other wise endanger the safe operation of the system. If abnormal operation or any damage is observed, the pump must cease operation immediately. • If the breakdown or failure of any system or unit could lead to people being hurt or property being damaged, such system or unit must be provided with alarm devices and/or spare modules, and they should be tested regularly to ensure that they function properly. • If there is any risk of injury from hot or cold machine parts, these parts must be protected against con tact by the user, or suitable warning signs must be affixed. • Contact protection on moving parts (e.g. coupling guards) must not be removed from systems that are in operation. • If the sound level of a pump or aggregate is above 85 dB(A) an ear protection has to be used when staying near the pump for some time. • If dangerous media (e.g. explosive, toxic, hot) leak out (e.g. from shaft seals), these must be directed away so that there is no danger to people or the environment. The provisions of the law must be ob served. • Measures should be taken to exclude any danger from electricity (e.g. by complying with the local regulations on electrical equipment). If work is carried out on live electrical components, they should be unplugged from the mains or the main switch turned off and fuse unscrewed. A motor protection switch is to be provided. ICB 100-en Artikel Nr. 1999991 5 Operating Instructions • Basically, all work on the pump or pump unit should only be carried out when the pump is stationary and not under pressure. All parts must be allowed to return to ambient temperature. Make sure that no-one can start the motor during such work. It is essential that the procedure for stopping the system described in the Operating Instructions be observed. Pumps or pump systems that carry media that are dangerous to health must be decontaminated before being taken apart. Safety Data Sheets for the various liquids handled. Immediately the work has been completed, all safety and protective devices must be replaced or restarted. • Under EC Machinery Directives, every machine must be fitted with one or more emergency command devices by which situations which represent an immediate danger or which could later be dangerous can be avoided. This does not include machines in which the emergency switches cannot reduce the danger, either because they do not reduce the time required to stop the machine or because the do not allow the measures required by the danger to be taken. This emergency switch must: • have controls that are clearly marked, easy to see and within easy reach; • stop the dangerous movement as quickly as possible without causing any additional danger; • trigger any specified safety movements or allow these to be started up. • If the emergency command device is no longer operated after an emergency "off" switch has been triggered, this must be maintained by blocking the emergency command device until it is released again. It should not be possible to block the device without this triggering an emergency "off" switch. It should only be possible to release the device through an appropriate action; this release should not start the machine up again - it should only make it possible to start it up again. • If the power supply is interrupted or restored after being interrupted or if it is changed in any other way, this should not cause any danger (e.g. pressure surges). Speed, Pressure, Temperature Suitable safety measures must be taken at the plant to ensure that the speed, pressure and tempera ture of the pump and the shaft sealing do not exceed the limit values given in the Data Sheet. The given admission pressures (system pressures) must also be sufficiently high. In addition, the pump must be protected against pressure surges such as can be caused by switching off the plant quickly (e.g. by non-return valve on the pressure side, flywheel, air vessel). Quick temperature changes must be avoided. They may cause a temperature shock and therefore lead to destruction or impairment of the function of several components. Permitted forces on flanges Basically, the suction and pressure lines should be such that the forces on the pump are kept to a minimum. If this is not feasible, the figures given in the Appendix "Permitted forces and moments" should not under any circumstances be exceeded. This is valid as well for the operation as for the standstill of the pump and therefore for all possible pressures and temperatures of the unit. NPSH When entering the impeller, the liquid being handled must have a minimum pressure NPSH to prevent cavitation or breaking off of flow. This requirement is met if the unit NPSH value (NPSHa) is well above the pump NPSH value (NPSHr) under all operating conditions. Attention must be paid to the NPSH value in particular when liquids close to boiling point are being handled. If the value falls below the pump NPSHr value, this can lead to damage resulting from cavita tion or serious damage from overheating. The NPSHr for each pump type is given in the sheets of characteristic curves. Sealing, Flushing, Cooling Suitable facilities for the regulation and monitoring of sealing, flushing or cooling are to be provided. When handling dangerous liquids or if temperatures are high, care should be taken to ensure that the pump ceases operating if the sealing, flushing or cooling system fails. Sealing, flushing and cooling systems must always be operational before the pump is started up. They should not be taken out of operation until the pump has stopped, provided that the nature of the op eration allows this at all. 6 Artikel Nr. 1999991 ICB 100-en ICB Minimum flows If the pump is started against a closed pressure line valve, it should be noted that the power taken up by the pump is transmitted to the liquid handled in the form of heat. This can cause the liquid to heat up excessively within a relatively short time, which will then cause damage to the pump's internal fit tings. After the pump has reached operating speed, the discharge valve should therefore be opened as quickly as possible (within 30 seconds). Note instructions about minimum flows in the Data Sheet. If operating conditions mean that Q = 0 is unavoidable, or if hot water is circulating, a free flow non return valve, or, on smaller systems, a by-pass pipe, should be provided. We should be pleased to ad vise on determining the minimum flow or designing the by-pass line. Protection against running dry The pumps must not run dry under any circumstances, since overheating can damage pump compo nents (e.g. mechanical seals). Back flow In systems where pumps are operating in closed circuits under pressure (gas cushions, steam pressure), the pressure of the gas cushion must not be reduced via the pump, since the back flow speed may be much higher than the operating speed, which would destroy the unit. Vw- 2. Description 2.1 Model ICB-Pumps are single stage endsuction pumps in block design with electric motor acc. IEC. The hy draulic design complies with ISO 2858/EN 22858, the technical design complies with ISO 5199/EN 25199. The motors comply with DIN 42677-IM B5. motor and pump shaft are rigid coupled. The permissible operation conditions and details of design are specified in the Data Sheet. The matching sectional drawing, with the designation of parts, and the appropriate dimensional dra wing (for e.g. shaft sealing), for the delivered pump, you will find in the Data Sheet and the enclosu res. Position of installation: the ICB pump is intended to be used with horizontal shaft, discharge branch up. Other positions of installation have to be released by the manufacturer. 2.2 Shaft sealing The ICB pump design is exclusively sealed with mech. seals. You can use all mech. seals with installati on measures regarding DIN 24960/EN 12756, design K, shape U. The actual installed mech. seal is mentioned in the Data Sheet. Attention The mech. seal used in the standard version is not resistant against mineral oil. Attention More information about mech. seals and the risks of accidents that may be involved you will find under point 4.5 "Operation and Monitoring" as well as under point 5 "Maintenance, Ser vicing". You can learn the nominal size (d,) of the mech. seal from following chart: ICB 100-en Artikel Nr. 1999991 7 Z u l a s s i g e r P u m p e n e n d d r u c k - P r e s s i o n d e s e r v i c e a t u b u l u r e d e r e f o u l e m e n t M a x i m u m t o t a l w o r k i n g p r e s s u r e Operating Instructions Type Nominal size d, ICB 50-32-160 33 ICB 50-32-200 33 ICB 50-32-250 43 ICB 65-40-160 33 ICB 65-40-200 33 ICB 65-40-250 43 ICB 65-40-315 43 Icb 80-50-160 33 ICB 80-50-200 33 ICB 80-50-250 43 ICB 80-50-315 43 ICB 100-65-160 43 ICB 100-65-200 43 Type Nominal size d. ICB 100-65-250 43 ICB 100-65-315 53 ICB 125-80-160 43 ICB 125-80-200 43 ICB 125-80-250 43 ICB 125-80-315 53 ICB 125-100-200 43 ICB 125-100-250 53 ICB 125-100-315 53 ICB 150-125-250 53 ICB 150-125-315 53 ICB 200-150-250 53 2.3 Bearing and Lubrication The pump shaft is guided in ball bearings of the motor. The bearings are lubricated with grease for life and therefore don't have to be maintained. 2.4 Permissible pressures and temperatures Basically the specified datas regarding pressures and temperatures that are mentioned in the Data Sheet are valid. It is not permitted to exceed or fall short of this value. If no pressures and/or tempera tures are mentioned in the Data Sheet, the following pressure and temperature limits are valid: Suction pressure (System pressure) = Pressure at suction branch: max. 5 bar Ambient temperature max. 40°C. Observe also local regulations (e.g. DIN 4747 or DIN 4752, para 4.5). For all pump sizes, except: Only for: 65-40-315 65-40-315 80-50-315 80-50-315 100-65-315 100-65-315 125-80-315 125-80-315 125-100-315 125-100-315 t [*F] MPa bar . 100 o 100 200 300 3.0 - 2.5 - 2. 0 - 1.5 - 1. 0 - 0.5 - 0- A.B.C B.C A B A B C C A psig - 400 - 350 - 300 - 250 - 200 - 150 - 100 - 50 0 D Q) O) c_ -a c_ cr c_ cn <u=3 c CZr-H -i-t <u :d Q £ 1 L EE 13 O OJ (_) O o>-*-• -*-* z) a> x MPa bar . jqo 3.0 -i 30 2.5 - 2. 0 - 1.5 - 1. 0 - 0.5 - 0 - 100 t [*F] 200 300 25 20 15 10 5 0 A.B.C B.C VJ 8 A B C C A psig - m - 350 - 300 - 250 - 200 - 150 - 100 - 50 0 -100 -50 0 50 100 150 200 Temperatur - Temperature - Temperature t [’C] -100 -50 0 50 100 150 200 Temperatur - Temperature - Temperature t [*C] 8 Artikel Nr. 1999991 ICB 100-en ICB Curve Material Casing Description A 1.4408 Austenitic Stainless Steel B 1.4517 Duplex Stainless Steel C EN-GJS-400-18-LT (0.7043) Ductile Iron The mentioned pressure and temperature limits are valid for standard mech. seals. Operating conditions for other materials on request. 2.5 Water of condensation If motors are exposed to variations of temperature or other extreme climates, we recommend the use of a motor with an anti-condensation heating to prevent the rise of water of condensation. During the operation of the motor the anti-condensation heating must not be switched on. 3. Transport, Handling, Storage 3.1 Transport, Handling • Check the pump/ pump unit immediately upon delivery/receipt of despatch for damage or missing parts. • The pump/ pump unit must be transported carefully and by competent personnel. Avoid serious im pacts. • Keep the pump/ pump unit in the same position in which it was supplied from the factory. Take note of the instructions on the packaging. • The intake and discharge side of the pump must be closed with plugs during transport and storage. Attention Dispose of all packing materials in accordance with local regulations. • Lifting devices (e.g. fork-lift truck, crane, crane device, pulleys, sling ropes, etc.) must be sufficiently strong and must only be used by authorised persons. The weight of the pump/ pump unit is given in the Data Sheet. • The pump/ pump unit may only be lifted by solid points such as the casing, flanges or frame. The fol lowing illustration (pict. 3.1.) shows the correct method of carrying by crane. Attention Sling ropes must not be fixed to ends of shafts or ring loops of the motor. Do not stand underneath suspended loads. Take note of the general regulations on prevention of accidents. The pump/ pump unit must be secured against tipping over and slipping until it has been fixed in its final location. ICB 100-en pict. 3.1. Artikel Nr. 1999991 9 Operating Instructions 3.2 Storage Pumps or pump units that are stored for a long time (6 months max) before use must be protected against moisture, vibrations and dirt (e.g. by wrapping in oil paper or plastic sheeting). Pumps must basically be stored in a place where they are protected from the weather, e.g. under cover. During this time, all suction and discharge branches and all other intakes and outlets must be closed with dummy flanges or plugs. Please contact factory for storage instructions for storage periods longer than 6 months. 4. Installation, Operation 4.1 Assembly of pump unit ICB pumps must be fastened with screws on a solid foundation (e.g. concrete foundation, steel plate, steel girder, a.s.o.) The foundation must withstand all loads arising during operation. Position and size of pump feet and foundation screws you can take from the dimension drawing. As foundation screws you can use concrete expansion bolts, epoxy capsle anchor bolts or foundation anchors (stone screws). Attention Sufficient space must be provided for maintenance and repair work, especially for replacing ~the drive motor or the complete pump unit. The motor fan must be able to take in enough cool air, and the intake grille must therefore be at least 10 cm away from any wall, etc. • If vibrations are transmitted to the foundation from adjoining components, it must be guarded through adequate vibration damping paddings (vibrations from outside can impair the bearing). • To prevent vibrations being transmitted to adjoining components, the foundation should be laid on a suitable insulating base. Attention The size of these insulating panels will vary, depending on circumstances, and should there- fore be determined by an experienced specialist. The unit has to be levelled horizontal. If levelling shins are used they must be inserted next to the foundation anchors. 4.2 Connecting the pipes to the pump Suction and discharge pipe • The pipes must be of a size and design that liquid can flow freely into the pump and that the pump functions without problems. Particular attention is to be paid to ensuring that suction pipes are air tight and that the NPSH values are observed. Under suction lift condition lay the suction pipe in the horizontal section towards the pump so that it is slightly inclined upwards so that no air traps occur. Under positive suction head condition install the suction pipe work slightly declined towards the pump. Do not install fittings or bends right before the suction nozzle. • In most cases, it is recommended that a check valve be installed in the discharge pipe shortly after the pump. • If the suction supply is under vacuum and entrained gas may be present in the liquid, it is recommended that a vent line be considered upstream of the pump suction with return to the suction supply, above the max liquid level. This vent will prevent air binding problem during operation and facilitate proper filling and vent of the pump during start-up. An additional flushed piping -- discharge branch-vent line - makes it easier to de- aerate the pump before start-up. • When laying the pipes, make sure that the pump is accessible for maintenance, installation and disassembly. 10 Artikel Nr. 1999991 ICB 100-en ICB • Notice "Permitted Forces on Flanges" (point 1.4). • If expansion joints are used in the pipes, they have to be supported in such a way that the pump is not loaded unduly high because of the pressure in the pipes. • Before connecting up to pump: remove protective coverings from suction and discharge branches. • Before starting up, the pipe system, fittings and equipment must be cleaned to remove weld spatter, scale etc. Any pollutants are to be completely removed from pump units that are directly or indirectly connected to drinking water systems before being installed and taken into use. • To protect the shaft sealing (especially mechanical seals) against foreign bodies, it is recommended that a sieve, 800 micron, be installed in the suction/intake pipe when the motor is being started up. • If the pipe system is tested with the pump installed, do not exceed the maximum permitted casing pressure of the pump and/or shaft sealing (see Data Sheet). • When emptying the pipe after the pressure test, make sure that the pump is treated properly (danger of rust and problems when starting up). 4.3 Electrical connection A Electrical connection work may only be carried out by an authorised professional. The rules and regulations valid for electrical technology, especially those concerned with safety measures, must be observed. The regulations of the national power supply companies operating in that area must also be observed. Before starting work, check that the information on the motor rating plate is the same as the local mains network. The power supply cable of the coupled drive motor must be connected up in accor dance with the wiring diagram produced by the motor manufacturer. A protective motor switch is to be provided. Attention The direction of rotation should only be checked when the pump is full. Dry running will cause damage to the pump. 4.4 Starting up A The plant may only be started up by people who are familiar with the local safety regulations and with these Operating Instructions (especially with the safety regulations and safety instruc tions given here). Starting up for the first time • You don't need to lubricate the pump before the initial start-up. • Pump and suction pipe must be filled completely with liquid when starting up. • Open isolation valve in suction/intake pipe. • Set discharge side isolation valve to approx. 25% of rated flow quantity. With pumps with a discharge branch rated width less than 200, the isolation valve can remain closed when starting up (see also Point 1.4 "Minimum quantities"). • Check direction of rotation by switching on and off briefly. It must be the same as the directional ar row. • Start drive device. • As soon as it reaches normal operating speed, open discharge valve immediately and adjust the re quired operating point. You must observe the area of application given on the Data Sheet. A A On starting-up without back-pressure, the back-pressure must be produced through throttling at the discharge side. After reaching full back-pressure open slide. If pump does not reach attended head or if atypical sounds or vibrations do occur: Switch off pump (see point 4.6) and seek for causes (see point 7). ICB 100-en Artikel Nr. 1999991 11 Operating Instructions Restarting Basically, the same procedure should be followed as for starting up for the first time. You don't need to check the direction of rotation. The pump should only be automatically restarted if it has been made sure that the pump has remained filled whilst lying idle. 4.5 Operation and Monitoring Be particularly careful not to touch hot machine parts and when working in the unprotected shaft seal area. Remember that automatically controlled systems may switch themselves on suddenly at any time. Suitable warning signs should be affixed. Attention Regular monitoring and maintenance will extend the life of your pump or pump system. • The operating data mentioned in the Data Sheet or in the order confirmation must be followed. • Do not exceed the output given on the motor rating plate. • Avoid dry running, running against closed discharge valves or operation whilst the liquid handled is in the vapour phase. • Avoid sudden changes in temperature (temperature shocks). • The pump and motor should run evenly and without vibrations; check at least once a week. • Check oil level at least once a week and top up if necessary. • Pumps which are exposed to corrosive chemicals or to wear through abrasion must be inspected peri odically for corrosion or wear and tear. The first inspection should be carried out after six months. All further inspection intervals should be determined on the basis of the state of the pump. Permitted number of starts Do not exceed the pump's permitted number of starts - see diagram. With electric motors, the permitted number of starts is given in the attached motor operating instructions. 2o If two different figures are given, the c lower fiqure is valid. s 3 | 10 v Cl 2 1 1 2 5 10 20 50 100 200 500 motor power P [kW] 4.6 Shutting down • Close the isolation valve in discharge pipe right before (max. 30 seconds) switching off the motor. This is not necessary if there is a spring-loaded check valve. • Switch off motor (make sure it runs down quietly). • Close the isolation valve on suction side. • On danger of freezing drain pump and pipes completely. • If the pump remains on stand-by during standstill test drives (in the length of at least 5 min.) should be made in regular intervals. The span between the test drives depends on the unit, but they should be made at least once a week. 12 Artikel Nr. 1999991 ICB 100-en ICB 5. Maintenance, Servicing a Work should only be carried out on the pump or pump unit when it is not in operation. You / | \ must observe Point 1.4 “Safety instructions". Attention Maintenance and servicing work must only be carried out by trained, experienced staff who are familiar with the contents of these Operating Instructions, or by the Manufacturer's own service staff. The work carried out must be duly entered in the "Log Book" (see Point 11) and confirmed by being signed. Mechanical seals A Before opening the pump, it is essential that you note Point 1.4 "Safety Instructions" and Point 8 “Repairs". If the liquid being handled drips out at the mechanical seal, it is damaged and must be replaced. For replacement of mech. seal refer to instruction in the appendix. Motor bearing On an average the grease in the motor bearings is so dirty after five years that it is recommended to change the motor bearings. Cleaning the pump Dirt on the outside of the pump has an adverse effect on transmission of heat. The pump should there fore be cleaned with water at regular intervals (depending on the degree of dirt). Attention The pump must not be cleaned with pressurized water - water will get into the motor. 6. Longer periods of non-operation Attention When starting up, follow the instructions for starting up for the first time (see Point 4.4)! 6.1 Drained pumps • Rotate shaft at least 1x week (do not switch on because of dry running). • Replace motor bearing after 5 years. 6.2 Filled pumps • Switch stand-by pumps on and immediately off again once a week. Possibly use as main pump. • Replace motor bearing after 5 years. 7. Faults - Causes and Solutions The following notes on causes of faults and how to repair them are intended as an aid to recognising the problem. The manufacturer's Customer Service Department is available to help repair faults that the operator cannot or does not want to repair. If the operator repairs or changes the pump, the de sign data on the Data Sheet and Points 1.2-1.4 of these Operating Instructions should be particularly taken into account. If necessary, the written agreement of the manufacturer must be obtained. ICB 100-en Artikel Nr. 1999991 13 Operating Instructions Faults Code no. for cause and method of repair Discharge too low 1, 4, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15 Discharge stops after a time 8, 10, 11, 12, 24 Head too low 2, 4, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 24, 28 Head too high 3, 5, 28 Drive mechanism overloaded 2, 3, 5, 15, 19, 21 Pump not running quietly 7, 10, 14, 18, 19, 23, 24, 27 Temperature in the pump too high 7, 10, 24 Temperature in the shaft sealing too high 16, 17 Temperature at the bearing too high 2, 14, 19, 20, 23, 25, 26 Pump leaking 19, 22 Leakage rate at shaft sealing too high 17, 18, 19 Meaning of code number for cause and method of repair 1. Back-pressure too high • open discharge valve further • reduce resistance in discharge pipe (e.g. clean filter if necessary) • use larger impeller (note available motor power) 2. Back-pressure too low, discharge too low • throttle discharge valve 3. Speed too high • reduce speed • compare speed of motor with specified pump speed (rating plate) • when adjusting speed (frequency transformer) check reference value setting 4. Speed too low • increase speed (check available motor power) • compare speed of motor with specified pump speed (rating plate) • when adjusting speed (frequency transformer) check reference value settings 5. Impeller diameter too large • use smaller impeller 6. Impeller diameter too small • use larger impeller (check available motor power) 7. Pump and/or pipes not completely filled with liquid • fill • vent 8. Pump or suction/intake pipe blocked • clean 9. Air pocket in pipeline • vent • improve course of pipe 10. NPSH of system too small • increase liquid level • increase admission pressure • reduce resistance in the intake/suction pipe (change course and rated width, open shutoff valves, clean filters) 11. Air being sucked in • increase liquid level • check suction pipe is vacuum-tight • provide spindles in suction pipe fittings with water seal 12. Air being sucked in through shaft sealing • replace shaft sealing 13. Direction of rotation is wrong • swap over two phases of power supply (to be done by a specialist electrician) 14. Inner components suffering from wear • replace worn parts 15. Density and/or viscosity of liquid handled is too high 14 Artikel Nr. 1999991 ICB 100-en ICB • seek assistance ' 5 Shaft sealing worn • replace mechanical seal • avoid dry running 17. Deposits on mechanical seal • clean • replace mechanical seal if necessary • if necessary provide additional rinsing or quench 18. Impeller out of balance • remove blocks/deposits • replace if broken or unevenly worn • check shafts to ensure that they are running true 19. Forces in pipeline too high (pump unit under strain) • change (support pipes, use compensators, etc.) • pump correct mounted on foundation? 20. Too much, too little or the wrong type of lubricant • change 21. Electricity supply not right • check voltage of all phases (2-phase running) • check cable connections • check fuses 22. Sealing insufficient • tighten screws • replace sealing 23. Bearing damaged • replace 24. Discharge too small • increase minimum amount carried (open slide valves, bypass) 25. Discharge too high • reduce amount carried (throttle slide valve) 26. Relief fittings insufficient • clean relief openings in impeller • replace worn parts (impeller, split rings) • adjust in line with the system pressure/intake pressure given on ordering 27. System-related vibrations (resonance) • seek assistance 28. Manometer indicator wrong • check manometer • get rid of blockages • put manometer in suitable place (no flow distortion or burbling) 8. Disassembling the pump and Repair 8.1 Safety instructions When disassembling the pump pay attention to point 1.4 "Safety instructions" and point 3.1 A A "Transport, Handling". Repairs to the pump or pump system may only be carried out by authorised skilled personnel or by the manufacturer s specialist staff. For mounting and repair you can order specialized personnel if you want. ICB 100-en Artikel Nr. 1999991 15 Operating Instructions The spezialized staff of the operator or manufacturer must be informed about the handled li quid. If dangerous liquids are pumped the appropriate disposal of the handled liquid is neces sary before the disassembly of the pump. Pay attention to the fact, that even in drained pumps there are remainders of the handled liquid. If necessary the pump must be flushed or deconta minated. • Before the disassembly the pump has to be secured in such a way, that it can't be started. • The pump casing must be drained and without pressure. • All locking devices in the suction- and discharge-pipe must be closed. • All parts must have taken on the temperature of the environment. Secure disassembled pumps, units or single parts against tipping over or rolling off. While disassembling the pump use of an open flame (blowlamp, etc.) only, when there is no danger of setting fire, cause an explosion or cause injurious vapours. Never apply heat to remove the impeller nut. Use of heat may result in severe physical injury and property damage. Attention Use only original spare parts. Pay attention to the right materials and the matching design. 8.2. General Carry out Disassembly and mounting according to the appropriate secrional drawing. You will only need common tools. Before disassembly check if required parts are ready. Disassemble the pump only so far, as required for the replacement of the repair part. 8.3 Dismantling and mounting of screen of the motor lantern The guard plates (680) are fixed in the windows of the motor lantern (681). For dismantling insert a screwdriver about 4 cm into the last row with punches of the guard plate. Then pull up the screwdriver until the lower edge of the guard plate lifts off the window. Now you can remove the screwdriver together with the guard plate from the window (see pict. 8.1.). On building in insert the screwdriver about. 4 cm into the last row with punches of the guard plate. Then put the upper part of the guard plate into the upper edge of the window. Now pull up the screw driver until the guard plate is bent through so much, that it can be inserted into the lower edge of the window of the motor lantern. Attention Pull up screw driver only so far as is absolutely necessary to insert the guard plate into the window. I f the guard plate doesn t stick fast in the window after building in: Dismantle guard plate once again, flatten it and build in again. pict. 8.1. 16 Artikel Nr. 1999991 ICB 100-en ICB 8.4 Dismounting of the Back Pull Out Assembly The Back Pull Out Assembly includes all parts of the pump except the volute casing (102V). Because ICB-pumps are constructed for process design the volute casing (102V) can stay on the base frame and in the pipes unless the volute casing itself must be repaired. • Drain volute casing (102V) through the drain plug (912.11). • Loosen screws of support food (183) from the base frame. • Hang the Back Pull Out Assembly onto a lifting device, so that it won't sink down or press into the vo lute casing during the dismounting. Example see pict. 8.2. for lifting recommendations. • Using the jack screws provided (901.42), separate the Back Pull Out Assembly from the casing. 8.5 Impeller removal • If the impeller has back vanes check the axial clearance "a" between the impeller (230) and casing cover (161) before you continue the dismounting. Refer to Sect. 8.8.1. • Loosen impeller nut with a sensitive hit on the wrench (right-hand thread). If necessary back up with a pry bar in the cross boring of the stud shaft (in clamp area). • For further dismounting the Back Pull Out Assembly should be placed in the vertical position (with ver tical shaft, see pict. 8.4). Attention: Precautions should be taken to prevent the Back Pull Out As sembly from tipping! • Draw off the impeller (230) with two screw drivers or pry bars (pict. 8.4.). Remove key (940.31). Attention Be sure to locate pry bars under impeller vanes to prevent damage to the impeller. pict. 8.4. ICB 100-en Artikel Nr. 1999991 17 Operating Instructions 8.6 Removal of the Shaft Sealing The dismounting as well as the assembly of the shaft sealing is described in the enclosed operation in struction for the particular used shaft sealing (see Data Sheet). 8.7 Dismantling of stub shaft Loosen screws (920.41) and pull motor with stub shaft (210) out of the motor lantern (341). Loosen radial stub shaft screwing (904.41 and 904.42) (stud bolts) and deduct stub shaft (210) from motor shaft. For support (break loose) you can insert a solid screw driver into the cross boring, press it against the front face of the motor and move both shafts against each other. 8.8 Reconditioning After disassembly all parts must be cleaned and checked for wear carefully. Worn or damaged parts must be replaced by new parts (spare parts). It is recommended in most cases to replace mech. seal, ball bearings and seals (flat seal, O-rings). Deposits on the impeller (230), in the volute casing (102V) or on the casing cover must be removed. 8.8.1 Clearance at impeller Suction side at impeller Back vanes of impeller Drive side of impeller only for pump size ICB 100-65-315 ICB 125-80-315 ICB 125-100-315 ICB 150-125-315 Nominal diameter 0D (mm) 68 85 100 120 135 155 175 220 Radial clearance s (mm) new min 0,15 0,17 0,20 0,22 0,25 max 0,19 0,22 0,24 0,27 0,30 wear limits 0,78 0,85 0,90 1,05 1,15 Axial clearance a (mm) new 0,8 - 1,2 wear limits max. 1,7 When the wear limits has been reached or exceeded, the worn parts must be replaced. 18 Artikel Nr. 1999991 ICB 100-en ICB For volute casings (102V) with a wear ring (502.11) and cover casings (161) with a wear ring (502.31) there are the following possibilities to restore the correct clearance: a) Renew impeller (230) and wear ring. Then the original measures are restored. b) A customized wear ring (bored to fit) can be supplied to avoid replacement of the impeller. Please contact factory for details. When volute casing (102V) or casing cover (161) without wear ring must be repaired, a wear ring can be installed to renew pump performance. A remachine to the volute casing and/or casing cover is re quired. Please contact the factory for details and assistance. 8.9 Installation 8.9.1 Generate Re-assemble the pumps using the reverse order of steps as completed for pump disassembly. However the following observations should be considered: • Pay attention to the utmost cleanliness when reassembling the pump. • For tight tolerances, e.g. between stub shaft (210) and motor shaft or impeller (230) and shaft (210) as well as thread use a suitable anti-galling compound (e.g. Molykote/Never-Seeze), so that the assembly and the next disassembly will be easier. a Anti-galling compound must be compatible with the pumpage. • Screws should be tightened, with the following torque: Location Screw size Screw torqi Lubricated threads ie in Nm Dry threads Casing screws M12 35 50 M16 105 150 M20 210 305 All other screws M10 35 50 M12 60 90 M16 150 220 A Don't forget any sealing or key (see sectional drawing). Mounting of stub shaft see point 8.9.3. For mounting of mech. seal refer to separate discription (see point 8.6.). For impellers with back vanes the axial clearance between the back vanes and the casing cover (161) should be checked after mounting the impeller (230) and tightening the impeller nut (922) (see point 8.8. 1). After the mounting of the back pull out assembly, and its assembly into the volute casing, turn the shaft and contrail the free moving of the pump in this way. The shaft sealings will cause slightly resi stance when turning, but there must not be any contact between metal parts. Before staring the pump do not forget to install and connect all security devices (for guard pla te refer to point 8.3). 8.9.2 New motor • If a new motor is installed during the repair, the following must be noted: • The motor must comply with the requirements in list T 623 (if required order from manufacturer). • Clean motor stump and motor flange of the new motor carefully (remove remainder of varnish). 8.9.3 Mounting of stub shaft • Insert key into the motor stump. • Put anti-galling compound onto the motor stump (see point 8.9.1.). • Push stub shaft up the motor shaft to measure A (see pict. 8.6. and chart). ICB 100-en Artikel Nr. 1999991 19 Operating Instructions DETAIL Z 904.42 pict. 8.6. Type 80 90 Vleasu 100 re A b 112 y mot 132 or size 160 180 200 ICB 50-32-160 157 157 197 197 197 232 ICB 50-32-200 157 157 197 197 197 232 ICB 50-32-250 162 162 202 202 202 237 237 237 ICB 65-40-160 157 157 197 197 197 232 ICB 65-40-200 157 157 197 197 197 232 232 ICB 65-40-250 162 162 202 202 202 237 237 237 ICB 65-40-315 202 202 197 237 237 237 ICB 80-50-160 157 157 197 197 197 232 232 ICB 80-50-200 157 157 197 197 202 232 232 232 ICB 80-50-250 162 202 202 202 237 237 237 ICB 80-50-315 202 202 202 237 237 237 ICB 100-65-160 162 162 202 202 202 237 237 237 ICB 100-65-200 162 202 202 202 237 237 237 ICB 100-65-250 162 202 202 206 237 237 237 ICB 100-65-315 206 206 202 241 241 241 ICB 125-80-160 162 202 202 202 237 237 237 ICB 125-80-200 162 202 202 202 237 237 237 ICB 125-80-250 202 202 202 237 237 237 ICB 125-80-315 206 206 241 241 241 ICB 125-100-200 202 202 202 237 237 237 ICB 125-100-250 216 216 216 251 251 251 ICB 125-100-315 206 241 241 241 ICB 150-125-250 216 251 251 251 ICB 150-125-315 241 241 241 ICB 200-150-250 251 251 251 • Drill countersink into motorshaft, appr. 2-3 mm depth, through the radial bore in the motor shaft (see pict. 8.6.), by useing a twistdrill with 90° tip. 20 Artikel Nr. 1999991 ICB 100-en ICB • Remove cuttings out of the stud hole (e.g. with compressed-air), screw in and make safe thread pins (904.41 and 904.42) (e.g. with Omnifit 100 M or Loctite). • Check smooth running of stub shaft opposite to motor flange with a dial gauge (see pict. 8.6.). The pointer deflection of the dial gauge must not exceed 0,1 mm. 9. Spare parts. Spare pumps 9.1 Spare parts Spare parts should be selected to last for two-years continuous operation. If no other guidelines are applicable, we recommend that you stock the number of parts listed below (in accordance with VDMA 24296). Attention To ensure optimum availability, we recommend that suitable quantities of spare parts are held in stock, especially if these are made from special materials and in the case of mechanical se als, because of the longer delivery times. Number of pumps (incl. stand-by pumps) 2 3 4 5 6/7 8/9 10/more Spare parts Stuckza il der Ersatzteile Impeller 1 1 1 2 2 3 30% Wear ring-casing 2 2 2 3 3 4 50% Shaft with key and nuts 1 1 2 2 2 3 30% Joints for pump casing sets 4 6 8 8 9 12 150% Other joints sets 4 6 8 8 9 10 100% Mechanical seal 2 3 4 5 6 7 90% bearing frame incl. adapter and impeller - - - - - 1 2 Ordering spare parts When ordering spare parts, please supply the following information: • Type_____________________________________ • S/N (Order no.)___________________________ • Part designation_______________________ in sectional drawing____________ All the information is given in the Data Sheet and the relevant sectional drawing. Attention Store spare parts in dry and clean rooms. 9.2 Stand-by pumps A lt is essential that a sufficient number of stand-by pumps are kept ready for use in plants where failure of a pump could endanger human life or cause damage to property or high costs. Regu lar checks should be carried out to ensure that such pumps are always ready for use (see Point 6.2). Attention Store stand-by pumps according to point 3.2. ICB 100-en Artikel Nr. 1999991 21 Operating Instructions 10. Plant Manager List Each plant manager should sign below to confirm that he has received, read and understood these Operating Instructions. He undertakes to follow the instructions conscientiously. If these instructions are not followed, the manufacturer's guarantee and liability shall cease to apply. Name: Date: Signature: 22 Artikel Nr. 1999991 ICB 100-en ICB 11. Log Book Each plant operator shall duly enter all maintenance and service work that has been carried out, and shall see that the person responsible confirms such work by siqninq below. Maintenance work: Date: Signature Plant opera tor: Confirmed by Person responsible: ICB 100-en Artikel Nr. 1999991 23 _______Mounting Instruction for shaft sealing_______ Valid for pump type ICB Single mech. seal without shaft sleeve For single mechanical seals with installation dimensions acc. to DIN 24960 / EN 12756, Design "K". API Plan 02 / ISO Plan 00 Because of the patented Cyclone-seal chamber no additional flushing of the seal chamber is necessary. For description of materials and operational range of the mech. seals supplied please refer to the Data Sheet in the Operation Instruction. Internal seal design refer to enclosed seal Data Sheet. 922 412.21 433 210 Index of parts: 161 Casing cover 210 Shaft 230 Impeller 412.21 O-ring 433 Mechanical seal 527**) Fixing ring 560*) Pin 904.31**) Setscrew 922 Impeller nut *) only for mech. seals with Teflon-O-rings standard **) not for all designs This leaflet is subject to alteration! ITT Industries Engineered for life Nominal size 0d, 0d7 11K B 33 48 42,5 50 43 61 45 52,5 53 73 47,5 57,5 Replacement of mech. seal For that purpose use the appropriate sectional drawing and the enclosed data sheet of the mech. seal. 1. Safety Instructions Please follow the instructions provided under point 8.1 of the Operation Instruction! A The following descriptions are only valid commonly, as far as they refer to the inner design of the mech. seal. For possible particularities refer to the Data Sheet of the mech. seal or instruction of the mech. seal-manufacturer. 2. Removal of the mech. seal • Remove and disassemble the pump referring to the repair instructions point 8.4 inclusive. • Remove fixing ring (527) (if existing) and rotating part of the mech. seal (433) from shaft (210). Refer to the enclosed data sheet of the mech. seal, if set screws are to be loosened at the mech. seal at first. • Remove stationary part of the mech. seal (433) out of the casing cover (161). • Clean casing cover (161) bore (0d7) and surface of the shaft (210). Attention The reuse of mech. seals, which have already been used for a longer time, can lead to leaking ~~at the seal faces after reinstallation. Therefore the replacement of the mech. seal through a new one is recommended. The dismounted mechanical seal can be reconditioned by the manu facturer and serve as a replacement mech.seal. 3. Installation of a mech. seal Attention ?ay attention to the utmost cleanness! Especially the seal faces must be clean, dry and un- damaged. Don t apply lubrication on the seal faces of the mech. seal. • If a lubricant is provided with the replacement mech. seal, you should use this. Attention Use mineral grease or oil only, if you are completely sure that the elastomers of the mech. seal are oil resistant. Use no silicone. Use only lubricants when you are sure that there can t occur any dangerous reactions between | \ the pumpage and the lubricant. A Attention Make all required parts available, so that assembly can be completed quickly. The lubricants are only effective for a short time. Attention Don t push elastomers over sharp edges. If necessary use mounting devices. • Press the stationary part of the mech. seal in the casing cover (161). For this you can eventually use a stamp with a soft surface. Unequal load can lead to cracking of the seal face. • Don't damage seal face! • Pay attention that the stationary ring is in solid contact with the casing cover. The seal face must be in stalled perpendicular to the shaft. • If a pin (560) is existing, be careful that it fits into the slot of the mech. sealing, without touching the mech. seal. ITT Industries Engineered for life • Push the rotating unit of the mech. seal on the shaft (210). • Complete the face on the impeller side of the mech. seal exactly with the shaft (measure l,K). For mech. seals without own set screws the fixing ring (527) serves as a stop. Attention Push mech. seals with bellows in such a way, that the bellow is compressed and not stretched (danger of tearing apart!). • Further mounting and installation of the pump referring to the repair instructions. ITT Industries Engineered for life I 2100 A Foreword John Crane Type 2100 Mechanical Seal________ Installation Instructions 1 J 4 ...... This instruction manual is provided to familiarise the user with the seal and its designated use. The instructions must be read and applied when ever work is done on the seal, and must be kept available for future refer ence. I ATTENTION | These instructions are tor the installation and operation of a single seal running against a seat/mating ring of appro priate material and design as used in rotating equipment: the instructions will help to avoid danger and increase reliability. The information required may change with other types of equipment or installation arrangement, and this manual must be read iri conjunction with the instruction manual supplied with the seat/mating ring and the instruction manuals for both the pump and any ancillary equipment. If the seal is to he used for an application other than that originally intend ed or outside the recommended performance limits, John Crane must be contacted before its installation and use. Any warranty may be affected by improper handling, installation, or use of this seal, contact the Company for information as to exclusive product warranty and limitations of liability. If questions or problems arise, contact your local John Crane Sales/ Service Engineer or the original equipment manufacturer, as appropriate. Foreword (cont'd) John Crane mechanical seals and seats/mating rings are precision prod ucts and must be handled appropriately. Take particular care to avoid damage to lapped sealing faces and flexible sealing rings. Do not exces sively compress the seal before or during installation. Safety Instructions 1. The following designations are used in this instruction manual to highlight instructions of particular importance: NOTE: Refers to special information on how to install or operate the seal most efficiently. Refers to special information or instructions directed towards the prevention of damage to the seal or its surroundings. Refers to mandatory instructions designed to prevent personal injury or extensive damage to the seal or its surroundings. 2. Installation and removal of the seal must be carried out only by qualified personnel who have read and understood this instruction manual. ATTENTION A 3. The seal is designed exclusively for sealing rotating shafts. The manufacturer cannot be held liable for use of the seal for purposes other than this. 4. The seal must only be used in technically perfect condition and in conjunction with a suitable seat/mating ring, and must be operated within the recommended performance limits in accordance with its designated use and the instructions set out in this manual. 5. If the pumped fluid is hazardous or toxic, appropriate precautions must be taken to ensure that any seal leakage is adequately contained. Further information on sealing hazardous or toxic fluids should be obtained fromJohn Crane prior to installation. 6. PTFE and fluorocarbon components should never be burned or incin erated as the fumes are highly toxic. If fluorocarbons are accidentally heated above 400°C they can decompose, and protective gloves must be worn when handling as hydrofluoric acid may be present. Storage and Transport Instructions for the handling, packaging, storage and transport of seal units and seats/mating rings are given in the John Crane Instruction Sheet ref. I-Storage-E. available on request. Checking the Equipment Successful operation and life of this seal is dependent on acceptable equip- NOTE: ment dimensions, alignments, and finishes. Before installation of the seal, the following checks should be made with respect to the seal housing and the shaft, especially (where marked ') at the seal position. The usual equipment to measure these features would include a micrometer and dial indicator. Shaft/Sleeve Outside Diameter ' Refer to Dimension Tables Seal Chamber Bore Diameter Refer to Dimension Tables Shaft/Sleeve Finish t______________ 0.8 to 1.2 urn Ra (Machined) Shaft/Sleeve Ovality/ <0.1 mm/0.004 in. Out-of-Roundness 1 Shaft End Play/Axial Float <0.08 mm/0.003 in. F.I.M. Shaft/Sleeve Lead-On Refer to Lead-On Chamfer Shaft/Sleeve Run-Out ' <0.08 mm/0.003 in. F.I.M. <1800 rpm <0.05 mm/0.002 in. F.I.M. >1800 rpm Seal Housing End Face Squareness Refer to Housing Squareness Graph to Shaft/Sleeve Concentricity of the Seal Chamber <0.15 mm/0.006 in. F.I.M. to the Shaft/Sleeve If the measured dimensions exceed the values given, correct the equipment to meet the specifications before installing the seal. If the seal is installed on a sleeve, the sleeve must be liquid- and pressure-tight through its bore. The thickness of the gland plate must be sufficient to retain the service pres sure without distortion. Typical Type 2100 Seal Arrangement Part Name________________________ _________________________ 1Bellows_______ 4 Face/Primary Ring______________ 2 Drive Band______ 5 Seat/Mating Ring and Seat Ring' 3 Spring_______________________________________ ‘ Rofor to scat/mating ring instruction manual Type 2100 Inch Range Dimensional Data (inches) Seal Size Seal Size Code 01 D3 D4 L3 0.375 0095 0.375 0.787 0.856 0.591 0.500 0127 0.500 0.945 1.024 0.591 0.625 0158 0.625 1.024 1.102 0.591 0.750 0190 0.750 1.260 1339 0 787 0.875 0222 0.875 1.417 1.496 0.787 1.000 0254 1.000 1.535 1.614 0.787 1.125 0285 1.125 1.654 1.732 1.024 1.250 0317 1.250 1.811 1.890 1.024 1.375 0349 1.375 1.929 2.008 1.024 1.500 0381 1.500 2.126 2.283 1.181 1.625 0412 1.625 2.205 2.362 1.181 1.750 0444 1.750 2.402 2.559 1.181 1.875 0476 1.875 2.520 2.677 1,181 2.000 0508 2.000 2.598 2.756 1,181 2.125 0539 2.125 2.717 2.874 1.181 Type 2100 Seal Installation Dimensions Type 2100 Inch Range Dimensional Data (inches cont'tr, Seal Size Seal Size Code D1 D3 04 L3 2.250 0571 2.250 3.031 3.189 1.299 2.375 0603 2.375 3.150 3346 1.299 2.500 0635 2.500 3.268 3.465 1.299 2.625 0666 2.625 3.465 3.661 1.299 2.750 0698 2.750 3504 3740 1.299 2.875 0730 2.875 3.780 3.976 1.299 3.000 0762 3.000 3.898 4.094 1.575 3.125 0793 3.125 4.055 4.252 1.575 3.250 0825 3.250 4.094 4.291 1.575 3.375 0857 3.375 4.252 4488 1.575 3.500 0889 3.500 4.409 4.606 1,575 3.625 0920 3.625 4488 4.685 1.575 3.750 0952 3.750 4.646 4 882 1.575 3.875 0984 3.875 4.803 5.000 1.575 4.000 1016 4.000 4882 5.079 1.575 Pressure/ V/ elocity (PV) Limits Housing Squareness to Shaft Pressure (bar g) Pressure (psig! 1-------- 1 0 .8 1.6 2.4 3.2 4 (inchesl Seal Size The maximum operating pressures shown apply under the following conditions carbon graphite face/ primary r ng running against a silicon carbide or tungsten carbide seat/ mating ring, with a lubricating sealed fluid at 8CTC/1 '/S' F. Maximum static/ test pressures should be taken as the relevant maximum oper ating pressure multiplied by a factor of 1.5. Axial Run-Out (mm) F.I.M. Axial Run-Out (Inches) F.I.M. 0.24 0.009 0.008 0.007 0.006 0.005 0.004 0.003 0.002 1000 2000 3000 4000 Shaft Speed (rpm) The seal must be installed to its correct working length L3. Setting pro cedure is described with respect to the shaft, but is equally applicable to a fitted sleeve. | ATTENTION | II L3 is overlength, the seal will be undercompressed and will leak: If L3 is underlength, the seal will be over- compressed and this will cause dry running and high wear of the seal faces. Find the true seal abutment position as follows: 1. Refer to the appropriate seat/mating ring instruction manual to obtain dimension 'X' fromthe face of the gland plate to the seat mating surface (Figure 1). 2. With the shaft in its working position, mark the surface at 'Y' in line with the seal housing end face, and mark the shaft again at'T the obtained distance away fromthe face position (Figure 2). This second mark is a datum for the seal working length L3. 3. From the dimension tables, find the dimension L3 for the size of seal being fitted, and measure the distance back fromposition 'T (Figure 3). The new marked position is the point on the shaft where the back of the seal is to be located. Setting the Seal Figure 1 Figure 2 Figure 3 1 Lead-On Chamfer For ease of installation, the lead-on edge of the shaft or sleeve should be chamfered as shown. p Seal sizes up to 25 mm/1.000" Above 25 mm to 63 mm/ 5.0 mm 1.000" to 2.500" 6.5 mm Above 63 mm /2.500" 8.0 mm Q 10“ R 1mmRadius Installing the Seal Before starting the installation, read the following instructions carefully, both to be aware of special information, and because the fittingsequence may be different depending on the construction of the pump. NOTE: II is essential to use a suitable lubricant when filling the seal. The recommended lubricants for elastomeric bellows are soft hand soap and water, or glycerine, do not use washing-up liquid, liquid soaps, or hand cleaning gels. Light mineral oil may be used spar ingly with nitrile and fluorocarbon. |ATTENTION | Do not use hydrocarbon-based liquids on ethylene propylene bellows, and do not use grease (includ ing silicone grease) on any elastomer bellows. 1. Remove the proleciive packaging Iromthe seal; check lor any damage, and wipe clean. 2. Fit the scat/mating ring into the gland plate as described in the appro priate seat instruction manual. Check that the gland plate O-ring or gasket is in position and will not be displaced during fitting, and then position the gland plate on the shaft clear of the seal location. [ATTENTION | Installation of the seal unit to its working length should be complete within 15 minutes to ensure that the elastomer bellows is correctly posi tioned before the neck of the bellows perma nently grips the shaft. 3. Clean the shaft, and lightly lubricate the shaft and the neck of the bellows. NOTE: Fit the seal by applying a steady pressure directly to the tail of the bellows, preferably using a closc-fitting shaft sleeve with the seal spring and spring locating ring temporarily removed. 5. Wipe (he lapped surface of the seal face perfectly clean. Install the pump casing/seal housing; loca(e the gland plate squarely on the seal housing studs, and pull on the plate to compress the seal spring as necessary to fit the retaining nuts. 6. Tighten the nuts in the manner recommended by the pump instruction manual and to its recommended torque. WORKING LENGTH Before Commissioning the Equipment Maintenance 1. Ensure that the gland plate nuts are evenly tightened according to the pump manual torque setting. 2. Complete the assembly ol the pump, and turn the shaft (by hand, if possible) to ensure free rotation. Check for correct alignment of the coupling and driver. 3. Consult all available equipment instruction manuals to check for cor rectness of all piping and connections, particularly seal recirculation/ flush, heating or cooling requirements, and services external to the seal. | ATTENTION | This mechanical sea is designed to operate in a liquid so that the heat energy it creates is adequately removed, and therelore the following check should be carried out, not only after seai installation, but also following a period of shut-down. 4. Check that the seal chamber fluid lines are open and free of any obstruction, and ensure that the seal chamber is filled with fluid and fully vented. Dry running—often indicated by a squealing noise from the seal area—will cause overheating and scoring or other damage to the sealing surfaces, resulting in excessive leakage or a much shortened seal life. ATTENTION During operation, periodic inspection of the seal should be carried out. A measure of seal condition is the level of leakage, and as no mainte nance is possible while installed, the seal should be replaced when leakage becomes unacceptable. It is recommended that a spare seal unit and seat/mating ring are held in stock to allow immediate replace ment of a removed seal. Decommissioning the Equipment 1. Ensure that the pump is electrically isolated. A If the equipment has been used on toxic or hazardous fluids, ensure that the equipment is correctly decontaminated and made safe prior to commencing work. Remember that fluid is often trapped during draining and may be present inside the seal chamber. The pump instruction manual should be con suited to check for any special precautions. 2. Ensure that the pump is isolated by the appropriate valves. Chock that the fluid is drained and pressure fully released. After Unit has Run 1. Ensure that the pump is electrically isolated. A If the equipment has been used on toxic or hazardous fluids, ensure that the equipment is correctly decontaminated and made safe prior to commencing work. Remember, fluid is often trapped during draining and may exist outside the seal. The pump instruction manual should be consulted to check for any special precautions. 2. Ensure that the pump is isolated by the appropriate valves. Check that the fluid is drained and pressure is fully released. Maintenance No maintenance of a seal is possible while installed, therefore, it is recommended that a spare seal unit and mating ring be held in stock to allow immediate replacement of a removed seal. It is recommended that used seals are returned to a John Crane Seal Rebuilding Center, as rebuilding to as-new specifications must be carried out by qualified personnel. , . It is the responsibility of the equipment user to ensure that any ' ' parts being sent to a third party have appropriate safe handling instructions externally attached to the package. A Removing the Seal 1. Referring to the pump instruction manual, dismantle the equipment sufficiently to expose the gland plate and seal housing. 2. Evenly slacken and remove the gland plate nuts, and carefully slide the plate off the studs. 3. Remove the seal housing, clean and oil the shaft, and then complete the removal of the seal and the gland plate assembly in the reverse order to installation. NOTE: Although the original seal position may be marked on the shaft or sleeve as a reference point before seal removal, the location must be checked even if the same seal and seat/mating ring specification is intended as a replacement. A seal unit should always be serviced after removal fromduty. It is recom mended that used seals are returned to a John Crane Service Centre, since rebuilding to as-new specification must be carried out by qualified personnel. A lt is the responsibility of the equipment user to ensure that any parts being sent to a third party have appropriate safe-handling instructions externally attached to the package John Crane Engineered Sealing Systems Europe, Middle East, Africa Slough, UK Tel: 44-1753-224000 Fax: 44-1753-224224 North and Latin America Morton Grove. Illinois USA Tel: 1-847-967-2400 Fax: 1-847-967-3915 1-800-SEALING II ihe producis featured will be used in a potentially dangerous and/or hazardous process, your John Crane representative should he consulted prior to their selection and use. In the interest of continuous development. John Crane Companies reserve the right to alter designs and specifications without prior notice. It is dangerous to smoke while handling products made fromPTFE Old and new PTFE products must not be incinerated Asia Pacific Singapore Tel: 65-222-9161 Fax: 65-223-5035 John Crane Sealol* Cranston. Rhode Island USA Tel: 1-401-463-8700 Fax: 1-401-463-6198 John Crane Safematic* Muurame. Finland Tel: 358-14-600-611 Fax: 358-14-600-600 e 1998 J ohn Crane Print 11/98 www.johncrane.com ISO 9001 Certified John Crane Flexibox* Manchester. UK Tel: 44-161-8722484 Fax: 44-161-8489812 CHEMIEBLOCKPUMPEN POMPE MONOBLOC POUR LA CHIMIE CHEMICAL PROCESS BLOCKPUMPS ICB 50-32-160 7200.1A610 Rev. 1 ( = = dt: i * ! J W in m u .100. J i 30 H kannje nach Motorerzeuger variieren H peut varier selon le constructeur de moteur H may vary depending on actual motor supplier G ... Gewicht fur Pumpe ohne Motor in kg G ... Poids de la pompe sans le moteur en kg G ... Weight for pump without motor in kg Toleranzen entsprechend DIN EN 735 Conforme aux tolerances DIN EN 735 Tolerancing to according DIN EN 735 Maf3e in mm / Dimensions en mm / Dimension in mm DN IS c o pr d 4 16 D K L DN C d D K L Ah NPS JSI c Claj d •s 15( D ) RF K L DN, X 50 20 102 165 125 4x19 2 20 92 165 120,54x19 DNn X 32 18 78 140 100 4x1 £ 11/2 18 63,5 140 89 4x16 IEC - Motor Bmax gi ~H h U n4 n5 w ~G 80 119 15 408 176 - - - - 31 X 90 119 15 457 176 - - - - 31 100 144 15 530 216 - - - - 37 112 144 15 539 216 - - - - 37 132 150 35 666 216 20 - - - 37 160 175 60 771 251 45 210 180 206 43 Order no.: SJ/CH/85/03 Type: ICB 50-32-160 S1VV2-222 Ex Date: 30.4.2003 Customer: EJ K SP.Z.O.O: Serial no.: 8,581.512 Item no.: - Sign: <&r S V Ei ITT Industries Engineered f o r life T e c h n i s c h e A n d e r u n g e n v o r b e h a l t e n ! M o d i f i c a t i o n t e c h n i q u e s s a n s p r e a v i s , r e s e r v e e s ! / T h i s l e a f l e t is s u b j e c t t o a l t e r a t i o n ! N i c h t m a ( 3 s t a b l i c h ! G r a p h i q u e n o n a I ' e c h e l l e ! D r a w n o t t o s c a l e ! M a ( 3 e n u r m i t U n t e r s c h r i f t v e r b i n d l i c h ! D i m e n s i o n s v a l a b l e s u n i q u e m e n t r e v e t u e s d ' u n e s i g n a t u r e ! C e r t i f i e d f o r c o n s t r u c t i o n p u r p o s e s o n l y w h e n s i g n e d ! ITT Industries Enginee red for life CHEMIEBLOCKPUMPEN POMPE MONOBLOC POUR LA CHIMIE CHEMICAL PROCESS BLOCKPUMPS Bauart i _ _ Construction | ( « B Design No S 740-400 Ausfuhrung: Einzel-GLRD, nicht entlastet (DIN 24960, l1k/ EN 12756, Ausf. K, Form U), Laufrad mit Ruckenschaufeln Execution: Garniture mecanique simple, non compensee (DIN24960, l!k/ EN 12756, modele K, forme U), roue de roulement avec ailettes dorsales Design: Single mech. Seal unbalanced (DIN 24960, l,k/ EN 12756, design K, form U), impeller with back vanes Order no.: SJ/CH/85/03 Type: ICB 50-32-160 S1VV2-222 Ex Date: 30.4.2003 Customer: EJ K SP.Z.O.O: Serial no.: 8,581.512 |Item no.: - No S 740-400 Seite 2 - No S 740-400 page 2 - No S 740-400 page 2 Nr. Teilbezeichnung Nomenclature Index of Parts 102 V Spiralgehause Volute Volute casing 161 Gehausedeckel Couvercle de corps Casing cover 183 ***) Stiitzfuss Bequille Support foot 183P **) Pumpenunterlage Cale de pompe Pump alignment 210 Steckwelle Arbre Stub-shaft 230 Laufrad Roue Impeller 341 Antriebslaterne Lanterne - support de moteur Motor lantern 400 Flachdichtung Joint plat Gasket 412.21 O-Ring Joint torique O-ring 433 Gleitringdichtung Garniture mecanique Mechanical seal 502.11 *) Spaltring Bague d' usure Wear ring 527 **) Stellring Bague d' arret Fixing ring 554.41 Unterlegscheibe Rondelle Washer 554.42 Kugelscheibe Rondelle frein Bevelwasher 554.43 ***^ Kegelpfanne Coussinet Bevelcup 554.44 Unterlegscheibe Rondelle Washer 681 Schutzblech Protecteur Guard plate 801 Flanschmotor Moteur a bride de fixation Flange motor 901.11 Sechskantschraube Vis a tete hexagonale Hexagon head bolt 901.31 **) Sechskantschraube Vis a tete hexagonale Hexagon head bolt 901.42 Sechskantschraube Vis £ tete hexagonale Hexagon head bolt 901.43 Sechskantschraube Vis a tete hexagonale Hexagon head bolt 902.41 Stiftschraube Goujon Stud 904.11 *) Gewindestift Vis d' arret Grub screw 904.31 Gewindestift Vis d' arret Grub screw 904.41 Gewindestift Vis d' arret Set screw 904.42 Gewindestift Vis d1arret Set screw 912.11 Entleerungsstopfen Bouchon de vidange Drain plug 920.41 Sechskantmutter Ecrou Hexagonal nut 922 Laufradmutter Ecrou de blocage de roue Impeller nut 940.31 Passfeder Clavette Key *)... optional **)... nicht bei alien Ausfuhrungen - pas pour tous les modeles - not for all designs ***)... nur bei lEC-MotorbaugroBe: 160MA, 160M, 160L, 180M, 180L, 200L, 200LA uniquement avec moteurs IEC de taille: 160MA, 160M, 160L, 180M, 180L, 200L, 200LA only for IEC - Motorsize: 160MA, 160M, 160L, 180M, 180L, 200L, 200LA Giiltig fur Type: 50-32-160 80-50-160 125-80-160 Valable pour type: 50-32-200 80-50-200 125-80-200 Valid for type: 50-32-250 80-50-250 125-80-250 65-40-160 80-50-315 125-100-200 65-40-200 100-65-160 125-100-250 65-40-250 100-65-200 150-125-250 65-40-315 100-65-250 200-150-250 Technische Anderungen vorbehalten! - Modifications techniques sans preavis! - This leaflet is subject to alternation without notice! ITT Industries Enginee red f o r life T e c h n i s c h e A n d e r u n g e n v o r b e h a l t e n ! M o d i f i c a t i o n t e c h n i q u e s s a n s p r e a v i s , r e s e r v e e s ! / ' T h i s l e a f l e t is s u b j e c t t o a l t e r a t i o n ! N i c h t m a B s t a b l i c h ! G r a p h i q u e n o n a I ' e c h e l l e ! D r a w n o t t o s c a l e ! M a B e n u r m i t U n t e r s c h r i f t v e r b i n d l i c h ! D i m e n s i o n s v a l a b l e s u n i q u e m e n t r e v e t u e s d ' u n e s i g n a t u r e ! C e r t i f i e d f o r c o n s t r u c t i o n p u r p o s e s o n l y w h e n s i g n e d ! CHEMIEBLOCKPUMPEN Bauart POMPE MONOBLOC POUR LA CHIMIE Construction | £ B CHEMICAL PROCESS BLOCKPUMPS Design L 7124-400 Anschlusse - Raccordement - Connections PM2 □ ! “ ft — _V- k ' C PS: LJ Code Anzahl Nombre Qty. Anschlusse Raccordement Connections Lagertrager Corps de palier Bearing bracket 24 |32,42,48 0 PM1 1 Druckmessung Mesurede la pression Pressure measurement 1/4-18 NPT 0 PM2 1 Druckmessung Mesure de la pression Pressure measurement 1/4-18 NPT 0 C01 1 Zirkulation-Austritt Sortie de la circulation Circulation outlet 1/4-18 NPT 3/8-18 NPT X S D 1 Entleerung (Gehause) Vidange (bortier) Drain (casing) 3/8-18 NPT X s DL 1 Entleerung (Lateme) Vidange (lanterne) Drain (Lantern) G 1/2 0 Ql 1 Quench-Eintritt Entree de transition supraconductrice Quench inlet 1/4-18 NPT 3/8-18 NPT 0 QO 1 Quench-Austritt Sortie de transition supraconductrice Quench outlet 1/4-18 NPT 3/8-18 NPT S = Standard; 0 = Option 0 Cl rder no.: SJ/CH/85/03 Type: ICB 50-32-160 S1VV2-222 Ex Date: 30.4.2003 jstomer: EJ K SP.Z.O.O: Serial no.: 8,581.512 Item no.: - Sign: ITT Industries Enginee red f o r life T e c h n i s c h e A n d e r u n g e n v o r b e h a l t e n ! M o d i f i c a t i o n t e c h n i q u e s s a n s p r e a v i s , r e s e r v e e s ! T h i s l e a f l e t is s u b j e c t t o a l t e r a t i o n ! N i c h t m a B s t a b l i c h ! G r a p h i q u e n o n a I ' e c h e l l e ! D r a w n o t t o s c a l e ! M a l 3 e n u r m i t U n t e r s c h r i f t v e r b i n d l i c h ! D i m e n s i o n s v a l a b l e s u n i q u e m e n t r e v e t u e s d ' u n e s i g n a t u r e ! C e r t i f i e d f o r c o n s t r u c t i o n p u r p o s e s o n l y w h e n s i g n e d ! CHEMIEBLOCKPUMPEN Bauart POMPE MONOBLOC POUR LA CHIMIE Construction CHEMICAL PROCESS BLOCKPUMPS Design CB T 701-400 J Zul. Stutzenkrafte und Momente in Anlehnung an die EUROPUMP-Empfehlung fur Pumpen nach ISO 5199-1986 La force et couple admissibles selon recommandations EUROPUMP d1apres ISO 5199-1986 Permissible loads and torques on pump flanges basing on suggestions by EUROPUMP acc. to ISO 5199-1986 for pumps PumpengroBe Grandeur de Pompe Pump size F„max[N] Fhmax [N] Mlmax[Nrn] X ICB 50-32-160 2500 1350 250 ICB 50-32-200 2500 1350 250 ICB 50-32-250 2550 1400 300 ICB 65-40-160 2550 1400 300 ICB 65-40-200 2550 1400 300 ICB 65-40-250 2650 1400 300 ICB 65-40-315 2750 1450 350 ICB 80-50-160 2700 1400 350 ICB 80-50-200 2700 1400 350 ICB 80-50-250 2850 1450 400 ICB 80-50-315 3100 1550 450 ICB 100-65-160 3800 1750 650 ICB 100-65-200 3500 1650 600 ICB 100-65-250 3500 1650 600 ICB 100-65-315 4100 1800 700 ICB 125-80-160 4800 2050 950 ICB 125-80-200 4500 1900 850 ICB 125-80-250 4500 1900 850 ICB 125-80-315 5100 2100 1050 ICB 125-100-200 5600 2300 1200 ICB 125-100-250 6400 2650 1400 ICB 125-100-315 6900 2850 1550 ICB 150-125-250 8900 3900 2200 ICB 150-125-315 9000 3950 2250 ICB 200-150-250 11700 5800 3045 Unbedingt riickseitige Berechnung der Summationsbedingung beachten! Se conformer imperativement au calcul des conditions d'addition au verso! Attention, refer to calculation of summary condition on back side! Order no.: SJ/CH/85/03 Type: ICB 50-32-160 S1VV2-222 Ex Date: 30.4.2003 Customer: EJ K SP.Z.O.O: Serial no.: 8,581.512 Item no.: - Sign: ITT Industries Engineered for life Zul. Stutzenkrafte und Momente in Anlehnung an die EUROPUMP-Empfehlung fur Pumpen nach ISO 5199-1986 La force et couple admissibles selon recommandations EUROPUMP d' apres ISO 5199-1986 Permissible loads and torques on pump flanges basing on suggestions by EUROPUMP acc. to ISO 5199-1986 for pumps Kraft- und Momentkomponenten Composante force et couple Load and torque components Druckstutzen - Bride de refoulement - On discharge flange Fxd. Fyd. Fjd M<d, My0, Mid Saugstutzen - Bride d' aspiration - On suction flange: F». Fys. F» M». M,s, M„ Dimensionen - Dimensions - Dimensions in: N. Nm T 701-400 Seite 2 - T 701-400 page 2 - T 701-400 page 2 Es bedeuten - Designation - It means: Betrag der Vertikalkraft auf den Druckstutzen Fvd = Fycl| Valeur de force verticale sur la bride de refoulement Amount of vertical load on the discharge flange Betrag der Vertikalkraft auf den Saugstutzen F« = Fys| Valeur de force verticale sur la bride d' aspiration Amount of vertical load on the suction flange ______ Betrag der Horizontalkraft auf den Druckstutzen Fhd = VFxd+F*d Valeur de force horizontale sur la bride de refoulement Amount of horizontal load on the discharge flange (______ Betrag der Horizontalkraft auf den Saugstutzen FiiS = +FjS Valeur de force horizontale sur la bride d' aspiration Amount of horizontal load on the suction flange ----------------------- Betrag des Momentes auf den Druckstutzen Md = V^'d+Myd+IVl'd Valeur du couple sur la bride de refoulement Amount of torque on the discharge flange ,--------------------- Betrag des Momentes auf den Saugstutzen Ms = yM„+M(l+M!S Valeur du couple sur la bride d'aspiration Amount of torque on the suction flange Man bilde - A etablir - Calculate: Summe der Vertikalkrafte ZFU= f Fv0+FW Addition des forces verticales Sum of vertical loads Summe der Horizontalkrafte I F h= Fhd+ Fhi ............................. Addition des forces horizontales Sum of horizontal loads Summe der Momente ZMt= Ma+Ms Addition des couples Sum of torques Die Stutzenbelastung ist zulassig, wenn die folgende Summationsbedingung erfiillt ist: L' effort sur les brides est admissible pour autant que les conditions de resultante suivantes soient remplies: The load on the flange is permissible if the following summary condition is fulfilles: fl| FvP 2 'xM 2 + +\——1 <1 Fhmax Die Werte F, ma„ Fhma„ M, fur die Summationsbedingung sind der Tabelle zu entnehmen. Les valeurs Fvma>, Fhma„ M, m„ pour les conditions de la resultante sont indiquees dans la tabelle suivante. The values of F„ max, Fhma„ M, for the summary condition are given in the attached tabula. Technische Anderungen vorbehalten! - Modifications techniques sans preavis! - This leaflet is subject to alternation without notice! ITT Industries Enginee red f or life SCHMIERMITTELEMPFEHLUNG FUR VOGEL PUMPEN TABLE DE LUBRIFICATION POUR DES POMPES VOGEL RECOMMENDATION OF LUBRICATION FOR VOGEL PUMPS T 011-810 Gultig fur Walz- und Gleitlager Pour des roulements a glissement et des roulement a rouleaux For plane bearings and roller bearings Firma maison company Schmiermitteltype / type de lubrification / type of lubricant * Fettschmierung lubrification a la graisse ’ grease lubrication NLGI GRADE 2 Olschmierung lubrification a I’huile oil lubrication Viskositat 46 cSl 40°C (=ISO 3448 VG 46) viscosite 46 cSt 40°C (=ISO 3448 VG 46) viscosity 46 cSt 40°C (=ISO 3448 VG 46) BP ENERGREASE LS 2 BP ENERGOL HLP - HM 46 BP VANELLUS C3 10 W BP VANELLUS MULTIGRAD 15 W-40 m sy OMV OMV SIGNUM L2 OMV LITHPLEX EP 2 OMV HYD HLP 46 OMV HYD HLP-M 46 OMV TRUCK 20W-20 OMV TRUCK M PLUS 15 W-40 Esso, BEACON EP 2 BEACON 2 UNIREX N 2 UNIVIS N 46 NUTO H 46 ESSOLUGE XT 301 ESSOLUBE XTS 301 IVfobil MOBILITH A W-2 MOBILUX 2 Oder MOBILUX EP 2 MOBILGREASE MP MOBILITH SHC 220 MOBILGREASE HP 222 MOBIL DTE 25 MOBIL DELVAC 1310 MOBIL DELVAC MX 15W-40 Shell RETINAX EP 2 ALVANIA GREASE G 2 TELLUS OIL S 46 TELLUS OIL T 46 MYRINA TX ROTELLA TX 10W-30 OPTIMOL OLISTA LONGTIME 2 OPTIMOL OLIT CLS (USDA H2 registiert) HYDO MV 46 HYDO 46 (USDA H2 registiert) Bei Fettschmierung nur Fette gleicher Basis verwenden. Alle in der Tabelle angefuhrten Fette sind Lithiumseifenfette. Die Reihentolge der angefuhrten Schmierstoftlieferanten besagt nichts iiber die Rangwertikgkeit ihrer Sorten. Bei Bedarf stehen unseren Abnehmern die Ingenieure des schmiertechnischen Dienstes der umseitig bezeichneten Mineralolgesellschaften zur Verfugung. A la lubrification de la graisse usez des graisses de la meme base. Les graisses indiquant dans le tableau sont du type de savon de lithium. La suite des fournisseurs de graisse ne signifie pas la qualite. Sur demande nos ingžnieurs de la service de graissage respektive seront a votre disposition. When grease lubrification only use grease of same beases. All greases indicated in the chart are of lithium soap type. The indication of the suppliers of the lubricants does not give information of the quality. On request our engineers of the lubricant service of the competent mineral-oil companies will be at your assistance. Pumpenf abr i k ERNST VOGEL NIEDERLASSUNGEN IN OSTERREICH BP Schmi erstoffe GmbH ZENTRALE 1041 Wien, Schwarzenbergplatz 13, Telefon 01/50 161-0 OMV AKTIENGESELLSCHAFT ZENTRALE 1020 Wien, LassallestraBe 3 HOTLINE FUR SCHMIERMITTEL-BESTELLUNGEN (fur ganz Osterreich) Telefon 07114/14 14 30, Telefax 07114/14 14 31 PRODUKTTECHNISCHE BERATUNG Telefon (01) 40 4 40/72 81, Telefax (01) 40 4 40/79 08, E-Mail:
[email protected] ESSO AUSTRIA AKTIENGESELLSCHAFT ArgentinierstraBe 23,1040 Wien SCHMIERSTOFFBESTELLUNGEN fur ganz OSTERREICH zum ORTSTARIF Telefon 0660/31 22 03, Telefax 01/50 140-601 MOBIL OIL SCHMIERSTOFFE AG & Co ZENTRALE 1041 Wien, Schwarzenbergplatz 13,Telefon 01/50 6 20-0 SHELL AUSTRIA AKTIENGESELLSCHAFT KUNDENSERVICE UND BESTELLUNG Telefon 01/79 7 97 DW 3401 bis 3412, Telefax 01/79 7 97 DW 3400 v er t r ieb in o s t er r ei c h : Ing. Gerhard NAGODE GesmbH Weinbergweg 27, A-2440 Gramatneusiedl Telefon und Telefax 02234/78 7 42 v er t r ieb in t er n a t io n a l : OPTIMOL OLWERKE Industri e GmbH FriedenstraBe 10, D-81671 Munchen/Germany Telefon 089/41 83-0, Telefax 089/41 83-200 Pumpenf abr i k ERNST VOGEL www.vogel-pumpen.com www. hyd rova r. com Pumpenfabrik ERNST VOGEL GmbH A-2000 Stockerau Ernst Vogel-StraGe2 Telefon: 02266<604 Telefax: 0226&65 311 E-Mail:
[email protected] A-8054 Graz-Seiersberg Karntner Stralie 518 Telefon: 0316'28 61 20 Telefax: 0316/ 28 70 42 A-9020 Klagenfurt Schachterlweg 58 Telefon: 0463/31 93 20 Telefax: 0463/31 93 17 A-4600 Weis HaidestraBe41 Telefon: 07242/ 66 8 51,52,53,54 Telefax: 07242/ 66 8 51/12 A-6175 Kematen BahnhofstraGe31 Telefon: 05232/ 20 0 01 Telefax: 05232/ 20 0 03 ..Hinweis goma'J Produkthaftungsgesetz. Die angefuhrten Ensatzmoglichkeiten sinG nur ais erne ProcJuktubersicM aufzufassen. Oie genauen E.n satzgrenzen s<nd dem Angebct, der Auftragsbestaiigung und Betriebs- anleitung zu entnehmen." Vogel Pumpen ITT Industri es Engineered for life