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Operating instructions Type series NE

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1. 4 2 2 Maximum admissible temperature of the liquid pumped The maximum admissible temperature of the liquid pumped depends on the materials of the pump housing and bellows for WERNERT bellows type mechanical seal In exceptional cases it may be exceeded on consultation with the manufacturer The maximum admissible temperature of the liquid pumped also depends on Ex the approved temperature class please refer to 2 9 6 and 2 9 7 above For WERNERT bellows type mechanical material temperature seal only material temperature UHMW PE PVDF 115 C Pac 80 C 100 C PTFE 115 C PFA 165 C Wernit 125 C Durapox 125 C PTFE 165 C For the employment of other mechanical seals the corresponding data in the order confirmation and data sheet are decisive 4 2 3 Admissible temperature range of the environment The admissible range of the ambient temperature is 10 C to 40 C The name plate for a pump according to EC Council Directive 94 9 receives the symbol X as additional marking for the limited ambient temperature Page 4 1 NE series 4 Description of product and accessories 4 2 4 Volume flow of the liquid pumped Unless specified otherwise in the characteristic curves or the documentation the following shall apply Qmin 0 1 x Qop for short time operation approx 5 min Qmin Qopt Volume flow in the optimum efficiency of the characteristic pump curve 0 15 x Qopt for continuous operati
2. Fault Possible cause ___ Rectification Pump not 8 1 1 Pump not filled sufficiently Refill again and de air pumping even though before starting up engine is working 8 1 2 Storage container empty or Install automatic monitoring device Train liquid level below inlet nozzle of personnel suction line therefore no liquid is flowing therefore ae does not flow level DISS I a aana therefore Suig does not flow ee Lay pipes correctly Check position of fittings therefore no Zur flow If necessary fit de airing fittings AT eee greater than that stated otherwise use different pump Impeller melted open in the hub Repair pump check operational conditions region or has been destroyed Train personnel due to faults as described in 8 6 8 7 or 8 8 8 1 8 Shaft broken in the pump Repair pump check operational conditions train personnel 8 2 Flow and or 8 2 1 Direction of rotation of pump is Change direction of motor to ensure pump delivery head to small incorrect rotates in the right direction Check pump for damage before starting up again with pump design necessary use a different pump unfavourably laid pipes bends create favourable transitions 8 2 5 High pressure loss in suction Clean suction basket or suction pipe possibly pipe therefore cavitation increase diameter of suction pipe Check foot valve to see if it opens fully 8 2 6 Suction height too great
3. Position pump lower and or position level of therefore cavitation liquid higher Temperature of liquid to be Reduce temperature of liquid to be pumped pumped too high therefore and or increase initial pressure cavitation High proportion of gas in liquid Calm liquid to be pumped Prevent water to be pumped spouts using guide crosses Lengthen circulation times Make gassing out possible Viscosity of liquid to be pumped Adapt pump if necessary use a different higher than originally assumed pump Alternative Dilute or heat liquid to be pumped 8 2 10 Impeller worn due to abrasion Replace impeller Page 8 1 NE series 8 Faults causes and remedies Fault Possible cause Rectification Motor is 8 3 1 Pump cannot generate intended Close fittings on discharge side until intended ae pressure due to system design pressure achieved If no regulators have been Actual operating point is fitted pump must be adapted to suit actual reached at a higher volume than system Impeller correction adjusting speed was intended with original install throttle flaps design This leads to increased power requirement 8 3 2 Only if speed regulation no of Reduce no of revs Remove causes which led revs too high to increased speed e g clean filter remove deposits in pipes greater than engine assumed i py ntl greater than originally assumed liquid or preheat liquid to be sd
4. The mechanical seal materials are coded according to the material code in EN 12756 for double acting mechanical seals however only the side facing the liquid is mentioned In field n 5 materials must be indicated 1st figure Material of the rotating seal ring this is always the spring suspended ring 2nd figure Material of the stationary seal ring Zrd figure Material of the auxiliary gaskets any additional material in parentheses 4th figure Material of the spring if available 5th figure Material of the other structural parts Field o Material of the shaft sleeve The following materials are used for WERNERT bellows type mechanical seals 1st 2nd figure B Carbon synthetic resin impregnated Special carbon Ol SSIC Silicon carbide sintered at zero pressure V Aluminum oxide ceramics Y PTFE glass reinforced Y2 PTFE carbon reinforced Zrd figure H CSM TS PTFE V FPM 4th figure Spring not available in case of WERNERT elastomer bellows Ta 1 1200 Halar other materials according to standard in case of WERNERT PTFE bellows 5th figure AS Other structural parts not available Carbon synthetic resin impregnated Special carbon 1 4571 MI Hastelloy B M2 Hastelloy C QI SSiC Silicon carbide sintered at zero pressure Titanium V Aluminum oxide ceramics Fur further material identifications please refer to Standard EN 12756 Page 10 4 Type NE Annex B Admissible Branch
5. this state there is a danger that after a short time already the medium pumped takes inadmissible temperatures and the maximum admissible temperature of the surface is exceeded Suction side modifications for example by closing valves pollution of filters pipelines valves or in the medium as such lead to the reduction of the supply pressure The result hereof may be insufficient lubrication or even dry running of the mechanical seal Ex Under these conditions the maximum admissible temperature limit can be exceeded and the mechanical seal destroyed The required pressure and volume flow at additional connections such as sealing flushing liquid etc must be ensured by the user refer to 5 4 and 7 2 This applies in particular to quenching and sealing liquid Here a sufficient cooling and lubrication of the radial shaft ring and or mechanical seal must be ensured Insufficient lubrication or dry Ex operation results in the maximum admissible surface temperature being exceeded and in the destruction of the parts to be lubricated When using attached tanks it must be ensured by the user that the tank is always sufficiently filled Here there is also a danger of dry running The bearing must be controlled and maintained please refer to 7 1 below The application limits mentioned under Section 4 2 above are to be observed 6 4 Switching the pump off for a short period of time The following procedure is to be performed
6. 4 4 Sectional drawing 4 Description of product and accessories vaun mine WA 7 2 aT TT mei us SS Sy s Hl Mn p NN IN V NS p LE 412 36 321 a A SANS All EEE aS 7 i ZZA eel Md Zw A Jaza N 1 i Seep Fl Fee ee BE RR 4 b N a Q sce 2 mn LL ASSASINS 412 04 360 507 552 2 505 420 1 210 Description Description Pump casing 443 Seal insert Annular casing 463 Drip plate Casing part 472 Stationary seal ring Adapter 475 Rotating seal ring Support foot 481 Bellows 482 Bellows seat 233 321 Counter clockwise impeller 501 Radial ball bearing 505 350 Bearing housing 506 1 360 506 2 361 507 412 01 412 01 O Ring oo 412 03 O Ring 5 412 04 O Ring 552 2 41205 O Ring 68 412 06 O Ring oa 412 36 O Ring Oa 932 940 Cap Shaft nut Lockwasher Circlip Key Fig 4 1 Section of a pump of the NE series with single WERNERT elastomere bellows mechanical seal Page 4 4 NE series 4 Description of product and accessories 4 5 Designs of mechanical seals 4 5 1 Single WERNERT elastomere bellows mechanical seal MS Usually the pumps are designed using the single WERNERT elastomere bellows mechanical seal The different designs of this have been shown in Fig 4 2 The stationary seal ring part 472 is positioned in the bellows part 481 made of CSM or FPM and pressed against the rotating s
7. This type of mechanical seal frequently also referred to as REA design supports by means of centrifugal forces the movement of the sealing liquid from the sealing chamber into the shaft sealing space which in turn is very large and easy to rinse This design avoids tight gaps and solids being deposited Two types are used as standard BURGMANN HS HRZ 8 shown in Fig 4 5 PACIFIC Allpac N 2132 shown in Fig 4 6 These models are also available with single seals or single seals with quench For further information about double acting mechanical seals please refer to section 4 5 5 4 5 5 General information about double acting mechanical seals Double acting mechanical seals must always be impinged with a suitable sealing fluid which is suited to be mixed with the liquid to be pumped The sealing liquid can also if the currently valid regulations permit this be the cleaned fluid which might have to be cooled but which can only be used if the metal elements within the sealing chamber do not corrode The sealing liquid must continuously circulate between the two mechanical seals and is removed via an outlet on the opposite side The sealing fluid must have a pressure of 1 to 1 5 bar above the pressure on the shaft sealing space However it must not exceed the pressure limit of the seal on the atmospheric side The maximum pressure in the shaft sealing space which is immediately behind the impeller is approx 25 of the maximum different
8. drive performance is pressure side at least so far that the minimum in its own juice completely transformed into pumping volume is achieved Train personnel increased pump temperatures if accordingly If necessary install automatic liquid cannot be exchanged device Repair pump properly This occurs if fittings on pressure side remains closed after pump has been started up or the pipe lines are blocked Clean pipelines repair pump is not achieved by the pump possibly use different pump 8 8 Pump is 8 8 1 Pump rotating in the wrong Change poles on motor in order to achieve destroyed because it was rotating the direction Impeller started up correct direction of rotation for the pump hub thread torn out of impeller Repair pump wrong way bearing cover destroyed liquid no longer being pumped 8 9 Increased 8 9 1 Motor aligned badly Coupling Realign motor Ensure axial coupling distance bearing temperature halves are displaced in an axial of 5 6 mm radial angled direction 8 9 2 Increased axial and or radial Operate pump with permissible volumes forces because pump is being operated with volumes which are too small or too large 8 9 3 Pump body is twisted by pipes Change position of pipes or position of pump to remove tension Then align motor Possibly position aggregate freely 8 9 4 Not sufficient too much used Correct this situation or unsuitable gr
9. 1 8 1 8 1 8 2 8 2 8 2 8 3 8 4 8 4 8 4 8 4 9 1 10 1 10 1 10 2 10 3 10 4 12 1 13 1 Page 0 3 NE series General 1 General 1 1 Application of the pump WERNERT chemical standard pumps of the NE series are horizontally positioned machines to pump liquids They are always and only intended to be installed in a suitable system As the liquids being pumped are usually dangerous poisonous flammable caustic it is very important that the safety instructions contained within these operating instructions are adhered to 1 2 Validity of the operating instructions These operating instructions only apply to pumps of the NE series in the standard designs We reserve the right to make technical changes In the case of special constructions and designs the documentation specific to the order must be taken note of If in doubt please contact the manufacturer 1 3 Declarations 1 3 1 Manufacturer s declaration as defined by EU directive Machines 98 37 EC Appendix II B Manufacturer WERNERT PUMPEN GMBH Oberhausener Str 67 79 45476 M lheim an der Ruhr B R Deutschland Germany General manufacturer s declaration for standard chemical pumps of the NE series The manufacturer hereby declares that the pump s of the type series NE are meant to be installed in a machine in this case plant The manufacturer would like to point out that starting up the above mentioned pump s is are not permitted until it has been de
10. 7 9 Push off back pull out unit from annular casing Depending on liquid pumped take safety measures Protect eyes Danger of cauterization NE series WER Fig 7 10 Back pull out unit is in disassembled state The pump casing annular casing can be left in the pipework Fig 7 12 Remove the multiple ring from the shaft using special tool part 052 and remove the rotating seal ring y Fig 7 14 Separate bearing housing and adapter using ejector screws Pull out bearing housing with the shaft Page7 7 7 Maintenance Repairs a wer Fig 7 11 Loosen the semi open impeller in sense of rotation of the pump using special tool part 051 Fix shaft beforehand Fig 7 13 Remove existing rinsing connections Loosen hexagon nuts to separate bearing housing from the adapter Fig 7 15 Take bellows with stationary seal ring and bellows seat off the seal insert NE series 7 Maintenance Repairs Fig 7 16 Fig 7 17 Loosen connection of stationary seal ring Press the centering ring from the adapter and bellows and bellows seat by means of easy remove centering ring pulling Fig 7 18 Fig 7 19 Remove retaining rings from the seal insert Separate adapter and seal insert using ejector Screws Fig 7 20 Fig 7 21 Pull shaft wearing sleeve with O ring and Remove retaining screws of bellows seat and locking disc system from the shaft remove drip plate Page7
11. Increased friction in double Check sealing pressure and if possible reduce acting mechanical seal it Otherwise check seal for correct installation or wear and tear Damage to pump Therefore Repair pump increased friction 8 4 WERNERT WERNERT Elastomere bellows Tighten bellows according to section 6 1 4 and Elastomere bellows not tightened before starting Fig 7 52 mechanical seal leaks up immediately after Starting up 8 5 Mechanical 5 Rotating seal ring stationary Mechanical seals are wearing parts Install seal leaks after longer seal ring bellows and or seal spare parts If necessary plane surface on period of operation elements worn Slightly impeller for rotating seal ring 0 1 0 2 mm damaged or attacked by If chemical attack check material used chemicals Pump not running evenly Shaft Check shaft for roundness and check rolling banging bearings Only exterior PTFE bellows MS Slightly tighten screws of clamping ring leak between clamping point of seal and shaft sleeve due to creeping of PTFE Page 8 2 NE series 8 Faults causes and remedies Fault Possible cause _ Rectification Single eee seal destroyed spontaneously therefore leaks is and 8 6 3 8 6 4 8 6 5 8 6 6 The pump has run dry i e there is no liquid in the entire pump Hence the sliding faces overheat and are they thermally mechanically destroyed plu
12. Loads Speeds 11 Annex B Admissible Branch Loads Speeds listed can be taken up irrespective of their direction Type series NE Size Bearing Vertical forces Horizontal forces housing Max speed Size Suction Delivery Suction br speed branch branch branch Delivery br Delivery br Delivery br N 579 334 203 149 81 712 401 271 210 129 712 401 271 210 129 712 401 271 210 129 890 467 366 271 176 779 amp 1113 579 4705 353 890 467 366 271 176 1068 579 461 353 230 1068 579 461 353 230 890 1335 712 949 475 1068 579 461 353 230 1424 712 705 664 353 1891 890 949 719 475 1335 2403 1068 1763 922 1891 890 949 719 475 1891 890 949 719 475 1891 1157 1329 1003 678 1891 1157 1329 1003 678 1891 1157 1329 1003 678 2492 1558 1763 1356 922 3783 2047 2305 1763 1180 200 150 400 3115 3115 4895 2492 3525 1763 1750 3783 2047 2305 1763 1180 250 200 400 4450 4895 6675 3783 5016 2440 1750 5340 3 15 3525 2576 1763 Tabelle B 1 Admissible branch loads and maximum speeds for Type NE branch Fy N 40 25 160 ee 3500 50 32 160 beg 3500 50 32 200 ee 3500 50 32 250 wal 3500 65 40 200 a ice 3500 65 40 250 aT 3500 80 50 200 wa ia 3500 80 50 250 ze 3500 80 50 315 ee 1750 2 2 2 1 min Size 100 65 250 oe 3500 125 80 200 a o 3500 12
13. SS AR H Z N IN E N IN y Pe Tey Description Description 412 05 Seal insert O Ring Ring Ring o O Ring 412 12 O Ring 505 Loose collar 412 30 O Rings soz Thrower Fig 4 6 PACIFIC Allpac N 2132 API Plan 54 lower half with pumping thread API Plan 53 Page 4 12 NE series 4 Description of product and accessories 4 6 Special tools The special tools described below are available from the manufacturer 4 6 1 Impeller key Part 051 Only for bearing support sizes O Ill To disassemble and assemble semi open impellers with screw attachment onto the drive shaft it is wise to use a so called impeller key Fig 4 7 The inside of this key is shaped to be a negative of the impeller blades The key is placed on the facing side of the impeller which is then removed from the shaft in the direction of rotation of the pump The shaft must be fixed in order to prevent it turning too Fig 4 7 impeller key part 051 4 6 2 Tensioning tools Part 052 Only for bearing support sizes Ill In order to be able to place the multiple ring Part 501 with zero force behind the threaded stem of the shaft part 210 the stationary seal ring and the shaft wearing sleeve must be displaced in the direction of the coupling against the force of the face plate This is done by using a tensioning tool as shown in Fig 4 8 052 501 475 412 05 524 507 552 2 505 I KA ZN Anl I JE lt a Fig 4 8 Assembly of th
14. channel of the constant level oiler Please take great care to ensure that the cork seal under the glass container of the constant level oiler is exactly central under the edge of the glass and that the glass container is screwed on tight Do not screw it too tight as this will cause the cork seal to slip and this in turn will cause oil to leak The glass container should also never be removed from its holder If an oil level sight glass is installed the oil must be visible in the middle of the sight glass Oil dipsticks must be wetted up to the mark A visual inspection must be performed at regular intervals The oil level being too low oil must be refilled An oil change should be performed annually at least however after 10 000 operating hours The lubricating oils are to be selected according to the ambient temperature In case of ambient temperatures between 0 C and 40 C C LP oils of viscosity class ISO VG 68 100 DIN 51517 part III are used SAE 20 30 For ambient temperatures deviating herefrom the required lubricating oil qualities must in each individual case be agreed with the manufacturer The volumes of oil required are listed below Bearing seat I approx 0 8 litres Bearing seat Ill approx 1 6 litres Bearing seat Il approx 1 0 litres Bearing seat IV approx 2 0 litres i VEOETEELS MATTE TEEE ns eae vn em at l p oR TE 1 TEE en ee ee KR TE SE U f i J J I i F I 1 GEITITITS EM oe en i ee il Af h
15. continuous rinsing in order to rinse the mechanical seal with clean liquid usually water and to keep contaminants away To limit the flow of rinsing liquid the shaft sealing space is equipped with a labyrinth seal towards the inside of the pump Depending on the size of the pump and the contamination of the liquid to be pumped 40 to 250 l h are used for rinsing The flushing quantity is indicated by the manufacturer in the order confirmation For the recommended flushing quantities please also refer to Annex D If for technical reasons the recommended flushing quantities must be deviated from please contact the manufacturer The installation of a liquid quantity meter rotameter in the flushing liquid line is recommended for the correct quantity to be set For the regulation of the flushing liquid flow a valve must be installed The pressure arising during regulation of the flushing quantity must be checked d Rinsing after use Fig 4 2d Rinsing after use is equivalent to continuous rinsing the only difference being that there is no labyrinth seal Stationary rinsing is to be used in those cases where contaminated liquids are to be pumped but where it is not possible to install the continuous flow of rinsing liquid due to system or process constraints It is used to rinse the pump immediately after it has been switched off Stationary rinsing is meant to prevent sedimentation and crystallisation processes in the interior of the pump e
16. direction of rotation on the top of the bearing housing part 350 by the factory Even if the motor runs in the wrong direction for only a short time the ATTENTION pump can be damaged Seite 6 1 NE series 6 Starting u Operation Shutting down 6 1 4 Tightening the WERNERT elastomere bellows The serial shaft seal is a patented WERNERT bellows type mechanical seal with the bellows made of elastomer CSM or FPM The bellows seat Part 482 acc to Figure 7 5 2 is to be tightened only to such a degree that the space between bellows and neck of the sealing insert is sealed A torque of approx 7 5 Nm is specified as reference value With the WERNERT PTFE bellows the tightening torque is approx 15 Nm By means of screws Part 901 76 the hoods removed Part 683 are to be fixed again to the bearing block During cleaning or mounting Ex the hoods or mounting the hoods see to it that there is no static discharge A non conducting material may be charged by friction This must be avoided If leaks occur due to advanced wear of the seal rings the bellows seat should not be tightened If a different shaft seal design has been intended tightening is not possible anyway ONLY FOR WERNERT ELASTOMERE BELLOWS The pump is supplied with a relaxed elastomere bellows so that the pre tension due to longer periods of storage are not decreased For this reason the elastomere bellows must be pretensioned before starting up by tightening the bellows s
17. if the pump is to be switched off for a short period of time 1 The shut down fitting on the discharge side must be closed or reduced to minimum flow close completely after the motor has been stopped 2 The drive machine is switched off ATTENTION Flushing and sealing liquid supply must continue even after the drive machine has been switched off 3 If there is the danger of freezing the liquid to be pumped must be removed from the pump 6 5 Shutting the pump down permanently The following steps must be carried out if the pump is to be shut down permanently 1 The shut down fitting on the discharge side is to be closed or turned to minimum volume after the motor has been switched off it must be closed completely 2 The drive is shut down Seite 6 3 NE series 6 Starting up Operation Shutting down 3 The entire plant systems including the pump must be relaxed and emptied 4 The rinsing and sealing liquid supply must be turned off 5 Ifthe liquid to be pumped tends to crystallise the pump must be rinsed with clean water Seite 6 4 NE series 7 Maintenance Repairs 7 Maintenance Repairs 7 1 Monitoring and maintaining the shaft bearing The pumps are equipped with rolling bearings In case of continuous operation the bearing temperature may be approx 60 C above the ambient temperature If a pump is employed in a potentially explosive atmosphere refer to 2 9 1 above the bearings must be exchanged a
18. in mm Field g Nominal flow rate Q in m3 h Field h Nominal delivery head H in m Field i Nominal speed in 1 min Field k Coupling power with density as per Field nominal drive power each in kW Field Liquid density in kg dm Field m WERNERT mechanical seal code WGC please also refer to Section A 2 Fieldn Mechanical seal materials product side please also refer to Section A 3 Field o Material of the shaft sleeve product side please also refer to Section A 3 eee O WERNERT PUMPEN GMB D 45476 MULHEIM AN DER RUHR Typ NEPO 200 150 250 Fabr Nr 971234 4 vol 3087262 shoe Je E a 36 zu 5 m n 1475 Pl 39 45 kWe 1 12 Figure A 2 Exemplary name plate NO Ww Page 10 1 T e NE Annex A Name Plate 10 1 1 Additional name plate for pumps according to EC Council Directive 94 9 EC Degree of explosion protection 2G TX P ech Doc Equipment group II applies to equipment for application in areas which may be endangered by an explosive atmosphere Except for underground workings of mines and their surface installations which may be endangered by fire damp and or combustible dust Category 2 comprises machines of such a structural design that they can be operated in agreement with the characteristic quantities specified by the manufacturer assuring a high degree of safety Machines of this category are intended for use in areas where an explosive atmosphere of g
19. is installed and operated in conformity with its intended use Information on the intended use can be found in the operating manual The manufacturer herewith declares that the pump type series NE is intended for installation in a machine in this case plant The manufacturer draws attention to the fact that commissioning of the aforementioned pump is prohibited until it has been established that the machine in this case plant in which the pump is to be installed complies with the requirements of Directive 94 9 EC governing equipment and protective systems destined for use in potentially explosive areas as well as of Directive 1999 92 EC concerning the minimum regulations for improving the health and safety of employees who may be endangered by potentially explosive atmospheres Applied Community Directive and harmonised standards Directive 94 9 EC governing equipment and protective systems destined for use in potentially explosive areas If the pump is delivered as a complete unit with motor and coupling this unit complies with the requirements of Machine Directive 98 37 EC EN 13463 1 EN 13463 5 EN 1127 1 Mulheim an der Ruhr 30 06 2003 ppa Christian Wallrodt Engineering and Sales Manager WERNERT PUMPEN GMBH Page 1 2 NE series General 1 4 Technical design The pumps of the NE series are horizontal rotary pumps with axial entry PN 16 as defined by standard ISO 2858 DIN EN 22858 A mechanical seal MS is installed as shaft sea
20. must be selected so that a flow velocity of 2 m s of water or of liquids of the same viscosity is not exceeded Greater losses in pressure due to long pipe lengths or baffles must be avoided The pipe must be completely leak proof pressure test and must not contain any air sacs Horizontal pieces of pipes should have an ascending gradient of at least 1 in the direction of the pump Sharp corners and bends must be avoided in the pipes as is suctioning over the mountain In the case of automatic suction pumps the suction pipe is easier to evacuate if the pump is switched on when the highest possible level of liquid is in the pump sump Gassing liquids should not be pumped in suction operation If in doubt ask the manufacturer 5 3 4 Automatic suction by means of liquid provision attached storage container By attaching a liquid provision system storage container to the pump suction nozzle a normal suctioning rotary pump can evacuate the suction pipe When using an attachment tank with inflammable media to be pumped Ex Dangerous Goods Ordinance Article 4 Dangerousness Characteristics the user must ensure that an explosive mixture can be developed neither in the pump nor in the attachment tank The useful volume of the storage container between bottom edge supply nozzle and top edge outlet nozzle must be at least 50 larger than the volume of the suction pipe Standard storage containers are allocated to the pump models fo
21. of pumps mounted on base plates 5 2 1 Aligning the base plate Before delivery the pump is aligned with the base plate and fixed If due to rough transport the position of the pump to the base plate has changed then the original position must be attained again by referring to the plans Otherwise the pump is aligned to the plant merely by positioning the base plate When installing the plant the base plates must be aligned so that 1 the level of the discharge nozzle is horizontal in every direction For example this can be checked with a machine spirit level 2 Suction and discharge pipelines must be connected with the pump nozzles in such a way that the admissible nozzle loads are not exceeded The admissible nozzle loads are listed in Appendix B The base plate is aligned according to the means of fixing selected for this aggregate There are three ways of fixing possible 1 Simple fixing to the foundations The base plate is fixed to the foundations by means of stone bolts or shear connectors which have been anchored into the foundation beforehand and which project through the corresponding holes in the base plate Before these are tightened the base plate must be aligned using spacers and thin pieces of metal The base plate is aligned in such a way that it is supported by three aligning spacers Each Spacer is positioned on the left and right longitudinal side in the area of the drive the third Spacer is positioned in the area
22. only for one minute at the most The manufacturer s consent is required if it is to be operated with closed shut down fittings for longer periods of time The pump may be started against a closed non return flap 4 The drive is started up 5 Regulators on the discharge side must be opened so far so that nominal flow is achieved Seite 6 2 NE series 6 Starting up Operation Shutting down If during operation it is expected that the shut down fittings on the discharge side will be closed down then a bypass must be installed in front of these and returned to the pump container not to the suction nozzle This is the only way in which overheating of the pump can be avoided If the pump is being switched continuously i e more than 3 switching on processes per hour an auxiliary start up device should be installed star triangle switch electronic smooth start up device hydraulic clutch or similar in order to reduce mechanical strain The use of this type of device depends on the utilisation factor of the machine coupling performance speed switching frequency and should be discussed with the manufacturer 6 3 Operating the pump During operation see to it that due to changes no inadmissible operating conditions may occur These are in particular Delivery side modifications for example by opening or closing valves In this connection see to it that the required minimum volume flow please refer to 4 2 4 is maintained In
23. these operating instructions resp the specific sectional drawing The manufacturer also provides suitable product training upon request Fig 7 2 shows all the individual parts of this pump in the correct order of assembly The tightening torques in Annex C must be maintained 7 3 1 Disassembly of the pump Any work on the machine may on principle be done only with the electric junctions disconnected The pump aggregate must be protected from unintended starting Prior to being dismounted the pump must be decontaminated and neutralized Always wear suitable protective clothing Contact with the liquid being pumped must be avoided under all circumstances When draining the medium pumped make sure to avoid any danger to personnel and environment Statutory provisions must be complied with Fig 7 3 Complete pump aggregate Page 5 Fig 7 4 Disconnect electric motor from power supply Remove safety guard Fig 7 6 Remove intermediate sleeve of the coupling Fig 7 8 Take away hexagon head bolts on bearing bracket Take away caps Page7 6 NE series Maintenance Repairs P bo Fig 7 5 Disassembly coupling between electric motor and bearing housing whilst safety guard is removed Remove cylindrical screw Fig 7 7 Take away hexagon nuts on adapter annular casing and hexagon head bolts on support foot AAN ENNINKRRLLRRKRET it MAA TIITII TTT u _ oF Fig
24. 1 1 1 Lifetime lubricated bearings 7 1 1 2 Grease lubrication with relubrication 7 1 2 Oil lubrication Supply for mechanical seals 7 2 1 Single mechanical seal as defined by section 4 5 1 4 5 2 7 2 2 Back to back mechanical seals DIN EN 12756 as defined by section 4 5 3 7 2 3 Stationary double acting mechanical seals as defined by section 4 5 4 Disassembly and assembly of the pump 7 3 1 Disassembly of the pump 7 3 2 Assembly of the pump Spare parts Faults causes and remedies 8 1 8 2 8 3 8 4 8 5 8 6 8 7 8 8 8 9 8 10 Pump not pumping even though engine is working Flow and or delivery head to small Motor is overloaded WERNERT Elastomere bellows mechanical seal leaks immediately after starting up Mechanical seal leaks after longer period of operation Single mechanical seal is destroyed spontaneously and therefore leaks Pump is destroyed by running in its own juice Pump is destroyed because it was rotating the wrong way Increased bearing temperature Uneven running noises vibrations Associated documentation Annex A Name Plate 10 1 10 2 10 3 Design of the name plate 10 1 1 Additional name plate for pumps according to EC Council Directive 94 9 EC WERNERT mechanical seal code WGC Mechanical seal materials Annex B Admissible Branch Loads Speeds Annex C Tightening Torques Annex D Permanent Flushing Table of contents 7 1 7 1 7 1 7 2 7 3 7 3 73 723 12 7 5 7 11 7 16 8
25. 5 80 250 T 3500 125 80 315 A u 1750 125 100 200 1558 3500 125 100 250 1558 3500 125 100 315 1558 1750 150 125 315 2047 1750 200 150 250 3115 1750 Page 11 1 Type NE Annex C Tightening Torques 12 Annex C Tightening Torques min ima 8 8 9 5 23 Mio 8 8 8 8 8 8 8 8 8 8 8 M20 8 8 8 8 8 8 8 8 min ima Ms amo O Os A2 A4 70 A2 A4 70 A2 A4 70 A2 A4 70 A2 A4 70 A2 A4 70 A2 A4 70 A2 A4 70 A2 A4 70 A2 A4 70 A2 A4 70 A2 A4 70 Table C 1 Tightening torques for screw connections Size of Bearing housing Tightening torque Nm SiO 20 Nm Size 0095 Nm 300 Nm 300 Nm Wellenmutter Table C 2 Tightening torques of the impellers The following applies to the outlet variant The screws for fastening the flange Part 723 and the cap Part 580 must be tightened with a tightening torque of 15 Nm Page 12 1 Type NE Annex D Permanent Flushing 13 Annex D Permanent Flushing The recommended flushing quantity for permanent flushing is listed in Table D 1 These data apply to all material pairings of the mechanical seal however except for SSiC SSiC For the material pairing SSiC SSiC half the flushing quantity of the values stated in the table must be considered A tolerance of 10 is admissible for the flushing quantity a a Type NE to speed 1750 1 min to speed 3500 1 min 40 BE ee 140 140 140 140 80 50 315 to G o O 140 125 80 315 fe 120 120 a 200 150 250 ow
26. 8 NE series 7 Maintenance Repairs Fig 7 22 Fig 7 23 Pull coupling part from shaft end Loosen Remove key Take shaft seal ring off the shaft safety screw first Fig 7 24 Fig 7 25 Remove screws at bearing end cover Take off bearing end cover and O ring Fig 7 26 Fig 7 27 Take shaft seal ring off the shaft Remove the Push shaft with radial ball bearings off the hexagon head bolts from the bearing cover bearing housing by carefully beating against Remove bearing cover the front face of the threaded journal with a plastic hammer Page7 9 Fig 7 28 When the bearing on the side of the motor lies exposed press the circlip together with a round nose pliers and remove it from the nut AAW Fig 7 30 Bearing housing pump shaft with radial ball bearings and circlip bearing covers with O rings and radial shaft seal rings NE series Maintenance Repairs I Fig 7 29 Now the pump shaft with the radial ball bearings can be completely drifted out Fig 7 31 Remove radial ball bearings by means of a removal device The removed shaft nut and circlip are lying beside it Fig 7 32 Loosen hexagon head bolts on the casing part and remove casing part Page7 10 Fig 7 33 Lever the retaining rings on pump casing Remove locking screws beforehand NE series Fig 7 34 Remove pump casing from annular casing 7 3 2 Assembly of the pump Fig 7 35 I
27. ANN SS a N mn RR Riz EEE ur ESEL EEE Rs A h pit ten a f Hn LASSA 475 472 481 4212 L G 41205 443 524 482 a wi vi Ka 7 7 PS am NH f ZWN ERS f 10 BEETE Bari N ERREICHT PERRET EA 7 SSE Sd ON EN 4 hj SIT Be SER Li f ae 4 x BI SS A 4 M ine 7 a i 774 SES A fA l 475 472 481 443 i 552 2 PQ 7 N 83 Nowe TiS SSN PORK 5 EZS I 5 gt RE RR 4 UV NN zz A 77 dA Sa 412 05 524 482 507 505 a EZ EEE TEN TEE EES ad en at AL ee A faq if NEE A AE HR F SS SR A aS ERS 5 Sn N SR u i RSR AKER I 2 A x ERAK RS aOR SANSOM 4 PL ZAKO SAN Be N Bellows seat Multiple ring Loose collar Thrower 524 Shaft wearing sleeve 472 Stationary seal ring 550 Diss o 552 2 Disc Hose coupling Fig 4 2 Representation of single WERNERT elastomere bellows mechanical seal a with interior rinsing product rinsing of mechanical seal API Plan 01 b with interior rinsing product rinsing and quench API Plan 62 c with rinsing connection and flow control continuous rinsing API Plan 32 d with rinsing connection without flow control for rinsing after use stationary rinsing Page 4 6 NE series 4 Description of product and accessories c Continuous rinsing API Plan 32 Fig 4 2c Pumps to pump polluted liquids can be equipped with a rinsing connection
28. Englisch Operating instructions Standard chemical pump of plastic material Type series NE ISO 2858 DIN EN 22858 Also for pumps according to EC Council Directive 94 9 ATEX WERNERT PUMPEN WERNERT PUMPEN GMBH gt Postfach 102153 gt 45421 M lheim an der Ruhr gt B R Deutschland Germany E Mail info wernert de i Internet www wernert de Tel 49 2 08 37 58 0 i Telefax 49 2 08 40 74 72 2006 11 NE series Table of contents 0 Table of contents 0 Table of contents 0 1 1 General 1 1 1 1 Application of the pump 1 1 1 2 Validity of the operating instructions 1 1 1 3 Declarations 1 1 1 3 1 Manufacturer s declaration 1 1 1 3 2 Declaration of Conformity Directive 94 9 EC 1 2 1 4 Technical design 1 3 1 5 Type description 1 3 1 6 Type plate 1 4 1 7 Liability 1 4 2 Safety 2 1 2 1 Marking of hints in the operation manual 2 1 2 2 Personnel qualification and training 2 2 2 3 Dangers in case of non compliance with the safety hints 2 2 2 4 Responsible working 2 2 2 5 Safety hints for the user operator 2 2 2 6 Safety hints for maintenance inspection and mounting operations 2 3 2 7 Unauthorized conversion and spare parts production 2 3 2 8 Inadmissible modes of operation 2 3 2 9 Explosion protection 23 2 9 1 Identifying marking 2 3 2 9 2 Filling of pump 2 4 2 9 3 Modes of operation affecting the explosion protection 2 4 2 9 4 Explosion protection group 2 4 2 9 5 Equipment category 2 4 2 9 6
29. Temperature class 2 5 2 9 7 Temperature limits 2 5 2 9 8 Pumping of inflammable media 2 6 2 9 9 Maintenance 2 6 3 Transport and intermediate storage 3 1 3 1 Transport of pumps and pump aggregates 3 1 3 2 Intermediate storage under normal environmental conditions 3 2 3 3 Intermediate storage under special environmental conditions 3 2 3 4 Longer term storage 3 2 4 Description of product and accessories 4 1 4 1 General description 4 1 4 2 Application limits 4 1 4 2 1 Maximum permissible testing pressure 4 1 4 2 2 Maximum admissible temperature of the liquid pumped 4 1 4 2 3 Admissible temperature range of the environment 4 1 4 2 4 Volume flow of the liquid pumped 4 2 4 2 5 Maximum admissible gas portion of the liquid pumped 4 2 4 2 6 Maximum dimensions of sporadic solid matters in the liquid pumped 4 2 4 2 7 Maximum admissible supply pressure for WERNERT bellows type mechanical seal4 2 4 2 8 Maximum speeds 4 2 Page 0 1 NE series Table of contents 4 3 Construction 4 3 4 3 1 Pump casing 4 3 4 3 2 Impeller 4 3 4 3 3 Shaft and bearing 4 3 4 3 4 Sealing the pump 4 3 4 4 Sectional drawing 4 4 4 5 Designs of mechanical seals 4 5 4 5 1 Single WERNERT elastomere bellows mechanical seal MS 4 5 4 5 2 Single WERNERT PTFE bellows mechanical seal 4 7 4 5 3 Back to back mechanical seals as defined by DIN EN 12756 4 9 4 5 4 Stationary double acting mechanical seal 4 10 4 5 5 General information about double acting mechanic
30. Ue i D ES 2 CLE g7 Kh tae BER RRR ot ad ce KO 5 4 I TE ECE IE RSG EI 4 il 7 EAA NAA 4 ul RR Nig NO Yu vA e Hf E af by UA ERED 3 EA ar 7 3 oo et a EA LA EA E _ 3 ARE NE Pi AGERE RI Sts Zz WA VA VINSON SS 475 472 476 481 443 LIT 482 4 eas a A I Imre TEE COU OOOO ee RESPEC sere sees aed IR oe 4 NPAs Description Description 412 05 o ring SL 477__ Spring for mechanical seal Bellows 482 Bellows seat Multiple ring Loose collar 41232 o ring 507 Thrower 39 Rotating seal ring HE EREES Fig 4 3 Representation of single WERNERT PTFE bellows mechanical seal a with interior rinsing product rinsing of mechanical seal API Plan 01 b with interior rinsing product rinsing and quench API Plan 62 c with rinsing connection and flow control continuous rinsing API Plan 32 d with rinsing connection without flow control for rinsing after use stationary rinsing Page 4 8 NE series 4 Description of product and accessories 4 5 3 Back to back mechanical seals as defined by DIN EN 12756 Back to back mechanical seals as defined by DIN EN 12756 Fig 4 4 are usually used for liquid to be pumped which have virtually no or only a small amount of solid material in them which endanger health water or the environment which would vaporise at a very small increase in temperature or if the pressure is decreased which tend to crysta
31. al seals 4 10 4 6 Special tools 4 13 4 6 1 Impeller key Part 051 4 13 4 6 2 Tensioning tools Part 052 4 13 4 7 Noise emission values 4 14 4 8 Accessories 4 14 4 9 Dimensions and weights 4 14 5 Erection 5 1 5 1 General 5 1 5 2 Erection of pumps mounted on base plates 5 1 5 2 1 Aligning the base plate 5 1 5 2 2 Connecting the pipes 5 2 5 2 3 Aligning the drive 5 2 5 3 Pipes 5 3 5 3 1 General 5 3 5 3 2 Notes on laying pipes 5 3 5 3 3 Suction pipe 5 4 5 3 4 Automatic suction by means of liquid provision attached storage container 5 4 5 3 5 Supply line 5 5 5 3 6 Discharge line throttling bush 5 5 5 3 7 Return flow preventer 5 5 5 4 Additional connections 5 6 5 5 Coupling protection 5 6 5 6 Final inspection and testing 5 6 5 7 Electric connection 5 6 6 Starting up Operation Shutting down 6 1 6 1 Measures to be taken before starting up 6 1 6 1 1 Cleaning and hydraulic pressure test of pipes 6 1 6 1 2 Ensure bearing lubrication 6 1 6 1 3 Checking the direction of rotation 6 1 6 1 4 Tightening the WERNERT elastomere bellows 6 2 6 1 5 Safety devices for the protection of people 6 2 6 2 Starting up the pump 6 2 6 3 Operating the pump 6 3 6 4 Switching the pump off for a short period of time 6 3 6 5 Shutting the pump down permanently 6 3 7 Maintenance Repairs 7 1 Monitoring and maintaining the shaft bearing 7 1 Page 0 2 NE series 10 11 12 13 7 2 7 3 7 4 7 1 1 Grease lubrication 7
32. anical seal is entered by means of a code which always consists of three capital letters The first letter encrypts the general design C Cartridge sealing according to EN 12756 metal free design within the liquid area D Double seal according to EN 12756 back to back design K shape UU E Single acting mechanical seal with stationary spring suspension and secondary O ring seal F Single acting external mechanical seal with rotating PTFE bellows K Single acting mechanical seal with rotating tapered ring R Single acting mechanical seal with rotating spring suspension and secondary O ring seal S Stationary double seal W WERNERT bellows type mechanical seals X Special design The second letter encrypts the manufacturer of the mechanical seal B Burgmann Crane Durametallic WERNERT CSM bellows Merkel Pacific WERNERT PTFE bellows WERNERT FPM bellows The third letter then distinguishes the special designs More detailed information is available from the manufacturer The following codes apply to WERNERT bellows type mechanical seals WERNERT CSM bellows WERNERT FPM bellows WERNERT PTFE bellows Internal flushing WHN wn wm Permanent flushing wp w w _ __ Conditional flushing ws w ws Quench conditional flushing Conditional quench WHA WVA permanent flushing conditional flushing Special design Page 10 3 Type NE Annex A Name Plate 10 3 Mechanical seal materials
33. ases vapours fogs may be occasionally expected Even in case of frequent equipment troubles or fault conditions which are normally to be expected the explosion protection measures of this category of equipment assure the required degree of safety Constructional safety type of protection c is a type of explosion protection where structural measures are taken to assure protection against potential ignition due to hot surfaces Sparks and adiabatic compressions EN 13463 5 Temperature classes Tl T6 of which only temperature classes TI to T4 are currently admitted As the maximum surface temperature mainly depends on the operating conditions heated liquid in the pump refer to temperature limits 2 9 7 above the manufacturer must not provide any designation with a temperature or temperature class EN 13463 1 14 2 g CE Conformity marking Special marking for the prevention of explosions CE amp Il 2 Gc TX 03 ATEX D093 X 2003 o o Baujahr year of construction Reference number of the technical documentation X Year of construction The admissible area of the ambient temperature is 10 C up to 40 C Behind the number of the technical documentation the name plate is provided with the symbol X as an additional marking for the limited ambient temperature Page 10 2 Type NE Annex A Name Plate 10 2 WERNERT mechanical seal code WGC In the field m of the name plate the design of the mech
34. ationary flushing Medium usually industrial water Volume approx 40 litres for a flushing period of 5 minutes minimum 7 2 2 Back to back mechanical seals DIN EN 12756 as defined by section 4 5 3 Medium usually clean filtered water Excess pressure 0 75 x suction pressure 0 25 x max final pressure 1 5 bar suction and final pressure measured at pump nozzle Volume 30 120 litres per hour depending on pump size and speed 7 2 3 Stationary double acting mechanical seals as defined by section 4 5 4 Medium usually clean filtered water Excess pressure 0 75 x suction pressure 0 25 x max final pressure 1 5 bar Suction and final pressure measures at pump nozzle Volume 30 120 litres per hour depending on pump size and speed Page7 3 Repairs 7 Maintenance NE series LE0 206 LE0 026 9 EL 106 QO LoS 90217 10 755 10 026 10755 10 026 OEL Fig 7 2 Exploded view of the individual parts of the pump with single WERNERT elastomere bellows mechanical seal and semi open impeller Page7 4 NE series 7 Maintenance Repairs 7 3 Disassembly and assembly of the pump Disassembly and assembly of the pump are explained in two series of photographs As a standard technical design we have chosen the WERNERT elastomer bellows mechanical seal and the lifetime ball bearings If you are disassembling or assembling a pump with different shaft seals please refer to the drawings in
35. ble of being turned by hand 5 7 Electric connection The electric connection may only be made by an electrical expert The suitability of the motor for the available mains voltage is to be checked against the data on the name plate A suitable circuit is to be selected The employment of a protective motor device is recommended In potentially Ex explosive atmospheres DIN EN 60079 14 must be observed Page 5 6 NE series 6 Starting up Operation Shutting down Starting up Operation Shutting down 6 1 Measures to be taken before starting up 6 1 1 Cleaning and hydraulic pressure test of pipes Before starting the pump up for the first time all foreign bodies which might be left in the pipes from the installation of the pump must be removed screws forging scales welding drops etc Then the pipes are checked for leaks Suction and discharge pipes must be hydraulically tested in accordance with the respective safety instructions Before starting up the pump again after repairs have been made to the pump all broken parts of any kind especially duroplastic or ceramic parts must be removed from the pipelines These broken parts can be caused when the mechanical seal is broken or if components made of Durapox or Wernit break suddenly due to overload or the action of foreign bodies ATTENTION Broken parts or foreign bodies remaining in the pipeline system can cause disastrous damage to the pump or other parts of the
36. cs are to be pumped must not be equipped with a single acting mechanical seal unless the operator due to suitable control systems is in a position to assure that no danger can be brought about by the medium pumped The manufacturer must be contacted Here the use of a double acting mechanical seal is to be preferred The required sealing pressure system must be designed and operated with pressure volume flow and temperature if necessary according to the requirements of the mechanical seal The specification of the sealing medium and the operating instructions for the sealing pressure system must be complied with Note Lubricants and or coolants which are required to avoid explosive hot surfaces here medium pumped or sealing medium to cool and lubricate the mechanical seal or mechanical sparks please refer to prEN 13463 8 must have an ignition temperature please refer to IEC 60079 4 of at least 50K above the maximum surface temperature of the equipment in which the liquid is used prEN 13463 5 2 9 9 Maintenance Only a pump or aggregate appropriately maintained and kept in a technically proper condition assures a safe and reliable operation The relubrication and exchange intervals please refer to 7 1 below of the bearing must be observed by all means The lubrication being insufficient or the bearings defective there is a danger of the maximum admissible surface temperature being Ex exceeded and even of sparking through friction Acc
37. ct this would even be damaging as it can lead to the bearing overheating New grease is applied in the spaces of the bearing cage The grease chambers must only be one third full of grease as too much grease causes the bearings to overheat All known grease manufacturers can supply suitable grease The greases which can be used have the following abbreviation according to DIN 51502 KP 2 K 30 Attributes of the grease Basicoil Mineral oil Basic oil viscosity at 100 C 11 mm s Soap Lithium Calcium Characteristic value of RPM 600 000 mm min Temperature range 30 bis 130 C Worked penetration at 25 C 265 295 Basic oil viscosity at 40 C 100 mm2 s Consistency class 2 Seite 7 1 NE series 7 Maintenance Repairs 7 1 2 Oil lubrication Ex factory the pumps are delivered without oil filling In case of oil lubricated bearings the bearing housing prior to commissioning must be filled through the top filling opening until the oil has reached the middle of the oil level gauge The bearing housing must not be filled with oil beyond this level If preferred the bearing bracket can be equipped with an oil regulator constant level oiler instead of the oil level sight glass Oil must be filled in via the filling port S1 until the oil appears in the screw in element of the tilted oil regulator see Fig 7 1 The oil level of the bearing housing must not exceed this level as ATTENTION otherwise oil leaks at the ventilation
38. dures give correct results In every case the data regarding the alignment accuracy can be found in the operating instructions for the coupling The angle and height of the drive depends on the aggregate supplied and can be adjusted with the help of thin pieces of material or regulating screws After aligning it the drive must be fixed Page 5 2 NE series 5 Erection 5 3 Pipes 5 3 1 General The pipe diameter and the layout of the pipes has usually been determined during the planning stage The recommendations for pipeline layout can only be basic considering that the final laying of the pipes will have to take the specific local situation which the pump manufacturer is usually not aware of into consideration 5 3 2 Notes on laying pipes Make sure that the forces and moments of the pipelines acting on the pump branches do not exceed the admissible branch loads according to Annex B This applies to both the standstill of the plant and its operation The pumps must in particular not serve as a fixed support within the pipeline system If necessary the pipelines must be supported by mounts so that they can neither distort the pump nor vibrate it during operation Any expansions of the pipelines caused by temperature differences and process conditioned impacts must be compensated for by taking suitable measures The installation of compensators in front of the suction and delivery branches of the pump is recommended For any increased flow re
39. e multiple ring Page 4 13 NE series 4 Description of product and accessories 4 7 Noise emission values The A weighted equivalent permanent sound level at a one meter 1 m distance from the reference cuboid according to EN ISO 3744 is below 85 dB A 4 8 Accessories Coupling Flexible coupling with or without intermediate coupling sleeve Protection against accidental contact for coupling Base plate of torsion resistant design of grey cast iron Foundation fastening and or installation Levelling elements stone bolts shear connectors Special accessories according to order 4 9 Dimensions and weights For the data on dimensions and weights please refer to the dimensional drawing and or installation plan of the pump Page 4 14 NE series 5 Erection 5 Erection 5 1 General A careful and proper installation is the prerequisite to a subsequent trouble free operation Installation errors may cause personal injuries and property damages as well as a premature wear of the pump In case of work not done by the manufacturer any liability for improper installation and for the consequences of non compliance with safety technical hints is excluded The EC Council Directive 1999 92 on minimum regulations for the improvement of the health protection and safety of the employees who may be endangered by explosive atmospheres must be complied with The EN 1127 1 Standard is to be observed explosion protection 5 2 Erection
40. e surface temperature is exceeded Due to the inadmissible stress the rapid pressure rise in the pump inside may lead to the destruction and even bursting of the pump The specified minimum volume flow must by all means be maintained please refer to 4 2 4 below Dry running is not admissible In case of dry running or lack of lubrication Ex sufficient lubrication and cooling of the mechanical seal is not possible In such a case the maximum admissible temperature limit may also be exceeded Dry running may be due to an insufficiently filled sealing chamber excessive gas portions in the medium pumped please refer to 4 2 5 below and to operating the pump outside the admissible range of operation When using shut off devices or filters excessive pressure drop on the suction side of the pump must be avoided At high temperatures of the medium pumped or low supply pressures the steam pressure in the sealing chamber may be fallen below As a result hereof a gas ring may be formed around the mechanical seal In addition there is a danger that owing to an insufficient supply pressure air is drawn through the mechanical seal With a single acting mechanical seal both will result in dry running and thus destruction of the pump This may be remedied by inserting a double acting mechanical seal In principle insertion of filters in the suction side of a pump must be strongly advised against The specified pressure and volume flow of additional conn
41. eal ring part 475 using elastic pretension supported by the pumping pressure The static seal of the sealing area is also achieved using the elastic bellows which is positioned between the bellows seat part 482 and the seal insert part 443 a Interior rinsing API plan 01 Fig 4 2a The model with interior rinsing product rinsing is suitable for non critical applications Rinsing holes in the impeller and the conical shape of the seal insert in the area of the stationary seal ring the MS is rinsed with fresh cool liquid to be pumped product b Interior rinsing and Quench API Plan 62 Fig 4 2b In this model a radial shaft ring part 421 2 is built into the bellows seat part 482 on the atmospheric side Together with the rotating seal ring on the product side this creates an area which is supplied with so called quench liquid which is not under pressure Usually clean filtered water or water at moderate temperatures or completely desalinated water is used The quenching liquid is mean to prevent crystals being formed on the atmospheric side of the MS when pumping media which can form crystals is being used This could lead to increased abrasion or if crystals grow the MS can become increasingly leaky In the case of excess pressure between 0 7 and 8 5 bar the flow of quenching liquid is limited to 30 litres per hour by an in built flow limiter The quenching device can provide a certain amount of protection against the rotat
42. ease or oil 8 10 Uneven 8 10 1 Motor aligned badly Coupling Realign motor make sure axial coupling running noises halves are displaced in an axial distance is 5 6 mm vibrations radial angled direction 8 10 2 Coupling packets worn Replace coupling packets 8 10 3 Bearing is damaged Replace roller bearings and shaft seal rings 8 10 4 Not fixed tightly to foundation Tighten fixing screws and anchors 8 10 5 Cavitation Take measure to avoid cavitation reduce volume being pumped increase preliminary pressure reduce losses on suction side Page 8 4 NE series 9 Associated documentation 9 Associated documentation Each pump of the NE series is supplied with these operating instructions Other documentation which describes the pump is not included in delivery as standard The scope of the documentation to be delivered is agreed for each order separately Page 9 1 Type NE Annex A Name Plate 10 Annex A Name Plate 10 1 Design of the name plate The design of the name plate is explained by means of code letters a o WERNERT PUMPEN GMB D 45476 MULHEIM AN DER RUHR w o a Fabr Nr oe HL Je oot ni eK welt Figure A 1 Name plate with code letters Field a Type designation Field b Serial number Field c Impeller Diameter in mm Field d Impeller Blade height in mm Field e Impeller Blade number Field f Possible throttling bush Diameter
43. eat 6 1 5 Safety devices for the protection of people Please ensure that before starting up rotating parts of the pump are not freely accessible Make sure that the protective device to prevent machinery being touched must be attached above the coupling Fig 7 3 as must the spray protection on the bearing housing Fig 7 55 If the pump is driven using belts all respective safety devices must be fixed above the discs and the belts Electrical motors and other devices must be installed in accordance with the currently valid safety regulations refer to 5 6 6 2 Starting up the pump When starting up the pump please follow the following procedures 1 If a flushing or sealing liquid supply is provided same must first be started with the required pressure and volume flow refer to 7 2 2 The supply and suction line as well as the pump body must be filled with liquid A complete ventilation of the pump body sufficient in time must be ensured Ex ATTENTION the pump must not run dry 3 Valves on the suction side must be completely opened Delivery side shut off valves should preferably be slightly opened so that the pump is not operated against a closed valve i e operation at zero delivery However if due to the plant conditions the pump must be started against closed shut off valves this may result in an inadmissible heating of the pump Ex The pump may be operated against a closed shut off valve only during starting and
44. echanical magnetic thermal or chemical influences as well as by explosion Danger to the environment by leakage of dangerous substances 2 4 Responsible working The safety hints mentioned in this operation manual the current national rules for the prevention of accidents as well as any internal working operating and safety regulations of the user must be observed 2 5 Safety hints for the user operator If hot or cold machine parts lead to dangers these parts must be protected by the user against accidental contact at the site according to EN 294 Protection against accidental contact with moving parts e g coupling must not be removed when the machine is in operation Leakages e g of the shaft seal of dangerous substances to be pumped e g explosive toxic hot must be discharged so as not to result in danger to personnel and the environment Legal stipulations are to be observed Dangers by electrical energy are to be excluded for details with regard hereto please refer e g to the VDE regulations and the local energy supply associations If the pumps are used in potentially explosive atmospheres any operating conditions must be avoided which may raise the surface temperature of the pump to an unacceptable degree or lead to sparking Page 2 2 NE series 2 Safety 2 6 Safety hints for maintenance inspection and mounting operations The user shall see to it that all maintenance inspection and mounting operations are perf
45. ections such as sealing Ex flushing liquid etc must be assured by the operator please refer to 5 4 and 7 2 below This applies in particular to quenching and sealing liquid Sufficient cooling and lubrication of the radial shaft sealing ring and the mechanical seal must be assured Lack of lubrication or dry running result in the maximum admissible surface temperature being exceeded and in the destruction of the parts to be lubricated 2 9 4 Explosion protection group Pumps with marking please refer to 2 9 1 above correspond to Group II i e they are provided for employment in explosive atmospheres In this group the employment in underground plants of mines and their above ground plants is excluded 2 9 5 Equipment category Pumps with identifying marking please refer to 2 9 1 above correspond to Category 2G thus they are intended for use in areas where occasional potentially explosive atmosphere of gases vapours and fogs must be expected Page 2 4 NE series 2 Safety 2 9 6 Temperature class As the maximum surface temperature mainly depends on the operating conditions heated liquid in the pump please refer to the temperature limits 2 9 7 the manufacturer may not provide any marking with a temperature or temperature class EN 13463 1 14 2 g Possible temperature classes of pumps with marking according to 2 9 1 as follows Bearing lubrication Medium temperature approved for temperature class Oil lubrication l
46. en up by a feather key connection The shaft is supported outside the transport area in the bearing housing part 350 The rolling bearing can consist of grease or oil lubrication and is protected by a bearing cover and bearing end cover parts 360 and 361 with inserted shaft seal rings parts 420 As standard version we have installed life time ball bearings If requested the pumps can also be provided with bearings for regreasing Additional grease is added via the grease nipples parts 636 Oil lubrication is installed upon customer request or if the temperature of the medium to be pumped is greater than 100 C As standard version we use an oil level sight glass part 642 for level monitoring Alternatively the oil level can be regulated by means of a constant level oiler which will be mounted at the side of the bearing housing part 350 4 3 4 Sealing the pump The shaft is sealed using a mechanical seal MS Depending on the application a number of seals are used These are described in more detail in section 4 5 The mechanical seal is taken up in every case by the seal insert part 443 which also seals the pump casing via the O ring part 412 04 Discharge and suction nozzles are also sealed using O rings parts 412 01 and 412 03 Gaskets are used in the WERNIT version Additional static seals are installed in the area of the mechanical seal and depend on its design Usually FPM is used for the O rings Page 4 3 NE series
47. er or any third party natural wear and tear incorrect or negligent treatment unsuitable operational equipment exchange materials defective construction work unsuitable subsoil chemical electro chemical or electric influences unless attributable to a fault of the supplier s Page 1 4 NE series 2 Safety 2 Safety This operation manual contains basic hints to be observed during installation operation and maintenance Therefore prior to mounting and commissioning this operation manual must by all means be read by the fitter as well as the responsible expert personnel user and must always be available at the place of installation of the machine plant Not only are the general safety hints listed under this Section Safety to be observed but also the special safety hints added to the other sections 2 1 Marking of hints in the operation manual The safety hints contained in this operation manual which in case of non compliance may cause danger to personnel are particularly marked with the general danger symbol Safety sign according to DIN 4844 W9 in case of warning against electric voltage with Safety sign according to DIN 4844 W8 When employed in potentially explosive atmospheres the safety hints to be additionally observed are marked with x Pumps which corresponding to EC Council Directive 94 9 are employed in potentially explosive atmospheres must be marked with this symbol and the CE sign on the name p
48. fter a maximum of 16 000 operating hours Bearings must be regularly checked and or controlled to avoid the risk of an ignition If the pump is not employed in a potentially explosive atmosphere the bearings must be checked and exchanged if necessary after approx 16 000 operating hours at the latest however after three years Insufficient lubrication may lead to an inadmissible temperature increase Due to an excessive wear it leads to a reduction of the service life through to the destruction of the bearings The limitation of the temperature class due to the kind of lubrication must be observed please refer to 2 9 6 above 7 1 1 Grease lubrication Unless otherwise specified lifetime lubricated bearings are provided Regreasable bearings may optionally be selected 7 1 1 1 Lifetime lubricated bearings The lifetime lubricated grooved ball bearings are serially designed with guard disks on both sides The bearings sealed on both sides are lifetime lubricated and maintenance free Therefore prior to installation they should by no means be heated to above 80 C or rinsed The grooved ball bearings are filled with standard lubricating greases The lubricating grease has good anti corrosive properties and contains lithium soap as thickener 7 1 1 2 Grease lubrication with relubrication Bearings lubricated using grease are filled with suitable grease at the manufacturer s It is not necessary to re lubricate before starting up in fa
49. hat the protection against mechanical and climatic stresses is sufficient The suction and delivery side pump openings must be kept closed The condition of the packing wooden box packing film and the like must be checked regularly at least once a year and repaired as required When using moisture binding agents these must be exchanged at least once a year Uncovered pump components such as shaft and coupling must be provided with an anti corrosive paint Prior to starting any pumps which have been stored for an extended period of time the condition of the bearing grease or oil must be checked After a storage period of two years the lubricant of the bearing must be generally exchanged Under climatic conditions of a low humidity the elastic properties of bellows and sealing elements of elastomer materials such as FPM or CSM may be reduced The replacement of these parts after several years of storage is then required Page 3 2 NE Series 3 Transport and intermediate storage If the pump remains out of operation for a minimum period of six months the pump shaft must be turned into a different position every three months by several manual rotations so as to avoid any pressure marks on the rolling bearings The mechanical seal has to be checked after two years Page 3 3 NE series 4 Description of product and accessories 4 Description of product and accessories 4 1 General description Pumps of the NE series are horizontal rotat
50. hh dk de Miete de fill de air refill drain off Fig 7 1 Oil lubrication and constant level oiler Page7 2 NE series 7 Maintenance Repairs 7 2 Supply for mechanical seals The appropriate rinsing and sealing liquid volumes and pressures have been listed below Section 4 5 contains detailed descriptions about the different types of mechanical seals In every case the information on the order confirmation or the data sheets is decisive as the values listed below are for guidance only When selecting quench rinsing and sealing media compatibility with the fluid to be pumped must be ensured Rinsing liquid requirements for the mechanical seal The liquid has to be selected in accordance to the expected environment temperature in order to prevent freezing of the fluid The chemical resistance of the blocking system of the sealing media must be taken into consideration 7 2 1 Single mechanical seal as defined by section 4 5 1 4 5 2 a Interior rinsing No exterior supply necessary b Interior rinsing with quench Medium usually clean filtered water Excess pressure 0 7 to 0 85 bar before flow regulator Volume 30 litres per hour will adjust itself c Continuous rinsing Medium usually clean filtered water Volume 70 400 litres per hour depending on the size of the pump 20 115 LPH liters per hour possible for SSIC SSIC mechanical seal arrangement In this case the sealing area is not rinsed completely d St
51. ial pressure which can be achieved in the pump with decreasing pumping flow plus the supply pressure pressure at the pump suction nozzle If the pump is not working it must be ensured that the pressure of the sealing liquid is higher than the interior pressure of the pump so that no liquid to be pumped reaches the sealing chamber If the sealing chamber is equipped with its own sealing aggregate with limited sealing liquid volume the sealing liquid must be forcibly cooled and circulated In this case the circulation of the sealing liquid flow is supported by a pumping thread in the mechanical seal If the sealing chamber is supplied with sealing liquid with the appropriate excess pressure and if the sealing liquid can flow freely from the sealing chamber the liquid flowing off must be throttled in order to maintain the excess pressure in the sealing chamber Page 4 10 N E series A 4 Description of product and accessories SCID be hee ee A C l Fal er ial ae BEN NS i pz lan vA Ly er ar a a A A A AMON NL a YT ET Vz dddi N NES rin f ESSARY j lye a L y IR 19 562 NW Si EHH DMT Page 4 11 NE series 4 Description of product and accessories A VIII III I PO TLTLLLL W 42 Sass i A RE ee Am NASEN ii 412 06 _ T SS 412 12 Oy 505 EN ZEN IR SAIN DRS Nee
52. ing seal rings overheating in the case of a vacuum in the shaft seal space This vacuum can be caused by high suction losses or suction heights ae The quench liquid should drain off freely If it is drained off through a S pipe the pressure built up in the quench chamber must not exceed 0 5 barg Too high a counter pressure will destroy the shaft seal ring Another quench type is the conditional quench where the supply is ensured via a quench tank with connected hose lines to the mechanical seal of the pump The temperature difference between supply and return line of the conditional quench tank results in different liquid densities The liquid columns of different heights resulting therefrom lead to a circulation of the quench liquid The conditional quench tank should be filled to three quarters The filling level must be checked regularly Page 4 5 NE series 4 Description of roduct and accessories ILE N 7 ar 3p A Ted kh3 PEATA ye RE KX oy as N N Y 12277 77 CCC CAS S SERA Scere L ae RI SM Md eter Ovary ER SSSI SESH NR F ATS 472 181 443 4 12 05 524 ASS SS Yo LZA Bl 412 05 412 06 412 09 421 2 443 472 475 481 En rae ae eae EZ F ET SEES TS RRT RIR py ET EERE RE ase Description 482 501 505 Radial shaft seal ring 507 Seal insert 524 Rotating seal ring Bellows 739 LASS AR Qe
53. ioned Page 14 Fig 7 56 Push rotating seal ring onto shaft insert multiple ring using special tool part 051 and remove assembly aid NE series 7 Maintenance Repairs Fig 7 57 Screw semi open impeller with inserted O ring onto shaft and tighten with special tool part 051 Fix shaft beforehand gt z 4 Fig 7 59 Tighten hexagon nuts on bellows seat following instructions section 6 1 4 Avoid excessive tightening d 5 Fig 7 61 Empty pump If the pump is to go into storage loosen hexagon nuts on the bellows By loosening the nuts the bellows is keeping its elasticity Page 15 Fig 7 58 Insert back pull out unit into pump casing and screw it to annular casing using locking screws and hexagon nuts Fig 7 60 Close pump nozzles tightly Perform leakage test Fig 7 62 Assemble caps NE series 7 Maintenance Repairs 7 4 Spare parts On principle replacement parts should only be ordered according to a parts list belonging to the pump stating the identification number of the part and or the serial number of the pump On principle every individual part can be supplied Standard parts are always in stock at the manufacturer s or his representatives and this guarantees short delivery periods However we recommend that the client should also keep the parts listed below in his stores All parts of the mechanical seal i e for the single WERNERT elas
54. l Pump sizes NE 40 25 160 and NE 250 200 400 have been designed based on ISO 2858 DIN EN 22858 trans standard pumps The dimensions f and w of pumps with torque flow design hydraulic design identification F do not comply with the standard ISO 2858 DIN EN 22858 They are longer in the axial direction other dimensions are identical The letter D is added to the type designation of pumps equipped with throttling bush e g NEPO 50 32 160 D This throttling bush which is not part of the pump is centrally positioned on the delivery connector and secured between pump and the piping to be connected 1 5 Type description The type description is made up of a four letter code and the size as defined by standard ISO 2858 DIN EN 22858 The letter D is added to the type designation of pumps equipped with throttling bush please refer to 1 4 and 5 3 6 Ist and 2nd letter Series identification here NE 3rd letter Main material A PTFE antistatic or PFA antistatic B Polypropylene PP E epoxy resin bound special moulding compound Durapox K Polyvinylidenfluoride PVDF L UHMW PE antistatic P ultra high molecular low pressure polyethylene UHMW PE T Polytetrafluorethylene PTFE or Perfluoralkoxy PFA W reinforced mineral cast Wernit 4th letter Hydraulic design F semi open impeller in torque flow model G closed impeller with sealing strips O semi open impeller S closed impeller with front and back va
55. late please refer to Annex A For safety hints non compliance with which may cause danger to the machine and its functions the word Hints directly attached to the machine such as rotation arrow sign for fluid connections must by all means be observed and maintained in completely legible condition Page 2 1 NE series 2 Safety 2 2 Personnel qualification and training The personnel for operation maintenance inspection and mounting must have the corresponding qualification for these operations Range of liability competence and the supervision of the personnel must be exactly defined by the user If the personnel do not have the required knowledge same must be trained and instructed If required this may be effected by the manufacturer supplier on behalf of the machine user In addition it must be ensured by the user that the contents of this operation manual and the operation manuals of the plant are fully understood by the personnel 2 3 Dangers in case of non compliance with the safety hints Non compliance with the safety hints may result not only in danger to personnel but also to environment and machine Non compliance with the safety hints may lead to the loss of any claims for damages In detail non compliance may for example entail the following dangers Failure of important functions of the machine plant Failure of specified methods for maintenance and servicing Danger to personnel by electrical m
56. ler cross section in the delivery branch The working point of this pump has been designed with a throttling bush therefore the pump must be operated with ATTENTION the same In case of changes to the cross sectional area of the throttling bush considerable damages to the pump must be expected 5 3 7 Return flow preventer A return flow preventer must be arranged above the delivery branch of the pump so that during commissioning the pump is safely filled with the medium pumped even if an air cushion is formed in front of the return flow preventer Page 5 5 NE series 5 Erection 5 4 Additional connections For the dimensions and position of the additional connections required for the pump sealing liquid flushing liquid etc please refer to the installation plan ATTENTION These connections are decisive for the function and must therefore be properly attached The required volume flows and pressures are to be set please refer to 7 2 below 5 5 Coupling protection The pump may only be operated with a suitable coupling protection Due to its strength distance to the coupling and material a coupling protection contained in the scope of supply of an aggregate corresponds to the employment in a potentially explosive atmosphere 5 6 Final inspection and testing The alignment according to Item 5 2 above as well as the proper distance of coupling and coupling protection are to be checked At the coupling the shaft must be capa
57. llisation A single mechanical seal is installed back to back on the product side and atmospheric side The so called sealing chamber is situated between the two pairs of mechanical seals Usually the seal rings on the product side are secured against inadmissible axial and radial movement For further information about double acting mechanical seals please refer to section 4 5 5 ASSIA ES S z N ENS fa WH i I h Fa aa Mig Mg Pes es aaia a aia 412 07 Part No Loose collar Ei Part No 52a 528 543 Description 412 07 _ O Ring 5241 Shaft wearing sleeve 412 08 O Ring 5242 Shaft wearing sleeve Mechanical seal Locating collar 528 443 seal insert 543 Spacer bush 76 552 2 01 4 A 552 2 spanner Fig 4 4 Diagram of a back to back mechanical seal as defined by DIN EN 12756 API Plan 54 lower half with pump thread API Plan 53 Page 4 9 NE series 4 Description of product and accessories 4 5 4 Stationary double acting mechanical seal Stationary double acting mechanical seals are usually used for problematical liquid to be pumped which have a medium to high solid content which contain a high proportion of gas or air which endanger health water or the environment which would vaporise if the temperature increased only slightly or if the pressure was reduced which tend toward crystallisation
58. mbering comply with DIN 24250 4 3 1 Pump casing The solid pump casing is made of plastic material part 101 and is completely enclosed by a metal annular casing part 103 Suction and discharge nozzle are fixed to this pump casing The suction nozzle is supported by a two part retaining ring part 506 2 the discharge nozzle is supported by the casing part part 130 and therefore fixed into the annular casing The pump can be designed with an outlet in the area underneath the suction nozzle This is either closed with a cap or equipped with a valve 4 3 2 Impeller Semi open wheels are used as impellers part 233 Semi open impellers are also suitable for transporting media containing solids The material used is solid plastic The torque of the shaft is taken up by a metal hub pressed into the impeller The impeller is fixed on the shaft in an axial direction by the multiple ring part 501 Closed impellers can also be used in special cases Closed impellers are used on standard designed pumps size IV 4 3 3 Shaft and bearing In general the impeller is connected with the metal shaft part 210 via a thread In the sealed area the shaft is protected by a shaft wearing sleeve part 524 which is either made of carbon or a ceramic material This shaft wearing sleeve is tensioned with the rotating seal ring part 475 via a spanner part 552 2 which is situated between thrower part 507 and loose collar part 505 The shaft s torque is tak
59. nes X Special hydraulics Example A pump of size 200 150 250 as defined by DIN ISO 2858 DIN EN 22858 with semi open impeller material UHMW PE is described as type NEPO 200 150 250 Page 1 3 NE series General 1 6 Type plate Every pump has a type plate attached to it It lists the following details Name and address of the WERNERT company as manufacturer Type description Serial number of the pump Impeller diameter impeller blade height and number of blades Diameter of a possibly used throttling bush Designed volume flow m h and associated delivery head m Necessary coupling power and nominal power of driver kW Nominal speed Density of the liquid to be pumped Data regarding the mechanical seal used The additional name plate for a pump according to EC Council Directive 94 9 ATEX contains the following data Marking for the potentially explosive atmosphere with equipment group equipment category type of protection and temperature class TX and as additional marking the symbol X for the limited ambient temperature of 10 C Ta 40 C Tech Doc Manufacturer s reference number for the Technical Documentation Year of construction Explanations regarding the name plate can be found in Annex A to this operation manual 1 7 Liability No warranty is furnished for any damages due to the following reasons Unsuitable or improper use incorrect mounting and or commissioning by the custom
60. nsert pump casing into annular casing er In ARE N HR Me Si SR va J l Fig 7 37 Insert O rings into nuts on suction and discharge nozzle Slide pump casing under the discharge nozzle and screw it on Attach all studs Page7 11 7 Maintenance Repairs Fig 7 36 Insert retaining rings on suction nozzle then tighten locking screws Fig 7 38 Slide circlip over the antinode heat radial ball bearings and pull them onto shaft In case of grease lubrication sealing discs must point inwards Lubricate bearings according to operating instructions 7 Maintenance Repairs NE series Fig 7 39 Slide lockwasher onto shaft Tighten shaft nut with spanner Lock shaft nut and lockwasher Fig 7 41 Push shaft into bearing housing Press circlip together with a round nose pliers and insert it into nut in bearing housing Fig 7 40 Bearing housing pump shaft with radial ball bearings and circlip bearing covers with O rings and radial shaft seal rings Fig 7 42 When the shaft has reached its stop screw the bearing end cover with O ring onto bearing housing Fig 7 43 At bearing end cover slip radial shaft seal ring over shaft Grease lip of radial shaft seal ring beforehand For exact positioning use a special tool if necessary Page7 12 Fig 7 44 Fit bearing cover with inserted O ring into bearing housing and screw it on Oil groove must be orientated down
61. o OO EEE 7 DE Lo o o o o 200 150 400 250 250 200 400 250 Table D 1 Required flushing quantity for one or both parts of the mechanical seal of carbon Page 13 1
62. of the pump on the short side If the base plate is longer than 1600 mm more spacers might be necessary The exact height should be achieved using pieces of thin metal of different thicknesses 2 Fixing on foundations with subsequent casting The base plate is fixed to the foundations by means of stone bolts or shear connectors which have been anchored into the foundation beforehand and which project through the corresponding holes in the base plate Before casting the base plate must be aligned using Spacers and thin pieces of metal as described in 1 The foundation screws are tightened once the casting mass has hardened 3 Erection on levelling elements without foundation The position of the base plate is adjusted using levelling elements The pump aggregate is supported above the floor on oscillation absorbers No foundation screws are necessary Page 5 1 NE series 5 Erection The above three types of fixing are suitable for all pumps of the NE series supplied on base plates Pumps of Type NE supplied on base plates are in principle suited for all three fastening types mentioned above If the pump aggregate is installed isolated as is the case for example with the foundation free installation a separate earthing is to be provided in order to avoid potential differences 5 2 2 Connecting the pipes Before aligning the drive the pump must be connected to the pipes making sure that the pipes do not twist the pump The admissible no
63. on Qmax according to characteristic diagram In case of a deviating working point please contact the manufacturer 4 2 5 Maximum admissible gas portion of the liquid pumped Gas portions in the liquid pumped are only permissible after consulting the manufacturer Gas portions in the liquid pumped reduce the capacity and the delivery head of the pump 4 2 6 Maximum dimensions of sporadic solid matters in the liquid pumped The dimensions of sporadic solid matters in the liquid pumped must not exceed the dimension of half the blade height and or half the nominal delivery branch diameter whatever dimension is smaller 4 2 7 Maximum admissible supply pressure for WERNERT bellows type mechanical Seal The maximum admissible excess pressure at the suction branch of the pump with a WERNERT bellows type mechanical seal depends on the material of the bellows and the speed of the pump Bellows material Speed up to 1800 1 min Speed over 1800 1 min CSM 2 bar FPM 2 bar PTFE 4 2 8 Maximum speeds The maximum admissible speed must not be exceeded by mechanical transmission ratios or the employment of a frequency converter For the maximum admissible speed for the respective pump size please refer to Table B 2 of Annex B Page 4 2 NE series 4 Description of product and accessories 4 3 Construction Fig 4 1 shows a pump of the NE series in section which is representative for all sizes The naming of the individual parts and the nu
64. ording to the environmental conditions the bearing bracket must be cleaned at suitable intervals Proper functioning of the mechanical seal and the supply of the additional connections please refer to 5 4 and 7 2 below must be assured by the user through regular controls Page 2 6 NE Series 3 Transport and intermediate storage 3 Transport and intermediate storage 3 1 Transport of pumps and pump aggregates Pumps and pump aggregates must always be transported in such a way that the pump parts are not subjected to impact or shock Figs 3 1 and 3 2 show possible points at which lifting gear can be attached during transport of an individual pump and during transport of a pre assembled pump aggregate Fig 3 2 Transport of a pump aggregate Page 3 1 NE Series 3 Transport and intermediate storage 3 2 Intermediate storage under normal environmental conditions Under normal environmental conditions i e within a temperature range of 10 C to 40 C Special provisions need not be made for an intermediate storage By closing the pump openings with sealing caps or dummy flanges it must be assured that pollutions or foreign bodies in lumps are prevented from getting into the pump housing The pumps must be placed in an intermediate storage so as not to be exposed to any shock or impact stresses If this cannot be excluded the pumps should be protected by means of solid wooden packings The pumps should likewise not be exposed to an
65. ormed by authorized and qualified expert personnel who have sufficiently informed themselves by thoroughly studying the operation manual The pump must have taken ambient temperature and be depressurized and emptied Pumps pumping media injurious to health must be decontaminated Basically operations at the machine may be performed during standstill only The procedure for stopping the machines described in the operation manual must by all means be observed Immediately upon completion of the operations all safety and protective devices must be mounted and or made operational again Prior to restarting the items listed in Section Initial operation must be observed 2 7 Unauthorized conversion and spare parts production Conversion of or changes to the machine are only admissible on consultation with the manufacturer Original spare parts and accessories authorized by the manufacturer serve safety purposes The use of other parts may cancel the liability for the consequences resulting therefrom 2 8 Inadmissible modes of operation Safe working conditions of the machine supplied is ensured only in case of intended use in line with this operation manual The service limits specified in order related documents and under Item 4 2 below must by no means be exceeded or fallen below Order related documents shall prevail 2 9 Explosion protection If pumps are used in potentially explosive atmospheres it is imperative to comply with the Ex meas
66. ory pumps as defined by standards ISO 2858 DIN EN 22858 chemical pump standards using the process design This makes it possible to quickly remove or exchange the complete bearing support with running gear and shaft gasket without having to disassemble the pipeline connections and the motor The parts which will be covered with liquid are made of plastic materials or other suitable materials the respective chemical thermal and mechanical stresses were decisive in their selection All statical parts made of plastic materials have been surrounded in metal or are supported by metal The standard version is equipped with a semi open impeller without covering disc the special version can also be equipped with a closed impeller with covering disc The standard version of size IV is equipped with a closed impeller The axial thrust for semi open impellers will be reduced by back vanes and for closed impellers by sealing elements Usually a WERNERT bellows mechanical seal is used as a shaft seal For special applications mechanical seals by other manufacturers can also be used 4 2 Application limits 4 2 1 Maximum permissible testing pressure Static pressure is determined according to ISO 2858 DIN EN 22858 as 1 3 to 1 5 times the maximum delivery pressure and can be used up to the temperature stated in section 4 2 2 The admissible testing pressure depends on the version of the mechanical seal in this case the manufacturer should be consulted
67. plant 6 1 2 Ensure bearing lubrication a Bearings lubricated with grease Bearings are lubricated with suitable grease before delivery ATTENTION It is not necessary to re lubricate before starting up in fact this could cause damage as too much lubrication can cause the bearings to overheat b Oil lubricated bearings Before starting up the system the bearing housing must be filled with oil Filling with oil is effected as described in Section 7 1 2 below Operation of the pump with insufficient lubrication of the bearings leads to ATTENTION the maximum admissible temperature of the surface being exceeded through to sparking caused by friction 6 1 3 Checking the direction of rotation Pump aggregates with intermediate sleeves are supplied in an uncoupled state To do this the cam plate of the coupling is unscrewed but still projects into the packet part of the coupling The screws are on the inside of the intermediate sleeve which must be removed before the direction of rotation is checked Pump aggregates without intermediate sleeves are if possible also supplied in an uncoupled State Only check that the direction of rotation of the motor is identical to the direction of rotation of the pump in an uncoupled state Please ensure that the motor has been cut off from the electricity supply when the intermediate sleeve is being removed and re installed ATTENTION Each pump has been given an arrow to indicate the
68. r rests fully on a level surface and is properly secured 5 3 5 Supply line The supply line is to be laid with a constant inclination towards the pump suction branch and should never be smaller than the suction branch of the pump The cross section of the supply line must be selected so that a flow speed of 2 5 m s in case of water or liquids of the same viscosity is not exceeded For repair purposes the installation of a shut off valve at a sufficient distance to the suction branch approx 2 to 3 times the pipeline diameter is recommended which must be completely opened during the operation of the pump The shut off devices in the supply and or suction line are to be arranged so that according to the valve design no air pockets may be formed The control of the flow rate may only be effected by control instruments in the discharge line To avoid increased flow resistances additional instruments which must be installed should have the nominal diameter of the supply line Sharp edges and bends are to be avoided 5 3 6 Discharge line throttling bush The discharge line should not be smaller than the delivery branch of the pump In addition the diameter depends on economic aspects however the flow velocity should not be selected above 5 m s A shut off and or control instrument is to be installed as close as possible to the pump Pumps whose type designation bears the supplementary letter D e g NEPO 80 50 315 D are designed with a smal
69. r the following suction ratios Overall length stretched length of suction pipe 5 m Nominal width of suction pipe according to nominal width of the suction nozzle Maximum geodesic suction height 3 m Page 5 4 NE series 5 Erection If the volume of the suction pipe and or the geodesic suction height is larger than the above figures the storage containers must be adapted to suit the suction conditions When suctioning via the storage container the pump should be equipped with a reflux valve refer to 5 3 7 below on the discharge side in order to avoid the pump and container emptying by siphon effect once the pump has been switched off Prior to initial start up or after draining the attachment tank must be filled up with liquid at the filling opening Thereafter the filling opening must be closed gas tight In addition it must be assured that the suction line is sufficiently vacuum resistant Pipes which are to be connected to the attached storage container must be secured without tension They must be supported by brackets or retainers The pipes must not apply any forces or moments to the container and connectors The attached storage container must be connected as close to the pump as possible If possible pump and attached storage container should be mounted on a common base plate If the attached storage container is not placed on the base plate care must be taken to ensure that the bottom of the attached storage containe
70. s frequently plastic parts nearby such as impeller and bellows are destroyed by the heat so called running hot Semi running dry in case of i e even though a liquid with the it does not reach the Stall ring is rotating impeller interior sliding faces Therefore the seal runs hot Due to increased gas particles in liquid being pumped a gas ring is formed around the rotating and stationary seal rings This the Sliding surfaces by the excess the pump Therefore the seal runs hot The pumped at boiling temperature the temperature in the seal gap due gas is pressed through pressure on liquid is virtually being Due to increase in to friction and simultaneous decrease in pressure the liquid being pumped evaporates in the seal gap Possible crystals in the liquid might crystallise out Therefore the seal runs hot High pressure losses on the suction side due to blockage or throttled fittings cause a low pressure at the mechanical seal Air is the atmosphere through the sliding sucked from surfaces Seal runs hot Due to pressure losses on the suction side due to increased volume of liquid being pumped with decrease on pressure nozzle simultaneous pressure causes low pressure in the area Air is sucked from the atmosphere of the mechanical seal through the sliding areas Seal runs hot Running dry is a typical operating error The pump must be filled completely and de aired before it is s
71. sistances to be avoided compensators should have the nominal diameter of the respective pipeline The pipeline forces being exceeded leaks may be caused at the pump resulting in the penetration of the medium pumped Danger of life in case of toxic or hot media pumped Inadmissible deformations may furthermore result in problems at the mechanical seal Tightening connection screws on the pump flanges may not cause any twisting Up to and including DN 125 the torque should be approx 35 Nm and above that up to and including DN 250 approx 70 Nm for each screw When laying and connecting the pipes care must be taken that seals do not project into the clear diameter Fig 5 2 shows the correct arrangement on the left hand side and the incorrect arrangement on the right hand side SEESSESSSSERBESSSSSESESSESZSESSSESS correct incorrect Fig 5 2 Connection of pipelines ATTENTION The alignment of the drive to the pump must be checked and if necessary corrected after the pipes have been connected and before starting up Page 5 3 NE series 5 Erection 5 3 3 Suction pipe The suction pipe should be as short as possible and its diameter should never be smaller than that of the suction nozzle If the suction pipe is larger an eccentric transition with synchronous upper edge which prevents the formation of air sacs must be used Fig 5 3 Fig 5 3 Transition between suction pipe and pump suction nozzle The diameter of the suction pipe
72. specially in the area of the mechanical seal as during longer Standing periods the rotating seal ring and the stationary seal ring can stick together Rinsing volume is 40 for a rinsing period of 5 minutes minimum Normal industrial water can be used for rinsing 4 5 2 Single WERNERT PTFE bellows mechanical seal If the fluid excludes the use of bellows made of elastomeres PTFE bellows mechanical seals can be used Fig 4 3 shows WERNERT PTFE bellows mechanical seals which can be used in place of elastomere bellows without any constructional changes being made to the seal insert The function and action of the models shown in Figs 4 3a to d are equivalent to the single WERNERT elastomere bellows mechanical seals shown in Fig 4 2 and described in section 4 5 1 Page 4 7 NE series 4 Description of product and accessories En i ee r 7 by 4 Ee Ree tt Vise SE N A By 7 N Eoy 44 Ley EA eA reat a Wee CRRA RI N iS Ball Dr ANN NNNINANLS SANT LIS 472 474 481 443 477 482 1412 05 412 23 524 412 22 421 2 507 N AA AN N iS SH 05 TAN AN PP L T BN Seas WW Peer AN TF PEt VA EAA N ay Hizi e r Yl ON NN 5 LAREN IK G 4 N Be ae AI baz am lass MY RRR RR 45 gt SE SRNR ARR Z Cat 7 RRKT a ee EK RHE NS RRR RS A RER VV RE x oe NG Se Na NY 505 Ae y EZEL L E 8 A U oo 7 UNS NE eK SINN ER ij j Ya 2 Ses fg Ns A
73. t 160 C T3 Grease lifetime Iubricated lt 160 C Grease with relubrication lt 160 C Oil lubrication 100 C Grease lifetime lubricated lt 100 C Grease with relubrication lt 100 C 1 The maximum admissible medium temperatures on the basis of the material of the pump housing and the bellows please refer to 4 2 2 below are to be observed The type of the bearing lubrication can be taken from the piece list or can be inquired at the manufacturer s by indicating the serial number 2 9 7 Temperature limits The operation of the pump outside the admissible ambient temperatures is not admissible please refer to 4 2 3 below The maximum admissible temperature of the liquid pumped depends on the respective specified temperature class and the material of the pump housing and or mechanical seal please refer to 4 2 2 below Depending upon the material the maximum admissible temperature of the liquid pumped may be below the following values Temperature class as per EN 50014 for Maximum temperature electric equipment of Group II temperature C of the liquid pumped C Tab 2 1 Temperature classes Please contact manufacturer The admissible temperature class depends on the lubrication of the bearing please refer to temperature class 2 9 6 Page 2 5 NE series 2 Safety 2 9 8 Pumping of inflammable media Pumps by means of which inflammable media Dangerous Goods Ordinance Article 4 Dangerousness Characteristi
74. tarted up Fittings on the suction side must be completely open Train personnel accordingly Repair pump Take interrupted measures to prevent flow being Install automatic monitoring device Train personnel Repair pump Equip single mechanical seal with continuous rinsing or if necessary install double acting mechanical seal Calm liquid being pumped Prevent water spout by using guiding crosses Lengthen circulating times Make de gassing possible Repair pump Equip single mechanical seal with continuous rinsing or if necessary equip with double acting mechanical seal Repair pump Equip single mechanical seal with continuos rinsing or possibly equip with double acting mechanical seal Minimise losses on suction size Train personnel accordingly Possibly decrease diameter of vane on the back of the impeller Equip single mechanical seal with quench or possibly equip with double acting mechanical seal Throttle pressure side fittings in order to get into the admissible operational range Train personnel accordingly Repair pump Possibly decrease diameter of vane on the back of the impeller Equip single mechanical seal with quench or possibly equip with double acting mechanical seal Page 8 3 NE series 8 Faults causes and remedies Fault Possible cause Rectification 8 7 Pump is 8 7 1 Pump running in its own juice After starting up pump open fittings on destroyed by running i e
75. termined whether the machine here plant into which the above mentioned pump s is are to be installed conform s with the EU directive Machines 98 37 EC Applied harmonised standards EN 292 Parts 1 and 2 DIN EN 294 DIN EN 394 EN 809 DIN EN 12162 DIN EN 1050 DIN EN 22858 Mulheim an der Ruhr 30 06 2003 ppa Christian Wallrodt Engineering and Sales Manager WERNERT PUMPEN GMBH Page 1 1 NE series General 1 3 2 Declaration of Conformity Directive 94 9 EC refer 2 9 1 In accordance with Directive 94 9 EC of the European Parliament and Council of 23 March 1994 concerning the harmonisation of legal regulations of the Member States governing equipment and protective systems destined for used in potentially explosive areas Annex IX B Manufacturer WERNERT PUMPEN GMBH Oberhausener Str 67 79 45476 Mulheim an der Ruhr B R Deutschland Germany Products WERNERT chemical standard pumps of the NE series are horizontally positioned machines to pump liquids qualify as equipment in accordance with Article 1 Para 3a The conformity assessment procedure is based on Article 8 Para 1 b ii The pump is intended for use as equipment of Group Il category 2 gas atmosphere G in accordance with Directive 94 9 EC for use in potentially explosive areas Il 2 G c TI T4 Information on the temperature class and maximum working temperature of the pumped medium can be found in the operating manual It is presumed that the product
76. tomere bellows mechanical seal which come into contact with liquid need to be replaced after one year 9 000 operating hours Part 472 Stationary seal ring Part 475 Rotating seal ring Part 481 Bellows The following O rings should also be replaced regularly Part 412 04 O ring casing seal Part 412 05 O ring shaft wearing sleeve Part 412 06 O ring impeller For the single WERNERT elastomere bellows mechanical seal the following parts are regarded as replacement parts after two years of operation of the pump Part210 Shaft Part 233 Left hand impeller Part 321 Radial ball bearing 2 pieces Part 412 01 O ring discharge nozzle Part 412 03 O ring suction nozzle Part 412 36 O ring bearing Part 420 1 Shaft seal ring on bearing cover Part 420 3 Shaft seal ring on bearing end cover Part 482 Bellows seat Part 501 Multiple ring Part 505 Loose collar Part507 Thrower Part 524 Shaft wearing sleeve Part 552 2 Spanner in locking system for shaft wearing sleeve Part 921 Shaft nut Part 931 Lockwasher Part 932 Circlip Part 940 Key In case of oil lubrication Part 322 Radial rollerbearing Part 323 Thrust ball bearing The manufacturer can at any time if the serial number of pump is stated provide an offer for the replacement parts required for the pump in question Page7 16 NE series 8 Faults causes and remedies 8 Faults causes and remedies
77. ures and hints attached to the pump and described in the following paragraphs and the safety hints provided with the symbol to warrant the explosion protection Standard EN 1127 1 explosion protection must be complied with 2 9 1 Identifying marking Pumps which are intended to be used in potentially explosive atmospheres must be marked according to EC Council Directive 94 9 please refer to Annex A 1 1 and the conformity declaration according to EC Council Directive 94 9 must be available The marking only refers to the pump Coupling and motor must be marked separately according to EC Council Directive 94 9 and their conformity declarations according to EC Council Directive 94 9 must also be available Page 2 3 NE series 2 Safet 2 9 2 Filling of pump During pump operation the interior pump space in contact with the liquid must be constantly filled with the medium pumped 2 9 3 Modes of operation affecting the explosion protection Dangers affecting the explosion protection are to be avoided Unintended use may lead to that the admissible surface temperature is exceeded or sparks are produced which may result in a possible ignition Friction on non conducting surfaces is to be avoided Operation with closed shut off devices in the suction and or discharge line is not Ex admissible In this state there is a danger that after a short period of time already the medium pumped takes inadmissible temperatures and the maximum admissibl
78. ward NE series 7 Maintenance Repairs Fig 7 45 Slip radial shaft seal ring over shaft at bearing cover Grease lip of radial shaft seal ring beforehand For exact positioning use a Special tool if necessary Fig 7 47 Insert drip plate into bearing housing Screw grub screws into bearing cover and screw on nuts Fit washers Fig 7 49 Assemble bellows with stationary seal ring and bellows seat Take care to line up grooves and cams on all three components Page7 13 Fig 7 46 Fasten the support foot to bearing housing bus gt gt Fig 7 48 Pull locking disc system and then shaft wearing sleeve with O ring onto shaft Pay attention to orientation of the locking disc system Fig 7 50 Place pre assembled bellows seat onto the pins NE series Fig 7 51 Insert seal ring into adapter and secure it with the retaining ring made up in four parts Fig 7 53 Carefully slide the pre assembled adapter over the bellows into the bearing housing centre and screw together 7 Maintenance Repairs Fig 7 52 Fit the centering ring which secures the four part retaining ring into the adapter Align nut for flushing connection Fig 7 54 Insert key into shaft pull on coupling part and secure with grub screw Grub screw must not project out Fig 7 55 Place casing seal O ring onto the seal insert make sure it is correctly posit
79. y extraordinary weather and environmental influences Plastic pumps need not be filled with liquid preservatives Acid or lye residues must not remain in the pumps as these crystallize out and lead to damages to the mechanical seal Water must likewise not remain in the machines Danger of freezing up 3 3 Intermediate storage under special environmental conditions Particular environmental conditions are as follows Ambient temperatures below 10 C or above 40 C Intermediate storage or installation in the open Particularly high or very low air humidity e g tropical or desert atmosphere Intermediate storage in an environment with corrosive parts in the atmosphere e g sea air or corrosive gases and aerosols The following are to be provided as protective measures Special protection by solid wooden packing against impact and shock influences Storage in areas not directly exposed to atmospheric influences If necessary provide protective roofs Separate packing of the pumps with protective films and use of moisture binding agents Anti corrosive coatings of uncovered metallic parts exposed to the atmosphere Sealing of the suction and delivery side pump openings In each individual case please contact the manufacturer for any measures to be taken regarding an intermediate storage under special environmental conditions 3 4 Longer term storage In case of storage periods of more than one year make sure t
80. zzle loads listed in Appendix B must not be exceeded Section 5 3 lists suggestions on the design of the pipeline layout If subsidiary pipeline connections have been intended e g for sealing rinsing or quench media the necessary pipeline attachments and connections must be made 5 2 3 Aligning the drive The manufacturer s alignment of the drive to the pump must be checked ATTENTION P under all circumstances and if necessary it must be corrected Please refer to the operating instructions for the coupling The position of the drive shaft to the pump shaft is measured via the coupling Usually intermediate sleeve couplings are straight edge used for pumps of the NE series Fig 5 1 shows this type of coupling the Bee lt iZ R WIL nn sleeve can be removen after g the connecting screws Distance S2 between pin and packet part of the i coupling must be 5 mm all around the circumference for smaller couplings up to size 140 and for larger couplings it must be 6mm and can be determined using a feeler gauge lt feeler gauge Fig 5 1 Intermediate sleeve coupling measurement using feeler gauge and straight edge After checking and if necessary creating this gap by aligning the drive in an axial direction the angle and height of the drive must be checked Three procedures are usual here measurement with a straight edge measurement with a dial gauge and measurement with the help of a laser beam All proce

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