"user manual"
Contents
1. Shaft key VW61 002 01 vi 17 Spare parts drawing BADU Block Model with screwed on pressure cover 1 3 124 903 3 Drawing No VW61 001 Spare parts list BADU Block Model with screwed on pressure cover Valid for BADU Block 32 200 32 250 40 200 40 250 50 200 50 250 50 315 65 200 65 250 65 315 80 250 80 315 100 250 100 315 125 250 150 250 Spiral casing Pre filter housing 143 Suction filter 160 Cover 163 Pressure 230 Impeller Lantern bracket 400 Gasket 400 2 Gasket 411 3 Sealing ring 411 4 Sealing ring 412 9 Round sealing ring 433 Mechanical Seal 502 1 Split ring 502 2 Split ring Clamping ring 523 Shaft sleeve 550 1 Disc 68 3 Cover plate Circulation pipe 743 Air bleed valve 801 Flanged motor 901 3 Hexagonal bolt 902 2 Stud bolt 902 4 Stud bolt 902 5 Stud bolt 903 1 Locking screw 903 3 Locking screw 903 4 Locking screw 920 1 Hexagonal nut 920 2 Hexagonal nut 920 4 Hexagonal nut 920 5 Hexagonal nut 920 6 Hexagonal nut 925 Star handle 930 Spring washer 931 Locking plate When ordering spare parts please include the following information the type of pump the serial number and the article numbers of the parts VW61 001 01 speck DUMpeEn VERKAUFSGESELLSCHAFT GmbH EG Konformitatserklarung D claration CE de conformit EC declaration of conformity Di2. 210 Shaft 1 1 1 2 2 2 20 230 Impeller including split ring 502 2 1 1 1 2 2 2 230 1 2 Impeller set 1 1 1 2 2 2 d 400 1 2 Gaskets set 4 6 8 8 9 12 412 3 O ring 2 3 4 4 4 5 433 Mechanical seal 1 1 2 2 2 3 5 a 502 1 Splitring ele 3 8D 523 Shaft sleeve 2 2 2 3 3 4 50 12 8 Faults causes and remedies too little pumped volume from the pump unacceptable temperature increase in the pump drive equipment overloaded motor protection switch is de energised increased bearing temperature leakage at the pump the pump is not running smoothly excessive leakage at the shaft seal Cause Remedy ke Pump operates against too much pressure set new operating point kel Back pressure too high check installation for contamination Ge Pump or piping not fully de aerated de aerate or top up or not topped up Supply line or impeller blocked remove deposits in the pump or piping ke Formation of air pocket in piping change piping insert an air bleed valve Suction height too large NPSHpjant infeed too small correct the fluid level open the shut off valve in the supply line change the supply line if necessary if the resistances in the supply line are too large check the installed filter suction openings Incorrect direction of rotation reverse two phases of the power supply Wear
3. lines must be closed The pump must be at ambient temperature zero pressure and must be empty Disassembly and assembly may only be carried out with reference to the exploded diagrams Basic regulations instructions Repair and maintenance work on the pump may only be carried out by specially trained personnel and only using original spare parts see 2 7 The safety provisions according to 7 1 must be observed When working on the motor follow the instructions and provisions of the motor ma nufacturer Disassembly and reassembly must be carried out in the sequence shown in the ex ploded diagrams on pages 52 to 54 In case of damage please contact our nearest cus tomer services facility See the attached list of addresses for our customer services locations 7 4 2 Preparatory work for disassembly 1 Disconnect the electrical power supply 2 Disassembly of the complete unit 2 1 Disconnect the motor leads 2 2 Disconnect the discharge and suction connecti ons from the pipes 2 3 Disconnect the fixing bolts attaching the filter housing to the foundations 2 4 Pull out the complete unit from the piping 3 The pump casing remains in the piping du ring disassembly 3 1 Disconnect the motor leads 3 2 Unscrew the hexagonal nut 920 2 or 920 4 3 3 Pull out the installation set and motor from the pump casing 4 The pump remains in the piping disassem bly of the motor 4 1 Disconnect the motor leads 4 2 Pr
4. made from stainless steel and braided PVC hose only for types 32 160 32 200 32 250 40 160 40 200 40 250 50 160 50 200 50 250 50 315 65 160 65 200 65 250 65 315 All rights reserved to make changes Erection installation Checks prior to erection The structural layout must be prepared in accor dance with the dimension and assembly draw ings The foundations should be of sufficient concrete strength min class X0 according to DIN 1045 The concrete for the foundations must be set before the unit is erected on it The surface must be hori zontal and smooth 5 1 1 Substratum foundations wall The foundations must be prepared in such a way that the pump or the complete unit can be safely erected and is free of stress Stresses can lead to premature wear on the pump Make sure that the foundations do not transfer vibrations 5 1 2 Space requirements for operation and mainten ance The pump unit must be installed in such a way that it is possible to exchange parts or even the complete unit Heavy units must be equipped with appropriate facilities for fastening and supporting lifting tools and other devices Suitable access routes must be pro vided for delivery and removal 5 2 5 3 5 3 1 Erection of the unit During erection on the foundations the unit must be aligned to the pressure connections using a spirit level The spiral casing and pressure cover take on the approximate
5. on internal parts renew worn parts kel Pump back pressure is smaller than adjust the operating point was stated in the purchase order Higher density or higher viscosity of the pumped A fluid than was stated in the purchase order Defective seal renew the seal between the spiral casing and pressure cover Io Shaft seal worn renew shaft seal Formation of scores or roughness on the shaft sleeve renew the shaft sleeve renew the shaft seal Pump runs irregularly correct the suction conditions increase the pressure on the pump suction connections Pump is twisted check pipe connections and pump fixings if necessary reduce the spacing of the pipe clamps affix the piping using vibration reducing material Increased axial stroke 2 Too little too much or unsuitable lubricant Running on 2 phases clean the impeller relief bores replace the split ring increase reduce or replace the lubricant replace blown fuse check the connection of the electrical leads Rotor out of balance Damaged bearing Pumped volume is too low Motor protection switch is not set correctly clean the impeller re balance the impeller renew increase the minimum pumped volume check the setting replace the motor protection switch The transport safety devices have not been removed from the keyseat remove The pump must be depressurized before corr
6. required when draining the fluid to avoid any risk to personnel and the environment Legal regulations must be complied with to avoid dan ger to life Maintenance inspection Monitoring CAUTION The pump must always run quietly and without vi brations Dry running the pump must be avoided In order to avoid heating the pumped fluid the pump must not be operated for long periods of time against a closed shut off valve Maximum permissible ambient temperature 40 C The storage temperature may be up to 50 C above ambient temperature However it must not exceed 90 C measured externally on the motor casing For the required mimimum volume see 6 2 3 The shut off valve in the supply line must not be closed when the pump is in operation A functioning mechanical seal must have no or only a small amount of visible leakage losses vapo rous It is maintenance free Installed reserve pumps must be operated at least once weekly by rapid sequential on and off swit ching in order to ensure the constant operational readiness The function of the supplementary connections must be monitored 7 2 1 1 Prefilter housing suction filter CAUTION The suction filter in the prefilter housing must be cleaned periodically If the suction filter is contaminated the flow volume capacity of the pump is reduced and there is insuffi cient filtration Contamination of the suction filter can be identified by a chan
7. 000000 0000000000000 e 000000000000 0000000000000 oooooooooooog 0000000000000 0000000000000 SOOCOO000000 o 000000000 ood ood ood ood ood o000000000 0000000000 0000000000 00000000000000000000000000000000 oodo000000000 oodg0000000000 oodo000000000 oi E S 000000 ooo0000 LY 2000000 000000 000000 EWS e 000000000000 e 000000000000 299999999999 YY oo y 20000 00000 9 9 9 9 9 Z Namn Xx LZZZYZZ 000000 000000 299 909 Y CS SE VW 61 003 Fig 7 5 2 Bolt tightening points for pump unit Thread si mm M 10 M 12 M 16 M 20 Item ze M 20 x 1 5 M 30 x 1 5 M 8 M 10 M 12 M 16 Refers to non lubricated threads Tightening torque Ma Nm 40 55 90 140 25 85 140 15 30 45 80 10 25 A Bolt connections on the casing parts B Impeller nut C Bolt connections lantern bracket motor D Bolt clamp ring stub shaft 7 6 Ordering spare parts The following information from the rating plate must be included with each order for spare parts e g Type BADU Block 50 160 Serial No Model Year of manufacture 2002 or the spiral housing e g 50 160 7 6 1 Recommended spares holding for two year continuous operation according to DIN 24 296 Part No Part name Quantity of pumps including reserve pumps 2 3 4 5 6and7 8and9 10 or more Quantity of spare parts
8. Installation and operation manual BADU Block ma gd gt E z e i a St S J ee 04 09 VG 766 1330 050 2 04 09 D F GB BA 1 1 1 2 General information CAUTION Speck Pumpen Verkaufsgesellschaft GmbH Neunkirchen am Sand BADU Block Series Country of origin Federal Republic of Germany This Speck pump has been developed according to the latest technical standards manufactured with great care and is subject to continuous quality control The present operation manual should provide an easy introduction to the pump and the range of possible ap plications for which it is intended The operation manual contains important information for the safe proper and efficient operation of the pump These instructions must be adhered to in order to ensure the reliability and longevity of the pump as well as to avoid danger Local regulations are not considered in this Operation Manual The responsibility for these and also for their observance by installation personnel lies with the user alone The operation manual does not account for locally ap plicable provisions compliance with which is the re sponsibility of the user also for the installation per sonnel involved This unit may not be operated above the values specified in the technical documentation or any other instructions contained in the operation manual or contractual do
9. a minimum pumping volume of t 30to 70 C sl of Oo must be provided during this time 6 2 4 Density of the pumped fluid 6 3 6 3 sch The power consumption of the pump changes in pro portion to the density of the pumped fluid In order to avoid overloading the motor and pump the density must be consistent with the order data Out of operation storage rust proofing Every pump is carefully assembled before it leaves the factory If start up is to be delayed for any length of time after delivery it is recommended to store the pump as described below Storing new pumps New pumps are packed ready for storing in the factory Protection appropriate for internal storage for a maximum of 12 months Store the pump in a dry location 6 3 2 Procedures for an extended non operational 6 4 period 1 The pump remains installed and has its functi ons checked periodically In order to ensure a constant operational readi ness and to avoid the build up of deposits in the internal areas of the pump and the areas imme diately next to the pump supply during extended non operational periods the pump should be functionally tested for a brief time approx 5 mi nutes in a period every 1 3 months Before star ting the procedure the pump must be supplied with a sufficient amount of fluid 2 The pump is removed and put into storage Before putting the pump into storage carry out the checks according to 7 1 to 7 4 Then
10. alingen cumple las siguientes disposiciones pertinentes vastaa seuraavia asiaan kuuluvia m r yksi EG Maschinenrichtlinie 98 37 EG CE Directives europ ennes 98 37 CE EC machinery directive 98 37 EC CE Direttiva Macchine 98 37 CE EG Machinerichtlijn 98 37 EG EU konedirektiivi 98 37 EU directiva europea de maquinaria 98 37 CE EMV Richtlinie 89 336 EWG i d F 93 68 EEC Directives CE sur la compatibilit lectromagn tique 89 336 CEE modifi es par 93 68 CEE EMC Machinery directive 89 336 EEC in succession 93 68 EEC Direttiva di compatibilita elettromagnetica 89 336 CEE mod 93 68 CEE Richtlijn 89 336 EEG gewijzigd door 93 68 EEG Sahk magneettinen yhteensopivuus EMC konedirektiivi 89 336 EEC jota on muutettu direktiivill 93 68 EEC directiva 89 336 CEE EG Niederspannungsrichtlinie 2006 95 EG CE Directives basse tension 2006 95 CE EC Low voltage directive 2006 95 EC CE Direttiva di bassa tensione 2006 95 CE EG aagspannings richtlijn 2006 95 EG EU pienjannitedirektiivi 2006 95 EU directiva de baja tension 2006 95 CE EG Richtlinie 2002 96 EG WEEE Directive 2002 96 CE DEEE Directive 2002 96 EC WEEE Direttiva UE 2002 96 EG WEEE EG Richtlin 2002 96 EG WEEE E U direktiivi 2002 96 EC WEEE CE Directiva 2002 96 EG tratamiento de residuos de componentes de aparatos el ctricos y electr nicos en desuso EG Richtlinie 2002 95 EG RoHS Directive 2002 95 CE RoHS Dir
11. be reduced by wetting the sur faces with water CAUTION Elastomers made from EP rubber must never come into contact with oil or grease Use water to help with the assembly Only hand or finger pressure should be used when 7 5 3 pressing the counter ring into the pressure cover 163 Ensure even pressure distribution Assembly of the motor The motor is mounted in the reverse sequence to that used for dismantling During installation and be fore start up particular care must be taken to pull the locking plates 931 out of the shaft keyseat and to secure them with the hexagonal bolts 901 3 CAUTION When mounting the shaft 210 to the motor stub shaft ensure that the keyseat on the motor shaft end and the slot of shaft 210 are congruent and aligned opposite to the slot of clamping ring 515 901 3 Section A A Fig 7 5 1 210 515 VW 60 006 1 Shaft assembly Part name Shaft Clamping ring 901 3 Hexagonal bolt 914 1 Allen head screw 931 Locking plate 7 5 4 Screw tightening torques LA N ISS ZLEALLEL LE 2 Gi 4 YSZ De d A Z D gt E VJE SC Sch CT N EN N NJ KEE Q IN N a y d A E OB REN SS ANS gt TE A DA vi D LLL OOO0000000000 ooo0o0o000
12. cessary Gaskets must be replaced as a matter of course Al ways replace them with seals of the same thickness As a general practice gaskets made from asbestos free materials or graphite must be assembled with out the use of lubricants Assembly aids should be avoided if at all possible However if it is necessary use a commercially avai lable contact adhesive e g Pattex or HY LOMAR or Epple 33 sealant The sealant must be applied at selected points as a thin film Cyanoacrylate adhe sive instant glue must not be used If the sealing area between the impeller neck and the split ring is worn the split ring 502 1 and where fitted 502 2 must be renewed Play in the gap new 0 3 mm on maximum permissible extension to 0 9 mm on The assembly is carried out in the reverse sequence to that used for disassembly It is essential to main tain the correct sequence of individual parts 7 5 2 Mechanical Seal The insertion is carried out in the reverse sequence to that used for removal The basic rules for assem bly of a mechanical seal are as follows Maximum care extreme cleanliness Only remove the contact protection from the slide faces just before starting the assembly Damage to sealing surfaces and the O rings must be avoided Clean the shaft and the counter ring seat in the pres sure cover and carefully remove deposits During assembly of the seal the friction forces of the shaft sleeve 523 can
13. chiarazione CE di conformit EG verklaring van overeenstemming EU yhtapitavyysilmoitus Declaracion de conformidad im Sinne der EG Maschinenrichtlinie 89 392 EWG Anhang Il A conform ment a la directive CE relative aux machines 89 392 CEE Annex II A as defined by machinery directive 89 392 EEC Annexe Il A ai sensi della direttiva CE 89 392 relativa a macchinari Appendice II A inzake richtlijn van de raad betreffende machines 89 392 EEG bijlage Il A m riteltyn konedirektiivin 89 392 EEC liite Il mukaan segun se define en la directriz para maquinas de la CE 89 392 CEE Anexo Il A Hiermit erklaren wir dass das Pumpenaggregat Par la pr sente nous d clarons que le groupe moteur pompe Herewith we declare that the pump unit Si dichiara che la pompa hiermede verklaren wij dat het pompaggregaat Taten ilmoitamme etta pumppulaite Por la presente declaramos que la unidad de bomba Type Type Type Tipo Type Malli Tipo Auftrags Nr N d ordre Order no Numero d ordine Opdracht Nr Tilausnumero N pedido Baureihe S rie Series Serie Serie Mallisarja Serie O BADU Block folgenden einschl gigen Bestimmungen entspricht correspond aux dispositions pertinentes suivantes complies with the following provisions applying to it conforme alle s equenti disposizioni pertinenti in de door ons geleverde uitvoering voldoet aan de eisen van de in het vervolg genoemde bep
14. cumentation regarding the pumped fluid the pumped volume speed density pressure and temperature as well as motor power If necessary contact the manufacturer The nameplate identifies the series size the most im portant operating data and the identification number Please always quote this number for any queries re ordering and in particular when ordering spare parts Should any additional information or details be requi red such as in the event of damage please contact the nearest Speck customer care facility Certificates of conformity test symbols and similar The CE symbol is attached to the pump The certifi cate of conformity is included as an annex in the ope ration manual Noise level The noise level is very dependent on the pipes con nected to the pump The stated noise level is only applicable to the pump on its own Refer to the technical data sheet in the annex if avai lable for the noise level If there is no value given for the noise level it is below 75 dBA Safety This Operation Manual contains basic instructions which must be observed during mounting operation and maintenance Therefore the Operation Manual should be carefully read before installation and start up by the person in charge of the installation as well as by all other technical personnel operators and should at all times be available at the installation site 2 1 2 2 2 3 It is important that not only all general sa
15. d before installation in the piping Before any new installation is commissioned the tanks pipes and connections must be thoroughly cleaned rinsed and air purged Weld beads scale and other contaminants often come loose only after an extended period of time Supplementary connections The dimensions and position of the supplementary connection draining required for the pump is defi ned in the installation drawing or pipe layout dia gram 5 3 2 Dimensioning of the pipes In order to avoid friction losses in the pipes as far as possible the maximum operating flow rates in the suction or supply lines should be 1 5 m s and in the pressure lines 2 5 m s Pipe layouts and fluid quantities must be configured in accordance with the standards for piping to pre vent the pump from sucking in air Dry running of the pump can cause considerable damage to the pump and seals 5 3 3 Measuring point schematic Pressure measurements on centrifugal pumps are carried out according to ISO 2548 standardized ex perimental arrangements sketch 1 page 43 However it should be ensured that the flow rate in the measuring pipes is not substantially higher than the stated values in Section 5 3 2 For flow rates hig her than the values stated in Section 5 3 2 adaptor pieces must be fitted to the pressure and or suction flanges sketch 2 page 43 In order to ensure that reliable measurements are obtained at the plant the pressure measure
16. e of resin and acid must not become brittle and should provide rust pro tection The grease should have a penetration value between 2 and 3 corresponding to a walk penetra tion of 220 to 295 mm 10 The drop point should not be below 175 C The cavities in the bearings may only be approximately half filled with grease If necessary the bearings can also be filled with greases having different soap bases As greases containing different soap bases may not be combi ned the cavities must first be washed clean The ne cessary subsequent lubrication periods must then be adjusted to match these greases CAUTION In regard to disposal the general legal requirements in force must be observed Sealed bearings with permanent lubrication 2 RS bearing or 2 Z bearing cannot be washed clean and refilled with grease In this case the bearings must be renewed Motors of model size 180 upwards are provided with relubrication devices and flange lubrication nipples in accordance with DIN 3404 Emptying disposal If the pump is used to convey fluids hazardous to health care is required when emptying the pump in order to avoid risk to personnel or the envi ronment Legal regulations must be observed Whe never necessary wear protective clothing and pro tective masks 7 4 7 4 1 Disassembly Before starting the disassembly make sure that the pump cannot be switched on again The shut off valves in the suction and discharge
17. ecting faults on parts which are under pressure 2 Enquiry required 13 The pages which follow contain the spare parts drawings and spare parts lists Please turn the page 9 15 Related documents Spare parts drawing BADU Block Model with clamped pressure cover 502 1 e e Kuer 902 3 925 res Seege Eelere 809 062 00 0308 Ee 020209092020209 EE EE 0200002020 124 1 3 903 3 Drawing No VW61 002 Spare parts list BADU Block Model with clamped pressure cover Valid for BADU Block 32 160 40 160 50 160 65 160 80 160 80 200 100 160 100 200 125 315 150 315 Spiral casing 124 Pre filter housing 143 Suction filter 160 Cover 163 Pressure coverl 210 Shaft Impeller Lantern bracket Gasket Gasket Gasket Sealing ring Sealing ring Round sealing ring Mechanical Seal Split ring Split ring Clamping ring Shaft sleeve Disc Cover plate Circulation pipe Air bleed valve Flanged motor Hexagonal bolt Stud bolt Stud bolt Stud bolt Stud bolt Locking screw Locki GA When ordering spare parts please include the following Locking screw information the type of pump the serial number and the Allen head bolt article numbers of the parts Hexagonal nut Hexagonal nut Hexagonal nut Hexagonal nut Star handle Spring washer Locking plate
18. ective 2002 95 EC RoHS Direttiva UE 2002 95 EG RoHS EG Richtlijn 2002 95 EG RoHS E _ U direktiivi 2002 95 EC RoHS CE Directiva 2002 95 EG limitaci n de utilizaci n de determinados productos peligrosos en aparatos el ctricos y electr nicos Angewendete harmonisierte Normen insbesondere Normes harmonis es utilis es notamment Applied harmonized standard in particular Norme armonizzate applicate in particola re Gebruikte geharmoniseerde normen in het bijzondere Kaytettyja harmonisoituja normeja erityisesti Normas armonizadas aplicadas especialmente EN 60335 1 EN 60335 2 Teil 41 Bes CAE We D 91233 Neunkirchen a Sand 01 04 2009 i V F Eisele ppa A Herger Ort Datum Technischer Leiter Produktmanager Faita le Directeur Technique Chef de produits Place date Technical director Product manager Localita data Direttore tecnico Responsabile prodotti Plaats Datum Technisch directeur Productmanager Paikka P iv ys Teknillinen johtaja Tuotep llikk Lugar Fecha Director tecnico Jefe de producci n Adresse Adresse Address Indirizzo Adres Osoite Direccion Hauptstra e 1 3 D 91233 Neunkirchen a Sand VG 766 1330 050 2 04 09 D F GB BA
19. ed Important components can be destroyed if the pump is run dry In case of the wrong direction of rotation reverse any two phases L1 L2 or L3 of the mains supply leads in the motor terminal box Start up switching off Initial start up CAUTION Before starting the pump ensure that the unit is connected electrically with all of the pro tective devices in accordance with regulations the pump is filled with pumping fluid the direction of rotation has been checked all supplementary connections are made 6 1 1 Shaft seal Shaft seal see 7 4 4 and 7 5 2 6 1 2 Filling and checking the pump The pump and the supply line must be de aerated and filled with pumping fluid before it is started up The non return valve in the suction line must be fully open CAUTION Running the pump without fluid will cause increased wear and must be avoided 6 1 3 Final check It must be possible to easily turn the shaft by hand Check all connections for correctness and function 6 1 4 Protection against accidental contact According to accident prevention regulati ons the pump may only be operated if it has protection against accidental contact 6 1 5 Switching on Only switch the unit on with the shut off valve on the pressure side closed This should be slowly opened and adjusted to the operating point only once it has reached full speed CAUTION After reaching operating temperature and or in the event o
20. ed Operation The operational safety of the machine delivered is only guaranteed if the machine is used in accordance with the directions contained in the subsequent secti ons of the Operating Instructions Limits stated in the data sheets may not be exceeded under any cir cumstances 3 Transport temporary storage 3 1 Transporting The unit must be transported correctly It must be en sured that the unit is transported in a vertical position and that it does not slide off the transport hanger It is not permitted to hang the rope on the free end of the pump shaft or the eye bolt of the motor The transport eye bolts on the motor are only appro ved for transporting the motor itself and not for the complete pump If the pump unit slides off the transport hanger this may cause physical injury or damage to pro perty VD 61 007 If the pump is transported without the motor shaft 210 must be locked in position 1 Press the cover panels 68 3 lightly together and re move them through the windows of the lantern bra cket 341 2 Pull the lock washer 931 into the wellnut and secure with the hexagon head screws 901 3 EER K KLLK CER x VD 60 016 3 2 Temporary storage 4 2 internal storage rust proofi
21. ess the cover panels 68 3 lightly together and remove them from the windows of the lantern bracket 341 4 3 Unscrew the hexagonal nuts 920 5 4 4 Unscrew the hexagonal bolts 901 3 4 5 Place both locking plates 931 on the shaft key seat 210 4 6 Tighten hexagonal bolts 901 3 4 7 Detach the motor After a long period of operation individual parts may possibly be difficult to detach from the shaft In this case one of the well known rust solvents can be used or possibly a suitable extractor tool Under no circumstances force should be used 7 4 3 Pump Disassembly of the pump must be carried out in the sequence shown in the exploded diagrams on pages 52 to 54 7 4 4 Mechanical Seal 7 5 1521 In order to change the mechanical seal it is neces sary to disassemble the pump After the impeller 230 has been removed the mechanical seal 433 can be pulled from the shaft by hand Clean the shaft sleeve 523 before assembly and if required remove any scores or scratches with emery cloth If scoring or pitting is still visible replace the shaft sleeve clean the counter ring seat Reassembly Pump The assembly of the pump must be carried out in ac cordance with the machinery regulations in force Before starting the assembly the mating areas of in dividual parts must be brushed with graphite or a si milar substance This applies equally to bolt con nections Check O rings for damage and replace where ne
22. f leaks tighten the hexagonal nut 920 2 or 3 or 4 with the unit switched off 6 1 6 Switching off 6 2 6 2 1 Close the shut off valve in the pressure line If a non return valve is installed in the pressure line the shut off valve can remain open as long as there is back pressure The shut off valve in the supply line must not be closed when the pump is switched off Switch off the motor Make sure that it coasts quietly to a stop Depending on the installation the pump with the heat source switched off should coast for long enough to reduce the temperature of the pumped fluid far enough that an accumulation of heat inside the pump is avoided For a long standstill close the shut off valve in the supply line Close the supplementary connections The pump should be emptied in case of a long standstill and to protect it against frost Operating range limits Temperature of the pumped fluid CAUTION Do not operate the pump at tempertures higher than those specified in the data sheet or on the rating plate 6 2 2 Switching frequency In order to avoid large temperature increases in the motor and excessive loading of the pump motor seals and bearings the following number of swit ching cycles per hour hr must not be exceeded BADU Block 15 switching cycles per hour 6 2 3 Minimum volume If the type of installation includes the possibility of operating against a closed shut off valve on the discharge side
23. fety measu res appearing under the above heading Safety should be adhered to but also all other specialized safety instructions appearing under the other hea dings e g for private use Symbols for Safety Instructions in the Operation Manual All safety warnings contained in the Operation Manual which when ignored may constitute danger for hu mans are specially marked with general danger sym bols Safety symbol according to ISO 7000 04324 In case of electrical hazards they are specially mar ked with Safety symbol according to IEC 417 5036 For safety warnings which when ignored may consti tute a hazard for the machine and its functions as well as for the surrounding the word CAUTION is added Symbols directly attached to the machine like e g arrow denoting the direction of rotation symbol for fluid connections must be heeded and kept fully legible at all times Personnel Qualification and Training All personnel for the operation maintenance in spection and installation must be fully qualified to per form that type of job Responsibility competence and the supervision of such personnel must be strictly regulated by the user Should the available personnel be lacking the neces sary qualification they must be trained and instructed accordingly If necessary the operator may require the manufacturer supplier to provide such training Furthermore the operator user must make sure that the
24. ge of or an increase in the displayed value of the suction side manovacuumeter vacuum pressure gauge 7 2 1 2Cleaning the suction filter Switch off the pump and take precautions to pre vent it being switched on again A A Only carry out the work with the electric power switched off Close the shut off valves in the supply suction and pressure lines Empty the prefilter housing using the drain plug 903 3 Unscrew the star handle 925 and remove the fil ter cover 160 Take out the suction filter 143 clean and put it back in its place Screw on the filter cover 160 uniformly using the star handle 925 evenly Open the shut off valves CAUTION De aerate the pump unit using the ball valve 743 7 2 2 Lubrication and lubricants 7 2 2 1 Lubrication The roller bearings in the IEC motor are lubricated with grease The intervals quality and quantity are given below 7 2 2 2 Grease quality grease replacement 7 3 The bearings are provided with high quality lithium soap grease The filling will last for 15 000 operating hours or 2 years under normal operating conditions In the case of unfavourable operating conditions e g high ambient temperature high humidity dusty air aggressive industrial atmosphere etc the be arings should be checked correspondingly earlier and if necessary cleaned For this purpose a grease containing lithium soap should be used it should be fre
25. ment should be made taking into account the flow rates according to Section 5 3 2 and the corresponding sketch Pipe elbows valves adaptor pieces etc can falsify the measurement values and therefore must not be located too close to the pressure measurement drill holes The set up for flow rate measurement must be in ac cordance with the provisions of the manufacturer of the specific measuring equipment Sketch 1 ca 3 x D1 min amp x D min 4 x D2 ca 3 x PD Sketch 2 a min 4 x D1 min 2 x D4 ca 3 x D1 ca 3 x D2 min 2 x D Druckseitig d 4 2xd Delivery side d 2xd Saugseitig d 6 2xd Suction side d 6 2xd min 4 x D2 LZ KH 5 4 Electrical conection 5 4 ch Electrical connection may only be carried out by a qualified electrical technician Compliance with the relevant DIN VDE 0100 and ex plosive atmosphere 0165 regulations is required Check the available mains voltage against the data on the motor rating plate and select the appropriate connection In making the connection the technical con nection provisions of the local power supply company must be observed The use of a motor protection device is strongly re commended Motor connection The direction of rotation of the three phase AC motor is strictly clockwise in accordance with DIN VDE 0530 Part 8 viewed from the motor
26. minimum wear Constructional design Construction Spiral pumps single stage with power rating accor ding to EN 733 Shaft fitted with a replaceable shaft sleeve in the area of the shaft seal The spiral casing and impeller are fitted with replaceable split rings Flanged pump and motor are close coupled to form a block unit with norm motor The pump shaft is rigidly connected to the motor shaft Shaft seal Mechanical seal in accordance with EN 12 756 Drive Electric motor Protection against accidental contact Cover plates on the lantern bracket in accordance with EN 294 4 3 Table of materials Casing parts Tin bronze CC480K GS Tin bronze CC480K GS SiC SIC HNBR Cast iron EN JL 1040 Tin bronze CC480K GS Carbon SiC EPDM on request SIC SIC HNBR CC495 GS 1 4571 X6 Cr Ni Mo Ti 17 12 2 1 4571 X6 Cr Ni Mo Ti 17 12 2 Cast iron EN JL 1040 Cast iron EN JL 1040 enamelled internally 1 4571 X6 Cr Ni Mo Ti 17 12 2 Tin bronze CC480K GS PA6 6 GF30 VD 61 002 Impeller Mechanical seal CC495 GS 1 4571 X6 Cr Ni Mo Ti 17 12 2 1 4571 X6 Cr Ni Mo Ti 17 12 2 Cast iron EN JL 1040 Cast iron EN JL 1040 enamelled internally 1 4571 X6 Cr Ni Mo Ti 17 12 2 Tin bronze CC480K GS PA6 6 GF30 Split ring Pump shaft Shaft protection bush Lantern bracket Pre filter housing Suction filter Filter cover Circulation pipes and ventilation ball valve
27. ng In case of temporary storage only the components made from low alloy materials in contact with fluids e g cast iron JL 1040 need to be rust proofed Commercially available preserving substances can be used for this For application removal follow the spe cific instructions of the manufacturer The procedure is described in Section 6 3 The unit oump should be stored in a dry room with as far as possible constant humidity For outside storage it is essential that the unit and the packing case are protected by a watertight cover in order to avoid contact with moisture CAUTION Protect stored goods against moisture dirt pests and unauthorized entry All of the assembled components of the unit are enclosed and must only be opened when required for installation All uncoated parts and surfaces of the pump are oiled or greased for rust protection silicone free oil or grease Product description and accessories General description BADU Block centrifugal pumps are non self priming single stage spiral casing pumps in a vertical block construction A block pump and pre filter housing are flange connected to make a block unit The compact construction provides high circulation performance with minimum space requirement The back pullout design allows the drive unit to be re placed without disconnecting the pipework for ease of assembly or disassembly Due to the low speed the pumps operate with little noise and
28. overnment regu lations must be observed at all times Any danger to persons etc by electrical energy must be excluded For details see e g regulations of VDE and the local utilities 2 6 Safety Directions for Maintenance Inspection and Assembly Work It is the user s responsibility to make sure that all maintenance inspection and assembly work is per formed exclusively by authorized and qualified experts sufficiently informed through careful perusal of the Operating Instructions The pump must be at ambient temperature depres surized and emptied Basically all work on the machine is to be performed while the machine is not in operation The sequence for shutting the machine down described in the Ope rating Instructions must be strictly observed Pumps or pump units handling hazardous liquids must be decontaminated Immediately upon completion of the work all safety and protective equipment must be restored and acti vated Before restarting the machine all points contained in chapter Initial Start up must be observed 2 7 Unauthorized Changes and Manufacturing of Spare Parts Any conversion or changes of the machine may only be undertaken after consulting the manufacturer Ori ginal spare parts and accessories authorized by the manufacturer guarantee operational safety Using non authorized parts may void any liability on the part of the manufacturer in case of consequential damage 2 8 Unauthoriz
29. personnel fully understands the contents of the Operation Instructions Dangers of Ignoring the Safety Symbols Ignoring the safety directions and symbols may cause danger to humans as well as to the environment and the machine itself Non observance of the safety instructions may void any warranties Non observance of safety directions and symbols may for example entail the following Failure of important functions of the machine plant Failure of prescribed methods for maintenance and repair Endangerment of persons by electrical mechanical and chemical effects Danger to the environment because of leakage of hazardous material Danger of damage to equipment and buildings 2 4 Safety oriented Operation The safety directions contained in the Operation In structions existing national regulations for the pre vention of accidents as well as internal working ope rational and safety regulations of the operator user must be observed at all times 2 5 General Safety Directions for the Operator User If hot or cold machine parts cause a danger such parts must be protected by the operator user against contact with personnel Protective covers for moving parts e g coupling must not be removed when the machine is running Leakages e g at the shaft seal of hazardous pum ping media e g explosive toxic hot liquids must be disposed of without causing any danger for per sonnel and the environment All g
30. proceed with rust proofing spray the inside of the pump casing with preser ving substance in particular the area around the impeller gap Spray the preserving agent through the suction and discharge connections It is re commended to close off the connections e g with plastic caps or similar Restart after storage Before restarting the pump carry out the check and maintenance procedures according to 7 1 and 7 2 In addition the points listed in the sections ini tial start up 6 1 and operational range limits 6 2 must be observed when starting to use the pump again Immediately after completion of this work all of the safety and protection equipment must be connected properly and functionally tested Maintenance inspection General information The user is responsible for ensuring that all main tenance inspection and assembly work is carried out by qualified and authorized personnel who have sufficiently informed themselves by thoroughly stu dying the operation manual 7 2 7 2 1 By preparing a maintenance plan expensive repairs can be avoided and fault free and reliable operation of the pump can be obtained with minimum main tenance effort No work must be carried out without first disconnecting the equipment electrically To avoid any danger to life the pump unit must be protected against accidental switch on Pumps which operate with fluids hazar dous to health must be decontaminated Care is
31. stub shaft The direction of rotation of the pump is anti clock wise viewed from the suction flange In order to convert the motor to the direction of rota tion of the pump it should be connected as shown in Fig 5 4 1 or Fig 5 4 2 AA LY Ke i IN i UM A connection low voltage AE oO W2 QU OV 2 EY our Ovi Ow i K EL 1b VD 61 008 Fig 5 4 1 Connection diagram for AC motors A connection Y connection high voltage P1 P2 OO 6 a W2 U2 V2 AY our Ou Ow i L2 L1 L3 VD 25 226 Fig 5 4 2 Connection diagram for AC motors Y connection If required connect the PTC thermistor according to DIN 44081 44082 with downstream trip device as per Fig 5 4 3 Fig 5 4 3 Connection diagram for PTC thermistor 5 4 2 Timer relay setting For AC motors connected in star delta circuit must be ensured that the switchover points between star and delta rapidly succeed each other in very short intervals Long switchover times will damage the pump For star delta circuits set the timer relay to lt 3 s 5 4 3 Checking the direction of rotation The direction of rotation of the motor must be the same as the direction of rotation of the arrow on the spiral casing clockwise as viewed from the motor side Check by switching the motor on and then im mediately off again Checking the direction of rotation should only be car ried out with the pump and pipes prim
32. temperature of the pumped fluid The pressure cover and lantern bracket must not be insulated Appropriate security measures must be taken to avoid burns Connecting the piping CAUTION Under no circumstances may the pump be used as an anchor point for the pipes The piping system must not exert forces or torques e g from torsion thermal expansion on the pump The suction pipe must be fitted with an upward incline to the pump the supply with a downward incline The pipes must be supported directly in front of the pump and have stress free connections For short pipes the nominal diameter must be at least the equivalent of the pump connections For long pipes the most economic nominal diameter should be determined separately in each case Adaptor pieces for larger nominal diameters should be designed with an enlargement angle of approx 8 in order to avoid increased pressure losses Depending on the type of installation and of the pump it is recommended to fit non return valves and shut off valves Suitable measures must be taken to compensate for the thermal expansion of the pipes in order not to load the pump beyond the permitted pipe forces and pipe torques If the pipe forces are exceeded it is possible for example that leakage may occur on the pump leading to the escape of pumped fluid Danger to life from hot pumped medium The flange covers on the suction and pressure con nections must be remove
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