BE7100 Operating Instructions BRINKMANN
Contents
1. cap screws 16 3 Loosen and remove intake cover 5 from canal cover 4 Remove the gasket 28 at KC21 and KC31 or the O ring at KC35 to KC60 4 Push impeller 6 with help of two screwdrives from the shaft 9 Set the screwdrivers between the impeller 6 and the canal cover 4 5 Remove woodruff key 19 from the shaft 9 and remove the canal cover 4 Remove the gasket 27 6 Remove fan cover 11 retaining ring 29 KC60 and fan 10 from shaft 9 Remove parallel pin 21 KC60 7 Loosen stud bolts 13 and remove stator 1 with end shield 7 8 Push shaft 9 with ball bearing 20 out of end shield 2 9 Take locking ring 22 and the supporting ring 24 out of thing annexed 3 10 Remove rotary shaft seal 23 Clean pump components before re assembling Position of the rotary shaft seal 23 may be ex changed with the supporting ring 24 if neces sary to ensure contact of the new sealing lip with unused surface 11 Fill the rotary shaft seal 23 with grease 1 3 of the volume and press it with a drift flat into the thing annexed 3 12 The remaining assembly occurs in reverse order of item 3 to 9 If required exchange the O ring 28 gaskets 27 28 and impeller 6 13 Screw the hexagon head cap screws 16 Check up the tightening torque 14 After having completed the assembly possible distortions can be eliminated by light tap upon intake cover 5 with a plastic ha2. thing an nexed 3 Push the rotary mechanical seal part 24a 24d onto the pump shaft 9 and secure with locking ring 22 O lt N lt a The remaining assembly occurs in reverse order of item 3 to 5 9 Screw the hexagon head cap screws 16 Check up the tightening torque 10 After having completed the assembly possible distortions can be eliminated by light tap upon intake cover 5 with a plastic hammer BE7100 Edition 03 2015 11 Reconnect pump to the electrical supply Fill up the pump Check direction of rotation Ade SC APSR 5 sel 12 Disposal When disposing of the pump or the packaging materials the local and national regulation for proper disposal must be complied with Prior to its disposal the pump must be completely drained and decontaminated if necessary Page 9 of 10 13EC declaration of conformity DEUTSCH ENGLISH FRANGAIS ESPANOL Sage EG Konformitatserklarung EC declaration of conformity D claration de conformit CE Declaraci n de conformidad CE Hersteller Manufacturer Constructeur Fabricante Brinkmann Pumpen K H Brinkmann GmbH amp Co KG FriedrichstraRe 2 D 58791 Werdohl Produktbezeichnung Product name D signation du produit Designaci n del producto Kleinkreiselpumpen Miniature Centrifugal Pumps Petites pompes centrifuges Bombas centrifugas Typ Type Tipo KC21 KC60 Das bezeic
3. BE7100 LIEU SN PUMPS Operating Instructions Translation of original BRINKMANN Miniature Centrifugal Pumps Series KC21 KC60 Brinkmann Pumpen K H Brinkmann GmbH amp Co KG FriedrichstraRe 2 D 58791 Werdohl Tel 49 2392 5006 0 Fax 49 2392 5006 180 Subject to change without prior notice www brinkmannpumps de sales brinkmannpumps de Order No BE7100 ENGLISH Brinkmann Pumpen Edition 03 2015 Page 1 of 10 Brinkmann Miniature Centrifugal Pumps Series KC21 KC60 Contents 1 Indication to the manual 2 2 Description of product eeen 2 3 3 Safety instructions sessese neneeese sree neeese 3 4 Transport and storage 0 cccceeseeeeeeeeeeeees 4 5 Installation and Connection eee 4 5 6 Start up Shut down 5 T Operation 5 8 Servicing and Maintenance seseneeeeeeee nee 5 1 Indication to the manual This operating manual gives basic instructions which are to be observed during installation opera tion and maintenance of the pump It is therefore imperative that this manual be read by the respon sible personnel and operator prior to assembly and commissioning It is always to be kept available at the installation site 1 1 Identification of safety instructions in the operating manual Safety instructions given in this manual non compliance with which would affect safety are identified by the following symbol A Safety sign according w
4. IN 912 OO JO Om P GO ND 7 21 14 8 Item Description 16 Hexagon head cap screw DIN 931 17 Spring washer DIN 127 18 Spring washer DIN 127 19 Woodruff key DIN 6888 20 Ball bearing DIN 625 21 Parallel pin KC60 DIN 7 22 Locking ring DIN 472 23 Rotary shaft seal 24 Supporting ring 25 Splash ring 26 Gasket 27 Gasket 28 Gasket KC21 KC31 28 O ring KC35 KC60 29 Retaining ring KC60 In the special version UO12 a rotary mechanical seal is used instead in positions 23 and 24 10 2 Indications to the spare part order Spare parts are available from the supplier Standard commercially available parts are to be purchased in accordance with the model type The ordering of spare parts should contain the following details 1 Pumptype e g KC60 2 Pump No e g 11107100 The date of the construction year is a compo nent of the pumps type number 3 Voltage Frequency and Power Take item 1 2 and 3 from the nameplate 4 Spare part with item No e g Impeller item No 6 Tightening torques for screwed connections Thread M4 M5 Strength 4 8 A2 80 8 8 classes Tightening 1Nm 2Nm 5 Nm 2Nm torque Nm Item 14 Item 13 Item 16 Item 15 BE7100 Edition 03 2015 Page 7 of 10 11 Repair Brinkmann miniature centrifugal pumps series KC21 KC60 11 1 Exchange the rotary shaft seal 1 Disconnect the pump from the power supply Check up the marks on the pump unit 2 Loosen hexagon head
5. Please see above sample wiring diagrams 5 2 1 Circuit Wiring diagram e g y Star connection ig 3 x 400 V 50 Hz BO resp 380 420 V 50 Hz Delta connection 3 x 230 V 50 Hz resp 220 240 V 50 Hz There may be no foreign objects such as dirt particles or humidity inside the terminal board Mount terminal board cover to motor tight against dust and humidity and close up all unused wiring ports ATTENTION When Variable Frequency Drives are used interfer ing signals might occur Non sinus shaped supply voltage from a variable frequency drive might result in elevated motor temperatures BE7100 Edition 03 2015 6 Start up Shut down 6 1 Start up ATTENTION Switch off at the mains After connection the electrical wires close the terminal box Briefly start the motor max 30 sec and check the rotation according to the arrow on the top of the motor If the direction is incorrect change over two of the power leads 6 2 Shut down All service work must be carried out by qualified service personnel Pump must be disconnected from the power source and all rotating parts must stand still Reassure that pump is disconnected from power source and cannot be switched on Verify that there is no voltage at the terminal board Open terminal box and disconnect the power leads Empty out the pump 7 Operation Liquid level Filling of the pump The pumps are self priming af
6. allation montage et de mise en service de la pompe pr vues dans l instruction d emploi doivent tre suivies Tenga en cuenta las instrucciones en el manual para la instalaci n y puesta en marcha de la bomba Brinkmann Pumpen K H Brinkmann GmbH amp Co KG Werdohl 02 03 2015 Dr H Abou Day K H Brinkmann GmbH amp Co KG Friedrichstra e 2 D 58791 Werdohl Norbert Burkl Leiter Qualit tsmanagement Manager of quality Dokumentationsbevollm chtigter Representative of management Directeur de gestion de la qualit documentation Mandataire de documentation Mandatario Director de gesti n de calidad de documentacion BE7100 Edition 03 2015 Page 10 of 10
7. d with name plate rating Check air flow at motor fan Pump does not pump liquid level too low Pump mechanism faulty Pipe blocked Fill up liquid replace pump mechanism Clean pipe The pump does not sucking Suction pipe leaking Suction height to high Air cannot escape from the dis charge pipe No fluid in pump Seal suction pipe Place pump at lower level or move suction tank up Inspect check valve for leaks and refill pump Refill pump Insufficient flow and pressure Wrong direction of rotation of impeller Pump mechanism silted up Worn pump mechanism Change over two power supply leads Clean pump mechanism Replace pump mechanism Incorrect flow or pressure Wrong power supply voltage or cycles Power supply must correspond with name plate rating Running noise Vibration BE7100 Foreign objects in pump end Impeller damaged Bearing Bushing broken Cavitation Edition 03 2015 Remove foreign objects Replace impeller Replace bearing bushing Reduction of pump on pressure side Page 6 of 10 10 Spare part 10 1 Spare part list for the miniature centrifugal pumps series KC21 KC60 LI ON Item Description 1 Stator with terminal board End shield Thing annexed Canal cover Intake cover Impeller End shield Terminal box 9 Shaft with rotor 10 Fan 11 Fan cover 12 Stator base 13 Stud bolt with bond 14 Socket head cap screw DIN 84 15 Slotted cheese head screw D
8. hnete Produkt stimmt mit den folgenden Richtlinien des Rates zur Angleichung der Rechtsvorschriften der EG Mitgliedsstaaten Uberein The named product conforms to the following Council Directives on approximation of laws of the EEC Member States Le produit sus mentionn est conforme aux Directives du Conseil concernant le rapprochement des l gislations des Etats membres CEE El producto designado cumple con las Directivas del Consejo relativas a la aproximaci n de las legislaciones de los Estados Miembros de la CEE 2006 42 EG Richtlinie fur Maschinen 2006 42 EC Council Directive for machinery 2006 42 CEE Directive du Conseil pour les machines 2006 42 CEE Directivas del Consejo para maquinas 2004 108 EG Richtlinie fur elektromagnetische Vertraglichkeit 2004 108 EC Council Directive for Electromagnetic compatibility 2004 108 CEE Directive du Conseil pour Compatibilit lectromagn tique 2004 108 CEE Directivas del Consejo para Compatibilidad electromagn tica Hinsichtlich der elektrischen Gefahren wurden gem Anhang Nr 1 5 1 der Maschinenrichtlinie 2006 42 EG die Schutz ziele der Niederspannungsrichtlinie 2006 95 EG eingehalten With respect to potential electrical hazards as stated in appendix No 1 5 1 of the machine guide lines 2006 42 EG all safety protection goals are met according to the low voltage guide lines 2006 95 EG Conform ment a l annexe N 1 5 1 de la Directive Machines 2006 42 CE les objectifs de s curit
9. igns on the pump It is imperative that signs affixed to the machine e g e arrow indicating the direction of rotation e symbols indicating fluid connections be observed and kept legible 3 8 Unauthorized alterations and production of spare parts Any modification may be made to the machine only after consultation with the manufacturer Using spare parts and accessories authorized by the manufacturer is in the interest of safety Use of other parts may exempt the manufacturer from any liability 4 Transport and storage Protect the pump against damage when transport ing Pumps must be drained prior to their storage Store pump in dry and protected areas and protect it against penetration of foreign bodies Always store pump above the freezing point 5 Installation and Connection 5 1 Mechanical installation The pumps can be mounted horizontally or vertical ly Be sure that the pipe connections are on the top in the case of horizontal installation For vertical installation the pump unit must be lower than the motor Pumps must be mounted securely Piping tank and pumps must be mounted without any tension The suction and pressure connections are marked with arrows of the pump body To obtain the full flow rate it is recommended to choose for the pipework the nominal bore diameter of the pumps cross section for connection There fore pipe bends should be used not pipe angles The pipework must be qualified for occurri
10. ith ISO 3864 B 3 1 or where electrical safety is involved with AN Safety sign according with ISO 3864 B 3 6 Where non compliance with the safety instructions may cause a risk to the machine and it s function the word ATTENTION is inserted 2 Description of product 2 1 General description of the pump The miniature centrifugal pump operate according to the bypass duct principle with self priming function following the initial priming Pump and motor form a complete unit The impeller is fixed on the driving shaft extension The shaft sealing is effected with a rotary shaft seal in stand ard versions and a rotary mechanical seal in special versions UO12 The sealing for the case is effect ed with two gaskets in KC21 to KC31 and with a gasket and O ring in KC35 to KC60 The pump is to be protected against coarse parti cles The KC pumps are mounted next to or on top of the tank The pumps are foot mounted and must be screwed down in order to ensure a secure stance BE7100 9 Trouble shooters goude 6 10 Spare Datt d feces ces EES EENS N E aes 7 IL Repais wie ee Mane aan 8 9 12 Disposal iiini iiie is 9 13 EC declaration of conformity c 10 2 2 Intended use The pumps KC are suitable for pumping thin bodied fluids within the limiting application in accordance with table 1 Limit of Application Table 1 Type KC21 KC60 Mediums Industry water coolants fuel
11. mmer BE7100 Edition 03 2015 15 Reconnect pump to the electrical supply Fill up the pump Check direction of rotation Page 8 of 10 Brinkmann miniature centrifugal pumps series KC21 KC60 UO12 special make 11 2 Exchange the rotary mechanical seal 1 Disconnect the pump from the power supply Check up the marks on the pump unit 2 Loosen hexagon head cap screws 16 3 Loosen and remove intake cover 5 from canal cover 4 Remove the gasket 28 at KC21 and KC31 or the O ring at KC35 to KC60 Push impeller 6 with help of two screwdrives from the shaft 9 Set the screwdrivers between the impeller 6 and the canal cover 4 oa a Remove woodruff key 19 from the shaft 9 and remove the canal cover 4 Remove the gasket 27 Remove locking ring 22 and the rotating mechanical seal assembly 24a 24d Remove the stationary mechanical seal part 24e 24f from the thing annexed 3 Clean pump parts and seat surfaces of all seals The rotary mechanical seal 24 shoud be re placed completely If required renew gasket 27 28 or O ring 28 and impeller 6 Fit new rotary mechanical seal The running surfaces of the rotary mechanical seal must be free from dirt and grease Wet the packing 24f with water containing washing up liquid and press the stationary rotary mechanical seal part 24e 24f into the
12. n compliance with the safety instructions may produce a risk to the personnel as well as to the environment and the machine and results in a loss of any right to claim damages For example non compliance may involve the following hazards e Failure of important functions of the ma chines plant e Failure of specified procedures of maintenance and repair e Exposure of people to electrical mechanical and chemical hazards e Endangering the environment due to hazardous substances being released 3 2 Unauthorized modes of operation e Pump may not be used in potentially explosive environments e Pump and discharge piping are not designed to hold any weight and may not be used as a step ladder 3 3 Remaining Risk Risk of Injury Risk of squeezing or crushing body parts when installing or removing the pump exists Proper and secured lifting tools must be used Risk of burns The pump must have cooled down sufficiently prior to commencing any repair maintenance or installa tion BE7100 Edition 03 2015 3 4 Qualification and training of operating personnel The personnel responsible for operation mainte nance inspection and assembly must be adequate ly qualified Scope of responsibility and supervision of the personnel must be exactly defined by the plant operator If the staff does not have the neces sary knowledge they must be trained and instruct ed which may be performed by the machine manu facturer or sup
13. ng hy draulic pressure 51 G 3 4 M20x1 5 KC60 ATTENTION Pay attention of the max tightening torque for piping connection KC21 KC45 BE7100 Edition 03 2015 Type Pipe Brass connection KC21 45 G 35 Nm KC60 G 40 Nm When installed the space around the pump must be large enough to provide sufficient cooling of the motor Do not prop up the pressure line via the joining socket Page 4 of 10 5 2 Electric wiring LN All service work must be carried out by quali fied service personnel Pump must be discon nected from the power source and all rotating parts must stand still Reassure that pump is disconnected from power source and cannot be switched on Verify that there is no voltage at the terminal board According to the European Standard EN809 a motor overload must be installed and properly set to the full load amps stated on the pump name plate It is the responsibility of the machine operator to decide whether or not an additional emergency switch must be installed A Tension voltage and frequency must correspond with the shown specification on the nameplate The pump must be wired so that a solid long term electrical connection is ensured Establish a solid ground connection The electrical wiring must be performed accord ing to the wiring diagram shown inside the terminal box cover
14. oil Kinetic viscosi 12 mm s ty of the medi um Temperature of 0 80 C medium 2 m without check valve 6 m with check valve Suction height Particle size in 1mm Edition 03 2015 the medium min delivery 1 of Q max volume Dry running The pumps are not suitable for dry running Switching on Motors less 3 kW max 200 frequency per hour Ambient tem 40 C perature Set up altitude 1000 m ATTENTION The pumps are to be operated within their design limits Applications outside of these limits are not approved The manufacturer is not responsible for any damages resulting from use of the pumps in such applications Page 2 of 10 2 3 Technical data Max del Max del Height pressure volume bar spec Type weight 1 l min H mm KC21 KC31 KC35 KC45 KC60 1 Dimensions in accordance with page 4 Pipe con Weight Power Noise nection level dBA 50 Hz 2 Noise emissions measured in accordance with DIN 45635 at a distance of 1 m The motor is surface cooled and compliant with DIN IEC 34 and EN 60034 protection degree IP 55 3 Safety instructions When operating the pump the safety instructions contained in this manual the relevant national accident prevention regulations and any other service and safety instructions issued by the plant operator are to be observed 3 1 Hazards in the event of non compliance with the safety instructions No
15. plier on behalf of the plant operator Moreover the plant operator is to make sure that the contents of the operating manual are fully understood by the personnel 3 5 Safety instructions relevant for operation e f hot or cold machine components involve hazards they must be guarded against acci dental contact e Guards for moving parts e g coupling must not be removed from the machine while in opera tion e Any leakage of hazardous e g explosive toxic hot fluids e g from the shaft seal must be drained away so as to prevent any risk to per sons or the environment Statutory regulations are to be complied with e Hazards resulting from electricity are to be prevented see for example the VDE Specifica tions and the bye laws of the local power supply utilities e The pumps are only secured safely if properly attached to the floor or top of the tank 3 6 Safety instructions relevant for mainte nance inspection and assembly work Any work on the machine shall only be performed when it is at a standstill it being imperative that the procedure for shutting down the machine described in this manual be followed Pumps and pump units which convey hazardous media must be decontaminated On completion of work all safety and protective facilities must be re installed and made operative again Prior to restarting the machine the instructions listed under Start up are to be observed Page 3 of 10 3 7 S
16. relatifs au mat riel lectrique de la Directive Basse Tension ont t respect s Con respecto al potencial peligro el ctrico como se indica en el ap ndice No 1 5 1 del manual de la maquina 2006 42 EG todos los medios de protecci n de seguridad se encuentran seg n la guia de bajo voltaje 2006 95 EG Die Ubereinstimmung mit den Vorschriften dieser Richtlinien wird nachgewiesen durch die vollstandige Einhaltung folgen der Normen Conformity with the requirements of this Directives is testified by complete adherence to the following standards La conformit aux prescriptions de ces Directives est d montr e par la conformit int grale avec les normes suivantes La conformidad con las prescripciones de estas directivas queda justificada por haber cumplido totalmente las siguientes normas Harmonisierte Europ Normen Harmonised Europ Standards Normes europ harmonis es Normas europ armoniza das EN 809 1998 A1 2009 AC 2010 EN ISO 12100 2010 EN 60204 1 2006 AC 2010 EN 61000 3 2 2006 A2 2009 EN 61000 3 3 2013 EN 61000 6 2 2005 AC 2005 EN 61000 6 3 2007 A1 2011 AC 2012 Nationale Normen National Standards Normes nationales Normas nacionales EN 60034 1 2010 AC 2010 Die Hinweise in der Betriebsanleitung f r den Einbau und die Inbetriebnahme der Pumpe sind zu beachten The instructions contained in the operating manual for installation and start up the pump have to be followed Les indications d inst
17. ter initial filling Suction height is 2 m without check valve and 6 m with check valve Pump must be protected from contamination A If the pump should lock up and cease shut pump down see 6 2 and disconnect from power supply Pump must be uninstalled and removed from the system prior to its repair 8 Servicing and Maintenance ATTENTION The surface of the motor must be kept free of dirt The motor shaft is spinning in permanently greased ball bearings with special grease and increased bearing play and does not require any special maintenance Page 5 of 10 9 Trouble shooter s guide Fault Cause Remedy Motor does not start no motor noise At least two of the power supply leads have failed Overload has tripped Check fuses terminals and supply leads Inspect overload Motor does not start humming noise One of the supply leads has failed Impeller faulty Motor bearing faulty See above Replace impeller Replace bearing Overload trips Pump locked up mechanically High on of cycling frequency Inspect pump hydraulics Check application Power consumption is too high Wrong direction of rotation of impeller Lime or other deposits mechanical friction See above Clean pump mechanism repair pump Motor overheats High on off cycling frequency Wrong power supply voltage or cycles Insufficient cooling See above Power supply must correspon
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