External Documentation C0

External Documentation

9 M 25 C

Engine No.: 45401 Record No.: 271283

45402

en / 23.01.2014 AA048545 1
 Total Index C0.01

External Documentation C0
Total Index C0.01
Table of contents C5.01

en / 23.01.2014 AA047685 1/1

 Table of contents C5.01

Table of contents C5.01

Engine, exhaust gas system/supercharging C5.05.06

A Engine Adjusting Valve C5.05.06.09.15.00
B Turbocharger - HPR 6000 - Description - (KBB) C5.05.06.10.11.26
C Charge Air Cooler C5.05.06.30.17.39
D Silencer Spark arrester C5.05.06.40.05.48

Engine, fuel system C5.05.07

E Fuel Pump (Leistritz) C5.05.07.07.22.10
F Heat Exchanger C5.05.07.08.30.06

Engine, lubricating oil system C5.05.08

G Lub.-Oil Pump (Leistritz) C5.05.08.10.21.46
H Back-Flushing-Filter Automatic C5.05.08.12.03.19
I Plate Heat Exchangers C5.05.08.40.02.93
J Plate Heat Exchangers -Oil- (GEA) Description C5.05.08.50.00.02

Engine, cooling water system C5.05.09

K Cooling Pump Unit HT C5.05.09.01.12.32
L Cooling Pump Unit LT C5.05.09.01.22.55
M Cooling Water Preheating Set C5.05.09.09.10.27
N Engine Adjusting Valve C5.05.09.09.15.00
O Plate Heat Exchangers Description C5.05.09.40.02.20

Engine control equipment C5.05.11

P Oil Mist Detector C5.05.11.02.03.07

Engine auxiliary units C5.05.12

Q Flange - Coupling - RATO (Vulkan) C5.05.12.13.06.30

Engine additional installation 01 C5.05.13

R Engine Adjusting Valve C5.05.13.09.15.00

en / 23.01.2014 AA020086 1/1

 Engine Adjusting Valve C5.05.06.09.15.00
-

Engine Adjusting Valve

en / 30.03.2010 FD043485 1/10

Electrically Operated MOV - 81
Control Valves
Electrical Motor Drive
MOV - S - 81
MOV - 3 - 81
Types Technical Data
Single-seat valve in straight-way form Overall length: according to DIN 3300
Type MOV-81
Dimension sheet EK-413 Flanges: PN 10 DIN 2532
PN 16 DIN 2533
Seat valve in straigth-way form PN 25 DIN 2544
with noise attenuating cone PN 40 DIN 2545
Type MOV-S-81
Dimension sheet EK-413 Operating pressures: according to DIN 2401
Three-way valve
Type MOV-3-81 Differential in accorddance with tables
Dimension sheet EK-414 pressures: EK-413 and EK-414

Positioning ratio: 1:50

Construction
Positioning - normal
Straight-way valves up to DN 200 with shrunk seats, beginning speed: 25mm/min; 50mm/min possible
with DN 250 with screwed seats
cone characteristics linear or equi-percentage different Kv values Strokes: DN 15- 50 25 mm
are possible at equal nominal width DN 65- 100 35 mm
DN 125-175 50 mm
three-way valves with screwed-in double-seat bushes with linear DN 200 58 mm
characteristics of flow and disk cones DN 250-350 65 mm
inserted stuffing-box flanges
Installing position: vertical to horizontal
cast housing
driven by spur gearing with linear actuator Electrical data: according tables „electrical Drive Data“

4 drive sizes, having different positioning forces are available

Additional Equipment
E-motors for 50 or 60 HzAC and three-phase voltages
Soft seal in the cone
drives with emergency manual operation and mechanical cone with multi-hole sleeve
position display
ribbed stuffing-box
drive covered with steel cover spindle sealing by bellows W. No. 1.4571

General
The motor valves are used as electrically operated continuous
Materials control elements (control valves) and as on-off controller for the
control of gaseous and liquid agents. The control is established
Valve housing: PN10/16 GG20 by means of two-point or three-point controllers as a function of
PN25/40 GS-C-25 temperature, pressure, quantity etc. or manually with push-
othermaterials, such as special steel cast, button or switch.
chromium-nickel steel, gun metal, bronze,
etc. and hard rubber lining on request
Construction and Operation
Valve seats: W. No. 1.4401
for three-way valves DN 65-200 -Straight-way valves in single-seat construction.
W. No. 1.4410 or bronze G Sn Bz 10 Dimension sheet EK-413
other materials on request with cooling rib assembly or bellows sealing, respectively.
Dimension sheet EK-425
Valve conel: W. No. 1.4401
for straight-way valves DN 125-350 - Three-way valves.
and three-way valves DN 250-350 Dimension sheet EK-414
W. No. 1.4410 or bronze G Sn Bz 10 with cooling rib assembly or bellows sealing, respectively.
other materials on request Dimension sheet EK-419
Valve spindle: W.-Nr. 1.4401 or bronze AlBz 10Ni
other materials on request - 4 different drives (1.2 kN; 4.5 kN; 12 kN; 24 kN) are optionally
available to meet the operational requirements.
Stuffing-box PTFE, silkyam (reinforced)
packing: orpure graphite The switching-off at the end position is established for
straightway valves in the closing position torque-dependent,
Housing: steel casting GS-C-25 and in
the opening position travel dependent, with an additional limit Electrical and technical drive data
switch, being torque dependent, wired in parallel, for three-way
valves in both end positions, torque dependent. Data for The motors are designed for intermittent
regulating duty S4 acc. to VDE 530 with a relative
In addition, a further free travel dependent limit switch with operation: duty cycle of 30%.
switch-over contact is provided. switching frequencymax.600/h
The valve position is indicated by a pointer at the drive spindle minimum pulse duration: 250 ms
and a scale at the housins. minimum pulse pause: 40ms

For the analog remote transmission of the valve position, the Electrical at the terminal via cable sorewings
installation of 2 potentiometers is possible. wiring: according to DIN 89280

In addition, a further travel dependent limit switch can be Power supply: normally
installed. The built-in electro motor (a) drives the linear actuator 230 V- 50 or. 60 Hz, single-phase-AC,
via a spur gear. In the last gear (b) of the geartrain, a bushing with or
internal thread is shrunk in, which runs in ball bearings. In this 380 V- 50 or. 60 Hz three-phase current
thread runs the upper part of the push-rod (d), provided against other supply voltages on request
torsion by a key and groove. Type of protection: DIN 40050 · IP 65
When the gear is driven, the push-rod and the valve spindle Allowable ambient temperature: - 20 to + 60°C
performs a push / pullmotion, depending on direction of rotation.
Limit switch: torque dependent switches max. 230 V
On power failure, the final control element can manually be ohmic loadmax.10A
actuated. inductive loadmax.5A
The gear ist dustproof separated from the electrical components travel dependent switchesmax.230V
in an aluminium pressure housing. Terminals, motor, limit switch ohmic loadmax.5A
and potentiometers are easily accessible by removing of the inductive loadmax.3A
steel cover electric bulb max. 1 A
Potentiometer: max. 50 V, 100 mA

Motor data
Positioning time mm/min 25 50 25 50 30 60
Voltage Volt
single-phase
three-phase three-phase
AC current
400 V 50 Hz 440 V 60 Hz
230 V 50 Hz
Drive 1,2 kN
Rated current mA 29 15 14,3
Power consumption Watt 6,6 9,9 9,35
Power output Watt 2,4 3,1 3,1
Rotational speed motor U/min 500 500 600

Positioning time mm/min 25 50 25 50 30 60

Voltage Volt
single-phase
three-phase three-phase
AC current
400 V 50 Hz 440 V 60 Hz
Drive 4,5 kN 230 V 50 Hz
Rated current mA 135 160 110 80 100 100
Power consumption Watt 28 32 35 32 35 45
Power output Watt 5,3 12 10 16 12 19
Rotational speed motor U/min 1350 2700 1350 2700 1620 3240

Positioning time mm/min 25 50 25 50 30 60

Voltage Volt
single-phase
three-phase three-phase
AC current
400 V 50 Hz 440 V 60 Hz
Drive 12 kN 230 V 50 Hz
without brake Rated current mA 320 700 210 290 220 265
Power consumption Watt 60 130 75 120 80 138
Power output Watt 22 72 28 63 28 85
Rotational speed motor U/min 1300 2750 1300 2750 1600 3300

Positioning time mm/min 25 50 25 50 30 60

Voltage Volt
single-phase
three-phase three-phase
AC current
400 V 50 Hz 440 V 60 Hz
Antrieb 24 kN 230 V 50 Hz
without brake Rated current mA 660 930 400 700 342 640
Power consumption Watt 145 206 163 337 180 370
Power output Watt 67 110 75 215 88 235
Rotational speed motor U/min 1350 2700 1350 2750 1560 3300
Connection Diagrams The pipes have thouroughly to be cleaned prior to assembling,
in order to prevent a later damage to the seats and cones.
AC 2/2 way valve RTA-264
3/2 way valve RTA-265 The installation of a dirt tr,ap in front of each control valve is
strongly recommended.
Three-phase 2/2 way valve
current: linear actuator 1,2 + 4,5 kN RTA-264/3 On mounting of straight-way and angle valves pay attention to
linear actuator 12 + 24 kN RTA-264/4 the direction of arrow on the valve housing.

3/2 way valve Mix and partitioning valves are provided with the figures 1,2 and
linear actuator 1,2 + 4,5 kN RTA-265/3 3 on their connecting flanges. Observe the correct installation in
linear actuator 12 + 24 kN RTA-265/4 accordance with piping diagram.1 is always the joint
connection, whereas to 2 and 3 the incoming or leaving part
Installation streams are connected.
"These actuator valves shall be mounted with the drive towards The wiring and connecting of the electrical circuitry has to be
the top. For any other position ask before ordering." performed in accordance with the regulations for the installation
of power plants and with the respective wiring diagrams.

Start-up and
Adjustment instructions
For start-up of the valve place the drive by means of the hand
wheel (e) in the middle of the positioning travel, switch on power
and give shortACpulses to the drive; watch whether the push rod
(d) moves into the correct direction. Otherwise, exchange the
motor connections at the terminal strips 2 + 3.

Drive 1.2 kN and 4.5 kN

Operate manually only with the motor at standstill.
For this purpose press the bolt (f) mounted below at the drive
housing with the hexagonal head into the housing until the spring
lever (h) engages into the notch of the bolt. Hereby rotate the
handwheel (e) a little bit. On rotating of the handwheel ciockwise,
the push spindle is extended rotating ccw draws the spindle in.
On pressing of spring lever (h) in the direction of the valve shaft
the bolt jumps out on its own and the drive is switched back to
motor drive.

Drive 12 kN and 24 kN
Change over to hand-operating:
Push hand disengaging lever into direction -1- (at the time turn
hand wheel slightly if necessary), then swivel hand disengaging
lever above the hexagon screw into direction -2-.
Now hand operating position is locked.
Change over to motor drive:

Swivel hand disengaging lever into direction - 3 - and release. All

further engaging proceedings will occur automatically with
starting up of themotor.
Figure travel dependent switch and message devices

With the end position reached with extended push spindle, the
two slotted levers (1) are parallel. A'ter loosening of the nut, the
carrier bolt (7) can be moved into the slot of the lever allowing the
stroke of the drive to be adjusted by means of the auxiliary scale.
After this being done, re-fasten the bolt. In this position, the
potentiometers (5) (in case there are any) have to be in the end
position. They can be adjusted by rotating the slider.
After that move the drive by the required travel for 2/2 valves or
the possible travel for 3/2-way valves in the opposite direction the
potentiometer will then turn into the other end position.
For the adjustment of the travel dependent limit switch "S 3" for
the limiting of the travel in the position open, the knurled head nut
(4) has to be loosened. Adjust the cam washer (4) to make the
switch shut off. The second built-in travel dependent switch "S 4"
and another possible "S 5" may freely be adjusted inbetween the
two end positions. Re-fasten the knurled head nut after the
switches being adjusted.
The switches provided for the end positioning are factory
adjusted. The torques of the load dependent switches are fixed
and can not be changed.

1 Slotted levers; the lower one is marked for the set travel
2 Travel-dependent switches
3 Knurled nut
4 Cam disks
5 Potentiometer for position indication
6 Scale for setting the travel
7 Connection bolt

Maintenance

Valve assembly Drive

Re-fasten the screws and flange connections at the housing after Grease the drive at normal operating conditions every three
start-up of the installation as the sealings are settling a bit at the years, at higher loads after approx. 200 000 double strokes with
beginning. The maintenance of the stuffing-box is also important. "Fett Klüber Structoris P 00" or a similar grease.
In case of leakage, the stuffing-box gland has to be fastened at
once. If this is no longer possible, the stuffing-box has to be re-
packed.
Take care to use the right material, depending on the agent, the
temperature etc. Keep the part of the spindle being in contact with
the stuffing-box always clean and grease at regular intervals with
a suitable grease. If the sealing surfaces at the seat and the cone
are damaged by dirt or foreign particles, no longer giving a tight
seat, they can be ground with a fine emery paste. With valves
having PTFE inserts in the cone, the latter can easily be replaced.

The above information and our technical advice for application in word, in writing and by tests
are given to the best knowledge. They shall be applied, however, only as hints without
obligation, also with reference to any protective rights of third parties. The advice does not
relieve you from examining our advisory hints and our products by yourself with regard to their
suitability for the intended procedures and purposes. Application and use of our products and
those products manufactured by you on the basis of our technical advice for application are
beyond our possibilities of control and, therefore, exclusively belong to your responsibility. The
sale of our products is subject to our General Terms and Conditions of Sale and Delivery.

Ausgabe/EDITION 06/02

Pleiger Maschinenbau Postfach 32 63 ( +49 / (0) 2324 398-0

GmbH & Co KG D-58423 Witten Fax +49 / (0) 2324 398-380
 Turbocharger - HPR 6000 - C5.05.06.10.11.26
Description - (KBB)

Turbocharger - HPR 6000 -

Description - (KBB)

en / 02.01.2008 FD025923 1/57

 Operating Instructions
HPR6000 Exhaust Gas Turbocharger

OPERATING
and
MOUNTING INSTRUCTIONS
for
EXHAUST GAS
TURBOCHARGER
HPR6000

For information only!

Kompressorenbau Bannewitz GmbH

Windbergstraße 45
01728 Bannewitz
Federal Republic of Germany

Phone: +49 (351) 40 85 603 (Sales)

+49 (351) 40 85 633 (Service)
+49 (172) 35 16 045 (24-hour phone)
Fax: +49 (351) 40 85 840
+49 (351) 40 85 648 (Service)

HPR6000En08.doc 8th Edition (07/2010) Page 1 of 56

Issued: 08/2008 Ro Checked: Released:
5588903en
 Operating Instructions
HPR6000 Exhaust Gas Turbocharger

Name plate

The data given in the operating instructions only apply to the exhaust gas turbocharger with the serial
number mentioned above. The name plate is affixed at the side of the bearing housing of the exhaust
gas turbocharger.

In case you have questions regarding the exhaust gas turbocharger, it is important to give the correct
x TC type (Type)
x Serial No. (Serial)
x Specification No. (Spec.)
Only if these data are known, the request can be handled properly and promptly.

Direct your inquiries to the following address:

Kompressorenbau Bannewitz GmbH

Windbergstr. 45
01728 Bannewitz
Federal Republic of Germany

Fax: +49 (351) 40 85 840

+49 (351) 40 85 648 (Service)
Phone: +49 (351) 40 85 603 (Sales)
+49 (351) 40 85 633 (Service)
+49 (172) 35 16 045 (24-hour phone)
E-mail: [email protected]

Page 2 of 56 8th Edition (07/2010) HPR6000En08.doc

 Operating Instructions
HPR6000 Exhaust Gas Turbocharger Contents

Table of Contents
Chapter Title Page

1 TECHNICAL DATA ....................................................................... 5

1.1 Operating data ...............................................................................................5
1.2 Alarm values ..................................................................................................6
1.3 Dimensions ....................................................................................................6
1.4 Test connections ...........................................................................................7
1.5 Dimensions of important subassemblies ....................................................7
1.6 Vibrations .......................................................................................................8
2 SAFETY......................................................................................... 9
2.1 Built-in safety systems..................................................................................9
2.2 Safety measures (to be taken by user) ........................................................9
2.3 Declaration of incorporation.......................................................................10
3 GENERAL INFORMATION ABOUT DANGER........................... 11
3.1 Danger zone .................................................................................................11
3.2 Operators and maintenance personnel .....................................................11
3.3 Installation of spare and wear parts...........................................................12
4 DESIGN ....................................................................................... 13
4.1 Brief description ..........................................................................................13
4.2 Construction ................................................................................................13
4.3 Function........................................................................................................13
4.4 Usage to the intended purpose ..................................................................13
5 OPERATION ............................................................................... 14
5.1 Commissioning............................................................................................14
5.2 Starting-up....................................................................................................14
5.3 Stopping .......................................................................................................15
5.4 Failures .........................................................................................................15
5.5 Emergency operation of the exhaust gas turbocharger...........................15
5.6 Measures for extended period without operation.....................................16
6 MAINTENANCE .......................................................................... 17
6.1 General .........................................................................................................17
6.2 Maintenance work........................................................................................17
6.3 Cleaning........................................................................................................18
6.4 Maintenance schedule.................................................................................19
6.4.1 Maintenance for operation with Marine Diesel Oil (MDO) ..............................19
6.4.2 Maintenance for operation with Heavy Fuel Oil (HFO) ..................................20
6.5 Trouble-shooting table ................................................................................21

HPR6000En08.doc 8th Edition (07/2010) Page 3 of 56

 Operating Instructions
Contents HPR6000 Exhaust Gas Turbocharger
Chapter Title Page

7 DISASSEMBLY AND ASSEMBLY ............................................. 22

7.1 Introduction ................................................................................................. 22
7.2 Checking the components ......................................................................... 22
7.3 Service report.............................................................................................. 24
7.4 Clearance sheet .......................................................................................... 27
7.5 Work sheets................................................................................................. 28
7.5.1 Compressor washing .................................................................................... 28
7.5.2 Turbine washing............................................................................................ 29
7.5.3 Shutting down the exhaust gas turbocharger................................................ 31
7.5.4 Bearing check ............................................................................................... 32
7.5.5 Disassembly of the complete turbocharger ................................................... 33
7.5.6 Assembly of the complete turbocharger........................................................ 34
7.5.7 Disassembly and assembly of the silencer or air-intake housing .................. 35
7.5.8 Cleaning the silencer .................................................................................... 36
7.5.9 Disassembly and assembly of the compressor housing ............................... 37
7.5.10 Disassembly and assembly of the cartridge.................................................. 38
7.5.11 Disassembly of the rotor, complete............................................................... 39
7.5.12 Assembly of the rotor, complete.................................................................... 41
7.5.13 Disassembly of the exhaust-gas elbow ......................................................... 44
8 SPARE PARTS AND TOOLS ..................................................... 45
8.1 General......................................................................................................... 45
8.2 Spare parts .................................................................................................. 46
8.2.1 Exhaust gas turbocharger, complete (1000) ................................................. 46
8.2.2 Exhaust gas turbocharger, basic unit (1100)................................................. 47
8.2.3 Cartridge (1200)............................................................................................ 48
8.2.4 Rotor (2000).................................................................................................. 49
8.2.5 Bearings (4000) ............................................................................................ 49
8.2.6 Turbine housing (5000) ................................................................................. 50
8.2.7 Compressor housing (6000).......................................................................... 51
8.2.8 Gasket set (9910) ......................................................................................... 52
8.2.9 Standard parts 1 (9920) ................................................................................ 53
8.2.10 Standard parts 2 (9930) ................................................................................ 54
8.2.11 Standard parts 2.1 (9931) ............................................................................. 54
8.3 Tools ............................................................................................................ 55
8.3.1 Tool set (9800).............................................................................................. 55
8.3.2 Further tools.................................................................................................. 56

Page 4 of 56 8th Edition (07/2010) HPR6000En08.doc

 Operating Instructions
HPR6000 Exhaust Gas Turbocharger Chapter 1

1 TECHNICAL DATA

1.1 Operating data

Specification 558xxxx
Max. speed 34,600 rpm
Max. exhaust gas temperature upstream of turbine 650 °C

Lubricating oil
Types of lubricating oil: engine oil with a cinematic viscosity of 60 ... 115 mm²/s
at 50 °C, e.g. SAE30, SAE40
Nominal oil filter fineness upstream of TC max. 25 µm
Lubricating oil pressure upstream of TC 300 + 150 kPa
Admissible lubricating oil pressures for special operating states
at start-up min. 50 kPa
from start-up to idle running min. 50 kPa
at standstill (prelubrication or relubrication/standby mode) see diagram below
Lubricating oil temperature upstream of TC 40 ... 105 °C
Lubricating oil temperature downstream of TC max. 120 °C
Lubricating oil flow 20 ... 40 l/min
Sound power level (measured on silencer at 100 mm distance 108 dB(A)
from compressor housing) at 32,500 rpm
Counter-pressure downstream of turbine max. 2.5 kPa(g)
Underpressure upstream of compressor max. 1.5 kPa(g)

poil
(kPa)

toil (oC)
Admissible lubricating oil pressure for prelubrication or relubrication
(standby operation)

HPR6000En08.doc 8th Edition (07/2010) Page 5 of 56

 Operating Instructions
Chapter 1 HPR6000 Exhaust Gas Turbocharger

1.2 Alarm values

Measurement Alarm value

TC speed 0.97 * n max
Exhaust gas temperature before turbine t max – 15K
Lubricating oil outlet temperature of TC < 120 °C
Lubricating oil pressure before TC > 125 kPa (1.25 bar)

If alarm values are adapted accordingly to the engine data, the values
specified above are not to be exceeded and/or be fallen below in the case
of lubricating oil pressure!
The maximum speed and the maximum exhaust gas temperature before
turbine are indicated on the name plate and the test certificate!

1.3 Dimensions

)
All dimensions are specified in mm!

Length *) 1,440 ... 1,570

Width **) max. 742

Height **) max. 853

*) Exhaust gas turbocharger with silencer or intake housing and exhaust gas elbow
**) Dimensions depend on the housing position

Exhaust gas Inlet single-nozzle housing 1x Ø 182 mm

Inlet double-nozzle housing 2x Ø 120 mm

Inlet triple-nozzle housing 3x Ø 100 mm

Outlet Ø 357 mm

Charge air Outlet Ø 208 mm

Lubricating oil Inlet at bearing housing Ø 14.5 mm

Outlet at bearing housing Ø 54 mm

Compressor washing Air piping M18 x 1.5

Water piping M16 x 1.5

Turbine washing Water piping M18x1.5

Drainage Ø 90

Further connection dimensions can be taken from the assembly drawing.

Page 6 of 56 8th Edition (07/2010) HPR6000En08.doc

 Operating Instructions
HPR6000 Exhaust Gas Turbocharger Chapter 1

)
The piping for the pipe connections listed is not included in the scope of
supply of Kompressorenbau Bannewitz GmbH.

Pipes have always to be laid free of stress.

1.4 Test connections

The TC is equipped with the following test connections which can be used as required.
x There are two threads each (M18x1.5) provided at the air intake housing, compressor
housing and turbine-inlet housing and at the exhaust-gas elbow for measuring the
temperature and pressure.
x For measuring the speed, the bearing housing can be equipped with a speed sensor.

1.5 Dimensions of important subassemblies

Exhaust gas turbocharger, compl. *) 565 kg

Exhaust gas turbocharger, basic unit 415 kg
Insulation 18 kg
Silencer 63 kg
Air-intake housing 24 kg
Compressor housing 145 kg
Turbine inlet housing 125 kg
Exhaust-gas elbow 70 kg
Cartridge 151 kg
Bearing housing 80 kg
Rotor 32 kg
Shaft 23 kg
Compressor impeller 8 kg

*) Basic unit including silencer and exhaust-gas elbow (see name plate)

HPR6000En08.doc 8th Edition (07/2010) Page 7 of 56

 Operating Instructions
Chapter 1 HPR6000 Exhaust Gas Turbocharger

1.6 Vibrations

Maximum admissible vibration load at engine for 2 ... 250 Hz :

Admissible value at TC at silencer

(at place LG) (at place SD)

Velocity VRMS (mm/s) max. 45 mm/s max. 71 mm/s

Amplitude SRMS mm max. 0,7 mm max. 1,1 mm

Acceleration aRMS (m/s²) max. 70 m/s² max. 111 m/s²

Page 8 of 56 8th Edition (07/2010) HPR6000En08.doc

 Operating Instructions
HPR6000 Exhaust Gas Turbocharger Chapter 2

2 SAFETY
The exhaust gas turbocharger has been designed on the basis of the following standards
and regulations:
1. Machinery directive 2006/42/EC
2. Risk assessment and evaluation for ISO 14121-1

2.1 Built-in safety systems

x A safety system for the turbocharger is not necessary as its design and connection with
the engine to which it is attached require an inherent safety.
x For general speed monitoring, i.e. without a turn-off function being included, the
turbocharger can be equipped with a tachometer.

Assembly and disassembly work must not be done during operation.

See chapters 7.5.1 and 7.5.2 for maintenance and cleaning jobs which
may be done while the engine is running.

2.2 Safety measures (to be taken by user)

x These operating instructions are part of the exhaust gas turbocharger and shall be
always accessible for the operators and maintenance personnel.
x The operating instructions should be read before commissioning the turbocharger.
Particular attention should be paid to directions and information relating to dangers.
The user is required
x to make his operators and maintenance personnel familiar with safe working methods
x to supervise the observance of the safety regulations.
The individual jobs in these instructions are described such that they can be understood by
skilled workers.
The necessary tools and testing/inspection means must be made available to these
workers.
The user must obtain permission to operate the unit from the local authorities and observe
the following:
1. labour safety
2. cleaning and maintenance of the machines
3. product disposal
4. environmental protection

HPR6000En08.doc 8th Edition (07/2010) Page 9 of 56

 Operating Instructions
Chapter 2 HPR6000 Exhaust Gas Turbocharger

2.3 Declaration of incorporation

In accordance with Directive 2006/42/EC, Annex II, part 1, section B
Manufacturer : Kompressorenbau Bannewitz GmbH
Windbergstraße 45
01728 Bannewitz
Federal Republic of Germany
Product : Exhaust turbocharger
Type, specification , serial-no. see name plate
The head of the engineering department, Klaus Buchmann, Windbergstraße 45, 01728
Bannewitz, is authorized to compile all the special documents in accordance with Annex VII
B.
The exhaust turbocharger is defined as a partly completed machinery in accordance with
article 2g and intended to be assembled to a combustion engine only. The special technical
documents in accordance with Annex II B were compiled and in response to a reasonable
request of a national authority transmitted on an electronic base.
The exhaust turbocharger must not put into service until the final machinery into which is it
to be incorporated has been declared in conformity with the provisions of this Directive.
Ingolf Ulbricht
Corporate Quality

Page 10 of 56 8th Edition (07/2010) HPR6000En08.doc

 Operating Instructions
HPR6000 Exhaust Gas Turbocharger Chapter 3

3 GENERAL INFORMATION ABOUT DANGER

3.1 Danger zone

The danger zone is defined by the engine as the turbocharger is an integral part of the
engine.

)
During turbocharger operation, the user must keep the danger zone free
of any objects so to ensure unhindered access to the unit.

Ear muffs should be worn as the sound level is high. Care should also be
taken when approaching the hot housings.

x The exhaust gas turbocharger is mounted on the engine. It may not be interfered with
when the engine is running.
x Make sure the exhaust gas pipes at the turbine side cannot come loose during operation
since exhaust gas might escape at this point.
x As the exhaust gas turbocharger is an integral part of the engine, its operation is
described in connection with the engine. However, its maintenance is described
separately in the operating instructions.

3.2 Operators and maintenance personnel

Operators and maintenance personnel are persons who are responsible for transport,
assembly, installation, operation, setting, maintenance, cleaning and troubleshooting.

Make sure to observe the following accident prevention regulations:

x winches, hoisting and drawing gear (BGV D 8)
x load take-up devices for hoisting operations (BGR 500 chapter 2.8)
If these regulations are not observed, your life and limb may be endangered!
1. The turbocharger may only be maintained by duly qualified and authorised persons.
2. In maintaining the turbocharger, the responsibilities shall be clearly defined and must be
adhered to so as to prevent confusing competencies with respect to the safety aspect.
3. The operating instructions shall be followed irrespective of what kind of work (operation,
maintenance, repair etc.) is concerned.
4. The cleaning, maintenance and repair work described in these instructions are easy to
understand by persons skilled in mechanical, cleaning and maintenance work.
The necessary tools and testing/inspection means must be available to these persons.
5. Operators are not allowed to interfere with the unit in a way that would affect machine
safety.
6. It is also within the responsibility of the operator to see to it that no unauthorised person
works on the turbocharger.

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 Operating Instructions
Chapter 3 HPR6000 Exhaust Gas Turbocharger
7. The operator must inform the user without delay of any safety-affecting changes to the
turbocharger.
8. In order to ensure a long service life, the exhaust gas turbocharger has to be operated in
accordance with the technical specification.

3.3 Installation of spare and wear parts

It is emphasised that spare parts and accessories not supplied by us are not
tested/inspected and approved by us. The installation and use of such products may
negatively affect the performance of your turbocharger. We assume no liability for damage
caused by the use of components and accessories not made by us.
For ordering spare parts and tools, please refer to the
x spare parts list
x tools list.
The spare parts lists attached (see chapter 8.2) contain all spare parts for the turbocharger.
DIN (standard) parts may be bought from specialised dealers.
For the assembly, disassembly and commissioning of the turbocharger, refer to the
respective chapters in these operating instructions.

Before doing any maintenance, cleaning or repair work, the engine must
have come to a standstill. Therefore turn the engine off and secure it
against unintentional re-starting.
See chapters 7.5.1 and 7.5.2 for maintenance jobs which can be done
during engine operation.
Make sure to observe the following accident prevention regulations:
x winches, hoisting and drawing gear (BGV D 8)
x load take-up devices for hoisting operations (BGR 500 chapter 2.8).
If these regulations are not observed, your life and limb may be
endangered!

)
See the inspection schedule (see chapter 6.4) for the maintenance
intervals.

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 Operating Instructions
HPR6000 Exhaust Gas Turbocharger Chapter 4

4 DESIGN

4.1 Brief description

Exhaust gas turbocharger (TC): Type HPR6000
Specification number: 558xxxx
Mass : 565 kg

4.2 Construction
The exhaust gas turbocharger (TC) HPR6000 is equipped with a single-stage radial flow
turbine and a single-stage radial flow compressor.
The turbine wheel and the shaft consist of one part, the compressor impeller is mounted on
the shaft. The rotor has a bearing consisting of two plain bearings in a bearing housing. The
compressor housing and the turbine inlet housing are flanged to the bearing housing. You
can use a silencer or alternatively an intake housing (intake elbow) at the entrance of the
compressor housing.
The plain bearings are lubricated by the lubricating oil system of the engine. The lubricating
oil flow depends on the oil temperature, oil pressure and TC speed.

4.3 Function
The rotor is driven by the exhaust-gas energy of the diesel engine. The exhaust gases
reach the turbine wheel via the turbine inlet housing and the turbine nozzle ring.
The compressor impeller mounted on the same shaft takes in the required combustion air
via a silencer, compresses the air to a higher pressure and transports the compressed air to
the engine via a charge air cooler.
The TC is not equipped with a special control device. The TC speed is adjusted depending
on the operating conditions of the engine.

4.4 Usage to the intended purpose

The exhaust gas turbocharger is intended for supercharging combustion engines. Any other
usage is not permitted and has to be cleared up with Kompressorenbau Bannewitz GmbH
(KBB) in advance.
Modifications and additional attachments to the TC are subject to a written consent of
Kompressorenbau Bannewitz GmbH, non-observance of the aforementioned invalidates
any rights of warranty claim.
The usage to the intended purpose also includes that the specified maintenance and
inspection work is carried out regularly and to the full extent (see Chapter 6.4).
The TC specification attached to the engine is thermodynamically adjusted and is binding
for this engine variant, i.e. if the TC has to be replaced, use the same TC specification
again.

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 Operating Instructions
Chapter 5 HPR6000 Exhaust Gas Turbocharger

5 OPERATION

5.1 Commissioning
Prior to commissioning, it is imperative to make sure that the plain bearings of the TC are
supplied with oil. The plain bearings are lubricated by the lubricating oil system of the
engine. The lubricating oil flow depends on the oil temperature, oil pressure and TC speed.
The lubricating oil pressures required for special operating conditions are listed in chapter
1.1.
Ensure and check the free return flow of the lubricating oil.
The following has to be checked :
x lubricating oil pressure upstream of TC,
x lubricating oil temperature upstream of TC.

x Ensure the lubricating oil supply of the plain bearings

(see chapter 1.1).
x Lubrication has to be started prior to start-up processes.
Pay special attention to prevent leakages in the oil supply and return
pipes to prevent oil from flowing onto the hot, gas-carrying housings in
order to prevent the formation of hazardous oil vapours (and fire risk).

5.2 Starting-up
The exhaust gas turbocharger is driven by the exhaust gases of the engine and is started
together with the engine.
The TC speed is adjusted depending on the operating conditions of the engine. The charge
air pressure required for the engine is fixed by adjusting the turbine nozzle ring and the
compressor diffuser during the TC tuning.
If the corresponding meters are available, enter the following measured values into the
engine log during engine operation (at least once every 24 operating hours):
x Speed of exhaust gas turbocharger
x Exhaust gas temperature upstream of turbine or downstream of cylinder
x Charge air temperature downstream of compressor or downstream of charge air cooler
x Charge air pressure downstream of compressor
x Lubricating oil temperature upstream of TC
x Lubricating oil pressure upstream of TC

x The engine has to be stopped immediately when the oil pressure falls
below the minimum value.
x Pay special attention to prevent leakages in the oil supply and return
pipes to prevent oil from flowing onto the hot, gas-carrying housings
in order to prevent the formation of hazardous oil vapours (and fire
risk).

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 Operating Instructions
HPR6000 Exhaust Gas Turbocharger Chapter 5

Additionally perform the following checks at regular intervals :

x Tightness of the exhaust gas, charge air and oil piping
x Smooth running of the exhaust gas turbocharger
The charge air pressure is utilised as a parameter for the exhaust gas turbocharger speed.
Unsteady operation (vibration of TC) indicates an increased unbalance of rotating parts
possibly resulting in the rotor or bearing being damaged (see chapter 6.5).

5.3 Stopping
After the engine has been stopped, the exhaust gas turbocharger continues to run for some
time.
The run out period depends on the installation.
If the rotor comes to an immediate standstill, this can be caused by one of the following
reasons:
x damaged bearings
x compressor impeller or turbine blades come in contact with the housing as the clearance
is compensated due to extensive forces caused by thermal distortion
x clamped foreign matters

)
The turbocharger must lubricated 15 minutes after the engine is turned
off.
The lubricating time is to be extended in case of engines with a turbine
inlet temperature >580°C (at full load) or oil inlet temperature >80°C.
Pay attention to the operating instructions of the engine manufacturer.

5.4 Failures
Failures can be detected by abnormal measured values (exhaust gas temperature, charge
air pressure, speed), heavy noise or leakages of lubricating oil pipes.
In case of irregularities on the TC, reduce the engine load or stop the engine.
Since even minor failures may cause heavy consequential damage, determine and
immediately eliminate the cause of failure (see chapter 6.5)

5.5 Emergency operation of the exhaust gas turbocharger

If the exhaust gas turbocharger has to be shut down due to a defect and the engine has to
run in emergency operating mode, perform the work according to chapter 7.5.3.

After shutting down the exhaust gas turbocharger, limit the engine output
in order to prevent the exhaust gas temperature from exceeding
admissible values downstream of the outlet valves.
Pay attention to the operating instructions of the engine manufacturer.

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 Operating Instructions
Chapter 5 HPR6000 Exhaust Gas Turbocharger

5.6 Measures for extended period without operation

When shutting down an exhaust gas turbocharger, which was operated with an engine
before, for more than twelve month, it has to be dismounted from the engine.
An inspection should be carried out in accordance with the maintenance schedule in chapter
6.4.
It is necessary to completely dismantle the exhaust gas turbocharger. All components are to
be cleaned and slightly rubbed with oil. Then the exhaust gas turbocharger can be
reassembled. All machined surfaces and flanges are to be evenly coated with an
anticorrosive agent (such as “Tectyl”). All openings should be sealed. Additionally, a
hygroscopic drying agent can be put into the interior spaces of the compressor housing and
the turbine inlet.
The preserved exhaust gas turbochargers and spare parts should be kept in a dry room
(humidity of 60 % max.) and protected from moisture, aggressive gases and vapours. At
rest, the exhaust gas turbocharger should be protected against steady vibration which may
damage the bearings.
The state of the preserved parts and exhaust gas turbochargers should be checked every
twelve months.
Before re-operating the exhaust gas turbocharger, it is necessary to clean off the
anticorrosive agent.

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 Operating Instructions
HPR6000 Exhaust Gas Turbocharger Chapter 6

6 MAINTENANCE

6.1 General
Maintenance and monitoring work is summarised in the maintenance schedule in chapter
6.4.
Proper maintenance work enables failures to be detected in time. Maintenance work also
indicates necessary overhauls as well as work to be scheduled during yard or harbour times
or on interruptions.
The operating hours specified in the maintenance schedule are to be considered as average
values. They can be extended or shortened according to existing operating conditions as
well as adjusted to the maintenance intervals of the engine.
It is important to eliminate even minor, apparently insignificant defects immediately and to
determine and eliminate their causes in order to prevent consequential damage at the
engine or exhaust gas turbocharger.
If the engine is not equipped with an automatic monitoring system with data recording,
entries into the engine log are required at least once every 24 operating hours. Thereby,
deviations can be detected in time.

6.2 Maintenance work

In order to keep the exhaust gas turbocharger in a safe condition, perform the inspection
and check of various subassemblies and components according to the maintenance
schedule in chapter 6.4.
The chapter 7.5 includes detailed instructions on the work sequence for assembly and
disassembly work.

Make sure to observe the following accident prevention regulations:

x winches, hoisting and drawing gear (BGV D 8)
x load take-up devices for hoisting operations (BGR 500 chapter 2.8)
If bolts and nuts cannot be loosened immediately, do not apply excessive force in order to
avoid damage of threads causing subsequent machining. Apply diesel fuel and wait for half
an hour. In this way, "seizing" of threads can be avoided in most cases.
For bolted connections under heavy thermal load, bolts and nuts are made of high-
temperature material. Make sure that you do not confuse these bolts and nuts with
conventional ones during assembly work. In order to prevent burning and to facilitate
subsequent disassembly, apply a suitable bolt paste (e.g. molybdenum sulphide paste,
graphite) to those bolted connections prior to assembly. Contaminations have to be
previously removed from the threads.

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 Operating Instructions
Chapter 6 HPR6000 Exhaust Gas Turbocharger
During assembly, all bolted connections equipped with locking elements (lock nut, locking
plate, spring washer) have to be properly locked.

)
For a basic overhaul or repairs affecting essential parts of the exhaust
gas turbocharger, it is recommended to document their condition. The
"Service report" form can be used as a sample (see chapter 7.3).

6.3 Cleaning
Cleaning the silencer
x see chapter 7.5.8

Cleaning the compressor

x Cleaning during operation: see chapter 7.5.1
x Mechanical cleaning: see chapters 7.5.7 and 7.5.9
Remove the compressor housing and silencer. (The compressor impeller remains on the
shaft.) Remove all deposits with diesel fuel or another admissible liquid cleansing agent.

Make sure to observe the accident prevention regulations!

While washing, make sure to prevent the cleansing agent from entering
the charge air piping or the interior of the turbocharger.

Cleaning the turbine

x Cleaning during operation: see chapter 7.5.2
(for heavy fuel oil operation only)

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 Operating Instructions
HPR6000 Exhaust Gas Turbocharger Chapter 6

6.4 Maintenance schedule

6.4.1 Maintenance for operation with Marine Diesel Oil (MDO)

)
The operating hours given in the table are guidelines which can be
reduced for adjustment to the maintenance intervals of the engine.

Item Chapter Maintenance work Required Maintenance interval

parts (operating hours)

1. Check for abnormal noise 24

2. 7.5.1 Compressor washing during 24 - 48

operation, actuate compressor
washing system
3. 7.5.8 Replace filter mat at silencer approx. 500
or on demand
4. Check fastening bolts at the feet, once after
tighten all housing bolts and commissioning, then
piping joints every 1,000 hours
5. 7.5.4 - Inspection I (9910) max. 12,500
7.5.12 x disassembly (9920)
x cleaning (9930)
x checking of rotor & bearings
x checking of housings
x assembly
6. 7.5.4 - Inspection II (4000) max. 25,000
7.5.12 x like inspection I (9910)
x replacement of the bearings (9920)
(9930)
7. 7.5.4 - Inspection III (2000) max. 50,000
7.5.12 x like inspection I (4000)
x replacement of the rotor (9910)
(9920)
(9930

(2000) Rotor (9910) Set “Gaskets”

(4000) Bearings (4010) and (4020) (9920) Set “Standard parts 1”
(9930) Set “Standard parts 2”

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 Operating Instructions
Chapter 6 HPR6000 Exhaust Gas Turbocharger
6.4.2 Maintenance for operation with Heavy Fuel Oil (HFO)

)
The operating hours given in the table are guidelines which can be
reduced for adjustment to the maintenance intervals of the engine.
The interval of the inspection “I” are to be shortened dependent on the
fuel quality.

Item Chapter Maintenance work Required Maintenance

parts interval
(operating hours)

1. Check for abnormal noise 24

2. 7.5.1 Compressor washing during 24 - 48

operation, actuate compressor
washing system
3. Turbine washing during operation, Approx. 300
actuate turbine washing system depending on HFO
7.5.2 Cleaning with water quality
4. 7.5.8 Replace filter mat at silencer Approx. 500
or on demand
5. Check fastening bolts at the feet, once after
tighten all housing bolts and piping commissioning, then
joints every 1,000 hours
6. 7.5.4 - Inspection I (9910) max. 12,500
7.5.12 x disassembly (9920)
x cleaning (9930)
x checking rotor and bearings
x checking housing
x assembly
7. 7.5.4 - Inspection II (4000) max. 25,000
7.5.12 x like inspection I (9910)
x replacement of bearings (9920)
(9930)
8. 7.5.4 - Inspection III (2000) max. 50,000
7.5.12 x like inspection I (4000)
x replacement of the rotor (9910)
x assembly (9920)
(9930)

(2000) Rotor (9910) Set “Gaskets”

(4000) Bearings (4010) and (4020) (9920) Set “Standard parts 1”
(9930) Set “Standard parts 2”
The nozzle ring is subject to an increased wear for heavy fuel oil
operation. Therefore it is a wear part.
The lifetime of the nozzle ring is approximately 12,500 hours, but it
depends on HFO quality and operating conditions.
After exceeding the lifetime the nozzle ring should be replaced in case of
fundamental change of performance data as charge air pressure and
exhaust temperature.

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 Operating Instructions
HPR6000 Exhaust Gas Turbocharger Chapter 6

6.5 Trouble-shooting table

Charge air pressure and/or speed too high

Charge air pressure and/or speed too low
Temp. upstream of turbine too high

Lubricating oil pressure too low

Fault

Delayed start, short coasting

Lubricating oil leakage

Turbocharger vibrates
Turbocharger pumps
Heavy noise
Causes
Chapter
Silencer or air filter contaminated 7.5.8
Compressor contaminated 7.5.9
Charge air cooler contaminated engine
Leaking exhaust gas piping engine
Exhaust gas counter pressure too high engine
downstream of turbine
Turbine wheel or compressor impeller 7.5.10 -
damaged (unbalanced) 7.5.12
Defective bearing 7.5.4
Rotor in contact with housing 7.5.11
Foreign matter in turbine or compressor 7.5.9,
(unbalanced) 7.5.10
Turbine contaminated 7.5.2
Turbine nozzle ring contaminated 7.5.2
Failure of fuel injection at engine engine
Leaking charge air piping engine
High air intake temperature engine
Inlet or outlet valves of the engine engine
contaminated
Low air intake temperature engine
Lubricating oil filter contaminated engine
Lubricating oil pressure gauge defective engine
Lubricating oil inlet temperature too high engine
Excessive pressure in oil return engine
Sealing air ineffective
Gaskets damaged, connections leaking
Plain compression rings damaged 7.5.11

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 Operating Instructions
Chapter 7 HPR6000 Exhaust Gas Turbocharger

7 DISASSEMBLY AND ASSEMBLY

7.1 Introduction
The chapter 7.5 shall enable the user to perform certain repair and maintenance work by
himself.
Work sheets are sorted according to the sequence required to disassemble the exhaust gas
turbocharger.
It is assumed that the staff is familiar with the work and that the tools required are ready at
hand. Furthermore, the exhaust gas turbocharger has to be accessible and corresponding
hoists have to be available.

Make sure to observe the following accident prevention regulations:

x winches, hoisting and drawing gear (VBG 8)
x load take-up devices for hoisting operations (VBG 9a)

7.2 Checking the components

The check list shown below can be used as instruction for checking the condition of the
exhaust gas turbocharger and its major components. As a rule, the user is able to eliminate
minor damage. Major damage effecting rigidity, balance and smooth running of rotating
components should be eliminated by the manufacturer or an authorised workshop. If
damaged parts are returned for repair, ensure an appropriate protection against
transportation damage.
After having disassembled the exhaust gas turbocharger, perform the following checks at
the cleaned parts. The condition is to be recorded in the "Service report" form, chapter 7.3.

Rotor, compl. - Are the turbine blades damaged or did they contact the housing?
- Are contact traces visible at the housing?
- Are contact traces visible at the rotor?
- Does the shaft run smoothly?
- How is the condition of the bearings?
- Are the plain compression rings heavily worn?

If re-working is performed or if rotor parts are replaced, rebalancing has

to be executed! For admissible residual unbalance, refer to clearance
sheet, chapter 7.3)

)
Wear occurs at the plain compression rings at the turbine and
compressor sides in axial direction during running-in, which is intended
and could be max. 0.5 mm.

Compressor impeller
- Can you detect any sliding traces or cracks at the compressor impeller?
- Are the bore and the axial surface OK?

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 Operating Instructions
HPR6000 Exhaust Gas Turbocharger Chapter 7

Bearing - Is the axial clearance of the rotor impeller inadmissible high?

- Are the running surfaces of the compressor and/or turbine bearings heavily
worn?

)
For evaluation of bearings, refer to chapter 7.5.4 .

Turbine nozzle ring

- Are the guide vanes twisted or worn out?
- Is foreign matter clamped into the ducts?
- Can you detect traces of foreign matter?

Housing - Are the housings heavily contaminated by oil, dust or soot?

- Is there any leakage at the housing? (Main items: connection flanges, charge
air, exhaust gas and oil connections)
- Are all bolts and nuts tight?

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 Operating Instructions
Chapter 7 HPR6000 Exhaust Gas Turbocharger

7.3 Service report

Turbocharger type ฀ HPR6000

Specification - no.: Serial - no.:
Commissions - no.:
Engine type : Engine no.:

Fuel: ฀ HFO ฀ MDO ฀ Gas ฀ other

Application :
Name of customer :
Address (place of :
installation, name of vessel)
Date of commissioning T/C :
Operating hours T/C (since commissioning) :
Inspection/Repair on : by :

Reason of Inspection: ฀ modification ฀ planned inspection

฀ warranty ฀ breakdown/damage
Results of the component inspection

Rotor/ shaft IMO - no. :T

Serial - no. (old) :L Serial – no. (new) : L

Turbine blades condition: ฀ well ฀ cracked ฀ blade parts missing

฀ traces of foreign matter ฀ scratch marks
Contamination / deposit ฀ no ฀ slight ฀ heavy
Bearing seats ฀ good ฀ marks ฀ bearing material applied
Scratch marks on the shaft ฀ no ฀ yes
Piston rings run in ฀ no ฀ yes
Rotor rebalanced ฀ no ฀ yes
Notes:

Compressor impeller IMO no. :C

Serial – no. (old) :G Serial – no. (new) : G

Contamination / deposit ฀ no ฀ slight ฀ heavy

Condition of bore ฀ good ฀ marks ฀ fretting corrosion
Blades tarnished ฀ no ฀ yes
Blades cracked ฀ no ฀ yes
Notes:

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 Operating Instructions
HPR6000 Exhaust Gas Turbocharger Chapter 7

Thrust ring ฀ used ฀ replaced Cause :

Bearing surface: ฀ good ฀ marks ฀ bearing material applied
Spacer ฀ used ฀ replaced Cause :

Bearing surface: ฀ good ฀ marks ฀ bearing material applied

Turbine nozzle ring
Cross section : IMO no. :T
Serial – no. (old) : Serial – no. (new) :

Contamination, guide vanes ฀ no ฀ slight ฀ heavy

Condition, guide vanes ฀ good ฀ part torn out
฀ twisted ฀ traces of foreign matter
฀ scaled ฀ worn
Notes:
Compressor diffuser ฀ used ฀ replaced Cause :
IMO no. :C

Contamination, guide vanes ฀ no ฀ slight ฀ heavy

Damages ฀ no ฀ yes
Notes:

Turbine housing ฀ used ฀ replaced Cause :

Contamination / deposit ฀ no ฀ slight ฀ heavy

Incipient cracks ฀ no ฀ yes
Scratch marks ฀ no ฀ yes
Notes:

Compressor housing ฀ used ฀ replaced Cause :

Contamination / deposit ฀ no ฀ slight ฀ heavy

Incipient cracks ฀ no ฀ yes
Scratch marks ฀ no ฀ yes
Notes:

Bearing housing ฀ used ฀ replaced Cause :

Contamination / deposit ฀ no ฀ slight ฀ heavy

Sealing air bore ฀ clean ฀ narrowed ฀ blocked
Piston ring bore ฀ good ฀ damaged
Notes:

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 Operating Instructions
Chapter 7 HPR6000 Exhaust Gas Turbocharger
Compressor bearing ฀ used ฀ replaced Cause :
Carrying surface radial bearing Carrying surface thrust bearing
B(rad) : ................ mm B(ax) : ................. mm

Grooves ฀ no ฀ yes Grooves ฀ no ฀ yes

Notes:

Turbine bearing ฀ used ฀ replaced Cause :

Carrying surface radial bearing
B(rad) : ................ mm

Grooves ฀ no ฀ yes
Notes:

Silencer ฀ used ฀ replaced Cause :

Contamination / deposit ฀ no ฀ slight ฀ heavy

Replaced ฀ no ฀ yes
Felt mat ฀ good ฀ loose
Notes:

Engine test run ฀ no ฀ yes

Notes:

Other defects / component:

) Please make pictures to record the condition of the turbocharger!

Please sent the service report to:

Service Department of Kompressorenbau Bannewitz GmbH

Fax-no.: +49 351 40 85 648
E-Mail.: [email protected]

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 Operating Instructions
HPR6000 Exhaust Gas Turbocharger Chapter 7

7.4 Clearance sheet

V a l u e s (in mm)

New condition Limit

Measured during
clear.
Clear. Parts designation min max max *) dismantling assembly
1 Compressor impeller - compressor 0.55 0.65 0.9
housing (radial)
2 Compressor impeller - compressor 0.5 0.9 1.2
housing (axial)
5 Tilting clearance (rotor – bearing) 0.6 0.8
(measured at location E)
12 Turbine wheel - turbine housing 0.55 0.65 1.0
(radial)
14 Turbine wheel - turbine housing (axial) 0.5 0.75 1.1
15 Rotor - compressor bearing (axial) 0.12 0.2 0.23
18 Compression ring - turbine side 0.2 0.5 -
19 Compression ring - compressor 0.1 0.3 -
bearing cover
Admissible radial deviation of rotor 0.020
measured at location E
*) re-working or replacement required if exceeded
Admissible residual unbalance of rotor: 26.5 gmm compressor bearing
and 21.3 gmm turbine bearing
Tightening torque of rotor nut: 220 (+ 5) Nm

Clear. 19 (S19 = L2 – L3) Clear. 18

a) compressor b) compressor
bearing fixed bearing loosened
X – reference edge bearing housing

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 Operating Instructions
Chapter 7 HPR6000 Exhaust Gas Turbocharger
7.5 Work sheets
7.5.1 Compressor washing

(Every 25 - 50 operating hours)

Legend
1 Ball valve
2 Water tank
3 Water piping
4 Air piping

Work sequence:
1. Operate the engine close to full load.
2. Open the water tank (2), fill with clean water (no sea water) (approx. 0,5 l), close the
water tank.
3. Open the ball valve (1), wait for approx. 20 sec., close valve (1). The compressed air
flows through the air piping via the ball valve (1) into the water tank. The water is
pressed through the water piping into the injection pipe, atomised by the air taken in
and hits the compressor blades at high speed.

x Perform cleaning with warm engine close to full load operation only.
x Continue to operate the engine for at least 10 to 15 min. after cleaning.
x Do not wash before a pause of operation. Corrosion risk!
x Washing is ineffective in case of hardened deposits, thus perform
washing at regular intervals.
x Do not use any chemical additives!

)
If the negative pressure upstream of the compressor is too high, water is
already taken in when the water is filled into the water tank and the
cleaning effect is reduced. In order to avoid this, you can:
x install the water tank at a lower level or
x include a second stop valve, which is opened after the water tank has
been closed, into the water piping.

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 Operating Instructions
HPR6000 Exhaust Gas Turbocharger Chapter 7

7.5.2 Turbine washing

(For heavy fuel oil operation only, every 300 operating hours approximately respective
depending on HFO quality)

)
Heavy fuel oil operation results in contamination and deposits on nozzle
ring and turbine wheel reducing the efficiency. Due to these deposits the
charge air pressure will be increased.
The washing intervals depend on the fuel quality and operating
conditions. That's why they must be adjusted based on the experience
gained during engine operation if necessary later on.
The increase of charge air pressure by for e.g. more than 0.1 bar (at same
engine power) could be used for adjusting the washing interval, which
could be adjusted within 25 to 600 hours.
Read and take down the charge air pressure and exhaust gas
temperatures at a reference point (at 75 % or 100 % of the output) before
and after washing to check the washing effect.

Legend (Example, could vary depending on engine installation)

1 Sanitary fresh water 5 Stop valve 9 Valve
2 Regulating valve 6 Wash-water piping 10 Escape funnel or sight
glass
3 Fresh-water piping 7 Injector 5000 Turbine housing
4 Removable flexible tube 8 Drain 9100 Exhaust gas elbow
Work sequence:
1. Check injection nozzle/ valve (7) for free passage!
2. Connect the flexible tube (4) to fresh-water piping (3).
3. Reduce the engine output so that the temperature before turbine has come down
to its specified value. (see table)

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 Operating Instructions
Chapter 7 HPR6000 Exhaust Gas Turbocharger

)
If the temperature before turbine is not available, the temperature after
turbine can be used as reference point!

4. Wait for approx. 10 minutes!

5. Open the valve (9) of the drain (8) (if present).
6. Open valve (2) and adjust the water pressure (see table).
7. Open stop valve (5) for approx. 30 seconds and close again.
8. Wait for approx. 3 minutes so that the injected water can evaporate.
9. Repeat steps 7. and 8. twice or three times.
10. Close the stop valve (5), valve (2) and the valve (9) of the drain.
11. Run dry the exhaust gas turbocharger at constant load for approx. 30 minutes,
increase engine load slowly!
12. Repeat the washing process if the exhaust gas turbocharger is affected by vibrations
which did not occur before.
13. Remove the piece of flexible tube (4).

)
The effect of the turbine washing could be controlled by changing of
charge air pressure and exhaust temperature!
Water pressure and washing period could be increased for improvement
of washing effect, if necessary!

Operating values for turbine washing

Exhaust gas Exhaust gas Exhaust gas Water pressure Total

temperature temperature after temperature (gauge) washing period
before turbine turbine after cylinder
400 – 420 °C <330 °C 300 – 330 °C 2.4 – 4.5 bar 3-4x 30 sec

x Hot exhaust gas can escape from the drain - Risk of burning!
x Continue to operate the engine for at least 30 minutes after cleaning.
x Do not wash before stoppage of engine. Corrosion hazard!
x Washing is ineffective in case of hardened deposits, thus perform
washing at regular intervals from the beginning.
x In the case of ineffective washing the turbine is to be cleaned
mechanically. For this purpose the turbine housings are to be
dismantled.
x Pay attention also to instruction of the engine’s operating manual!

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 Operating Instructions
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7.5.3 Shutting down the exhaust gas turbocharger

)
In case of a TC damage especially at the rotor or bearing, it is
recommended to shut down the TC in order to avoid any further damage.
Pay attention to the operating instructions of the engine manufacturer.

When the engine is operated with a defective exhaust gas turbocharger,

limit the engine output in order to prevent the exhaust gas temperature
from exceeding admissible values downstream of the cylinder.

Related chapters
7.5.7, 7.5.9, 7.5.10

Initial condition: The turbocharger is mounted on the engine.

Mass of the silencer approx. 63 kg
Mass of the air intake housing approx. 24 kg
Mass of the compressor housing approx. 145 kg
Mass of the cartridge approx. 151 kg
Mass of the sealing device (9804) approx. 32 kg
Work sequence:
1. Disassemble the silencer (9010) / air intake housing (9020) (see chapter 7.5.7).
2. Loosen all piping at the compressor housing (6010).
3. Disassemble the compressor housing (6010) (see chapter 7.5.9).
4. Remove the cartridge (1200) (bearing housing with rotor) and turbine nozzle ring
(7010) from the turbine inlet housing (5010) (see chapter 7.5.10).
Use a hoist!

)
Caution in removing the cartridge in order to avoid damage to the turbine
blades.

5. Attach the sealing device (9804) to the turbine inlet housing (5010) and tight with
ripped washers (5100) and hexagon nuts (5090).
6. Screw the sealing device (9804) to the engine console.

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 Operating Instructions
Chapter 7 HPR6000 Exhaust Gas Turbocharger
7.5.4 Bearing check

Related chapters 7.5.7 to 7.5.11

New bearing
Thrust bearing (4020)
Sliding surface

Radial bearing (4010/4020)

Wedge-
shaped
Load- sector
carrying
surface
Legend
D Bearing diameter
R Radius of wedge surface
B(ax) Load-carrying surface width of
thrust bearing Bearing after
B(rad) Load-carrying surface width longer
of radial bearing operation
Tools required Sliding surface
1 Micrometer screw
1 Calibre gauge
Initial condition: Compressor bearing (4020) and turbine bearing (4010) are disassembled.
Work sequence 1 : Load-carrying surface of radial bearings
1. Carefully clean the bearing!
2. Determine the width of the load-carrying surface B(rad)!
3. Visual inspection!

)
Replace bearing if :
x the width of the load-carrying surface B(rad) at the compressor and
turbine has reached 18 mm,
x heavy dirt marks can be seen.
Determine the causes!

Work sequence 2 : Load-carrying surface of thrust bearings

1. Carefully clean the bearing.
2. Determine the width of the load-carrying surface B(ax).
3. Determine the axial clearance S15.
4. Visual inspection!

)
Replace bearings if :
x B(ax) is larger than 2/3 of the sliding surface,
x the sliding surfaces reveal heavy dirt marks.

If bearing material is deposited on the bearing surfaces of the shaft, a

repair is required in an authorised workshop.

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7.5.5 Disassembly of the complete turbocharger

a)

b)

Mass of complete TC is approx. 565 kg

Make sure to observe the following accident prevention regulations:
x winches, hoisting and drawing gear (BGV D 8)
x load take-up devices for hoisting operations (BGR 500 chapter 2.8)
Pay attention to piping and sheathings!
Work sequence :
1. Remove the sheathings from the turbine housing and loosen the exhaust gas piping if
necessary.
2. Loosen the exhaust gas piping from the turbine housings. Pay attention to gaskets!
3. Loosen the piping at the compressor housing (6010), remove them if necessary.
4. Attach the exhaust gas turbocharger to a hoist. For this purpose
a) Screw the eye screw into the bearing housing (3010) or
b) Put two ropes around the flange between the silencer and the compressor housing
and between the turbine inlet housing and the exhaust-gas elbow.
5. Loosen and remove the fastening screws at the sides of the bearing housing (3010).
6. Lift and carefully place the exhaust-gas turbocharger on a wooden base, secure
against tilting.
7. Cover the openings of the lubricating oil pipes in the engine console in order to prevent
dirt from entering the lubricating oil system.

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 Operating Instructions
Chapter 7 HPR6000 Exhaust Gas Turbocharger
7.5.6 Assembly of the complete turbocharger

a)

b)

Mass of complete TC is approx. 565 kg

Make sure to observe the following accident prevention regulations:
x winches, hoisting and drawing gear (BGV D 8)
x load take-up devices for hoisting operations (BGR 500 chapter 2.8)
Pay attention to piping and sheathings!
Work sequence :
1. Attach the complete TC to a hoist (see chapter 7.5.5) and put it onto the engine
console. Pay attention to the pipe connections!
2. Screw in and tighten the fastening screws at the sides of the bearing housing (3010).
3. Connect the exhaust gas piping to the turbine housings.
4. Attach the sheathing.
5. Connect the charge air piping.
6. Connect the water and air piping for compressor washing.
7. Tighten the bolts at the connecting pipes.
8. Supply lubricating oil to TC and check all flanged connections for leakages.

After having installed the TC, check that the assembly is free of stresses
and forces. Rework piping, if necessary.

)
Only use perfect gaskets for the pipe joints. Apply molybdenum sulphide
lubricant to the connecting bolts of the exhaust gas piping prior to
installation.

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7.5.7 Disassembly and assembly of the silencer or air-intake housing

Mass of the silencer approx. 63 kg

Mass of the air-intake housing approx. 24 kg
Tightening torque of V-band 35 Nm !
Work sequence 1 : Disassembly of silencer / air-intake housing
1. Put a rope around the silencer (9010) or intake housing (9020) and attach it to a hoist.
2. Slightly loosen the V-band (6020) at both screws (6190).
3. Remove the V-band (6020) from the flange.
4. Pull off the silencer/air-intake housing in axial direction from the compressor housing
(6010).
Work sequence 2 : Assembly of silencer / air-intake housing
1. Put a rope around the silencer (9010) or intake housing (9020) and attach it to a hoist.
2. Slide silencer / air-intake housing in axial direction onto the compressor housing
(6010).
3. Install the V-band (6020) and tighten at both screws (6190).

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 Operating Instructions
Chapter 7 HPR6000 Exhaust Gas Turbocharger
7.5.8 Cleaning the silencer

(Every 250 or 12,500

operating hours)
Related chapter 7.5.7

General
In most cases merely the filter mat has to be replaced. For this purpose the silencer may
stay at the exhaust gas turbocharger.
The given maintenance interval of 250 operating hours is just a mean guide value, since the
accumulation of dirt in the filter mat and the pressure drop resulting there from are largely
dependent on the environment. For operation under extreme conditions, it is recommended
to add a maintenance indicator (water gauge) signalling the right moment for cleaning.
This indicator shall be adjusted so as to give the cleaning signal when a vacuum of
app. 100 mm w.g. is reached at point A intended for mounting (e.g. a MANN maintenance
indicator for air filters, max. 200 mm w.g. = 20 mbar).
Work sequence: Replacing the filter mat
1. Open and remove the tension tapes (9014)
2. Pull the filter mat (9012) from the silencer (9010) .
3. Install the new filter mat (9012) and tension tapes (9014).
Work sequence: Cleaning the silencer

)
If the silencer is heavily contaminated or if an inspection is carried out,
the silencer has to be cleaned completely..

1. Dismount the silencer (9010) (see chapter 7.5.7).

2. Externally clean with a soft brush and let dry.
3. Install the silencer (9010).
To operate the exhaust gas turbocharger without a filter mat is not
permitted!
Pay attention to applicable accident prevention regulations (handling of
hazardous, volatile, combustible solvents) and fire protection regulations
(DIN 14096). Cleaning by P3-solution or trichlorethylene is prohibited. If
other solvents are used, check the compatibility with the filter material. In
case of ship operation pay attention to the regulations of the
classification societies with regard to washing liquids.

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7.5.9 Disassembly and assembly of the compressor housing

Mass of cartridge (bearing housing with rotor) approx. 151 kg.

Mass of compressor housing approx. 145 kg.
Make sure not to damage the compressor impeller during assembly and
disassembly of the compressor housing.
Work sequence 1 : Disassembly of the compressor housing
1. Slightly loosen the hexagon nuts (6160) at the clamping flanges (6140).
2. Turn the compressor housing (6010) until the eye bolt can be attached to the hoist.
3. Completely loosen and remove the clamping flanges (6140).
4. Remove the compressor housing (6010) and put it on a wooden base.
5. Loosen and remove the screws (6070) and washers (6080).
6. Remove the compressor housing (6010) from the insert (6040), pay attention to the
shims (6131 – 6135) .
7. Loosen and remove the screws (8040) together with stop bushings (8020).
8. Remove the compressor diffuser (8010).
9. Remove O-rings (6030, 6090 and 8030) and check for damage.
Work sequence 2 : Assembly of the compressor housing
1. Install and, if necessary, replace the O-rings (6030, 6090 and 8030).
2. Lay the insert (6040) with shim (6131 – 6135) on a wooden base. And then lay the
compressor housing (6010) on the insert (6040).
3. Tighten the insert (6040) with screws (6070) and washers (6080).
4. Slide the compressor diffuser (8010) onto the bearing housing centring (3010) and
fasten with the stop bushings (8020) and screws (8040).
5. Attach the compressor housing (6010) to a hoist and slide it onto the bearing housing
(3010).
6. Install the clamping flanges (6140) and slightly fasten with washers (6170) and
hexagon nuts (6160).
7. Turn the compressor housing (6010) into the required housing position.
8. Tighten the hexagon nuts (6160) at the clamping flanges (6140).

)
x Mark the position of the compressor housing (6010)!

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 Operating Instructions
Chapter 7 HPR6000 Exhaust Gas Turbocharger
7.5.10 Disassembly and assembly of the cartridge

Mass of cartridge (bearing housing and rotor) approx. 151 kg.

Mass of the turbine inlet housing approx. 145 kg.
Caution in disassembling and assembling in order to avoid damage to
the turbine blades.
Caution in disassembling the turbine inlet housing in order to prevent the
turbine nozzle ring from falling out!
Work sequence 1 : Disassembly of the cartridge
1. Slightly loosen the hexagon nuts (5090) and ripped washers (5100) and take away.
2. Screw eye screws in the turbine inlet housing (5010) and hoist it.
3. Loosen both screws on the feet side of cartridge (1200) and take away.
4. Forcing-off uniformly the cartridge (1200) with forcing screw. Are the connection with
carbon glued, net with diesel fuel and wait a minute.
5. Move careful the cartridge (1200) out of the turbine housing (5010) in axial direction.
Put it on a wooden plate.
6. Remove the turbine nozzle ring (7010) from the turbine housing (5010).
Work sequence 2 : Assembly of the cartridge
1. Clean the connecting flange between the bearing housing and turbine housing from
combustion residues using fine abrasive cloth. Subsequently, apply a molybdenum
sulphide lubricant to the flange.
2. Insert the turbine nozzle ring (7010) into the turbine inlet housing (5010), pay attention
to the position of the locating bolts (7020)!
3. Fasten the turbine inlet housing (5010) by means of a rope at the hoist and move it
towards the cartridge (1200)
4. Carefully slide the turbine inlet housing (5010) onto the bearing housing. Screw fast the
hexagon nut (5090) with the ripped washers (5100).
5. Tighten the screws for the feet on the engine console.
6. Check the rotor for contact by slightly rotating it.

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7.5.11 Disassembly of the rotor, complete

) For disassembling the rotor, mount the cartridge on a rack (9822) (see
chapter 8.3.2)

Mass of the cartridge approx. 151 kg

Mass of the complete rotor 32 kg

Work sequence :
1. Disassemble the speed sensor (9110) - if provided – and remove it.
2. Put the locking device (9801) on the turbine wheel and attach the device to the flange
of bearing housing (3010).
3. Loosen the rotor nut (2060) with a torque spanner.
4. Remove the rotor nut (2060) and clutch disc (2050).
5. Carefully remove the compressor impeller (2040) from the shaft (2010).

)
The installation position of the compressor impeller in relation to the
shaft is marked or has to be remarked with a scriber.

6. Loosen the hexagon socket screws (3090).

7. Remove the bearing cover of the compressor (3040); if necessary force off the cover
with hexagon socket screws (3090). The plain compression ring (2070) is located in
the bearing cover.

)
Pay attention to the gaskets (3081/3/5) under the bearing cover (3040)!

8. Remove the spacer (2030) from the shaft.

9. Loosen the hexagon socket screws (3100).
10. Remove the compressor bearing (4020), force off if necessary.

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Chapter 7 HPR6000 Exhaust Gas Turbocharger

11. Put the extractor (9803) on the shaft (2010) and screw it into the thread of the thrust
collar (2020).
12. Remove the thrust collar (2020) from the shaft.
13. Move the guide sleeve (9805) on the shaft (2010).
14. Carefully pull the shaft (2010) out of the bearing housing (3010).
15. Remove the plain compression ring (2070) from the shaft.
16. Remove the feather key (2080) from the shaft.

17. Remove the heat shield (3030).

18. Pull the bearing guide sleeve (3020) out of the bearing housing (3010) by using forcing
screws, do not cant.

)
Pay attention to the gaskets (3081/3/5) under the bearing guide sleeve
(3020)!

19. Loosen the screw plugs (3120), remove the separating plate (3060).
20. Loosen the screw plug (3200) and remove with washer (3210).
21. Pull the turbine bearing (4010) out of the bearing guide sleeve (3020).

)
Now the turbocharger is disassembled. Check, evaluate and clean the
parts according to chapters 7.2 and 7.3.

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HPR6000 Exhaust Gas Turbocharger Chapter 7

7.5.12 Assembly of the rotor, complete

Related chapters 7.5.5 - 7.5.11

Mass of the cartridge approx. 151 kg

Mass of the complete rotor 32 kg

)
x For assembling the rotor, mount the bearing housing on an
assembling trestle.

x Prior to the assembly, check the cleanliness of the bearing housing,

oil-conducting ducts and sealing air piping.

x If all components and gaskets are to be reused, it is not necessary to

check the clearances, otherwise pay attention to the specification
given in the clearance sheet, chapter 7.4.

Work sequence :
1. Insert the turbine bearing (4010) into the bearing guide sleeve (3020) and tighten with
screw plug (3200) and washer (3210).
2. Check that the thread plug (3110) is screwed into the bearing guide sleeve (3020)!

Always install the turbine bearing (4010) with 3 cylindrical pins (4050)
(protection against torsion)!
Always insert the thread plug (3110) in the bearing guide sleeve (3020). Do
not forget the thread plug when components are replaced!

3. Insert the separating plate (3060), fasten with screw plugs (3120).
4. Insert the bearing guide sleeve (3020) with the original gasket (3081/3083/3085) or a
gasket of the same thickness into the bearing housing (3010), do not cant.
5. Fasten the bearing guide sleeve (3020) with two screws.
6. Attach the heat shield (3030) to the centring on the bearing housing.

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 Operating Instructions
Chapter 7 HPR6000 Exhaust Gas Turbocharger

7. Insert the plain compression ring of the turbine (2070) into the shaft groove.
8. Insert the feather key (2080) into the groove.
9. Use the guide sleeve (9805) to move in the shaft.
10. Apply clean oil to the turbine bearing. Carefully insert the shaft (2010) into the bearing
housing (3010).
11. Apply oil to the thrust collar (2020) and put the collar onto the shaft.

12. Apply oil to the compressor bearing (4020). Put the bearing onto the shaft with its flat
flange side pointing downward and fasten with Hexagon socket screws (3100) with
ripped washers(3130).
13. Check clearance S18: (only if components are replaced)
a) b)

a) Fasten the compressor bearing (4020) with the hexagon socket screws (3100). Press
the shaft (2010) against the bearing housing. Apply a dial gauge to the shaft end
and adjust it to zero.
b) Loosen the hexagon socket screws (3100) and again force-off the compressor bearing

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HPR6000 Exhaust Gas Turbocharger Chapter 7

(4020) by approx. 1 mm. The shaft is displaced by the clearance S18; correct by
changing the thickness of the gasket (3081-3085) under the bearing guide sleeve if
necessary.
14. Attach the locking device (9801) for the rotor to the turbine wheel and fasten it to the
flange of the bearing housing.
15. Slide the spacer (2030) onto the shaft up to the shoulder; pay attention to the assembly
position.
16. Check clearance S19: (S19 = L2 – L3)
(X – reference edge at bearing housing)

x Determine the dimension L3.

x Again remove the spacer (2030).
x Install the compressor bearing cover (3040).
x Determine the dimension L2 and calculate S19.
x Correct S19 by changing the thickness of the gasket under the compressor
bearing cover (3040).
17. Install and fasten the compressor bearing cover (3040) with hexagon socket screws
(3090) and ribbed washers (3130) (Nm).
18. Insert the plain compression ring (2070) into the bearing cover (3040).
19. Slide the compressor impeller (2040) onto the shaft (2010); pay attention to the
assembly position.
20. Grease the threads with a lubricant containing MoS2. Install the clutch disc (2050) and
rotor nut (2060).
The mounting marks at the shaft and the compressor impeller must
match.

)
Lock the rotor by means of the locking device (9801). It is imperative to
use a universal joint with the torque spanner!

21. Tighten the rotor nut (2060) - tightening torque see in chapter 7.4.
22. Check the rotor for smooth running: Slowly rotate the rotor. It must be possible to
rotate the rotor easily without sensible resistance.
23. Check the rotor for truth of rotation: Apply a dial gauge to the shoulder of the
compressor impeller and measure the radial run-out of the rotor while slowly rotating
the rotor. For the radial run-out refer to the Clearance sheet in chapter 7.4.

Now the bearing housing with rotor is assembled. The exhaust gas turbocharger can be
completed according to chapters 7.5.5 to 7.5.10.

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 Operating Instructions
Chapter 7 HPR6000 Exhaust Gas Turbocharger
7.5.13 Disassembly of the exhaust-gas elbow

Mass of the exhaust-gas elbow 70 kg

Initial condition: Exhaust gas piping is disassembled.

Work sequence:
1. Attach the exhaust-gas elbow (9100) by means of a rope to a hoist.
2. Loosen and remove the hexagon nuts (5090) together with the ribbed washers (5100).
3. Remove the exhaust-gas elbow (9100) in axial direction from the turbine housing
(5010) and put it on a wooden base.
4. Loosen the cylindrical screws (5070).
5. Force the turbine housing insert (5020) with forcing screws off the turbine housing
(5010).

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 Operating Instructions
HPR6000 Exhaust Gas Turbocharger Chapter 8

8 SPARE PARTS AND TOOLS

8.1 General
The following details are required for an order:
1. Address of orderer
2. Type of turbocharger
3. Serial number of turbocharger (see name plate on page 2)
4. Specification number of turbocharger (see name plate on page 2)
5. Part number, designation and quantity
6. Shipment address
The spare parts box supplied by order contains a selection of the most important wear parts
and a relevant listing.

)
The parts contained in the spare parts box are preserved for a storage
period of two years.

A certain selection of tools is also supplied if ordered. These tools are necessary to maintain
and repair the exhaust gas turbocharger and are not included in the basic equipment of
every workshop.

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8.2 Spare parts

8.2.1 Exhaust gas turbocharger, complete (1000)

Part No. Quantity Designation Remarks

1200 1 Cartridge
3140 1 Screw plug only available within the 'Standard parts 1' (9920) set
3150 1 Gasket only available within the 'Standard parts 1' (9920) set
5000 1 Turbine housing
6000 1 Compressor housing
6020 2 V-band, compressor
6190 2 Cylindrical screw only available within the 'Standard parts 1' (9920) set
9010 1 Silencer
9012 1 Filter mat
9014 2 Tension tape
9020 1 Intake housing
9030 1 Screw plug only available within the 'Standard parts 1' (9920) set
9040 1 Gasket only available within the 'Standard parts 1' (9920) set
9050 2 Screw plug only available within the 'Standard parts 2 ' (9930) set
9055 1 Screw plug only available within the 'Standard parts 2 ' (9930) set
9060 2 Gasket only available within the 'Standard parts 2 ' (9930) set
9065 1 Gasket only available within the 'Standard parts 2 ' (9930) set
9070 1 Screw plug only available within the 'Standard parts 1' (9920) set
9080 1 Gasket only available within the 'Standard parts 1' (9920) set
9100 1 Exhaust gas elbow
9101 3 Cover
9102 12 Hexagon screw only available within the 'Standard parts 2 ' (9930) set
9103 12 Ripped washer only available within the 'Standard parts 2 ' (9930) set
9104 3 Gasket
9110 1 Speed sensor
9120 1 O-ring only for turbocharger on gas engines

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8.2.2 Exhaust gas turbocharger, basic unit (1100)

Part No. Quantity Designation Remarks

1200 1 Cartridge
5000 1 Turbine housing
5090 36 Hexagon nut only available within the 'Standard parts 2' (9930) set
5100 36 Ripped washer only available within the 'Standard parts 2' (9930) set
6000 1 Compressor housing
6010 1 Compressor housing
6030 1 O-Ring, compressor only available within the gasket set (9910)
housing
6140 8 Clamping flange
6150 24 Stud bolt only available within the 'Standard parts 1' (9920) set
6160 24 Hexagon nut only available within the 'Standard parts 1' (9920) set
6170 24 Ripped washer only available within the 'Standard parts 1' (9920) set
7010 1 Turbine nozzle ring
7020 3 Locating bolt only available within the 'Standard parts 2' (9930) set
8010 1 Compressor diffuser
8020 2 Stop bushing only available within the 'Standard parts 1' (9920) set
8030 1 O-Ring, compressor only available within the gasket set (9910)
diffuser
8040 2 Cylindrical screw only available within the 'Standard parts 1' (9920) set

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8.2.3 Cartridge (1200)

Part No. Quantity Designation Remarks

2000 1 Rotor
3010 1 Bearing housing
3020 1 Bearing guide sleeve
3030 1 Heat shield
3040 1 Bearing cover, compressor
3060 1 Separator plate
3081 *) Gasket, bearing cover (0.1) only available within the gasket set (9910)
3083 *) Gasket, bearing cover (0.2) only available within the gasket set (9910)
3085 *) Gasket, bearing cover (0.5) only available within the gasket set (9910)
3090 7 Cylindrical screw only available within the 'Standard parts 1' (9920)
set
3100 6 Cylindrical screw only available within the 'Standard parts 1' (9920)
set
3110 1 Thread plug only available within the 'Standard parts 1' (9920)
set
3120 3 Screw plug only available within the 'Standard parts 1' (9920)
set
3130 14 Ripped washer only available within the 'Standard parts 1' (9920)
set
3140 1 Screw plug only available within the 'Standard parts 1' (9920)
set
3150 1 Gasket only available within the 'Standard parts 1' (9920)
set
3200 1 Screw plug only available within the 'Standard parts 1' (9920)
set
3210 1 Spring washer only available within the 'Standard parts 1' (9920)
set
4010 1 Turbine bearing
4020 1 Compressor bearing
4050 3 Cylindrical pin only available within the 'Standard parts 1 ' (9920)
set
*) according clearance setting

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8.2.4 Rotor (2000)

Part No. Quantity Designation Remarks

2010 1 Shaft
2020 1 Thrust ring
2030 1 Spacer
2040 1 Compressor impeller
2050 1 Clutch disc
2060 1 Rotor nut
2070 2 Plain compression ring also available within the gasket set (9910)
2080 2 Feather key only available within the 'Standard parts ' (9920)
set

8.2.5 Bearings (4000)

Part No. Quantity Designation Remarks

4010 1 Turbine bearing (inclusive 3x4050 assembled)
4020 1 Compressor bearing

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8.2.6 Turbine housing (5000)

Part No. Quantity Designation Remarks

5010 1 Turbine housing
5020 1 Insert, turbine housing
5050 2 Screw plug only available within the 'Standard parts 2' (9930) set
5060 2 Gasket only available within the 'Standard parts 2' (9930) set
5070 2 Cylindrical screw only available within the 'Standard parts 2' (9930) set
5090 36 Hexagon nut only available within the 'Standard parts 2' (9930) set
5100 36 Ripped washer only available within the 'Standard parts 2' (9930) set
5110 12 Stud bolt only available within the 'Standard parts 2' (9930) set
5120 4 Stud bolt only available within the 'Standard parts 2' (9930) set
5130 24 Stud bolt only available within the 'Standard parts 2' (9930) set
7020 3 Locating bolt only available within the 'Standard parts 2.1' (9931) set

Page 50 of 56 8th Edition (07/2010) HPR6000En08.doc

 Operating Instructions
HPR6000 Exhaust Gas Turbocharger Chapter 8

8.2.7 Compressor housing (6000)

Part No. Quantity Designation Remarks

6010 1 Compressor housing
6030 1 O-Ring, compressor housing only available within the gasket set (9910)
6040 1 Insert, compressor housing
6050 1 Screw plug only available within the 'Standard parts ' (9920)
set
6060 1 Gasket only available within the 'Standard parts ' (9920)
set
6070 6 Cylindrical screw only available within the 'Standard parts ' (9920)
set
6080 6 Ripped washer only available within the 'Standard parts ' (9920)
set
6090 1 O-Ring, compressor housing only available within the gasket set (9910)
insert
6110 2 Screw plug optional connection for jet-assist
6120 2 Gasket optional connection for jet-assist
6131 *) Shim (0.1) only available within the gasket set (9910)
6132 *) Shim (0.15) only available within the gasket set (9910)
6135 *) Shim (0.2) only available within the gasket set (9910)
6140 8 Clamping flange
6150 24 Stud bolt only available within the 'Standard parts ' (9920)
set
6160 24 Hexagon nut only available within the 'Standard parts ' (9920)
set
6170 24 Ripped washer only available within the 'Standard parts ' (9920)
set
*) according clearance setting

HPR6000En08.doc 8th Edition (07/2010) Page 51 of 56

 Operating Instructions
Chapter 8 HPR6000 Exhaust Gas Turbocharger

8.2.8 Gasket set (9910)

Part No. Quantity Designation Remarks

2070 2 Compression ring only available within the gasket set (9910)
3081 2 Gasket, bearing cover (0.1) only available within the gasket set (9910)
3083 2 Gasket, bearing cover (0.2) only available within the gasket set (9910)
3085 1 Gasket, bearing cover (0.3) only available within the gasket set (9910)
6030 1 O-Ring, compressor housing only available within the gasket set (9910)
6090 1 O-Ring only available within the gasket set (9910)
6131 2 Shim (0.1) only available within the gasket set (9910)
6133 1 Shim (0.15) only available within the gasket set (9910)
6135 2 Shim (0.2) only available within the gasket set (9910)
8030 1 O-Ring, compressor diffuser only available within the gasket set (9910)
9104 3 Gasket only available within the gasket set (9910)

Page 52 of 56 8th Edition (07/2010) HPR6000En08.doc

 Operating Instructions
HPR6000 Exhaust Gas Turbocharger Chapter 8

8.2.9 Standard parts 1 (9920)

Part No. Quantity Designation Remarks

2080 2 Feather key only available within the 'Standard parts 1' (9920) set
3090 7 Cylindrical screw only available within the 'Standard parts 1' (9920) set
3100 6 Cylindrical screw only available within the 'Standard parts 1' (9920) set
3110 1 Thread plug only available within the 'Standard parts 1' (9920) set
3120 3 Screw plug only available within the 'Standard parts 1' (9920) set
3130 7 Ripped washer only available within the 'Standard parts 1' (9920) set
3140 1 Screw plug also available within the 'Standard parts 2' (9930) set
3150 1 Gasket also available within the 'Standard parts 2' (9930) set
3160 6 Ripped washer only available within the 'Standard parts 1' (9920) set
3200 1 Screw plug only available within the 'Standard parts 1' (9920) set
3210 1 Washer only available within the 'Standard parts 1' (9920) set
4050 3 Cylindrical pin also available within the 'Bearings' (4000) set
5140 4 Hexagon-head bolt only available within the 'Standard parts 1' (9920) set
6050 1 Screw plug also available within the 'Standard parts 2' (9930) set
6060 1 Gasket also available within the 'Standard parts 2' (9930) set
6070 6 Cylindrical screw only available within the 'Standard parts 1' (9920) set
6080 6 Ripped washer only available within the 'Standard parts 1' (9920) set
6110 2 Screw plug only available within the 'Standard parts 1' (9920) set
6120 2 Gasket only available within the 'Standard parts 1' (9920) set
6150 24 Stud bolt only available within the 'Standard parts 1' (9920) set
6160 24 Hexagon nut also available within the 'Standard parts 2' (9930) set
6170 24 Ripped washer only available within the 'Standard parts 1' (9920) set
6190 2 Cylindrical screw only available within the 'Standard parts 1' (9920) set
8020 2 Stop bushing only available within the 'Standard parts 1' (9920) set
8040 1 Cylindrical screw only available within the 'Standard parts 1' (9920) set
9030 2 Screw plug also available within the 'Standard parts 2' (9930) set
9040 2 Gasket also available within the 'Standard parts 2' (9930) set
9070 1 Screw plug only available within the 'Standard parts 1' (9920) set
9080 1 Gasket only available within the 'Standard parts 1' (9920) set

HPR6000En08.doc 8th Edition (07/2010) Page 53 of 56

 Operating Instructions
Chapter 8 HPR6000 Exhaust Gas Turbocharger
8.2.10 Standard parts 2 (9930)

Part No. Quantity Designation Remarks

5050 9 Screw plug also available within the 'Standard parts 1' (9920) set
5060 9 Gasket also available within the 'Standard parts 1' (9920) set
5070 2 Cylindrical screw only available within the 'Standard parts 2' (9930) set
5090 12 Hexagon nut also available within the 'Standard parts 1' (9920) set
5100 12 Ripped washer also available within the 'Standard parts 1' (9920) set
5110 12 Stud bolt only available within the 'Standard parts 2' (9930) set
5120 4 Stud bolt only available within the 'Standard parts 2' (9930) set
9050 2 Screw plug also available within the 'Standard parts 1' (9920) set
9055 1 Screw plug only available within the 'Standard parts 2' (9930) set
9060 2 Gasket also available within the 'Standard parts 1' (9920) set
9065 1 Gasket only available within the 'Standard parts 2' (9930) set
9102 12 Hexagon-head bolt only available within the 'Standard parts 2' (9930) set
9103 12 Ripped washer only available within the 'Standard parts 2' (9930) set
9220 4 Hexagon screw optional for insulation
9221 4 Washer optional for insulation
9222 4 Hexagon screw optional for insulation
9223 4 Washer optional for insulation
9931 1 Standard parts 2.1

8.2.11 Standard parts 2.1 (9931)

Part No. Quantity Designation Remarks

5090 24 Hexagon nut
5100 24 Ripped washer
5130 24 Stud bolt
7020 3 Locating bolt
9230 24 Hexagon screw optional for insulation
9231 24 Washer optional for insulation

Page 54 of 56 8th Edition (07/2010) HPR6000En08.doc

 Operating Instructions
HPR6000 Exhaust Gas Turbocharger Chapter 8

8.3 Tools

)
Tools are an option and therefore should be purchased separately by an
official order from customer.

8.3.1 Tool set (9800)

Part No. Quantity Designation Remarks

9801 1 Locking device
9803 1 Extractor, thrust ring
9805 1 Guide sleeve
9806 2 Hexagon head screw forcing screw for turbine housing
9807 4 Hexagon head screw for (9801)
9808 1 Eye bolt
9809 2 Eye bolt
9810 1 Eye bolt

9807

HPR6000En08.doc 8th Edition (07/2010) Page 55 of 56

 Operating Instructions
Chapter 8 HPR6000 Exhaust Gas Turbocharger

8.3.2 Further tools

Part No. Quantity Designation Remarks

9804 1 Sealing device stoppage of the exhaust gas turbocharger

Page 56 of 56 8th Edition (07/2010) HPR6000En08.doc

 Charge Air Cooler C5.05.06.30.17.39
-

M25

Charge Air Cooler

en / 12.10.2010 FD044421 1/11

 Content

1. DESCRIPTION

2. WORKING PRINCIPLE

3. INSTALLATION

4. MAINTENANCE

5. CLEANING THE COOLER

6. INSTRUCTIONS FOR REPARING AIR COOLER TUBES

7. OUT OF SERVICE PERIODS

8. DIFFICULTIES IN SERVICE

9. ORDERING SPARE PARTS

10. TECHNICAL DATA

1. DESCRIPTION
Vestas aircoil charge air coolers consist of a number of tube stacks, each built
up on aluminium-brass or more commonly cupro-nickel tubes. Both types are
fitted with copper fins. Each fin is mechanically bonded to all the tubes in a
stack. Depending on cooler type, the fins are either expanded or dip-soldered on
to the tubes. The cooler type is described in section 10. ”TECHNICAL DATA.”
The tube stacks are mounted between two tube plates, into which the tube ends
are expanded to give a secure and permanent seal. Furthermore, each tube
inlet is bell formed to minimise the risk of local turbulence which can cause
erosion/corrosion.

The tube plates of the cooler are either fitted with an end cover or a reversing
chamber. The end cover provides the connection to the inlet and outlet pipes of
the cooling water system. Further information is given in engine manufacturer's
instructions. The end cover is fitted with plugs for venting and draining of the
cooler. Depending on cooler type the reversing chamber is also fitted with plugs
for the same reason.

IMPORTANT: If the cooler has been Cover

drained for any reason, proper venting
of the water side is essential. Failure to
bleed off the air can lead to cavitation Bloc

of tubes and plates. On sea water

cooled systems, failure to vent can lead
to a build up of salt on the upper rows
of tubes.

The covers are either welded or cast in

an alloy to fit the application. Side plate
Depending on the alloy and cooling tube plates
water quality, the inside can be treated
with a protective coating.

The two side plates of the air cooler are bolted onto the tube plates. Depending
on the size of the cooler, the side covers are supported by stays.

Please refer to article 10 “Technical Data” for information on materials used in

the cooler.
2. WORKING PRINCIPLE
General:

Charge air coolers are installed on supercharged diesel engines, to remove heat
from the charge air. The heat builds up in the inlet air as it is pressurised by the
turbo charger. When the charged air passes through the tube and fin cooling
block, heat is transferred to the cooling water in the tubes. In this way the engine
receives cold air at high pressure to ensure efficient combustion, and cooling of
highly heat-loaded engine components. The cooler can either be one stage or
have multiple stages.

1-stage 2-stage

A one stage cooler can consist of a single cooler block, with one water inlet and
one water outlet pipe.

A two stage cooler consists of two separate cooler blocks assembled in one unit.
The coolers in such a unit are specified as High Temperature (HT) stage and
Low Temperature (LT) stage. Each of the stages have separate water
connections. Often the water for the HT stage comes directly from the cylinder
cooling jacket. The water temperature in the HT stage outlet pipe becomes very
hot. This makes it useful for purposes such as waste heat recovery for fuel
heating, feed water preheating and freshwater production. When working after
this principle, it is essential to ensure that the temperature in the HT stage does
not reach boiling point. This can cause severe damage to the cooler. To avoid
boiling of the HT water the minimum pressure is very important. Proper
monitoring of pressure and temperature is essential, especially during the start
up and shut down procedure.
3. INSTALLATION

NOTE: All coolers must be mounted with air flow according to the direction plate
on the cooler. This is to ensure correct thermal expansion.

Prior to installation all bolts for the supporting stays must be checked, to ensure
that all locking plates are in place and correctly locked. Re-tighten all bolts to the
specified momentum. This is to ensure that the vibrations during transport have
not loosened any of the parts and connections.

Vestas aircoil A/S recommend, that air intake for the turbo charger is made
through filters from outside the engine room, in a way that exhaust gas is
avoided in the charge air.

Please refer to article 9 “Technical Data” for information on materials used in the
cooler.

IMPORTANT: To avoid corrosion/erosion of the air cooler material, the chemical

composition of the cooling water and charge air must be in accordance with the
properties of the specified materials.

4. MAINTENANCE

IMPORTANT: During start up of the cooling system, accumulated and trapped

air is bled off through the venting plunges. It is recommended that the cooling
system is feed slowly to avoid water hammering which can cause high local
pressure in the cooler. Sudden increases might result in damage to gaskets,
tubes and other components in the cooler.

For registration of the cooler operation, it is recommended that a U-tube

pressure gauge is installed between the air inlet and outlet of the cooler. Then,
by comparing pressure drop values across the air side of the cooler against the
engine load, it is possible to monitor pressure drop changes or fouling. The
recommendation from Vestas aircoil A/S is to clean the cooler before the
pressure drop exceeds the clean-cooler value, by max. 50 per cent. The
maximum cleaning interval must not exceed 6 months of operation.
Frequent cleaning increases the life time of the cooler, and reduces fuel
consumption.

Fouling of coolers on the water side can be monitored in a similar way. Here, a
differential pressure gauge is connected between the cooling water inlet and
outlet pipes. This makes it possible to compare pressure drops for a constant
cooling system setting, during operation. Fouling of tube and water side will
drastically decrease the capacity of the cooler.
 MAKE SURE THAT MANOMETER MERCURY NEVER ENTERS THE
COOLING SYSTEM!

5. CLEANING THE COOLER

5.1. General
The amount of fouling at the air and water side of the charge air cooler will
determine the operating conditions of the engine. Deposits reduce the capacity
of the cooler and thus engine output, fuel consumption will also increase.
Therefore the cooler should be cleaned at regular intervals.

5.2. Air side. - Cooler removed from engine.

5.2.1 Immersion
The removed cooler is immersed in to a bath containing a cleaning fluid. The
fluid is agitated to give the most effective cleaning of fins and tubes. After
cleaning, the cooler is thoroughly flushed with pure water and is blown dry with
compressed air before being refitted on the engine. See section 5.4. for
recommended cleaning agents.

5.2.2 High-pressure cleaning - not recommended

5.2.3 Ultrasonic cleaning

Ultrasonic cleaning is normally performed by companies specialised in this area.
The procedure is to immerse the cooler in cleaning fluid through which a
transducer transmits a high-frequency sound wave to loosen deposits on fins
and tubes by "impact". This cleaning method is not recommended for coolers
where the fins are expanded on to the tubes, as it can cause the fin collars to
loosen from the tubes, resulting in serious performance drop of the cooler.

Please refer to article 9 “Technical Data” for information on your cooler type.

5.3. Water side

Cleaning of the water side is only possible after removing both end covers and
return flow chambers for thorough cleaning. After final cleaning, any damage to
cover surface treatment should be repaired.

Deposits and fixed impurities inside the tubes are best removed with a rotary
steel brush. If deposits in tubes are thick and calciferous it might be necessary
to carefully drill them out using a carbide bit. The inside diameter of tubes is
given in the spare part section. Be aware that in some case deposits may have
caused pitting or corrosion to the tubes. Consequently removing the deposits
can lead to leaks occurring after the cleaning process is completed.
 5.4 Cleaning agents

The following cleaning agents are recommended by the suppliers:

Supplier Product
Nordtec Maritime Services ApS Nordtec Air Cooler Cleaner (air and water
side)
Drew Ameroid Marine ACC-9
Nalfleet Marine Chemicals Nalfleet ACCC
VECOM Air Cooler Cleaner

Please refer to the producer's instructions before using any of the above
products. Vestas aircoil A/S can accept no responsibility for any consequences
arising from use of the products.

6. INSTRUCTIONS FOR REPARING AIR COOLER TUBES

The following is the recommended procedure, for repairing tubes in a
Vestas aircoil charge air cooler.

1. Drill the defect tube with a special drill to remove old scaling from the tube.
But do it slowly.

2. Clean the rolled areas in both ends for all impurities and avoid scratching the
surface. See fig 1.

3. Blow the tube and ensure that the tube is clean.

4. Put some heat transferring compound (White) all over the outside of the new
tube.
 5. Mount the new tube with cork in the defect tube under constant rotation of the
tube. (The corked end first to prevent the compound contaminating the inside of
the new tube). See fig. 2.

6. Remove the cork; roll both tube ends using a three-rolled expander.

7. Chamfer the edges of the tube inlets.

8. Necessary tools/parts:
- Tubes
- Heat compound
- Expander, optimal with 2 sizes
- Cork
- Special drill
- Cleaning brush

If the repair is carried out according to the above mentioned procedure, it can be
done to approximately 5-10% of the cooling tubes, with only a minor effect on the
cooler performance.

7. OUT OF SERVICE PERIODS

During longer periods out of service, the air cooler must be drained and left with
drain and venting plugs open. Recommendations for the entire system are given
on the following pages.
 8. DIFFICULTIES IN SERVICE

Difficulty Item Possible Cause Investigate/Remedy

Charge air Abnormally high charge air Dirty or defective
temperature too temperature ahead of air turbocharger.
high cooler High engine room temperature
Increased coolant inlet Maladjusted cooling system.
temperature. Blocked filter in sea chest.
Inadequate coolant flow Air cooler tubes partly blocked.
Defective pump.
Maladjusted cooling system.
Air in the coolant.
Fouling of tubes. Clean air cooler tubes.
Fouling of air side. (High Clean air cooler air side.
pressure drop)
Charge air Inadequate supply of hot Maladjusted cooling system.
temperature too water to heating stage.
low.
Charge air cooled in low Low temperature cooler stage
temperature cooler stage. to be bypassed or throttled.
High pressure Air side fouled. Clean air cooler fins.
drop in air side
Pressure gauge connections Re-tighten connections and
leaking. check with soapy water.
High pressure Air cooler water side fouled or Clean air cooler water side.
drop on water partly blocked.
side. (High temperature rise in
coolant).
Coolant flow too high. (Low Maladjusted coolant system.
temperature rise in coolant) Coolant pump capacity too
high.
Pressure gauge connection Re-tighten connections.
leaking. NOTE: Only when CAC is
cold.
External water Gasket between cover in-and Re-tighten cover and pipe
leakage. outlet pipe/cover and tube connections, if necessary
plate leaking. replace gasket. NOTE: Only
when CAC is cold.
Internal water Leakage between cooler tubes Use tube expander to secure
leakage. and tube plate. tube in tube plate.
Cooler tubes leaking. An insert tube is rolled into the
defect tube, using a tube-
repair kit.
Tubes to be plugged at both
ends.
9. ORDERING SPARE PARTS
To ensure the best performance OEM spares are recommended. Original,
approved spares and replacements are now available form Vestas aircoil A/S at
competitive prices. Please contact:

Phone +45 97 34 18 00
Fax: +45 97 34 14 14
E-mail [email protected]
Home page: www.vestas.biz

When ordering spare parts please state the following data:

- Type of air cooler and No. in accordance with data on name plate.

- Designate parts with plate No. and item No.

_ Five digit order number from name plate.

 10. TECHNICAL DATA.

COOLER TYPE: ***

MAXIMUM ALLOWABLE SERVICE CONDITIONS:

TEMPERATURE PRESSURE
C° bar (g)
Water side ** *.*

TIGHTENING TORQUE:

Quality: 8.8, greased, zink plated.

For bolts secured with loctite the values must be increased by +10%

TORQUE Nm kpm
Thread size: M8 21 2.0
M10 41 4.0
M12 70 7.0
M16 169 17.0

THE TUBE INSIDE DIAMETER: **.* mm

Tube material: CuNi10Fe1Mn CuZn20Al2

Tube plates: Steel Brass El. galvanized steel
End cover: GG25 GGG40 GGG50
Reverse cover: GG25 GGG40 GGG50
Fin material: Cu Cu, hot dip tin soldering
 Silencer C5.05.06.40.05.48
Spark arrester

M20/M25/M32

Silencer

Spark arrester

en / 20.11.2013 FD049438 1/9

 ® Gebrauchs- / Wartungsanweisung 2007-08-30
Funkenfänger und Abgasschalldämpfer
Version 1.0

1.0 Einbau
Grundsätzlich ist eine horizontale bis vertikale Einbaulage möglich. Jedoch ist die genaue
Einabulage bei der Bestellung anzugeben und einzuhalten.
Die Strömungsrichtung ist mit einem Pfeil gekennzeichnet.
Übertragungen von Motorschwingungen und Körperschall sind zu beachten.
Die Wärmeausdehnung ist zu berücksichtigen.
Zur Vermeidung von Taupunktunterschreitungen - speziell im Schwerölbetrieb - ist der
Schalldämpfer ausreichen zu isolieren.

1.1 Regelmäßige Überprüfungen

Der Kondensatablauf ist in regelmäßigen Abständen (mindestens alle 6 Monate) zu überprüfen.
Eventuell anfallendes Kondensatwasser muss frei ablaufen können.

Erstmalig nach 5 Jahre ist der Funkenfängerun –und Schalldämpferbausatz komplett zu

überprüfen. Diese Überprüfung ist danach alle 24 Monate zu wiederholen.

Prüfungen:
x Alle Schraubenverbindungen sind zu kontrollieren
x Schwingelementezustand kontrollieren
x Sind Durchrostungen vorhanden?
x Sind mechanische Verformungen vorhanden?

Defekte Komponenten sind zu ersetzen

1.2 Außergewöhnliche Überprüfungen

der Funkenfänger- und Schalldämpferbausatz ist komplett zu überprüfen:

Bei außergewöhnlichen mechanischen Belastungen sind die Schwingelemente auszutauschen,

da meist eine Kontrolle vor Ort nicht möglich ist

Bei Turboladerschäden des Dieselmotor

x Gefahr eines Schalldämpferbrandes
x Überhitzung des Materiales bzw. der Komponenten möglich.

Bei Brandschäden im Bereich des Schalldämpferbausatzes

x Überhitzung des Materiales bzw. der Komponenten möglich.

Bei Motorschäden mit einem ungewöhnlichen Ölausstoß des Dieselmotor.

x Schalldämpferleistung lässt durch interne ölhaltige Beläge im Abgaskanal nach
x Gefahr eines Schalldämpferbrandes

Bei allen sonstigen nicht spezifizierten Belastungen des Bausatzes.

R:\Büro\ETBdaten\Dokumentation\Schalldämpfer\MAN Doku\Gebrauchsanweisung Schalldämpfer.DOC Seite

1 von 1

Scipiostraße 8, D-28279 Bremen, Tel. +49 (0)421 83952-0, Fax +49 (0)421 83952-90
ENERGIETECHNIK BREMEN GmbH E-mail: [email protected], www.etb-bremen.com
 ® User’s / maintenance instructions 2007-08-30
Spark arrestor and Exhaust-gas Silencer
Version 1.1

1. Installation:
Vertical up to a horizontal position.
Transfer of motor vibrations and impact sound should be taken into account.
Rurthermore, ample heat expansion must be reckoned with. The silence should be sufficently
insulated in order to avoid a falling below the dew point - especially when heavy oil is used.

1.1 Regular checks

The condensate drain of the tail pipe item has to be checked periodical (minimum all 6 months).
An undisturbed flowing off of the possibly arisen condensate has to be ensured.

The complete check of the spark arrestor and silencer kit should be executed after 5 years.
This maintenance has to be repeated all 24 months.

Checks after deinstallation of the silencer:

x all screw connections have to be checked
x check of the condition of the vibration elements
x any rust through?
x are there any mechanical deformations?

Components being defectly have to be replaced.

3.2 Exceptional checks

The spark arrestor and silencer kit has totally be checked:

An exceptional mechanical burden requires an exchange of the vibration elements, if a control

on spot is not possible (see producer’s description).

Damages of the turbo-supercharger of the diesel engine

x combustion of the silencer may arise
x overheat of the material resp. the components may be possible

Damages by fire in the area of the silencer kit

x overheat of the material resp. the components may be possible

Damages of the diesel engine with an exceptional ejection of oil

x reduced capacity of silencer caused by internal oily cover within
the exhaust-gas conduit
x combustion of the silencer may arise

All other possible non-specified burden of the kit.

R:\Büro\ETBdaten\Dokumentation\Schalldämpfer\MAN Doku\Gebrauchsanweisung Schalldämpfer ENGL.DOC

Scipiostraße 8, D-28279 Bremen, Tel. +49 (0)421 83952-0, Fax +49 (0)421 83952-90
ENERGIETECHNIK BREMEN GmbH E-mail: [email protected], www.etb-bremen.com
 ®

Operating- and Service manual

spark arrestor and silencer
Type EFX

The spark arrestor type EFX cleans exhaust gases by mechanical collection
of compact combustion deposits.

Operation Silencer:

The silencer operates on the absorption principle. Thus an extensive

sound absorption within a wide range of frequency can be obtained.
As the flow is conducted in a straight line, the flow resistance is kept
very small. Mineral wool consisting of long fibre absorbing material is
particularly heat resistant and of a very solid consistency.

Operation Spark arrestor:

The operation of the spark arrestor is based on the centrifugal principle.

Via rigid guide blades, gases are made to swirl in such a manner that the
combustion residues (particles) which have been brought along are pressed
to the outer wall. The combustion residues are deposited in a collecting
chamber which is independent of the gas stream.

The operative range of the spark arrestors extends from 6 to 60 m/sec.

Installation: The spark arrestor has to be installed acc. to the flow direction

marked on the type plate.

To clean the spark arrestor it should be easily accessible arranged.

The shown control socket at the outlet of the spark arrestor and silencer

is provided for endoscopical tests.

maintenance: Cleaning and examination of the spark arrestor

has to be carried out within adequate time intervals!

The time intervals depend on the quantity of the

compact combustion deposits.

We recommend to carry out first examination after the

first four weeks in operation.

Scipiostraße 8, D-28279 Bremen, Tel. +49 (0)421 83952-0, Fax +49 (0)421 83952-90
ENERGIETECHNIK BREMEN GmbH E-mail: [email protected], www.etb-bremen.com
 TRANSPORT

Gerät / Appliance : Schalldämpfer und Funkenfänger /

Spark arrestor and silencer

Typ / Type: EFX 35-1300-MAN-FD

Ident-Nr. / Ident-N°: EFX-005188-1300-M001

Transport /
Transport
Es gilt zu beachten, daß die Behälter in geeigneter Weise mit Vorsicht
zu befördern und abzuladen sind.

Please pay attention that the appliances will be carefully transported and
discharged in a suitable manner.

Für gewöhnlich erfolgt die Anlieferung der Schalldämpfer per LKW,

unverpackt, in Containern gestaut oder seemäßig verpackt in Holzverschlägen.
Die Schalldämpfer und Funkenfänger können mit Textilbändern oder mit dem
Gabelstapler entladen werden.
Der Kunde ist verpflichtet für die Entladung entsprechende Ausrüstung und
qualifiziertes Personal bereitzustellen.
In den meisten Fällen ist für die Entladung ein Kran oder Gabelstapler
erforderlich.
Für Schalldämpfer und Funkenfänger mit einer Länge ab 6.000 mm sollte auf
jeden Fall ein Kran mit Textilbändern eingesetzt werden.
Für jeden Transport gelten grundsätzlich die jeweiligen Transport- und
Sicherheitsvorschriften.
Die Schalldämpfer und Funkenfänger können an den Ein- und Austrittsstutzen
oder an entsprechend vorgesehenen Kranösen angehoben werden.

Normally silencers will be delivered by truck. The silencers can be unpacked,

stowed in Container or seaworthy packed in wooden cradles. The silencers can
be handled by Textile Stripes or Forklift. The customer is responsible for
resourcing of unloading equipment and staff. That usually needs, depending
on length and weight, a crane potentially with lifting beam or a forklift.
At crane of silencers over 6.000 mm length in every case lifting beams with
textile stripes should be used.
For every transport the respective rules and regulations valid for transport
and safety must be observed.
The silencer can be hooked at the pipe ends on both side of the silencer
or at the lifting lugs designed for.
Vor dem Einbau /
Before installation
Die Behälter müssen bei Anlieferung auf Schäden hin überprüft werden.

When receiving the appliances please check for damages.

Transportschäden müssen umgehend dem Spediteur für die Meldung

an die Versicherung angezeigt werden.

Damage during transport has to be reported to the forwarding agent

for insurance.
 ®

SCHALLDÄMPFER UND FUNKENFÄNGER

für Verbrennungsmotoren Typ EFX
Spark arrestor and silencer for internal-combustion engines
L

H Lieferprogramm
EFX 25 Schallpegelminderung ca. 25 dB (A)
EFX 35 Schallpegelminderung ca. 35 dB (A)
D
Einbau: Vertikal bis horizontal. Übertragungen von
DN Motorschwingungen und Körperschall sind zu beachten. Die
Wärmeausdehnung ist zu berücksichtigen. Zur Vermeidung
d
von Taupunktunterschreitungen - speziell im Schwerölbetrieb -
ist der Schalldämpfer ausreichend zu isolieren. Tragkonsolen
auf Anfrage lieferbar.
Reinigungsöffnung
Cleaning port Werkstoff: Unlegierter Stahl mit einem äußeren
0
Schutzanstrich.Sonderausführungen auch aus rost- bzw.
Strömungswiderstände (Mittelwerte bei 400 C) hitzebeständigem Material.
0
Flow resistance (average values at 400 C)
30 Bestelldaten:
25
Folgende Daten benötigen wir zur Angebotserstellung
20
a) Motorfabrikat und Typ
15
b) Leistung (KW) und Drehzahl
Strömungswiderstand mbar

10 0 c) Abgasmenge (kg/KWh oder Nm^3/h)

8 50 d) Abgastemperatur
0
Für dieses Blatt behalten wir uns alle Rechte vor

W
00

N
e) Durchmesser der Abgasleitung
-1

6 s
bi
0
60

5
f) geforderter dB(A)-Schalldruckpegel mit Entfernungsangabe
Flow resistance

N
W

4
All rights reserved for this sheet

2 Efficiency:
EFX 25 reduction of noise level approx. 25 dB (A)
EFX 35 reduction of noise level approx. 35 dB (A)
1
10 15 20 25 30 40 50 60 70 80 90 100 Installation: vertical up to a horizontal position. Transfer of
Abgasgeschwindigkeit im Anschlußrohr m/s motor vibrations and impact sound should be taken into
Exhaust gas velocity in joining pipe
account. Furthermore, ample heat expansion must be
reckoned with. The silence should be sufficently insulated in
Charakteristische Leistungskurven (Mittelwerte)
Characteristical performance graphs
order to avoid a falling below the dew point - especially when
heavy oil is used.
40
EF Material: Carbon steel with an outer protective coat of paint.
X3
Durchgangs-Dämm-Maß dB

5 Special execution available, made of corrosion resistant or heat

30 resistant material.
EFX
25 Data required on the purchase order
20 When elaborating an order, we would need the following data:
a) make and typ of engine
Insertion loss

b) engine capacity (kW) and speed

10
c) quantity of exhaust gas
d) exhaust gas temperature
0 e) diameter of the exhaust gas pipe
31,5 63 125 250 500 1000 2000 4000 8000 f) required dB(A) noise level with indication of distance to
Frequenz Hz / Frequency Hz source of sound

Abmessungen in ca. mm Dimensions in mm (approx.)

Nennweite DN 300 350 400 500 600 700 800 900 1000 1100 1200
nominal diameter
Anschluß-Rohr 323,9 355,6 406,4 508 609,6 711,2 812,8 914,4 1016 1120 1220
Æ
joining pipe
ca. H 180 190 200 210 230 250 270 280 300 300 300

D 700 800 850 950 1100 1300 1500 1600 1800 1900 2100
d 688 788 838 938 1080 1280 1480 1580 1780 1880 2070

EFX 25 L 2360 2880 2950 3420 3960 4000 4540 5060 5350 5600 5850
ca. kg 360 420 540 780 1000 1300 1990 2460 2900 3380 3800

EFX 35 L 3360 3630 3950 4670 4690 5000 5290 5820 6110 6860 7600
ca. kg 470 540 680 900 1350 1640 2900 3100 3400 4850 5400
Flanschanschlußmaße: nach DIN 86044.
Änderungen vorbehalten. Subject to modifications.
AUSGABE

Verbindliche Maßblätter und weitere Größen auf Anfrage. Dimension tables and further dimensions on request.
05/97

Scipiostraße 8 . D-28279 Bremen

ENERGIETECHNIK BREMEN GmbH Telefon (04 21) 8 39 52-0 . Telefax (04 21) 8 39 52-90 · e-mail: [email protected]
 SCHALLDÄMPFER-BEFESTIGUNGEN
â

Silencer supports

Tragkonsolen senkrecht
Standard

ÆD F

ÆC
B

E
X

Dopplungen bei
Edelstahlbehältern!
Für dieses Blatt behalten wir uns alle Rechte vor

Das kundenseitige Anschweißen selbstgefertigter Halterungen ist

bei allen Schalldämpfer-Typen möglich.
All rights reserved for this sheet

With all types of silenecers it is possible for clients to weld

on their own brackes.

Konsolen-Anschlußmaße in mm Bracket companion dimensions in mm

D A B C E F G X

350 280 1x100 14 40 200 6

400 305 1x100 14 40 200 6 370
490 350 1x100 14 40 200 6
550 380 1x100 14 40 200 6

600 425 1x230 17 45 350 8

700 475 1x230 17 45 350 8
800 525 1x230 17 45 350 8 550
850 550 1x230 17 45 350 8
minimum dimension

950 600 1x230 17 45 350 8

1100 700 2x230 17 50 600 10

1200 750 2x230 17 50 600 10
1300 800 2x230 17 50 600 10 700
1400 850 2x230 17 50 600 10
1500 900 2x230 17 50 600 10
Mindestmaß

1600 975 3x210 22 55 800 12

1700 1025 3x210 22 55 800 12
1800 1075 3x210 22 55 800 12 850
1900 1125 3x210 22 55 800 12
2000 1175 3x210 22 55 800 12
2100 1225 3x210 22 55 800 12

2200 1275 4x210 22 55 1000 12

2300 1325 4x210 22 55 1000 12
2400 1375 4x210 22 55 1000 12 1000
2500 1425 4x210 22 55 1000 12
2600 1475 4x210 22 55 1000 12
2700 1525 4x210 22 55 1000 12
Ausgabe
06/06

Scipiostraße 8 . D-28279 Bremen

ENERGIETECHNIK BREMEN GmbH Telefon (04 21) 8 39 52-0 . Telefax (04 21) 8 39 52-90 · e-mail: [email protected]
 SCHALLDÄMPFER-BEFESTIGUNGEN
Silencer supports
Tragkonsolen waagerecht
Aufstellung: hängend und stehend für elastische Lagerungen
Installation: trailing and vertically for elastic mounting
D

H
G
Dopplungen bei
Edelstahlbehältern
X X B

K A
F

H = für Typ EF auf Anfrage

H = upon special request for typ EF
C
Æ
ÆM

M
15

Das kundenseitige Anschweißen selbstgefertigter Halterungen ist

Für dieses Blatt behalten wir uns alle Rechte vor

N O
bei allen Schalldämpfer-Typen möglich.

E E With all types of silenecers it is possible for clients to weld

All rights reserved for this sheet

on their own brackes.
Festsitz Schiebesitz
rigid mounting slide mounting

Konsolen-Anschlussmaße in mm Bracket companion dimensions in mm

D A B C E F G H K M N O X

350 350 230 120 120 -- 6 230 16 13,5 60 50 250

400 400 280 120 120 -- 6 270 16 13,5 60 50 250
490 490 370 120 120 -- 6 310 16 13,5 60 50 250
550 550 430 120 120 -- 6 350 16 13,5 60 50 250

600 600 480 120 160 -- 8 400 22 17,5 80 70 350

700 700 580 120 160 -- 8 450 22 17,5 80 70 350
800 800 680 120 160 -- 8 500 22 17,5 80 70 350
minimum dimension

850 850 730 120 160 -- 8 520 22 17,5 80 70 350

950 950 830 120 160 -- 8 570 22 17,5 80 70 350

1100 1100 950 150 280 140 12 700 27 23 70 57 400

1200 1200 1050 150 280 140 12 750 27 23 70 57 400
1300 1300 1150 150 280 140 12 800 27 23 70 57 400
1400 1400 1250 150 280 140 12 850 27 23 70 57 400
1500 1500 1350 150 280 140 12 900 27 23 70 57 400

1600 1600 1400 200 350 180 15 1000 27 23 85 72 500

Mindestmaß

1700 1700 1500 200 350 180 15 1050 27 23 85 72 500

1800 1800 1600 200 350 180 15 1100 27 23 85 72 500
1900 1900 1700 200 350 180 15 1150 27 23 85 72 500
2000 2000 1800 200 350 180 15 1200 27 23 85 72 500
2100 2100 1900 200 350 180 15 1250 27 23 85 72 500

2200 2200 2000 200 350 180 20 1300 33 27 85 69 500

2300 2300 2100 200 350 180 20 1350 33 27 85 69 500
2400 2400 2200 200 350 180 20 1400 33 27 85 69 500
2500 2500 2300 200 350 180 20 1450 33 27 85 69 500
2600 2600 2400 200 350 180 20 1500 33 27 85 69 500
2700 2700 2500 200 350 180 20 1550 33 27 85 69 500
Ausgabe
06/06

Scipiostraße 8 . D-28279 Bremen

ENERGIETECHNIK BREMEN GmbH Telefon (04 21) 8 39 52-0 . Telefax (04 21) 8 39 52-90 · e-mail: [email protected]
 Fuel Pump C5.05.07.07.22.10
(Leistritz)

M25

Fuel Pump

(Leistritz)

en / 22.01.2014 FD049649 1/57

 Ihre Bestellung
36613/249
Your order

Auftragsbestätigung
N-41000245 0010
Order Confirmation
Technische Dokumentation Dieselöl Pumpe
Seriennummer
000234; 000235
Serial Number
Technical Documentation Diesel Oil Pump
Pumpentype
L3NG-038/060-AFOKII-G
Pump type

CAT-Sach-Nr.
273480232
CAT-Ref.-No.

CAT-KTR-Nr.
N/A
CAT-KTR-No.

Kontakt Abteilung E-Mail Telefondurchwahl / Direct Dial Datum

Contact Department e-mail +49 911 43 06 Date

M. Totzauer QSP [email protected] - 106 05.11.2013

Pumpe: Betriebs- und Wartungsvorschrift

01 E 185 5177 20
Pump: Instruction and Operating Manual
Pumpe: Einbauzeichnung
02 D 162 5222 1
Pump: General Arrangement Drawing
Pumpe: Maßblatt
03 E 168 5954 1
Pump: Dimensional Drawing
Pumpe: Schnittzeichnung inkl. Teileliste
04 E 160 6878 1
Pump: Sectional Drawing incl. parts list
Pumpe: EG – Konformitätserklärung
05 000234; 000235 2
Pump: EC – Declaration of Conformity
Pumpe: Abnahmeprüfzertifikat
06 000234; 000235 2
Pump: Inspection Test Certificate
Motor: Betriebs- und Wartungsvorschrift
07 AC-Motor 4
Driver: Instruction and Operating Manual
Motor: Zeugnis 1306033444
08 2
Driver: Certificate 1306033370
Kupplung: Betriebs- und Wartungsvorschrift
09 40210 21
Coupling: Instruction and Operating Manual

LEISTRITZ PUMPEN GMBH MANAGING DIRECTORS: REGISTERED OFFICE: BANK ACCOUNTS LEISTRITZ AG:
MARKGRAFENSTRASSE 29-39 Dipl.-Wirtsch.-Ing. Christoph Böhnisch Nürnberg, Germany Commerzbank Nbg. (BLZ 760 400 61) KTO. 5 200 167
D-90459 NÜRNBERG, GERMANY Dr.-Ing. Michael Radke Commercial Register: BIC COBA DE FF, IBAN DE28 7604 0061 0520 0167 00
INTERNET: www.leistritz.com Dipl.-Ing. (FH) Heinz-Dieter Roß HRB 17819 HSBC T&B, München (BLZ 300 308 80) KTO. 700 367 002
E-MAIL: [email protected] Nürnberg, GERMANY BIC TUBD DE DD , IBAN DE86 3003 0880 0700 3670 02
PHONE: +49 (0)911-4306-0 USt-IdNr.: DE813089359 VR Bank Nbg. (BLZ 760 606 18) KTO. 380 202
FAX: +49 (0)911-4306-439 VAT-No.: 241/115/90148 BIC GENO DE F1N02, IBAN DE81 7606 0618 0000 3802 02
 L3NG

Technical Documentation
Operation, Maintenance, Mounting and
Disassembly Instructions for the
Series L 3 N G Screw Pump

E 185 5177_e_Rev. 7_20.02.07

 L3NG
Contents

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.1. Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2. Information about the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.1. Addressing of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.2. Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.3. Names, Types and Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.4. Serial Number and Type Plate . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.5. Date of Manual Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.6. Change Notes and Manual Numbers . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.7. Copy Rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.8. Technical Documentation and Data Sheet . . . . . . . . . . . . . . . . Page 1
1.2.9. Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.10. Quality Assurance and Quality testing . . . . . . . . . . . . . . . . . . . . Page 1
1.2.11. Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

2. Safety ..................................................... Page 2

2.1. General Rules and Advice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.2. Dangers of not observing the Safety Advice . . . . . . . . . . . . . . . Page 2
2.3. Safety conscious Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.4. Warning and Advice Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.5. Safety Advice for the Operator . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.6. Safety Advice for the Service, Inspection and Mounting . . . . Page 2
2.7. Denial of Modifications and Changes without Approval . . . . . Page 2
2.8. Unallowable Running Conditions . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.9. Other Operations and Safety Hazards . . . . . . . . . . . . . . . . . . . . Page 2

3. Transport and Intermediate Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3

3.1. Safety Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.2. Transport Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.3. Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.4. Intermediate Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.5. Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.5.1. Aging of Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.5.2. Re--Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.5.3. Removal of the Preservation Fluid . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.6. Protection from the Environment . . . . . . . . . . . . . . . . . . . . . . . . Page 3

4. Description of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4

4.1. General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.2. Assembly and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3. Construction of the Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.1. Pump casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.2. Spindle Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.3. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.4. Casing Gasketing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.5. Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.6. End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.7. Drive Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.8. Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.9. Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.10. Drive and Shaft coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.4. Dimensioning and Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.4.1. Standard Overall and Single Dimension Drawings . . . . . . . . . Page 5
4.4.2. Standard Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5

E 185 5177_e_Rev. 7_20.02.07 Page i

 L3NG
4.4.3. Standard Sectional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.5. Execution Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.5.1. Type key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.5.2. Standard Material of Construction . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6. Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.1. General Operation Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.2. Use of pumps in potentially explosive areas . . . . . . . . . . . . . . . Page 5
4.6.3. Temperature-- and Pressure Limitations . . . . . . . . . . . . . . . . . . Page 5
4.6.4. Performance Data and Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.4.1. Performance Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.4.2. Power Consumption Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.5. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.5.1. Necessary Space for Operating and Maintenance . . . . . . . . . Page 5
4.6.5.2. Allowable Environmental Influences . . . . . . . . . . . . . . . . . . . . . . Page 6
4.6.5.3. Base, Foundation and Anchoring . . . . . . . . . . . . . . . . . . . . . . . . Page 6
4.6.5.4. Suction and Discharge Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
4.6.5.5. Support Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6

5. Mounting and Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7

5.1. Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7
5.2. Initial Installation of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7
5.3. Initial Installation of the Pump Unit . . . . . . . . . . . . . . . . . . . . . . . Page 7

6. Start up -- Shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8

6.1. Technical Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.2. Pipes Schematic and Measuring Points . . . . . . . . . . . . . . . . . . Page 8
6.3. Preparation for Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.4. Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.5. Shut down of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.6. Re--starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.7. Still Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.7.1. Shut down for up to 3 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.7.2. Shut down from 3 to 6 Months . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.7.3. Shut down for more than 6 Months . . . . . . . . . . . . . . . . . . . . . . Page 8
6.8. Operation Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.9. Bearing of the Driving Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9

7. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
7.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
7.2. Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
7.3. Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
7.3.1. General Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
7.3.2. Customer Service/Personnel/Danger . . . . . . . . . . . . . . . . . . . . . Page 10
7.3.3. Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
7.3.4. Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
7.4. Disassembly of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
7.5. Assembly of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11
7.5.1. Notice to the valve adjusting pressures . . . . . . . . . . . . . . . . . . . Page 12
7.6. Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12

8. Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 13

8.1. Table to define Reason and solving of Problems . . . . . . . . . . . Page 13
8.2. Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 14
8.3. Allowable pipe forces and moments . . . . . . . . . . . . . . . . . . . . . . Page 14
8.4. Allowable pipe forces and moments . . . . . . . . . . . . . . . . . . . . . . Page 14

9. Drawings, Data Sheets, Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 14

E 185 5177_e_Rev. 7_20.02.07 Page i

 L3NG
1. General 1.2.10. Quality Assurance and Quality testing
1.1. Application A complex quality assurance system guaranties high quality standard
This screw pump is used for pumping oils or other lubricating media at levels for Leistritz screw pumps. The quality assurance, according to
pressures up to 16 bar. DIN ISO 9001, covers all production steps, which are necessary to ful-
fill all the quality requirements for this product.
1.2. Information about the Product
Quality assurance measures (i.e. size, type of test and certification)
1.2.1. Addressing of the Manual
are issued by the purchaser in writing, including the necessary forms
This manual was made for the pump series L 3 N G. and documents. Prior to shipment all pumps are rigorously tested.
For other executions different manuals are valid. They may be ordered Only pumps which fulfill the confirmed test data will be shipped.
from the manufacturer separately if not on hand. Use of this manual will help to assure a trouble free operation and full
1.2.2. Manufacturing flow performance. The proof of test data on the bench follows the gen-
The manufacturer of the screw pump type L 3 N G , is eral test recommendations for rotary positive displacement pumps per
LEISTRITZ Pumpen GmbH VDMA 24284.
residing in the The proof of test and their results are documented in test certificates
Federal Republic of Germany ”M” per DIN 55350 P18.
90459 Nürnberg, Markgrafenstraße 29 - 39
1.2.11. Warranty
or 90014 Nürnberg, Postfach 30 41
DIN-- Parts, accessories and additional parts are purchased from Our liability for defects of shipped goods is outlined in our delivery and
sub--suppliers. payment conditions, which are part of our Sales Conditions and Terms.

1.2.3. Names, Types and Sizes Damages which may occur as a result of disregard of the instruction
Name: Three-- rotor screw pump manual and replacement conditions are not covered under warranty. If
Type: L3NG at a later date operation conditions change, for example different prod-
Sizes: 20, 25, 32, 38, 45, 52, 60, 70, 80, 90, 100, 112, 125, 140, 160, uct, viscosity, temperature, speed or inlet condition, these conditions
180, 200, 225, 250 and 275 have to be reviewed and acknowledged by LEISTRITZ. If no other
For additional information see the type key. agreements have been made with LEISTRITZ the delivered pumps
can only be disassembled and modified by LEISTRITZ or LEISTRITZ--
1.2.4. Serial Number and Type Plate Service Representatives. Otherwise the warranty for occurred dam-
Each unit is equipped with a standard type plate, which shows the ages will be voided.
manufacturers serial number and type key. Enlarged type plates are
available on request.
1.2.5. Date of Manual Execution
Dated October 17, 1994.
Technical and design changes, improvements and amendments may
be made without notice.
1.2.6. Change Notes and Manual Numbers
All executed changes are listed on the final page of this manual. The
type of change, date, executor and proof reader are noted.
Manual number E 185 5177/e includes additional documentation in the
form of drawings.
1.2.7. Copy Rights
All manuals, documents and drawings are copy righted according to
DIN 34.
1.2.8. Technical Documentation and Data Sheet
For in depth explanations see the following chapters:
Safety Chapter 2.
Transport and Storage Chapter 3.
Description of the Pump Chapter 4.
Mounting and Installation Chapter 5.
Mounting at Start--up and Shut down Chapter 6.
Maintenance Chapter 7.
Trouble Shooting Chapter 8.
Drawings and documents Chapter 9.

1.2.9. Customer Service

If service is required or questions need to be answered, please contact
our headquarters or someone in our sales organization.

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 L3NG
2. Safety 2.6. Safety Advice for the Service, Inspection and Mounting
2.1. General Rules and Advice
This manual includes general rules which have to be observed for The entire scope of service, including inspection and
installation, operation and maintenance. Therefore this manual has to mounting, has to be done by an authorized specialist, who
be read before installation and operation by the installer, as well as by has knowledge of this manual. Any work on the machine
the responsible specialist/user. It has to be made available at the job is only allowed when the unit is standing still. The shut--
site for reference at a later date. down of the unit described in the manual has to be fol-
2.2. Dangers of not observing the Safety Advice lowed.
Ignoring the safety advice can endanger people, the environment and
the pump unit. For example:
Damage to the pump units or certain functions of these units, can en-
danger personnel through electric, mechanical and chemical in-
fluences, endangering the environment by leakage of harmful prod- Immediately at the end of any work all safety and protec-
ucts and other pollutants. tion devices have to be installed completely. Before
start--up, points mentioned under 6.4 have to be followed.
2.3. Safety conscious Working
The safety rules listed in this manual, applicable preventive practices
as well as internal safety rules of the user always have to be followed.
2.7. Denial of Modifications and Changes without Approval
2.4. Warning and Advice Signs
In this manual safety symbols are mentioned which can help to prevent Changes or modifications on the unit which have not been confirmed
accidents to personnel. A general safety sign identifies hazards which by Leistritz, are not allowed.
will endanger the unit and its function.

2.8. Unallowable Running Conditions

The operational safety of the delivered unit is only assured by operat-

ing according to the confirmed design and data. Units should not be
used under different operating conditions without the manufacturer’s
approval. The limitation of the performance data sheets should never
be exceeded. Safety hazards may result if they are exceeded.

The word ”Attention” is inserted in the text to note these additional ad-
vice signs and is labeled directly on the unit. 2.9. Other Operations and Safety Hazards

All packing material of the pump or the unit shall only be

Attention removed directly before the installation of the pump.
For example: No foreign particles are allowed to enter the pump!
Direction of Rotation and Flow The danger of an accident at installation and mounting of
Electrical Current Warning the unit has to be observed at any time.
Marking of the Nozzles (inlet, outlet arrows) Balance stability always has to be existing, assembly
Marking Vent and Drain Opening parts have to be secured against falling.
”No rub--dry” sign and others.
Loose parts have to be secured by proper means.
2.5. Safety Advice for the Operator The pump unit is not allowed to be lowered or lifted by the
power supply lines or by the piping.

--Hot or extremely cold machine parts are potential dangers and must Connecting the power supply line to the Motor starter has
be protected against access.
to be done an Electrician and following the electrical lay-
--Coupling guards, which protect the flexible coupling and shaft from
out of the motor supplier.. Proper dimensioning of the lines
assess, shall NOT be removed during running of the equipment.
--Leakage of hazardous products at the seal, by such as, explosive, has to be observed. All dangers by electrical energy have
toxic or hot fluids have to be collected and drained to a safe place not to be eliminated. NEMA/VDA rules and the rules of the lo-
to endanger operating personnel and the environment. cal Energy and Supply company have to be observed as
All general rules of law, applicable to the site have to be followed. well.

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 L3NG
3. Transport and Intermediate Storage The listed preservative agent are meant to be a recommendation.
3.1. Safety Measures Other manufacturers can be used as well. Preserving the internals of
the pump is achieved by filling the pump with the preservation agent.
During filling the Page 6., power rotor has to be rotated in reverse very
slowly. Continue filling the pump until the preservation fluid exits the
suction nozzle with any air bubbles.

Larger screw pumps and all pump/driver units have to be transported

to the installation by means of lifting devices. Lifting and lowering of the
3.5.1. Aging of Preservation
unit have to be done in a balanced manner. Cranes and Lifting devices
have to be specified properly. It has to be assured that the unit will NOT According to the preservation fluid manufacturer, the shelf life of TEC-
”tip over”. Shelves and racks used for storage of the units have to be TYL 506 is 4 to 5 years at inside storage and 12--24 months at outside
designed to accommodate the weight and size.
storage; TECTYL 511 M is approx. 18 months at indoor storage only.
3.2. Transport Precautions By mixing TECTYL 506 and 511 M 50/50, conservation preservation
time of 2--1/2 -- 4 years indoors and 12 months outdoors can be ex-
pected.

Additional packing will extend the preservation time accordingly. The

ingredients in these preserving agent will allow proper corrosion
Damage during transport of the unit should NOT occur. Lifting, using protection even at high humidity, independent of any temperature.
parts like the motor, conduit box or a power supply cable is not per-
mitted. Sufficient care should be taken that the unit cannot slide or fall
during the transport. The packing material of the unit shall not be dam-
3.5.2. Re-- Preservation
aged. All advise on the packing crate or box have to be strictly followed.
For longer storage the user of the pump has
3.3. Unpacking
Attention to check the preservation of the pump regu-
Upon receipt of the pump, immediately inspect the unit for potential larly. Avoid damages which occur due to im-
transport damage. Transport damages have to be reported immedi- proper preservation.
ately to the Insurance Company.
Before installing the unit all packing material has to be removed com-
pletely. All uncovered openings of the unit, for example, the access
3.5.3. Removal of the Preservation Fluid
hole on the bell housing, is to be inspected for loose material, such as
wooden splinters, nails, bolts, metals clamps and others. Such items
Before start--up of the pump the preservation agent needs to be re-
need to be removed. End covers, blind plugs, etc., have to be removed
moved. The fluid which was used on the inside of the pump normally
as well.
can be removed by flushing the pump with product , provided the prod-
3.4. Intermediate Storage uct is allowed to get contaminated by this. In addition proper solvents
can be used to remove the inner and outer preservatives. Proper sol-
The delivered screw pumps are already preserved for shorter storage vents could be Kerosene, Diesel or de--mineralized spirits, industrial
time. For longer shut--down time, the pumps have to be further pro- solvents, cleaners and other paraffin solvents. Hot steam cleaners
tected from corrosion. An outside/inside preservation needs to be with according attachments can be used as well.
done as outlined under 3.5.
The pump always needs to be filled with
3.5. Preservation Attention product to avoid seizing the pump rotors at
start--up. If at the installation site the piping,
The time limitation of the preserving material is dependent on the com- tanks and other parts in various circulation systems are covered with
position of the material. Therefore preserving materials should be used paraffin containing preservation material, the whole system needs to
which will be stable for at least 12 months. The following materials can be flushed. This is necessary because paraffin lowers the degassing
be used for an inside and outside preservation. capability of the products. This might cause a rough running pump in
connection with loud noise development (aeration).
Preservation Points: Preservation agents:
All machined and unpainted TECTYL 506
surfaces like shaft end and or compound
flange covers TECTYL 506 and 3.6. Protection from the Environment
TECTYL 511--M (*)
When storing the screw pump, the discharge and suction flange al-
Pump casing internals, rotor compound
set and end covers TECTYL 506 and ways need to be covered by blind flanges, blind plugs or similar mate-
TECTYL 511--M (*) rial. The storage shall take place in a dust free and dry room. During
storage , it is recommended to turn the inner parts of the pump manu-
---- (*) Manufacturing: VALVOLINE OEL GmbH & Co. ----
ally every 4 weeks. The rotor set and bearing change their position dur-
The preservative agent shall be spread by means of brushing or ing this process. If the storage and packing is done properly, the unit
spraying. can be preserved for a very long time.

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4. Description of the Pump 4.3.3. Shaft Seal
4.1. General Description Sealing the stub shaft of the driving spindle against the product, a sim-
The Leistritz Screw Pumps of the L3NG Series are low pressure ple non--balanced maintenance free mechanical seal (position 62)
pumps up to 16 bars. They are self priming positive displacement mounted directly in the driving side cover (position 045).
pumps and are used to move oils or other lubricating products. Materials and means of construction (manufacturer of the mechanical
seal) will be adjusted to the according operating conditions and char-
4.2. Assembly and Operation acteristics of the product being pumped.
Due to the special profile of the three turning spindles, sealed cavities
are produced. The double--lead driving spindle (position 150) rotates, 4.3.4. Casing Gasketing
sealing with the double--lead idler spindle (position 151) in the spindle The pump is sealed off using flat gasket (position 031) and seals rings
bore of the pump casing (position 001) which encloses the spindle set (position 006) depending on the operating conditions and the pumped
with tight tolerances. products.
The motion of the two idler spindle is caused by the calculated hydrau-
lic forces leaving only the resulting moment caused by the fluid friction 4.3.5. Bearing
to be transmitted over the flanks of the spindle profile. Therefore the The outboard, greased, shielded and maintenance free bearing (posi-
spindle set is almost without any load and will not wear. With this princi- tion 170) according to DIN 625, mounts the power rotor (position 015)
pal the pumps continually move fluid without sheer and turbulence into the drive side cover (position 045).
from the suction to the discharge side. This constructive design in
working principle assures a low noise level and an almost pulsation
4.3.6. End Cover
free discharge.
The complete spindle geometry is chase in in a way that no axial thrust The end side cover or immersion tube (position 030, 450) or the pedes-
is effected on the grooved ball bearing (position number 170). The tal (position 040) shuts the pump casing (position 001) at suction side.
grooved ball bearing (position 170) fixes the driving spindle (position
150) in axial direction. 4.3.7. Drive Side Cover
The bearing application of the idler spindles (position 151) is effected in The drive side cover (position 045) serves for integration of the me-
the pump casing (position 001). chanical seal and for fixing of the complete pump. The mounting face is
Depending on the operating pressure, an appropriate choke gap is according to DIN 3019, position 2, section 4, squared mounting
built between the balancing piston of the driving spindle (position 150) flanges. With this four hole mounting flange, the complete pump can be
and the idler spindles (position 151), which guarantees the hydrody- rotated in 90q increments.
namic bearing of the idler spindles. At the discharge connection, a cast in error describes the
The subsequent tightening area is connected with the suction side flow direction of the product. Before start up that flow
pump room by means of a boring and stands thus always under direction has to be checked. Mounting the complete pump
suction pressure. By this geometric design of the spindle package the to the driver, screws acc.to DIN 938 or DIN 939 have to be
axial thrust balancing is guaranteed. used together with hex head bolts and nuts.

4.3. Construction of the Parts 4.3.8. Pressure Relief Valve

4.3.1. Pump casing As described on 4.3.1, the pump can be executed with an integral pres-
Depending on the mounting configuration, the execution of the pump sure relief valve. Exaggerating the adjusted values, the poppet (posi-
casing will be made (position 001). The complete pump casing can be tion 219) lifts from the seat and the product circulates into the suction
mounted turned by each time 4 x 90q to the main shaft of the driving area of the pump casing. The opening pressure is adjusted by com-
aggregate. The suction area will be closed off with the non--drive side pressing the valve spring (position 235) with the adjusting screw (posi-
cover (position 30). The drive side cover (position 45) is mounted on tion 222) at the factory or at the user, depending on the requirement.
the discharge side. As an option the pump casing can be executed with Notice to the valve adjusting pressures see chapter 7.5.1
an integrated relief valve. Using the pump with a pressure limitation valve, care
The relief valve protects the pump only against overload should be taken that the poppet will always stay movable
and is not meant to be used as a pressure regulating in it’s axis. A complete closing of the valve bore by means
valve! Operation and manual of the pressure regulating of locking the adjustment screw and the connected valves
valves, see section 4.3.8. The pump casing can be spring by complete compression, shall not be allowed,
drained in any mounting configuration. Therefore, check before start since this could cause damage to the pump. If a pressure
up on eventually not plugged openings. regulation is necessary, this shall be done with separate
On the suction connection the casting is executed with a regulating devices, executed and installed by the user.
cast in flow direction arrow. Before start up the flow direc-
tion needs to be checked. 4.3.9. Nozzles
Suction and discharge connection are executed as a DIN or ANSI--
flanged connection, marked with flow direction arrows cast into the
4.3.2. Spindle Set pattern. Weldneck counter flanges according DIN or ANSI can be sup-
The driving spindle (position 150) is double--lead, hardened and axially plied with a price adder.
positioned with a grooved ball bearing (position 170). The idler Maximum allowable forces and moments are depending
spindles (position 151) double--lead as well, hardened or unhardened, on the pump size, and are listed on the dimension print of
are paired to the driving spindle. During operation both idler spindles the pump or on the assembly drawings. These values
are pushed in axial direction against the driving side balancing piston shall never be exceeded. Connections for drain, vent or
of the driving spindle (position 150). heating, if not needed, need to be plugged before start up.

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 L3NG
4.3.10. Drive and Shaft coupling 4.5. Execution Modifications
The pump will be directly coupled to an electric motor or other drive via 4.5.1. Type key
a bell housing with foot angle or a bell housing with a mounting plate in a The type key, listed at the end of this manual, does include all combina-
vertical mount arrangement. tions of pump modifications via number and letter code. Every stan-
Always observe the correct direction of the rotation and dard pump can be described by that.
proper drive speed. The pumps can be mounted in any
mounting position. Because of safety reasons, mounting 4.5.2. Standard Material of Construction
the motor below the pump is not allowed. The shaft cou-
Pump casing 0.6025 or 0.7040
pling transmits the turning moment form close with a three
Drive side cover 1.0037
piece elastic form connecting coupling, which balances
End cover 1.0421
axial, radial and angular misalignment of the connecting
Driving spindle 1.7139 hardened
shafts. Different execution (manufacturer and material
Idler spindle 1.7139 hardened or 0.6025
combinations) are available with price adder
Gasket CENTELLEN WS 3820

4.4. Dimensioning and Geometry 4.6. Operating

4.4.1. Standard Overall and Single Dimension Drawings 4.6.1. General Operation Fields
Standard overall dimensions for the size 020 through 070 are accord- General industry technology, oil burning energy, ship building and off
ing to drawing E 168 5954 with DIN flange connections. shore technology, machine and heavy machinery manufacturing, tank
farms, chemical and petro chemical and OEM Industries, food proces-
Standard single dimension drawings for the size sing and others.
with DIN flange connections
020 + 025 drawing E 168 5918 4.6.2. Use of pumps in potentially explosive areas
032 drawing E 168 5919 These pumps and pump units are suitable for use in
038 drawing E 168 5920 potentially explosive areas according to EC Directive 94/9/EC (ATEX).
045 drawing E 168 6026 The condition is:
052 drawing E 168 6027 that the pump units are designed according to the specifications and
060 drawing E 168 6028 that this design is confirmed in the project--related pump data sheets.
070 drawing E 168 6029 Proper operation and the permissible application limits must be com-
080 + 090 drawing E 168 6393 plied with as specified in the corresponding chapters of the data sheets
100 + 112 drawing E 168 6394 and of the operating manual. Also see Chapter 6 of this operating man-
ual (Commissioning).
125 + 140 drawing E 168 6395
The confirmation for the permissible area of use is:
160 + 180 drawing E 168 6431
documented in the EC Declaration of Conformity for the corresponding
200 + 225 drawing E 168 6446 project. Detailed documents are included in the project documenta-
250 + 275 drawing E 168 6657 tion, in particular ATEX certificates on devices or attached parts requir-
ing verification.
further project related drawings will be attached.
4.6.3. Temperature-- and Pressure Limitations

If separate single dimension sheets have been executed for the user
they have to be requested.

4.4.2. Standard Assembly Drawings

The nominal pressure, viscosity and temperature details must be
Assembly drawing for the size 020 through 070 with DIN flange needed (see data sheet). If no details are given to the contrary, the
connections and various motor size are available: values given can be considered as relief values and may not be
For foot pumps D 161 9247 exceeded. If protective measures are required as a result of the
For submerged pumps D 161 9249 operating temperatures or temperature limits to prevent disturbance
For tank top mounted pumps D 161 9248 of the surface, these are to be applied by the customer and may not
Assembly drawing for the size 080 through 275 with DIN flange be removed in operation.
connections and various motor size are available:
For pedestal pumps D 162 1327 4.6.4. Performance Data and Speeds
For flange pumps D 162 1328
further project related drawings will be attached. 4.6.4.1. Performance Tables
Performance tables according to pump size and lead angle for various
speeds and viscosity’s, see E 165 6448, page 1--21.
If separate mounting drawings had been made for the user, they have
to be requested.
4.6.4.2. Power Consumption Diagrams
Power consumption’s diagrams for pump size and lead angle for vari-
4.4.3. Standard Sectional Drawings
ous speeds and viscosity’s, they have to be requested.
Standard cross sectional drawings for all sizes and possible execu-
tions according to drawing E 160 6878 or C160 7631. 4.6.5. Installation

If special cross sectional drawings for the user have been made, they 4.6.5.1. Necessary Space for Operating and Maintenance
have to be requested. Choose the mounting space that way that an undisturbed operation
All above drawings are available in different languages on request. and uncomplicated maintenance of the unit is possible. Follow all
safety regulations as well.

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4.6.5.2. Allowable Environmental Influences We recommend the installation of suction strainers with the following
Existing environmental influences which would have mesh sizes:
negative influence on the operation of unit, i.e., high heat
radiance from neighboring machine parts, splash water Mesh size viscosity
and so forth, have to be avoided as much as possible. All 0.3 -- 0.5 mm >150 mm2/s
environmental influences and mounting configurations have to be 0.1 -- 0.3 mm 37 -- 150 mm2/s
stated upon ordering. Additionally operation measures, i.e., insulating, 0.06 -- 0.1 mm <37 mm2/s
vibration dampers, have to be stated at order.
During the connection of the piping to the pump the flow direction
4.6.5.3. Base, Foundation and Anchoring through the pump has to be observed (arrows on the pump). The con-
The anchoring is depending on the type and the size of the unit. If the nection of a pressure gauge on the pump body should be planned.
unit is mounted via L--bracket, the mounting holes, respective elon-
gated holes of the foot bracket have to be used. The cleaning of the pipework should not be executed with water
The mounting should be chosen that no movement of the or with fluids with minimum viscosity below the minimum indica-
unit is possible. All sub bases and foundations must be ted viscosity shown in the pump data sheet. During hydrostatic
statically sound. The unit should not be exposed to the test of the whole pipework system, the pump must be isolated.
vibrations of other machines. If vibrations cannot be The hydrotest of the pump (dynamic or static) will cause damage
avoided vibration isolators have to be installed. to the pump (especially to the shaft sealing system). If this proce-
If the unit is mounted with a lid plate onto a tank, ensure dure is not maintained, the guarantee is not void.
that the tank can support the weight of the pump. It is rec- 4.6.5.5. Support Connections
ommended to use vibration isolators. This will reduce the All other support connections have to be dimensioned properly and
noise at the tank walls drastically. Leistritz cannot be brought towards the unit. The user is solely responsible for the sizing
made liable for damages of the unit due to unstable anchoring. and material selection. In principal no mechanical forces are allowed to
4.6.5.4. Suction and Discharge Piping take place. Damaged support pipes have to be repaired or exchanged
The pump unit is not permitted to act as a mounting point immediately.
for piping. The maximum allowable forces and moments
on the flanges mentioned in the dimension sheets and
assembly drawings may not to be exceeded. This is true
for possible temperature forces as well, see section 8.3.The pipe sizes
on the suction and discharge side should be at least the size of the
pump connections. The selection of the pipe has to be done using the
existing flow velocity. The flow velocity in the suction line should not
exceed 1 meter per second and in the discharge line, 3 meters per se-
cond. When piping up suction and discharge lines, care should be
taken that the flow of the medium is not disturbed by mounting short
radius elbows, right angle valves or check or back pressure valves in
the suction line. Unavoidable diameter changes in the flow lines have
to be executed with smooth reducers. Any sudden direction changes
should be avoided. The suction and discharge lines have to be sealed
tightly and piped in such a manner that no air bubbles can build up.
Therefore the piping must always be layed in a rising manner. The
spindles of gate valves should be positioned horizontally or vertically
downward to allow venting of the lines at the highest point. Flange gas-
kets cannot be permitted to protrude into the I.D. of the pipe and instal-
lation of isolation valves before and after the pump as well as a check
valve at the discharge side is recommended. The isolation valves are
only used to close the lines for pulling the unit out of service. They have
to be completely open during normal operation. All pipes and valves
have to be cleaned thoroughly before the pump is mounted in order to
flush out weld slag, weld beads and possible mounting debris, like
bolts, nuts and so forth. No liability can be claimed for damages to the
pump which have been caused by solid particles in the product. Mount
the pump onto the tank in such matter that air bubbles and foam par-
ticles, which might have been produced in the fluid are kept out of the
pump inlet.

The tank has to be dimensioned and mounted in such

fashion that the use of maximum allowable flow and media
temperatures are not exceeded, proper installations mea-
sures achieve this goal.
The lifetime of a screw pump is determined by the cleanliness of the
product and it’s relationship to the tight tolerances between the rotors
and the rotor sleeve.

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 L3NG
5. Mounting and Installations When using special couplings the recommendations of the manufac-
turer cannot be exceeded. Axial forces are not allowed to be trans-
5.1. Tools mitted through the coupling into the pump.
Careful and accurate adjustment of the shaft ends will
For the total mounting or disassembly standard tools are necessary: lengthen the life time of the coupling. The coupling half on
-- Allen head wrenches according to DIN 911 the pump side is not allowed to be installed with a hammer.
-- Open end wrenches according to DIN 838 ISO 3318
-- Open end wrenches according to DIN 3110 Bell housing or other support measures of the pump have to be thor-
-- Machinist hammer according to DIN 1041 oughly checked for possible defective manufacturing. The referenced
-- Rubber mallet minimum allowable values for radial, axial and angular offset of the
-- Screw driver according to DIN 5.264/A shafts according to DIN 42955 (table 1,N and table 2,N) have to be
-- Screw driver insulated (electrical) achieved manufacturing the bell housing. Mounting advises of the cou-
-- Gear puller 2 or 3 armed pling manufacturer have to be observed.
-- Pliers for snap rings according to DIN 5254
-- Snap ring pliers according to DIN 5256 All rotating parts have to be protected
-- Mounting sleeves for ball bearings against unintentional touch! Damages
5.2. Initial Installation of the Pump caused by improper mounting or adjust-
ment of the pump and motor, are not
The shaft end of the pump and driver have to be aligned covered under warranty.
carefully, since eccentricity, non--parallelisms and plain
arrows will fast destroy the elastic element of the coupling 5.3. Initial Installation of the Pump Unit
and furthermore can cause damage to the pump. Mount-
ing the pump to a driver, care should be taken that the side offset of the The pump unit has to be inspected at the job site for damages. If the unit
shafts (distance between shafts) the maximum eccentricity (center off- is assembled at the job site, follow 5.2. After proper alignment, the
set between the shafts) and the maximum angularity of the two shafts complete unit has to be anchored accordingly. Base and foundations,
do not exceed the recommended data of the coupling manufacturers. see 4.6.

Lifting the base frame

units
fig. 1. With pump, motor and
baseframe
fig. 2. With pump and motor
and without baseframe
fig. 3. With pump, motor and
baseframe

fig. 1
Lifting the pedestal
units
fig. 4. Pump and motor in
pedestal form

Measuring the...
fig. 5. ...concentricity...
fig. 6. ...parallelism...

...of both shafts.

fig. 2 fig. 3 fig. 4

{ Mounting the indicator on the drive shaft and rotation of both shafts; | Mounting indicator on one shaft and turning of both shafts;
checking the concentricity and correction if necessary. checking the parallelism and correction if necessary

fig. 5 fig. 6

E 185 5177_e_Rev. 7_20.02.07

Page 7 of Page 14
 L3NG
6. Start up - Shut down The discharge line has to be vented until product exits the vent valve or
vent screw. The venting devices have to be closed after this proce-
6.1. Technical Documentation dure.
After start up of the pump, total pump pressure, flow rate, viscosity,
Before start up check all technical demands temperature, speed and horse power have to be compared to the order

Attention and documentation’s. Especially check the

pump unit on:
and operation data. Check especially that with higher specific gravity
or higher viscosity of the product as original assumed, the driver will
not be over loaded and NPSH required of the pump is not exceeded.
- serial no.
Otherwise cavitation will take place. Check the liquid level in the tank,
- type and size
especially at tank mounted units, that the suction opening always
- flow direction and operation type
stays flooded.

6.2. Pipes Schematic and Measuring Points

To the save and troublefree operation, the valve adjusting pres-
The total piping arrangement, proper connection and dimension of sure is to be examined - see chapter 7.5.1
measuring and governing devices have to be observed. 6.5. Shut down of the Pump
If the pump is used in potentially explosive areas, the measuring and
control technology must be checked with regard to the approval of the For the shut down of the driver no preparations are needed. If the pump
devices. The declarations of conformity are included in the project is shut down against full pressure, it will stand still immediately (un-
documentation. problematic for pump and electric motor). It is recommended to install a
The cleaning of the pipework should not be executed with water check valve between the isolation valve and discharge line. At longer
or with fluids with minimum viscosity below the minimum indica- shut down the isolation valves should be closed. If a change of the fluid
ted viscosity shown in the pump data sheet. During hydrostatic concentration, crystallization, solidification and others have to be
test of the whole pipework system, the pump must be isolated. taken in to consideration, the pump has to be drained and flushed with
The hydrotest of the pump (dynamic or static) will cause damage a proper fluid.
to the pump (especially to the shaft sealing system). If this proce-
dure is not maintained, the guarantee is not void. 6.6. Re-- starting
Damages which occur due to improper positioning or di-
mensioning of measuring and governing devices, are not After a short shut down, the pump can be re--started without any prepa-
covered under warranty. rations. After longer still standing time or re--installation of the pump,
the procedure according to section 6.3, preparation for start up has to
be followed.
6.3. Preparation for Start up

6.7. Standstill
Before initial start up the following scopes have to be
completed:
6.7.1. Shut down for up to 3 Months
-- Cleaning of the piping, section 4.6.5.4.
-- Checking of the anchoring, section 4.6.5.3.
If the start up of the pump is within 3 months of installation or the shut
-- Checking on power supply to the motor
down of the pump is less than 3 months, no special preservation is re-
-- Check the direction of rotation of the driving motor,
quired.
the direction of rotation must correspond to the direc-
tion of rotation arrow on the pump. By an incorrect 6.7.2. Shut down from 3 to 6 Months
direction of rotation, the pump will produce no suction,
this will cause the pump to be damaged. Before the initial start up the suction and discharge port
-- Remove blind plugs on suction and discharge lines, section 3.3. have to be covered with a blank. At shut down, suction
-- Check piping according to flow direction, section 4.3.9. and discharge insulation valves have to be closed. With
and 4.6.5.4. that measure the pump remains filled with product. If the
-- Visual checking of the pump unit, section 6.1. product includes aggressive particles which might attack the materials
-- Opening of the separation valves of construction of the pump, follow according section.
-- Fill pump with pumping liquid and be sure to protect against running
dry. For filling information and recommendations, see Document E 6.7.3. Shut down for more than 6 Months
185 5504 (see Appendix).
-- All governing and control equipment have to be checked on func- The pump has to be closed off and sealed off according to
tion after installation ( i.e., emergency switch off, needle pressure 6.7.2. and has to be filled with preservation material. To
gauge and others ) protect the running surfaces of the bearings against com-
-- To protect people, all equipment has to be according to rules and pression marks caused by vibrations or shocks, the
regulations power rotor is to be turned in according time intervals. (I.e. all 4 weeks
rotated manual, so that parts like the rotor set and the bearing should
6.4. Start up end in a different position each time).

Before start up, the rotation direction and speed has to be 6.8. Operation Supervision
checked. Suction and pressure gauges have to be ob-
served and compared to order and operation data. Tem- The necessary supervision of a Leistritz screw pump is
perature and viscosity of the product should be checked. very minor. In proper time intervals, discharge pressure,
On the drive side cover in the ball bearing area, the tem- flow rate, excess power consumption of the electrical mo-
perature can be 20--30 qC, below the product tempera- tor, alignment of the pump (coupling), seal, filter, contami-
ture, but has to be below 120 qC. nation and unusual noises should be observed. The cleanliness of the
product is the main factor in the life time of the pump. A visual check of

E 185 5177_e_Rev. 7_20.02.07

Page 8 of Page 14
 L3NG
the pump should be done at least once a month. The pump should al- grease - filling - quantities
ways run quiet and vibration free. The pump is not permitted to run dry!
Shaft seal should be checked, especially during start up time, leakage type of pump grease filling quantity
might occur.
The leakage of one drop of product per hour is an average L3NG 20 5g
for an undamaged mechanical seal. If the pumps are L3NG 25 5g
mounted as spares, they should be started up from time to L3NG 32 5g
time for a short period of time, to assure they are ready L3NG 38 8g
when needed. Furthermore, the shaft should be rotated according to L3NG 45 8g
section 6.7.3. L3NG 52 14 g
L3NG 60 14 g
6.9. Bearing of the Driving Spindle
L3NG 70 18 g
The bearing on the power rotor is a maintenance free, L3NG 80 20 g
grease packed sealed ball bearing. The bearing is de- L3NG 90 22 g
signed for 17500 hours running under the conditions de- L3NG 100 22 g
scribed under section 4.6.2. In a rough service, high tem- L3NG 112 26 g
peratures or others, the design life can be shortened drastically. L3NG 125 26 g
L3NG 140 30 g
If there is a regreasing--possibility at the pump, the groove ball bearing L3NG 160+180 35 g
has to be regreased regularly. The regreasing intervals depend on the L3NG 200+225 40 g
grease service life of the used grease--media and on the operational L3NG 250+275 50 g
charges.A monthly inspection respectively an inspection after 500 op-
erating hours would be recommended by the manufacturer.
The indicated lubricants exclusively apply to
For the lubrication, all high--quality and temperature--resistant ball bea-
ring -- greases as proposed as follows, can be used. Attention the pump. Please you consider their regula-
tions with further components for lubrication.

manufacturer up to 130_C up to 180_C

Aral Aralub HLP 2

BP BP--Enerrease LS--EP2
Castrol Spheerol Ap2
DEA Glissando EP2 Diskor Plus 2
Esso Beacon Ep2 Unirex S 2
Fuchs Renolit FEP 2 Renoplex EP 3
Mobil Mobilux EP 2 Mobiltemp SHC 32
Optimol Olit 2 EP oder Optitemp HT 2
Longtime PD 2
Shell Alvania Grease EP 2 Darina Grease 2

or comparable grease - products

E 185 5177_e_Rev. 7_20.02.07

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 L3NG
7. Maintenance For pumps handling dangerous substances
Attention and/or environmentally hazardous media,
the owner must inform its own assembly per-
7.1. General
sonnel on site of this fact, or our factory personnel in case
The maintenance work includes almost exclusively checking of pump of return. In this case, we must be presented with proof of
parts for wear and damage. Leistritz Screw Pumps of the Series L3NG the pumping medium, e.g. in the form of a DIN Safety Data
Sheet, together with the request for customer service.
need minimum maintenance, as long as the confirmed operating data
are kept and the fluid is as free as possible from abrasive particles. The Dangerous substances are:
cleanliness and the capability to lubricate the product, are dominant in
S Toxic, carcinogenic, embryotoxic substances, gene--
the expectancy life of a pump. If a high operation safety is necessary,
altering substances or substances which are other-
we recommend the following maintenance intervals according to sec-
wise harmful to the health of and dangerous to human
tion. beings.
S Caustic substances
S Irritants, explosive, fire promoting, highly flammable
7.2. Maintenance and Inspection
and flammable materials
-- After 500 hours of operation the pump should be ex- S Corrosive materials.
amined, the pump should be checked for unusual
noises and it shall be checked with a temperature sen- The user is solely responsible for mounting on site warn-
sor. The temperature difference between the fluid and ing signs, which naturally shall be observed at all times.
the drive side cover should not exceed 22--25 qC. The During all activities on site, the owner’s own personnel
leakage of the mechanical seal should not exceed a few and LEISTRITZ employees must be informed of all
dangers which can occur during dismantling and/or repair
drops per hour.
work.
-- After 2 years the pump should be disassembled and all inner parts
For mounting and repair LEISTRITZ personnel can be made available
should be examined for damage and wear, especially the mechanical
to the user upon request.
seal has to be checked in the sliding surfaces. The idler rotor head
7.3.3. Disassembly and Assembly
surfaces have to be checked for wear as well.
The most important disassembling and mounting steps
-- Worn parts need to be replaced. Check the casing and the flow pock-
are described in the following:
ets in the relief valve for dirt contamination. If dirt deposits are noted, it
No warranty claims can be accepted if all necessary as-
needs to be cleaned out. sembly steps have not been kept in order, or damages
due to improper disassembly or assembly occurred.

7.3.4. Tools
7.3. Disassembly and Assembly Necessary Assembly Tools (see Section 5.1)

7.3.1. General Precaution 7.4. Disassembly of the Pump

-- The power lines have to be disconnected by an Elec-
With proper supervision of the pump, operation interruptions which trician. Motor or driver have to be made unfunctional.
might make a disassembly necessary, are very rare. If an interruption -- Checking of the insulation valves in suction and dis-
occurs, the possible cause should be determined before disassembly, charge line, they have to be closed.
if at all possible. The trouble shooting table in section 8.1 gives hints -- Let pump cool down to surrounding environment tem-
about possible causes. At all disassembly and assembly, all parts perature.
have to be handled with care. Shocks and impacts have to be always -- Disconnect suction and discharge flanges.
avoided. All parts have to be carefully cleaned, possibly re--condi- -- By unbolting the mounting flange, the pump can be
tioned or exchanged for spare parts. After assembly the Driving lifted from the mounting unit.
-- Couplings half on pump shaft has to be pulled via
spindle has to rotate freely, otherwise the bearing and mechanical seal
gear puller, remove key (position 180) from pump
could be damaged. At all work the proper cross sectional drawing has
shaft.
to be used as work base.
-- Valves spring (position 235) needs to be released via
adjusting screw 222, the seal nut (position 281) needs
to be loosened for this purpose (only with integral
pressure relief valve).
7.3.2. After Sales Service Technicians/Dangers
-- To remove end side cover or the pedestal (position 30 or 40) take
out bolts (position 32 or 47) and remove gaskets (position 31).
LEISTRITZ--Service Technicians for mounting and repairs can be
-- Remove valve parts (position 219, 220 and 235) (only with integral
made available to the user upon request.
relief valve).
If repair work is to be carried out by the owner or by LEIS- -- Loosen screws (position 50) on drive side cover (position 45) and
TRITZ service personnel, the pump must always be de- remove drive side cover and gasket (position 46) from pump cas-
pressurised, completely drained and cleaned. This is es- ing (position 001). Doing that, watch for spindle set, mechanical
pecially applicable for pumps that are returned to our fac- seal and grooved ball bearing. See valid sectional drawing.
tory for repair. In order to protect our employees, and for -- Separate idler spindles (position 151) from driving spindle (position
environmental protection reasons, pumps filled with pumping medium 150).
will not be accepted for repair. Otherwise the owner will be charged for -- Remove circlip (position 174 and 173) and supporting disk (position
the costs for an environmentally appropriate disposal. 172).

E 185 5177_e_Rev. 7_20.02.07

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 L3NG
-- Pull driving spindle (position 150) through the I.D. of the grooved with the supporting disk (position 172) in place, through the drive
ball bearing (position 170) towards suction side through the drive side cover and the ball bearing. Never drive the driving spindle
side cover. Remove supporting disk (position 172). through the ball bearing with impact by a hammer nor the ball
-- The rotary part of the mechanical seal has to be carefully pulled bearing over the shaft via hammer. The driving spindle, slightly
from the driving spindle. Depending on the manufacturer the lock- greased, needs to engage with the inner diameter of the ball bear-
ing device has to be removed. ing all the way on to the shoulder on the driving spindle. After-
-- The stationary face of the mechanical seal with O--ring or seal ring wards mount the supporting disk (position 172) and circlip (posi-
can now be pressed out carefully of the drive side cover. tion 173).
-- Remove grooved ball bearing (position 170) in direction shaft end -- Put O--ring (part 46) in place on to drive side cover (position 45).
with a gear puller out of the drive side cover (position 45). -- Position the idler spindles (position 151) as a pair on to the driving
spindle and slide spindle set into the casing. Watch for the posi-
7.5. Assembly of the Pump tion of the running surfaces ( mark), the casing box should be
slightly oiled for this purpose. Bolt the pump casing with screws
A re--assembly can only be permitted if full functional and
(position 047) onto drive side cover, note that the screws need to
undefective parts are used. We recommend as well a
be pulled simultaneously and the proper position of the connection
cleaning of heavily stained parts
flanges has to be noted.
-- Assembly valve parts, position number 219, 220 with 235, in the
-- The grooved ball bearing (position 170) needs to be checked for
proper order in to the valve cavity (only with existing relief valve).
damages*, defective seal disks, then it should be pressed into the
-- Place gasket (position 031) onto the end side cover of the pump
drive side cover (position 45). *Like smooth run, grease filling.
casing (position 001).
Never force the bearing in place by means of a hammer, this
-- Turn set screw (position 222) that far into the end side cover
would cause damage of the running surfaces and the bearing
(position 030) that the tip of the adjustment screw touches the
balls. Secure in place by means of the circlip (position174).
spring plate (position 220) without tensioning the valve spring
-- Mounting of the mechanical seal needs absolute cleanliness.
(position 235). Afterwards pull the end side cover tight by means
Especially a damage of the sliding surfaces and elastomers have
of using screws (position 030) seal nut (position 281) on to adjust-
to be avoided.
ment screw and after adjusting the relief valve to proper operating
-- The stationary element of the mechanical seal
pressures, seal tight (only if a relief valve exists).
(position 62) can be pressed into the drive side cover with the
-- Heat pump side coupling half to app. 110qC and slide
O--ring in place. Watch for equal pressure distribution over the
on to shaft end of the driving spindle with the key
whole ring. Watch as well for the position of the edged adjusting
(180) in place. The coupling half shall not be installed
pin (position 61) in drive side cover (position 45). If necessary,
with impact by a hammer.
spacer ring (position 63) on to driving spindle (position 150).
Watch for absolutely undamaged driving spindle surface in the After complete re--assembly the pump has to be installed into the driv-
mechanical seal area. ing unit and be mounted according to section 5.2. Thereafter the dis-
-- To reduce the friction forces at assembly of the mechanical seal, charge suction and supply lines have to be connected properly. At the
oil driving spindle (position 150) in the area of the rotating element restart--up, section 6.0 have to be followed and the pressure limitation
with oil or silicone grease fill. It is not permitted that Teflon oil ring valve, safety valve, if existing has to be adjusted
gets in contact with mineral oil or grease. Silicone grease is rec- -- The down valve spring (position 235) hard via adjustment screw
ommended, depending on seal execution, the rotary part needs to (position 222).
be locked onto the shaft. -- Start pump with the throttle valve A open.
Above is not applicable for rubber bellows -- Throttling valve A, so that the pressure gauge shows the required
Attention seals, they have to be mounted with a proper
solvent, water or alcohol.
valve opening pressure and the flow meter B shall show steady
flow.
-- Release valve spring via adjustment screw (position 222) until the
-- Never grease the sliding surfaces, always mount completely dry flow rate on the flow meter number B lowers. This means the relief
and dust free. valve opening pressure is reached.
-- After mounting of the rotary element (position 062) on to the driv- -- Close throttle valve A. Now the pressure gauge will show the
ing spindle (position 150) the driving spindle needs to be mounted pressure where the total flow is cycled over the valve

281

222 235

E 185 5177_e_Rev. 7_20.02.07

Page 11 of Page 14
 L3NG
-- - Design variant with sealing nut and adjusting screw
-- Lock seal nut (281)tightly.

-- - Design variant cap nut sealing of adjusting screw

For fixing of the adjusting screw (position 222) this one has to be
countered with the hexagonal nut (position 215) and the sealing ring
(position 216). Afterwards the cap nut (position 281) has to be tight-
ened withe the second sealing ring (position 216).

Further steps see section 6.4.

7.5.1. Notice to the valve adjusting pressures

Like all positive--displacement pumps, this screw pump requires a
pressure relief valve to protect against overloading. This valve can be
installed externally, as an external valve in the piping system, or di-
rectly as an attached part on the pump. The respective model is speci-
fied in the data sheet or the valid drawings.
If no other agreement has been made, the valve actuation pressure is
pre--set at the factory on the test bench. The opening pressure is ap-
prox. 10 to 20 % above the operating pressure. However, the values on
the system must be checked prior to commissioning.
The following distinction is made for valves:
-- Valve actuating pressure; this is the pressure at which the valve
begins to open.
-- Valve short-- circuit pressure; this is the pressure at which the en-
tire pump feed quantity flows off via the valve.
-- Valve closing pressure; this is the pressure at which the valve has
closed again following relief.
It must be noted that at low operation pressures, the adjustment values
are selected so that the valve closing pressure is always above the
operating pressure and the valve short-- circuit pressure does not
lead to overloading of the pump and drive.
If this is not observed, damage to the pump and drive may result. We
shall assume no liability whatsoever for damage resulting from a failure
to observe this fact.

7.6. Spare Parts

In general, we recommend that the user should keep a complete set of
spare parts for the pump unit on stores. It is also possible to select a set
of appropriate spares acc. to our spare parts list for the individual user.
In order to do this, the following information shall be supplied when or-
dering.
-- Pump Type
-- Pump Size
-- Leistritz Serial Number
-- Cross Sectional Drawing Number
-- Purchaser / User
-- Name
-- Address and Telephone Number
An interchangeability can only be guarantied
Attention if accurate information is given.

Conserving and intermediate storage of spare parts or spare pumps,

see section 3.4. and 3.5...

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 L3NG
8. Trouble Shooting not listed in the trouble shooting list, we recommend a check back with
the factory or the sales forces.
8.1. Table to define Reason and solving of Problems
Solving all of the particular disturbances the
The table below is used to define eventually happening disturbances at pump needs to be without system pressure
the pump unit. If problems occur during operation of the unit, which are and needs to be drained.

Problems at the pump unit

Pressure and flow rate too low
Pump does not lift discharge

Noise creation in the pump

Motor over loaded

Fluctuating flow

Pump is seized

Unit vibrates
Pump leaks

Reasons and Resolution

Compare direction of rotation arrow on pump with direction of rotation of motor.

If necessary reverse motor.
Check suction pipelines and stopcocks for leaks. Vacuum suction head to high,
shorten suction pipeline, mount pump at a lower position
Reduce flow turbulence, lay suction pipelines straighter.
System and pump are empty. Fill tank with media.
Drive speed too low. Check motor for speed and power output. Compare motor
speed, supply voltage and frequency to designating plate.
Discharge pressure too high. Check operating data of pump, media viscosity.
Compare operating data. Heat media if necessary
Viscosity too low. Compare operating data, increase drive speed as required.
Select a pump with steeper spindle pitch or next larger size of motor. Increase
media viscosity by changing media temperature.
During operation the media tank was not filled with media.
Air bubbles in suction and discharge system. Vent pump at highest point. Se-
lect a larger media tank with better deaerating characteristics. Submerge return
line under the media level in the tank.
Mechanical seal damaged by dirt in the pump media. Floating ring seal sur-
faces worn or abraded. Mechanical ring seal overheated and defective as a
result of running dry. Completely replace floating ring seal.
Shafts or spindles have seized in the housing borings. If the surfaces are only
slightly damaged these can be honed or lapped. Check operating data and do
no exceed.
Internal parts of pump worn, fit spare parts, fill with media or change filter insert,
monitor operating characteristics and do not exceed.
Pump and coupling are not correctly aligned and mounted. Realign the unit.
Check manufacturers data for the coupling and ”allowable displacements
E1855270”.
Pressure and vacuum lines are under tension. Refit lines in atension free man-
ner. If necessary fit compensators into the lines. Support and secure pressure
and vacuum lines.
Mounting bolts not uniformly tightened. Tighten uniformly without distorting the
pump.
Ball bearing defective, dismantle and replace.
Dismount pump, find out defective parts, remove and renew them. In case of
defective magnetic coupling, the complete unit should be returned to the factory
for repair.
Coupling components defective. Dismantle unit and replace..

E 185 5177_e_Rev. 7_20.02.07 Page 13 of Page 14

 L3NG
8.2. Torque Requirements 8.3. Allowable pipe forces and moments
Necessary torque requirements according BDI 2230, sheet 1, (me- Forces and moments shown on assembly and dimensional drawings
dium friction) factor 0.14 for shafts, screws and metric standard thread shall not be exceeded.
according to DIN 13, part 13, and head dimension of hex head screws
according to DIN 913 or Allen head screws according to DIN 912 Violating and exceeding these values can damage the
pump causing operating problems. Eventually occurring
thread size property class starting torque in Nm
thermo tensions have to be corrected by design modifica-
M6 8.8 10.4 tion ( flexible piping).
M8 8.8 25
M10 8.8 51
M12 8.8 87
M16 8.8 215
M20 8.8 430

8.4. Allowable pipe forces and moments

Rev--No. Chapter Page Modification Date Name Checked

1 6 9 lubrication information added 271196 Frbg.
2 all sizes 80 -- 140 add. to 121099 Frbg.
3 4, 8 4--6, Remarks to ”temperature-- and pressure limitations” add. to 07.00 Frbg
13--14
4 4.6.4.4+6.2+ 6+8 Cleaning, pressure test and filling of the pipe work 7.06.04 HB Frbg
6.3
5 1, 4, 6 1, 5, 9 lubrication information added L3NG160 up to L3NG 275 27.8.04 Frbg
6 4, 6, 7 4, 5, 8, Information ”EX--appl.” and ”valve adjusting pressures” added. 7.12.05 Frbg
12
7 6 9 lubrication information added 20.2.07 Frbg

First edition Prepared Checked .......................... Approval ....................................

Date 17.Oct.1994 ............................. .......................... ....................................
Department KSP..................... ......................... ....................................

9. Drawings, Data Sheets, Appendix

10.

E 185 5177_e_Rev. 7_20.02.07 Page 14 of Page 14

 Additional for Shaft Seal
Pumpen GmbH
”Oil Receiver Mechanical Seal” L3NG
(optional)

Oil Receiver Tank Oil Receiver Tank

pump position pump position
horizontal line vertical line

Regreasing
device

Function of the oil receiver: On sealing leakage and higher atmospheric pressure at the suction (in-
The contact between the hot conveying medium and the cool ambient air take) of the pump, the level raises.
has to be avoided for conveying lubricants at temperatures from 120qC, Inspection and filling intervals:
for example heavy oils. When leakage escapes, which is to a less degree The inspection and the refilling of the receivers is dependent on the re-
inevitable for mechanical seals, the escaping liquid is cracking and cau- spective operating data of the system. The level and the consumption
ses malfunctions of the mechanical seal. should be checked in short intervals during the break--in period. We sug-
gest to check the level on operating start daily and after a period of opera-
Installation of the oil receiver:
tion weekly. On contamination of the oil filling, visible on the change of the
The installation is described in the illustrations above. The oil receiver is
oil color, the oil should be exchanged after cleansing.
placed upwards when pump has a horizontal arrangement and in direc-
tion of the driving, when the pump has a vertical arrangement. Regreasing installation ball bearing:
Design of the oil receiver: The ball bearings are exclusivly fit out with a regreasing installation.
The oil receiver allows a dust--proof filling of unpressurized recipient me-
We recommend a monthly regreasing or a regreasing after max. 500 run-
diums. The transparent cylinder jackets consist optional of plexi or natu-
ning hours. Informations about the grease levels and the suggested lu-
ral glas, the seals consist of NBR or viton. The materials will be designed
bricants could be found in the operating instructions E 185 5177.
to meet the requirements.
Recipient medium:
For filling to convey the heavy oil, heat transfer oil should be used exclu-
sively. The receivers are empty on delivery. The filling has to be procee-
ded preoperational. The recipient medium should be chosen in the way
that the viscosity amounts from approx. 10 to 60 mm_/s on temperature
during operation. The reservoir should be filled to approx. 60 % in order to
let sufficient compensation place on leakage. On sealing leakage and lo-
wer atmospheric pressure at the suction of the pump, the level reduces.

Appendix to E 185 5177

 L2 / L5
L EISTRITZ PUMPEN GMB H

Appendix onto pump operation manual for L2- and L5 pumps onto chapter 4.6.5.4 pres -
sure- and suction line
Recommended, maximum Mesh Sizes for L2-- and L5 Pumps
Ref. note: The recommended filter mesh sizes are able to avoid Under no circumstances can these filter
larger particles in the pump media. Attention mesh sizes completely prevent damage to
the pump caused by particles.

Type sizes
L2 / L5 30 40 48 62 70 82 96
Filter mesh sizes
[mm] 1 1 1 2 2 2 2
[Pm] 1000 1000 1000 2000 2000 2000 2000
[inches] 0,0394 0,0394 0,0394 0,0787 0,0787 0,0787 0,0787
[P-- 39,4 39,4 39,4 78,7 78,7 78,7 78,7
inches]

Type sizes
L2 / L5 106 116 126 140 164 186
Filter mesh sizes
[mm] 2 2 2 2 3 3
[Pm] 2000 2000 2000 2000 3000 3000
[inches] 0,0787 0,0787 0,0787 0,0787 0,1181 0,0787
[P-- 78,7 78,7 78,7 78,7 118,1 118,1
inches]

E 185 5600_en_Rev1_31.03.2011 Appendix onto the respective operation manuals

 Allowable displacements
appendix to all pump instructions

da

R
A

speed n= up to max 1500 rpm speed n= up to max 3600 rpm

Ø coupling
R max [mm] A max [mm] R max [mm] A max [mm]
up to da = [mm]
30 0,06 0,06 0,04 0,04
40 0,07 0,07 0,05 0,05
50 0,08 0,08 0,05 0,05
65 0,09 0,09 0,06 0,06
80 0,10 0,10 0,07 0,07
100 0,12 0,12 0,08 0,08
120 0,14 0,14 0,09 0,09
140 0,16 0,16 0,10 0,10
160 0,17 0,17 0,11 0,11
180 0,19 0,19 0,12 0,12
200 0,21 0,21 0,13 0,13
225 0,23 0,23 0,15 0,15
250 0,25 0,25 0,16 0,16

Chapter 5 (Mounting and Installation) of the pump op- Pump units or a pump and lantern unit are designed to
erating instructions specifies that the shaft ends of the comply with these requirements in the original state
pump and driving motor must be carefully aligned. In (supplied by Leistritz). If attached parts are purchased
the above table the quality of this alignment can be de-
separately (not included in Leistritz delivery scope),
termined with reference to the coupling size [da].
the requirements for the geometry of these parts must
It should be noted that an alignment of the type shown
also be complied with.
can only be carried out in horizontally installed pump
units. In special cases an alignment of the pump relative to
For units with a ”lantern arrangement” it must be en- the lantern is permissible, however this adjustment
sured that the position of the pump shaft is determined should be secured with a suitable locating device.
by the geometry of the lantern relative to the mounting If special couplings are used, e.g. with removable el-
flange of the driving motor. The shape and position of ements, special documents are added to the project
the lantern must be such that the alignment values of documentation. In case of specific questions, please
the above table are achieved. contact our agents or the plant.

E 185 5270/e Rev.: 03_18. July 2005

 LEISTRITZ PUMPEN GMBH

Safety and Health Declaration

Please include with shipment or send to us by mail or fax +49/911/4306-251

Dear Customer,

We need to protect our staff against hazards caused by contaminated pumps.

Please understand that we can only undertake repairs / modifications / provide cost
estimates, after receiving this declaration that you have completely filled-in and signed.

Please return the pump(s) to us in a cleaned state and confirm that the cleaned pumps or its
medium which was piped does not bear any health hazard.

In case of toxic or hazardous media or products which are subject to the Regulation on
Dangerous Chemicals (German: Gefahrenstoffverordnung), the Material Safety Data Sheet
(MSDS) must be included to this Safety and Health Declaration.

We reserve the right of returning contaminated pumps back to you for cleaning!

King regards
Customer Service – After Sales and Services
Leistritz Pumpen GmbH
Markgrafenstr. 29-39
D - 90459 Nürnberg - Germany

Pump type: …………………………………… Pump serial no.: ……………………….

Shipment date: ………………………………. Delivery note No.: ……………….........

We herewith confirm that the above mentioned pump is clean, i.e. free of liquid
or solid media. Possible present residues from the medium are:

Medium: harmless yes no

The pump was cleaned with: Can be dissolved with:

Company (stamp) ……………………………………….

Name (in block letters)

……………………………………….
Position / Department

Phone / Fax / Email ……………………………………….

Date, signature

20 682 01 - E Rev. 0 vom 20.04.2007

EG-Konformitätserklärung
im Sinne der EG-Maschinenrichtlinie 2006/42/EG, Anhang II; 1; A

Hiermit erklären wir, LEISTRITZ Pumpen GmbH

Markgrafenstraße 29-39
90459 Nürnberg
Germany

dass die Pumpen (-aggregate) Ref. Type Serien-Nr(n).

N-41000245 Pos. 1 L3NG-038/060 000234; 000235

in der von uns gelieferten Ausführung den Bestimmungen der EG-Richtlinie Maschinen in der Fassung
2006/42/EG entspricht.

Diese Erklärung bezieht sich nur auf die Maschine / Maschinen in dem Zustand, in dem sie in Verkehr
gebracht wurde; vom Endnutzer nachträglich angebrachte Teile und / oder nachträglich
vorgenommene Eingriffe bleiben unberücksichtigt.

Angewendete harmonisierte Normen, insbesondere

DIN EN 809:2012
DIN EN ISO 12100:2011

Angewendete nationale technische Normen / Spezifikationen, insbesondere Auftragsbestätigungen

und / oder Datenblätter.

....................................................................................
Torsten Pfennig
Leiter Qualitätssicherung, Anschrift siehe oben

Die oben genannte Person ist dazu bevollmächtigt, die technischen Unterlagen zusammenzustellen.

Nürnberg, den 05.11.2013

 _EN_ _IT_
EC-Declaration of conformity CE-Dichiarazione di conformità
as defined by machinery directive 2006/42/EC Annex II; 1; A ai sensi della Direttiva Macchine 2006/42/CE, Allegato II; 1; A
Herewith we declare, LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39, Con la presente il fabbricante LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39,
90459 Nürnberg, Germany 90459 Nürnberg, Germany
that the pumps (aggregates) Ref. Type Serial No(s). dichiara che le pompe (gruppi) Rif. Tipo Numero di serie
correspond to the provisions of EC directive machines of the issue 2006/42/EC. nel nella versione da noi fornita sono conformi alle disposizioni della direttiva CE sui
macchinari nell'edizione 2006/42/CE.
This Declaration relates exclusively to the machine(s) in the condition in which it was / they
were first commissioned; any parts subsequently fitted by, or modifications subsequently Questa dichiarazione si riferisce solo alla macchina / alle macchine nello stato in cui è
undertaken by the end user are not taken into account. stata commercializzata e non considera parti applicate successivamente e/o interventi
eseguiti in un secondo tempo dall’utente finale.
Applied harmonized standards in particular DIN EN 809:2012
DIN EN ISO 12100:2011 Norme armonizzate applicate, nella fattispecie DIN EN 809:2012
DIN EN ISO 12100:2011
Applied national technical standards / specifications, in particular order confirmations and / or data sheets.
Norme / specifiche tecniche nazionali applicate, nella fattispecie conferme d’ordine
Torsten Pfennig
e/o schede tecniche.
Manager Quality Assurance, Address as above
The person mentioned above is authorized signatory to arrange the technical documents. Torsten Pfennig
Direttore Garanzia di Qualità, Indirizzo vedi sopra
La persona sopra indicata è autorizzato a costituire la documentazione tecnica.

_RU_ _FI_
EC-Ⱦɟɤɥɚɪɚɰɢɹ ɨ ɫɨɨɬɜɟɬɫɬɜɢɢ EY-Vaatimustenmukaisuusvakuutus
ɫɨɝɥɚɫɧɨ Ⱦɢɪɟɤɬɢɜɟ ɩɨ ɨɛɨɪɭɞɨɜɚɧɢɸ 2006/42/ȿɋ, ɩɪɢɥɨɠɟɧɢɟ II; 1; A EY-konedirektiivin 2006/42/EY, liitteen II; 1; A tarkoittamassa mielessä
ɇɚɫɬɨɹɳɢɦ ɦɵ, ɮɢɪɦɚ ɡɚɹɜɥɹɟɦ, LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39, Täten vakuutamme, LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39,
90459 Nürnberg, Germany 90459 Nürnberg, Germany
ɱɬɨ ɧɚɫɨɫɧɵɣ(ɵɟ) ɚɝɪɟɝɚɬ(ɵ) ɇɨɦ. Ɍɢɩ Ɂɚɜ. ʋ: että pumput (-aggregaatit) viite tyyppi sarjanro(t)
ɜ ɩɨɫɬɚɜɥɟɧɧɨɦ ɧɚɦɢ ɢɫɩɨɥɧɟɧɢɢ ɫɨɨɬɜɟɬɫɬɜɭɸɬ ɩɨɫɬɚɧɨɜɥɟɧɢɹɦ ɞɢɪɟɤɬɢɜɵ ȿɋ vastaa meidän toimittamanamme mallina EY-konedirektiivin painoksen 2006/42/EY vaatimuksia.
ɩɨ ɦɚɲɢɧɚɦ ɜ ɪɟɞɚɤɰɢɢ 2006/42/EG. Tämä vakuutus koskee konetta/koneita vain siinä kunnossa, jossa ne on tuotu
ɇɚɫɬɨɹɳɚɹ ɞɟɤɥɚɪɚɰɢɹ ɤɚɫɚɟɬɫɹ ɬɨɥɶɤɨ ɦɚɲɢɧɵ / ɦɚɲɢɧ ɜ ɫɨɫɬɨɹɧɢɢ, ɜ markkinoille; se ei koske loppukäyttäjän jälkikäteen liittämiä osia ja/tai jälkikäteen tekemiä muutoksia.
ɤɨɬɨɪɨɦ ɨɧɢ ɛɵɥɢ ɜɜɟɞɟɧɵ ɜ ɷɤɫɩɥɭɚɬɚɰɢɸ; ɭɫɬɚɧɨɜɥɟɧɧɵɟ ɜɩɨɫɥɟɞɫɬɜɢɢ ɤɨɧɟɱɧɵɦ Sovelletut yhdenmukaistetut standardit, erityisesti DIN EN 809:2012
ɩɨɥɶɡɨɜɚɬɟɥɟɦ ɞɟɬɚɥɢ ɢ / ɢɥɢ ɩɪɟɞɩɪɢɧɹɬɵɟ ɜɦɟɲɚɬɟɥɶɫɬɜɚ ɧɟ ɭɱɢɬɵɜɚɸɬɫɹ. DIN EN ISO 12100:2011
ɉɪɢɦɟɧɟɧɧɵɟ ɝɚɪɦɨɧɢɡɢɪɨɜɚɧɧɵɟ ɧɨɪɦɵ (ɫɪɟɞɢ ɩɪɨɱɟɝɨ) DIN EN 809:2012 Sovelletut kansalliset tekniset standardit/spesifikaatiot, erityisesti tilausvahvistukset ja/tai tietolehdet.
DIN EN ISO 12100:2011
Torsten Pfennig
ɉɪɢɦɟɧɟɧɧɵɟ ɧɚɰɢɨɧɚɥɶɧɵɟ ɬɟɯɧɢɱɟɫɤɢɟ ɧɨɪɦɵ, ɫɩɟɰɢɮɢɤɚɰɢɢ, ɜ ɬ.ɱ. Laatuvarmistuksen johtaja, Osoite katso edeltä
ɩɨɞɬɜɟɪɠɞɟɧɢɹ ɡɚɤɚɡɚ ɢ/ɢɥɢ ɬɟɯ. ɩɚɫɩɨɪɬɚ. Yllä mainittu henkilö on valtuutettuna kokoamaan tekniset asiakirjat.
Torsten Pfennig
Ɂɚɜ. ɨɬɞɟɥɨɦ ɨɛɟɫɩɟɱɟɧɢɹ ɤɚɱɟɫɬɜɚ Ⱥɪɦɢɧ Ƚɪɨɰ, Ⱥɞɪɟɫ ɫɦ. ɜɵɲɟ
ɍɤɚɡɚɧɧɨɟ ɜɵɲɟ ɥɢɰɨ ɢɦɟɟɬ ɩɪɚɜɨ ɫɨɫɬɚɜɥɹɬɶ ɬɟɯɧɢɱɟɫɤɭɸ ɞɨɤɭɦɟɧɬɚɰɢɸ.

_FR_ _PT_
CE-Déclaration de conformité CE-Declaração de conformidade
conformément à la directive “CE“ relative aux machines 2006/42/CE, Annexe II; 1; A nos termos da directiva de máquinas CE 2006/42/CE, Anexo II; 1; A
Par la présente, nous déclarons, LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39, Declaramos por este meio, nós, a LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39,
90459 Nürnberg, Germany 90459 Nürnberg, Germany
que le/les system(s) pompage(s) Ref. Type No. de serie que as bombas (sistemas) Refª. Tipo Nº de série.
correspond de la directive CE machines, version 2006/42/CE. se encontram em conformidade com a Diretiva de Máquinas CE, versão 2006/42/CE.
Cette déclaration concerne exclusivement la machine/les machines dans l'état dans lequel Esta declaração aplica-se à máquina / máquinas no estado em que foi/foram colocada(s) no
elle(s) a (ont) été mise(s) sur le marché ; les composants ajoutés et/ou les interventions mercado; componentes instalados posteriormente pelo utilizador final ou intervenções pelo
réalisées ultérieurement par l'utilisateur final ne sont pas pris en compte. mesmo efetuadas não são considerados.
Normes harmonisées utilisées, notamment DIN EN 809:2012 Normas harmonizadas particularmente aplicadas DIN EN 809:2012
DIN EN ISO 12100:2011 DIN EN ISO 12100:2011
Normes harmonisée utilisées nationales et techniques, notamment confirmations de Normas técnicas nacionais aplicadas / Especificações, particularmente confirmações de
commande et / ou fiches techniques. ordens de compra e / ou folhas de dados técnicos.
Torsten Pfennig Torsten Pfennig
Directeur Assurance Qualité, Adresse voir ci-dessus Director da Garantia de Qualidade, Endereço, ver acima
La personne ci-dessus nommée est autorisée à établir la documentation technique. A pessoa supramencionada está autorizado a compilar a documentação técnica.

_ES_ _PL_
CE-Declaración de conformidad EC-Deklaracja zgodnoĞci
conforme a la Directiva Máquinas 2006/42/CE, Anexo II; 1; A wg 2006/42/EC, Aneks II; 1; A
Por la presente declaramos LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39, Niniejszym deklarujemy, LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39,
90459 Nürnberg, Germany 90459 Nürnberg, Germany
las bombas (grupos motobomba) Ref. Tipo Serie N°(s) Īe pompy (agregaty pompowe) zam. Typu nr seryjny
se corresponden, en la ejecución suministrada por nosotros, con las disposiciones de w dostarczonej przez nas wersji są zgodne z nową Dyrektywą Maszynową 2006/42/WE.
la versión 2006/42/CE de la Directiva de Máquinas de la Comunidad Europea. Niniejsza deklaracja dotyczy wyłącznie maszyny / maszyn w stanie, w którym została
Esta declaración se refiere únicamente a la máquina / las máquinas en el estado en el wprowadzona do obrotu; dodatkowo zainstalowane przez uĪytkownika koĔcowego
que fue puesta en servicio; quedan excluidas las piezas instaladas posteriormente y/o czĊĞci i / lub póĨniej dokonane zmiany w maszynie pozostają nieuwzglĊdnione.
las intervenciones realizadas con posterioridad por el usuario final. Zastosowane zharmonizowane standardy: DIN EN 809:2012
Normas armonizadas aplicadas, en particular DIN EN 809:2012 DIN EN ISO 12100:2011
DIN EN ISO 12100:2011 Zastosowano narodowe standardy techniczne / specyfikacje, w szcególnoĞci
Normas técnicas nacionales aplicadas / especificaciones, en particular las confirmaciones potwierdzenia zamówieĔ i / lub karty danych technicznych
de pedidos y / u hoja de características técnicas. Torsten Pfennig
Torsten Pfennig Directeur Assurance Qualité, Adres jak podano powyĪej
Director Aseguramiento de la Calidad, Dirección: véase más arriba WyĪej wymieniona osoba jest upowaĪniony do zestawienia dokumentacji technicznej.
La persona arriba mencionada esta apoderado a recopilar la documentación técnica.

_EL_ _NL_
ǻȒȜȦıȘ ıȣȝȝȩȡijȦıȘȢ ǼȀ EG-verklaring van overeenstemming
ıȪȝijȦȞĮ ȝİ IJȘȞ ȠįȘȖȓĮ IJȘȢ ǼȀ ʌİȡȓ ȝȘȤĮȞȫȞ 2006/42/EȀ, ʌĮȡȐȡIJȘȝĮ II, 1, A volgens de Machinerichtlijn 2006/42/EG, bijlage II; 1; A
Ȃİ IJȘȞ ʌĮȡȠȪıĮ įȘȜȫȞȠȣȝİ İȝİȓȢ, Ș İIJĮȚȡİȓĮ LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39, Hierbij verklaren wij, LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39,
90459 Nürnberg, īİȡȝĮȞȓĮ 90459 Nürnberg, Germany
ȩIJȚ ȠȚ ĮȞIJȜȓİȢ (IJĮ ıȣȖțȡȠIJȒȝĮIJĮ ĮȞIJȜȚȫȞ) IJȪʌȠȢ ĮȞĮij. ĮȡȚș. ıİȚȡȐȢ
dat de pompen (pompaggregaten) ref. type serienummer(s)
ıIJȘȞ ȑțįȠıȘ ʌȠȣ ȑȤȠȣȞ ʌĮȡĮįȠșİȓ Įʌȩ İȝȐȢ ıȣȝȝȠȡijȫȞȠȞIJĮȚ ȝİ IJȚȢ įȚĮIJȐȟİȚȢ
IJȘȢ ȠįȘȖȓĮȢ ʌİȡȓ ȝȘȤĮȞȘȝȐIJȦȞ IJȘȢ ǼȀ ıIJȘȞ ȑțįȠıȘ 2006/42/EȀ. in de door ons geleverde uitvoering in overeenstemming zijn met de bepalingen
van de Machinerichtlijn in de versie 2006/42/EG.
ǹȣIJȒ Ș įȒȜȦıȘ ĮijȠȡȐ ȝȩȞȠ IJȠ ȝȘȤȐȞȘȝĮ / IJĮ ȝȘȤĮȞȒȝĮIJĮ ıIJȘȞ țĮIJȐıIJĮıȘ
Deze verklaring betreft uitsluitend de machine/machines in de toestand waarin
ʌȠȣ IJȑșȘțİ / -ĮȞ ıİ țȣțȜȠijȠȡȓĮ. ȉİȝȐȤȚĮ ʌȠȣ ıȣȞĮȡȝȠȜȠȖȒșȘțĮȞ Įʌȩ IJȠȞ IJİȜȚțȩ ȤȡȒıIJȘ ȝİIJĮȖİȞȑıIJİȡĮ
zij in de handel zijn gebracht, met uitsluiting van de later door de eindgebruiker
țĮȚ / Ȓ İʌİȝȕȐıİȚȢ ʌȠȣ ȑȖȚȞĮȞ ȝİIJĮȖİȞȑıIJİȡĮ įİȞ ȜĮȝȕȐȞȠȞIJĮȚ ȣʌȩȥȘ. toegevoegde componenten en/of verrichte bewerkingen.
ǼijĮȡȝȠıȝȑȞĮ İȞĮȡȝȠȞȚıȝȑȞĮ ʌȡȩIJȣʌĮ ȚįȓȦȢ IJĮ DIN EN 809:2012 Gehanteerde geharmoniseerde normen, met name NEN-EN 809:2012
DIN EN ISO 12100:2011 NEN-EN-ISO 12100:2011
ǼijĮȡȝȠȗȩȝİȞĮ İșȞȚțȐ IJİȤȞȚțȐ ʌȡȩIJȣʌĮ / ʌȡȠįȚĮȖȡĮijȑȢ, ȚįȚĮȓIJİȡĮ
ȕİȕĮȚȫıİȚȢ İȞIJȠȜȫȞ țĮȚ / Ȓ ijȪȜȜĮ įİįȠȝȑȞȦȞ. Gehanteerde nationale technische normen/specificaties, met name
Torsten Pfennig orderbevestigingen en/of gegevensbladen.
ǻȚİȣșȣȞIJȒȢ ʌȠȚȠIJȚțȠȪ İȜȑȖȤȠȣ, ǻȚİȪșȣȞıȘ ȩʌȦȢ ʌĮȡĮʌȐȞȦ Torsten Pfennig
ȉȠ ĮȞȦIJȑȡȦ ʌȡȩıȦʌȠ İȓȞĮȚ İȟȠȣıȚȠįȠIJȘȝȑȞȠ ȞĮ ıȣȖțİȞIJȡȫıİȚ Hoofd kwaliteitsborging, adres zie boven
IJĮ IJİȤȞȚțȐ ȑȖȖȡĮijĮ. De bovengenoemde persoon is gemachtigd het technische
dossier samen te stellen.

_RO_ _SV_
DeclaraĠie de conformitate CE Försäkran om överensstämmelse
în sensul Directivei CE Echipamente tehnice 2006/42/CE, Anexa II; 1; A enligt EU-maskindirektiv 2006/42/EG, bilaga II; 1; A
Prin prezenta noi, LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39, Härmed förklarar vi, LEISTRITZ Pumpen GmbH, Markgrafenstrasse 29-39,
90459 Nürnberg, Germany 90459 Nürnberg, Tyskland
declarăm că pompele (agregatele de pompare) Ref. Tip Seria/seriile Nr./numerele att pumparna (-aggregaten) ref. typ serienr.
în varianta de execuĠie livrată de noi respectă Directiva CE Echipamente tehnice i det av oss levererade utförandet uppfyller bestämmelserna i
în versiunea acesteia 2006/42/CE. EU-maskindirektiv i version 2006/42/EG.
DeclaraĠia de faĠă se referă numai la maúina/maúinile în starea în care a/au fost Denna försäkran avser endast maskinen/maskinerna i det skick i vilket den/de
pusă/e în circulaĠie; piese ataúate ulterior de către utilizatorul final úi/sau levererades ut i handeln; genom slutanvändaren i efterhand påmonterade delar
intervenĠii ulterioare asupra echipamentului rămân neluate în seamă. och/eller i efterhand gjorda ingrepp beaktas ej.
Normele armonizate aplicate sunt în special DIN EN 809:2012 Tillämpade harmoniserade standarder, i synnerhet DIN EN 809:2012
DIN EN ISO 12100:2011 DIN EN ISO 12100:2011
Norme/specificaĠii tehnice naĠionale, îndeosebi Tillämpade nationella tekniska standarder/specifikationer, i synnerhet
confirmări de comandă úi /sau fiúe de date. orderbekräftelser och/eller datablad.
Torsten Pfennig Torsten Pfennig
ùeful SecĠiei CTC, adresa vezi mai sus Kvalitetssäkringschef, adress se ovan
Persoana susnumită este autorizată să întocmească documentaĠia tehnică. Ovannämnda person har befogenhet att sammanställa de tekniska
underlagen.

_SL_ _HU_
ES-Izjava o skladnosti EK megfelelĘségi nyilatkozat
v skladu z ES-direktivo o strojih 2006/42/ES, priloga II, 1, A a gépekre vonatkozó 2006/42/EC irányelv, II. függeléke; 1; A értelmében
S tem izjavljamo, LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39, Ezennel a LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39,
90459 Nürnberg, Nemþija 90459 Nürnberg, Németország kijelenti,
da so vse þrpalke (-agregati) ref. serijske številke tipa hogy a … referenciaszámú … típusú …. sorozatszámú szivattyúk (aggregátok)
v dostavljeni izvedbi skladne z doloþili ES direktive o strojih v razliþici 2006/42/ES. az általunk kiszállított változatban megfelelnek a gépekre vonatkozó irányelv
Ta izjava se nanaša le na stroj/stroje v stanju, ki je veljalo v trenutku prodaje. Deli, ki jih je kasneje nanesel konþni 2006/42/EC változatának.
uporabnik, in/ali naknadno izvedeni posegi niso upoštevani, A jelen nyilatkozat csak arra a gépre / a gépre abban az állapotában vonatkozik, amelyben forgalomba helyezték;
Uporabljene usklajene norme, zlasti: DIN EN 809:2012 a végfelhasználó által utólag rászerelt részek és/vagy utólag végrehajtott beavatkozások nem tartoznak bele.
DIN EN ISO 12100:2011 Alkalmazott harmonizált szabványok, fĘként DIN EN 809:2012
Uporabljene državne tehniþne norme/specifikacije, zlasti potrdilo o naroþilu in/ali podatkovni listi. DIN EN ISO 12100:2011
Torsten Pfennig Alkalmazott nemzeti mĦszaki szabványok / specifikációk, különösen
vodja zagotavljanja kakovosti, za naslov glej zgoraj. megrendelési visszaigazolások és/vagy adatlapok.
Zgoraj navedena oseba je pooblašþena za sestavo tehniþnih dokumentov. Torsten Pfennig
minĘségbiztosítási vezetĘ, a címeket lásd fent
A fent nevezett személyt meghatalmazzuk a mĦszaki dokumentáció összeállításával.

Nürnberg, den 05.11.2013

Betriebs- und Wartungsanleitung Operating- and maintenance instructions
Lagerung und Transport Storage and transport
Motoren gegen mechanische Beschädigung sichern und nur in The motors have to be protected against mechanical
geschlossenen, trockenen Räumen lagern. Bei kurzzeitiger damages and if possible they are to be stored in closed and
Lagerung im Freiluftbereich gegen schädliche Umwelteinflüsse dry rooms. In case of short-term outdoor storage they have
schützen. Motoren nicht auf der Lüfterhaube transportieren/ lagern. to be protected against all harmful influences. Never
Bei Transport drauf achten, dass die Motoren nicht beschädigt transport or store the motors on the fan cowl. During
werden. transportation the motors should be kept from any damage.

Montage – Übertragungselemente Mounting – transmission components

Beim Aufziehen eines Übertragungselementes unbedingt When pulling a transmission component onto the shaft it is
Aufziehvorrichtung benutzen oder das aufzuziehende Teil necessary to use a pull-on device or to warm up the
erwärmen. Auf keinen Fall Übertragungselemente auf die Welle component to be pulled on. To prevent shaft, bearings and
aufgeschlagen werden, da Welle, Lager und andere Teile des other parts from damages the transmission components
Motors dadurch beschädigt werden. must never be driven onto the shaft by hammer blows

Montage – Wuchten Mounting – balancing

Alle am Wellenende angebauten Teile sind sorgfältig dynamisch zu All components attached to the shaft end are to be balanced
wuchten. Die Läufer sind werkseitig mit halber Passfeder gewuchtet. dynamically. On the part of the manufacturer the rotors are
balanced with half key.
Montage – Aufstellen Mounting – installation
Motoren schwingungsfrei aufstellen. Bei Kupplung den Motor zu If possible, the motors are to be installed free from vibration.
angetriebenen Maschine genau ausrichten. Die Achsen beider In the case of direct coupling the motor is to be accurately
Maschinen müssen fluchten. Es dürfen keine Spannungen aligned to the driven machine. The axles of the machines
auftreten. must be in line and no stresses should occur.

Montage – Belüftung Mounting – ventilation

Belüftungsöffnungen und Kühlrippen freihalten und Vent holes and cooling fins are to be kept free and the
Mindestabstände einhalten. Erneutes Ansaugen der erwärmten required minimum distances must be observed. It is to be
Kühlluft vermeiden. Bei Freiluftaufstellung gegen unmittelbare avoided that the heated up cooling air is taken in again. In
Witterungseinflüsse (Regen, Schnee- und Eiseinfall, Festfrieren des case of outdoor-installation the motors have to be protected
Lüfters) schützen. against influences (rain, snow and ice, freezing of the fan)

Inbetriebnahme – Voraussetzungen Commissioning – prerequisites

• Alle Arbeiten nur von geschultem Fachpersonal im • All operations have to be carried out by skilled staff
spannungslosen Zustand durchführen with the motor in dead state
• Netzverhältnisse mit den Typenschildangaben vergleichen. • The power supply has to correspond with the name
Zulässige Spannungstoleranzen nach EN 60034-1 plate. Voltage tolerance in acc. with EN 60034-1
• Abmessungen der Anschlusskabel den Nennströmen des • The dimensions of the connection cables have to
Motors anpassen. be adapted to the rated motor currents.

Inbetriebnahme – Überlastschutz Commissioning – overload protection

Motoren bei direkter Einschaltung mit 3-poligem Motorschutzschalter In case of direct starting, the motors are to be provided with
versehen. Auch bei Stern/Dreieck-Anlauf ist ein Motorschutzschalter triple-pole protection switch. A protection is also needed for
empfehlenswert. Für Motoren mit Kaltleitertemperaturfühlern ist ein Delta/Star starting. For motors with PTC-thermistors a
Auslösegerät erforderlich. Bei Motoren mit Bi-Metall-Thermofühlern tripping device is required. For motors with bi-metal
wird empfohlen, den Motor bei Überlast über ein Schütz thermistors it is needed to switch off the motor with a
abzuschalten. contactor in case of overload.

Inbetriebnahme – Drehrichtung prüfen Commissioning – rotation direction

Drehrichtung vor dem Ankoppeln der Arbeitsmaschine überprüfen. The rotation direction is to be checked before coupling the
Die Drehrichtung ggf. durch Tauschen der Anschlüsse zweier machine. If necessary, the rotation direction can be altered
Phasen ändern. by changing the connections of two phases.

Inbetriebnahme – Klemmkasten Commissioning – terminal box

• Alle Klemmkastenanschlüsse auf festen Sitz prüfen • Check all terminal box connections are tightened
• Innenseite sauber und frei von Fremdkörpern • The inside is clean and free from particles
• Unbenutzte Kabeleinführungen verschlossen und • Unused cable entries are closed and threaded
Verschlussschrauben fest angezogen plugs are tightened
• Dichtung sauber einlegen; auf Beschaffenheit der • The packing in the terminal box lid is inserted
Dichtflächen der Gewährleistung der Schutzart achten correctly

Technische Änderungen und Irrtümer vorbehalten./Technical modifications reserved, errors excepted

Inbetriebnahme – Schalten des Motors Commissioning – switching the motor
Vor dem Einschalten, während des Betriebes und beim Before switching the motor on, during operation and when
Abschalten des Motors prüfen, ob alle Sicherheitsbestimmungen switching it off it should be checked whether all safety
eingehalten werden. Bei Inbetriebnahme Stromaufnahme unter regulations are followed. When switching the motor on the
Belastung beobachten um mögliche Überlastung sofort zu current under load should be observed to detect possible
erkennen. overloads.

Inbetriebnahme – Isolationswiderstand Commissioning – insulation

Als letzte Arbeit vor der Inbetriebnahme einer neuen Maschine Before starting a new motor and after long periods of inactivity
oder nach längerem Stillstand ist der Isolationswiderstand der or storage, the insulation resistance of the windings is to be
Wicklungen zu prüfen. Dieser sollte bei einer Temperatur von measured. The resistance should be higher than 5MΩ at 25°C
25°C höher als 5M Ω sein. Ergibt die Messung nicht den Wert, liegt ambient temperature.
dies daran, dass sich Feuchtigkeit in den Wicklungen befindet. If this value cannot be obtained, the winding is damp and must
Das Trocknen der Wicklung sollte in einer dafür eingerichteten be dried out.
Werkstatt durchgeführt werden.

Wartung Maintenance
Der Motor und eventuelle Zubehörteile sollten sauber gehalten The motor as well as possible accessories should always be
werden, sodass kein Staub, Schmutz, Öl oder sonstige kept clean, free from dust trace, oil or other grime
Verunreinigung den einwandfreien Betrieb stören können.
Es wird außerdem empfohlen: - The motor operates without any vibrations or
- Ob der Motor ohne Schwingungen oder anormale anomalous noises
Geräuschentwicklung läuft. - The tension of a possible driving belt is correct
- Dass die Zugspannung des möglicherweise eingesetzten - The inlet of the ventilations circuits is not obscured
Treibriemens korrekt eingestellt ist causing overheating of the windings
- Dass die Öffnungen für die Kühlluftzufuhr nicht zugestellt
oder verengt sind.

Kugellager Bearings
Alle Motoren sind mit hochwertigen, lebensdauergeschmierten All motors are fitted with high-quality, lifetime-lubricated
Kugellagern der Hersteller FAG, SKF, INA, NSK oder bearings from the manufacturer FAG, SKF, INA, NSK or NTN.
NTN ausgerüstet. Die nominelle Lagerlebensdauer in waagerechter The nominal rating life of the bearings used in horizontal
Bauform beträgt bei Kupplungsbetrieb mounted motors without any axial load is 40.000 operating
ohne axiale Zusatzlasten mind. 40.000 Betriebsstunden. Unter hours, for power take-off via shaft-coupling. Under the use of
Ausnutzung der max. Belastung beträgt die Lebensdauer mind. maximal load the lifetime of the bearings is min. 20.000
20.000h operating hours.
Ab Baugröße 315 sind die Motoren mit offenen Lagern und From framesize 315 all motors have open bearings and
Nachschmiereinrichtung ausgestattet. Die Nachschmierfristen lubrication devices.
sind diesem Katalog zu entnehmen. The lubrication intervals are in this catalogue.
Baugröße A-Seite B-Seite Size Driving end Non-driving end
2-polig 4;6;8-polig 2-polig 4;6;8-polig 2-pole 4;6;8-pole 2-pole 4;6;8-pole
ACA 56 6201.ZZ.C3 6201.ZZ.C3 ACA 56 6201.ZZ.C3 6201.ZZ.C3
ACA 63 6201.ZZ.C3 6201.ZZ.C3 ACA 63 6201.ZZ.C3 6201.ZZ.C3
ACA 71 6202.ZZ.C3 6202.ZZ.C3 ACA 71 6202.ZZ.C3 6202.ZZ.C3
ACA 80 6204.ZZ.C3 6204.ZZ.C3 ACA 80 6204.ZZ.C3 6204.ZZ.C3
ACA 90 6205.ZZ.C3 6205.ZZ.C3 ACA 90 6205.ZZ.C3 6205.ZZ.C3
ACA 100 6206.ZZ.C3 6206.ZZ.C3 ACA 100 6206.ZZ.C3 6206.ZZ.C3
ACA 112 6306.ZZ.C3 6306.ZZ.C3 ACA 112 6306.ZZ.C3 6306.ZZ.C3
ACA 132 6308.ZZ.C3 6308.ZZ.C3 ACA 132 6308.ZZ.C3 6308.ZZ.C3
ACM 160 6309.ZZ.C3 6309.ZZ.C3 ACM 160 6309.ZZ.C3 6309.ZZ.C3
ACM 180 6311.ZZ.C3 6311.ZZ.C3 ACM 180 6311.ZZ.C3 6311.ZZ.C3
ACM 200 6312.ZZ.C3 6312.ZZ.C3 ACM 200 6312.ZZ.C3 6312.ZZ.C3
ACM 225 6313.ZZ.C3 6313.ZZ.C3 ACM 225 6313.ZZ.C3 6313.ZZ.C3
ACM 250 6314.ZZ.C3 6314.ZZ.C3 ACM 250 6314.ZZ.C3 6314.ZZ.C3
6314.ZZ. 6317.ZZ. 6314.ZZ. 6317.ZZ. 6314.ZZ. 6317.ZZ. 6314.ZZ. 6317.ZZ.
ACM 280 ACM 280
C3 C3 C3 C3 C3 C3 C3 C3
ACM 315 6317.C3 6319.C3 6317.C3 6319.C3 ACM 315 6317.C3 6319.C3 6317.C3 6319.C3
ACM 355 6319.C3 6322.C3 6319.C3 6322.C3 ACM 355 6319.C3 6322.C3 6319.C3 6322.C3
ACM 400 6320.C3 6324.C3 6320.C3 6324.C3 ACM 400 6320.C3 6324.C3 6320.C3 6324.C3
ACM 450 6322.C3 6326.C3 6322.C3 6326.C3 ACM 450 6322.C3 6326.C3 6322.C3 6326.C3

Technische Änderungen und Irrtümer vorbehalten./Technical modifications reserved, errors excepted

Schaltbilder / wiring diagram

Dreieckschaltung:
Delta-connection:

Sternschaltung:
Star-connection:

Schaltbilder für polumschaltbare Motoren /

Wiring diagram for speed switchable motors

niedrige Geschwindigkeit: niedrige Geschwindigkeit:

(Dahlander) (getrennte Wicklung)
low speed: low speed:

Hohe Geschwindigkeit: Hohe Geschwindigkeit:

(Dahlander) (getrennte Wicklung)
High speed: High speed:

Technische Änderungen und Irrtümer vorbehalten./Technical modifications reserved, errors excepted

Nachschmierintervalle / lubrication intervals

Schmierfett / Grease: ESSO BEACON 3 / SKF LGMT3

Lagertyp 2 polig 4 polig 6 polig 8 polig Fettmenge in Gramm

Bearing type 2-poles 4-poles 6-poles 8-poles Grease in grs.

6312.C3 1400 4000 6000 8000 20
6313.C3 1200 4000 6000 8000 23
6314.C3 1100 3300 5500 7700 26
6316.C3 800 2800 4900 7000 33
6317.C3 650 2600 4600 6600 37
6319.C3 / 2300 4200 6100 45
6320.C3 / 2100 3900 5800 51
6322.C3 / 1700 3500 5300 60
NU 317 / 1300 2300 3300 37
NU 319 / 1100 2000 3000 45
NU 320 / 1000 1900 2900 51
NU 322 / 890 1700 2600 60

Ab Baugröße 315 sind alle Motoren mit offenen Lagern und Nachschmiereinrichtung ausgerüstet.
Motoren kleinerer Baugrößen sind auf Kundenwunsch mit Nachschmiereinrichtung erhältlich.
Die Nachschmierfristen sind aus der oben stehenden Tabelle zu entnehmen.

Technische Änderungen und Irrtümer vorbehalten./Technical modifications reserved, errors excepted

 Heat Exchanger C5.05.07.08.30.06
-

M25/M32

Heat Exchanger

en / 09.07.2010 FD043935 1/7

 Lub.-Oil Pump C5.05.08.10.21.46
(Leistritz)

M25

Lub.-Oil Pump

(Leistritz)

en / 22.01.2014 FD049651 1/53

 Ihre Bestellung
Your order

Auftragsbestätigung
Order Confirmation
Technische Dokumentation Schmierölpumpe
Seriennummer
Technical Documentation Lupe oil Pump Serial Number

Pumpentype
L3NG-100/172-ASOKII-G
Pump type

CAT-Sach-Nr.
273480287
CAT-Ref.-No.

CAT-KTR-Nr.
N/A
CAT-KTR-No.

Pumpe: Betriebs- und Wartungsvorschrift

01 E 185 5177 20
Pump: Instruction and Operating Manual
Pumpe: Einbauzeichnung
02 D 162 5320 1
Pump: General Arrangement Drawing
Pumpe: Maßblatt
03 D 168 6394 1
Pump: Dimensional Drawing
Pumpe: Schnittzeichnung inkl. Teileliste
04 C 160 7631 1
Pump: Sectional Drawing incl. parts list
Pumpe: EG – Konformitätserklärung
05 135755-000 2
Pump: EC – Declaration of Conformity

Motor: Betriebs- und Wartungsvorschrift

06 AC-Motor 4
Driver: Instruction and Operating Manual

Kupplung: Betriebs- und Wartungsvorschrift

07 40210 21
Coupling: Instruction and Operating Manual

LEISTRITZ PUMPEN GMBH MANAGING DIRECTORS: REGISTERED OFFICE: BANK ACCOUNTS LEISTRITZ AG:
MARKGRAFENSTRASSE 29-39 Dipl.-Wirtsch.-Ing. Christoph Böhnisch Nürnberg, Germany Commerzbank Nbg. (BLZ 760 400 61) KTO. 5 200 167
D-90459 NÜRNBERG, GERMANY Dr.-Ing. Michael Radke Commercial Register: BIC COBA DE FF, IBAN DE28 7604 0061 0520 0167 00
INTERNET: www.leistritz.com Dipl.-Ing. (FH) Heinz-Dieter Roß HRB 17819 HSBC T&B, München (BLZ 300 308 80) KTO. 700 367 002
E-MAIL: [email protected] Nürnberg, GERMANY BIC TUBD DE DD , IBAN DE86 3003 0880 0700 3670 02
PHONE: +49 (0)911-4306-0 USt-IdNr.: DE813089359 VR Bank Nbg. (BLZ 760 606 18) KTO. 380 202
FAX: +49 (0)911-4306-439 VAT-No.: 241/115/90148 BIC GENO DE F1N02, IBAN DE81 7606 0618 0000 3802 02
 L3NG

Technical Documentation
Operation, Maintenance, Mounting and
Disassembly Instructions for the
Series L 3 N G Screw Pump

E 185 5177_e_Rev. 7_20.02.07

 L3NG
Contents

1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.1. Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2. Information about the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.1. Addressing of the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.2. Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.3. Names, Types and Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.4. Serial Number and Type Plate . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.5. Date of Manual Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.6. Change Notes and Manual Numbers . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.7. Copy Rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.8. Technical Documentation and Data Sheet . . . . . . . . . . . . . . . . Page 1
1.2.9. Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1
1.2.10. Quality Assurance and Quality testing . . . . . . . . . . . . . . . . . . . . Page 1
1.2.11. Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1

2. Safety ..................................................... Page 2

2.1. General Rules and Advice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.2. Dangers of not observing the Safety Advice . . . . . . . . . . . . . . . Page 2
2.3. Safety conscious Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.4. Warning and Advice Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.5. Safety Advice for the Operator . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.6. Safety Advice for the Service, Inspection and Mounting . . . . Page 2
2.7. Denial of Modifications and Changes without Approval . . . . . Page 2
2.8. Unallowable Running Conditions . . . . . . . . . . . . . . . . . . . . . . . . Page 2
2.9. Other Operations and Safety Hazards . . . . . . . . . . . . . . . . . . . . Page 2

3. Transport and Intermediate Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3

3.1. Safety Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.2. Transport Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.3. Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.4. Intermediate Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.5. Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.5.1. Aging of Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.5.2. Re--Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.5.3. Removal of the Preservation Fluid . . . . . . . . . . . . . . . . . . . . . . . Page 3
3.6. Protection from the Environment . . . . . . . . . . . . . . . . . . . . . . . . Page 3

4. Description of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4

4.1. General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.2. Assembly and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3. Construction of the Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.1. Pump casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.2. Spindle Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.3. Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.4. Casing Gasketing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.5. Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.6. End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.7. Drive Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.8. Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.9. Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
4.3.10. Drive and Shaft coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.4. Dimensioning and Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.4.1. Standard Overall and Single Dimension Drawings . . . . . . . . . Page 5
4.4.2. Standard Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5

E 185 5177_e_Rev. 7_20.02.07 Page i

 L3NG
4.4.3. Standard Sectional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.5. Execution Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.5.1. Type key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.5.2. Standard Material of Construction . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6. Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.1. General Operation Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.2. Use of pumps in potentially explosive areas . . . . . . . . . . . . . . . Page 5
4.6.3. Temperature-- and Pressure Limitations . . . . . . . . . . . . . . . . . . Page 5
4.6.4. Performance Data and Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.4.1. Performance Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.4.2. Power Consumption Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.5. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
4.6.5.1. Necessary Space for Operating and Maintenance . . . . . . . . . Page 5
4.6.5.2. Allowable Environmental Influences . . . . . . . . . . . . . . . . . . . . . . Page 6
4.6.5.3. Base, Foundation and Anchoring . . . . . . . . . . . . . . . . . . . . . . . . Page 6
4.6.5.4. Suction and Discharge Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6
4.6.5.5. Support Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6

5. Mounting and Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7

5.1. Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7
5.2. Initial Installation of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7
5.3. Initial Installation of the Pump Unit . . . . . . . . . . . . . . . . . . . . . . . Page 7

6. Start up -- Shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8

6.1. Technical Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.2. Pipes Schematic and Measuring Points . . . . . . . . . . . . . . . . . . Page 8
6.3. Preparation for Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.4. Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.5. Shut down of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.6. Re--starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.7. Still Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.7.1. Shut down for up to 3 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.7.2. Shut down from 3 to 6 Months . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.7.3. Shut down for more than 6 Months . . . . . . . . . . . . . . . . . . . . . . Page 8
6.8. Operation Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8
6.9. Bearing of the Driving Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9

7. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
7.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
7.2. Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
7.3. Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
7.3.1. General Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
7.3.2. Customer Service/Personnel/Danger . . . . . . . . . . . . . . . . . . . . . Page 10
7.3.3. Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
7.3.4. Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
7.4. Disassembly of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 10
7.5. Assembly of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11
7.5.1. Notice to the valve adjusting pressures . . . . . . . . . . . . . . . . . . . Page 12
7.6. Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12

8. Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 13

8.1. Table to define Reason and solving of Problems . . . . . . . . . . . Page 13
8.2. Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 14
8.3. Allowable pipe forces and moments . . . . . . . . . . . . . . . . . . . . . . Page 14
8.4. Allowable pipe forces and moments . . . . . . . . . . . . . . . . . . . . . . Page 14

9. Drawings, Data Sheets, Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 14

E 185 5177_e_Rev. 7_20.02.07 Page i

 L3NG
1. General 1.2.10. Quality Assurance and Quality testing
1.1. Application A complex quality assurance system guaranties high quality standard
This screw pump is used for pumping oils or other lubricating media at levels for Leistritz screw pumps. The quality assurance, according to
pressures up to 16 bar. DIN ISO 9001, covers all production steps, which are necessary to ful-
fill all the quality requirements for this product.
1.2. Information about the Product
Quality assurance measures (i.e. size, type of test and certification)
1.2.1. Addressing of the Manual
are issued by the purchaser in writing, including the necessary forms
This manual was made for the pump series L 3 N G. and documents. Prior to shipment all pumps are rigorously tested.
For other executions different manuals are valid. They may be ordered Only pumps which fulfill the confirmed test data will be shipped.
from the manufacturer separately if not on hand. Use of this manual will help to assure a trouble free operation and full
1.2.2. Manufacturing flow performance. The proof of test data on the bench follows the gen-
The manufacturer of the screw pump type L 3 N G , is eral test recommendations for rotary positive displacement pumps per
LEISTRITZ Pumpen GmbH VDMA 24284.
residing in the The proof of test and their results are documented in test certificates
Federal Republic of Germany ”M” per DIN 55350 P18.
90459 Nürnberg, Markgrafenstraße 29 - 39
1.2.11. Warranty
or 90014 Nürnberg, Postfach 30 41
DIN-- Parts, accessories and additional parts are purchased from Our liability for defects of shipped goods is outlined in our delivery and
sub--suppliers. payment conditions, which are part of our Sales Conditions and Terms.

1.2.3. Names, Types and Sizes Damages which may occur as a result of disregard of the instruction
Name: Three-- rotor screw pump manual and replacement conditions are not covered under warranty. If
Type: L3NG at a later date operation conditions change, for example different prod-
Sizes: 20, 25, 32, 38, 45, 52, 60, 70, 80, 90, 100, 112, 125, 140, 160, uct, viscosity, temperature, speed or inlet condition, these conditions
180, 200, 225, 250 and 275 have to be reviewed and acknowledged by LEISTRITZ. If no other
For additional information see the type key. agreements have been made with LEISTRITZ the delivered pumps
can only be disassembled and modified by LEISTRITZ or LEISTRITZ--
1.2.4. Serial Number and Type Plate Service Representatives. Otherwise the warranty for occurred dam-
Each unit is equipped with a standard type plate, which shows the ages will be voided.
manufacturers serial number and type key. Enlarged type plates are
available on request.
1.2.5. Date of Manual Execution
Dated October 17, 1994.
Technical and design changes, improvements and amendments may
be made without notice.
1.2.6. Change Notes and Manual Numbers
All executed changes are listed on the final page of this manual. The
type of change, date, executor and proof reader are noted.
Manual number E 185 5177/e includes additional documentation in the
form of drawings.
1.2.7. Copy Rights
All manuals, documents and drawings are copy righted according to
DIN 34.
1.2.8. Technical Documentation and Data Sheet
For in depth explanations see the following chapters:
Safety Chapter 2.
Transport and Storage Chapter 3.
Description of the Pump Chapter 4.
Mounting and Installation Chapter 5.
Mounting at Start--up and Shut down Chapter 6.
Maintenance Chapter 7.
Trouble Shooting Chapter 8.
Drawings and documents Chapter 9.

1.2.9. Customer Service

If service is required or questions need to be answered, please contact
our headquarters or someone in our sales organization.

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 L3NG
2. Safety 2.6. Safety Advice for the Service, Inspection and Mounting
2.1. General Rules and Advice
This manual includes general rules which have to be observed for The entire scope of service, including inspection and
installation, operation and maintenance. Therefore this manual has to mounting, has to be done by an authorized specialist, who
be read before installation and operation by the installer, as well as by has knowledge of this manual. Any work on the machine
the responsible specialist/user. It has to be made available at the job is only allowed when the unit is standing still. The shut--
site for reference at a later date. down of the unit described in the manual has to be fol-
2.2. Dangers of not observing the Safety Advice lowed.
Ignoring the safety advice can endanger people, the environment and
the pump unit. For example:
Damage to the pump units or certain functions of these units, can en-
danger personnel through electric, mechanical and chemical in-
fluences, endangering the environment by leakage of harmful prod- Immediately at the end of any work all safety and protec-
ucts and other pollutants. tion devices have to be installed completely. Before
start--up, points mentioned under 6.4 have to be followed.
2.3. Safety conscious Working
The safety rules listed in this manual, applicable preventive practices
as well as internal safety rules of the user always have to be followed.
2.7. Denial of Modifications and Changes without Approval
2.4. Warning and Advice Signs
In this manual safety symbols are mentioned which can help to prevent Changes or modifications on the unit which have not been confirmed
accidents to personnel. A general safety sign identifies hazards which by Leistritz, are not allowed.
will endanger the unit and its function.

2.8. Unallowable Running Conditions

The operational safety of the delivered unit is only assured by operat-

ing according to the confirmed design and data. Units should not be
used under different operating conditions without the manufacturer’s
approval. The limitation of the performance data sheets should never
be exceeded. Safety hazards may result if they are exceeded.

The word ”Attention” is inserted in the text to note these additional ad-
vice signs and is labeled directly on the unit. 2.9. Other Operations and Safety Hazards

All packing material of the pump or the unit shall only be

Attention removed directly before the installation of the pump.
For example: No foreign particles are allowed to enter the pump!
Direction of Rotation and Flow The danger of an accident at installation and mounting of
Electrical Current Warning the unit has to be observed at any time.
Marking of the Nozzles (inlet, outlet arrows) Balance stability always has to be existing, assembly
Marking Vent and Drain Opening parts have to be secured against falling.
”No rub--dry” sign and others.
Loose parts have to be secured by proper means.
2.5. Safety Advice for the Operator The pump unit is not allowed to be lowered or lifted by the
power supply lines or by the piping.

--Hot or extremely cold machine parts are potential dangers and must Connecting the power supply line to the Motor starter has
be protected against access.
to be done an Electrician and following the electrical lay-
--Coupling guards, which protect the flexible coupling and shaft from
out of the motor supplier.. Proper dimensioning of the lines
assess, shall NOT be removed during running of the equipment.
--Leakage of hazardous products at the seal, by such as, explosive, has to be observed. All dangers by electrical energy have
toxic or hot fluids have to be collected and drained to a safe place not to be eliminated. NEMA/VDA rules and the rules of the lo-
to endanger operating personnel and the environment. cal Energy and Supply company have to be observed as
All general rules of law, applicable to the site have to be followed. well.

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 L3NG
3. Transport and Intermediate Storage The listed preservative agent are meant to be a recommendation.
3.1. Safety Measures Other manufacturers can be used as well. Preserving the internals of
the pump is achieved by filling the pump with the preservation agent.
During filling the Page 6., power rotor has to be rotated in reverse very
slowly. Continue filling the pump until the preservation fluid exits the
suction nozzle with any air bubbles.

Larger screw pumps and all pump/driver units have to be transported

to the installation by means of lifting devices. Lifting and lowering of the
3.5.1. Aging of Preservation
unit have to be done in a balanced manner. Cranes and Lifting devices
have to be specified properly. It has to be assured that the unit will NOT According to the preservation fluid manufacturer, the shelf life of TEC-
”tip over”. Shelves and racks used for storage of the units have to be TYL 506 is 4 to 5 years at inside storage and 12--24 months at outside
designed to accommodate the weight and size.
storage; TECTYL 511 M is approx. 18 months at indoor storage only.
3.2. Transport Precautions By mixing TECTYL 506 and 511 M 50/50, conservation preservation
time of 2--1/2 -- 4 years indoors and 12 months outdoors can be ex-
pected.

Additional packing will extend the preservation time accordingly. The

ingredients in these preserving agent will allow proper corrosion
Damage during transport of the unit should NOT occur. Lifting, using protection even at high humidity, independent of any temperature.
parts like the motor, conduit box or a power supply cable is not per-
mitted. Sufficient care should be taken that the unit cannot slide or fall
during the transport. The packing material of the unit shall not be dam-
3.5.2. Re-- Preservation
aged. All advise on the packing crate or box have to be strictly followed.
For longer storage the user of the pump has
3.3. Unpacking
Attention to check the preservation of the pump regu-
Upon receipt of the pump, immediately inspect the unit for potential larly. Avoid damages which occur due to im-
transport damage. Transport damages have to be reported immedi- proper preservation.
ately to the Insurance Company.
Before installing the unit all packing material has to be removed com-
pletely. All uncovered openings of the unit, for example, the access
3.5.3. Removal of the Preservation Fluid
hole on the bell housing, is to be inspected for loose material, such as
wooden splinters, nails, bolts, metals clamps and others. Such items
Before start--up of the pump the preservation agent needs to be re-
need to be removed. End covers, blind plugs, etc., have to be removed
moved. The fluid which was used on the inside of the pump normally
as well.
can be removed by flushing the pump with product , provided the prod-
3.4. Intermediate Storage uct is allowed to get contaminated by this. In addition proper solvents
can be used to remove the inner and outer preservatives. Proper sol-
The delivered screw pumps are already preserved for shorter storage vents could be Kerosene, Diesel or de--mineralized spirits, industrial
time. For longer shut--down time, the pumps have to be further pro- solvents, cleaners and other paraffin solvents. Hot steam cleaners
tected from corrosion. An outside/inside preservation needs to be with according attachments can be used as well.
done as outlined under 3.5.
The pump always needs to be filled with
3.5. Preservation Attention product to avoid seizing the pump rotors at
start--up. If at the installation site the piping,
The time limitation of the preserving material is dependent on the com- tanks and other parts in various circulation systems are covered with
position of the material. Therefore preserving materials should be used paraffin containing preservation material, the whole system needs to
which will be stable for at least 12 months. The following materials can be flushed. This is necessary because paraffin lowers the degassing
be used for an inside and outside preservation. capability of the products. This might cause a rough running pump in
connection with loud noise development (aeration).
Preservation Points: Preservation agents:
All machined and unpainted TECTYL 506
surfaces like shaft end and or compound
flange covers TECTYL 506 and 3.6. Protection from the Environment
TECTYL 511--M (*)
When storing the screw pump, the discharge and suction flange al-
Pump casing internals, rotor compound
set and end covers TECTYL 506 and ways need to be covered by blind flanges, blind plugs or similar mate-
TECTYL 511--M (*) rial. The storage shall take place in a dust free and dry room. During
storage , it is recommended to turn the inner parts of the pump manu-
---- (*) Manufacturing: VALVOLINE OEL GmbH & Co. ----
ally every 4 weeks. The rotor set and bearing change their position dur-
The preservative agent shall be spread by means of brushing or ing this process. If the storage and packing is done properly, the unit
spraying. can be preserved for a very long time.

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 L3NG
4. Description of the Pump 4.3.3. Shaft Seal
4.1. General Description Sealing the stub shaft of the driving spindle against the product, a sim-
The Leistritz Screw Pumps of the L3NG Series are low pressure ple non--balanced maintenance free mechanical seal (position 62)
pumps up to 16 bars. They are self priming positive displacement mounted directly in the driving side cover (position 045).
pumps and are used to move oils or other lubricating products. Materials and means of construction (manufacturer of the mechanical
seal) will be adjusted to the according operating conditions and char-
4.2. Assembly and Operation acteristics of the product being pumped.
Due to the special profile of the three turning spindles, sealed cavities
are produced. The double--lead driving spindle (position 150) rotates, 4.3.4. Casing Gasketing
sealing with the double--lead idler spindle (position 151) in the spindle The pump is sealed off using flat gasket (position 031) and seals rings
bore of the pump casing (position 001) which encloses the spindle set (position 006) depending on the operating conditions and the pumped
with tight tolerances. products.
The motion of the two idler spindle is caused by the calculated hydrau-
lic forces leaving only the resulting moment caused by the fluid friction 4.3.5. Bearing
to be transmitted over the flanks of the spindle profile. Therefore the The outboard, greased, shielded and maintenance free bearing (posi-
spindle set is almost without any load and will not wear. With this princi- tion 170) according to DIN 625, mounts the power rotor (position 015)
pal the pumps continually move fluid without sheer and turbulence into the drive side cover (position 045).
from the suction to the discharge side. This constructive design in
working principle assures a low noise level and an almost pulsation
4.3.6. End Cover
free discharge.
The complete spindle geometry is chase in in a way that no axial thrust The end side cover or immersion tube (position 030, 450) or the pedes-
is effected on the grooved ball bearing (position number 170). The tal (position 040) shuts the pump casing (position 001) at suction side.
grooved ball bearing (position 170) fixes the driving spindle (position
150) in axial direction. 4.3.7. Drive Side Cover
The bearing application of the idler spindles (position 151) is effected in The drive side cover (position 045) serves for integration of the me-
the pump casing (position 001). chanical seal and for fixing of the complete pump. The mounting face is
Depending on the operating pressure, an appropriate choke gap is according to DIN 3019, position 2, section 4, squared mounting
built between the balancing piston of the driving spindle (position 150) flanges. With this four hole mounting flange, the complete pump can be
and the idler spindles (position 151), which guarantees the hydrody- rotated in 90q increments.
namic bearing of the idler spindles. At the discharge connection, a cast in error describes the
The subsequent tightening area is connected with the suction side flow direction of the product. Before start up that flow
pump room by means of a boring and stands thus always under direction has to be checked. Mounting the complete pump
suction pressure. By this geometric design of the spindle package the to the driver, screws acc.to DIN 938 or DIN 939 have to be
axial thrust balancing is guaranteed. used together with hex head bolts and nuts.

4.3. Construction of the Parts 4.3.8. Pressure Relief Valve

4.3.1. Pump casing As described on 4.3.1, the pump can be executed with an integral pres-
Depending on the mounting configuration, the execution of the pump sure relief valve. Exaggerating the adjusted values, the poppet (posi-
casing will be made (position 001). The complete pump casing can be tion 219) lifts from the seat and the product circulates into the suction
mounted turned by each time 4 x 90q to the main shaft of the driving area of the pump casing. The opening pressure is adjusted by com-
aggregate. The suction area will be closed off with the non--drive side pressing the valve spring (position 235) with the adjusting screw (posi-
cover (position 30). The drive side cover (position 45) is mounted on tion 222) at the factory or at the user, depending on the requirement.
the discharge side. As an option the pump casing can be executed with Notice to the valve adjusting pressures see chapter 7.5.1
an integrated relief valve. Using the pump with a pressure limitation valve, care
The relief valve protects the pump only against overload should be taken that the poppet will always stay movable
and is not meant to be used as a pressure regulating in it’s axis. A complete closing of the valve bore by means
valve! Operation and manual of the pressure regulating of locking the adjustment screw and the connected valves
valves, see section 4.3.8. The pump casing can be spring by complete compression, shall not be allowed,
drained in any mounting configuration. Therefore, check before start since this could cause damage to the pump. If a pressure
up on eventually not plugged openings. regulation is necessary, this shall be done with separate
On the suction connection the casting is executed with a regulating devices, executed and installed by the user.
cast in flow direction arrow. Before start up the flow direc-
tion needs to be checked. 4.3.9. Nozzles
Suction and discharge connection are executed as a DIN or ANSI--
flanged connection, marked with flow direction arrows cast into the
4.3.2. Spindle Set pattern. Weldneck counter flanges according DIN or ANSI can be sup-
The driving spindle (position 150) is double--lead, hardened and axially plied with a price adder.
positioned with a grooved ball bearing (position 170). The idler Maximum allowable forces and moments are depending
spindles (position 151) double--lead as well, hardened or unhardened, on the pump size, and are listed on the dimension print of
are paired to the driving spindle. During operation both idler spindles the pump or on the assembly drawings. These values
are pushed in axial direction against the driving side balancing piston shall never be exceeded. Connections for drain, vent or
of the driving spindle (position 150). heating, if not needed, need to be plugged before start up.

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 L3NG
4.3.10. Drive and Shaft coupling 4.5. Execution Modifications
The pump will be directly coupled to an electric motor or other drive via 4.5.1. Type key
a bell housing with foot angle or a bell housing with a mounting plate in a The type key, listed at the end of this manual, does include all combina-
vertical mount arrangement. tions of pump modifications via number and letter code. Every stan-
Always observe the correct direction of the rotation and dard pump can be described by that.
proper drive speed. The pumps can be mounted in any
mounting position. Because of safety reasons, mounting 4.5.2. Standard Material of Construction
the motor below the pump is not allowed. The shaft cou-
Pump casing 0.6025 or 0.7040
pling transmits the turning moment form close with a three
Drive side cover 1.0037
piece elastic form connecting coupling, which balances
End cover 1.0421
axial, radial and angular misalignment of the connecting
Driving spindle 1.7139 hardened
shafts. Different execution (manufacturer and material
Idler spindle 1.7139 hardened or 0.6025
combinations) are available with price adder
Gasket CENTELLEN WS 3820

4.4. Dimensioning and Geometry 4.6. Operating

4.4.1. Standard Overall and Single Dimension Drawings 4.6.1. General Operation Fields
Standard overall dimensions for the size 020 through 070 are accord- General industry technology, oil burning energy, ship building and off
ing to drawing E 168 5954 with DIN flange connections. shore technology, machine and heavy machinery manufacturing, tank
farms, chemical and petro chemical and OEM Industries, food proces-
Standard single dimension drawings for the size sing and others.
with DIN flange connections
020 + 025 drawing E 168 5918 4.6.2. Use of pumps in potentially explosive areas
032 drawing E 168 5919 These pumps and pump units are suitable for use in
038 drawing E 168 5920 potentially explosive areas according to EC Directive 94/9/EC (ATEX).
045 drawing E 168 6026 The condition is:
052 drawing E 168 6027 that the pump units are designed according to the specifications and
060 drawing E 168 6028 that this design is confirmed in the project--related pump data sheets.
070 drawing E 168 6029 Proper operation and the permissible application limits must be com-
080 + 090 drawing E 168 6393 plied with as specified in the corresponding chapters of the data sheets
100 + 112 drawing E 168 6394 and of the operating manual. Also see Chapter 6 of this operating man-
ual (Commissioning).
125 + 140 drawing E 168 6395
The confirmation for the permissible area of use is:
160 + 180 drawing E 168 6431
documented in the EC Declaration of Conformity for the corresponding
200 + 225 drawing E 168 6446 project. Detailed documents are included in the project documenta-
250 + 275 drawing E 168 6657 tion, in particular ATEX certificates on devices or attached parts requir-
ing verification.
further project related drawings will be attached.
4.6.3. Temperature-- and Pressure Limitations

If separate single dimension sheets have been executed for the user
they have to be requested.

4.4.2. Standard Assembly Drawings

The nominal pressure, viscosity and temperature details must be
Assembly drawing for the size 020 through 070 with DIN flange needed (see data sheet). If no details are given to the contrary, the
connections and various motor size are available: values given can be considered as relief values and may not be
For foot pumps D 161 9247 exceeded. If protective measures are required as a result of the
For submerged pumps D 161 9249 operating temperatures or temperature limits to prevent disturbance
For tank top mounted pumps D 161 9248 of the surface, these are to be applied by the customer and may not
Assembly drawing for the size 080 through 275 with DIN flange be removed in operation.
connections and various motor size are available:
For pedestal pumps D 162 1327 4.6.4. Performance Data and Speeds
For flange pumps D 162 1328
further project related drawings will be attached. 4.6.4.1. Performance Tables
Performance tables according to pump size and lead angle for various
speeds and viscosity’s, see E 165 6448, page 1--21.
If separate mounting drawings had been made for the user, they have
to be requested.
4.6.4.2. Power Consumption Diagrams
Power consumption’s diagrams for pump size and lead angle for vari-
4.4.3. Standard Sectional Drawings
ous speeds and viscosity’s, they have to be requested.
Standard cross sectional drawings for all sizes and possible execu-
tions according to drawing E 160 6878 or C160 7631. 4.6.5. Installation

If special cross sectional drawings for the user have been made, they 4.6.5.1. Necessary Space for Operating and Maintenance
have to be requested. Choose the mounting space that way that an undisturbed operation
All above drawings are available in different languages on request. and uncomplicated maintenance of the unit is possible. Follow all
safety regulations as well.

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 L3NG
4.6.5.2. Allowable Environmental Influences We recommend the installation of suction strainers with the following
Existing environmental influences which would have mesh sizes:
negative influence on the operation of unit, i.e., high heat
radiance from neighboring machine parts, splash water Mesh size viscosity
and so forth, have to be avoided as much as possible. All 0.3 -- 0.5 mm >150 mm2/s
environmental influences and mounting configurations have to be 0.1 -- 0.3 mm 37 -- 150 mm2/s
stated upon ordering. Additionally operation measures, i.e., insulating, 0.06 -- 0.1 mm <37 mm2/s
vibration dampers, have to be stated at order.
During the connection of the piping to the pump the flow direction
4.6.5.3. Base, Foundation and Anchoring through the pump has to be observed (arrows on the pump). The con-
The anchoring is depending on the type and the size of the unit. If the nection of a pressure gauge on the pump body should be planned.
unit is mounted via L--bracket, the mounting holes, respective elon-
gated holes of the foot bracket have to be used. The cleaning of the pipework should not be executed with water
The mounting should be chosen that no movement of the or with fluids with minimum viscosity below the minimum indica-
unit is possible. All sub bases and foundations must be ted viscosity shown in the pump data sheet. During hydrostatic
statically sound. The unit should not be exposed to the test of the whole pipework system, the pump must be isolated.
vibrations of other machines. If vibrations cannot be The hydrotest of the pump (dynamic or static) will cause damage
avoided vibration isolators have to be installed. to the pump (especially to the shaft sealing system). If this proce-
If the unit is mounted with a lid plate onto a tank, ensure dure is not maintained, the guarantee is not void.
that the tank can support the weight of the pump. It is rec- 4.6.5.5. Support Connections
ommended to use vibration isolators. This will reduce the All other support connections have to be dimensioned properly and
noise at the tank walls drastically. Leistritz cannot be brought towards the unit. The user is solely responsible for the sizing
made liable for damages of the unit due to unstable anchoring. and material selection. In principal no mechanical forces are allowed to
4.6.5.4. Suction and Discharge Piping take place. Damaged support pipes have to be repaired or exchanged
The pump unit is not permitted to act as a mounting point immediately.
for piping. The maximum allowable forces and moments
on the flanges mentioned in the dimension sheets and
assembly drawings may not to be exceeded. This is true
for possible temperature forces as well, see section 8.3.The pipe sizes
on the suction and discharge side should be at least the size of the
pump connections. The selection of the pipe has to be done using the
existing flow velocity. The flow velocity in the suction line should not
exceed 1 meter per second and in the discharge line, 3 meters per se-
cond. When piping up suction and discharge lines, care should be
taken that the flow of the medium is not disturbed by mounting short
radius elbows, right angle valves or check or back pressure valves in
the suction line. Unavoidable diameter changes in the flow lines have
to be executed with smooth reducers. Any sudden direction changes
should be avoided. The suction and discharge lines have to be sealed
tightly and piped in such a manner that no air bubbles can build up.
Therefore the piping must always be layed in a rising manner. The
spindles of gate valves should be positioned horizontally or vertically
downward to allow venting of the lines at the highest point. Flange gas-
kets cannot be permitted to protrude into the I.D. of the pipe and instal-
lation of isolation valves before and after the pump as well as a check
valve at the discharge side is recommended. The isolation valves are
only used to close the lines for pulling the unit out of service. They have
to be completely open during normal operation. All pipes and valves
have to be cleaned thoroughly before the pump is mounted in order to
flush out weld slag, weld beads and possible mounting debris, like
bolts, nuts and so forth. No liability can be claimed for damages to the
pump which have been caused by solid particles in the product. Mount
the pump onto the tank in such matter that air bubbles and foam par-
ticles, which might have been produced in the fluid are kept out of the
pump inlet.

The tank has to be dimensioned and mounted in such

fashion that the use of maximum allowable flow and media
temperatures are not exceeded, proper installations mea-
sures achieve this goal.
The lifetime of a screw pump is determined by the cleanliness of the
product and it’s relationship to the tight tolerances between the rotors
and the rotor sleeve.

E 185 5177_e_Rev. 7_20.02.07 Page 6 of Page 14

 L3NG
5. Mounting and Installations When using special couplings the recommendations of the manufac-
turer cannot be exceeded. Axial forces are not allowed to be trans-
5.1. Tools mitted through the coupling into the pump.
Careful and accurate adjustment of the shaft ends will
For the total mounting or disassembly standard tools are necessary: lengthen the life time of the coupling. The coupling half on
-- Allen head wrenches according to DIN 911 the pump side is not allowed to be installed with a hammer.
-- Open end wrenches according to DIN 838 ISO 3318
-- Open end wrenches according to DIN 3110 Bell housing or other support measures of the pump have to be thor-
-- Machinist hammer according to DIN 1041 oughly checked for possible defective manufacturing. The referenced
-- Rubber mallet minimum allowable values for radial, axial and angular offset of the
-- Screw driver according to DIN 5.264/A shafts according to DIN 42955 (table 1,N and table 2,N) have to be
-- Screw driver insulated (electrical) achieved manufacturing the bell housing. Mounting advises of the cou-
-- Gear puller 2 or 3 armed pling manufacturer have to be observed.
-- Pliers for snap rings according to DIN 5254
-- Snap ring pliers according to DIN 5256 All rotating parts have to be protected
-- Mounting sleeves for ball bearings against unintentional touch! Damages
5.2. Initial Installation of the Pump caused by improper mounting or adjust-
ment of the pump and motor, are not
The shaft end of the pump and driver have to be aligned covered under warranty.
carefully, since eccentricity, non--parallelisms and plain
arrows will fast destroy the elastic element of the coupling 5.3. Initial Installation of the Pump Unit
and furthermore can cause damage to the pump. Mount-
ing the pump to a driver, care should be taken that the side offset of the The pump unit has to be inspected at the job site for damages. If the unit
shafts (distance between shafts) the maximum eccentricity (center off- is assembled at the job site, follow 5.2. After proper alignment, the
set between the shafts) and the maximum angularity of the two shafts complete unit has to be anchored accordingly. Base and foundations,
do not exceed the recommended data of the coupling manufacturers. see 4.6.

Lifting the base frame

units
fig. 1. With pump, motor and
baseframe
fig. 2. With pump and motor
and without baseframe
fig. 3. With pump, motor and
baseframe

fig. 1
Lifting the pedestal
units
fig. 4. Pump and motor in
pedestal form

Measuring the...
fig. 5. ...concentricity...
fig. 6. ...parallelism...

...of both shafts.

fig. 2 fig. 3 fig. 4

{ Mounting the indicator on the drive shaft and rotation of both shafts; | Mounting indicator on one shaft and turning of both shafts;
checking the concentricity and correction if necessary. checking the parallelism and correction if necessary

fig. 5 fig. 6

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 L3NG
6. Start up - Shut down The discharge line has to be vented until product exits the vent valve or
vent screw. The venting devices have to be closed after this proce-
6.1. Technical Documentation dure.
After start up of the pump, total pump pressure, flow rate, viscosity,
Before start up check all technical demands temperature, speed and horse power have to be compared to the order

Attention and documentation’s. Especially check the

pump unit on:
and operation data. Check especially that with higher specific gravity
or higher viscosity of the product as original assumed, the driver will
not be over loaded and NPSH required of the pump is not exceeded.
- serial no.
Otherwise cavitation will take place. Check the liquid level in the tank,
- type and size
especially at tank mounted units, that the suction opening always
- flow direction and operation type
stays flooded.

6.2. Pipes Schematic and Measuring Points

To the save and troublefree operation, the valve adjusting pres-
The total piping arrangement, proper connection and dimension of sure is to be examined - see chapter 7.5.1
measuring and governing devices have to be observed. 6.5. Shut down of the Pump
If the pump is used in potentially explosive areas, the measuring and
control technology must be checked with regard to the approval of the For the shut down of the driver no preparations are needed. If the pump
devices. The declarations of conformity are included in the project is shut down against full pressure, it will stand still immediately (un-
documentation. problematic for pump and electric motor). It is recommended to install a
The cleaning of the pipework should not be executed with water check valve between the isolation valve and discharge line. At longer
or with fluids with minimum viscosity below the minimum indica- shut down the isolation valves should be closed. If a change of the fluid
ted viscosity shown in the pump data sheet. During hydrostatic concentration, crystallization, solidification and others have to be
test of the whole pipework system, the pump must be isolated. taken in to consideration, the pump has to be drained and flushed with
The hydrotest of the pump (dynamic or static) will cause damage a proper fluid.
to the pump (especially to the shaft sealing system). If this proce-
dure is not maintained, the guarantee is not void. 6.6. Re-- starting
Damages which occur due to improper positioning or di-
mensioning of measuring and governing devices, are not After a short shut down, the pump can be re--started without any prepa-
covered under warranty. rations. After longer still standing time or re--installation of the pump,
the procedure according to section 6.3, preparation for start up has to
be followed.
6.3. Preparation for Start up

6.7. Standstill
Before initial start up the following scopes have to be
completed:
6.7.1. Shut down for up to 3 Months
-- Cleaning of the piping, section 4.6.5.4.
-- Checking of the anchoring, section 4.6.5.3.
If the start up of the pump is within 3 months of installation or the shut
-- Checking on power supply to the motor
down of the pump is less than 3 months, no special preservation is re-
-- Check the direction of rotation of the driving motor,
quired.
the direction of rotation must correspond to the direc-
tion of rotation arrow on the pump. By an incorrect 6.7.2. Shut down from 3 to 6 Months
direction of rotation, the pump will produce no suction,
this will cause the pump to be damaged. Before the initial start up the suction and discharge port
-- Remove blind plugs on suction and discharge lines, section 3.3. have to be covered with a blank. At shut down, suction
-- Check piping according to flow direction, section 4.3.9. and discharge insulation valves have to be closed. With
and 4.6.5.4. that measure the pump remains filled with product. If the
-- Visual checking of the pump unit, section 6.1. product includes aggressive particles which might attack the materials
-- Opening of the separation valves of construction of the pump, follow according section.
-- Fill pump with pumping liquid and be sure to protect against running
dry. For filling information and recommendations, see Document E 6.7.3. Shut down for more than 6 Months
185 5504 (see Appendix).
-- All governing and control equipment have to be checked on func- The pump has to be closed off and sealed off according to
tion after installation ( i.e., emergency switch off, needle pressure 6.7.2. and has to be filled with preservation material. To
gauge and others ) protect the running surfaces of the bearings against com-
-- To protect people, all equipment has to be according to rules and pression marks caused by vibrations or shocks, the
regulations power rotor is to be turned in according time intervals. (I.e. all 4 weeks
rotated manual, so that parts like the rotor set and the bearing should
6.4. Start up end in a different position each time).

Before start up, the rotation direction and speed has to be 6.8. Operation Supervision
checked. Suction and pressure gauges have to be ob-
served and compared to order and operation data. Tem- The necessary supervision of a Leistritz screw pump is
perature and viscosity of the product should be checked. very minor. In proper time intervals, discharge pressure,
On the drive side cover in the ball bearing area, the tem- flow rate, excess power consumption of the electrical mo-
perature can be 20--30 qC, below the product tempera- tor, alignment of the pump (coupling), seal, filter, contami-
ture, but has to be below 120 qC. nation and unusual noises should be observed. The cleanliness of the
product is the main factor in the life time of the pump. A visual check of

E 185 5177_e_Rev. 7_20.02.07

Page 8 of Page 14
 L3NG
the pump should be done at least once a month. The pump should al- grease - filling - quantities
ways run quiet and vibration free. The pump is not permitted to run dry!
Shaft seal should be checked, especially during start up time, leakage type of pump grease filling quantity
might occur.
The leakage of one drop of product per hour is an average L3NG 20 5g
for an undamaged mechanical seal. If the pumps are L3NG 25 5g
mounted as spares, they should be started up from time to L3NG 32 5g
time for a short period of time, to assure they are ready L3NG 38 8g
when needed. Furthermore, the shaft should be rotated according to L3NG 45 8g
section 6.7.3. L3NG 52 14 g
L3NG 60 14 g
6.9. Bearing of the Driving Spindle
L3NG 70 18 g
The bearing on the power rotor is a maintenance free, L3NG 80 20 g
grease packed sealed ball bearing. The bearing is de- L3NG 90 22 g
signed for 17500 hours running under the conditions de- L3NG 100 22 g
scribed under section 4.6.2. In a rough service, high tem- L3NG 112 26 g
peratures or others, the design life can be shortened drastically. L3NG 125 26 g
L3NG 140 30 g
If there is a regreasing--possibility at the pump, the groove ball bearing L3NG 160+180 35 g
has to be regreased regularly. The regreasing intervals depend on the L3NG 200+225 40 g
grease service life of the used grease--media and on the operational L3NG 250+275 50 g
charges.A monthly inspection respectively an inspection after 500 op-
erating hours would be recommended by the manufacturer.
The indicated lubricants exclusively apply to
For the lubrication, all high--quality and temperature--resistant ball bea-
ring -- greases as proposed as follows, can be used. Attention the pump. Please you consider their regula-
tions with further components for lubrication.

manufacturer up to 130_C up to 180_C

Aral Aralub HLP 2

BP BP--Enerrease LS--EP2
Castrol Spheerol Ap2
DEA Glissando EP2 Diskor Plus 2
Esso Beacon Ep2 Unirex S 2
Fuchs Renolit FEP 2 Renoplex EP 3
Mobil Mobilux EP 2 Mobiltemp SHC 32
Optimol Olit 2 EP oder Optitemp HT 2
Longtime PD 2
Shell Alvania Grease EP 2 Darina Grease 2

or comparable grease - products

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 L3NG
7. Maintenance For pumps handling dangerous substances
Attention and/or environmentally hazardous media,
the owner must inform its own assembly per-
7.1. General
sonnel on site of this fact, or our factory personnel in case
The maintenance work includes almost exclusively checking of pump of return. In this case, we must be presented with proof of
parts for wear and damage. Leistritz Screw Pumps of the Series L3NG the pumping medium, e.g. in the form of a DIN Safety Data
Sheet, together with the request for customer service.
need minimum maintenance, as long as the confirmed operating data
are kept and the fluid is as free as possible from abrasive particles. The Dangerous substances are:
cleanliness and the capability to lubricate the product, are dominant in
S Toxic, carcinogenic, embryotoxic substances, gene--
the expectancy life of a pump. If a high operation safety is necessary,
altering substances or substances which are other-
we recommend the following maintenance intervals according to sec-
wise harmful to the health of and dangerous to human
tion. beings.
S Caustic substances
S Irritants, explosive, fire promoting, highly flammable
7.2. Maintenance and Inspection
and flammable materials
-- After 500 hours of operation the pump should be ex- S Corrosive materials.
amined, the pump should be checked for unusual
noises and it shall be checked with a temperature sen- The user is solely responsible for mounting on site warn-
sor. The temperature difference between the fluid and ing signs, which naturally shall be observed at all times.
the drive side cover should not exceed 22--25 qC. The During all activities on site, the owner’s own personnel
leakage of the mechanical seal should not exceed a few and LEISTRITZ employees must be informed of all
dangers which can occur during dismantling and/or repair
drops per hour.
work.
-- After 2 years the pump should be disassembled and all inner parts
For mounting and repair LEISTRITZ personnel can be made available
should be examined for damage and wear, especially the mechanical
to the user upon request.
seal has to be checked in the sliding surfaces. The idler rotor head
7.3.3. Disassembly and Assembly
surfaces have to be checked for wear as well.
The most important disassembling and mounting steps
-- Worn parts need to be replaced. Check the casing and the flow pock-
are described in the following:
ets in the relief valve for dirt contamination. If dirt deposits are noted, it
No warranty claims can be accepted if all necessary as-
needs to be cleaned out. sembly steps have not been kept in order, or damages
due to improper disassembly or assembly occurred.

7.3.4. Tools
7.3. Disassembly and Assembly Necessary Assembly Tools (see Section 5.1)

7.3.1. General Precaution 7.4. Disassembly of the Pump

-- The power lines have to be disconnected by an Elec-
With proper supervision of the pump, operation interruptions which trician. Motor or driver have to be made unfunctional.
might make a disassembly necessary, are very rare. If an interruption -- Checking of the insulation valves in suction and dis-
occurs, the possible cause should be determined before disassembly, charge line, they have to be closed.
if at all possible. The trouble shooting table in section 8.1 gives hints -- Let pump cool down to surrounding environment tem-
about possible causes. At all disassembly and assembly, all parts perature.
have to be handled with care. Shocks and impacts have to be always -- Disconnect suction and discharge flanges.
avoided. All parts have to be carefully cleaned, possibly re--condi- -- By unbolting the mounting flange, the pump can be
tioned or exchanged for spare parts. After assembly the Driving lifted from the mounting unit.
-- Couplings half on pump shaft has to be pulled via
spindle has to rotate freely, otherwise the bearing and mechanical seal
gear puller, remove key (position 180) from pump
could be damaged. At all work the proper cross sectional drawing has
shaft.
to be used as work base.
-- Valves spring (position 235) needs to be released via
adjusting screw 222, the seal nut (position 281) needs
to be loosened for this purpose (only with integral
pressure relief valve).
7.3.2. After Sales Service Technicians/Dangers
-- To remove end side cover or the pedestal (position 30 or 40) take
out bolts (position 32 or 47) and remove gaskets (position 31).
LEISTRITZ--Service Technicians for mounting and repairs can be
-- Remove valve parts (position 219, 220 and 235) (only with integral
made available to the user upon request.
relief valve).
If repair work is to be carried out by the owner or by LEIS- -- Loosen screws (position 50) on drive side cover (position 45) and
TRITZ service personnel, the pump must always be de- remove drive side cover and gasket (position 46) from pump cas-
pressurised, completely drained and cleaned. This is es- ing (position 001). Doing that, watch for spindle set, mechanical
pecially applicable for pumps that are returned to our fac- seal and grooved ball bearing. See valid sectional drawing.
tory for repair. In order to protect our employees, and for -- Separate idler spindles (position 151) from driving spindle (position
environmental protection reasons, pumps filled with pumping medium 150).
will not be accepted for repair. Otherwise the owner will be charged for -- Remove circlip (position 174 and 173) and supporting disk (position
the costs for an environmentally appropriate disposal. 172).

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 L3NG
-- Pull driving spindle (position 150) through the I.D. of the grooved with the supporting disk (position 172) in place, through the drive
ball bearing (position 170) towards suction side through the drive side cover and the ball bearing. Never drive the driving spindle
side cover. Remove supporting disk (position 172). through the ball bearing with impact by a hammer nor the ball
-- The rotary part of the mechanical seal has to be carefully pulled bearing over the shaft via hammer. The driving spindle, slightly
from the driving spindle. Depending on the manufacturer the lock- greased, needs to engage with the inner diameter of the ball bear-
ing device has to be removed. ing all the way on to the shoulder on the driving spindle. After-
-- The stationary face of the mechanical seal with O--ring or seal ring wards mount the supporting disk (position 172) and circlip (posi-
can now be pressed out carefully of the drive side cover. tion 173).
-- Remove grooved ball bearing (position 170) in direction shaft end -- Put O--ring (part 46) in place on to drive side cover (position 45).
with a gear puller out of the drive side cover (position 45). -- Position the idler spindles (position 151) as a pair on to the driving
spindle and slide spindle set into the casing. Watch for the posi-
7.5. Assembly of the Pump tion of the running surfaces ( mark), the casing box should be
slightly oiled for this purpose. Bolt the pump casing with screws
A re--assembly can only be permitted if full functional and
(position 047) onto drive side cover, note that the screws need to
undefective parts are used. We recommend as well a
be pulled simultaneously and the proper position of the connection
cleaning of heavily stained parts
flanges has to be noted.
-- Assembly valve parts, position number 219, 220 with 235, in the
-- The grooved ball bearing (position 170) needs to be checked for
proper order in to the valve cavity (only with existing relief valve).
damages*, defective seal disks, then it should be pressed into the
-- Place gasket (position 031) onto the end side cover of the pump
drive side cover (position 45). *Like smooth run, grease filling.
casing (position 001).
Never force the bearing in place by means of a hammer, this
-- Turn set screw (position 222) that far into the end side cover
would cause damage of the running surfaces and the bearing
(position 030) that the tip of the adjustment screw touches the
balls. Secure in place by means of the circlip (position174).
spring plate (position 220) without tensioning the valve spring
-- Mounting of the mechanical seal needs absolute cleanliness.
(position 235). Afterwards pull the end side cover tight by means
Especially a damage of the sliding surfaces and elastomers have
of using screws (position 030) seal nut (position 281) on to adjust-
to be avoided.
ment screw and after adjusting the relief valve to proper operating
-- The stationary element of the mechanical seal
pressures, seal tight (only if a relief valve exists).
(position 62) can be pressed into the drive side cover with the
-- Heat pump side coupling half to app. 110qC and slide
O--ring in place. Watch for equal pressure distribution over the
on to shaft end of the driving spindle with the key
whole ring. Watch as well for the position of the edged adjusting
(180) in place. The coupling half shall not be installed
pin (position 61) in drive side cover (position 45). If necessary,
with impact by a hammer.
spacer ring (position 63) on to driving spindle (position 150).
Watch for absolutely undamaged driving spindle surface in the After complete re--assembly the pump has to be installed into the driv-
mechanical seal area. ing unit and be mounted according to section 5.2. Thereafter the dis-
-- To reduce the friction forces at assembly of the mechanical seal, charge suction and supply lines have to be connected properly. At the
oil driving spindle (position 150) in the area of the rotating element restart--up, section 6.0 have to be followed and the pressure limitation
with oil or silicone grease fill. It is not permitted that Teflon oil ring valve, safety valve, if existing has to be adjusted
gets in contact with mineral oil or grease. Silicone grease is rec- -- The down valve spring (position 235) hard via adjustment screw
ommended, depending on seal execution, the rotary part needs to (position 222).
be locked onto the shaft. -- Start pump with the throttle valve A open.
Above is not applicable for rubber bellows -- Throttling valve A, so that the pressure gauge shows the required
Attention seals, they have to be mounted with a proper
solvent, water or alcohol.
valve opening pressure and the flow meter B shall show steady
flow.
-- Release valve spring via adjustment screw (position 222) until the
-- Never grease the sliding surfaces, always mount completely dry flow rate on the flow meter number B lowers. This means the relief
and dust free. valve opening pressure is reached.
-- After mounting of the rotary element (position 062) on to the driv- -- Close throttle valve A. Now the pressure gauge will show the
ing spindle (position 150) the driving spindle needs to be mounted pressure where the total flow is cycled over the valve

281

222 235

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Page 11 of Page 14
 L3NG
-- - Design variant with sealing nut and adjusting screw
-- Lock seal nut (281)tightly.

-- - Design variant cap nut sealing of adjusting screw

For fixing of the adjusting screw (position 222) this one has to be
countered with the hexagonal nut (position 215) and the sealing ring
(position 216). Afterwards the cap nut (position 281) has to be tight-
ened withe the second sealing ring (position 216).

Further steps see section 6.4.

7.5.1. Notice to the valve adjusting pressures

Like all positive--displacement pumps, this screw pump requires a
pressure relief valve to protect against overloading. This valve can be
installed externally, as an external valve in the piping system, or di-
rectly as an attached part on the pump. The respective model is speci-
fied in the data sheet or the valid drawings.
If no other agreement has been made, the valve actuation pressure is
pre--set at the factory on the test bench. The opening pressure is ap-
prox. 10 to 20 % above the operating pressure. However, the values on
the system must be checked prior to commissioning.
The following distinction is made for valves:
-- Valve actuating pressure; this is the pressure at which the valve
begins to open.
-- Valve short-- circuit pressure; this is the pressure at which the en-
tire pump feed quantity flows off via the valve.
-- Valve closing pressure; this is the pressure at which the valve has
closed again following relief.
It must be noted that at low operation pressures, the adjustment values
are selected so that the valve closing pressure is always above the
operating pressure and the valve short-- circuit pressure does not
lead to overloading of the pump and drive.
If this is not observed, damage to the pump and drive may result. We
shall assume no liability whatsoever for damage resulting from a failure
to observe this fact.

7.6. Spare Parts

In general, we recommend that the user should keep a complete set of
spare parts for the pump unit on stores. It is also possible to select a set
of appropriate spares acc. to our spare parts list for the individual user.
In order to do this, the following information shall be supplied when or-
dering.
-- Pump Type
-- Pump Size
-- Leistritz Serial Number
-- Cross Sectional Drawing Number
-- Purchaser / User
-- Name
-- Address and Telephone Number
An interchangeability can only be guarantied
Attention if accurate information is given.

Conserving and intermediate storage of spare parts or spare pumps,

see section 3.4. and 3.5...

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 L3NG
8. Trouble Shooting not listed in the trouble shooting list, we recommend a check back with
the factory or the sales forces.
8.1. Table to define Reason and solving of Problems
Solving all of the particular disturbances the
The table below is used to define eventually happening disturbances at pump needs to be without system pressure
the pump unit. If problems occur during operation of the unit, which are and needs to be drained.

Problems at the pump unit

Pressure and flow rate too low
Pump does not lift discharge

Noise creation in the pump

Motor over loaded

Fluctuating flow

Pump is seized

Unit vibrates
Pump leaks

Reasons and Resolution

Compare direction of rotation arrow on pump with direction of rotation of motor.

If necessary reverse motor.
Check suction pipelines and stopcocks for leaks. Vacuum suction head to high,
shorten suction pipeline, mount pump at a lower position
Reduce flow turbulence, lay suction pipelines straighter.
System and pump are empty. Fill tank with media.
Drive speed too low. Check motor for speed and power output. Compare motor
speed, supply voltage and frequency to designating plate.
Discharge pressure too high. Check operating data of pump, media viscosity.
Compare operating data. Heat media if necessary
Viscosity too low. Compare operating data, increase drive speed as required.
Select a pump with steeper spindle pitch or next larger size of motor. Increase
media viscosity by changing media temperature.
During operation the media tank was not filled with media.
Air bubbles in suction and discharge system. Vent pump at highest point. Se-
lect a larger media tank with better deaerating characteristics. Submerge return
line under the media level in the tank.
Mechanical seal damaged by dirt in the pump media. Floating ring seal sur-
faces worn or abraded. Mechanical ring seal overheated and defective as a
result of running dry. Completely replace floating ring seal.
Shafts or spindles have seized in the housing borings. If the surfaces are only
slightly damaged these can be honed or lapped. Check operating data and do
no exceed.
Internal parts of pump worn, fit spare parts, fill with media or change filter insert,
monitor operating characteristics and do not exceed.
Pump and coupling are not correctly aligned and mounted. Realign the unit.
Check manufacturers data for the coupling and ”allowable displacements
E1855270”.
Pressure and vacuum lines are under tension. Refit lines in atension free man-
ner. If necessary fit compensators into the lines. Support and secure pressure
and vacuum lines.
Mounting bolts not uniformly tightened. Tighten uniformly without distorting the
pump.
Ball bearing defective, dismantle and replace.
Dismount pump, find out defective parts, remove and renew them. In case of
defective magnetic coupling, the complete unit should be returned to the factory
for repair.
Coupling components defective. Dismantle unit and replace..

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 L3NG
8.2. Torque Requirements 8.3. Allowable pipe forces and moments
Necessary torque requirements according BDI 2230, sheet 1, (me- Forces and moments shown on assembly and dimensional drawings
dium friction) factor 0.14 for shafts, screws and metric standard thread shall not be exceeded.
according to DIN 13, part 13, and head dimension of hex head screws
according to DIN 913 or Allen head screws according to DIN 912 Violating and exceeding these values can damage the
pump causing operating problems. Eventually occurring
thread size property class starting torque in Nm
thermo tensions have to be corrected by design modifica-
M6 8.8 10.4 tion ( flexible piping).
M8 8.8 25
M10 8.8 51
M12 8.8 87
M16 8.8 215
M20 8.8 430

8.4. Allowable pipe forces and moments

Rev--No. Chapter Page Modification Date Name Checked

1 6 9 lubrication information added 271196 Frbg.
2 all sizes 80 -- 140 add. to 121099 Frbg.
3 4, 8 4--6, Remarks to ”temperature-- and pressure limitations” add. to 07.00 Frbg
13--14
4 4.6.4.4+6.2+ 6+8 Cleaning, pressure test and filling of the pipe work 7.06.04 HB Frbg
6.3
5 1, 4, 6 1, 5, 9 lubrication information added L3NG160 up to L3NG 275 27.8.04 Frbg
6 4, 6, 7 4, 5, 8, Information ”EX--appl.” and ”valve adjusting pressures” added. 7.12.05 Frbg
12
7 6 9 lubrication information added 20.2.07 Frbg

First edition Prepared Checked .......................... Approval ....................................

Date 17.Oct.1994 ............................. .......................... ....................................
Department KSP..................... ......................... ....................................

9. Drawings, Data Sheets, Appendix

10.

E 185 5177_e_Rev. 7_20.02.07 Page 14 of Page 14

 Additional for Shaft Seal
Pumpen GmbH
”Oil Receiver Mechanical Seal” L3NG
(optional)

Oil Receiver Tank Oil Receiver Tank

pump position pump position
horizontal line vertical line

Regreasing
device

Function of the oil receiver: On sealing leakage and higher atmospheric pressure at the suction (in-
The contact between the hot conveying medium and the cool ambient air take) of the pump, the level raises.
has to be avoided for conveying lubricants at temperatures from 120qC, Inspection and filling intervals:
for example heavy oils. When leakage escapes, which is to a less degree The inspection and the refilling of the receivers is dependent on the re-
inevitable for mechanical seals, the escaping liquid is cracking and cau- spective operating data of the system. The level and the consumption
ses malfunctions of the mechanical seal. should be checked in short intervals during the break--in period. We sug-
gest to check the level on operating start daily and after a period of opera-
Installation of the oil receiver:
tion weekly. On contamination of the oil filling, visible on the change of the
The installation is described in the illustrations above. The oil receiver is
oil color, the oil should be exchanged after cleansing.
placed upwards when pump has a horizontal arrangement and in direc-
tion of the driving, when the pump has a vertical arrangement. Regreasing installation ball bearing:
Design of the oil receiver: The ball bearings are exclusivly fit out with a regreasing installation.
The oil receiver allows a dust--proof filling of unpressurized recipient me-
We recommend a monthly regreasing or a regreasing after max. 500 run-
diums. The transparent cylinder jackets consist optional of plexi or natu-
ning hours. Informations about the grease levels and the suggested lu-
ral glas, the seals consist of NBR or viton. The materials will be designed
bricants could be found in the operating instructions E 185 5177.
to meet the requirements.
Recipient medium:
For filling to convey the heavy oil, heat transfer oil should be used exclu-
sively. The receivers are empty on delivery. The filling has to be procee-
ded preoperational. The recipient medium should be chosen in the way
that the viscosity amounts from approx. 10 to 60 mm_/s on temperature
during operation. The reservoir should be filled to approx. 60 % in order to
let sufficient compensation place on leakage. On sealing leakage and lo-
wer atmospheric pressure at the suction of the pump, the level reduces.

Appendix to E 185 5177

 L2 / L5
L EISTRITZ PUMPEN GMB H

Appendix onto pump operation manual for L2- and L5 pumps onto chapter 4.6.5.4 pres -
sure- and suction line
Recommended, maximum Mesh Sizes for L2-- and L5 Pumps
Ref. note: The recommended filter mesh sizes are able to avoid Under no circumstances can these filter
larger particles in the pump media. Attention mesh sizes completely prevent damage to
the pump caused by particles.

Type sizes
L2 / L5 30 40 48 62 70 82 96
Filter mesh sizes
[mm] 1 1 1 2 2 2 2
[Pm] 1000 1000 1000 2000 2000 2000 2000
[inches] 0,0394 0,0394 0,0394 0,0787 0,0787 0,0787 0,0787
[P-- 39,4 39,4 39,4 78,7 78,7 78,7 78,7
inches]

Type sizes
L2 / L5 106 116 126 140 164 186
Filter mesh sizes
[mm] 2 2 2 2 3 3
[Pm] 2000 2000 2000 2000 3000 3000
[inches] 0,0787 0,0787 0,0787 0,0787 0,1181 0,0787
[P-- 78,7 78,7 78,7 78,7 118,1 118,1
inches]

E 185 5600_en_Rev1_31.03.2011 Appendix onto the respective operation manuals

 Allowable displacements
appendix to all pump instructions

da

R A

speed n= up to max 1500 rpm speed n= up to max 3600 rpm

Ø coupling
R max [mm] A max [mm] R max [mm] A max [mm]
up to da = [mm]
30 0,06 0,06 0,04 0,04
40 0,07 0,07 0,05 0,05
50 0,08 0,08 0,05 0,05
65 0,09 0,09 0,06 0,06
80 0,10 0,10 0,07 0,07
100 0,12 0,12 0,08 0,08
120 0,14 0,14 0,09 0,09
140 0,16 0,16 0,10 0,10
160 0,17 0,17 0,11 0,11
180 0,19 0,19 0,12 0,12
200 0,21 0,21 0,13 0,13
225 0,23 0,23 0,15 0,15
250 0,25 0,25 0,16 0,16

Chapter 5 (Mounting and Installation) of the pump op- Pump units or a pump and lantern unit are designed to
erating instructions specifies that the shaft ends of the comply with these requirements in the original state
pump and driving motor must be carefully aligned. In (supplied by Leistritz). If attached parts are purchased
the above table the quality of this alignment can be de-
separately (not included in Leistritz delivery scope),
termined with reference to the coupling size [da].
the requirements for the geometry of these parts must
It should be noted that an alignment of the type shown
also be complied with.
can only be carried out in horizontally installed pump
units. In special cases an alignment of the pump relative to
For units with a ”lantern arrangement” it must be en- the lantern is permissible, however this adjustment
sured that the position of the pump shaft is determined should be secured with a suitable locating device.
by the geometry of the lantern relative to the mounting If special couplings are used, e.g. with removable el-
flange of the driving motor. The shape and position of ements, special documents are added to the project
the lantern must be such that the alignment values of documentation. In case of specific questions, please
the above table are achieved. contact our agents or the plant.

E 185 5270/e Rev.: 03_18. July 2005

 LEISTRITZ PUMPEN GMBH

Safety and Health Declaration

Please include with shipment or send to us by mail or fax +49/911/4306-251

Dear Customer,

We need to protect our staff against hazards caused by contaminated pumps.

Please understand that we can only undertake repairs / modifications / provide cost
estimates, after receiving this declaration that you have completely filled-in and signed.

Please return the pump(s) to us in a cleaned state and confirm that the cleaned pumps or its
medium which was piped does not bear any health hazard.

In case of toxic or hazardous media or products which are subject to the Regulation on
Dangerous Chemicals (German: Gefahrenstoffverordnung), the Material Safety Data Sheet
(MSDS) must be included to this Safety and Health Declaration.

We reserve the right of returning contaminated pumps back to you for cleaning!

King regards
Customer Service – After Sales and Services
Leistritz Pumpen GmbH
Markgrafenstr. 29-39
D - 90459 Nürnberg - Germany

Pump type: …………………………………… Pump serial no.: ……………………….

Shipment date: ………………………………. Delivery note No.: ……………….........

We herewith confirm that the above mentioned pump is clean, i.e. free of liquid
or solid media. Possible present residues from the medium are:

Medium: harmless yes no

The pump was cleaned with: Can be dissolved with:

Company (stamp) ……………………………………….

Name (in block letters)

……………………………………….
Position / Department

Phone / Fax / Email ……………………………………….

Date, signature

20 682 01 - E Rev. 0 vom 20.04.2007

EG-Konformitätserklärung
im Sinne der EG-Maschinenrichtlinie 2006/42/EG, Anhang II; 1; A

Hiermit erklären wir, LEISTRITZ Pumpen GmbH

Markgrafenstraße 29-39
90459 Nürnberg
Germany

dass die Pumpen (-aggregate) Ref. Type Serien-Nr(n).

KB 26428 Pos. 2 L3NG-100/172 135755-000

in der von uns gelieferten Ausführung den Bestimmungen der EG-Richtlinie Maschinen in der Fassung
2006/42/EG entspricht.

Diese Erklärung bezieht sich nur auf die Maschine / Maschinen in dem Zustand, in dem sie in Verkehr
gebracht wurde; vom Endnutzer nachträglich angebrachte Teile und / oder nachträglich
vorgenommene Eingriffe bleiben unberücksichtigt.

Angewendete harmonisierte Normen, insbesondere

DIN EN 809:2012
DIN EN ISO 12100:2011

Angewendete nationale technische Normen / Spezifikationen, insbesondere Auftragsbestätigungen

und / oder Datenblätter.

....................................................................................
Torsten Pfennig
Leiter Qualitätssicherung, Anschrift siehe oben

Die oben genannte Person ist dazu bevollmächtigt, die technischen Unterlagen zusammenzustellen.

Nürnberg, den 05.11.2013

 _EN_ _IT_
EC-Declaration of conformity CE-Dichiarazione di conformità
as defined by machinery directive 2006/42/EC Annex II; 1; A ai sensi della Direttiva Macchine 2006/42/CE, Allegato II; 1; A
Herewith we declare, LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39, Con la presente il fabbricante LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39,
90459 Nürnberg, Germany 90459 Nürnberg, Germany
that the pumps (aggregates) Ref. Type Serial No(s). dichiara che le pompe (gruppi) Rif. Tipo Numero di serie
correspond to the provisions of EC directive machines of the issue 2006/42/EC. nel nella versione da noi fornita sono conformi alle disposizioni della direttiva CE sui
macchinari nell'edizione 2006/42/CE.
This Declaration relates exclusively to the machine(s) in the condition in which it was / they
were first commissioned; any parts subsequently fitted by, or modifications subsequently Questa dichiarazione si riferisce solo alla macchina / alle macchine nello stato in cui è
undertaken by the end user are not taken into account. stata commercializzata e non considera parti applicate successivamente e/o interventi
eseguiti in un secondo tempo dall’utente finale.
Applied harmonized standards in particular DIN EN 809:2012
DIN EN ISO 12100:2011 Norme armonizzate applicate, nella fattispecie DIN EN 809:2012
DIN EN ISO 12100:2011
Applied national technical standards / specifications, in particular order confirmations and / or data sheets.
Norme / specifiche tecniche nazionali applicate, nella fattispecie conferme d’ordine
Torsten Pfennig
e/o schede tecniche.
Manager Quality Assurance, Address as above
The person mentioned above is authorized signatory to arrange the technical documents. Torsten Pfennig
Direttore Garanzia di Qualità, Indirizzo vedi sopra
La persona sopra indicata è autorizzato a costituire la documentazione tecnica.

_RU_ _FI_
EC-Ⱦɟɤɥɚɪɚɰɢɹ ɨ ɫɨɨɬɜɟɬɫɬɜɢɢ EY-Vaatimustenmukaisuusvakuutus
ɫɨɝɥɚɫɧɨ Ⱦɢɪɟɤɬɢɜɟ ɩɨ ɨɛɨɪɭɞɨɜɚɧɢɸ 2006/42/ȿɋ, ɩɪɢɥɨɠɟɧɢɟ II; 1; A EY-konedirektiivin 2006/42/EY, liitteen II; 1; A tarkoittamassa mielessä
ɇɚɫɬɨɹɳɢɦ ɦɵ, ɮɢɪɦɚ ɡɚɹɜɥɹɟɦ, LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39, Täten vakuutamme, LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39,
90459 Nürnberg, Germany 90459 Nürnberg, Germany
ɱɬɨ ɧɚɫɨɫɧɵɣ(ɵɟ) ɚɝɪɟɝɚɬ(ɵ) ɇɨɦ. Ɍɢɩ Ɂɚɜ. ʋ: että pumput (-aggregaatit) viite tyyppi sarjanro(t)
ɜ ɩɨɫɬɚɜɥɟɧɧɨɦ ɧɚɦɢ ɢɫɩɨɥɧɟɧɢɢ ɫɨɨɬɜɟɬɫɬɜɭɸɬ ɩɨɫɬɚɧɨɜɥɟɧɢɹɦ ɞɢɪɟɤɬɢɜɵ ȿɋ vastaa meidän toimittamanamme mallina EY-konedirektiivin painoksen 2006/42/EY vaatimuksia.
ɩɨ ɦɚɲɢɧɚɦ ɜ ɪɟɞɚɤɰɢɢ 2006/42/EG. Tämä vakuutus koskee konetta/koneita vain siinä kunnossa, jossa ne on tuotu
ɇɚɫɬɨɹɳɚɹ ɞɟɤɥɚɪɚɰɢɹ ɤɚɫɚɟɬɫɹ ɬɨɥɶɤɨ ɦɚɲɢɧɵ / ɦɚɲɢɧ ɜ ɫɨɫɬɨɹɧɢɢ, ɜ markkinoille; se ei koske loppukäyttäjän jälkikäteen liittämiä osia ja/tai jälkikäteen tekemiä muutoksia.
ɤɨɬɨɪɨɦ ɨɧɢ ɛɵɥɢ ɜɜɟɞɟɧɵ ɜ ɷɤɫɩɥɭɚɬɚɰɢɸ; ɭɫɬɚɧɨɜɥɟɧɧɵɟ ɜɩɨɫɥɟɞɫɬɜɢɢ ɤɨɧɟɱɧɵɦ Sovelletut yhdenmukaistetut standardit, erityisesti DIN EN 809:2012
ɩɨɥɶɡɨɜɚɬɟɥɟɦ ɞɟɬɚɥɢ ɢ / ɢɥɢ ɩɪɟɞɩɪɢɧɹɬɵɟ ɜɦɟɲɚɬɟɥɶɫɬɜɚ ɧɟ ɭɱɢɬɵɜɚɸɬɫɹ. DIN EN ISO 12100:2011
ɉɪɢɦɟɧɟɧɧɵɟ ɝɚɪɦɨɧɢɡɢɪɨɜɚɧɧɵɟ ɧɨɪɦɵ (ɫɪɟɞɢ ɩɪɨɱɟɝɨ) DIN EN 809:2012 Sovelletut kansalliset tekniset standardit/spesifikaatiot, erityisesti tilausvahvistukset ja/tai tietolehdet.
DIN EN ISO 12100:2011
Torsten Pfennig
ɉɪɢɦɟɧɟɧɧɵɟ ɧɚɰɢɨɧɚɥɶɧɵɟ ɬɟɯɧɢɱɟɫɤɢɟ ɧɨɪɦɵ, ɫɩɟɰɢɮɢɤɚɰɢɢ, ɜ ɬ.ɱ. Laatuvarmistuksen johtaja, Osoite katso edeltä
ɩɨɞɬɜɟɪɠɞɟɧɢɹ ɡɚɤɚɡɚ ɢ/ɢɥɢ ɬɟɯ. ɩɚɫɩɨɪɬɚ. Yllä mainittu henkilö on valtuutettuna kokoamaan tekniset asiakirjat.
Torsten Pfennig
Ɂɚɜ. ɨɬɞɟɥɨɦ ɨɛɟɫɩɟɱɟɧɢɹ ɤɚɱɟɫɬɜɚ Ⱥɪɦɢɧ Ƚɪɨɰ, Ⱥɞɪɟɫ ɫɦ. ɜɵɲɟ
ɍɤɚɡɚɧɧɨɟ ɜɵɲɟ ɥɢɰɨ ɢɦɟɟɬ ɩɪɚɜɨ ɫɨɫɬɚɜɥɹɬɶ ɬɟɯɧɢɱɟɫɤɭɸ ɞɨɤɭɦɟɧɬɚɰɢɸ.

_FR_ _PT_
CE-Déclaration de conformité CE-Declaração de conformidade
conformément à la directive “CE“ relative aux machines 2006/42/CE, Annexe II; 1; A nos termos da directiva de máquinas CE 2006/42/CE, Anexo II; 1; A
Par la présente, nous déclarons, LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39, Declaramos por este meio, nós, a LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39,
90459 Nürnberg, Germany 90459 Nürnberg, Germany
que le/les system(s) pompage(s) Ref. Type No. de serie que as bombas (sistemas) Refª. Tipo Nº de série.
correspond de la directive CE machines, version 2006/42/CE. se encontram em conformidade com a Diretiva de Máquinas CE, versão 2006/42/CE.
Cette déclaration concerne exclusivement la machine/les machines dans l'état dans lequel Esta declaração aplica-se à máquina / máquinas no estado em que foi/foram colocada(s) no
elle(s) a (ont) été mise(s) sur le marché ; les composants ajoutés et/ou les interventions mercado; componentes instalados posteriormente pelo utilizador final ou intervenções pelo
réalisées ultérieurement par l'utilisateur final ne sont pas pris en compte. mesmo efetuadas não são considerados.
Normes harmonisées utilisées, notamment DIN EN 809:2012 Normas harmonizadas particularmente aplicadas DIN EN 809:2012
DIN EN ISO 12100:2011 DIN EN ISO 12100:2011
Normes harmonisée utilisées nationales et techniques, notamment confirmations de Normas técnicas nacionais aplicadas / Especificações, particularmente confirmações de
commande et / ou fiches techniques. ordens de compra e / ou folhas de dados técnicos.
Torsten Pfennig Torsten Pfennig
Directeur Assurance Qualité, Adresse voir ci-dessus Director da Garantia de Qualidade, Endereço, ver acima
La personne ci-dessus nommée est autorisée à établir la documentation technique. A pessoa supramencionada está autorizado a compilar a documentação técnica.

_ES_ _PL_
CE-Declaración de conformidad EC-Deklaracja zgodnoĞci
conforme a la Directiva Máquinas 2006/42/CE, Anexo II; 1; A wg 2006/42/EC, Aneks II; 1; A
Por la presente declaramos LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39, Niniejszym deklarujemy, LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39,
90459 Nürnberg, Germany 90459 Nürnberg, Germany
las bombas (grupos motobomba) Ref. Tipo Serie N°(s) Īe pompy (agregaty pompowe) zam. Typu nr seryjny
se corresponden, en la ejecución suministrada por nosotros, con las disposiciones de w dostarczonej przez nas wersji są zgodne z nową Dyrektywą Maszynową 2006/42/WE.
la versión 2006/42/CE de la Directiva de Máquinas de la Comunidad Europea. Niniejsza deklaracja dotyczy wyłącznie maszyny / maszyn w stanie, w którym została
Esta declaración se refiere únicamente a la máquina / las máquinas en el estado en el wprowadzona do obrotu; dodatkowo zainstalowane przez uĪytkownika koĔcowego
que fue puesta en servicio; quedan excluidas las piezas instaladas posteriormente y/o czĊĞci i / lub póĨniej dokonane zmiany w maszynie pozostają nieuwzglĊdnione.
las intervenciones realizadas con posterioridad por el usuario final. Zastosowane zharmonizowane standardy: DIN EN 809:2012
Normas armonizadas aplicadas, en particular DIN EN 809:2012 DIN EN ISO 12100:2011
DIN EN ISO 12100:2011 Zastosowano narodowe standardy techniczne / specyfikacje, w szcególnoĞci
Normas técnicas nacionales aplicadas / especificaciones, en particular las confirmaciones potwierdzenia zamówieĔ i / lub karty danych technicznych
de pedidos y / u hoja de características técnicas. Torsten Pfennig
Torsten Pfennig Directeur Assurance Qualité, Adres jak podano powyĪej
Director Aseguramiento de la Calidad, Dirección: véase más arriba WyĪej wymieniona osoba jest upowaĪniony do zestawienia dokumentacji technicznej.
La persona arriba mencionada esta apoderado a recopilar la documentación técnica.

_EL_ _NL_
ǻȒȜȦıȘ ıȣȝȝȩȡijȦıȘȢ ǼȀ EG-verklaring van overeenstemming
ıȪȝijȦȞĮ ȝİ IJȘȞ ȠįȘȖȓĮ IJȘȢ ǼȀ ʌİȡȓ ȝȘȤĮȞȫȞ 2006/42/EȀ, ʌĮȡȐȡIJȘȝĮ II, 1, A volgens de Machinerichtlijn 2006/42/EG, bijlage II; 1; A
Ȃİ IJȘȞ ʌĮȡȠȪıĮ įȘȜȫȞȠȣȝİ İȝİȓȢ, Ș İIJĮȚȡİȓĮ LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39, Hierbij verklaren wij, LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39,
90459 Nürnberg, īİȡȝĮȞȓĮ 90459 Nürnberg, Germany
ȩIJȚ ȠȚ ĮȞIJȜȓİȢ (IJĮ ıȣȖțȡȠIJȒȝĮIJĮ ĮȞIJȜȚȫȞ) IJȪʌȠȢ ĮȞĮij. ĮȡȚș. ıİȚȡȐȢ
dat de pompen (pompaggregaten) ref. type serienummer(s)
ıIJȘȞ ȑțįȠıȘ ʌȠȣ ȑȤȠȣȞ ʌĮȡĮįȠșİȓ Įʌȩ İȝȐȢ ıȣȝȝȠȡijȫȞȠȞIJĮȚ ȝİ IJȚȢ įȚĮIJȐȟİȚȢ
IJȘȢ ȠįȘȖȓĮȢ ʌİȡȓ ȝȘȤĮȞȘȝȐIJȦȞ IJȘȢ ǼȀ ıIJȘȞ ȑțįȠıȘ 2006/42/EȀ. in de door ons geleverde uitvoering in overeenstemming zijn met de bepalingen
van de Machinerichtlijn in de versie 2006/42/EG.
ǹȣIJȒ Ș įȒȜȦıȘ ĮijȠȡȐ ȝȩȞȠ IJȠ ȝȘȤȐȞȘȝĮ / IJĮ ȝȘȤĮȞȒȝĮIJĮ ıIJȘȞ țĮIJȐıIJĮıȘ
Deze verklaring betreft uitsluitend de machine/machines in de toestand waarin
ʌȠȣ IJȑșȘțİ / -ĮȞ ıİ țȣțȜȠijȠȡȓĮ. ȉİȝȐȤȚĮ ʌȠȣ ıȣȞĮȡȝȠȜȠȖȒșȘțĮȞ Įʌȩ IJȠȞ IJİȜȚțȩ ȤȡȒıIJȘ ȝİIJĮȖİȞȑıIJİȡĮ
zij in de handel zijn gebracht, met uitsluiting van de later door de eindgebruiker
țĮȚ / Ȓ İʌİȝȕȐıİȚȢ ʌȠȣ ȑȖȚȞĮȞ ȝİIJĮȖİȞȑıIJİȡĮ įİȞ ȜĮȝȕȐȞȠȞIJĮȚ ȣʌȩȥȘ. toegevoegde componenten en/of verrichte bewerkingen.
ǼijĮȡȝȠıȝȑȞĮ İȞĮȡȝȠȞȚıȝȑȞĮ ʌȡȩIJȣʌĮ ȚįȓȦȢ IJĮ DIN EN 809:2012 Gehanteerde geharmoniseerde normen, met name NEN-EN 809:2012
DIN EN ISO 12100:2011 NEN-EN-ISO 12100:2011
ǼijĮȡȝȠȗȩȝİȞĮ İșȞȚțȐ IJİȤȞȚțȐ ʌȡȩIJȣʌĮ / ʌȡȠįȚĮȖȡĮijȑȢ, ȚįȚĮȓIJİȡĮ
ȕİȕĮȚȫıİȚȢ İȞIJȠȜȫȞ țĮȚ / Ȓ ijȪȜȜĮ įİįȠȝȑȞȦȞ. Gehanteerde nationale technische normen/specificaties, met name
Torsten Pfennig orderbevestigingen en/of gegevensbladen.
ǻȚİȣșȣȞIJȒȢ ʌȠȚȠIJȚțȠȪ İȜȑȖȤȠȣ, ǻȚİȪșȣȞıȘ ȩʌȦȢ ʌĮȡĮʌȐȞȦ Torsten Pfennig
ȉȠ ĮȞȦIJȑȡȦ ʌȡȩıȦʌȠ İȓȞĮȚ İȟȠȣıȚȠįȠIJȘȝȑȞȠ ȞĮ ıȣȖțİȞIJȡȫıİȚ Hoofd kwaliteitsborging, adres zie boven
IJĮ IJİȤȞȚțȐ ȑȖȖȡĮijĮ. De bovengenoemde persoon is gemachtigd het technische
dossier samen te stellen.

_RO_ _SV_
DeclaraĠie de conformitate CE Försäkran om överensstämmelse
în sensul Directivei CE Echipamente tehnice 2006/42/CE, Anexa II; 1; A enligt EU-maskindirektiv 2006/42/EG, bilaga II; 1; A
Prin prezenta noi, LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39, Härmed förklarar vi, LEISTRITZ Pumpen GmbH, Markgrafenstrasse 29-39,
90459 Nürnberg, Germany 90459 Nürnberg, Tyskland
declarăm că pompele (agregatele de pompare) Ref. Tip Seria/seriile Nr./numerele att pumparna (-aggregaten) ref. typ serienr.
în varianta de execuĠie livrată de noi respectă Directiva CE Echipamente tehnice i det av oss levererade utförandet uppfyller bestämmelserna i
în versiunea acesteia 2006/42/CE. EU-maskindirektiv i version 2006/42/EG.
DeclaraĠia de faĠă se referă numai la maúina/maúinile în starea în care a/au fost Denna försäkran avser endast maskinen/maskinerna i det skick i vilket den/de
pusă/e în circulaĠie; piese ataúate ulterior de către utilizatorul final úi/sau levererades ut i handeln; genom slutanvändaren i efterhand påmonterade delar
intervenĠii ulterioare asupra echipamentului rămân neluate în seamă. och/eller i efterhand gjorda ingrepp beaktas ej.
Normele armonizate aplicate sunt în special DIN EN 809:2012 Tillämpade harmoniserade standarder, i synnerhet DIN EN 809:2012
DIN EN ISO 12100:2011 DIN EN ISO 12100:2011
Norme/specificaĠii tehnice naĠionale, îndeosebi Tillämpade nationella tekniska standarder/specifikationer, i synnerhet
confirmări de comandă úi /sau fiúe de date. orderbekräftelser och/eller datablad.
Torsten Pfennig Torsten Pfennig
ùeful SecĠiei CTC, adresa vezi mai sus Kvalitetssäkringschef, adress se ovan
Persoana susnumită este autorizată să întocmească documentaĠia tehnică. Ovannämnda person har befogenhet att sammanställa de tekniska
underlagen.

_SL_ _HU_
ES-Izjava o skladnosti EK megfelelĘségi nyilatkozat
v skladu z ES-direktivo o strojih 2006/42/ES, priloga II, 1, A a gépekre vonatkozó 2006/42/EC irányelv, II. függeléke; 1; A értelmében
S tem izjavljamo, LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39, Ezennel a LEISTRITZ Pumpen GmbH, Markgrafenstraße 29-39,
90459 Nürnberg, Nemþija 90459 Nürnberg, Németország kijelenti,
da so vse þrpalke (-agregati) ref. serijske številke tipa hogy a … referenciaszámú … típusú …. sorozatszámú szivattyúk (aggregátok)
v dostavljeni izvedbi skladne z doloþili ES direktive o strojih v razliþici 2006/42/ES. az általunk kiszállított változatban megfelelnek a gépekre vonatkozó irányelv
Ta izjava se nanaša le na stroj/stroje v stanju, ki je veljalo v trenutku prodaje. Deli, ki jih je kasneje nanesel konþni 2006/42/EC változatának.
uporabnik, in/ali naknadno izvedeni posegi niso upoštevani, A jelen nyilatkozat csak arra a gépre / a gépre abban az állapotában vonatkozik, amelyben forgalomba helyezték;
Uporabljene usklajene norme, zlasti: DIN EN 809:2012 a végfelhasználó által utólag rászerelt részek és/vagy utólag végrehajtott beavatkozások nem tartoznak bele.
DIN EN ISO 12100:2011 Alkalmazott harmonizált szabványok, fĘként DIN EN 809:2012
Uporabljene državne tehniþne norme/specifikacije, zlasti potrdilo o naroþilu in/ali podatkovni listi. DIN EN ISO 12100:2011
Torsten Pfennig Alkalmazott nemzeti mĦszaki szabványok / specifikációk, különösen
vodja zagotavljanja kakovosti, za naslov glej zgoraj. megrendelési visszaigazolások és/vagy adatlapok.
Zgoraj navedena oseba je pooblašþena za sestavo tehniþnih dokumentov. Torsten Pfennig
minĘségbiztosítási vezetĘ, a címeket lásd fent
A fent nevezett személyt meghatalmazzuk a mĦszaki dokumentáció összeállításával.

Nürnberg, den 05.11.2013

Betriebs- und Wartungsanleitung Operating- and maintenance instructions
Lagerung und Transport Storage and transport
Motoren gegen mechanische Beschädigung sichern und nur in The motors have to be protected against mechanical
geschlossenen, trockenen Räumen lagern. Bei kurzzeitiger damages and if possible they are to be stored in closed and
Lagerung im Freiluftbereich gegen schädliche Umwelteinflüsse dry rooms. In case of short-term outdoor storage they have
schützen. Motoren nicht auf der Lüfterhaube transportieren/ lagern. to be protected against all harmful influences. Never
Bei Transport drauf achten, dass die Motoren nicht beschädigt transport or store the motors on the fan cowl. During
werden. transportation the motors should be kept from any damage.

Montage – Übertragungselemente Mounting – transmission components

Beim Aufziehen eines Übertragungselementes unbedingt When pulling a transmission component onto the shaft it is
Aufziehvorrichtung benutzen oder das aufzuziehende Teil necessary to use a pull-on device or to warm up the
erwärmen. Auf keinen Fall Übertragungselemente auf die Welle component to be pulled on. To prevent shaft, bearings and
aufgeschlagen werden, da Welle, Lager und andere Teile des other parts from damages the transmission components
Motors dadurch beschädigt werden. must never be driven onto the shaft by hammer blows

Montage – Wuchten Mounting – balancing

Alle am Wellenende angebauten Teile sind sorgfältig dynamisch zu All components attached to the shaft end are to be balanced
wuchten. Die Läufer sind werkseitig mit halber Passfeder gewuchtet. dynamically. On the part of the manufacturer the rotors are
balanced with half key.
Montage – Aufstellen Mounting – installation
Motoren schwingungsfrei aufstellen. Bei Kupplung den Motor zu If possible, the motors are to be installed free from vibration.
angetriebenen Maschine genau ausrichten. Die Achsen beider In the case of direct coupling the motor is to be accurately
Maschinen müssen fluchten. Es dürfen keine Spannungen aligned to the driven machine. The axles of the machines
auftreten. must be in line and no stresses should occur.

Montage – Belüftung Mounting – ventilation

Belüftungsöffnungen und Kühlrippen freihalten und Vent holes and cooling fins are to be kept free and the
Mindestabstände einhalten. Erneutes Ansaugen der erwärmten required minimum distances must be observed. It is to be
Kühlluft vermeiden. Bei Freiluftaufstellung gegen unmittelbare avoided that the heated up cooling air is taken in again. In
Witterungseinflüsse (Regen, Schnee- und Eiseinfall, Festfrieren des case of outdoor-installation the motors have to be protected
Lüfters) schützen. against influences (rain, snow and ice, freezing of the fan)

Inbetriebnahme – Voraussetzungen Commissioning – prerequisites

• Alle Arbeiten nur von geschultem Fachpersonal im • All operations have to be carried out by skilled staff
spannungslosen Zustand durchführen with the motor in dead state
• Netzverhältnisse mit den Typenschildangaben vergleichen. • The power supply has to correspond with the name
Zulässige Spannungstoleranzen nach EN 60034-1 plate. Voltage tolerance in acc. with EN 60034-1
• Abmessungen der Anschlusskabel den Nennströmen des • The dimensions of the connection cables have to
Motors anpassen. be adapted to the rated motor currents.

Inbetriebnahme – Überlastschutz Commissioning – overload protection

Motoren bei direkter Einschaltung mit 3-poligem Motorschutzschalter In case of direct starting, the motors are to be provided with
versehen. Auch bei Stern/Dreieck-Anlauf ist ein Motorschutzschalter triple-pole protection switch. A protection is also needed for
empfehlenswert. Für Motoren mit Kaltleitertemperaturfühlern ist ein Delta/Star starting. For motors with PTC-thermistors a
Auslösegerät erforderlich. Bei Motoren mit Bi-Metall-Thermofühlern tripping device is required. For motors with bi-metal
wird empfohlen, den Motor bei Überlast über ein Schütz thermistors it is needed to switch off the motor with a
abzuschalten. contactor in case of overload.

Inbetriebnahme – Drehrichtung prüfen Commissioning – rotation direction

Drehrichtung vor dem Ankoppeln der Arbeitsmaschine überprüfen. The rotation direction is to be checked before coupling the
Die Drehrichtung ggf. durch Tauschen der Anschlüsse zweier machine. If necessary, the rotation direction can be altered
Phasen ändern. by changing the connections of two phases.

Inbetriebnahme – Klemmkasten Commissioning – terminal box

• Alle Klemmkastenanschlüsse auf festen Sitz prüfen • Check all terminal box connections are tightened
• Innenseite sauber und frei von Fremdkörpern • The inside is clean and free from particles
• Unbenutzte Kabeleinführungen verschlossen und • Unused cable entries are closed and threaded
Verschlussschrauben fest angezogen plugs are tightened
• Dichtung sauber einlegen; auf Beschaffenheit der • The packing in the terminal box lid is inserted
Dichtflächen der Gewährleistung der Schutzart achten correctly

Technische Änderungen und Irrtümer vorbehalten./Technical modifications reserved, errors excepted

Inbetriebnahme – Schalten des Motors Commissioning – switching the motor
Vor dem Einschalten, während des Betriebes und beim Before switching the motor on, during operation and when
Abschalten des Motors prüfen, ob alle Sicherheitsbestimmungen switching it off it should be checked whether all safety
eingehalten werden. Bei Inbetriebnahme Stromaufnahme unter regulations are followed. When switching the motor on the
Belastung beobachten um mögliche Überlastung sofort zu current under load should be observed to detect possible
erkennen. overloads.

Inbetriebnahme – Isolationswiderstand Commissioning – insulation

Als letzte Arbeit vor der Inbetriebnahme einer neuen Maschine Before starting a new motor and after long periods of inactivity
oder nach längerem Stillstand ist der Isolationswiderstand der or storage, the insulation resistance of the windings is to be
Wicklungen zu prüfen. Dieser sollte bei einer Temperatur von measured. The resistance should be higher than 5MΩ at 25°C
25°C höher als 5M Ω sein. Ergibt die Messung nicht den Wert, liegt ambient temperature.
dies daran, dass sich Feuchtigkeit in den Wicklungen befindet. If this value cannot be obtained, the winding is damp and must
Das Trocknen der Wicklung sollte in einer dafür eingerichteten be dried out.
Werkstatt durchgeführt werden.

Wartung Maintenance
Der Motor und eventuelle Zubehörteile sollten sauber gehalten The motor as well as possible accessories should always be
werden, sodass kein Staub, Schmutz, Öl oder sonstige kept clean, free from dust trace, oil or other grime
Verunreinigung den einwandfreien Betrieb stören können.
Es wird außerdem empfohlen: - The motor operates without any vibrations or
- Ob der Motor ohne Schwingungen oder anormale anomalous noises
Geräuschentwicklung läuft. - The tension of a possible driving belt is correct
- Dass die Zugspannung des möglicherweise eingesetzten - The inlet of the ventilations circuits is not obscured
Treibriemens korrekt eingestellt ist causing overheating of the windings
- Dass die Öffnungen für die Kühlluftzufuhr nicht zugestellt
oder verengt sind.

Kugellager Bearings
Alle Motoren sind mit hochwertigen, lebensdauergeschmierten All motors are fitted with high-quality, lifetime-lubricated
Kugellagern der Hersteller FAG, SKF, INA, NSK oder bearings from the manufacturer FAG, SKF, INA, NSK or NTN.
NTN ausgerüstet. Die nominelle Lagerlebensdauer in waagerechter The nominal rating life of the bearings used in horizontal
Bauform beträgt bei Kupplungsbetrieb mounted motors without any axial load is 40.000 operating
ohne axiale Zusatzlasten mind. 40.000 Betriebsstunden. Unter hours, for power take-off via shaft-coupling. Under the use of
Ausnutzung der max. Belastung beträgt die Lebensdauer mind. maximal load the lifetime of the bearings is min. 20.000
20.000h operating hours.
Ab Baugröße 315 sind die Motoren mit offenen Lagern und From framesize 315 all motors have open bearings and
Nachschmiereinrichtung ausgestattet. Die Nachschmierfristen lubrication devices.
sind diesem Katalog zu entnehmen. The lubrication intervals are in this catalogue.

Baugröße A-Seite B-Seite Size Driving end Non-driving end

2-polig 4;6;8-polig 2-polig 4;6;8-polig 2-pole 4;6;8-pole 2-pole 4;6;8-pole
ACA 56 6201.ZZ.C3 6201.ZZ.C3 ACA 56 6201.ZZ.C3 6201.ZZ.C3
ACA 63 6201.ZZ.C3 6201.ZZ.C3 ACA 63 6201.ZZ.C3 6201.ZZ.C3
ACA 71 6202.ZZ.C3 6202.ZZ.C3 ACA 71 6202.ZZ.C3 6202.ZZ.C3
ACA 80 6204.ZZ.C3 6204.ZZ.C3 ACA 80 6204.ZZ.C3 6204.ZZ.C3
ACA 90 6205.ZZ.C3 6205.ZZ.C3 ACA 90 6205.ZZ.C3 6205.ZZ.C3
ACA 100 6206.ZZ.C3 6206.ZZ.C3 ACA 100 6206.ZZ.C3 6206.ZZ.C3
ACA 112 6306.ZZ.C3 6306.ZZ.C3 ACA 112 6306.ZZ.C3 6306.ZZ.C3
ACA 132 6308.ZZ.C3 6308.ZZ.C3 ACA 132 6308.ZZ.C3 6308.ZZ.C3
ACM 160 6309.ZZ.C3 6309.ZZ.C3 ACM 160 6309.ZZ.C3 6309.ZZ.C3
ACM 180 6311.ZZ.C3 6311.ZZ.C3 ACM 180 6311.ZZ.C3 6311.ZZ.C3
ACM 200 6312.ZZ.C3 6312.ZZ.C3 ACM 200 6312.ZZ.C3 6312.ZZ.C3
ACM 225 6313.ZZ.C3 6313.ZZ.C3 ACM 225 6313.ZZ.C3 6313.ZZ.C3
ACM 250 6314.ZZ.C3 6314.ZZ.C3 ACM 250 6314.ZZ.C3 6314.ZZ.C3
6314.ZZ. 6317.ZZ. 6314.ZZ. 6317.ZZ. 6314.ZZ. 6317.ZZ. 6314.ZZ. 6317.ZZ.
ACM 280 ACM 280
C3 C3 C3 C3 C3 C3 C3 C3
ACM 315 6317.C3 6319.C3 6317.C3 6319.C3 ACM 315 6317.C3 6319.C3 6317.C3 6319.C3
ACM 355 6319.C3 6322.C3 6319.C3 6322.C3 ACM 355 6319.C3 6322.C3 6319.C3 6322.C3
ACM 400 6320.C3 6324.C3 6320.C3 6324.C3 ACM 400 6320.C3 6324.C3 6320.C3 6324.C3
ACM 450 6322.C3 6326.C3 6322.C3 6326.C3 ACM 450 6322.C3 6326.C3 6322.C3 6326.C3

Technische Änderungen und Irrtümer vorbehalten./Technical modifications reserved, errors excepted

Schaltbilder / wiring diagram

Dreieckschaltung:
Delta-connection:

Sternschaltung:
Star-connection:

Schaltbilder für polumschaltbare Motoren /

Wiring diagram for speed switchable motors

niedrige Geschwindigkeit: niedrige Geschwindigkeit:

(Dahlander) (getrennte Wicklung)
low speed: low speed:

Hohe Geschwindigkeit: Hohe Geschwindigkeit:

(Dahlander) (getrennte Wicklung)
High speed: High speed:

Technische Änderungen und Irrtümer vorbehalten./Technical modifications reserved, errors excepted

Nachschmierintervalle / lubrication intervals

Schmierfett / Grease: ESSO BEACON 3 / SKF LGMT3

Lagertyp 2 polig 4 polig 6 polig 8 polig Fettmenge in Gramm

Bearing type 2-poles 4-poles 6-poles 8-poles Grease in grs.

6312.C3 1400 4000 6000 8000 20
6313.C3 1200 4000 6000 8000 23
6314.C3 1100 3300 5500 7700 26
6316.C3 800 2800 4900 7000 33
6317.C3 650 2600 4600 6600 37
6319.C3 / 2300 4200 6100 45
6320.C3 / 2100 3900 5800 51
6322.C3 / 1700 3500 5300 60
NU 317 / 1300 2300 3300 37
NU 319 / 1100 2000 3000 45
NU 320 / 1000 1900 2900 51
NU 322 / 890 1700 2600 60

Ab Baugröße 315 sind alle Motoren mit offenen Lagern und Nachschmiereinrichtung ausgerüstet.
Motoren kleinerer Baugrößen sind auf Kundenwunsch mit Nachschmiereinrichtung erhältlich.
Die Nachschmierfristen sind aus der oben stehenden Tabelle zu entnehmen.

Technische Änderungen und Irrtümer vorbehalten./Technical modifications reserved, errors excepted

 Back-Flushing-Filter C5.05.08.12.03.19
Automatic

Back-Flushing-Filter

Automatic

en / 13.07.2005 FD029768 1/30

 DESCRIPTION AND OPERATING INSTRUCTIONS
FOR BACK-FLUSHING FILTER TYPE 6.46

Order No.

LIST OF CONTENTS
1. Type sheet
2. General notes on the automatic filter
3. Installation of the filter
Installation drawings Z39347 + Z39349
4. Commissioning
5. Filtration phase
Filtration phase Z39293 sheet 1
6. Back-flushing phase
Back-flushing phase Z39293 sheet 2
7. Functioning of the overflow valves
Overflow valves Z39293 sheet 3
8. Maintenance
9. Filter candle inspection and cleaning
10. Technical information BOLL CLEAN 2000
11. Sources of faults and their remedy
12. Spare parts drawing for type 6.46
13. Spare parts list for type 6.46
14. Type sheet differential pressure contact indicator
15. Spare parts drawing for the differential pressure indicator

BOLL & KIRCH assumes no liability for any mistakes by improper use of the product.
We reserve the right to change this description without prior notice!
2. General notes on the automatic filter

The back-flushing Filter type 6.46 satisfies the safety standard

for ships' main propulsion units. It is registered by GL, LRS
and other ship classification bodies.

The back-flushing filter type 6.46 is suitable for filtering oils with a viscosity of max.
50 cSt. and an operating pressure of min. 3 bar to max. 10 bar.

The filter works with permanent back-flushing using its own process fluid; the back-
flushed fluid is fed back into the circulation tank or the oil trough again.

No external power is required to operate the automatic filter.

The function of the automatic filter is to protect the bearings, journals and shafts in
the engine from noxious impurities in the oil.

Treating the lubricating oil, i.e. removing the solids discharge, is carried out by a
separator, a centrifuge, a bypass filter or the attached flushing oil treatment unit.

The filter can be mounted both vertically and horizontally directly on the engine or
on the base frame.

In order to satisfy the different requirements of the engine manufacturers, the filter
type 6.46 can be combined with a wide variety of engine attachments.
The filter type 6.46 mainly consists of the following:

- the housing with the inlet and outlet flanges

- the filter element with the appropriate number of filter candles, depending on the
nominal width
- the excess pressure safety devices
- the downstream second filter stage [protective filter (8)]
- the entire flushing facility
- the gear unit including drive turbine.
3. Installation of the filter

Care must be taken during installation of the filter to ensure that clean pipes are
connected to the filter inlet and the filter outlet without any strain.
The inlet and outlet of the filter are marked.
The flushing oil line is to be at least as large as specified in the information sheet.
This line is to be laid without any shut-off device but with a gradient and vented to
prevent any build-up in the pipe.

The potential-free contacts of the differential pressure indicator (24) installed (see
"Differential pressure indicator, section 14) must be wired to monitor the degree of
contamination of the filter elements (7) and the protective filter (8).

The filter housings are only designed for internal overpressure in

accordance with the AD Information Sheets. Additional external
forces and moments at the filter connection flanges are to be
avoided (possibly by supporting the supply lines).

When installing the filters, make sure that any oil or fuel which
leaks due to improper handling cannot result in a fire or injury.
 Z39347
TYP6.46
26.10.99

ZUM VERBRAUCHER
TO CONSUMER
VERS LE RECEPTEUR NORMALER LIEFERUMFANG
NORMAL SUPPLY
LIVRAISON NORMALE

AUTOMATIKFILTER
AUTOMATIC FILTER
FILTRE AUTOMATIQUE

SPUELOELLEITUNG MIT GEFAELLE

GEGENDRUCKLOS VERLEGT
DRAIN LINE WITH
DOWNWARD SLOPE
TUYEAU DE VIDANGE AVEC
PENTE SANS CONTRE PRESSION

PUMPE
PUMP
POMPE

SCHMIEROELTANK
LUBE OIL TANK
TANK D'HUILE DE LUBRICATION

SEPARATOR
SEPARATOR
SEPARATEUR

SCHEMA INSTALLATION EINBAUSCHEMA ZUM TYP 6.46 SCHEME D` INSTALLATION

MIT SEPARATOR
 Z39349
TYP6.46
26.10.99

ZUM VERBRAUCHER
TO CONSUMER
VERS LE RECEPTEUR
NORMALER LIEFERUMFANG
NORMAL SUPPLY
LIVRAISON NORMALE

AUTOMATIKFILTER
AUTOMATIC FILTER
FILTRE AUTOMATIQUE

SPUELOELLEITUNG MIT GEFAELLE

GEGENDRUCKLOS VERLEGT
DRAIN LINE WITH
DOWNWARD SLOPE
TUYEAU DE VIDANGE AVEC
PENTE SANS CONTRE PRESSION

FREISTRAHLZENTRIFUGE
CENTRIFUGE
CENTRIFUGE

PUMPE
PUMP
POMPE

SCHMIEROELTANK
LUBE OIL TANK
TANK D'HUILE DE LUBRICATION

SCHEMA INSTALLATION EINBAUSCHEMA ZUM TYP 6.46 SCHEME D` INSTALLATION

MIT FREISTRAHLZENTRIFUGE
4. Commissioning

4.1 Check to see whether all connections have been made properly.

4.2 Check to see whether the ball cocks in the control line to the differential pressure
indicator are open.

4.3 The following must be observed before switching on the pump:

- Close shut-off device in the bypass line
- Open shut-off device at the filter outlet
- Only partially open the shut-off device at the filter inlet and, after switching
on the pump (to prevent pressure surges), slowly open it fully.

4.4 If the pressure downstream of the filter is less than 2 bar, the shut-off device
downstream of the filter is to be regulated until the appropriate operating pressure
has built up.

4.5 The rotary motion of the flushing facility can now be seen at the visible shaft end in
the filter cover.

If there is an inadmissible rise in the differential pressure during

commissioning (with new plants poss. greater initial
contamination) in spite of perfect back-flushing, a signal is
emitted via the differential pressure indicator. The Filter must be
taken out of service (open the bypass line and close the shut-off
devices on the Filter). Dismantle the Filter element completely
and clean the Filter candles individually (oberserve section 9
"Filter candle inspection and cleaning").
5. Filtration phase
(see drawing Z39293 sheet 1 or Z101308 sheet 1 )

The fluid to be filtered passes through the inlet flange and turbine (14) to the
bottom end of the filter candles (7); a partial stream of about 50% is passed
through the central connection tube (4) to the top end of the filter candles (7). This
means that the fluid flows through the filter candles (7) at both ends from the inside
outwards and most of the dirt particles are retained in the inside of the filter candles
(7).
The fluid filtered in this way now passes through the protective filter (8) to the filter
outlet.
 Z39293BL.1
TYP6.46
09.05.96
4 9

14

FILTRATIONSPHASE
TYP 6.46 FILTRATION-PHASE
PHASE DE FILTRATION
6. Back-flushing phase
(see drawing Z39293 sheet 2 or Z101308 sheet 2)

The back-flushing filter type 6.46 operates as a continuous flushing filter and
does not require any external power to drive the back-flushing facility.

The flow energy drives the turbine (14) installed in the inlet flange. The high speed
of the turbine (14) is reduced by the worm gear unit (13) and gear (15) to the lower
speed required for turning the flushing arm (3).

The individual filter candles (7) are now connected successively to the atmosphere
by means of the continuously rotating flushing arm (3), the flushing bush (17) and
nozzle (21).

The pressure gradient thus produced (operating pressure to atmosphere)

results in an extremely efficient cleaning action.

The unfiltered fluid passes through the optimally designed bores of the top cover
plate (9) into the individual filter candles (7) from above. The resultant turbulent
stream in the longitudinal direction of the filter candles (7) (cross-flow back-flushing)
and the counter-flow back-flushing through the filter candles (7) result in a
particularly effective and lasting back-flushing action.

Counter flow back-flushing:

The lower pressure in the interior of the filter candles (7)
during the back-flushing operation (connected with the
atmosphere) and the higher pressure (operating pressure)
outside the filter candles (7) produce a counter-flow through
the mesh from the clean filter side through the dirty filter side
to the atmosphere.

This newly developed cross-flow back-flushing feature in conjunction with

the time-tested counter-flow back-flushing principle means that the pressure
drop at the filter remains constant for a longer period.
 Z39293BL.2
TYP6.46
09.05.96
9

15

13
14
17

21
RUECKSPUELPHASE
TYP 6.46 BACK-FLUSHING-PHASE
PHASE DE DECOLMATAGE PAR CONTRE-COURANT
7. Functioning of the overflow valves
(see drawing Z39293 sheet 3 or Z101308 sheet 3)

Should for any reason the filter candles (7) (first filter stage) no longer be
adequately cleaned, the overflow valves (19) are opened at a differential pressure
of 2 bar upwards and some of the fluid is filtered through the protective filter (8)
(second filter stage).

However, before this situation arises, the installed differential pressure indicator
(24) emits a differential pressure warning (first contact). The cause must now be
localised and remedied.

If this warning is not heeded, an alarm is emitted by the second contact of the
differential pressure indicator (24).

The filter may only be operated in this emergency condition for

a short time (opened overflow valves and differential pressure
warning). Prolonged operation in this mode can result in
damage to downstream components.

The overflow valves are closed under normal operating conditions, even
during start-up at lower fluid temperatures.
 Z39293BL.3
TYP6.46
09.05.96

24

19

WIRKUNGSWEISE UEBERSTROEMVENTIL
TYP 6.46 FUNCTION SPILL VALVE
FONCTIONNEMENT SOUPAPES ANTIREFOULEUSES
8. Maintenance

Section 9 - Filter candle inspection and cleaning - must also be observed.

Even with automatic filters inspections and maintenance must be performed at

regular intervals.
It is extremely important to remember that in spite of constant back-flushing the
mesh may become clogged over the course of time, depending on the quality of the
fluid and whether a bypass treatment unit installed.

In order to maintain trouble-free operation, the following aspects are to be observed

during maintenance:

8.1 The filter must be switched off for all maintenance work.

8.2 Check filter and connections for leaks.

8.3 Conduct visual inspection of all filter candles (7) once a year.

Should a higher differential pressure occur beforehand, all the

filter candles (7) and the protective filter (8) must be checked
and, if necessary, cleaned.
Observe section 9 "filter candle inspection and cleaning".

A highly contaminated protective filter (8) is a sign of

prolonged operation with defective or clogged filter candles (7)
and thus (from a differential pressure of 2 bar upwards)
opened overflow valves (19).
It is imperative to check these components.
8.4 Check the ease of movement of the worm gear unit (13), the turbine (14)
including gear (15) with flushing arm (3).

To this end the cover (34) or the screw plug (34) must be removed. Now check
the ease of movement with a suitable spanner (on the hexagon of the worm
gear unit).
If movement is sluggish, refer to section "Sources of faults and their remedy".

8.5 Replace the dyn. loaded seals (66) as and when required.
It is advisable to replace all static seals during an overhaul.
9. Filter candle inspection and cleaning
(see drawing Z39293 sheet 2 or Z101308 sheet 2)

9.1 Open bypass line.

9.2 Close shut-off devices at the filter inlet and outlet.
9.3 Now drain the filter from the drain screw.
9.4 Pull the entire filter element incl. flushing arm (3) and gear (15) out of the
housing.

Make sure that the exposed gear (15) is not damaged.

9.5 Remove the upper cover plate (9).

9.6 The filter candles (7) can now be pushed out from below or pulled out from
above.
9.7 Place the filter candles (7) in the cold cleaner BOLL CLEAN 2000, max.
soaking time 24 hours.
9.8 After immersing the filter candles (7), clean them from the outside inwards
using high pressure.

It must be ensured that the filter candles are cleaned at a

pressure of max. 60 bar and at a minimum distance of the
cleaning nozzle of 20 cm. Otherwise, damage to the mesh is
possible.

In our experience it is only possible to achieve an almost 100

% cleaning effect by hand with the high-pressure cleaning unit
type 5.04 using BOLL CLEAN 2000.
Refer to the separate description "Filter cleaning unit type
5.04".
 9.9 If operating an engine on heavy fuel

If operating on heavy fuel, the filter elements must be

checked after 2 years at the latest and any damaged ones
must be replaced.
We recommend the general replacement of all filter elements
after 4 years.

If operating an engine on diesel oil

If operating on diesel oil, the filter elements must be checked

after 4 years at the latest and any damaged ones must be
replaced.
We recommend the general replacement of all filter elements
after 6 years.

Defective filter candles (7) must not be used again.

Before installation of the entire filter element, the ease of

motion of the flushing facility must be checked.
The flushing arm (3) must not grind against the bottom filter
plate (5).

9.10 Now push the entire filter element into the housing.
By slightly turning the flushing shaft (10), the gear (15) is forced into the
drive pinion of the gear unit (13).

Now re-assemble the filter in the reverse sequence to that described

under points 9.1 - 9.9.
10. Technical information BOLL CLEAN 2000
Solvent-free cold cleaner

Product description
BOLL CLEAN 2000 is a liquid cleaning and degreasing agent for a wide range of
applications. It can be used for virtually all cleaning and degreasing work.
BOLL CLEAN 2000 is miscible with any water - even sea water.
BOLL CLEAN 2000 cleans quickly and thoroughly and is extremely economical.
Even mixed with water in concentration ranges of 1:50, it exhibits good cleaning
and degreasing properties. When BOLL CLEAN 2000 is used, no safety
precautions are needed. BOLL CLEAN 2000 exhibits these outstanding properties
without having the disadvantages of solvent cleaners.
BOLL CLEAN 2000 is non-flammable
does not need to be identified
does not have a pungent smell
is a non-irritant
is physiologically safe
is biodegradable
Federal Office of the Environment Reg. No. 04860019
BOLL CLEAN 2000 can become cold or hot during storage but can be readily used
again at normal temperature.

Field of application
BOLL CLEAN 2000 is suitable for cleaning and degreasing all metals, plastics,
highly adhesive paints etc. It removes oil, wax, grease, rust and numerous other
kinds of dirt.
BOLL CLEAN 2000 is used, for example, in the automobile, engine, aviation, oil (for
drilling equipment), food and drinks, and metalworking industries, in overhauling
and machine workshops, shipping, diesel and electric locomotives, and in electricity
works for cleaning the generators.
Mesh contaminated with heavy oil
Filters contaminated with heavy oil must be soaked in a commercially available
solvent. After being soaked, the filters are cleaned in the BOLL & KIRCH cleaning
unit type 5.04 with BOLL CLEAN 2000 and a high-pressure pump.

Instructions for use

The use of BOLL CLEAN 2000 does not involve any specific cleaning method.
BOLL CLEAN 2000 can be employed in an immersion bath, in a spraying plant, in a
steam jet cleaner or using a manual application process with a cloth, brush or
sponge, depending on the circumstances.
It can be used either cold or warm.
BOLL CLEAN 2000 is miscible with water - even sea water.
Concentration for cleaning mesh: 1:2.5
Temperature: up to max. 60°C
The concentration depends on the type and thickness of the adhering material to
be removed. When used in a concentration of 1:30 and more, rinsing is not
necessary. No visible film remains on the surface.
11. Sources of faults and their remedy

Fault Cause Reasons and remedy

Viscosity too high Wait for normal operating

conditions
High volume of dirt Check bypass treatment unit for
operability
Filter candles clogged Clean candles
Flushing volume too low Check flow control device in outlet
and sludge discharge line for
clogging
Shaft end does not turn Turbine jammed
Remove parts jammed between
turbine and wall
∆p rises — Gear unit defective
Check for ease of movement
(as per section 8 "Maintenance")
Replace gear unit if necessary
Flushing arm (3) jammed, Remove
any foreign matter
Operating pressure < 2 bar
Run for prolonged period at higher
pressure 5-6 bar and thus eliminate
the blockage
Oil quantity too low / Increase oil
quantity
UNTERLAGE VERS STUECKLISTE DATUM BLATT
LIST-NO PARTS-LIST DATE PAGE

19032 03 14.10.02 1

ZPOS IDENTNR BENENNUNG-NENNMASS-NORM MENGE ME

IDENTITY DESIGNATION-DIMENSIONS-STANDARD QUANTITY ME

0000 0629032 6.46 NW100 RUECKSP. 19032 03 1.000 ST

BACK FLUSHING FILTER
................................................................................
ZUSAMMENSTELLUNG : Z42558
ASSEMBLY DRAWING
MASSBLATT : TYP6.46
DIMENSION PAGE
AUSLEGUNGSUEBERDRUCK: 10 BAR / 100 GRD C
DESIGN PRESSURE

.
................................................................................
********************
................................................................................
0001 6521234 GEHAEUSE 1.000 ST
HOUSING
................................................................................
0002 6020214 DECKEL 1.000 ST
COVER
................................................................................
0003 6552600 SPUELARM 1.000 ST
FLUSHING CANAL
................................................................................
0003 2007222 VERSCHLUSSCHRAUBE 2.000 ST
SCREW
................................................................................
0004 5151253 VERBINDUNGSROHR 1.000 ST
JOINING TUBE
................................................................................
0005 5250045 SIEBPLATTE (UNTEN) 1.000 ST
SIEVE PLATE
................................................................................
0006 5250046 SIEBPLATTE (OBEN) 1.000 ST
SIEVE PLATE
................................................................................
0007 1365425 FILTERKERZE 78.000 ST
FILTER ELEMENT
................................................................................
0008 5709912 SCHUTZSIEB 1.000 ST
SIEVE
................................................................................
0008 7108805 LOCHBLECHZUSCHNITT 1.000 ST
PERFORATED PLATE
................................................................................
0009 5107505 ABDECKPLATTE 1.000 ST
PLATE
................................................................................
0010 5309685 SPUELARMWELLE 1.000 ST
FLUSHING CANAL SHAFT
................................................................................
/ 2
UNTERLAGE VERS STUECKLISTE DATUM BLATT
LIST-NO PARTS-LIST DATE PAGE

19032 03 14.10.02 2

ZPOS IDENTNR BENENNUNG-NENNMASS-NORM MENGE ME

IDENTITY DESIGNATION-DIMENSIONS-STANDARD QUANTITY ME

0011 6853849 TURBINENGEHAEUSE 1.000 ST

TURBINE HOUSING
................................................................................
0012 5301235 FLANSCHBEFESTIGUNG 1.000 ST
FLANGE FASTENING
................................................................................
0013 2709131 SCHNECKENGETR.KURZ A 1.000 ST
GEAR
................................................................................
0014 2784402 FLUEGEL MIT NABE 1.000 ST
TURBINE WING WITH WH
................................................................................
0015 2705519 ZAHNRAD 1.000 ST
TOOTHED WHEEL
................................................................................
0016 5300723 BEFESTIGUNGSBUCHSE 1.000 ST
BUSH
................................................................................
0017 5060722 SPUELBUCHSE 1.000 ST
BUSH
................................................................................
0018 0209130 UEBERSTROEMVENTIL 6.46 D=34 19130 6.000 ST
VALVE
................................................................................
0021 5003166 DUESE 1.000 ST
NOZZLE
................................................................................
0022 2310058 DRUCKFEDER 1.000 ST
PRESSURE SPRING
................................................................................
0023 2703599 RILLENKUGELLAGER 2.000 ST
DEEP GROOVE BALL BEA
................................................................................
0024 0550001 4.36.2 P = 0.8 DDA 09322 08 1.000 ST
PRESSURE DIFFERENT.CONTACT INDICATOR
................................................................................
0025 2000257 ZYL.-SCHRAUBE 1.000 ST
SLOTTED CHEESE HEAD
................................................................................
0026 2301130 STECKKERBSTIFT 1.000 ST
PIN
................................................................................
0027 2300010 SPANNSTIFT 3.000 ST
SPRING TYPE STRAIGHT
................................................................................
0028 2560063 WINKELKUGELHAHN 2.000 ST
ANGLE BALL COCK
................................................................................
0029 2806480 VKT.GEGENFL. 2.000 ST
FLANGE
................................................................................
/ 3
UNTERLAGE VERS STUECKLISTE DATUM BLATT
LIST-NO PARTS-LIST DATE PAGE

19032 03 14.10.02 3

ZPOS IDENTNR BENENNUNG-NENNMASS-NORM MENGE ME

IDENTITY DESIGNATION-DIMENSIONS-STANDARD QUANTITY ME

0030 2009088 STIFTSCHRAUBE 8.000 ST

STUD BOLT
................................................................................
0031 2100007 SECHSKANTMUTTER 8.000 ST
HEXAGON NUT
................................................................................
0032 2009088 STIFTSCHRAUBE 8.000 ST
STUD BOLT
................................................................................
0033 2100007 SECHSKANTMUTTER 8.000 ST
HEXAGON NUT
................................................................................
0034 6402865 DECKEL 1.000 ST
COVER
................................................................................
0035 2000187 VERSCHLUSSCHRAUBE 5.000 ST
HEXAGON HEAD SCREW P
................................................................................
0036 2000155 ZYL.-SCHRAUBE 4.000 ST
HEXAGON SOCKET HEAD
................................................................................
0037 2000142 ZYL.-SCHRAUBE 6.000 ST
SLOTTED CHESSE HEAD
................................................................................
0038 2000130 ZYL.-SCHRAUBE 3.000 ST
SLOTTED CHESSE HEAD
................................................................................
0039 2000130 ZYL.-SCHRAUBE 3.000 ST
SLOTTED CHESSE HEAD
................................................................................
0040 2000197 ZYL.-SCHRAUBE 1.000 ST
HEXAGON SOCKET HEAD
................................................................................
0041 2003658 STIFTSCHRAUBE 1.000 ST
BOLT
................................................................................
0042 2000122 ZYL.-SCHRAUBE 2.000 ST
HEXAGON SOCKET HEAD
................................................................................
0043 2000154 ZYL.-SCHRAUBE 4.000 ST
HEXAGON SOCKET HEAD
................................................................................
0044 2000121 ZYL.-SCHRAUBE 2.000 ST
HEXAGON SOCKET HEAD
................................................................................
0045 2000121 ZYL.-SCHRAUBE 3.000 ST
HEXAGON SOCKET HEAD
................................................................................
0046 2200235 FEDERRING 3.000 ST
SPRING RING
................................................................................
/ 4
UNTERLAGE VERS STUECKLISTE DATUM BLATT
LIST-NO PARTS-LIST DATE PAGE

19032 03 14.10.02 4

ZPOS IDENTNR BENENNUNG-NENNMASS-NORM MENGE ME

IDENTITY DESIGNATION-DIMENSIONS-STANDARD QUANTITY ME

0047 5008712 SCHEIBE 1.000 ST

DISC
................................................................................
0048 2200007 SCHEIBE 1.000 ST
WASHER
................................................................................
0049 2200008 SCHEIBE 4.000 ST
WASHER
................................................................................
0050 2008438 SECHSKANTSCHRAUBE 4.000 ST
HEXAGON SCREW
................................................................................
0051 6024502 BODENBEF. 1.000 ST
BOTTOM FASTENING
................................................................................
0052 5708316 BEFESTIGUNGSBLECH 1.000 ST
PLATE
................................................................................
0053 2000122 ZYL.-SCHRAUBE 2.000 ST
HEXAGON SOCKET HEAD
................................................................................
0054 2100003 SECHSKANTMUTTER 2.000 ST
HEXAGON NUT
................................................................................
0055 2500024 VERSCHRAUB. 2.000 ST
SCREWING
................................................................................
0056 2500025 VERSCHRAUB. 2.000 ST
SCREWING
................................................................................
0057 7300002 PRAEZ.-ROHR NBK 1.000 M
TUBE
................................................................................
0060 3040136 O-RING 1.000 ST
GASKET
................................................................................
0061 3040018 O-RING 1.000 ST
GASKET
................................................................................
0062 3041700 O-RING 2.000 ST
GASKET
................................................................................
0063 3049400 O-RING 156.000 ST
GASKET
................................................................................
0064 3040115 O-RING 1.000 ST
GASKET
................................................................................
0065 3031743 O-RING 1.000 ST
GASKET
................................................................................
/ 5
UNTERLAGE VERS STUECKLISTE DATUM BLATT
LIST-NO PARTS-LIST DATE PAGE

19032 03 14.10.02 5

ZPOS IDENTNR BENENNUNG-NENNMASS-NORM MENGE ME

IDENTITY DESIGNATION-DIMENSIONS-STANDARD QUANTITY ME

0066 3040115 O-RING 1.000 ST

GASKET
................................................................................
0067 3382321 HOCHDRUCKDICH. 2.000 ST
GASKET
................................................................................
0068 3041106 O-RING 1.000 ST
GASKET
................................................................................
0069 3270002 DICHTRING 5.000 ST
GASKET
................................................................................
0070 3332814 FLACHDICHTUNG 1.000 ST
GASKET
................................................................................
0071 3048235 O-RING 1.000 ST
GASKET
................................................................................
0075 2209799 FEDERRING 3.000 ST
SPRING RING
................................................................................
0076 2000122 ZYL.-SCHRAUBE 3.000 ST
HEXAGON SOCKET HEAD
................................................................................
0077 2100047 SECHSKANTMUTTER 1.000 ST
HEXAGON NUT
................................................................................
0079 2000115 ZYL.-SCHRAUBE 1.000 ST
HEXAGON SOCKET HEAD
................................................................................
0080 9400997 SCHILD "EIN/IN 1.000 ST
LABEL " IN "
................................................................................
0080 9407569 SCHILD "AUS/OU 1.000 ST
LABEL " OUT "
................................................................................
0080 9402913 TYPENSCHILD WN26 1.000 ST
NAME PLATE
................................................................................
0081 3529686 ANZEIGEBUCHSE 1.000 ST
INDICATION BUSH
................................................................................
0082 5209684 SPANNRING 1.000 ST
TENSION RING
................................................................................
0083 4707080 SCHAUGLAS 1.000 ST
INSPECTION GLAS
................................................................................
0085 2311117 WELLENFEDER 1.000 ST
SPRING
................................................................................
 Z45550
TYP4.36.2
01.01.00

G1/4
- +

G1/4
PG13.5

CIRCUIT DIAGRAM
1 1a

P1 P2
SPECIFICATION:
PROTECTION CLASS: IP 65 2 3a 3

ELECTR. DATA: SWITCHING VOLTAGE V= MAX.= 250 220

FREQUENCY HZ MAX.= 0-60 0-60
SWITCHING CURRENT A MAX.= 1 0.8
MAKING AND/OR BREAKING CAPACITY
W/VA MAX.= 60/60 40/60
MATERIAL : GD - ALUMINIUM
RATING : MAX. PRESSURE 100 BAR
MAX. TEMPERATURE 150°C

RANGES OF PRESSURE DIFFERENTIAL: DELTA P = 0 - 0.5 BAR

0 - 0.8 BAR
0 - 1.2 BAR TO BE SPECIFIED WHEN ORDERING
0 - 2.0 BAR
0 - 3.0 BAR
DESCRIPTION:
THE PURPOSE OF THIS DEVICE IS THE MEASUREMENT, AND VISUAL INDICATION OF THE DIFFERENCE IN
PRESSURE BETWEEN TWO POINTS, AND THE ESTABLISHMENT OF AN ELECTRICAL CONTACT WHEN THE
PRESSURE DIFFERENTIAL ATTAINS A SPECIFIED FIGURE.

METHOD OF OPERATION:
A PLUNGER SEALED BY A DIAPHRAGM SEPARATES THE SPACE UNDER PRESSURE INTO TWO CHAMBERS.
A PRE-LOADED SPRING CAUSES THE PLUNGER TO TAKE UP ITS ZERO POSITION WHEN THE PRESSURE
DIFFERENCE DELTA P IS ZERO. AS THE PRESSURE DIFFERENCE INCREASES (DELTA P > 0), THE PLUNGER
IS FORCED TO MOVE AGAINST THE SPRING. AT THE SAME TIME, AN INDICATOR DISC IS MOVED
MAGNETICALLY, AND THEREFORE VIRTUALLY WITHOUT FRICTION, AND THE TWO REED CONTACTS ARE
ACTUATED.

THE RED SEGMENT OF THE INDICATOR DISC IS VISIBLE OVER A PRESSURE RANGE EQUAL TO
APROX.50-100% DELTA P . THE FIRST REED CONTACT IS ACTUATED AT 75% DELTA P1, AND THE SECOND
AT 100% DELTA P2.
DIFFERENTIAL PRESSURE CONTACT INDICATOR TYPE 4.36.2
 Z21434
TYP4.36.2+4.46.2
11.02.94

A
3a 3 2 1a 1 GEKLEBT
CEMENTED
COLLE

11

10

A-B

BEI BESTELLUNG ANGEBEN

TO BE MENTIONED IN CASE OF ORDER
A MENTIONNER LORS DE LA COMMANDE
AUFTR.NR.:
ORDER NO. TYP 4.36.2
NO DE COMMANDE

11 ROLLMEMBRAN DIAPHRAGM DIAPHRAGME

10 FEDER SPRING RESSORT
7 KOLBEN PISTON PISTON
3 DICHTUNG GASKET JOINT
POS.NR. BEZEICHNUNG DESIGNATION DESIGNATION

SPARE PARTS PLAN DES PIECES

ERSATZTEILZEICHNUNG DE RECHANGE
DRAWING
ZUM TYP 4.36.2 UND 4.46.2
 Plate Heat Exchangers C5.05.08.40.02.93
-

Plate Heat Exchangers

en / 22.01.2014 FD049653 1/2

 Plate Heat Exchangers -Oil- (GEA) C5.05.08.50.00.02
Description

Plate Heat Exchangers -Oil-

(GEA)

Description

en / 18.12.2012 FD044274 1/75

Plate Heat Exchangers

General Operation Manual

GEA Heat Exchangers

GEA Ecoflex
 Plate Heat Exchanger
General operating instructions

Version: 1.3, 2006-09-08

Englisch

1
General operating instructions 1.3 | 2006-09-08
2
 Contents

Contents

1 Preface ............................................................................................................... 5

2 Safety at the plate heat exchanger ........................................................... 6

2.1 General safety ........................................................................................... 6
2.2 Incorrect operating conditions ............................................................... 7
2.3 Permitted operators ................................................................................. 7
2.4 Residual dangers ...................................................................................... 8

3 Operating instructions .............................................................................. 10

3.1 Operating instructions ........................................................................... 10
3.1.1 User notes .................................................................................... 10
3.1.2 Safety notes in the text .............................................................. 11

4 Manager’s obligations ............................................................................... 12

5 Functional description ............................................................................... 14

6 Intended purpose ........................................................................................ 15

7 Overview and description ........................................................................ 16

7.1 Basic structure ......................................................................................... 16
7.2 Identification ........................................................................................... 17
7.3 Frames ...................................................................................................... 19
7.4 Heat exchanger plates ............................................................................ 21
7.4.1 Chevron pattern ......................................................................... 21
7.4.2 Free Flow design ........................................................................ 22
7.4.3 Plate evaporator design ............................................................ 22
7.5 Gaskets ..................................................................................................... 22

8 Delivery, installation, transport, disposal .......................................... 24

8.1 Delivery.................................................................................................... 25
8.2 Installation ............................................................................................... 26

3
General operating instructions 1.3 | 2006-09-08
Contents

8.3 Transport ................................................................................................. 30

8.3.1 Suspended transport with sling fastening at
the carrying beam and shackles on the fixed plate .............. 30
8.3.2 Suspended transport on ring bolts ......................................... 31
8.3.3 Suspended transport with sling fastening
on the clamping part ................................................................. 32
8.4 Installation .............................................................................................. 33
8.4.1 Space requirements ................................................................... 33
8.4.2 Pipe assembly............................................................................. 34
8.5 Disposal ................................................................................................... 34

9 Commissioning and decommissioning, operation ......................... 35

9.1 Start-up .................................................................................................... 36
9.2 Operation ................................................................................................ 37
9.3 Decommissioning .................................................................................. 38
9.3.1 Short-term shutdown ................................................................ 38
9.3.2 Long-term shutdown ................................................................ 39

10 Maintenance and repair ............................................................................ 40

10.1 Preparatory precautions ....................................................................... 40
10.2 Opening the plate heat exchanger and removing the plates ........... 45
10.2.1 Opening plate heat exchangers with a CD frame ................. 45
10.2.2 Opening plate heat exchangers with a B frame .................... 48
10.2.3 Removing the heat exchanger plates ...................................... 49
10.3 Fitting the plates and closing the plate heat exchanger ................... 50
10.4 Cleaning the plate heat exchanger ...................................................... 53
10.4.1 Cleaning the plates of the closed plate heat exchanger ....... 53
10.4.2 Cleaning the plates of the opened plate heat exchanger ..... 56
10.5 Replacing the gaskets ............................................................................ 58
10.6 Replacing the frame seals ..................................................................... 59
10.7 Maintaining the frame ........................................................................... 59

11 Troubleshooting .......................................................................................... 60
11.1 Output deficit ......................................................................................... 60
11.2 Leakages .................................................................................................. 61

12 Technical terms ............................................................................................ 63

4
 Preface

1 Preface
With GEA Ecoflex you use the technical know how of one of the worldwide
leading manufacturers of plate heat exchangers (PHE).

We would like to make the handling of the plate heat exchanger as safe and
simple as possible. For this reason, these comprehensive operating instruc-
tions serve as your personal adviser who explains everything understand-
ably and clearly: structure, function, installation, operation, maintenance,
troubleshooting, transport and repair.

We especially devote ourselves to the subject of safety, so that all possible

dangers or damage can be avoided from the start. For that reason alone, all
employees who deal with the plate heat exchanger should be able to refer to
these important operating instructions at all times.

In the concise table of contents you will quickly find what you are looking
for. If not, look in the index with page references. In the same way all tech-
nical terms are informatively explained. After all, no questions should
remain open, and in the case they do, your GEA Ecoflex agent or the central
service department is glad to assist you further.

Additional operating instructions for special applications supplement these

general operating instructions.

With this in mind, we wish you a trouble-free operation with GEA Ecoflex
plate heat exchangers.

GEA Ecoflex GmbH

Service department
Karl-Schiller-Str. 1-3
D-31157 Sarstedt
Phone: +49 (0) 5066 / 6 01 - 3 33
Telefax: +49 (0) 5066 / 6 01 - 1 05
Internet: http://www.gea-phe.com
e-Mail: [email protected]

5
General operating instructions 1.3 | 2006-09-08
Safety at the plate heat exchanger

2 Safety at the plate heat exchanger

2.1 General safety

This chapter advises you on general precautions for the proper handling of
the plate heat exchanger and on the dangers the user may encounter.

If the plate heat exchanger is employed improperly or not according to the

intended purpose, or if the safety notes are not observed, dangers to persons
and property can arise.

NOTE
Read this chapter attentively. It contains important information and obliga-
tions. It concerns your health and the trouble-free operation of the plate heat
exchanger.

CAUTION
The operator is responsible for the safe operation of the plate heat
exchanger.
The following points must be observed:
➔ Always adhere to the general, national, and operational safety regula-
tions, for example, wear protective glasses, close-fitting protective
clothing, and safety shoes.
➔ Always adhere to the safety instructions in the individual chapters of
these operating instructions.
➔ The plate heat exchanger may only be operated in perfect condition.
Each change on the plate heat exchanger must be immediately reported
to the nearest person responsible available.
➔ Before beginning work with the plate heat exchanger, operators must
familiarise themselves with the possible dangers.
➔ Before each start of the plate heat exchanger, ensure that all parts of the
device are in perfect condition and function correctly.

6
 Safety at the plate heat exchanger

2.2 Incorrect operating conditions

Operation of the plate heat exchanger is not permitted if:
■ substantial faults or damage occurs,
■ the maintenance is not performed regularly,
■ the permissible operating conditions (including internal pressure,
temperature, media, external loads) are exceeded.

NOTE
GEA Ecoflex accepts no liability for damage caused by incorrect operating
conditions.

2.3 Permitted operators

For operation of the plate heat exchanger, everyone has to
■ be appropriately trained for the task to be performed,
■ be familiar with the work safety and accident prevention regulations,
■ be instructed in the handling of the plate heat exchanger and
■ have read and understood these operating instructions.

Persons who are responsible for the set-up, assembly, start-up, maintenance
or disassembly of the plate heat exchanger must have the knowledge
required.

7
General operating instructions 1.3 | 2006-09-08
Safety at the plate heat exchanger

2.4 Residual dangers

Residual dangers can never be fully excluded. You can only prevent these
dangers by appropriate behaviour.

CAUTION
Danger of injury!
➔ Heat exchanger plates:
The thin heat exchanger plates are sharp-edged. When handling heat
exchanger plates, always wear suitable protective gloves.
➔ External of the plate heat exchanger:
The burr, threads or similar present a risk of injury. Always wear suit-
able protective gloves when handling the outside of the plate heat
exchanger.

➔ The plate heat exchanger may topple over:

All plate heat exchangers that are standing and not fixed present the risk
of toppling over. This in particular applies to the NT50M, NT50X,
NT100X and VT10 plate heat exchangers. Always secure the upright
plate heat exchanger against toppling by preferably fixing it securely to
the ground.

8
 Safety at the plate heat exchanger

➔ Opening the plate heat exchanger:

Before opening the plate heat exchanger, ensure that it is unpressurised
and empty. When opening the plate heat exchanger, always ensure that
the heat exchanger plates do not unintendedly loosen from the frame
and tip over, see "Opening the plate heat exchanger and removing the
plates" (page 45). Also ensure that the pressure plate is secured against
unintended slippage (e.g. on ships).

➔ Transporting the plate heat exchanger:

Before transporting the plate heat exchanger, always ensure that the
hoisting gear is of sufficient dimensions and securely fixed. Never step
underneath suspended loads.

➔ Hazardous flow media:

Hazardous flow media present dangers of chemical burns, burning or
poisoning. Always wear suitable protective clothing when working on
the plate heat exchanger with hazardous flow media.

9
General operating instructions 1.3 | 2006-09-08
Operating instructions

3 Operating instructions

3.1 Operating instructions

These operating instructions are the instructions of the manufacturer for
operators of plate heat exchangers and for all persons who are responsible
for the set-up, operation, maintenance and repair of the device.

These operating instructions are generally applicable to all bolted/gasketted

(not welded) plate heat exchangers manufactured and supplied by
GEA Ecoflex.

3.1.1 User notes

Drawings and figures

The drawings in these operating instructions are exemplary. For reasons of
clarity, some drawings have been greatly simplified. The actual details
depend on the individually delivered plate heat exchanger. You find
diagrams and dimensions of the delivered plate heat exchanger in the tech-
nical documentation supplied.

Note for the operator of the plate heat exchanger

The operator of the plate heat exchanger is the person who is in charge of the
operation of the device.

Note for the technician who sets up the plate heat exchanger
These operating instructions contain no details about special tools that are
needed for the setting up and operating the plate heat exchanger.

10
 Operating instructions

3.1.2 Safety notes in the text

In these operating instructions, the following symbols are used in order to
draw your attention to dangers when handling the plate heat exchanger or
provide you with information about handling the plate heat exchanger:

CAUTION
This symbol means danger to the life and health of persons.
The following text explains the type of danger and its effects and provides
instructions for averting the danger.
➔ Not adhering to the instructions can have health effects up to and
including death.

DANGER
This symbol means danger for the plate heat exchanger, for parts, or for its
environment.
The following text explains the type of danger and its effects and provides
instructions for averting the danger.
➔ Not adhering to the instructions can cause substantial damage to the
plate heat exchanger.

NOTE
This symbol appears above paragraphs that provide you with useful or
important notes for the correct handling of the plate heat exchanger. This
information helps you to avoid problems and makes it easier to handle the
plate heat exchanger.

11
General operating instructions 1.3 | 2006-09-08
Manager’s obligations

4 Manager’s obligations

CAUTION
Danger of injury!
In the case of hazardous media (acids or similar media), high pressures and
high/low temperatures in the plate heat exchanger, there is a danger of
injury during maintenance or in the case of leakages.
➔ In this case you must be sure to provide a splash protector.
➔ This splash protector may only be removed when the plate heat
exchanger reaches room pressure and room temperature, or is empty.

As manager of the plate heat exchanger you must ensure that each operator
who is responsible for the set-up, operation, maintenance or repair of the
plate heat exchanger has read and understood, from beginning to end, the
parts of the operating instructions important for the job.

The plate heat exchanger is built according to state-of-the-art technology and

is reliable in service. Nevertheless the plate heat exchanger may present
dangers or may be damaged if you do not observe the following instruc-
tions:
■ These operating instructions must always be accessible to the operators
entrusted to work on the plate heat exchanger.
■ Only operators who are instructed in handling the plate heat exchanger
and the basic work safety and accident prevention regulations may work
on the plate heat exchanger. For safety reasons it is forbidden for other
persons to be in the area of the plate heat exchanger.
■ The safety-conscious operating by the operators has to be checked regu-
larly.
■ As manager you must ensure that:
– the plate heat exchanger remains in functional order.

– no premature wear of specific parts of the plate heat exchanger results

from unfavourable ambient conditions.

12
 Manager’s obligations

Unfavourable ambient conditions, for instance for

Sealing – Aggressive gases and/or aggressive aerosols in the
materials: surrounding air
– Effects of UV radiation (e.g. sunlight)
– Extreme ambient temperatures
Metallic compo- – Aggressive gases and/or aggressive aerosols in the
nents: surrounding air
– Humidity

■ all maintenance/inspections are carried out in regular intervals.

■ no changes or modifications are carried out on the plate heat exchanger
without permission of the manufacturer of the plate heat exchanger.
A change can lead to the expiration of the operating permit.
■ all laws and regulations – even if they are not explicitly mentioned here
– valid for the plate heat exchanger as well as the valid accident preven-
tion regulations are observed.

13
General operating instructions 1.3 | 2006-09-08
Functional description

5 Functional description
A series of contoured plates with transfer ports forms a pack of flow chan-
nels in the plate heat exchanger. The heat exchange media flow through
these flow channels in alternate channels.

Usually single-pass plate heat exchangers are used. In the case of single-pass
plate heat exchangers, all feed and return pipes are connected to the fixed
frame plate, i. e. on one side.

Close temperature differences between the media may demand the use of
multi-pass plate heat exchangers. In the case of multi-pass plate heat
exchangers, the connection pipes are placed at the fixed frame plate and at
the pressure plate, i. e. on both sides.

14
 Intended purpose

6 Intended purpose
This plate heat exchanger has been specially designed and manufactured for
your specified operating conditions concerning pressure, temperature, flow
rates, and type and composition of the flow media.

If a change in the specified operating conditions becomes necessary,

GEA Ecoflex must be consulted. The plate heat exchanger may only be oper-
ated under new operating conditions after GEA Ecoflex has examined,
approved, and, as the case may be, has altered the documentation of the
plate heat exchanger.

Intended use includes:

■ adhering to the valid national and international laws, decrees, regula-
tions, directives and other rules for the installation site .
■ following all safety instructions of these operating instructions.
■ adhering to regular inspection and maintenance work.

NOTE
GEA Ecoflex accepts no liability for damage caused by deviations from the
specified operating conditions for the plate heat exchanger.

15
General operating instructions 1.3 | 2006-09-08
Overview and description

7 Overview and description

7.1 Basic structure

The following figure represents the basic structure of a plate heat exchanger.
The actual design depends on the application.

4
1
5
2
6
3 7

No. Component
1 Carrying beam
2 Pipe connections
3 Fixed plate
4 Support column
5 Pressure plate
6 Heat exchanger plates
7 Lower guiding bar
8 Gaskets
9 Clamping part

16
 Overview and description

The plate pack consists of contoured heat exchanger plates (1) and the corre-
sponding gaskets (2) of varying number and arrangement.

7.2 Identification
Each GEA Ecoflex plate heat exchanger is provided with a nameplate. It is
fastened to the outside of the fixed frame plate of the plate heat exchanger.
Here you'll find information on:
■ Plate heat exchanger type
■ Serial no.
■ Permissible pressures [bar g]
■ Permissible temperatures [° C]
■ Test pressure [bar g]
■ Volume [L]
■ Net weight, year of manufacture
■ Compression dimensions:
■ "a max." / "a min." [mm]
■ Additional details [project specific]

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General operating instructions 1.3 | 2006-09-08
Overview and description

Examples for the nameplate design in conformity with the European Direc-
tive on Pressure Equipment 97/23/EC.

No. Component
1 Plate heat exchanger is exempt from CE-labelling requirements
2 Plate heat exchanger is subject to CE-labelling requirements

Each plate heat exchanger is supplied with a dimension sheet or, alterna-
tively, an assembly drawing, and a flow diagram.

The dimension sheet or the assembly drawing shows the external dimen-
sions as well as details of the type, size and position of the pipe connections.

The flow diagram shows the plate arrangement and type of plate heat
exchanger, the plate material of the plate heat exchanger, the plate thickness
as well as the sealing material and the part numbers.

18
 Overview and description

7.3 Frames
GEA Ecoflex plate heat exchangers are available in different application-
specific frame designs. There are two basic designs, B and CD. The design B
is especially employed for longer plate packs. Variants of this design addi-
tionally are labelled with the identification codes A, C, L and S.

B CD

Special stainless steel designs with intermediate elements for separating the
individual compartments are employed for the foodstuff and pharmaceu-
tical industries.

The frames made of structural steel are given a weather-protective coating.

The clamp screws and screw nuts are made of high-strength alloy steels and
can be zinc-plated.

The pipe connections can be attached to the fixed plate, to the pressure plate,
and possibly to intermediate elements.

The pipe connections on the fixed and pressure plate are positioned as
follows:
■ From an outside position looking onto the fixed plate, the connections
1F-4F are numbered consecutively anticlockwise. (1)
■ From an outside position looking onto the pressure plate, the connec-
tions 1L-4L are numbered consecutively clockwise. (2)

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General operating instructions 1.3 | 2006-09-08
Overview and description

1 2

In order to fulfil customer-specific requirements, different connection types

are available.

Partly these frames are equipped with height adjustable transport feet. In
this case, the feet are not anchored to the ground. Beneath the calotte feet
there are thrust plates. These thrust plates are not part of the standard equip-
ment.

20
 Overview and description

7.4 Heat exchanger plates

NOTE
The selection of the heat exchanger plate material is determined by
customer-specific operating conditions (including pressure, temperature,
media, operating mode). In the case of some specific applications a material
removal at the heat exchanger plates by the media used is a typical process.
This can lead to a malfunction of the heat exchanger plates and to a mixing
of the media.

The heat exchanger plates and gaskets are basic components in the plate heat
exchanger. GEA Ecoflex differentiates the following product groups:
■ Chevron pattern
■ Free Flow design
■ Plate evaporator design

7.4.1 Chevron pattern

This product group includes the heat exchanger plates of the VARITHERM
(VT), NT series, and LASER-welded cassettes (LWC).

these heat exchanger plates have horizontal and vertical stamping structures
that are respectively used individually or combined. They are used for clean
media with a low viscosity and also for high working pressures.

The gaskets of this product group can be fixed with adhesive. Additionally,
many plate types allow adhesive-free fixing (LocIn, EcoLoc).

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General operating instructions 1.3 | 2006-09-08
Overview and description

7.4.2 Free Flow design

This includes the heat exchanger plates of the FA, NF series and the N40
plate.

The special feature of this product group is the unrestricted broad flow cross
section between the heat exchanger plates. Highly viscose media or media
containing solids require the use of this product group.

The gaskets of this product group are fixed with adhesive. The plate type
N40 allows adhesive-free fixing (LocIn).

7.4.3 Plate evaporator design

The heat exchanger plates of the series CT (Concitherm) form this product
group.

Liquids are concentrated by evaporation using these plates ("evaporator").

The gaskets are fixed with adhesive. The plate type CT187 allows adhesive-
free fixing (LocIn). The plate type CT193 consists of LASER welded cassettes.

7.5 Gaskets

CAUTION
Damage to persons and property!
The use of inadmissible pressures, temperatures and media can lead to an
immediate failure of the gaskets and a grave endangerment of persons and
the surroundings.
➔ Therefore, never exceed the permissible operating parameters.

22
 Overview and description

WARNING
Leakage!
The gaskets are wearing parts and sensitive to chemical, thermal and
mechanical damage. The selection of the sealing frame material and its prop-
erties is effected on the basis of customised specifications (pressure, temper-
ature, media).
➔ Unintended use can lead to a reduction of the service life. Elastomer
gaskets are always subject to the ageing process (e.g. embrittlement).

There are two basic groups of gaskets:

■ Gaskets made of elastomers, available in different materials and design
types (e.g. 2-eye gaskets and 4-eye start and/or end gaskets). The gaskets
in principle can be fixed with adhesive, also often without adhesive
(LocIn, EcoLoc).
■ Gaskets made of mineral fibres ("hard gaskets"). They are principally
fixed with adhesive. In contrast to elastomer gaskets, these gaskets of
mineral fibre cannot compensate temperature load changes (e.g. start-up
and shut-down operation). Therefore, leakages may occur during these
operating phases.

All gaskets are designed to enable separating both media from each other at
the transfer ports by means of a double-gasket guidance system. The thus
formed leakage cavity in the case of leakages in this area has the function to
dissipate the leakage fluid to the outside via gaps in the gasket webs
(leakage grooves), and thus make leakages identifiable immediately.

The materials of the gaskets are clearly marked by coded colours. The
storage of the gaskets must be carried out appropriately.

➔ Never exceed the permissible parameters.

23
General operating instructions 1.3 | 2006-09-08
Delivery, installation, transport, disposal

8 Delivery, installation, transport, disposal

CAUTION
Damage to persons and property!
Improper and careless handling of the plate heat exchanger can lead to
danger to persons and property.
➔ The plate heat exchanger may never be lifted underneath the plate pack,
at the connections or at the tightening bolts.

24
 Delivery, installation, transport, disposal

8.1 Delivery
The fully assembled plate heat exchanger is packed and delivered either
lying on its side or upright, depending on the frame type.

If it is delivered lying on its side, the plate heat exchanger is anchored by the
back of the fixed plate to solid planks. A forklift truck can pick the plate heat
exchanger up from beneath the planks and transport it.

The plate heat exchanger that is packed upright and to be transported

upright is top heavy. It is bolted on timber planks in a manner that is safe for
transport and, according to the section "Transport" (page 30), has to be
unloaded and transported when it is floating. In no case may the device be
lifted under the heat exchanger plate pack because this inevitably leads to a
damaging of the plate pack.

In the BC frame, the height-adjustable transport feet replace the ball feet. The
transport feet can be found as an extra item to the plate heat exchanger.

Individual parts of the plate heat exchanger are packaged on pallets and in
appropriate cardboard boxes on pallets. Upon request, we will use special
air freight, container and wood packages. All packaging materials used
comply with EU packaging ordinance. The wood packaging materials are
designed in accordance with IPPC standard and are labelled accordingly.
The disposal of the packaging material is the sole responsibility of the
customer.

NOTE
If you notice damage to an item at delivery in spite of careful packaging,
please be sure to note the extent and type of the damage in the transport
documents and have it receipted by the supplier. Please take a photograph
of the damage and report it to us immediately. We need your notification of
claim within the legally stipulated period of time, together with the original
freight receipt and with receipted reservation.

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General operating instructions 1.3 | 2006-09-08
Delivery, installation, transport, disposal

8.2 Installation

WARNING
Danger to life!
When installing the plate heat exchanger, there always is the risk of
toppling. All plate heat exchangers that are standing and not fixed present
the risk of toppling over. Always ensure that:
➔ the hoisting gear are of sufficient dimensions,
➔ the hoisting gear cannot come loose or slide off,
➔ no swing movements to the side result when lifting the plate heat
exchanger,
➔ the floor at the installation site is sufficiently large, level and able to
support the load.
➔ all plate heat exchangers, in particular the NT50M, NT50X, NT100X and
VT10 plate heat exchangers immediately after the installation are prefer-
ably fixed to the ground in a secure manner. These plate heat exchangers
can topple over by a relatively small force effect.

DANGER
Damage on the plate heat exchanger!
The connecting pieces can bend or crack.
➔ Attach the hoisting gear (slings) only as in the following.
➔ When attaching the hoisting gear (slings), make sure that they are firmly
seated.
➔ Never use a chain or a steel rope, but only slings.

26
 Delivery, installation, transport, disposal

Carry out the following work steps:

1. Remove all of the fastening screws and elements from the plate heat
exchanger and from the pallet.

2. Attach a sling to the upper tightening nut on each side of the plate heat
exchanger.
➥ Do not use steel ropes or chains!

➔ If the clamping nuts for applying the round sling are not accessible,
slightly tilt the plate heat exchanger by using an additional round sling.
In doing this, always place the round sling between two clamping nuts.

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General operating instructions 1.3 | 2006-09-08
Delivery, installation, transport, disposal

➔ Then attach the slings around the top tightening nuts.

3. Lift the plate heat exchanger slowly from the pallet over its centre of
gravity.

28
 Delivery, installation, transport, disposal

4. Slowly lower the plate heat exchanger on the edge of the fixed plate or
on the feet of the plate heat exchanger. Align the plate heat exchanger
and bring it to its final position at the installation site.

5. Remove the slings and other aids.

6. Afterwards fix the plate heat exchanger firmly to the ground.

✓ The plate heat exchanger is installed.

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General operating instructions 1.3 | 2006-09-08
Delivery, installation, transport, disposal

8.3 Transport

WARNING
Danger to life! Damage of the plate heat exchanger!
Before transporting the plate heat exchanger, always ensure that:
➔ the hoisting gear are of sufficient dimensions,
➔ the hoisting gear cannot come loose or slide off,
➔ no swing movements to the side result when lifting the plate heat
exchanger,
➔ a sufficient safety distance is kept by the operating personnel,
➔ the floor at the installation site is sufficiently large, level and able to
support the load.
➔ particularly the NT50M, NT50X, NT100X and VT10 plate heat
exchangers are only transported upright if they are fixedly screwed to
the transport equipment.

The suspended transport always starts out from an upright position of the
plate heat exchanger.

8.3.1 Suspended transport with sling fastening at the

carrying beam and shackles on the fixed plate

Carry out the following work steps:

1. Attach two suitable shackles in both holes intended for that purpose on
the upper side of the fixed plate.

2. Attach a sufficiently long sling to the carrying beam directly behind the
pressure plate and to both shackles.
➥ Do not use steel ropes or chains!

30
 Delivery, installation, transport, disposal

3. Slowly lift the plate heat exchanger.

✓ The plate heat exchanger now can be transported.

8.3.2 Suspended transport on ring bolts

Carry out the following work steps:

1. Attach the hoisting gear to both transport eyes on the top side of the
carrying beam.

2. Slowly lift the plate heat exchanger.

✓ The plate heat exchanger now can be transported.

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General operating instructions 1.3 | 2006-09-08
Delivery, installation, transport, disposal

8.3.3 Suspended transport with sling fastening on

the clamping part
Use this transport method only when the above-described fastening possibil-
ities are not available.

Carry out the following work steps:

1. Attach a sling around the top tightening bolts on each side of the plate
heat exchanger.
➥ Do not use steel ropes or chains!

2. Slowly tilt the plate heat exchanger until it reaches a hanging position.

✓ The plate heat exchanger now can be transported.

32
 Delivery, installation, transport, disposal

8.4 Installation

WARNING
Danger to life!
When installing the plate heat exchanger, there always is the risk of
toppling. All plate heat exchangers that are standing and not fixed present
the risk of toppling over. Always ensure that:
➔ the hoisting gear is sufficiently dimensioned,
➔ the hoisting gear cannot come loose or slide off,
➔ a sufficient safety distance is kept by the operator,
➔ the floor at the installation site is sufficiently large, level and able to
support the load.
➔ all plate heat exchangers, in particular the NT50M, NT50X, NT100X and
VT10 plate heat exchangers immediately after the installation are prefer-
ably fixed to the ground in a secure manner. These plate heat exchangers
can topple over by a relatively small force effect.

In case of outdoor installation, take precautions against freezing the flow

media in the plate heat exchanger, if necessary.

8.4.1 Space requirements

Provide a sufficient free space around the plate heat exchanger. This facili-
tates access to the plate heat exchanger and necessary service tasks (e.g.
replacing individual plates, compressing the plate pack).

The values for the necessary space given in the adjacent figure are guide
values and are recommended by GEA Ecoflex. You provide an adequate
access to the plate heat exchanger.

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General operating instructions 1.3 | 2006-09-08
Delivery, installation, transport, disposal

8.4.2 Pipe assembly

The GEA Ecoflex plate heat exchangers are provided with different connec-
tion types according to the purpose. Pay attention to the following points
during pipe assembly:

DANGER
Damage on the pipe connections and on the plate heat exchanger!
By request, you can obtain an overview of the admissible forces and
moments for the plate heat exchanger.
➔ Make sure that no forces, moments, or vibrations that are too high are
transferred via the pipes onto the connections of the plate heat
exchanger.

NOTE
In order to avoid clogging problems during commissioning the plate heat
exchanger, GEA Ecoflex strongly recommends to use filters or bypasses for
the first flushing of the overall pipe system.

8.5 Disposal
As a customer, you are responsible for the disposal of the packing materials.

On request, GEA Ecoflex takes over the disposal of the plate heat exchanger.
For the cost of labour, the plate heat exchanger is disassembled, transported
away and professionally disposed.

NOTE
If the plate heat exchanger or its parts are contaminated, GEA Ecoflex cannot
take over the disposal. In this case, the disposal of the plate heat exchanger is
the manager‘s obligation.

34
 Commissioning and decommissioning, operation

9 Commissioning and decommissioning,

operation

CAUTION
Danger of injury!
Hazardous flow media (corrosive, poisonous, flammable, explosive etc.)
present dangers of chemical burns and burning.
➔ Inform yourself beforehand which flow media are used and make sure
that a protective covering is on hand.

DANGER
Environmental damage! Damage on the plate heat exchanger!
When ecologically harmful flow media flow out, serious environmental
damage are possible.
➔ Make sure that a possibility for draining the product and a catchment
tank for the entire filling capacity of the plate heat exchanger are
provided.
➔ If the plate heat exchanger is further compressed below "a min.", the
plates warp. Make sure that the plate pack is compressed to the neces-
sary compression dimension "a min." < "a" < "a max.".

35
General operating instructions 1.3 | 2006-09-08
Commissioning and decommissioning, operation

DANGER
Damage on the plate heat exchanger!
Fast switching operations (e.g. of valves in the pipes connected to the plate
heat exchanger) or process-related events (e.g. spontaneous vaporisation,
condensate impacts) can bring about high pressure surges.
➔ Avoid high-pressure surges through the flow media in order to avoid
damaging the plate heat exchanger.
➔ The retightening of the clamping parts of the plate heat exchanger may
only be carried out in the depressurised state, as otherwise the compres-
sion dimension "a min." might be underrun, see explanation of "a min."
in the chapter "Technical terms" (page 63).

9.1 Start-up
Before commissioning, carry out a visual check on the plate heat exchanger
and make sure that
■ the plate heat exchanger is not operated with impermissible flow media,
pressures and temperatures.
■ all pipe connections are firmly connected to the plate heat exchanger.
■ all required components of the plate heat exchanger are completely
installed.
■ the permissible compression dimension "a min." is not underrun, see
nameplate in the section "Identification" (page 17). The heat exchanger
plates might be permanently damaged.
■ when restarting, no residues of previous processes (e.g. cleaning agents)
are present in the plate heat exchanger.
■ the plate heat exchanger is bleeded.

36
 Commissioning and decommissioning, operation

■ pressure surges are avoided. The normal operation of the plate heat
exchanger may be jeopardised. Flow media could escape.

✓ If all of these conditions are fulfilled, you can start operating the plate
heat exchanger.

NOTE
If faults occur during commissioning the plate heat exchanger, see chapter
"Troubleshooting" (page 60).

In order to avoid clogging problems during commissioning the plate heat

exchanger, GEA Ecoflex strongly recommends to use filters or bypasses for
the first flushing of the overall pipe system.

9.2 Operation

CAUTION
Danger of injury! Damage on the plate heat exchanger!
If the plate heat exchanger is in operation, during operations on the plate
heat exchanger there is risk of injury or the danger that the plate heat
exchanger might be damaged.
➔ For maintenance or repair operations, always decommission the plate
heat exchanger first.

Visually inspect the plate heat exchanger regularly during operation and
make sure that:
■ the plate heat exchanger is not operated with impermissible flow media,
pressures and temperatures;
■ the minimum and maximum parameters given on the nameplate are not
exceeded. If the parameters are exceeded, the operating approval
dissolves and GEA Ecoflex accepts no liability for resulting damage.
■ pressure surges are avoided. The normal operation of the plate heat
exchanger could be jeopardised. Flow media could escape.

37
General operating instructions 1.3 | 2006-09-08
Commissioning and decommissioning, operation

NOTE
If faults occur during operation of the plate heat exchanger, see chapter
"Troubleshooting" (page 60).

9.3 Decommissioning

CAUTION
Danger of injury!
All plate heat exchangers that are standing and not fixed present the risk of
toppling over. Always ensure that:
➔ the plate heat exchanger only is transported in a suspended state, or
when it is lying on the base plate.
➔ particularly the NT50M, NT50X, NT100X and VT10 plate heat
exchangers are only transported upright if they are fixedly screwed to
the transport equipment.
➔ the plate heat exchanger always is secured against toppling, even if it
only is stored upright for a short time.

9.3.1 Short-term shutdown

DANGER
Escape of environmentally hazardous flow media possible!
Flow media can be dangerous and environmentally hazardous.
➔ Make sure that no flow media can escape during the shutdown period.
➔ In case of outdoor installation, take precautions (e.g. emptying, heating)
against freezing the flow media in the plate heat exchanger.

38
 Commissioning and decommissioning, operation

9.3.2 Long-term shutdown

DANGER
Premature component wear!
The components of the plate heat exchanger can prematurely wear due to
unfavourable ambient conditions or by flow media remaining within the
plate heat exchanger.
➔ If the plate heat exchanger is decommissioned for a longer period, it has
to be decompressed and completely emptied.
➔ Additionally we recommend a through cleaning and appropriate storage
until recommissioning.

NOTE
You can obtain detailed information about storage conditions from your
GEA Ecoflex service department (see back cover).

39
General operating instructions 1.3 | 2006-09-08
Maintenance and repair

10 Maintenance and repair

10.1 Preparatory precautions

Before operations are started, check the delivered frame type of the plate
heat exchanger on the basis of the documentation supplied.

CAUTION
Danger of injury!
During maintenance and repair work on the plate heat exchanger there is
risk of injury. For this reason, always adhere to the following points:
➔ Always wear suitable protective clothing.
➔ If a pressurised or filled plate heat exchanger is opened, the flow media
can escape uncontrollably. This is a danger of injury for the operator and
bystanders.
➔ Before beginning maintenance or repair work, ensure that the plate heat
exchanger is empty and has reached room pressure.
➔ When using hot or very cold flow media there is a danger of burning, or
respectively, freezing. Before beginning maintenance or repair work,
always ensure that the plate heat exchanger has reached room tempera-
ture.
➔ Hazardous flow media (corrosive, poisonous, flammable, explosive etc.)
present an acute danger of injury for the operator and bystanders. Make
sure that the regulations for flow media are followed during all work.
➔ Ensure that the pressure plate is secured against unintended slippage
(e.g. on ships).
➔ The plates of the heat exchanger can fall out sideways and cause severe
injuries. When fitting the plates of the heat exchanger and closing the
plate heat exchanger, always ensure that the heat exchanger plates do
not unexpectedly loosen from the guiding bar and tip over. For this
reason, at least two persons must work on a plate heat exchanger with
CD frame. The reliable procedure for opening and closing a plate heat
exchanger is described in the sections "Opening the plate heat exchanger
and removing the plates" (page 45). or "Fitting the plates and closing
the plate heat exchanger" (page 50).

40
 Maintenance and repair

DANGER
Danger of falling over during stacking!
In the case of uncontrolled stacking, the heat exchanger plates can tumble.
This causes injuries and damaged heat exchanger plates. Never stack the
plates higher than:
➔ 60 heat exchanger plates for Varitherm/NT
➔ 30 cassettes for LWC
➔ 30 heat exchanger plates for free flow/Concitherm/Safetytherm

Before opening the plate heat exchanger you must carry out a few work
steps. If necessary, remove the connected pipes.

Carry out the following work steps:

➔ Clean the guiding rail
➥ (for better plate mobility).

41
General operating instructions 1.3 | 2006-09-08
Maintenance and repair

➔ Clean the threads of the tightening bolts

➥ (to remove the contamination and prevent a fretting of the nuts).

➔ Apply a thin film of oil to the thread.

➔ To ensure that the plates are reassembled in the right order, we advise
painting a diagonal line across the side of the plate pack.

42
 Maintenance and repair

➔ Be sure to note the current "a" dimension.

NOTE
When removing the heat exchanger plates, document the order with the help
of the flow diagram.

The frames are provided with at least four clamping parts. For plate heat
exchangers with more than four clamping parts, as a rule four longer
clamping parts are used. These only pretension the heat exchanger plate
pack (so-called pretensioning bolts).

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General operating instructions 1.3 | 2006-09-08
Maintenance and repair

The HE plates are mounted in different ways in the frame, depending on the
frame design of the plate heat exchanger.
■ In CD frames the HE plates rest on the bottom guiding bar and are
guided by the top.
– In the CD frame the plates are guided by a top and a bottom guiding
bar.

VT NT

■ In the B frames the heat exchanger plates are suspended at the top
carrying beam with a special rail. The plates are hooked into the recess of
the guiding rail and are guided by the bottom guiding bar.
– Top carrying beam with a guiding rail and a guiding bar.

– Top carrying beam without a guiding rail.

VT NT

44
 Maintenance and repair

10.2 Opening the plate heat exchanger and

removing the plates

NOTE
Before unfastening/opening the plate heat exchanger, observe the safety
instructions in the section "Preparatory precautions" (page 40).

10.2.1 Opening plate heat exchangers with a CD frame

CD frames need to be equipped with a locking element (e.g., a pipe clamp).
Ensure that the HE plates can always be set up as described as step 3 below.
Attach the locking element accordingly.

The following HE types do not require locking elements:

■ VT 04
■ VT 10
■ VT 20

The drawings below show a CDL frame (with a support column). The
handling described also applies to CDS frames (without a support column).

The CDS frames feature an extra retaining lock at the end of the upper
guiding bar. This retaining lock limits the path along which the pressure
plate can be moved.

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General operating instructions 1.3 | 2006-09-08
Maintenance and repair

Carry out the following work steps:

1. Release the nuts of the tightening bolts on the pressure plate.

➥ Release the tightening bolts evenly in small steps on alternate sides (1-2-
3-4) and diagonally (1-2 and 3-4), in order to prevent overloading indi-
vidual tightening bolts and tilting the pressure plate.
➥ Proceed similarly in the case of frames with more than 4 tightening bolts.

1 32

4 22

2. Remove the nuts without removing the tightening bolts. Push the pres-
sure plate right up to the locking element.

46
 Maintenance and repair

3. Move the heat exchanger plates. The HE plates must afterwards safely
lean against the fixed plate.

4. Now remove the tightening bolts. To secure the unit, two tightening
bolts should be left in on either side of the frame.

5. Mark the position of the locking element. Then move the locking element
right up to the support column.

47
General operating instructions 1.3 | 2006-09-08
Maintenance and repair

6. Move up the pressure plate to the support column. The second operator
ensures that the plate pack does not slip. You can now take out the heat
exchanger plates.

➔ The procedure is the same for CD frames without a locking element (VT
04, VT 10, VT 20).

✓ The plate heat exchanger is opened.

NOTE
The best position of the locking element depends on the size and number of
heat exchanger plates. Please contact your GEA Ecoflex service department
(see back cover) if you have any questions on this point.

10.2.2 Opening plate heat exchangers with a B frame

Carry out the following work steps:

1. Release the nuts of the tightening bolts on the pressure plate.
➥ Proceed as in item 1 in the section "Opening plate heat exchangers with a
CD frame" (page 45).

2. Remove the nuts.

48
 Maintenance and repair

3. Remove all tightening bolts.

✓ The plate heat exchanger is opened.

10.2.3 Removing the heat exchanger plates

Carry out the following work steps:

1. Move the pressure plate right up to the support column.
➥ You now have access to the individual heat exchanger plates.

2. For removal, swing the heat exchanger plate out to the side and take it
out of the guiding rail of the carrying beam.
➥ In the case of some Varitherm carrying beams, swinging is only possible
to one side.

✓ The heat exchanger plates have been removed.

49
General operating instructions 1.3 | 2006-09-08
Maintenance and repair

10.3 Fitting the plates and closing

the plate heat exchanger

NOTE
Before the installation and before closing the plate heat exchanger, observe
the safety instructions in the section "Preparatory precautions" (page 40).

DANGER
Damage to the heat exchanger plates!
If the compression dimension "a min" is underrun, this generally causes the
damage of the heat exchanger plates and, as the case may be, faulty opera-
tion of the plate heat exchanger.
➔ Ensure that the plate pack is only compressed to the necessary dimen-
sion "a min." < "a" < "a max.".

NOTE
When all the heat exchanger plates are correctly installed, the outside of the
plate pack must show a continuous honeycomb pattern. You can also check
that the plates are in the right order by means of the diagonal line on the
outside of the plate pack, which you painted before opening the plate heat
exchanger.

50
 Maintenance and repair

Carry out the following work steps:

1. Make sure that the gaskets and heat exchanger plates are free of foreign
matter or contamination.
➥ If necessary, clean them with running water and a soft brush.

2. Check that the gaskets fit correctly in the grooves of the heat exchanger
plates.

3. Clean the sealing faces of the frame gaskets.

4. For a plate heat exchanger with a B frame: Clean the plate guiding of the
heat exchanger at the carrying beam and slightly lubricate them.

5. Clean the threads of the tightening bolts as well as the tightening nuts
and apply a thin layer of grease to these.

6. Mount all the HE plates into the plate heat exchanger frame in the
correct order according to the flow diagram.

51
General operating instructions 1.3 | 2006-09-08
Maintenance and repair

In the case of a CD frame, the following actions are required:

➔ Before installing the heat exchanger plates, screw in two tightening bolts
to serve as securing elements.

➔ Every HE plate you put in should safely lean against the fixed plate.

➔ Have another operator hold and secure the plate pack.

➔ Push the pressure plate against the plate pack and put in the remaining
tightening bolts.

➔ Attach the locking element at the correct position.

52
 Maintenance and repair

7. Determine the required compression dimension ("a" dimension).

➥ The required compression dimension "a" is
– in the case of a complete replacement of the gaskets: the "a max"
printed on the name plate.
– provided that the heat exchanger plates are only cleaned and no
gaskets are replaced: the compression dimension written down before
opening the plate heat exchanger.
– in case of a change in the number of heat exchanger plates: The new
"a max" dimension which can be gathered from the circuit diagram
and the changed plate to the nameplate supplied.

8. Tighten the clamping parts according to the procedure described in the

section "Opening the plate heat exchanger and removing the plates"
(page 45) alternately and diagonally to the required compression dimen-
sion "a".

9. Carry out a leak test before restarting the plate heat exchanger.

NOTE
The procedure in the case of leakages is described in the chapter "Trouble-
shooting" (page 60).

10.4 Cleaning the plate heat exchanger

10.4.1 Cleaning the plates

of the closed plate heat exchanger
Deposits on the heat exchanger plates
■ impair the heat transfer between the flow-through media,
■ increase the pressure loss,
■ can cause or accelerate HE plate corrosion.

53
General operating instructions 1.3 | 2006-09-08
Maintenance and repair

The particular application determines

■ the necessity,
■ the type and
■ the frequency of a plate heat exchanger cleaning.

CIP process

CAUTION
Danger to persons and environment!
The use of aggressive cleaning agents presents poisoning, chemical burns,
and burning dangers. Make sure that:
➔ before the CIP process, you have been instructed in the use and have a
good command of all work steps.
➔ during work with aggressive cleaning agents you always wear suitable
protective clothing.
➔ the cleaning agent you use is completely removed from the plate heat
exchanger after cleaning.

In the case of CIP ("Cleaning in Place"), a cleaning agent instead of the flow
media flows through the plate heat exchanger. Contaminants are removed
by the cleaning solution’s dissolving capacity, supported by the mechanical
action of the turbulence.

DANGER
Damage of the plate heat exchanger!
The improper use of CIP can damage the plate heat exchanger.
➔ Observe the notes for chemically cleaning the heat exchanger plates in
the section "Cleaning the plates of the opened plate heat exchanger"
(page 56).

54
 Maintenance and repair

Backflushing
This process is used if the flow media contain coarse particles of contamina-
tion and thus block the inlet channels. By briefly reversing the direction of
flow, the particles of contamination are removed from the plate heat
exchanger.

The direction of flow is reversed by using a suitable pipe configuration with

the appropriate valves. If there is a risk of the released particles of contami-
nation causing damage to the plate heat exchanger, preference should be
given to manual cleaning of the heat exchanger plates.

2F 1F

3F 4F

55
General operating instructions 1.3 | 2006-09-08
Maintenance and repair

10.4.2 Cleaning the plates

of the opened plate heat exchanger

Cleaning the heat exchanger plates manually

DANGER
Leakage!
Hard cleaning tools (e.g. brushes with metal bristles) can damage the
metallic surfaces of the heat exchanger plates and the surfaces of the gaskets.
Damaged metal surfaces can lead to corrosion of the heat exchanger plates.
Damaged gasket surfaces can bring about leakages of the plate heat
exchanger when it is recommissioned.
➔ Never use hard cleaning tools.
➔ At every cleaning, ensure that no particles can settle on or under the
gaskets because this leads to leakages.
➔ Ensure that the stream of the high-pressure jet always directs face-on at
the gaskets in order to avoid loosening them.

Carry out the following work steps:

1. For severely pollutions, use a high pressure cleaner nozzle first to
remove the particles.

56
 Maintenance and repair

2. Wash each plate from both sides with flowing, warm water and a soft
brush.

✓ The heat exchanger plates have been cleaned manually.

Cleaning the heat exchanger plates chemically

DANGER
Leakage!
Chemical cleaning processes can attack the gaskets materials and create
leaks.
➔ Always use cleaning agents that do not attack the gaskets materials.
➔ Choose a suitable temperature and do not let the cleaning agent take
effect on the materials for an unnecessarily long time.

Observe the following points:

■ Always follow the safety instructions and recommendations of the
cleaning agent manufacturer. Only use chloride-free or low-chloride
water with a low hardness value for the cleaning liquid.
■ Chlorides in the medium reduce the corrosion resistance of chrome-
nickel steels and chrome-nickel-molybdenum steels (including
Hastelloy, Incoloy and Inconel). The intensity of the effect of the chlo-
rides depends on the temperature, concentration and pH of the medium.

57
General operating instructions 1.3 | 2006-09-08
Maintenance and repair

■ Stubborn contamination, such as coatings on the plate surface, which are

not released by the above-described processes, can be loosened by
soaking in an open chemical bath.
■ Choose a cleaning agent suitable for the type of contamination and for
the properties of the heat exchanger plates and sealing materials.
– In any case, a confirmation by the manufacturer of the cleaning agent
should be available, stating that the agent does not affect the plate and
sealing materials used in the heat exchanger.
– Clean the heat exchanger plates according to the work instructions of
the cleaning product manufacturer.
■ Before reassembling the cleaned heat exchanger plates, always rinse
them with sufficient clean water. Remove foreign matter on the gaskets
with a soft brush.

10.5 Replacing the gaskets

You can find the fixing type of the gasket in the technical documentation of
the plate heat exchanger. The gaskets can be either fixed with adhesive into
the gasket grooves or pressed into the grooves without adhesive.

We recommend that you always replace all gaskets at the same time. Use
only original GEA Ecoflex gaskets.

NOTE
You can obtain detailed information about replacing gaskets from your
GEA Ecoflex service department (see back cover).

58
 Maintenance and repair

10.6 Replacing the frame seals

The type of port ring between the heat exchanger plate pack and the frame
components depends on the frame type.

NOTE
You can obtain detailed information about replacing port rings from your
GEA Ecoflex service department (see back cover).

10.7 Maintaining the frame

DANGER
Loss of operating approval!
You must consult your GEA Ecoflex service department (see back cover)
before changing or replacing frame components.
➔ Always use the original GEA Ecoflex parts, as otherwise the operation
permit for the plate heat exchanger expires.

Regularly carry out simple maintenance work, for example:

■ external cleaning,
■ greasing and
■ repairing damage to the paintwork at the frame of the plate heat
exchanger.

NOTE
You can obtain detailed information about maintenance of the frame from
your GEA Ecoflex service department (see back cover).

59
General operating instructions 1.3 | 2006-09-08
Troubleshooting

11 Troubleshooting
In the following you will find a few typical faults that can occur during oper-
ation of a plate heat exchanger.

NOTE
On principle, you should consult your responsible GEA Ecoflex service
department before eliminating faults (see last cover page), in order to
prevent inappropriately performed work on the plate heat exchanger and
possible consequences.

11.1 Output deficit

Fault Cause Remedy
Insufficient heat transfer Deposits on the heat Clean heat exchanger
exchanger plates plates
Flow paths, media etc. Have the design of the
changed from the design plate heat exchanger with
the new operating data
checked by GEA Ecoflex!
Too high-pressure loss Flow impeded by blockage Clean heat exchanger
of the flow channels of the plates
distributor
Flow impeded by incorrect Check the installation
mounting of the heat order by means of the flow
exchanger plates diagram
Flow paths, media etc. Have the design of the
changed from the design plate heat exchanger with
the new operating data
checked by GEA Ecoflex!

60
 Troubleshooting

11.2 Leakages
Fault Cause Remedy
sealing fault between false compression dimen- check the correct compres-
the HE plates sion of the plate heat sion dimension by means
exchanger of the data on the name
plate
too high working pres- check the working pres-
sures sures by means of the data
on the name plate
too high/too low working check the working temper-
temperatures atures by means of the
data on the name plate
gaskets fitted incorrectly open the plate heat
exchanger and correct the
gaskets’ position
gaskets are dirty open the plate heat
exchanger and clean the
gaskets
Gaskets are defective or open the plate heat
hardened exchanger and replace the
gaskets
sealing fault between heat gaskets or port rings fitted open the plate heat
exchanger plates and incorrectly exchanger, correct the
frame, intermediate plates, position of the gaskets or
intermediate elements port rings
gaskets or port rings are open the plate heat
dirty exchanger, clean gaskets
or port rings
gaskets or port rings are open the plate heat
defective exchanger, replace gaskets
or port rings

61
General operating instructions 1.3 | 2006-09-08
Troubleshooting

Fault Cause Remedy

sealing fault between pipe too high loads at the pipe reduce connection loads to
connection and frame connection due to the pipe the admissible parameters
plate
seal ring fitted incorrectly loosen the pipe connec-
tion and correct the posi-
tion of the seal ring
seal ring is dirty loosen the pipe connec-
tion and clean the seal ring
seal ring is defective loosen the pipe joint and
replace the seal ring
flange connection is not check the seal ring and
sufficiently tightened connection and tighten
any loose bolts
damage to the heat over-tightened plate packs replace defective heat
exchanger plates (compression dimension exchanger plates
less than "a min")
corrosion of the HE plate check the design of the
material plate heat exchanger
concerning flow-through
media, consult
GEA Ecoflex
damage to the start or end incorrect earthing during replace defective heat
heat exchanger plate welding of special connec- exchanger plates
tions to the open
connecting pipes of the
frame

62
 Technical terms

12 Technical terms
Term Meaning
B frame An especially stable frame design, which also allows
a high number of heat exchanger plates.
Backflushing A cleaning process in which the direction of flow is
regularly reversed Reversing the direction of flow
flushes the particles of contamination from the plate
heat exchanger.
Carrying beam The top component placed between the fixed plate and
support column upon which the heat exchanger plates
and the pressure plate are suspended.
Particularity: In CD frames the carrying beam guides
the heat exchanger plates.
CD frame A compact frame design of the plate heat exchanger
(compact design).. The number of heat exchanger
plates that can be stacked is lower in a CD frame than
in the corresponding B frame.
CIP process A cleaning process in which the flow channels of the
(Cleaning in Place) closed plate heat exchanger are flushed with specific
cleaning solutions.
Clamping part The frame component for compressing the heat
exchanger plate packs. It consists of tightening bolts,
tightening nuts and washers.
Collector channel The flow channel which is created by the total passage
openings of the heat exchanger plates.
Compression dimension Dimension referring to the depressurised (!) plate heat
"a" dimension exchanger. Tighten the heat exchanger plate pack
("a max."/"a min") placed between the frame plates to this dimension.
Going below the "a min" dimension can damage the HE
plate pack. The tightening units adjust the compression
dimension.

63
General operating instructions 1.3 | 2006-09-08
Technical terms

Term Meaning
Connection (pipe) The pipe connections intended for the fixed plate and,
if applicable, the pressure plate. The pipe connections
have different designs according to each application
(industrial design, rubber insert piece, metal liner,
flange connection etc.).
connection corner (pipe) Component of the intermediate element in the heat
exchanger plate pack. With this intermediate element,
multi-stage designs of a plate heat exchanger are real-
ised. The connection corners allow the connection of
additional pipes/media (especially for food applica-
tions).
Distributor channel See "Collector channel"
EcoLoc A fixing system without adhesive for gaskets of the NT
series.
Fixed plate The basic component of the plate heat exchanger frame.
The fixed plate is an unmovable frame plate. Normally,
the pipes are connected to this component.
Flow-through media The term for the media that are responsible for the heat
transfer in the plate heat exchanger.
Frame plates The fixed plate and the pressure plate of the plate heat
exchanger frame.
Gasket of the HE plates An elemental component for sealing the flow channels
from each other and between the heat exchanger plates
and the surroundings or leakage chamber. There are
gaskets that are fixed to the heat exchanger plates with
adhesive or without adhesive (LocIn, EcoLoc).
Guiding bar Component that guides the heat exchanger plates and
the pressure plate at the bottom.
Particularity: In CD frames the heat exchanger plates
rest on the bottom guiding bar.
Heat exchanger plate pack The collective term for all of the heat exchanger plates
located between the frame plates, including the
gaskets.
Heat exchanger plates An elemental component that keeps the flow media
separated from each other and transfers the heat.

64
 Technical terms

Term Meaning
Intermediate element A component placed within the heat exchanger plate
pack. The intermediate element has pipe connections
along the sides for multi-stage plate heat exchanger
designs.
Intermediate plate A component placed within the heat exchanger plate
pack. The intermediate plate has no pipe connections
and is used for special multi-pass plate heat exchanger
designs.
LocIn A fixing system without adhesive for some elastomer
gaskets.
Metal liner A liner of the frame plates in the area of the pipe
connections. The material used depends on the applica-
tion (stainless steel, titanium, etc.).
Multi-pass A special design of the plate heat exchanger with
plate heat exchanger internal deflection of the flow-through media. The
construction of multi-pass plate heat exchanger always
demands pipe connections to the pressure plate.
Multi-stage A special design of the plate heat exchanger with more
plate heat exchanger than two flow media (use of intermediate elements).
With this plate heat exchanger design, complex heat
transfer tasks are combined in one plate heat exchanger
(heating and cooling, e. g. in the food stuff industry).
Nameplate A label attached to the fixed plate of the PHE frame for
identification with the basic data of the PHE (also
designed as adhesive label).
PHE The short form of the term Plate Heat Exchanger.
Pressure plate A movable frame plate suspended at the carrying beam
of the plate heat exchanger frame. his frame plate
compresses the heat exchanger plate pack.
The pressure plate can have pipe connections.
Rubber insert piece A liner of the frame plates (elastomer) in the area of the
pipe connections. It seals off the pipe connection and
the heat exchanger plate pack.

65
General operating instructions 1.3 | 2006-09-08
Technical terms

Term Meaning
Single-pass The standard design of a plate heat exchanger with two
plate heat exchanger flow-through media. Normally, the connections are
placed on the fixed plate.
Splash protector A safety device attached to the heat exchanger plate
pack. GEA Ecoflex generally recommends attaching a
splash protector when using hazardous media.
Support column A fixed component of a PHE frame to which the
carrying beam and the guiding bar are fixed.
Suspending Suspending the pressure plate at the carrying beam
(the pressure plate) (normally with a movable roller). The suspension
makes it possible to move the pressure plate on the
carrying beam.

66
 Notes

Notes

67
General operating instructions 1.3 | 2006-09-08
Notes

Notes

68
 Notes

Notes

69
General operating instructions 1.3 | 2006-09-08
Notes

Notes

70
GEA PHE Systems
Competence in Heat Transfer
With emphasis on the highest quality standards and constant innovations, GEA PHE Systems continues to expand its market
position: Within the GEA Heat Exchangers segment, GEA Ecoflex together with GEA ViEX, GEA WTT, GEA Ecoflex India,
GEA PHE Systems NA and GEA EcoServe forms GEA PHE Systems, the Center of Competence and Service Center for gasketed,
fully welded and brazed plate heat exchangers of GEA Group.

• HVAC • Sugar • Paper • Power • Heavy Industry

• Refrigeration • Chemical • Food • Marine • Renewable Energy

Technical modifications reserved · PHE General Operation Manual · E · 10/06 · 01/10 · die werbestrategen
Argentina Canada Estonia Guatemala Italy Mauritius Portugal Spain The Netherlands
Australia Chile Finland Hungary Korea New Zealand Russia Sri Lanka Turkey
Austria China France India Latvia Pakistan Serbia Sweden UAE
Belgium Colombia Germany Indonesia Lithuania Peru Singapore Switzerland Ukraine
Brazil Croatia Great Britain Iran Luxembourg Philippines Slovenia Taiwan USA
Bulgaria Denmark Greece Israel Malaysia Poland South Africa Thailand Venezuela

Contact details at:

www.gea-phe.com

The specifications contained in this printing unit are intended only to serve the Your contact:
non-binding description of our products and services and are not subject to guarantee.
Binding specifications, especially pertaining to performance data and suitability for specific
operating purposes, are dependent upon the individual circumstances at the operation
location and can, therefore, only be made in terms of precise requests.

GEA Heat Exchangers

GEA Ecoflex GmbH
Karl-Schiller-Straße 1-3 · 31157 Sarstedt · Germany
Phone +49 5066 601-0 · Fax +49 5066 601-104
 Cooling Pump Unit C5.05.09.01.12.32
HT

M25

Cooling Pump Unit

HT

en / 22.01.2014 FD049657 1/52

IRON PUMP
Instruction Manual
Revision:1

Instructions for Installation, Operation, Maintenance and Repair of

Centrifugal pumps Type CNLB (X), CNV (X), CNHB (X) and CNBV (X)
-/160, 200, 250, 315, 400

Your Reference Iron Pump Reference

Purpose : Cooling water Pump Type : CNLB 80-80/160

Order No. : Order No. :
Art No. : Pump No. :
Project : SACH NO.273830196

READ THIS INSTRUCTION MANUAL BEFORE INSTALLING,

OPERATING OR SERVICING THE PUMP

 TECHNICAL DATA
Pump

Pump Type : CNLB 80-80/160

Technical Data

Flow, Q : 60,0 m3/h

Head (Diff. pressure), H : 30,60 mWc
Inlet pressure : -
Discharge pressure : -
Suction lift : -
Power Duty Point, P : 7,80 kW
Power max. : 8,00 kW
Media : Fresh water
Media temp. : 100 C
Seal type : Mechanical
Impeller no. : -
Coupling type : 1/1 Flex
Weight : 65,00 kg
Direction of rotation, Rot.: CW

Materials

Pump casing : Cast Iron GG25

Impeller : NiAl-bronze
Casing wear ring : NiAl-bronze
Shaft : Stainless Steel (AISI 329)
Seal : Carbon / Ceramics max 100 C

Motor

Type : SH MS 132 S2-2

Output : 9,40 kW
RPM, n : 3500
Voltage : 3 x 440 V, 60 HZ
Weight : 54,00 kg
NB! :

Type plate

Pump Type

Pump No. Year of manufacture

Test pressure, Bar Direction of rotation

Flow Head (Diff. pressure)

Power RPM
Duty Point

Miscellaneous

2
EC DECLARATION

EC Declaration of Conformity

EC Declaration
(In accordance with Annex II B of the Machinery Directive 2006/42/EC)

IRON Pump A/S

Generatorvej 10
2730 Herlev
Denmark

Declare that the pumps described in this document comply with the following standards:
',1(1(1,62DQGZLWKLQWKHOLPLWVVSHFL¿HGIRUWKHPDFKLQHU\LVLQFRQIRUPLW\
with the essential health and safety requirements of the Machinery Directive 2006/42/EC and
subsequent amending directives.

7KHPDFKLQHU\GHVFULEHGLQWKLVFHUWL¿FDWHPXVWQRWEHSXWLQWRVHUYLFHXQWLOWKHPDFKLQHU\LQ
which it is incorporated has been declared in conformity with the provisions of the Machinery
Directive and its amendments.

MANUFACTURER:

Michael Mazur
………………………………………………………………………………………………………….
(Signature)

3
 1. CONTENTS

Chapter Section Page

1
Contents

1. Contents 4

2. General 6
2.1 Introduction 6
 ,GHQWL¿FDWLRQ 
2.3 Directions & Warning signs 6
2.4 Warning symbols 6
2.5 General safety 6
3. Installation 8
3.1 Condition on delivery 8
3.2 Inspection on delivery 8
3.3 Storage instructions 8
3.4 Lifting instruction 8
3.5 Foundation 9
3.6 Environment conditions 9
3.7 Piping 9
3.8 Piping connections 9
3.9 Electrical installation 9
3.10 Recommended accessories 9
4. Operation 10
4.1 Start-up procedures 10
4.2 Starting the pump 10
4.3 Stand-by 10
4.4 Pump vibrations 10
4.5 Lubrication 11
5. Maintenance 12
5.1 Inspections 12
5.2 Assembly and Disassembly 12
5.3 EFLEX-R coupling 13
5.4 Fitting instructions for Mechanical seals 18
5.5 Special seal arrangement for Type CNLB-CNV-CNHB-CNBV 19
5.6 Special seal arrangement for Type CNLBX - CNVX - CNHBX - CNBVX 20
5.7 Centrifugal pump wear ring Clearances 22
6. Spare Parts 23
6.1 Repairs 23
6.2 Returning parts 23
6.3 Decommissioning 23
6.4 Table of Materials 23
6.5 Spare parts drawing for CNLB 160. 24
6.6 Spare parts drawing for CNLB(X) 200, 250 25
6.7 Spare parts drawing for CNLB(X) 315 26

4
1. CONTENTS

Chapter Section Page

1

Contents
6.8 Spare parts drawing for CNLB(X) 400 27
6.9 Spare parts drawing for CNHB 200, 250 28
6.10 Spare parts drawing for CNHB 315 29
6.11 Spare parts drawing for CNHB(X) 400 30
6.12 Spare parts drawing for Type A1/A2 seal arrangement 31
6.13 Spare parts drawing for Type F1/F2 seal arrangement 31
6.14 Spare parts drawing for Type E1/E2 seal arrangement 32
6.15 Spare parts drawing for Type C1 seal arrangement 32
7. Data 33
7.1 Type CNLB(X) / CNV(X) - Dimensional drawing and Details 33
7.2 Type CNHB(X) / CNBV(X) - Dimensional drawing and Details 34
7.3 Troubleshooting 35
8. Priming systems 37
8.1 Priming of centrifugal pumps 37
8.2 EA automatic ejector system 38
8.3 VATEC automatic aspirator 39
8.4 PA automatic priming system 40
8.5 Danfoss pressure controller for priming systems 41
8.6 Wiring diagrams for Priming systems 42
8.7 Spare Parts drawing for P-pump with gear - 1450 RPM 43
8.8 Spare Parts drawing for P-pump – 1750 RPM 44
9. Motor 45
9.1 General information 45
9.2 Inspection 45
9.3 Insulation resistance check 45
9.4 Handling 45
9.5 Installation 45
9.6 Repair and Maintenance 47
9.7 Spare Parts and Repair 48
9.8 Troubleshooting 49

5
 2. GENERAL

2.1 Introduction STOP!

This instruction manual contains relevant
This symbol is for all safety instructions which
information on installing, operating and
must be followed to avoid accidental injuries
2 maintaining the pump.
and hazards to life. Observe these safety
instructions carefully and proceed with great
7KH SXPS LV FRQ¿JXUHG IRU WKH VSHFL¿F
care.
FXVWRPHUUHTXLUHPHQWV7KHVSHFL¿FSXPSW\SH
General

is described in the technical data section.

ELECTRIC POWER!
The personnel in charge of installing,
This symbol signals possible danger due
operating and maintaining the pump must be
to presence of current electric power. Only
SURSHUO\TXDOL¿HGDQGWUDLQHGWRFDUU\RXWWKH
proceed if the operator is experienced with the
operations described in this manual. IRON
pump and procedures.
Pump recommends that you read this manual
before you install and operate the pump as this
will minimize any risk of incorrect handling. CAUTION!
IRON Pump A/S cannot be held responsible
for unauthorized use of the pump. This symbol is used for instructions of particular
importance and signals a risk of damage to
IRON Pump A/S does not provide any guarantee the pump or its components. Proceed only if
if working conditions are inappropriate. If the the parts or the pump have been assembled
working conditions differ from those given in according to the instructions.
the technical data sheet, please contact IRON
Pump before putting the pump into operation. 2.5 General safety
The following safety instructions apply for both
 ,GHQWL¿FDWLRQ pumps and motors supplied by IRON Pump
'HWDLOVRIWKHSXPSLGHQWL¿FDWLRQW\SHQXPEHU A/S.
and order No.) are on the front page. The Pump Observe:
1R FDQ DOVR EH IRXQG RQ WKH VXFWLRQ ÀDQJH ‡ The safety regulations
and on the Type plate on the pump. ‡ Accident prevention regulations
‡ &RXQWU\VSHFL¿FVDIHW\UHJXODWLRQV
‡ Guide lines and acknowledged technical
2.3 Directions & Warning signs rules cited in this operating manual.
Comply with all instructions located on the
pump or motor, such as direction of rotation, Non-compliance with safety regulations will
arrows, instruction signs, directions or warning result in danger to personnel and damage to
signs and remember to keep this information the unit, e.g:
in readable condition.
‡ Danger to personnel through contact with
2.4 Warning symbols voltage exceeding 42V.
‡ Failure to observe prescribed methods of
Important machine and safety-related transportation, assembly, maintenance
instructions in this manual are illustrated with and repair of pump or motor.
symbols. It is essential that these instructions
are followed to avoid accidents and damages
When working on the
to machines and/or personnel.
unit, observe all valid
accident prevention regulations
and generally acknowledged
technical rules!

6
2. GENERAL

2.5.1 Electrical hazards

Do not carry out any installation or maintenance
on the pump or motor while it is operating or
before it has been disconnected. Pumps with
motors must have appropriate connections. 2
Amp ratings are given in the pump Technical
data sheet and the power supply must be

General
adequate.

2.5.2 Temperature hazards

Before any maintenance is carried out, be
sure to empty the pump of liquid. If the pump
has been pumping hot liquid, the pump should
be cooled to the surrounding temperature.
As a precaution, the hot parts of the machine
should always be covered to avoid accidental
contact.

2.5.3 Chemical hazards

The pump should always be cleaned before
carrying out any maintenance or repairs. This
will prevent chemical reactions if the pump has
been pumping dangerous liquids.

2.5.4 Dry running

If the pump is not supplied with a priming
device, the pump must never be put into
RSHUDWLRQEHIRUHLWKDVEHHQ¿OOHGZLWKOLTXLG
If the pump is supplied with a priming device,
dry running is permissible for a short period
while the pump is primed.

2.5.5 Noise level

Under normal conditions the pump and the
motor will produce a noise level below 80 dB.
The exact noise level depends on motor type,
foundation and environment.

The operator must wear protective gear if the

noise level becomes harmful.

7
 3. INSTALLATION
3.1 Condition on delivery WKHEHDULQJVDQGWKHVHDOIDFHVLI¿WWHGIURP
sticking.
IRON Pump products are tested before
delivery to ensure perfect running condition.
3.3.1 Preservation procedure
A test run is made of the pump using water
to check the performance data stated in the Flush the pump with pure hot water and let it
WHFKQLFDOVSHFL¿FDWLRQV air dry. Close the valves on both sides of the
SXPS DQG ÀXVK WKH SXPS ZLWK ³0RELO $UPD
3 3.2 Inspection on delivery 25” or similar quality. Flushing can be done
through the manometer connections.
Check your shipment immediately upon arrival.
Make sure that the parts and accessories
Installation

3.3.2 Restarting
received are in accordance with your order.
,QWKHHYHQWRIGDPDJHGHIHFWVRUGH¿FLHQF\ When starting/restarting the pumps after
immediately report the problem to the transport VWRUDJHLWLVDGYLVDEOHWR¿OOWKHSXPSZLWKKRW
company and IRON Pump. water through the manometer connections and
to turn the pump shaft by hand before starting.
The packaging must be examined to make Then follow 4.1 Start-up procedures.
sure that it is in good condition to guarantee
protection in storage. 3.4 Lifting instruction

The packaging may only be opened when:

‡ 6WUDSV DUH PRXQWHG DURXQG WKH ÀDQJHV
(Lifting chains might damage the surface
‡ It is seriously damaged.
of the pump, and are not recommended).
‡ The product is to be stored longer than
A wooden bar is placed above the motor to
originally planned.
guide the strap.
‡ If the motor has lifting eyes at the top, these
In all other cases the packaging may only be
can be used to guide the pump so it does
opened at assembly. When the packaging has
QRWWLS2WKHUZLVHDVWUDS¿[HVWKHPRWRU
been removed, the product must be examined
IRUDQ\GH¿FLHQFLHVRUGHIHFWV

3.3 Storage instructions

The standard packaging protects the pump
against corrosion during land transport and
storage in dry conditions for at least three
months.

If the pump is not installed immediately

after delivery, it must be protected against
corrosion, vibrations, frost and kept in a dry
place.

If the pump has to be stored for a longer time,

maximum 2 Years, the pump has been treated
with LPS2® inside the pump casing (Pump
casing, Impeller and Casing wear rings). On
WKHRXWVLGH/36ŠLVXVHGRQÀDQJHVVKDIW
and other surfaces without paint.

/HDYHÀDQJHFRYHUVLQSODFHWRNHHSGLUWDQG
other foreign material out of the pump casing.

Turn the pump shaft by hand at regular

intervals of one month, to prevent brinelling of

8
3. INSTALLATION
3.5 Foundation 3.8 Piping connections
7KHSXPSPXVWEH¿[HGWRDULJLGIRXQGDWLRQ Before installing the pump, the entire piping
which is substantial enough to absorb vibrations must be pressure and leakage tested and
and to take up stress from the hydraulic strain ÀXVKHG FOHDQ EHIRUH LW LV FRQQHFWHG WR WKH
and loads from the pipelines. suction and discharge side of the pump. If
7KH SXPS VKRXOG EH LQVWDOOHG ZLWK VXI¿FLHQW the pressure test takes place with the pump
accessibility for inspection and maintenance. installed, the testing pressure must not exceed
The surface of the foundation where the
pump is installed must be level and horizontal.
the testing pressure of the pump, which is
stamped into the pump, usually in the suction
3
Damage due to an inadequate or faulty ÀDQJH7KHSXPS¶VJDVNHWVRUÀDQJHVIRUWKH

Installation
foundation is not covered by the guarantee. mechanical shaft seal might otherwise be
damaged.
If the pump and motor are delivered separately,
they must be assembled. (See 5.3). After Check that all other connections to the pump
assembly, the unit can be mounted directly on are in working order, such as lubrication,
to a suitable foundation. priming, heating, cooling media outlet, etc.,
and that the various measuring equipment
has been correctly connected. Take care that
no parts obstruct easy access to the pump for
3.6 Environment conditions inspection or replacement of important parts.

Standard pumps are intended for installion in

dry rooms free from aggressive atmosphere
3.9 Electrical installation
in temperatures between + 10 and 40 oC Connect the cables according to local electrical
Installing the pump in other conditions (e.g. regulations and standards, and by authorised
outdoors, in damp rooms etc.) is only allowed skilled stuff. The pump should be connected
if this is stated in the technical data sheet. to a motor starter.

3.7 Piping Check that there is enough cable to allow the

motor to be removed without disconnecting
Suction and pressure lines must be connected the wires. A switch (emergency stop) must be
WR WKH ÀDQJHV RI WKH SXPS IUHH IURP VWUDLQ installed close to the pump.
DVDQ\VWUHVVHVDUHWDNHQXSDW¿[HGSRLQWV Kilowatt ratings are given in the pump Technical
and suitable compensators should therefore data sheet.
EH LQVWDOOHG LQ WKH SLSH V\VWHP 7KH ÀDQJHV
between which the pump is installed must be
absolutely parallel.
3.10 Recommended accessories
As the pump, especially the mechanical
7RNHHSSUHVVXUHORVVDQGÀRZUHVLVWDQFHDW shaft sealing, is designed to run with clean
a minimum, tight bends and substantial size ZDWHU ZLWKRXW VOXGJH D VXLWDEOH ¿OWHU PXVW
reductions in the piping system should be be installed in the suction line, and if the
avoided. mechanical seal is not furnished with external
FRROLQJ D ¿OWHU PXVW EH LQVWDOOHG LQ WKH
Loss of pressure in the suction line must be FLUFXODWLRQ SLSH $ ¿OWHU KDYLQJ D ODUJH DUHD
kept at a minimum in order to avoid cavitation and which can be cleaned is recommended.
in the pump. Static suction height + loss of
pressure in the suction line + NPSH value for ,5213XPS$6FDQVXSSO\VXLWDEOH¿OWHUV
the pump + steam pressure must not exceed
10 mWc at sea level. Long suction pipes that
make air pockets possible should be avoided.

9
 4. OPERATION

4.1 Start-up procedures 4.2 Starting the pump

Ensure that the pump and motor are mounted When the pump is ready, it is started with the
according to instructions, all connections are discharge valve closed. After starting, the
correct and the necessary screens and guards discharge valve is slowly opened until the
are in order. working point is reached. If the pump runs
with closed valves for a period, it should be
‡ Check the direction of rotation (marked equipped either with temperature control
with an arrow). The motor must turn in the equipment or recirculation. Running with the
direction in which the arrow is pointing. If valves closed for a long period can damage
4 the direction is wrong, the connections to
the terminals of the electric motor should
the pump.
Check bearing temperature (max. 105o C)
be changed.
‡ Check that the pump can be turned by
Operation

Do not run pump with closed valve on

hand. discharge side for prolonged time.
‡ Check that the motor has been lubricated
with grease. 4.3 Stand-by
‡ Make sure that there is grease in the
bearing housing (Item 330) (See 6.5-6.11). If the pump is going to be on stand-by for a
‡ Make sure that the piping is clean and free long period, it must be started or rotated at
IURP IRUHLJQ REMHFWV /LTXLG VKRXOG ÀRZ least once a week to avoid damage to the
regularly into the pump. mechanical seals.
‡ Check that the pump and suction pipe are
¿OOHG ZLWK OLTXLG $Q\ DLU RU JDV PXVW EH 4.4 Pump vibrations
carefully released before start-up.
'XULQJ RSHUDWLRQ EH DZDUH WKDW VLJQL¿FDQW
‡ Check the pump for noise and vibrations
YLEUDWLRQVKDYHDPDMRUDIIHFWRQWKHSXPS¶V
immediately after starting. At the normal
SHUIRUPDQFH ,I YLEUDWLRQV DUH VLJQL¿FDQW WKH
head it should have a very steady motion
pump should immediately be turned of to be
without unusual noise and vibrations after
able to locate possible errors.
one minute.
‡ Check the priming device (if any).
‡ Check the shaft seal housing for leakages
Never operate the pump without
(Item 441). (See 6.12)
the coupling guard .

4.1.1 Pumps with Priming device

Pumps provided with a mechanical priming
pump should be checked for supply/content of
liquid before starting.

The valve on the discharge side of the pump

must be closed during priming. The operating
instructions for the priming system should be
strictly followed (See Chapter 8).
After priming the pump, open the valve on
the discharge side slowly and adjust it in such
a way that the permissible vacuum is not
exceeded.

10
4. OPERATION

4.5 Lubrication
The pump bearings are greased with
Mobilth SHC 100 or similar grease.

The pump is lubricated in accordance with the

following tables:

Pump type Grease amount Lubricating interval

- / 160 10 g. per bearing 2000 hours 4
- / 200 16 g. per bearing 2000 hours
50-100/250 16 g. per bearing 2000 hours

Operation
125-200/250 25 g. per bearing 2000 hours
80-250/315 25 g. per bearing 2000 hours
- / 400 35 g. per bearing near housing 1000 hours
55 g. per bearing near coupling

Grease -all types

Nato code/DIN G 395

BP ENERGREASE LS-EP2
CASTROL SPHEEROL AP 2/3
CHEVRON DURA LITH GREASE EP2
ESSO BEACON EP2
MOBIL MOBILITH SHC 100
Q8 REMBRANDT EP2
SHELL ALVANIA GREASE EP2
TEXACO MULTIFAK ALL PURPOSE EP2

11
 5. MAINTENANCE

5.1 Inspections Study the Spare Parts drawing for the

actual pump before starting disassembly
Before any inspection and maintenance of the
the pump.
pump, the operator must ensure that the pump
cannot be unintentionally started. The pump
5.2.1 Disassembly CNLB/CNV
must be stopped, and all electronic contacts
must be disconnected.
Ensure that the pump has been drained of
liquid
The system must be de-pressurized and the
‡ Unscrew bolts connecting pump casing
pump must be emptied of liquid and washed.
(Item 101) and casing cover (Item 161).
If the pump has been pumping hazardous
Lift the disconnected part of the pump
liquids, the liquid must be collected, and the
comprising of the motor, motor stool (Item
SXPS VKRXOG EH ÀXVKHG ZLWK FOHDQ ZDWHU RU
5 another suitable liquid.
341), bearing bracket housing (Item 344)
and casing cover.
‡ If the space is too small or the motor is too
It is important to ensure that
ELJWKHPRWRUPXVWEHUHPRYHG¿UVW
Maintenance

the pump does not contain ‡ The impeller (Item 230) will follow the
dangerous amounts of removed part, enabling direct access.
corrosive, toxic or similar ‡ Gentle disconnection is recommended to
substances when maintenance prevent any damage to the mechanical
is taking place. seal (Item 433).

5.1.1 Three-month inspection 5.2.2 Assembly CNLB/CNV

‡ Check suction and discharge pressure. (See 6.5-6.11)

‡ Check for unusual noise, vibrations and ‡ Before reassembling, clean the inside of
leakages. the pump casing and paint with appropriate
‡ Inspect the motor as per the instructions coating.
from the manufacturer. ‡ In order to make disconnection of the pump
‡ The mechanical seal must be inspected for easier at a later stage, lubrication of all
leaks. The seal must not leak either during EROWVDQGDVVHPEOLQJVXUIDFHVZLWK³1HYHU
stand-by or during operation. Seez” lubricant is recommended.
‡ Assemble bearing bracket (Item 330),
If any faults are found during inspection, they bearings (Item 321) and bering covers
must immediately be corrected, since any (Item 360.1+360.2).
defects can be of major importance for the ‡ Assemble the bearing bracket housing
functioning of the pump and its life spare. (Item 344) and the complet bearing bracket
with bracket (Item 341) and the motor.
5.1.2 Twelve-month inspection ‡ Fit the thrower (Item 507) on the shaf (Item
210) .
Take the pump apart (See 5.2). The rotating ‡ Casing cover (Item 161), with the seat ring of
parts are checked and repaired if necessary. the mechanical shaft seal (Item 433), must
Normal clearance between the impeller and EH¿WWHGJHQWO\RQWKHVKDIWDQGWLJKWHQHG
casing wear ring is 0,45-0,50 mm. Maximum to the bearing bracket housing (Item 344)
clearance is 0,8-1,0 mm. depending on the by screws. The O-ring (Item 412) must be
Size and Capacity (See 5.7). ¿WWHGWRWKHFRYHU
‡ The rotating part of the shaft seal is carefully
5.1.3 Lubrication placed on the shaft.
(See 4.5.) ‡ The casing wear ring (Item 502.1) and the
The pump bearings are greased with Mobilith LPSHOOHU PXVW EH ¿WWHG DQG WLJKWHQHG E\
SHC 100 or similar grease. screws.
‡ 7KHURWDWLQJDVVHPEO\FDQEH¿WWHGWRWKH
5.2 Assembly and Disassembly pump casing ( where the second casing

12
5. MAINTENANCE

wear ring (Item 502.2) is already tightened pump casing ( where the second casing
by screws) and tightened by screws. wear ring (Item 502.2) is already tightened
‡ Before any up-start, the shaft must be by screws) and tightened by screws.
turned by hand in order to check for any ‡ Mount the spacer coupling.
blockages. ‡ Before any up-start, the shaft must be
‡ Bearings must be lubricated and the turned by hand in order to check for any
pump primed in order to prevent any dry blockages. Bearings must be lubricated
running. and the pump primed in order to prevent
any dry running.
5.2.3 Disassembly CNHB/CNBV
5.2.5 Torque Table
Ensure that the pump is emptied of liquid
‡ The rotating parts can be removed without When the pump is assembled and all bolts
removing the motor and nuts are in place, they can be tightened. 5
‡ Remove the spacer coupling (Item 860.5 This chart is valid for bolts greased with an
+ 860.7) appropriate compound (e.g. ”Never Seez”).

Maintenance
‡ Unscrew bolts connecting pump casing
and casing cover. Lift the disconnected part Bolt size Fastening Moment Nm
of the pump comprising bearing bracket
housing (Item 344) and casing cover.
Stainless Steel
‡ The impeller will follow the removed part, steel
enabling direct access. M6 9 10
‡ Gentle disconnection is recommended to M8 22 24
prevent any damage to the mechanical
M10 44 45
seal.
M12 75 80
5.2.4 Assembly CNHB/CNBV M16 185 200
‡ Before reassembling clean the inside of M20 360 380
the pump casing and paint with appropriate
coating. 5.3 EFLEX-R coupling
‡ In order to make disconnection of the pump
easier at a later stage, lubrication of all Never operate the pump without
EROWVDQGDVVHPEOLQJVXUIDFHVZLWK³1HYHU the coupling guard .
Seez” lubricant is recommended.
‡ Assemble bearing bracket (Item 330), 5.3.1 Mounting
bearings (Item 321 + 323) and bearing ‡ Before mounting the hubs, carefully clean
cover (Item 360.1 + 360.2). the shaft ends and the coupling parts.
‡ Assemble the bearing bracket housing (Item ‡ 7KH LQVLGH KXEV PXVW EH ÀXVK ZLWK WKH
344) and the complet bearing bracket shaft ends. Tighten the set screw to secure
‡ Fit the thrower (Item 507) on the shaft (Item the hubs axially.
210) . ‡ Bring the coupling hubs together, observing
‡ Casing cover (Item 161), with the seat ring of the dimension S1/Sz according to the Table
the mechanical shaft seal (Item 433), must 5.3.7.
EH¿WWHGJHQWO\RQWKHVKDIWDQGWLJKWHQHG ‡ Tighten the set screw only with a hexagon
to the bearing bracket housing (Item 344) socket wrench according to DIN 911 without
by screws. The O-ring (Item 412) must be extension piece.
¿WWHGWRWKHFDVLQJFRYHU,WHP ‡ 5HPRYHÀH[LEOHHOHPHQWVIURPWKHIHPDOH
‡ The rotating part of the shaft seal is placed part, and heat the coupling parts to approx.
carefully on the shaft. 80oC.
‡ The casing wear ring ( Item 502.1) and ‡ (QVXUHWKDWWKHÀH[LEOHHOHPHQWVDUHWXUQHG
WKHLPSHOOHU,WHPPXVWEH¿WWHGDQG correctly when they are remounted - (See
tightened by screws. 5.3.8 and 5.3.9)
‡ 7KHURWDWLQJDVVHPEO\FDQEH¿WWHGWRWKH

13
 5. MAINTENANCE

‡ Check all screw connections with screw before replacement is required.

tightening torques of the table.
 5HSODFHPHQWRIÀH[LEOHV
5.3.2 Alignment
Type EFLEX-RN
‡ EFLEX-R couplings will accommodate (See 5.3.8)
deviations in the relative position of shafts ‡ Continuous torque transmission and
to be connected.(See 5.3.3). reliability of operation cannot be guaranteed
‡ When aligning the coupling halves, the XQOHVV RULJLQDO ()/(;5 ÀH[LEOHV DUH
angular and parallel offset misalignments used.
of interrelative shafts should be reduced ‡ $IWHU¿WWLQJQHZÀH[LEOHVHQVXUHWKDWWKH\
as much as possible. Alignment must are turned correctly.
be carried out in two planes as shown in ‡ Check the mounting before starting up.
5 Fig.1 (See 5.3.8) with a ruler (Fig.4, offset Type RZ with spacer
misalignment) and spacer bar (Fig. 3, (See 5.3.9)
angular misalignment). For better accuracy ‡ Uninterrupted torque transmission and
Maintenance

use a dial indicator. reliability of operation cannot be guaranteed

‡ The gap dimension S1/Sz should be within XQOHVV RULJLQDO ()/(;5 ÀH[LEOHV DUH
the limits listed in the table. used.
‡ 7KH ÀH[LEOHV FDQ EH UHSODFHG ZLWKRXW
5.3.3 Possible misalignments moving connected shafts or machines.
‡ Loosen screw connection and force parts
‡ The axial distance Ka must be within the
A and B out of their centrings with the aid
limits for S1/Sz (See Table 5.3.7).
of the forcing screw in part B. Push part C
‡ Angular misalignment Kw is measured
as far as possible into part D. Part B can
as the difference between Smax. and Smin.
now be removed radially. Bring part C back
Possible values are calculated with values
RXWRISDUW'7KHÀH[LEOHVDUHQRZIUHHO\
from the table.
accessible.
‡ Parallel offset misalignment Kr – (See the
‡ $IWHU¿WWLQJQHZÀH[LEOHVEHVXUHWKH\DUH
Table 5.3.7) Angular and parallel offset
turned correctly. Reassemble in reverse
misalignment might occur at the same
order.
time. The total of both alignments should
not exceed the values Kr or Kw.
‡ K W and KR apply in a shock-free operation
at ambient temperature -30oC to 80oC.

5.3.4 Operation
‡ Before starting initial operation, check
alignment and gap dimension S1/Sz and
make corrections if required. Also check
the screw connections.

5.3.5 Maintenance
‡ EFLEX-R couplings do not require
any regular maintenance except for an
occasional check on the torsional play or
backlash between the driving and driven
halves. When EFLEX-R couplings are used
in drives which do not require a minimum of
torsional play or backlash in the coupling,
WKH FRXSOLQJ ÀH[LEOHV FDQ EH DOORZHG WR
wear down 2/3 of their original thickness

14
5. MAINTENANCE

5.3.7 Table EFLEX-R

Coupling S1 Sz Angular Offset

size/ Misalignment Misalignment
Type RN Type RZ Kw Kr
outside diam. Spacer Smax. - Smin
mm mm mm mm.
mm
1800 RPM 3600 RPM 1800 RPM 3600 RPM
2/80 3-4.5 5-10 1.4 0.28 0.26 0.05
3/94 3-4.5 5-10 1.6 0.32 0.30 0.06
4/110 4-6 5-10 1.9 0.38 0.36 0.07
5/125 4-6 5-10 2.2 0.44 0.42 0.08 5
6/140 5-7.5 5-10 2.4 0.48 0.50 0.10
7/165 5-7.5 5-10 2.9 0.58 0.60 0.12

Maintenance
8/180 5-7.5 6-12 3.1 0.62 0.70 0.14
9/210 6-9 7-14 3.7 0.76
10/240 6-9 7-14 4.2 0.84
11/260 7-10.5 7-14 4.5 0.95
12 / 300 8-12 5.2 1.00
13 / 325 8-12 5.7 1.15
14 / 360 10-15 6.3 1.30

15
 5. MAINTENANCE

5.3.8 Instruction drawing for EFLEX-R coupling type RN

Female S1 Male
Part 2 Part 1

5
Maintenance

Straight edge

Fig. 1
Spacer bar

Ka Kw
Smax Smax
Kr

Smin Smin

Axial movement Angular misalignment Offset misalignment

Fig. 2 Fig. 3 Fig. 4
28118E

16
5. MAINTENANCE

5.3.9 Instruction drawing for EFLEX-R coupling type RZ

SZ
Part D Part C Part B Part A

5
2
2

2
2

Maintenance
Straight edge

Spacer bar
Fig. 1

Smax Smax
Ka
Kw

Kr

Smin Smin

Axial movement Angular misalignment Offset misalignment

Fig. 2 Fig. 3 Fig. 4
28277E

17
 5. MAINTENANCE
5.4 Fitting instructions for ‡ Check that the shaft diameter corresponds
Mechanical seals with the dimension of the seal within a
tolerance of 0.05 mm.
A mechanical seal is a very high-precision ‡ The bore in the housing and the seat must
product and should be treated with the utmost be lubricated. Use only liquid soap, soapy
FDUHEHIRUHDQGGXULQJ¿WWLQJ'RQRWXQSDFN water or glycerine with ethylene-propylene
until ready for use. The rotating wear ring and elastomer. The elastomer must also be
the seat have been lapped to a high degree of lubricated on the inside where it slides on
accuracy. the shaft. Lubricants containing silicone
must never be used.
IRON PUMP/BURGMANN mechanical seal ‡ Press the seat into position with your
used for pumps ¿QJHUV ,I WKH VSDFH LV WLJKW XVH D EXVK
when pressing the seat into position. Take
5 IRON Pump STANDARD care not to damage the surface of the seat.
For example, use a piece of plastic for
protection between the bush and the seat.
After pressing the seat into position, make
Maintenance

sure that it is fully in place by measuring

the depth with a depth calliper.
‡ 7KH FRPSUHVVHG OHQJWK DIWHU ¿WWLQJ PXVW
33.5(ø30-40)
25(ø10-ø25)

41(ø42-ø60)

correspond to the working length of the

size of seal in question given in the table of
measurements.
‡ Be aware of changes that can occur when
bearing arrangements and gaskets etc. are
replaced.
‡ %HIRUHWKHSXPSLVVWDUWHGLWPXVWEH¿OOHG
07.47.06E with liquid and the air allowed to escape.
Air should be bled frequently during the
IRON/BURGMANN period after starting.

:KHQ¿WWLQJVKDIWVHDOVWKH
instructions should be read
carefully, especially when the
media is dangerous (poisonous,
KRWÀDPPDEOHHWF
33.5(ø30-40)
25(ø10-ø25)

41(ø42-ø60)

07.47.06E
Fitting instructions:

‡ Remove the protective packaging from the

seal, check for damage, and wipe clean.
‡ Make sure that the pump is ready and
switched off.
‡ The shaft should be clean and free of
burrs, and the machined place where the
VHDW ¿WV PXVW EH FOHDQHG YHU\ FDUHIXOO\
Edges should be rounded so that they are
not sharp or penetrating.

18
5. MAINTENANCE

5.5 Special seal arrangement for ATTENTION!

Type CNLB-CNV-CNHB-CNBV
Set screws with cup points may be used only
once. Repeated fastening endangers the
5.5.1 CHETRA 900/CHESTERTON 891 safety of the power transmission.
Fitting instructions:
‡ Remove the colour-marked assembly
(See 5.4) ¿[WXUH,WHP
‡ Make sure that the compressed lenght is ‡ Turn the pump shaft carefully by hand and
corresponding with the working length of the WLJKWHQ WKH RWKHU VHW VFUHZV ¿UPO\ WR WKH
size of seal in question given on the drawing. shaft step by step.
Normaly there is no distance ring behind ‡ 5HPRYHWKHUHPDLQLQJDVVHPEO\¿[WXUHV
the shaft seal to keep the compressed ‡ .HHSWKHDVVHPEO\¿[WXUHVIRUODWHUUHPRYDO
lenght for this seal type. of the seal. 5
‡ Turn the pump shaft carefully once by hand.
The shaft should turn steadily.

Maintenance
‡ Connect the piping and tighten it securely.

9 13
12
44,5(ø35-ø60)

471
35(shaft ø30)

433
433
14
210

Secure screw with LOCTITE

433
161
5.5.2 Cartridge seal
Fitting instructions:

‡ Remember the packing (Item 14) when

mounting the mechanical seal (Item 433).
‡ Loosen the set screws (Item 9). Do not
unscrew them. Spare Parts list Item. No.
‡ Move the mechanical seal down to the
casing cover (Item 161). Screw 9
&RORXUPDUNHGDVVHPEO\¿[WXUH 
‡ Bolt the cover of the mechanical seal to the Screw 13
casing cover. Packing 14
‡ 7LJKWHQ WKH DFFHVVLEOH VHW VFUHZV ¿UPO\ Casing cover 161
Shaft 210
to the shaft ( Item 210) crosswise. Do not Mechanical seal 433
rotate the shaft.
‡ Degrease the set screws (Item 9) and
secure with 1 drop each of liquid screw
retention, e.g. Loctite .

19
 5. MAINTENANCE
5.6 Special seal arrangement Type A2 - with Mechanical seal
for Type CNLBX - CNVX - without Constant Level Oiler
CNHBX - CNBVX Mechanical shaft seal without The Constant
Level Oiler.
5.6.1 TYPE A1/A2
Fitting instructions:
(See 5.4 and 6.12).
(See 5.4 and 6.12)
Type A1 - with Mechanical seal
with Constant Level Oiler 5.6.2 TYPE C1
‡ Mechanical shaft seal ( Item 433) with The
Constant Level Oiler ( Item 638) to prevent Double mechanical shaft seal designed for
overheating during priming. external cooling water max. 60oC.
5 ‡ The Constant Level Oiler is used to prevent
the mechanical shaft seal from dry running. Fitting instructions:
,W RQO\ KDV WR EH ¿OOHG ZLWK RLO ZKHQ WKH
Maintenance

pump is running without water for very (See 5.4 and 6.15).
short periods of the time (during priming
etc.). Use Tool /(Item 969) for mounting the seals on
‡ 7KH &RQVWDQW /HYHO 2LOHU  PXVW EH ¿OOHG the shaft.
with lubricating oil (Type SAE10-SAE40), Type C1
when taking the pump into operation as
well as during times when the pump can be
operated without water for shorter periods
(during priming etc.).
‡ During normal operation the Constant
Level Oiler can be left empty.
638
Type A1/A2

23270

23270

ALWAYS FILL
NEVER BOTTLE HER!
FILL Use lubricating oil SAE10-SAE40
HER!

074205E

20
5. MAINTENANCE

5.6.3 TYPE E1/E2 + F1/F2 Type E1

(See 5.4 and 6.14 + 6.13).

6WXI¿QJ ER[ ZLWKRXW RU ZLWK H[WHUQDO FRROLQJ

water max 60oC, with or without exchangeable
shaft wearring sleeve (Item 524).

Fitting instructions:

Observe all decompression cooling

requirements, maintenance and safety
procedures before installation. Read all Type E2 5
instructions before proceeding.

Maintenance
‡ Follow normal cleaning procedures.
Remove all old packing rings. Make sure
the shaft wearring sleeve is true (0.03”
(0.08 mm) run out maximum) and smooth
with no burrs or grooves.
‡ Make butt-cut rings. The preferred way is
to wind the desired number of rings (Gland
packing, Item 461) on a mandrel with the
same diameter as the shaft, and cut the
rings by making one straight cut parallel
with the mandrel.
‡ ,QVHUW JODQG SDFNLQJ LQWR WKH VWXI¿QJ ER[ Type F1
housing (Item 451) - not more than two at
a time, and seat to location by tamping,
preferably by using a tamping tool. Stagger
all ring joints at 90 o intervals. Turn the shaft
occasionally to assist seating the gland
packing rings.
‡ 7DNH XS WKH JODQG QXWV ¿QJHUWLJKW RQO\
Make sure there is initial leakage (a
minimum of 20-30 drops per minute).
Loosen the gland nuts if necessary. Never
allow the gland (Item 452) to heat up. Allow
ample time before subsequent adjustments
are made to allow for proper break-in. Take
XS  WXUQ  ÀDW DW D WLPH QR PRUH Type F2
than every 15 minutes. Make sure the
gland adjustments are applied evenly.

2327001

21
 5. MAINTENANCE

5.7 Centrifugal pump wear ring Clearances

CLEARANCE

5
WEAR RING DIAMETER
Maintenance

THE CLEARANCES STATED ARE AVERAGE VALUES,

AND MUST IN EACH SINGLE CASE BE COMPARED
WITH THE NEEDS FOR THE NECESSARY OPERATION DATA.

1,0

0,9

0,8
CLEARANCE (mm)

0,7

0,6

0,5

0,4

0,3

0,2

0,1

100 200 300 400

WEAR RING DIAMETER (mm) 22531E1

22
 6. SPARE PARTS

6.1 Repairs 6.4 Table of Materials

When ordering Spare Parts or requesting our Table of materials with the total content
assistance, please advise the following: calculated as percentage by weight.

‡ Pump type CNLB CNHB

‡ Serial number (i.e. P. no. CNL ####, from
Description Material % %
Type plate, it is also stamped in the suction
Pump casing See Technical data 38 35
ÀDQJH
‡ IRON Pump A/S order number (5 or 7 Casing cover See Technical data 7 6.5

digits.) Shaft AISI 329 4 3.5

‡ Item No. and description of part (See Spare Impeller See Technical data 5,5 5
Parts drawing). Casing wear See Technical data 0.6 0.6
ring
7R HVWDEOLVK WKH FRUUHFW µGLDJQRVLV¶ D EULHI Mechanical Carbon/ceramics 0.3 0.3
seal
description of the breakdown is also required.
O-Ring
Base
Viton
Cast iron
0.1
9
0.1
8
6
Spares are normally available from stock.
Motor stool Cast iron 21 25

Spare Parts
If you do the repairs yourself, you are requested Coupling Cast iron 2.5 2
to follow the instructions regarding assembly Accessories Steel 1 1
and disassembly or to contact our service
department.

6.2 Returning parts

Before returning parts to IRON Pump A/S,
please note that all liquids must be removed
and parts should be cleaned and neutralized.

The sender is liable for damage suffered by

the pump or other goods caused by leaking of
liquid during transport.

6.3 Decommissioning
Do not dump old or used parts. Metal parts
should be recycled as scrap or sent back to
IRON Pump.

When decommissioning the pump, it should be

neutralized and cleaned, and any hazardous
liquids,should be removed and sent to a
recycling facility.

None of the materials in the pump can be

considered hazardous, but we urge you to act
with care and to take the steps needed when
decommissioning the pump or its parts.

23
 6. SPARE PARTS

6.5 Spare parts drawing for CNLB 160.

341.1
861.1
867
861.2
341
210
420
636.1
360.1
330

321
6 636.2

360.2
Spare Parts

420

433
344

161
412
502.1
101

230
502.2
554
906
182
Secure screw with LOCTITE

Casing for pump type CNV(X) 160

101

2461611

Spare Parts list Item. No. Spare Parts list Item No. Spare Parts list Item No.

Pump casing 101 0RWRUVWRROÀDQJH   Casing wear ring 502.2

Casing cover 161 Bearing bracket housing 344 Washer 554
Foot 182 Bearing cover 360.1 Grease nipple 636.1
Shaft 210 Bearing cover 360.2 Grease nipple 636.2
Impeller 230 O-Ring for pump casing 412 Coupling half 861.1
Radial ball bearing 321 Shaft seal ring 420 Coupling half 861.2
Bearing bracket 330 Mechanical seal 433 &RXSOLQJÀH[LEOHV  
Motor stool 341 Casing wear ring 502.1 Impeller screw 906

24
6. SPARE PARTS

6.6 Spare parts drawing for CNLB(X) 200, 250

341.1
861.1
867
861.2
341
210
636.1
420.1
360.1
321
330
323
636.2
420.2
6
360.2

Spare Parts
507

344
433

161
412
502.1
101

230
502.2
554
906
182
Secure screw with LOCTITE

Casing for pump type CNV(X) 200, 250

101

2461613

Spare Parts list Item. No. Spare Parts list Item No. Spare Parts list Item No.

Pump casing 101 0RWRUVWRROÀDQJH   Casing wear ring 502.2

Casing cover 161 Bearing bracket housing 344 Thrower 507
Foot 182 Bearing cover 360.1 Washer 554
Shaft 210 Bearing cover 360.2 Grease nipple 636.1
Impeller 230 O-Ring for pump casing 412 Grease nipple 636.2
Radial ball bearing 321 Shaft seal ring 420.1 Coupling half 861.1
Trust ball bearing 323 Shaft seal ring 420.2 Coupling half 861.2
Bearing bracket 330 Mechanical seal 433 &RXSOLQJÀH[LEOHV  
Motor stool 341 Casing wear ring 502.1 Impeller screw 906

25
 6. SPARE PARTS

6.7 Spare parts drawing for CNLB(X) 315

341.1
CNLB(X)-/315
861.1
867
861.2
341
210
636.1
420
360.1
321
330
323
636.2
6 420
360.2
507
Spare Parts

471
400
344
433
161
412
502.1
101
504
230
502.2
554
906
182
Secure screw with LOCTITE

Casing for pump type CNV(X) 80-150/315 Casing for pump type CNV(X) 200-250/315

101 101
412
162
2461614

Spare Parts list Item. No. Spare Parts list Item. No. Spare Parts list Item No.

Pump casing 101 0RWRUVWRROÀDQJH   Casing wear ring 502.2

Casing cover 161 Bearing bracket housing 344 Spacer ring 504
Suction cover 162 Bearing cover 360.1 Thrower 507
Foot 182 Bearing cover 360.2 Washer 554
Shaft 210 Gasket for seal cover 400 Grease nipple 636.1
Impeller 230 O-Ring for pump casing 412 Grease nipple 636.2
Radial ball bearing 321 Shaft seal ring 420 Coupling half 861.1
Trust ball bearing 323 Mechanical seal 433 Coupling half 861.2
Bearing bracket 330 Seal cover 471 &RXSOLQJÀH[LEOHV  
Motor stool 341 Casing wear ring 502.1 Impeller screw 906

26
6. SPARE PARTS

6.8 Spare parts drawing for CNLB(X) 400

CNLBX-/400
861.1
867 341
861.2 420.1
923 360.1
636 354
931 323
330
210

420.2 322
507 360.2
636 344
433 471
412.1 441 6
412.2 161
504 230

Spare Parts
400 502.1
412 502.2

101

554
Secure screw with 906
LOCTITE
182

Casing for pump CNVX-200+250/400 Casing for pump CNVX-300/400

101
412.3
101 509
2636411 162

Spare Parts list Item. No. Spare Parts list Item. No. Spare Parts list Item No.

Pump casing 101 Bearing cover 360.1 Casing wear ring 502.1
Casing cover 161 Bearing cover 360.2 Casing wear ring 502.2
Suction cover 162 Gasket for casing cover 400 Spacer ring 504
Foot 182 O-Ring for pump casing 412 Thrower 507
Shaft 210 O-Ring for seal 412.1 Intermediate ring 509
Impeller 230 O-Ring for seal 412.2 Washer 554
Radial roller bearing 322 O-Ring for suction cover 412.3 Grease nipple 636
Thrust ball bearing 323 Shaft seal ring 420.1 Coupling half 861.1
Bearing bracket 330 Shaft seal ring 420.2 Coupling half 861.2
Motor stool 341 Mechanical seal 433 &RXSOLQJÀH[LEOHV  
Bearing bracket housing 344 Shaft seal housing 441 Impeller screw 906
Thrust bearing housing 354 Seal cover 471 Bearing nut 923
Lock washer 931

27
 6. SPARE PARTS

6.9 Spare parts drawing for CNHB 200, 250

341.1
CNHB-/200+/250 861.1
867
860.7
860.6
860.5
341
210
636.1
420
360.1
321
330
6 323
636.2
420
Spare Parts

360.2
507
344
433
161

412
502.1
101

230
502.2
554
906
182
Secure screw with LOCTITE

Casing for pump type CNBV(X) 200, 250

101

2566311
Spare Parts list Item. No. Spare Parts list Item. No. Spare Parts list Item No.

Pump casing 101 0RWRUVWRROÀDQJH   Thrower 507

Casing cover 161 Bearing bracket housing 344 Washer 554
Foot 182 Bearing cover 360.1 Grease nipple 636.1
Shaft 210 Bearing cover 360.2 Grease nipple 636.2
Impeller 230 O-Ring for pump casing 412 Coupling part 860.5
Radial ball bearing 321 Shaft seal ring 420 Spacer bush 860.6
Trust ball bearing 323 Mechanical seal 433 Coupling part 860.7
Bearing bracket 330 Casing wear ring 502.1 Coupling half 861.1
Motor stool 341 Casing wear ring 502.2 &RXSOLQJÀH[LEOHV  
Impeller screw 906

28
6. SPARE PARTS

6.10 Spare parts drawing for CNHB 315

341.1
CNHB-/315 861.1
867
860.7
860.6
860.5
341
210
636.1
420
360.1
321
330
323
636.2 6
420
360.2

Spare Parts
507
471
400
433
344
161
412
502.1
101
504
230
502.2
554
906
182
Secure screw with LOCTITE

Casing for pump type CNBV(X) 80-150/315 Casing for pump type CNBV(X) 200-250/315

101
101
412
162
2566411

Spare Parts list Item No. Spare Parts list Item No. Spare Parts list Item No.

Pump casing 101 Bearing bracket housing 344 Thrower 507

Casing cover 161 Bearing cover 360.1 Washer 554
Suction cover 162 Bearing cover 360.2 Grease nipple 636.1
Foot 182 Gasket for seal cover 400 Grease nipple 636.2
Shaft 210 O-Ring for pump casing 412 Coupling part 860.5
Impeller 230 Shaft seal ring 420 Spacer bush 860.6
Radial ball bearing 321 Mechanical seal 433 Coupling part 860.7
Trust ball bearing 323 Seal cover 471 Coupling half 861.1
Bearing bracket 330 Casing wear ring 502.1 &RXSOLQJÀH[LEOHV  
Motor stool 341 Casing wear ring 502.2 Impeller screw 906
0RWRUVWRROÀDQJH   Spacer ring 504

29
 6. SPARE PARTS

6.11 Spare parts drawing for CNHB(X) 400

CNHBX-300/400
861.1
867
860.7

860.6
341
860.5 420.1
923 360.1
636 354
931 323
330
210
6 420.2 322
507 360.2
636 344
Spare Parts

433 471
412.1 441
412.2 161
504 230
400 502.1
400.1 502.2

101
Secure screw with 554
LOCTITE 906
182

Casing for pump CNBVX-200+250/400 Casing for pump CNBVX-300/400

101
101 412.3
509
2514311 162
Spare Parts list Item No. Spare Parts list Item No. Spare Parts list Item No.

Pump casing 101 Bearing cover 360.2 Spacer ring 504

Casing cover 161 Gasket for pump casing 400 Thrower 507
Suction cover 162 Gasket for casing cover 400.1 Intermediate ring 509
Foot 182 O-Ring for seal 412.1 Washer 554
Shaft 210 O-Ring for seal 412.2 Grease nipple 636
Impeller 230 O-Ring for suction cover 412.3 Coupling part 860.5
Radial roller bearing 322 Shaft seal ring 420.1 Spacer bush 860.6
Thrust ball bearing 323 Shaft seal ring 420.2 Coupling part 860.7
Bearing bracket 330 Mechanical seal 433 Coupling half 861.1
Motor stool 341 Shaft seal housing 441 &RXSOLQJÀH[LEOHV  
Bearing bracket housing 344 Seal cover 471 Impeller screw 906
Thrust bearing housing 354 Casing wear ring 502.1 Bearing nut 923
Bearing cover 360.1 Casing wear ring 502.2 Lock washer 931

30
6. SPARE PARTS

6.12 Spare parts drawing for Type A1/A2 seal arrangement

Constant Level Oiler (only Type A1)

638 412.2 400 412.1 433 504 441 471

Oil level

Spare Parts
23670 A1/A2

Spare Parts list Item No. Spare Parts list Item No.

Gasket for casing cover 400 Shaft seal housing 441

O-Ring for seal 412.1 Seal cover 471
O-Ring for seal 412.2 Spacer ring 504
Mechanical seal 433 Oil level sight glass 638

6.13 Spare parts drawing for Type F1/F2 seal arrangement

524

524 452
452 461
461 451
451 400.1

400.1 Cooling
water
412.1
412.1
412.2
412.2

23679 F1
2367901 F2

Spare Parts list Item No. Spare Parts list Item No.

Gasket for casing cover 400.1 6WXI¿QJER[KRXVLQJ  

O-Ring for seal 412.1 Gland 452
O-Ring for seal 412.2 Gland packing 461
Shaft wearring sleeve 524

31
 6. SPARE PARTS

6.14 Spare parts drawing for Type E1/E2 seal arrangement

452
452 451
461 461
451 400.1
400.1 Cooling
water
504
504
412.1 412.1

6 23674 E1 2367401 E2
Spare Parts

Spare Parts list Item No. Spare Parts list Item No.

Gasket 400.1 Gland 452

O-Ring for seal 412.1 Gland packing 461
6WXI¿QJER[KRXVLQJ   Spacer ring 504

6.15 Spare parts drawing for Type C1 seal arrangement

2334003

412.1 433.1 471 525

969
1/4 PT

Cooling water 8 l/min.

15

35
Max. temp. of o
cooling water 60 C

To suction ø4mm
side 14 L Mounting of
the mechanical shaft seals:

Shaft dim. L Tool (969)

ø35 64,4 233240123 969
ø45 61,0 254140123
412.2 475 433.2 504 441

Spare Parts list Item No. Spare Parts list Item No.

O-Ring for seal 412.1 Seal cover 471

O-Ring for seal 412.2 Stationary seal ring 475
Mechanical seal 433.1 Spacer ring 504
Mechanical seal 433.2 Spacer sleeve 525
Housing for shaft seal 441 Tool 969

32
7.
7. DATA
DATA
7.1 Type CNLB(X) / CNV(X) - Dimensional drawing and Details

G
G

J
E

E
H

H
Suction Delivery Suction Delivery Delivery

D
DN

DN

DN

DN
DN
D
D

D
k

k
k
k

A2
A1
A

ød DN
ød ød
T

ød k ød
ød
øM D
øF

Suction
4-øS O O
4-øR

7
N 4-øR N
P

P
K

Data
B1 B2 B1 B2 B2 23919

In-line In-line End suction

Base mounted Bulk head mounted Bulk head mounted
Dimensions in mm.
PUMP FLANGES, PUMP
A A1 A2 B1 B2 E F G H J K M N O P R øS T WEIGHT,
SIZE PN10 KG
DN k D øD

65-65/160 65 145 185 4-18 125 95 180 180 140 60

100 445 90 300 70
80-80/160 80 160 200 8-18 140 110 200 200 160 65

25-25/200 25 85 115 4-14 75

80 180 180 140
40-40/200 40 110 150 4-18 280 330 20 16 75
125 95
565 341
50-50/200 50 125 165 4-18 80
200 200 160
65-65/200 65 145 185 4-18 100 135 80

80-80/200 80 160 200 8-18 140 110 225 225 130 120 180 90
140 200
100-100/200 100 180 220 8-18 175 125 250 250 190 100
125
125-125/200 125 210 250 8-18 205 155 280 280 210 115

50-50/250 50 125 165 4-18 100 110

575 380 351 440
145 95 225 225 200
65-65/250 65 145 185 4-18 110

80-80/250 80 160 200 8-18 160 110 125 250 250 115

100-100/250 100 180 220 8-18 180 130 210 18 125

280 280
125-125/250 125 210 250 8-18 210 155 230 190
140
150-150/250 150 240 285 8-22 235 180 355 355 240 210

200-200/250 200 295 340 8-22 280 225 160 450 450 300 24 25 240

80-80/315 80 160 200 8-18 175 120 280 280 240 195
125 520 180 250
100-100/315 100 180 220 8-18 180 125 675 450 150 420 130 160 250 210
315 315
125-125/315 125 210 250 8-18 200 145 260 225
140
150-150/315 150 240 285 8-22 220 165 355 355 280 235

200-200/315 200 295 340 8-22 315 260 160 450 450 310 290

250-250/315 250 350 395 12-22 335 280 180 710 455 330 335
500 500
200-200/400 200 295 340 8-22 280 225 160 370 370
955 230
250-250/400 250 350 395 12-22 335 280 180 560 410 405
560
300-300/400 300 400 445 12-22 400 345 250 630 975 560 630 450 26 30 575

33
 7. DATA

7.2 Type CNHB(X) / CNBV(X) - Dimensional drawing and Details

CNHB(X) CNHB(X) CNBV(X)

23921

G
G

4-øR

J
J

E
E

Suction Delivery Delivery

H
H

DN
DN

DN

D
k
D

D
k

A2
A1
A
Data

ød ød DN
P k ød
ød
D
øM

øF

4-øS
K Suction
O
N
4-øR
B2

K
O
N

B1

B1 B2 B2

In-line In-line End suction

Base mounted Bulk head mounted Bulk head mounted

Dimensions in mm.
PUMP FLANGES PUMP
SIZE PN10 A A1 A2 B1/B2 E F G H J K M N O P øR øS T WEIGHT
KG
DN k D øD

100-100/200 100 180 220 8-18 180 130 250 190 125
125 720
125-125/200 125 210 250 8-18 205 155 280 210 140

50-50/250 50 125 165 4-18 145 95 100 225 135

380 130 440
200
80-80/250 80 160 200 8-18 160 110 250 674 310 140
125
100-100/250 100 180 220 8-18 180 130 210 150
205 180 260
280
125-125/250 125 210 250 8-18 210 155 220 230 215
140 18 24 25
150-150/250 150 240 285 8-22 235 180 355 770 240 235

200-200/250 200 295 340 8-22 280 225 160 450 300 265

80-80/315 80 160 200 8-18 175 120 280 240 225

125 520
100-100/315 100 180 220 8-18 180 125 460 330 250 240
315 810 160 235 220 300
125-125/315 125 210 250 8-18 200 145 260 255
140
150-150/315 150 240 285 8-22 220 165 355 280 265

200-200/315 200 295 340 8-22 315 260 160 450 310 320

250-250/315 250 350 395 12-22 335 280 180 840 330 365
500
200-200/400 200 295 340 8-22 280 225 160 310 395
1195
250-250/400 250 350 395 12-22 335 280 180 560 230 330 430

300-300/400 300 400 445 12-22 400 345 250 630/560 1225 560 410 400 320 630 300 400 420 30 26 30 600

34
7. DATA

7.3 Troubleshooting
The diagram below describes the most common faults which can occur during operation of the
pumpunit. Should additional information be required, please contact IRON Pump A/S.

Problem Possible cause

Pump and motor cannot be actuated: Impeller or shaft blocked.
Motor fault.
Motor running but no pumping effect: Motor rotation is not transmitted through coupling.
Discharge valve closed.
Non-return valve or other valves are closed.
Suction line closed.
Air in pump casing.
Suction line leaking.
Shaft seal leaking.
Bottom valve defective. 7
Suction lift too high.
Priming pump defective.

Data
,QVXI¿FLHQWFDSDFLW\ Wrong direction of rotation.
Number of revolutions too low.
Counter-pressure too high.
Suction line or impeller partly clogged.
Air in pump casing.
Air in pumping media.
Suction lift too high (inlet pressure too low).
Cavitation.
Suction line leaking.
Shaft seal leaking.
Pump worn out.
Pump pressure too high: Number of revolutions too high.
Impeller oversized.
Too many pressure stages.
6SHFL¿FJUDYLW\RISXPSLQJPHGLDWRRKLJK
Viscosity of pumping media too low.
Inlet pressure too high.
Manometer defective.
Capacity too large: Number of revolutions too high.
Impeller diameter too big.
Counter-pressure too low.
Discharge head too low: Number of revolutions too low.
Impeller diameter too small.
6SHFL¿FJUDYLW\RISXPSLQJPHGLDWRRORZ
Viscosity of pumping media to high.
Manometer defective.

35
 7. DATA

Problem Possible cause

Power consumption too large: Motor too small.
Motor fault.
Capacity too large.
Counter-pressure too low.
6WXI¿QJER[WLJKWHQHGWRRPXFK
Shaft ends out of alignment.
Electricity supply incorrect.
Pump output decreases or stops: Suction line leaking.
Shaft seal leaking.
Increasing suction lift.
Filter clogged.
Cavitation.
Irregular running: Bearings defective.

7 Motor fault.
Increasing noise level: Cavitation beginning.
Air in pumping media.
Data

Capacity too large.

Clamping to base loosened.
Base bolts loosened.
,QÀXHQFHVIURPSLSHFRQQHFWLRQVRUEDVH
Leaks: Cracks in pump casing.
Faulty assembly of pump.
Pipe connections leaking.
6KDIWVHDOOHDNLQJLQFDVHRIVRIWVWXI¿QJER[SDFNLQJ
minor leaks are necessary).
Bearing temperature too high: Faulty lubrication or wrong lubricant.
Defective pump alignment.
,QÀXHQFHVIURPSLSHOLQH
Coupling distance wrong.
Shaft bent.
Foreign bodies or impurities in bearings.
Pump wears out quickly: Wrong pump in relation to liquid.
Cavitation.
6WXI¿QJER[WLJKWHQHGWRRPXFK
Shaft bent.
Defective alignment.
,QÀXHQFHVWKURXJKSLSHOLQH
Strong vibrations: Impurities in pump.
Worn or loose bearings.
Operating the pump at a critical speed.
Unbalanced motor or rotating components.
Loose hold-down bolts or loose or damaged parts.

36
8. PRIMING SYSTEM
SYSTEMS

8.1 Priming of centrifugal pumps 8.1.3 PA automatic priming pump

IRON Pump A/S provides three different types Automatic priming system driven by a
of priming systems for centrifugal pumps. mechanical vacuum pump. The system is
designed for centrifugal pumps where dry
8.1.1 EA automatic ejector system running is admissible for a short period of the
time.
Automatic ejector-driven priming system
7KH SUHVVXUH FRQWUROOHU FDQ EH VHW WR ¿W WKH
designed for centrifugal pumps, where dry
pump pressure.
running is admissible for a short period and
compressed air is available.
The ejector can be supplied in sizes 1/2” PT or
3/4” PT with different capacities. The pressure
FRQWUROOHUFDQEHVHWWR¿WWKHSXPSSUHVVXUH

8.1.4 Mounting of Priming devices

Priming devices must always be connected 8
to the highest point on the suction side of the
pump/suction line, and there must be no air

Priming System
pockets in the suction line.

The valve on the pressure side of the pump

must always be closed during priming, or a
8.1.2 VATEC automatic aspirator spring-loaded counter valve which opens as
Automatic aspirator designed for centrifugal soon as 60-70% of the working pressure is
pumps where dry running is admissible for reached must be installed.
short periods of the time and compressed air
is available. The capacity of the priming pump must match
The ejector can be supplied with different the volume of the pump and the suction pipe
capacities and different pressure switches for which has to be primed, so that priming will
different pump pressures. take no longer than 3 minutes.

37
 8. PRIMING SYSTEM

8.2 EA automatic ejector system Compressed air for:

Automatic ejector system designed for Air ejector 1/2” : 5 - 9 Bar - 1000 -1700 NL/min,
Air ejector 3/4” : 5 - 9 Bar - 1200 -1950 NL/min
centrifugal pumps, where dry running is
admissible for short periods of the time. 1/2"PT 1

1A
2

Pressure switch
connection
5

EA-inst3
From pump
EA-INST4 Outlet

8 8.2.3 Installation
7KHDXWRPDWLFHMHFWRUV\VWHPPXVWEH¿WWHG
8.2.1 Function above the highest point to be evacuated (eg.
Priming System

the pump casing).

When the centrifugal pump is turned on, power
The ejector is supplied with compressed air
is also connected to the automatic ejector
at 5-9 bar by solenoid valve (Item 1). The
system, and the ejector starts evacuating air
compressed air passes through the ejector
from the suction line and the centrifugal pump
whose suction side is connected to the suction
through non-return valve (Item 4) and solenoid
side of the pump through solenoid valve (Item
valve (Item 1A).
1A) and non-return valve (Item 4). The non-
On the discharge pipe of the main pump, a
return valve prevents the compressed air from
spring-loaded counter valve must be mounted
being led into the pipe system in the event of
which opens as soon as 60-70% of the working
an obstruction of the ejector outlet.
pressure is reached. As soon as the centrifugal
The solenoid valves are electrically connected
pump has built up the necessary discharge
so that both valves are open at the current-
pressure, the ejector system is switched off
carrying coil and closed at the current-less
via the pressure switch. Should the discharge
coil.
pressure fall again during pump operation
through gas accumulation, the automatic
lmpulse to the solenoid valve is controlled by
ejector system restarts for re-evacuation.
the pressure switch, which is connected to the
discharge side of the pump.
8.2.2 Design
The pressure switch must be set to switch off
Pressure-controlled priming system with a at 50-70% of the lowest working pressure. The
compressed air ejector acting as a vacuum neutral zone must be set to at least 10% of the
generator. working pressure (See 8.5).

Components: ‡ Important note: outlet of air and water from

Solenoid valve Item 1 ejector must always have free access to
Solenoid valve Item 1A bilge.
Pressure switch Item 2 ‡ Length of pipe - if any - to be very short.
Air ejector 1/2” PT or 3/4” PT Item 3 ‡ &KHFN WKDW WKH ¿OWHU ,WHP  LV DOZD\V
Non-return valve Item 4 clean.
Filter Item 5

38
8. PRIMING SYSTEM

8.3 VATEC automatic aspirator Vatec

E
Automatic aspirator designed for centrifugal 4
pumps where dry running is admissible for C
short periods of the time.
3

A
2

B
Exhaust
EA-inst6

8.3.3 Installation
8
Connections:
Casing air vent Item A - G 3/4” PT

Priming System
Exhaust Item B - R 1 1/4” PT
8.3.1 Function Pressure switch Item C - G 3/8” PT
When the centrifugal pump is turned on, Cable Item E - 9 - 13 mm
the automatic aspirator will be activated. As Compressed air Item P - G 1/2” (AELD
soon as the centrifugal pump has built up the 35-55) /G 1”(AELD 65)
necessary discharge pressure, the aspirator is
switched off via the pressure switch. Should 7KH DXWRPDWLF DVSLUDWRU LV WR EH ¿WWHG DERYH
the discharge pressure fall again during pump the highest point to be evacuated (e.g. the
operation through gas accumulation, the pump casing).
automatic aspirator restarts for re-evacuation. The highest point to be evacuated is connected
to connection A by means of an ascending air
8.3.2 Design vent pipe.
Exhaust nozzle B must not be shut off.
Pressure-controlled automatic aspirator with Compressed air is to be connected to
a compressed air ejector acting as a vacuum connection P via manual or controlled shut-off
generator. With its polyethylene nozzle valve.
system, the unit is resistant to a high degree to The maximum installation height above the
DJJUHVVLYHÀXLGVHJVHDZDWHU ORZHVW VXFWLRQ VLGH ÀXLG OHYHO LV  P DIWHU
deducting the dynamic losses of the suction
Components: system.
Compressed air ejector
with integrated shut-off valve Item 1 The pressure range is to be chosen by its
Compressed air solenoid valve Item 2 shut-off point, which must be under the lowest
Pressure switch Item 3 working pressure of the pump. A later change
Terminal box Item 4 to another pressure range takes place by
changing the pressure switch module.

39
 8. PRIMING SYSTEM

8.4 PA automatic priming system Solenoid valve Item 5

Non-return valve Item 6
Automatic ejector system designed for
Filter Item 7
centrifugal pumps, where dry running is
Outlet to bilge Item 8
admissible for a short period of the time.
Water tank Item 9

The power output of the motor is 1.5 kW at

1450 RPM and 1.25 kW at 1750 RPM.
2
3 1
9

5
4
6
7

PA-inst3

8 PA-inst2
8.4.3 Installation
7KH SULPLQJ SXPS LV WR EH ¿WWHG DERYH WKH
Priming System

highest point to be evacuated (e.g. the pump

casing).
8.4.1 Function The impulse to the priming pump and the
solenoid valve is controlled by the pressure
When the centrifugal pump is turned on,
switch, which is connected to the discharge
power is also connected to the automatic
side of the pump.
priming system and the priming pump starts
The pressure switch must be set to switch off
evacuating air from the suction line and the
at 50-70% of the lowest working pressure. The
centrifugal pump through non-return valve
neutral zone must be set to at least 10% of the
(Item 6) and solenoid valve (Item 5). On the
working pressure. (See 8.5).
discharge pipe of the main pump, a spring-
loaded counter-valve which opens as soon as
Important note:
60-70% of the working pressure is reached
must be installed.
‡ outlet (Item 8) of air and water from priming
As soon as the centrifugal pump has built up
pump must always have free access to
the necessary discharge pressure, the priming
bilge.
pump is switched off via the pressure switch.
‡ Length of pipe - if any - to be very short.
Should the discharge pressure fall again during
‡ Check that the Filter (Item 7) always is
pump operation through gas accumulation, the
clean.
priming pump restarts for re-evacuation.
Before starting:
8.4.2 Design
Pressure-controlled priming system with a Check that the water tank (Item 9) in the
priming pump acting as a vacuum generator. SULPLQJSXPSLV¿OOHGZLWKZDWHU

Components:
Vacuum pump Item 1
Gearbox (for 50Hz systems) Item 2
Motor Item 3
Pressure switch Item 4

40
8. PRIMING SYSTEM

8.5 Danfoss pressure controller for priming systems

0.25 0.4 0.6 0.8 1.0 1.2

RT 200 Bаr

Мin. Маx.
1 2 3 4 5 6 7 8 9 10
Fig. 5

Маx. 70 оС
Мin. -40 оС

Маx. 100 о С

Priming System
Fig. 4

Data Example

Pressure controller type RT 200, max. test To control a priming device for a pump with a
pressure 25 Bar. working pressure of 4 Bar.:

Instructions Minimum pressure (50%):

0.5 x 4 Bar = 2 Bar.
The pressure controller is set by rotating the Differential:
knob (Item 5), at the same time reading the 0.1 x 4 Bar = 0.4 Bar.
main scale (Item 9). (See Fig. 1).
The differential is set by rotating the differential ‡ Connect the priming device to terminals
adjusting nut (Item 19) to the value indicated 1-2 of the pressure controller.
by the use of the monogram (See Fig. 5). The ‡ Set the pressure controller for 2 Bar by
maximum operating pressure in thus the sum rotating the knob (Item 5).
of the setting pressure and the differential. ‡ Set the differential adjusting nut (Item 19)
(See Fig.3) which is found by reading the
monogram (See Fig. 5).

41
 8. PRIMING SYSTEM

8.6 Wiring diagrams for Priming Care should be taken to ensure, before
systems connecting the coil to the mains, that the
voltage and the frequency of the coil are in
The customer is responsible for the wiring conformity with those of the mains; 10% over-
being done according to valid regulations. or under voltage is permissible in case of
normal frequency.

Automatic priming system Type EA Automatic aspirator Type VATEC

TO STARTER TO STARTER
115V 50/60Hz 400V 50Hz 400V 50Hz
230V 50/60Hz 440V 60Hz 440V 60Hz
440V 50/60Hz R S T 230V 50/60Hz R S T

Danfoss
Pressostat Vatec
2 1

0 1
P P
4 2 Motor Motor
Main Main
Pump Pump

8 Danfoss
Solenoid Valves

1 1A
Priming System

IRON's SUPPLY

Automatic priming pump Type PA

TO STARTER
115V 50/60Hz 400V 50Hz
230V 50/60Hz 440V 60Hz
440V 50/60Hz R S T

Danfoss
Pressostat

SHIPYARD's SUPPLY

0 1
P
4 2
green/yellow

white

blue

a 1 3 5

b 2 4 6

95

96
2 4 6

U V W

Motor Motor
Priming Main
Danfoss Pump Pump
Solenoid Valve

E010903 IRON's SUPPLY

42
8. PRIMING SYSTEM

8.7 Spare Parts drawing for P-pump with gear - 1450 RPM

FROM SUCT. SIDE PUMP

411 400.3 420.4 545 420.3 360.2 211 871.1 321 872.2 877 871.2 639

H Control oil level

once a month
OVERFLOW Mobilgear 600 xp 68

8
F

Priming System
591 135 231 101.1 106 636 420.4 360.4 321 872.1 321 360.3 420.5 845

P-PUMP, 1450 RPM - with gear Lubricate once a month with grease 17730
Mobilith SHC100 - 5 gram

Spare Parts list Item No. Spare Parts list Item No.

Pump casing 101.1 Shaft seal ring 420.4

Suction casing 106 Shaft seal ring 420.5
Wear plate 135 Bearing bush 545
Shaft for pump 211 Tank 591
Impeller 231 Grease nipple 636
Ball bearing 321 Oil level sight glass 639
Bearing cover 360.2 Toohted coupling 845
Bearing cover 360.3 Gear casing 871.1
Bearing cover 360.4 Cover for gear casing 871.2
Gasket 400.3 Gear wheel drive 872.1
Joint ring 411 Gear wheel 872.2
Shaft seal ring 420.3 Shaft drive 877

43
 8. PRIMING SYSTEM

8.8 Spare Parts drawing for P-pump – 1750 RPM

FROM SUCT. SIDE PUMP

411 400.3 420.4 545 420.3 360.2 211 341

OVERFLOW

F
8
Priming System

591 135 231 101.1 106 636 861.2 861.1

P-PUMP, 1750 RPM Lubricate once a month with grease 15544

Mobilith SHC100 - 5 gram

Spare Parts list Item No. Spare Parts list Item No.

Casing 101.1 Joint ring 411

Suction casing 106 Shaft seal ring 420.3
Wear plate 135 Shaft seal ring 420.4
Shaft for pump 211 Bearing bush 545
Impeller - suction stage 231 Tank 591
Motor stool 341 Grease nipple 636
Bearing cover 360.2 Coupling motor side 861.1
Gasket 400.3 Coupling pump side 861.2

44
9. MOTOR

9.1 General information If the resistance at room temperature is below

the reference value, the windings must be
The following instructions refer to all motors
oven dried at 90oC for 12-16 hours followed by
delivered by IRON Pump A/S. Read these
105oC for 6-8 hours.
instructions before you transport, install,
operate, maintain or repair motors.
9.4 Handling
Should additional data be required, consult
the manufacturer or an authorized service 9.4.1 Storage
workshop immediately.
Motors should always be stored in dry
IRON Pump A/S cannot be held responsible conditions, free from vibrations and dust.
for unauthorized use of the motor. Always remember to store the unit in the
transportation packaging.
9.2 Inspection Unprotected machined surfaces such as shaft
If any damage is observed on delivery, please HQGVDQGÀDQJHVVKRXOGDOZD\VEHSURWHFWHG
notify type of damage immediately to the with an anti-corrosive coating before being
transport company. It is important that the placed in storage.
motor is not put into operation if any damage
has been discovered. In order to prevent grease migration, it is
recommended that the motor shaft be rotated
Check that all data on the rating plate, especially periodically by hand. If the unit is stored for
voltage and winding connection (star or delta), more than one year, the bearings should be
DUH FRQVLVWHQW ZLWK WKH RUGHU VSHFL¿FDWLRQV checked for corrosion before the motor is
and pump provided by IRON Pump. installed and put into operation. 9
Some motors are protected against bearing 9.4.2 Transportation

Motor
damage during transport by means of a locking ,I WKH PRWRU LV ¿WWHG ZLWK F\OLQGULFDO UROOHU
device which must be removed before putting EHDULQJVWKHURWRUPXVWEH¿[HGE\XVHRID
the motor into operation. When the device suitable transportation locking device before
has been removed, turn the shaft by hand to any transportation is carried out.
ensure free rotation.

9.3 Insulation resistance check 9.4.3 Lifting

Insulation resistance of motors can be lowered Only suspend motors from the lifting eyes
considerably by moisture. Consequently provided. Do not attach any additional load to
insulation resistance must be checked after the motor as the lifting eyes are only intended
receipt and inspection or after extended for lifting the weight of the motor.
storage. Insulation resistance of the winding
must be measured to earth and between 9.5 Installation
phases at 25oC. The measured value should
normally exceed the reference value. The motors are suitable for indoor installation.
The motors may be operated at heights of
Windings should be discharged 1000 meters above sea level at ambient
immediately after measurement temperatures of – 20oC to + 40oC. Exceptions
DUHVSHFL¿HGRQWKHUDWLQJSODWH
to avoid risk of electric shock!

The insulation resistance of new winding

LV DERYH  0ȍ ,QVXODWLRQ UHVLVWDQFH LV
temperature dependent, i.e. if the ambient
temperature is increased/decreased by 20oC,
the resistance is halved/doubled respectively.

45
 9. MOTOR

9.5.1 Ventilation
As well as main winding and earthing terminals,
Normal ambient temperatures should not
the terminal box can also contain connections
exceed 45°C (Marine standard +45 or +50°C)
for thermistors, standstill heating elements,
if standard performance is to be achieved.
switches, or PT 100 resistance elements.
&KHFN WKDW WKH PRWRU KDV VXI¿FLHQW DLUÀRZ
Ensure that no nearby equipment, surfaces or
direct sunshine radiate additional heat to the Voltage may be connected at
motor. standstill inside the terminal
box for heating elements or
9.5.2 Alignment direct winding heating!
When motor is connected to the pump via a
coupling, the shafts must be radial and axial Connection diagrams for auxiliary elements
aligned to each other. The dial gauges must are found inside the terminal box cover or in
EH ¿UPO\ VHFXUHG &DUU\ RXW PHDVXUHPHQWV additional labels on the motor frame.
at four measuring points, each separated by
90°, whilst simultaneously turning both halves The capacitor in single-phase
of the coupling. motors can retain a charge that
appears across the motor
9.5.3 Angular alignment terminals even when the motor
Deviations should be equalised by means of has reached standstill.
shims placed under the motor feet. Permanent
inaccuracies must ba as small as possible, and Choose cable cross-sections in accordance
PXVWQHYHUH[FHHGWKUVSHFL¿FDWLRQVJLYHQIRU with the rated current. Unused cable entries
9 the coupling. must be closed by compression glands.

9.5.4 Parallel alignment The motor must be out of operation,

Motor

disconnected and secured against starting.

Compensate for any differences repositioning This also applies to auxiliary circuits (e.g.
or by inserting suitable plates so that the heaters). Make sure that there is no voltage.
residual inaccuracies must ba as small
as possible, and must never exceed thr The supply cables must be connected
VSHFL¿FDWLRQVJLYHQIRUWKHFRXSOLQJ with special care to ensure permanent and
Recheck alignment with the pump at operating reliable contact. Use suitable terminals for the
temperature. connection cables. Supply cables must be
relieved of stress so that no cantilever loads
9.5.5 Drain Holes are exerted on the terminals.
Make sure open drain holes face downwards.
Extremely dusty environments all require drain Cable entries which are not used and the
holes to be closed. terminal box itself must be sealed against dust
and water. In order to maintain the degree
Incorrect setup may cause damage to bearings of protection, always ensure that the original
and shaft extensions. gaskets are used and that the terminal box is
clean and dry when closing.
9.5.6 Connecting the motor
Normal motor design has the terminal box on
top with cable entry possible from both sides.

Some motors are available with top-mounted

terminal boxes rotatable 4 x 90°, and some
with side-mounted terminal boxes.

Unused cable entries must be closed.

46
9. MOTOR

9.5.7 Direction of rotation assembly bolts.

‡ Check the bearing condition by listening
The motors are normally suitable for both
for unusual noise, vibration measurement,
directions of rotation. Exceptions are indicated
bearing temperature, inspection of spent
on the rating plate by an arrow. For the desired
grease or SPM nipple monitoring.
direction of rotation, the stator winding is
connected as follows:
9.6.2 Cleaning

Connection of L1, Direction of Depending on local conditions, air passages

L2, L3 to: rotation when should be cleaned regularly.
viewing drive end:
9.6.3 Bearing maintenance and
U1, V1, W1 Clockwise
lubrication
W1, V1, U1 Counterclockwise

Mode of starting Measures to Before the First Start of the

and winding changing of motor it must be greased!
rotation direction
Direct-on-line starting and Reverse connections at
pole-changing motors with motor or switchboard. Observance of regreasing
separate windings
intervals is vital for the
Star/delta starting and Exchange two supply cable
pole-changing motors with conductors at the incoming operational reliabilty of the
Dahlander winding supply to the contactor motors!
combination

Test
Under normal operating conditions, motors can
be operated between 2-4.000 hours without
9
To check the direction of rotation, quickly maintenance depending on frame size and

Motor
switch the properly connected but uncoupled rpm. The maximum period of maintenance-
motor On/Off. free operation is four years. However, the
condition of the grease should be checked
 <ǻVWDUWLQJ occasionally even before this time limit. The
indicated number of service hours is only valid
In order to avoid excessive transient currents for operation at rated speed. The bearings
DQG WRUTXHV EHIRUH FKDQJLQJ IURP < WR ǻ VKRXOG RQO\ EH ¿OOHG  VLQFH D FRPSOHWH
wait until the starting current of the Y stage ¿OOLQJRIWKHEHDULQJVDQGEHDULQJFRYHUVZLWK
has died down or change when rated speed is grease leads to increased bearing temperature
reached. Centrifugal pumps are normaly not and therefore to increased wear.
suited for star/delta starting. The ball bearings and the bearing caps
should be washed with petrol or benzene. If
9.6 Repair and Maintenance QHFHVVDU\ UHSODFH WKH EHDULQJV +DOI ¿OO WKH
Before carrying out any work on the motor, spaces between the ball and the roller track
disconnect it and secure it against restarting. as well as the grease compartments with
grease. Coat shaft bushings in the bearing
In motors with greasing device, regrease caps or end shields with a thin layer of grease.
bearings with the motor running. Permanently greased bearings (2RS and 2Z
bearings) cannot be washed and regreased.
9.6.1 General Inspection Such bearings must therefore be replaced. To
dismantle the bearings, use pressing screws
‡ Inspect the motor at regular intervals. or other appropriate devices.
‡ Keep the motor clean and ensure free
YHQWLODWLRQDLUÀRZ
‡ Check the condition of shaft seals and
replace if necessary.
‡ Check the condition of connections and

47
 9. MOTOR

9.6.4 Bearings with regreasing device in the ambient temperature raises the
and grease slinger temperature of the bearings correspondingly.
The table values should be halved for a 15°C
Regreasing interval and required quantity
decrease in bearing temperature and may
of grease are indicated on the rating plate.
be doubled for a 15°C increase in bearing
Bearings and bearing caps must be washed
temperature.
with petrol or benzene after regreasing twelve
times.
Frame size Two pole Four and
With the outer bearing cap open but the inner design multipole
cap screwed on, the rotor should be turned design
slowly and grease pressed in through the 112 to 315 2000 hrs 4000 hrs
regreasing device until approximately half the 355 to 400 2000 hrs 3000 hrs
empty space between the rolling elements an
WKHUROOHUWUDFNVLV¿OOHGZLWKJUHDVH
9.7 Spare Parts and Repair
9.6.5 Lubricants Any repair work within the guarantee
period is subject to approval by the motor
When regreasing, use only special ball bearing
manufacturer.
grease with the following properties:
When regreasing, use only special ball bearing
When ordering Spare Parts, the full type must
grease with the following properties:
be designated and the product code as stated
‡ Good quality grease with lithium complex
RQWKHUDWLQJSODWHPXVWEHVSHFL¿HG
soap and with mineral or PAO oil
‡ Base oil viscosity 100–160 at 40°C
If the motor is stamped with a serial number,
9 ‡ Consistency NLGI grade 1.5–3 *
this should also be given.
‡ Temperature range -30° - +120°C
continuous.
9.7.1 Rewinding
Motor

*) For vertically mounted motors or in Rewinding should always be carried out by

hot conditions, a stiffer end of scale is TXDOL¿HGUHSDLUVKRSV
recommended.

Grease with the correct properties is available

from all major lubricant manufacturers.

Highly loaded or slowly rotating bearings

require EP grease.

The following (or similar) high performance

grease can be used:

Esso Unirex N3
Mobil Mobilith SHC 100
SKF LGHQ 3
BP Energrease LC 2
Shell Albida EMS 2

9.6.6 Lubrication intervals

The lubricantion intervals are based on
a bearing operation temperature of 80°C
(ambient temperature of 25°C) An increase

48
 9. MOTOR
9.8 Troubleshooting
The diagram below describes the most common faults which can occur during operation of motors.
Should additional information be required, please contact IRON Pump or the motor manufacturer.

Problem Possible cause Solution

Motor does not Blown fuses. Replace fuses with proper type and rating.
start: Overload. Check and reset overload in starter.
Improper power supply. Check if power supplied is consistent with
motor rating plate and load factor.
Improper line connections. Check connections with diagram supplied
with motor.
Open circuit in winding or Indicated by humming sound when
control switch. switch is closed. Check for loose wiring
connections. Also ensure that all control
contacts are closed.
Mechanical failure. Check if motor and drive turn freely. Check
bearings and lubrication.
Short circuited stator. Indicated by blown fuses. Motor must be
rewound.
Poor stator coil connection. Remove end bells, locate with test lamp.
Rotor defective. Look for broken bars or end rings.
Motor may be overloaded. Reduce load.
Motor stalls: One phase may be open. Check lines for open phase.
9
Wrong application. Change type or size. Consult manufacturer.

Motor
Overload. Reduce load.
Low voltage. Ensure the rating plate voltage is
maintained. Check connection.
Open circuit. Fuses blown, check overload relay, stator
and push buttons.
Motor runs and Power failure. Check fuses, control panel and lines for
suddenly stops: loose connections.
Motor does not Not applied properly. Consult supplier for proper type.
come up to speed: Voltage too low at motor Use higher voltage or transformer
terminals because of line terminals or reduce load. Check
drop. connections. Check conductors for proper
size.
Starting load too high. Check admissible load which motor is
supposed to carry at start.
Broken rotor bars or loose Look for cracks near the rings. A new rotor
rotor. may be required as repairs are usually
temporary.
Open primary circuit. Locate fault with testing device and repair.
Motor takes too long Excessive load. Reduce load.
to accelerate and/or Low voltage during start. Check for high resistance. Adequate wire
draws high current: size.
Defective squirrel cage rotor. Replace with new rotor.
Wrong rotation: Wrong phase sequence. Reverse connections at motor or
switchboard.

49
 9. MOTOR

Problem Possible cause Solution

Motor overheats Overloaded. Reduce load.
while running under Frame or bracket vents may Open vent holes and check for a
load: be clogged with dirt and continuous stream of air from the motor.
prevent proper ventilation of
motor.
Motor may have one phase Check to make sure that all leads are
open. properly connected.
Grounded coil. Locate and repair.
Unbalanced terminal Check for faulty leads, connections and
voltage. transformers.
Motor vibrates: Motor misaligned. Realign.
Weak support. Strengthen base.
Coupling out of balance. Balance coupling.
Driven equipment Rebalance driven equipment.
unbalanced.
Defective bearings. Replace bearings.
Bearings not in line. Line up properly.
Balancing weights shifted. Rebalance motor.
Discrepancy between Rebalance coupling or motor.
9 balancing of rotor and
coupling (half key - full key).
Polyphase motor running Check for open circuit.
Motor

single phase.
Excessive end play. Adjust bearing or add shim.
Scraping noise: Fan rubbing fan cover. Remove interference.
Fan striking insulation. Clear fan.
Motor loose on bedplate. Tighten holding bolts.
Noisy operation: Air gap not uniform. &KHFNDQGFRUUHFWEUDFNHW¿WVRUEHDULQJ
Rotor imbalance. Rebalance.
Bearing balls are Bent or sprung shaft. Straighten or replace shaft.
getting hot: Excessive belt pull. Decrease belt tension.
Pulleys too far away. Move pulleys closer to motor bearing.
Pulley diameter too small. Use larger pulleys.
Misalignment. Correct by realignment of drive.
,QVXI¿FLHQWJUHDVH Maintain proper quantity of grease in
bearing.
Deterioration of grease or Remove old grease, wash bearings
lubricant contaminated. thoroughly in kerosene and replace with
new grease.
Excess lubricant. Reduce some grease. Bearing should not
EHPRUHWKDQ¿OOHG
Overloaded bearing. Check alignment, side and end thrust.
Broken ball or rough races. Replace bearing. First clean housing
thoroughly.

50
 Cooling Pump Unit C5.05.09.01.22.55
LT

M25

Cooling Pump Unit

LT

en / 22.01.2014 FD049659 1/35

IRON PUMP
Instruction Manual
REVISION: 5

Instructions for Installation, Operation, Maintenance and Repair of

Centrifugal pumps Type DHBS and DHBF -/160, 200, 250,315, 400

Your Reference Iron Pump Reference

Purpose : Cooling water Pump Type : DHBS 100-100/315

Order No. : Order No. :
Art No. : Pump No. :
Project : Sach Nr. 273840295

PLEASE READ THIS INSTRUCTION MANUAL BEFORE INSTALLING,

OPERATING OR SERVICING THE PUMP

 TECHNICAL DATA

Pump
Technical data

Flow, Q : 80,0/90,0 m3/h

Head (Diff. pressure), H : 32,64/30,60 mWc
Inlet pressure : -
Discharge pressure : -
Suction lift : -
Power Duty Point, P : 14,00 kW
Power max. : 14,30 kW
Media : Fresh water
Media temp. : 100 C
Seal type : Mechanical
Impeller no. : -
Coupling type : Solid
Weight : 217,00 kg
Direction of rotation, Rot.: CW

Materials

Pump casing : Cast Iron GG25

Impeller : NiAl-bronze
Casing wear ring : NiAl-bronze
Shaft : Stainless Steel (AISI 329)
Seal : Carbon / Ceramics max 100 C

Motor

Type : SH IEC Y2E2 160 L-4

Output : 18,70 kW
RPM, n : 1750
Voltage : 3 x 440 V, 60 HZ
Weight : 138,00 kg
NB! :

Type plate

Pump Type

Pump No. Year of manufacture

Test pressure, Bar Direction of rotation

Flow Head (Diff. pressure)

Power RPM
Duty Point

2
1. CONTENTS

Chapter Section Page

1

Contents
1. Contents 3

2. General 5
2.1 Introduction 5
 ,GHQWL¿FDWLRQ 5
2.3 Directions & Warning signs 5
2.4 Warning symbols 5
2.5 General safety 5
3. Installation 7
3.1 Condition on delivery 7
3.2 Inspection on delivery 7
3.3 Storage instructions 7
3.4 Lifting instruction 7
3.5 Foundation 8
3.6 Environment conditions 8
3.7 Piping 8
3.8 Piping connections 8
3.9 Electrical installation 8
3.10 Recommended accessories 8
4. Operation 9
4.1 Start-up procedures 9
4.2 Starting the pump 9
4.3 Stand-by 9
4.4 Pump vibrations 9
4.5 Lubrication 9
4.6 Frost protection 9
5. Maintenance 11
5.1 Inspections 10
5.2 Assembly and Disassembly 10
5.3 Coupling 12
5.4 Fitting instructions for Mechanical seals 13
5.5 Centrifugal pump wear ring Clearances 14
6. Spare Parts 15
6.1 Repairs 15
6.2 Returning parts 15
6.3 Decommissioning 15
6.4 Table of Materials 15
6.5 Spare parts drawing for DHBF/DHBS 16

3
 1. CONTENTS

Chapter Section Page

1
Contents

7. Data 17
7.1 Type DHBF/DHBS - Dimensional drawing 17
7.2 Troubleshooting 18
8. Priming systems 20
8.1 Priming of centrifugal pumps 20
8.2 EA automatic ejector system 21
8.3 VATEC automatic aspirator 22
8.4 PA automatic priming system 23
8.5 Danfoss pressure controller for Priming systems 24
8.6 Wiring diagrams for Priming systems 25
8.7 Spare Parts drawing for P-pump with gear - 1450 RPM 26
8.8 Spare Parts drawing for P-pump – 1750 RPM 27
9. Motor 28
9.1 General information 28
9.2 Inspection 28
9.3 Insulation resistance check 28
9.4 Handling 28
9.5 Installation 28
9.6 Repair and Maintenance 30
9.7 Spare Parts and Repair 31
9.8 Troubleshooting 32

4
2. GENERAL

2.1 Introduction STOP!

This instruction manual contains relevant
This symbol is for all safety instructions which
information on installing, operating and
must be followed to avoid accidental injuries
maintaining the pump.
and hazards to life. Observe these safety 2
instructions carefully and proceed with great
7KH SXPS LV FRQ¿JXUHG IRU WKH VSHFL¿F
care.
FXVWRPHUUHTXLUHPHQWV7KHVSHFL¿FSXPSW\SH

General
is described in the technical data section.
ELECTRIC POWER!
The personnel in charge of installing,
This symbol signals possible danger due
operating and maintaining the pump must be
to presence of current electric power. Only
SURSHUO\TXDOL¿HGDQGWUDLQHGWRFDUU\RXWWKH
proceed if the operator is experienced with the
operations described in this manual. IRON
pump and procedures.
Pump recommends that you read this manual
before you install and operate the pump as this
will minimize any risk of incorrect handling. CAUTION!
IRON Pump A/S cannot be held responsible
for unauthorized use of the pump. This symbol is used for instructions of particular
importance and signals a risk of damage to
IRON Pump A/S does not provide any guarantee the pump or its components. Proceed only if
if working conditions are inappropriate. If the the parts or the pump have been assembled
working conditions differ from those given in according to the instructions.
the technical data sheet, please contact IRON
Pump before putting the pump into operation. 2.5 General safety
The following safety instructions apply for both
 ,GHQWL¿FDWLRQ pumps and motors supplied by IRON Pump
'HWDLOVRIWKHSXPSLGHQWL¿FDWLRQW\SHQXPEHU A/S.
and order No.) are on the front page. The Pump Observe:
1R FDQ DOVR EH IRXQG RQ WKH VXFWLRQ ÀDQJH ‡ The safety regulations
and on the Type plate on the pump. ‡ Accident prevention regulations
‡ &RXQWU\VSHFL¿FVDIHW\UHJXODWLRQV
‡ Guide lines and acknowledged technical
2.3 Directions & Warning signs rules cited in this operating manual.
Comply with all instructions located on the
pump or motor, such as direction of rotation, Non-compliance with safety regulations will
arrows, instruction signs, directions or warning result in danger to personnel and damage to
signs and remember to keep this information the unit, e.g:
in readable condition.
‡ Danger to personnel through contact with
2.4 Warning symbols voltage exceeding 42V.
‡ Failure to observe prescribed methods of
Important machine and safety-related transportation, assembly, maintenance
instructions in this manual are illustrated with and repair of pump or motor.
symbols. It is essential that these instructions
are followed to avoid accidents and damages
When working on the
to machines and/or personnel.
unit, observe all valid
accident prevention regulations
and generally acknowledged
technical rules!

5
 2. GENERAL

2.5.1 Electrical hazards

Do not carry out any installation or maintenance
on the pump or motor while it is operating or
before it has been disconnected. Pumps with
2 motors must have appropriate connections.
Amp ratings are given in the pump Technical
data sheet and the power supply must be
General

adequate.

2.5.2 Temperature hazards

Before any maintenance is carried out, be
sure to empty the pump of liquid. If the pump
has been pumping hot liquid, the pump should
be cooled to the surrounding temperature.
As a precaution, the hot parts of the machine
should always be covered to avoid accidental
contact.

2.5.3 Chemical hazards

The pump should always be cleaned before
carrying out any maintenance or repairs. This
will prevent chemical reactions if the pump has
been pumping dangerous liquids.

2.5.4 Dry running

If the pump is not supplied with a priming
device, the pump must never be put into
RSHUDWLRQEHIRUHLWKDVEHHQ¿OOHGZLWKOLTXLG
If the pump is supplied with a priming device,
dry running is permissible for a short period
while the pump is primed.

2.5.5 Noise level

Under normal conditions the pump and the
motor will produce a noise level below 80 dB.
The exact noise level depends on motor type,
foundation and environment.

The operator must wear protective gear if the

noise level becomes harmful.

6
3. INSTALLATION

3.1 Condition on delivery air dry. Close the valves on both sides of the
SXPS DQG ÀXVK WKH SXPS ZLWK ³0RELO $UPD
IRON Pump products are tested before
25” or similar quality. Flushing can be done
delivery to ensure perfect running condition.
through the manometer connections.
A test run is made of the pump using water
to check the performance data stated in the
3.3.2 Restarting
WHFKQLFDOVSHFL¿FDWLRQV
When starting/restarting the pumps after
VWRUDJHLWLVDGYLVDEOHWR¿OOWKHSXPSZLWKKRW
3
3.2 Inspection on delivery
water through the manometer connections and
Check your shipment immediately upon arrival.

Installation
to turn the pump shaft by hand before starting.
Make sure that the parts and accessories Then follow 4.1 Start-up procedures.
received are in accordance with your order.
,QWKHHYHQWRIGDPDJHGHIHFWVRUGH¿FLHQF\
3.4 Lifting instruction
immediately report the problem to the transport
company and IRON Pump. ‡ 6WUDSV DUH PRXQWHG DURXQG WKH ÀDQJHV
(Lifting chains might damage the surface
The packaging must be examined to make of the pump, and are not recommended).
sure that it is in good condition to guarantee A wooden bar is placed above the motor to
protection in storage. guide the strap.
‡ If the motor has lifting eyes at the top, these
The packaging may only be opened when: can be used to guide the pump so it does
QRWWLS2WKHUZLVHDVWUDS¿[HVWKHPRWRU

‡ It is seriously damaged.
‡ The product is to be stored longer than
originally planned.

In all other cases the packaging may only be

opened at assembly. When the packaging has
been removed, the product must be examined
IRUDQ\GH¿FLHQFLHVRUGHIHFWV

3.3 Storage instructions

The standard packaging protects the pump
against corrosion during land transport and
storage in dry conditions for at least three
months.

If the pump is not installed immediately after

delivery, it must be protected against corrosion,
vibrations, frost and kept in a dry place.

/HDYHÀDQJHFRYHUVLQSODFHWRNHHSGLUWDQG
other foreign material out of the pump casing.

Turn the pump shaft by hand at regular

intervals of one month, to prevent brinelling of
WKHEHDULQJVDQGWKHVHDOIDFHVLI¿WWHGIURP
sticking.

3.3.1 Preservation procedure

Flush the pump with pure hot water and let it

7
 3. INSTALLATION

3.5 Foundation 3.8 Piping connections

7KHSXPSPXVWEH¿[HGWRDULJLGIRXQGDWLRQ Before installing the pump, the entire piping
which is substantial enough to absorb vibrations must be pressure and leakage tested and
and to take up stress from the hydraulic strain ÀXVKHG FOHDQ EHIRUH LW LV FRQQHFWHG WR WKH
and loads from the pipelines. suction and discharge side of the pump. If
7KH SXPS VKRXOG EH LQVWDOOHG ZLWK VXI¿FLHQW the pressure test takes place with the pump
3 accessibility for inspection and maintenance.
The surface of the foundation where the
installed, the testing pressure must not exceed
the testing pressure of the pump, which is
pump is installed must be level and horizontal. stamped into the pump, usually in the suction
ÀDQJH7KHSXPS¶VJDVNHWVRUÀDQJHVIRUWKH
Installation

Damage due to an inadequate or faulty

foundation is not covered by the guarantee. mechanical shaft seal might otherwise be
damaged.
3.6 Environment conditions
Check that all other connections to the pump
Standard pumps are intended for installion in are in working order, such as lubrication,
dry rooms free from aggressive atmosphere priming, heating, cooling media outlet, etc.,
in temperatures between + 10 and 40 oC and that the various measuring equipment
Installing the pump in other conditions (e.g. has been correctly connected. Take care that
outdoors, in damp rooms etc.) is only allowed no parts obstruct easy access to the pump for
if this is stated in the technical data sheet. inspection or replacement of important parts.

3.7 Piping 3.9 Electrical installation

Suction and pressure lines must be connected Connect the cables according to local electrical
WR WKH ÀDQJHV RI WKH SXPS IUHH IURP VWUDLQ regulations and standards, and by authorised
DVDQ\VWUHVVHVDUHWDNHQXSDW¿[HGSRLQWV skilled stuff. The pump should be connected
and suitable compensators should therefore to a motor starter.
EH LQVWDOOHG LQ WKH SLSH V\VWHP 7KH ÀDQJHV
between which the pump is installed must be Check that there is enough cable to allow the
absolutely parallel. motor to be removed without disconnecting
the wires. A switch (emergency stop) must be
7RNHHSSUHVVXUHORVVDQGÀRZUHVLVWDQFHDW installed close to the pump.
a minimum, tight bends and substantial size Kilowatt ratings are given in the pump Technical
reductions in the piping system should be data sheet.
avoided.

Loss of pressure in the suction line must be

3.10 Recommended accessories
kept at a minimum in order to avoid cavitation As the pump, especially the mechanical
in the pump. Static suction height + loss of shaft sealing, is designed to run with clean
pressure in the suction line + NPSH value for ZDWHUZLWKRXWVOXGJHDVXLWDEOH¿OWHUPXVWEH
the pump + steam pressure must not exceed installed in the suction line.
10 mWc at sea level. Long suction pipes that
make air pockets possible should be avoided. ,5213XPS$6FDQVXSSO\VXLWDEOH¿OWHUV

8
4. OPERATION

4.1 Start-up procedures 4.2 Starting the pump

Ensure that the pump and motor are mounted When the pump is ready, it is started with the
according to instructions, all connections are discharge valve closed. After starting, the
correct and the necessary screens and guards discharge valve is slowly opened until the
are in order. working point is reached. If the pump runs with
closed valves for a period of the time, it should
‡ Check the direction of rotation (marked be equipped either with temperature control
with an arrow). The motor must turn in the equipment or recirculation. Running with the
direction in which the arrow is pointing. If valves closed for a long period can damage
the direction is wrong, the connections to
the terminals of the electric motor should
the pump.
Check bearing temperature (max. 105o C)
4
be changed.

Operation
‡ Check that the pump can be turned by Do not run pump with closed valve on
hand. discharge side for prolonged time.
‡ Check that the motor has been lubricated
with grease. 4.3 Stand-by
‡ Make sure that the piping is clean and free
IURP IRUHLJQ REMHFWV /LTXLG VKRXOG ÀRZ If the pump is going to be on stand-by for a
regularly into the pump. long period, it must be started or rotated at
‡ Check that the pump and suction pipe are least once a week to avoid damage to the
¿OOHG ZLWK OLTXLG $Q\ DLU RU JDV PXVW EH mechanical seals.
carefully released before start-up.
‡ Check the pump for noise and vibrations 4.4 Pump vibrations
immediately after starting. At the normal
'XULQJ RSHUDWLRQ EH DZDUH WKDW VLJQL¿FDQW
head it should have a steady motion
YLEUDWLRQVKDYHDPDMRUDIIHFWRQWKHSXPS¶V
without unusual noise and vibrations after
SHUIRUPDQFH ,I YLEUDWLRQV DUH VLJQL¿FDQW WKH
one minute.
pump should immediately be turned of to be
‡ Check the priming device (if any).
able to locate possible errors.
‡ Check the seal housing for leakages.
Never operate the pump without
4.1.1 Pumps with Priming device
the coupling guard .
Pumps provided with a mechanical priming
pump should be checked for supply/content of
4.5 Lubrication
liquid before starting.
The pump bearings are closed and not
The valve on the discharge side of the pump supposed to be greased.
must be closed during priming. The motor bearings are greased according
The operating instructions for the priming the motor instructions.
system should be strictly followed (See
Chapter 8). 4.6 Frost protection
After priming the pump, open the valve on
the discharge side slowly and adjust it in such If there are any risk of freezing of the liquid in
a way that the permissible vacuum is not the pump, removing the drain plug empties the
exceeded. pump casing.

9
 4. OPERATION

5.1 Inspections 5.1.3 Lubrication

Before any inspection and maintenance of the The pump bearings are greased for lifetime
pump, the operator must ensure that the pump and do not need no further service.
cannot be unintentionally started. The pump
must be stopped, and all electronic contacts 5.2 Assembly and Disassembly
must be disconnected.

The system must be de-pressurized and the Study the Spare Parts drawing for the
pump must be emptied of liquid. If the pump actual pump before starting disassembly
4 has been pumping hazardous liquids, the of the pump.
liquid must be collected, and the pump should
EHÀXVKHGZLWKFOHDQZDWHURUDQRWKHUVXLWDEOH 5.2.1 Rotating unit
Operation

liquid.
210
It is important to ensure that 360
412 321
the pump does not contain
161
dangerous amounts of 433
corrosive, toxic or similar
substances when maintenance
230
is taking place.
554
906

5.1.1 Three-month inspection

‡ Check suction and discharge pressure.

‡ Check for unusual noise, vibrations and
leakages. Spare Parts list Item Spare Parts list Item
‡ Inspect the motor as per the instructions
from the manufacturer. Casing cover 161 O-Ring 412
Shaft 210 Mechanical seal 433
‡ The mechanical seal must be inspected Impeller 230 Washer 554
for leaks by normal pressure at the suction Radial ball bearing 321 Impeller screw 906
side. The seal must not leak either during Bearing cover 360
stand-by or during operation .
‡ Check that the circulation pipe for the Table. Weight of rotating unit
mechanical seal is not blocked
If any faults are found during inspection, they Pump size Weight
must immediately be corrected, since any
defects can be of major importance for the (from-to) kg
functioning of the pump and its life spare. 40-40/200- 22
125-125/250
5.1.2 Twelve-month inspection 50-50/25- 35
‡ Disassemby of the pump is required. 125-125/250
‡ Take the pump apart (See 5.2). The 150-150/250- 40
rotating parts are checked and repaired if 200-200/250
necessary. 80-80/315- 50
‡ Check the clearance between the impeller 150-150/315
and casing wear ring. Normal clearance
is 0,45-0,50 mm. Maximum clearance is 200-200/315- 60
0,8-1,0 mm. depending on the Size and 250-250/3150
Capacity (See 5.5). 200-250/400- 94
300-300/400

10
5. MAINTENANCE
5.2.2 Disassembly DHBS/DHBF See 6.5
Table for holes in the casing cover (Item 161)

Threaded hole Threaded hole Free hole Mounting Mounting

for for puller bolt in cover hole in cover hole in cover

Dismantling of Dismantling of Fixing of Fixing of cover Fixing of cover

cover from motor motor stool from motor stool in in motor stool in pump casing
stool pump casing pump casing
A B C D E
2xM8 2xM8 2xM8 2xM8 12xM12
Max 5 NM Max 5 NM 10 NM 10 NM 15 NM

A
5
E C
E
E

Maintenance
D
B

B E
E

D
E
E
C
E A

Without removing motor:

The rotating unit can be removed without

removing the motor:

‡ Ensure that the pump has been drained of

liquid.
‡ Remove circulation pipe (Item 710, Se 6.5)
‡ Remove spacer bush (Item 860.6) and
FRXSOLQJ ÀH[LEOH VWHHO GLVF ,WHP   LI
any.
‡ Remove screws marked D+E.
‡ Mount puller bolts in holes marked A and
lift the casing cover.
‡ Lift the disconnected rotating unit and take
it out of the pump.
‡ Gentle disconnection is recommended to
prevent any damage to the mechanical
seal. (Use a cloth or the like during of
disasembly/assembly of the rotating unit).

11
 5. MAINTENANCE

With removing motor: of the mechanical shaft seal (Item 433),

PXVWEH¿WWHGJHQWO\RQWKHVKDIW
‡ Remove screws marked C + E ‡ 7KH2ULQJ,WHPPXVWEH¿WWHGWRWKH
‡ Remove the circulation pipe (Item 710) cover.
‡ Mount the puller bolts in the holes marked ‡ The rotating unit of the shaft seal ( Item
B 433) is carefully placed on the shaft (Item
‡ Lift the disconnected parts and remove 210).
them. ‡ The casing wear ring (Item 502) and the
LPSHOOHUPXVWEH¿WWHGDQGWLJKWHQHGE\
screws.
‡ Check the clearance between the impeller
and casing wear ring. (See 5.5).
‡ Before any up-start, the shaft must be
5 turned by hand in order to check for any
blockages.
‡ When the pump is assembled and all
Maintenance

bolts and nuts are in place, they can be

tightened.

5.3 Coupling
Never operate the pump without
the coupling guard .

(Only DHBF)
861.1
867
Note:
860.6
On mounting the screws are tightened by
hand, then cross-tightened by moments as
stated, in order to balance the casing cover:

Holes Fastening Moment

Please NOTE!
Bolt size Nm Way of mounting the bolts!
C 2-M8 10
D 2-M8 10 5.3.1 Mounting of coupling
 ZLWKÀH[LEOHVWHHOGLVN'+%)
E 12-M12 15
‡ Clean the shaft ends, and check for burrs.
OBS! Number of E-holes depends on ‡ Heating of the coupling half (Item 861.1) to
pump size. approx. 80oC facilitates the mounting of it
on the shaft.
5.2.3 Assembly DHBS/DHBF ‡ Mount the coupling half (Item 861.1) in line
with the motor shaft.
In order to prevent seizures in future repairs, ‡ Lock the coupling half by the pivot screws.
all joints and bolt threads should be treated ‡ 0RXQW FRXSOLQJ ÀH[LEOH VWHHO GLVN ,WHP
ZLWK DQ DSSURSULDWH FRPSRXQG HJ ³1HYHU 867), spacer bush (Item 860.6) and
Seez”) before assembly. coupling half (Item 861.1) , clamp the parts
‡ Before reassembling, clean the inside of and tighten the screws.
the pump casing and paint with appropriate
coating.
‡ Assemble the pump in opposite order of
the disassembly (See 5.2.2)
‡ Casing cover (Item 161), with the seat ring

12
5. MAINTENANCE

5.3.2 Mounting of coupling Fitting instructions:

 ZLWKRXWÀH[LEOHVWHHOGLVN'+%6
‡ Remove the protective packaging from the
‡ The coupling part on the motor shaft
seal, check for damage, and wipe clean.
must NOT EH D[LDOO\ ¿[HG FRQVLGHULQJ
‡ Make sure that the pump is ready and
the thermal expansion it must be axially
switched off.
movable.
‡ The shaft should be clean and free of
‡ Clean the motor shaft ends, and check for
burrs, and the machined place where the
burrs.
VHDW ¿WV PXVW EH FOHDQHG YHU\ FDUHIXOO\
‡ /XEULFDWH WKH PRWRU VKDIW HQG E\ ³1HYHU
Edges should be rounded so that they are
6HH]´ ¿WWLQJ SDVWH RU OLNH DQG SXVK WKH
not sharp or penetrating.
coupling half (Item 861.1) up on the shaft
‡ Check that the shaft diameter corresponds
end.
with the dimension of the seal within a
‡ Mount spacer bush (item 860.6) and
tolerance of 0.05 mm. 5
Coupling half (Item 861.1), clamp the
‡ The bore in the casing cover (Item 161)
parts.
and the seat must be lubricated. Use

Maintenance
only liquid soap, soapy water or glycerine
5.4 Fitting instructions for with ethylene-propylene elastomer. The
Mechanical seals elastomer must also be lubricated on
A mechanical seal is a very high-precision the inside where it slides on the shaft.
product and should be treated with the utmost Lubricants containing silicone must never
FDUHEHIRUHDQGGXULQJ¿WWLQJ'RQRWXQSDFN be used.
until ready for use. The rotating wear ring and ‡ Press the seat into position with your
the seat have been lapped to a high degree of ¿QJHUV ,I WKH VSDFH LV WLJKW XVH D EXVK
accuracy. when pressing the seat into position. Take
care not to damage the surface of the seat.
IRON pump STANDARD For example, use a piece of plastic for
protection between the bush and the seat.
After pressing the seat into position, make
sure that it is fully in place by measuring
the depth with a depth calliper.
‡ Place carefully and by hands the rotating
part on the shaft.
33.5(ø30-40)
41(ø42-ø60)
25(ø10-ø25)

‡ Mount the impeller on the shaft.

‡ 7KH FRPSUHVVHG OHQJWK DIWHU ¿WWLQJ PXVW
correspond to the working length of the
size of seal in question given in the table of
07.47.06E measurements.
‡ Be aware of changes that can occur when
IRON/BURGMANN bearing arrangements and gaskets etc. are
replaced.
‡ %HIRUHWKHSXPSLVVWDUWHGLWPXVWEH¿OOHG
with liquid and the air allowed to escape.
Air should be bled frequently during the
period after starting.

:KHQ¿WWLQJVKDIWVHDOVWKH
33.5(ø30-40)
41(ø42-ø60)
25(ø10-ø25)

instructions should be read

carefully, especially when the
media is dangerous (poisonous,
KRWÀDPPDEOHHWF

07.47.06E

13
 5. MAINTENANCE

5.5 Centrifugal pump wear ring Clearances

CLEARANCE

5
WEAR RING DIAMETER
Maintenance

THE CLEARANCES STATED ARE AVERAGE VALUES,

AND MUST IN EACH SINGLE CASE BE COMPARED
WITH THE NEEDS FOR THE NECESSARY OPERATION DATA.

1,0

0,9

0,8
CLEARANCE (mm)

0,7

0,6

0,5

0,4

0,3

0,2

0,1

100 200 300 400

WEAR RING DIAMETER (mm) 22531E1

14
6.
6. SPARE
SPARE PARTS
PARTS

6.1 Repairs 6.4 Table of Materials

When ordering Spare Parts or requesting our Table of materials with the total content
assistance, please advise the following: calculated as percentage by weight.

‡ Pump type DHBS/F

‡ Serial number (i.e. P.no. DHB ####, from
Description Material %
Type plate, it is also stamped in the suction
Pump casing See Technical data 28
ÀDQJH
‡ IRON Pump A/S order number (5 or 7 Casing cover See Technical data 13

digits.) Shaft AISI 329 3

‡ Item No. and description of part (See Spare Impeller See Technical data 6
Parts drawing). Casing wear See Technical data 0.5
ring
7R HVWDEOLVK WKH FRUUHFW µGLDJQRVLV¶ D EULHI Mechanical Carbon/ceramics 0.1
seal
description of the breakdown is also required.
O-Ring
Foot
Viton
Cast iron
0.1
13
6
Spares are normally available from stock.
Motor stool Cast iron 29

Spare Parts
If you do the repairs yourself, you are requested Coupling Cast iron 5
to follow the instructions regarding assembly Accessories Steel 2.3
and disassembly or to contact our service
department.

6.2 Returning parts

Before returning parts to IRON Pump A/S,
please note that all liquids must be removed
and parts should be cleaned and neutralized.

The sender is liable for damage suffered by

the pump or other goods caused by leaking of
liquid during transport.

6.3 Decommissioning
Do not dump old or used parts. Metal parts
should be recycled as scrap or sent back to
IRON Pump.

When decommissioning the pump, it should be

neutralized and cleaned, and any hazardous
liquids,should be removed and sent to a
recycling facility.

None of the materials in the pump can be

considered hazardous, but we urge you to act
with care and to take the steps needed when
decommissioning the pump or its parts.

15
 6. SPARE PARTS

6.5 Spare parts drawing for DHBS / DHBF

341.1
867 (Only DHBF)
860.6 341
210 861.1
321
On type DHBS
932 Item 861.1
must NOT be
6 731.1 axially fixed
731.2 360
505
Spare Parts

161
710 412

910

230
101
502
433
906
912
554
182 28824E

Spare Parts list Item. No. Spare Parts list Item No. Spare Parts list Item No.

Pump casing 101 Bearing cover 360 Threaded pipe union 731.2
Casing cover 161 O-Ring for pump casing 412 Spacer bush 860.6
Foot 182 Mechanical seal 433 Coupling half, incl. spacer 861.1
Shaft 210 Casing wear ring 502 &RXSOLQJÀH[VWHHOGLVF 
Impeller 230 Loose collar 505 Impeller screw 906
Radial ball bearing 321 Washer 554 Plug for pressure gauge 910
Motor stool 341 Pipe 710 Drain plug 912
0RWRUVWRROÀDQJH   Threaded pipe union 731.1 Circlip 932
2QO\'+%)

16
7. DATA
7.1 Type DHBS / DHBF - Dimensional drawing

E 1/4” PT 1/4” PT
ød

BC=K
DN

D
A

7
øM

Data
4 - øS
øF

B B
28650

Dimensions in mm
PUMP FLANGES PUMP
SIZE PN10, DIN 2501 A B E F M øS T WEIGHT
KG
NV k D ød
40-40/200 40 110 150 4-ø18 180 75
50-50/200 50 125 165 4-ø18 80
125 370 280 330 20 18
200
65-65/200 65 145 185 4-ø18 87
80-80/200 80 160 200 8-ø18 140 225 91
100-100/200 100 180 220 8-ø18 175 250 111
125-125/200 125 210 250 8-ø18 205 280 121
50-50/250 50 125 165 4-ø18 135
145 225 380 380 440
65-65/250 65 145 185 4-ø18 126
80-80/250 80 160 200 8-ø18 160 250 131
100-100/250 100 180 220 8-ø18 180 134
280
125-125/250 125 210 250 8-ø18 210 181
150-150/250 150 240 285 8-ø22 235 355 228
200-200/250 200 295 340 8-ø22 280 450 232
80-80/315 80 160 200 8-ø18 175 280 207
100-100/315 100 180 220 8-ø18 180 24 25 217
315 460 460 520
125-125/315 125 210 250 8-ø18 200 224
150-150/315 150 240 285 8-ø22 220 355 232
200-200/315 200 295 340 8-ø22 315 450 284
250-250/315 250 350 395 12-ø22 335 495 369
500
200-200/400 200 295 340 8-ø22 280 408
250-250/400 250 350 395 12-ø22 335 560 451
750
300-300/400 300 400 460 12-ø22 400 630/560 560 630 26 30 721

7KHLOOXVWUDWHGSXPSLVZLWKVWDQGDUGÀDQJH',131
For the remaining dimensions, see dimensioned drawing of the pump.

17
 7. DATA

7.2 Troubleshooting
The diagram below describes the most common faults which can occur during operation of the
pumpunit. Should additional information be required, please contact IRON Pump A/S.

Problem Possible cause

Pump and motor cannot be actuated: Impeller or shaft blocked.
Motor fault.
Motor running but no pumping effect: Motor rotation is not transmitted through coupling.
Discharge valve closed.
Non-return valve or other valves are closed.
Suction line closed.
Air in pump casing.
Suction line leaking.
Shaft seal leaking.
7 Bottom valve defective.
Suction lift too high.
Priming pump defective.
Data

,QVXI¿FLHQWFDSDFLW\ Wrong direction of rotation.

Number of revolutions too low.
Counter-pressure too high.
Suction line or impeller partly clogged.
Air in pump casing.
Air in pumping media.
Suction lift too high (inlet pressure too low).
Cavitation.
Suction line leaking.
Shaft seal leaking.
Pump worn out.
Pump pressure too high: Number of revolutions too high.
Impeller oversized.
6SHFL¿FJUDYLW\RISXPSLQJPHGLDWRRKLJK
Viscosity of pumping media too low.
Inlet pressure too high.
Manometer defective.
Capacity too large: Number of revolutions too high.
Impeller diameter too big.
Counter-pressure too low.
Discharge head too low: Number of revolutions too low.
Impeller diameter too small.
6SHFL¿FJUDYLW\RISXPSLQJPHGLDWRRORZ
Viscosity of pumping media to high.
Manometer defective.

18
7. DATA

Problem Possible cause

Power consumption too large: Motor too small.
Motor fault.
Capacity too large.
Counter-pressure too low.
Electricity supply incorrect.
Pump output decreases or stops: Suction line leaking.
Shaft seal leaking.
Increasing suction lift.
Filter clogged.
Cavitation.
Irregular running: Bearings defective.
Motor fault.
Increasing noise level: Cavitation beginning.
Air in pumping media.
Capacity too large. 7
Base bolts loosened.
,QÀXHQFHVIURPSLSHFRQQHFWLRQVRUEDVH

Data
Leaks: Cracks in pump casing.
Faulty assembly of pump.
Pipe connections leaking.
Bearing temperature too high: Defective pump alignment.
,QÀXHQFHVIURPSLSHOLQH
Coupling half is not in line with the motor shaft.
Shaft bent.
Foreign bodies or impurities in bearings.
Pump wears out quickly: Wrong pump in relation to liquid.
Cavitation.
Shaft bent.
Defective alignment.
,QÀXHQFHVWKURXJKSLSHOLQH
Strong vibrations: Impurities in pump.
Worn or loose bearings.
Operating the pump at a critical speed.
Unbalanced motor or rotating components.
Loose hold-down bolts or loose or damaged parts.

19
 8. PRIMING SYSTEMS
SYSTEM

8.1 Priming of centrifugal pumps 8.1.3 PA automatic priming pump

IRON Pump A/S provides three different types Automatic priming system driven by a
of priming systems for centrifugal pumps. mechanical vacuum pump. The system is
designed for centrifugal pumps where dry
8.1.1 EA automatic ejector system running is admissible for a short period of the
time.
Automatic ejector-driven priming system
7KH SUHVVXUH FRQWUROOHU FDQ EH VHW WR ¿W WKH
designed for centrifugal pumps, where dry
pump pressure.
running is admissible for a short period of the
time and compressed air is available.
The ejector can be supplied in sizes 1/2” or
3/4” with different capacities. The pressure
FRQWUROOHUFDQEHVHWWR¿WWKHSXPSSUHVVXUH

8.1.4 Mounting of Priming devices

8 Priming devices must always be connected
to the highest point on the suction side of the
pump/suction line, and there must be no air
Priming System

pockets in the suction line.

The valve on the pressure side of the pump

must always be closed during priming, or a
8.1.2 VATEC automatic aspirator spring-loaded counter valve which opens as
soon as 60-70% of the working pressure is
Automatic aspirator designed for centrifugal
reached must be installed.
pumps where dry running is admissible for
short periods of the time and compressed air
The capacity of the priming pump must match
is available.
the volume of the pump and the suction pipe
The ejector can be supplied with different
which has to be primed, so that priming will
capacities and different pressure switches for
take no longer than 3 minutes.
different pump pressures.

20
8. PRIMING SYSTEM

8.2 EA automatic ejector system Compressed air 5-7 bar

1400 NL/min
Automatic ejector system designed for 1/2"PT
centrifugal pumps, where dry running is
1
admissible for short periods of the time.

1A
2

Pressure switch
connection
5

From pump
Outlet
EA-INST4

EAinst11
8.2.3 Installation
8
7KHDXWRPDWLFHMHFWRUV\VWHPPXVWEH¿WWHG
above the highest point to be evacuated (eg.

Priming System
8.2.1 Function
the pump casing).
When the centrifugal pump is turned on, power The ejector is supplied with compressed air
is also connected to the automatic ejector at 5-7 bar by solenoid valve (Item 1). The
system, and the ejector starts evacuating air compressed air passes through the ejector
from the suction line and the centrifugal pump whose suction side is connected to the suction
through non-return valve (Item 4) and solenoid side of the pump through solenoid valve (Item
valve (Item 1A). 1A) and non-return valve (Item 4). The non-
On the discharge pipe of the main pump, a return valve prevents the compressed air from
spring-loaded counter valve must be mounted being led into the pipe system in the event of an
which opens as soon as 60-70% of the working obstruction of the ejector outlet. The solenoid
pressure is reached. As soon as the centrifugal valves are electrically connected so that both
pump has built up the necessary discharge valves are open at the current-carrying coil
pressure, the ejector system is switched off and closed at the current-less coil.
via the pressure switch. Should the discharge
pressure fall again during pump operation lmpulse to the solenoid valve is controlled by
through gas accumulation, the automatic the pressure switch, which is connected to the
ejector system restarts for re-evacuation. discharge side of the pump.
The pressure switch must be set to switch off
8.2.2 Design at 50-70% of the lowest working pressure. The
Pressure-controlled priming system with a neutral zone must be set to at least 10% of the
compressed air ejector acting as a vacuum working pressure (See 8.5).
generator.
‡ Important note: outlet of air and water from
Components: ejector must always have free access to
Solenoid valve Item 1 bilge.
Solenoid valve Item 1A ‡ Length of pipe - if any - to be very short.
Pressure switch Item 2 ‡ &KHFN WKDW WKH ¿OWHU ,WHP  LV DOZD\V
Air ejector 1/2” PT or 3/4” PT Item 3 clean.
Non-return valve Item 4
Filter Item 5

21
 8. PRIMING SYSTEM

8.3 VATEC automatic aspirator Vatec

E
Automatic aspirator designed for centrifugal 4
pumps where dry running is admissible for C
short period of the time.
3

A
2

B
Exhaust

8 EAinst12 8.3.3 Installation

Connections:
Casing air vent Item A - G 3/4” PT
Priming System

Exhaust Item B - R 1 1/4” PT

Pressure switch Item C - G 3/8” PT
8.3.1 Function
Cable Item E - 9 - 13 mm
When the centrifugal pump is turned on, Compressed air Item P - G 1/2” (AELD
the automatic aspirator will be activated. As 35-55) /G 1”(AELD 65)
soon as the centrifugal pump has built up the
necessary discharge pressure, the aspirator is 7KH DXWRPDWLF DVSLUDWRU LV WR EH ¿WWHG DERYH
switched off via the pressure switch. Should the highest point to be evacuated (e.g. the
the discharge pressure fall again during pump pump casing).
operation through gas accumulation, the The highest point to be evacuated is connected
automatic aspirator restarts for re-evacuation. to connection A by means of an ascending air
vent pipe.
8.3.2 Design Exhaust nozzle B must not be shut off.
Pressure-controlled automatic aspirator with Compressed air is to be connected to
a compressed air ejector acting as a vacuum connection P via manual or controlled shut-off
generator. With its polyethylene nozzle valve.
system, the unit is resistant to a high degree to The maximum installation height above the
DJJUHVVLYHÀXLGVHJVHDZDWHU ORZHVW VXFWLRQ VLGH ÀXLG OHYHO LV  P DIWHU
deducting the dynamic losses of the suction
Components: system.
Compressed air ejector
with integrated shut-off valve Item 1 The pressure range is to be chosen by its
Compressed air solenoid valve Item 2 shut-off point, which must be under the lowest
Pressure switch Item 3 working pressure of the pump. A later change
Terminal box Item 4 to another pressure range takes place by
changing the pressure switch module.

22
 8. PRIMING SYSTEM

8.4 PA automatic priming system Filter Item 7

Outlet to bilge Item 8
Automatic ejector system designed for
Water tank Item 9
centrifugal pumps, where dry running is
admissible for a short period of the time.
The power output of the motor is 1.5 kW at
1450 RPM and 1.25 kW at 1750 RPM.

2
1
9
8
3

5
6
7
4

Painst8

PA inst7 8.4.3 Installation

7KH SULPLQJ SXPS LV WR EH ¿WWHG DERYH WKH 8
highest point to be evacuated (e.g. the pump

Priming System
casing).
8.4.1 Function The impulse to the priming pump and the
solenoid valve is controlled by the pressure
When the centrifugal pump is turned on,
switch, which is connected to the discharge
power is also connected to the automatic
side of the pump.
priming system and the priming pump starts
The pressure switch must be set to switch off
evacuating air from the suction line and the
at 50-70% of the lowest working pressure. The
centrifugal pump through non-return valve
neutral zone must be set to at least 10% of the
(Item 6) and solenoid valve (Item 5). On the
working pressure. (See 8.5).
discharge pipe of the main pump, a spring-
loaded counter-valve which opens as soon as
Important note:
60-70% of the working pressure is reached
must be installed. ‡ Outlet (Item 8) of air and water from priming
As soon as the centrifugal pump has built up pump must always have free access to
the necessary discharge pressure, the priming bilge.
pump is switched off via the pressure switch. ‡ Length of pipe - if any - to be very short.
Should the discharge pressure fall again during ‡ Check that the Filter (Item 7) always is
pump operation through gas accumulation, the clean.
priming pump restarts for re-evacuation.
Before starting:
8.4.2 Design
Pressure-controlled priming system with a Check that the water tank (Item 9) in the
priming pump acting as a vacuum generator. SULPLQJSXPSLV¿OOHGZLWKZDWHU

Components:
Vacuum pump Item 1
Gearbox (for 50Hz systems) Item 2
Motor Item 3
Pressure switch Item 4
Solenoid valve Item 5
Non-return valve Item 6

23
 8. PRIMING SYSTEM

8.5 Danfoss pressure controller for Priming systems

0.25 0.4 0.6 0.8 1.0 1.2

RT 200 Bаr

Мin. Маx.
1 2 3 4 5 6 7 8 9 10
Fig. 5

Маx. 70 оС
Мin. -40 оС

Маx. 100 о С
8
Priming System

Fig. 4

Data Example

Pressure controller type RT 200, max. test To control a priming device for a pump with a
pressure 25 Bar. working pressure of 4 Bar.:

Instructions Minimum pressure (50%):

0.5 x 4 Bar = 2 Bar.
The pressure controller is set by rotating the Differential:
knob (Item 5), at the same time reading the 0.1 x 4 Bar = 0.4 Bar.
main scale (Item 9). (See Fig. 1).
The differential is set by rotating the differential ‡ Connect the priming device to terminals
adjusting nut (Item 19) to the value indicated 1-2 of the pressure controller.
by the use of the monogram (See Fig. 5). The ‡ Set the pressure controller for 2 Bar by
maximum operating pressure in thus the sum rotating the knob (Item 5).
of the setting pressure and the differential. ‡ Set the differential adjusting nut (Item 19)
(See Fig.3) which is found by reading the
monogram (See Fig. 5).

24
8. PRIMING SYSTEM

8.6 Wiring diagrams for Priming Care should be taken to ensure, before
systems connecting the coil to the mains, that the
voltage and the frequency of the coil are in
The customer is responsible for the wiring conformity with those of the mains; 10% over-
being done according to valid regulations. or under voltage is permissible in case of
normal frequency.

EA automatic ejector system Type VATEC automatic aspirator

TO STARTER TO STARTER
115V 50/60Hz 400V 50Hz 400V 50Hz
230V 50/60Hz 440V 60Hz 440V 60Hz
440V 50/60Hz R S T 230V 50/60Hz R S T

Danfoss
Pressostat Vatec
2 1

0 1
P P
4 2 Motor Motor
Main Main
Pump Pump

Danfoss
Solenoid Valves

1 1A 8
IRON's SUPPLY

Priming System
Automatic priming system Type PA

TO STARTER
115V 50/60Hz 400V 50Hz
230V 50/60Hz 440V 60Hz
440V 50/60Hz R S T

Danfoss
Pressostat

SHIPYARD's SUPPLY

0 1
P
4 2
green/yellow

white

blue

a 1 3 5

b 2 4 6

95

96
2 4 6

U V W

Motor Motor
Priming Main
Danfoss Pump Pump
Solenoid Valve

E010903 IRON's SUPPLY

25
 8. PRIMING SYSTEM

8.7 Spare Parts drawing for P-pump with gear - 1450 RPM

FROM SUCT. SIDE PUMP

411 400.3 420.4 545 420.3 360.2 211 871.1 321 872.2 877 871.2 639

H Control oil level

once a month
OVERFLOW Mobilgear 600 xp 68

8
F
Priming System

591 135 231 101.1 106 636 420.4 360.4 321 872.1 321 360.3 420.5 845

P-PUMP, 1450 RPM - with gear Lubricate once a month with grease 17730
Mobilith SHC100 - 5 gram

Spare Parts list Item No. Spare Parts list Item No.

Pump casing 101.1 Shaft seal ring 420.4

Suction casing 106 Shaft seal ring 420.5
Wear plate 135 Bearing bush 545
Shaft for pump 211 Tank 591
Impeller 231 Grease nipple 636
Ball bearing 321 Oil level sight glass 639
Bearing cover 360.2 Toohted coupling 845
Bearing cover 360.3 Gear casing 871.1
Bearing cover 360.4 Cover for gear casing 871.2
Gasket 400.3 Gear wheel drive 872.1
Joint ring 411 Gear wheel 872.2
Shaft seal ring 420.3 Shaft drive 877

26
 8. PRIMING SYSTEM

8.8 Spare Parts drawing for P-pump – 1750 RPM

FROM SUCT. SIDE PUMP

411 400.3 420.4 545 420.3 360.2 211 341

OVERFLOW

F
8

Priming System
591 135 231 101.1 106 636 861.2 861.1

P-PUMP, 1750 RPM Lubricate once a month with grease 15544

Mobilith SHC100 - 5 gram

Spare Parts list Item No. Spare Parts list Item No.

Casing 101.1 Joint ring for plug 411

Suction casing 106 Shaft seal ring 420.3
Wear plate 135 Shaft seal ring 420.4
Shaft for pump 211 Bearing bush 545
Impeller - suction stage 231 Tank 591
Motor stool 341 Grease nipple 636
Bearing cover 360 Coupling motor side 861.1
Gasket 400.3 Coupling pump side 861.2

27
 9. MOTOR

9.1 General information If the resistance at room temperature is below

the reference value, the windings must be
The following instructions refer to all motors
oven dried at 90oC for 12-16 hours followed by
delivered by IRON Pump A/S. Read these
105oC for 6-8 hours.
instructions before you transport, install,
operate, maintain or repair motors.
9.4 Handling
Should additional data be required, consult
the manufacturer or an authorized service 9.4.1 Storage
workshop immediately.
Motors should always be stored in dry
IRON Pump A/S cannot be held responsible conditions, free from vibrations and dust.
for unauthorized use of the motor. Always remember to store the unit in the
transportation packaging.
9.2 Inspection Unprotected machined surfaces such as shaft
If any damage is observed on delivery, please HQGVDQGÀDQJHVVKRXOGDOZD\VEHSURWHFWHG
notify type of damage immediately to the with an anti-corrosive coating before being
transport company. It is important that the placed in storage.
motor is not put into operation if any damage
has been discovered. In order to prevent grease migration, it is
recommended that the motor shaft be rotated
Check that all data on the rating plate, especially periodically by hand. If the unit is stored for
voltage and winding connection (star or delta), more than one year, the bearings should be
DUH FRQVLVWHQW ZLWK WKH RUGHU VSHFL¿FDWLRQV checked for corrosion before the motor is
9 and pump provided by IRON Pump. installed and put into operation.

Some motors are protected against bearing 9.4.2 Transportation

Motor

damage during transport by means of a locking ,I WKH PRWRU LV ¿WWHG ZLWK F\OLQGULFDO UROOHU
device which must be removed before putting EHDULQJVWKHURWRUPXVWEH¿[HGE\XVHRID
the motor into operation. When the device suitable transportation locking device before
has been removed, turn the shaft by hand to any transportation is carried out.
ensure free rotation.

9.3 Insulation resistance check 9.4.3 Lifting

Insulation resistance of motors can be lowered Only suspend motors from the lifting eyes
considerably by moisture. Consequently provided. Do not attach any additional load to
insulation resistance must be checked after the motor as the lifting eyes are only intended
receipt and inspection or after extended for lifting the weight of the motor.
storage. Insulation resistance of the winding
must be measured to earth and between 9.5 Installation
phases at 25oC. The measured value should
normally exceed the reference value. The motors are suitable for indoor installation.
The motors may be operated at heights of
Windings should be discharged 1000 meters above sea level at ambient
immediately after measurement temperatures of – 20oC to + 40oC. Exceptions
DUHVSHFL¿HGRQWKHUDWLQJSODWH
to avoid risk of electric shock!

The insulation resistance of new winding 9.5.1 Ventilation

LV DERYH  0ȍ ,QVXODWLRQ UHVLVWDQFH LV
temperature dependent, i.e. if the ambient Normal ambient temperatures should not
temperature is increased/decreased by 20oC, exceed 40°C (Marine standard +45 or +50°C)
the resistance is halved/doubled respectively. if standard performance is to be achieved.
&KHFN WKDW WKH PRWRU KDV VXI¿FLHQW DLUÀRZ

28
9. MOTOR

Ensure that no nearby equipment, surfaces or The supply cables must be connected
direct sunshine radiate additional heat to the with special care to ensure permanent and
motor. reliable contact. Use suitable terminals for the
connection cables. Supply cables must be
9.5.2 Drain Holes relieved of stress so that no cantilever loads
are exerted on the terminals.
Make sure open drain holes face downwards.
Extremely dusty environments all require drain
Cable entries which are not used and the
holes to be closed.
terminal box itself must be sealed against dust
and water. In order to maintain the degree
Incorrect setup may cause damage to bearings
of protection, always ensure that the original
and shaft extensions.
gaskets are used and that the terminal box is
clean and dry when closing.
9.5.3 Connecting the motor
Normal motor design has the terminal box on 9.5.4 Direction of rotation
top with cable entry possible from both sides.
The motors are normally suitable for both
directions of rotation. Exceptions are indicated
Some motors are available with top-mounted
on the rating plate by an arrow. For the desired
terminal boxes rotatable 4 x 90°, and some
direction of rotation, the stator winding is
with side-mounted terminal boxes.
connected as follows:
Unused cable entries must be closed.
Connection of L1, Direction of
As well as main winding and earthing terminals, L2, L3 to: rotation when
the terminal box can also contain connections
for thermistors, standstill heating elements, U1, V1, W1
viewing drive end:
Clockwise
9
switches, or PT 100 resistance elements. W1, V1, U1 Counterclockwise

Motor
Voltage may be connected at Mode of starting Measures to
standstill inside the terminal and winding changing of
box for heating elements or rotation direction
direct winding heating! Direct-on-line starting and Reverse connections at
pole-changing motors with motor or switchboard.
Connection diagrams for auxiliary elements separate windings
are found inside the terminal box cover or in Star/delta starting and Exchange two supply cable
additional labels on the motor frame. pole-changing motors with conductors at the incoming
Dahlander winding supply to the contactor
combination
The capacitor in single-phase
motors can retain a charge that Test
appears across the motor To check the direction of rotation, quickly
terminals even when the motor switch the properly connected but uncoupled
has reached standstill. motor On/Off.

Choose cable cross-sections in accordance  <ǻVWDUWLQJ

with the rated current. Unused cable entries
must be closed by compression glands. In order to avoid excessive transient currents
DQG WRUTXHV EHIRUH FKDQJLQJ IURP < WR ǻ
The motor must be out of operation, wait until the starting current of the Y stage
disconnected and secured against starting. has died down or change when rated speed is
This also applies to auxiliary circuits (e.g. reached. Centrifugal pumps are normaly not
heaters). Make sure that there is no voltage. suited for star/delta starting.

29
 9. MOTOR

9.6 Repair and Maintenance QHFHVVDU\ UHSODFH WKH EHDULQJV +DOI ¿OO WKH
spaces between the ball and the roller track
Before carrying out any work on the motor,
as well as the grease compartments with
disconnect it and secure it against restarting.
grease. Coat shaft bushings in the bearing
caps or end shields with a thin layer of grease.
In motors with greasing device, regrease
Permanently greased bearings (2RS and 2Z
bearings with the motor running.
bearings) cannot be washed and regreased.
Such bearings must therefore be replaced. To
9.6.1 General Inspection
dismantle the bearings, use pressing screws
‡ Inspect the motor at regular intervals. or other appropriate devices.
‡ Keep the motor clean and ensure free
YHQWLODWLRQDLUÀRZ 9.6.4 Bearings with regreasing device
‡ Check the condition of shaft seals and and grease slinger
replace if necessary.
Regreasing interval and required quantity
‡ Check the condition of connections and
of grease are indicated on the rating plate.
assembly bolts.
Bearings and bearing caps must be washed
‡ Check the bearing condition by listening
with petrol or benzene after regreasing twelve
for unusual noise, vibration measurement,
times.
bearing temperature, inspection of spent
grease or SPM nipple monitoring.
With the outer bearing cap open but the inner
cap screwed on, the rotor should be turned
9.6.2 Cleaning
slowly and grease pressed in through the
Depending on local conditions, air passages regreasing device until approximately half the
should be cleaned regularly. empty space between the rolling elements an
9 WKHUROOHUWUDFNVLV¿OOHGZLWKJUHDVH
9.6.3 Bearing maintenance and
lubrication 9.6.5 Lubricants
Motor

When regreasing, use only special ball bearing

Before the First Start of the grease with the following properties:
motor it must be greased! When regreasing, use only special ball bearing
grease with the following properties:
‡ Good quality grease with lithium complex
soap and with mineral or PAO oil
Observance of regreasing ‡ Base oil viscosity 100–160 at 40°C
intervals is vital for the ‡ &RQVLVWHQF\1/*,JUDGH±
operational reliabilty of the ‡ Temperature range -30° - +120°C
motors! continuous.

Under normal operating conditions, motors can  )RU YHUWLFDOO\ PRXQWHG PRWRUV RU LQ
be operated between 2-4.000 hours without hot conditions, a stiffer end of scale is
maintenance depending on frame size and recommended.
rpm. The maximum period of maintenance-
free operation is four years. However, the Grease with the correct properties is available
condition of the grease should be checked from all major lubricant manufacturers.
occasionally even before this time limit. The
indicated number of service hours is only valid Highly loaded or slowly rotating bearings
for operation at rated speed. The bearings require EP grease.
VKRXOG RQO\ EH ¿OOHG  VLQFH D FRPSOHWH
¿OOLQJRIWKHEHDULQJVDQGEHDULQJFRYHUVZLWK
grease leads to increased bearing temperature
and therefore to increased wear.
The ball bearings and the bearing caps
should be washed with petrol or benzene. If

30
9. MOTOR

The following (or similar) high performance

grease can be used:

Esso Unirex N3
Mobil Mobilith SHC 100
SKF LGHQ 3
BP Energrease LC 2
Shell Albida EMS 2

9.6.6 Lubrication intervals

The lubricantion intervals are based on
a bearing operation temperature of 80°C
(ambient temperature of 25°C) An increase
in the ambient temperature raises the
temperature of the bearings correspondingly.
The table values should be halved for a 15°C
decrease in bearing temperature and may
be doubled for a 15°C increase in bearing
temperature.

Frame size Two pole Four and

design multipole
design 9
112 to 315 2000 hrs 4000 hrs
355 to 400 2000 hrs 3000 hrs

Motor
9.7 Spare Parts and Repair
Any repair work within the guarantee
period is subject to approval by the motor
manufacturer.

When ordering Spare Parts, the full type must

be designated and the product code as stated
RQWKHUDWLQJSODWHPXVWEHVSHFL¿HG

If the motor is stamped with a serial number,

this should also be given.

9.7.1 Rewinding
Rewinding should always be carried out by
TXDOL¿HGUHSDLUVKRSV

31
 9. MOTOR
9.8 Troubleshooting
The diagram below describes the most common faults which can occur during operation of motors.
Should additional information be required, please contact IRON Pump or the motor manufacturer.

Problem Possible cause Solution

Motor does not Blown fuses. Replace fuses with proper type and rating.
start: Overload. Check and reset overload in starter.
Improper power supply. Check if power supplied is consistent with
motor rating plate and load factor.
Improper line connections. Check connections with diagram supplied
with motor.
Open circuit in winding or Indicated by humming sound when
control switch. switch is closed. Check for loose wiring
connections. Also ensure that all control
contacts are closed.
Mechanical failure. Check if motor and drive turn freely. Check
bearings and lubrication.
Short circuited stator. Indicated by blown fuses. Motor must be
rewound.
Poor stator coil connection. Remove end bells, locate with test lamp.
Rotor defective. Look for broken bars or end rings.
Motor may be overloaded. Reduce load.
9 Motor stalls: One phase may be open. Check lines for open phase.
Wrong application. Change type or size. Consult manufacturer.
Motor

Overload. Reduce load.

Low voltage. Ensure the rating plate voltage is
maintained. Check connection.
Open circuit. Fuses blown, check overload relay, stator
and push buttons.
Motor runs and Power failure. Check fuses, control panel and lines for
suddenly stops: loose connections.
Motor does not Not applied properly. Consult supplier for proper type.
come up to speed: Voltage too low at motor Use higher voltage or transformer
terminals because of line terminals or reduce load. Check
drop. connections. Check conductors for proper
size.
Starting load too high. Check admissible load which motor is
supposed to carry at start.
Broken rotor bars or loose Look for cracks near the rings. A new rotor
rotor. may be required as repairs are usually
temporary.
Open primary circuit. Locate fault with testing device and repair.
Motor takes too long Excessive load. Reduce load.
to accelerate and/or Low voltage during start. Check for high resistance. Adequate wire
draws high current: size.
Defective squirrel cage rotor. Replace with new rotor.
Wrong rotation: Wrong phase sequence. Reverse connections at motor or
switchboard.

32
9. MOTOR

Problem Possible cause Solution

Motor overheats Overloaded. Reduce load.
while running under Frame or bracket vents may Open vent holes and check for a
load: be clogged with dirt and continuous stream of air from the motor.
prevent proper ventilation of
motor.
Motor may have one phase Check to make sure that all leads are
open. properly connected.
Grounded coil. Locate and repair.
Unbalanced terminal Check for faulty leads, connections and
voltage. transformers.
Motor vibrates: Motor misaligned. Realign.
Weak support. Strengthen base.
Coupling out of balance. Balance coupling.
Driven equipment Rebalance driven equipment.
unbalanced.
Defective bearings. Replace bearings.
Bearings not in line. Line up properly.
Balancing weights shifted. Rebalance motor.
Discrepancy between Rebalance coupling or motor.
balancing of rotor and
coupling (half key - full key). 9
Polyphase motor running Check for open circuit.
single phase.

Motor
Excessive end play. Adjust bearing or add shim.
Scraping noise: Fan rubbing fan cover. Remove interference.
Fan striking insulation. Clear fan.
Motor loose on bedplate. Tighten holding bolts.
Noisy operation: Air gap not uniform. &KHFNDQGFRUUHFWEUDFNHW¿WVRUEHDULQJ
Rotor imbalance. Rebalance.
Bearing balls are Bent or sprung shaft. Straighten or replace shaft.
getting hot: Excessive belt pull. Decrease belt tension.
Pulleys too far away. Move pulleys closer to motor bearing.
Pulley diameter too small. Use larger pulleys.
Misalignment. Correct by realignment of drive.
,QVXI¿FLHQWJUHDVH Maintain proper quantity of grease in
bearing.
Deterioration of grease or Remove old grease, wash bearings
lubricant contaminated. thoroughly in kerosene and replace with
new grease.
Excess lubricant. Reduce some grease. Bearing should not
EHPRUHWKDQ¿OOHG
Overloaded bearing. Check alignment, side and end thrust.
Broken ball or rough races. Replace bearing. First clean housing
thoroughly.

33
 Cooling Water Preheating Set C5.05.09.09.10.27
-

M25

Cooling Water Preheating Set

en / 22.01.2014 FD049661 1/28

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OPERATING INSTRUCTIONS Page: 1 of: 23 KA

Wasservorwärmaggregat
Water Preheating Unit
Type KVE

ähnliches Bild / Similar picture

57645
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 ELWA Elektrowärme München A.Hilpoltsteiner GmbH & Co KG
Landsberger Str. 367-369 P.O.Box 210466 Tel: +49-89-546779-0
80687 München 80674 München Fax: +49-89-546779-10
E-mail: [email protected]
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Inhaltsverzeichnis / Contents
1 Sicherheitshinweise / Notes on safety............................................................................................. 4
1.1 Allgemeines / General ............................................................................................................ 4
1.2 Kennzeichnung von Hinweisen / Icons highlighting annotations ............................................ 4
1.3 Personalqualifikation / Qualifications of personnel ................................................................. 4
1.4 Gefahren / Dangers ................................................................................................................ 5
1.5 Sicherheitsbewusstes Arbeiten / Safe working practices ....................................................... 5
1.6 Sicherheitshinweise für den Betreiber/Bediener / Safety instructions for the operator........... 5
1.7 Sicherheitshinweise für Wartung-, Inspektions und Montagearbeiten / Safety instructions for
maintenance, inspection and installation ............................................................................................. 5
1.8 Unzulässige Verwendung / Non-designated use.................................................................... 6
1.9 Normen und Vorschriften / Standards and regulations .......................................................... 6
2 Allgemein / General......................................................................................................................... 7
2.1 Beschreibung / Description..................................................................................................... 7
2.2 Hauptbestandteile / Main components ................................................................................... 8
2.2.1 Druckbehälter / Pressure vessel (1)................................................................................... 8
2.2.2 Heizbatterie / Heating battery (2) ....................................................................................... 8
2.2.3 Pumpe / Pump (3) .............................................................................................................. 9
2.2.4 Schaltschrank / Switch cabinet (4) ................................................................................... 10
2.2.5 Rückschlagklappe / Non-return flap (5) ........................................................................... 10
2.2.6 Sicherheitsventil (optional) / Safety valve (optional) (6) ................................................... 11
2.2.7 Temperaturregler / Temperature controller ...................................................................... 12
2.2.8 Sicherheits-temperatur-begrenzer / Safety temperature limiter ATHF-70 ....................... 12
3 Montage / Installation .................................................................................................................... 13
3.1 Rohrleitungen / Piping system.............................................................................................. 13
3.2 Elektrischer Anschluß / Electrical connection....................................................................... 14
3.3 Drehrichtung der Pumpe / Pump (direction of rotation) ........................................................ 14
4 Inbetriebnahme / Commissioning.................................................................................................. 14
5 Wartung, Service und Reparatur / Maintenance, service and repair ............................................ 15
5.1 Erhitzer / Heater.................................................................................................................... 15
5.1.1 Ausbau-Einbau des Heizeinsatzes / Removing heating insert......................................... 16
5.1.2 Aus- und Einbau der Heizelemente / Removing heating elements .................................. 16
5.2 Schaltschrank / Switch cabinet............................................................................................. 17
Pumpe / Pump................................................................................................................................... 17
5.3.1 Service / Service .............................................................................................................. 17
5.3.2 Pumpenwelle justieren / Shaft adjustment ....................................................................... 18
6 Störungsübersicht / Troubleshooting ............................................................................................ 19
6.1 Erhitzer / Heater.................................................................................................................... 19
6.2 Schaltschrank / Switch cabinet............................................................................................. 19
6.3 Pumpe / Pump...................................................................................................................... 19
7 Technische Daten / Technical data............................................................................................... 21
8 Ersatzteile / Spare parts ................................................................................................................ 22
8.1 Ersatzteilliste / Spare parts list.............................................................................................. 22
8.2 Ersatzteilbevorratung / Stock of spare parts......................................................................... 23

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Landsberger Str. 367-369 P.O.Box 210466 Tel: +49-89-546779-0
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E-mail: [email protected]
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Anhang / Appendix
Anhang / Appendix 1: Herstellererklärung / Manufacturer Declaration
Anhang / Appendix 2: Konformitätserklärung / Declaration of Conformity
Anhang / Appendix 3: Maßzeichnung / Dimension drawing
Anhang / Appendix 4: Verdrahtungschema Heizbatterie / Wiring diagram of heating battery
Anhang / Appendix 5: Schaltplan Schaltschrank / Wiring diagram of switch cabinet

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 ELWA Elektrowärme München A.Hilpoltsteiner GmbH & Co KG
Landsberger Str. 367-369 P.O.Box 210466 Tel: +49-89-546779-0
80687 München 80674 München Fax: +49-89-546779-10
E-mail: [email protected]
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1 SICHERHEITSHINWEISE / NOTES ON SAFETY

1.1 ALLGEMEINES / GENERAL

Diese Montage- und Betriebsanleitung enthält These installation and operating instructions
grundlegende Hinweise, die bei Installation, contain basic information which must be fol-
Betrieb und Wartung zu beachten sind. Sie ist lowed during installation, operation and mainte-
daher unbedingt vor Montage und Inbetrieb- nance. Consequently, it is essential that the
nahme vom Monteur sowie dem zuständigen fitter reads these instructions before installing
Fachpersonal/Betreiber zu lesen. the unit and that the technical staff responsi-
Diese Montage- und Betriebsanleitung bezieht ble/the owner reads them before the unit is
sich auf elektrisch beheizte Wasservorwärmag- taken into operation.
gregate. These installation and operating instructions
Es sind nicht nur die unter diesem Abschnitt deal with electrically heated water preheating
„Sicherheitshinweise“ aufgeführten, allgemeinen units.
Sicherheitshinweise zu beachten, sondern auch As well as the general safety instructions con-
die unter den anderen Abschnitten angeführten tained in the "Notes on safety" section, also
, speziellen Sicherheitshinweise. comply with the specific safety notes given in
Für Schäden die durch Nichtbeachtung dieser the other sections.
Betriebsanleitung entstanden sind kann keine We cannot accept any liability for damage due
Gewährleistung übernommen werden. to failure to adhere to these operating instruc-
tions.

1.2 KENNZEICHNUNG VON HINWEISEN / ICONS HIGHLIGHTING ANNOTATIONS

Die in dieser Montage- und Betriebsanlei- The safety notes contained in these installa-
tung enthaltenen Sicherheitshinweise, die tion and operating instructions which, if not
bei Nichtbeachtung Gefährdungen für Per- complied with, may endanger the safety of
sonen hervorrufen können, sind mit dem personnel, are specifically identified with the
allgemeinen Gefahrensymbol „Sicherheits- general hazard symbol as defined in DIN
zeichen nach DIN 4844-W9“ besonders ge- 4844-W9.
kennzeichnet.

Direkt am Modul oder Gerät angebrachte Hin- Information such as the model plate, inlet, out-
weise wie z.B. Typenschild, Zulauf, Ablauf, usw. let, etc. applied directly to the module or unit
müssen unbedingt beachtet und in voll lesba- must be followed in all cases and must be kept
rem Zustand gehalten werden. in a fully legible condition.

1.3 PERSONALQUALIFIKATION / QUALIFICATIONS OF PERSONNEL

Das Personal für Bedienung, Wartung, Inspek- The personnel involved in operating, maintain-
tion und Montage muß die entsprechende Qua- ing, inspecting and installing the unit must be
lifikation für diese Arbeiten aufweisen. suitably qualified for this work. The owner of the
Verantwortungsbereich, Zuständigkeit und die unit must precisely define the areas of respon-
Überwachung des Personals müssen durch den sibility and monitoring duties of the personnel.
Betreiber genau geregelt sein.

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Landsberger Str. 367-369 P.O.Box 210466 Tel: +49-89-546779-0
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E-mail: [email protected]
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1.4 GEFAHREN / DANGERS

Die Nichtbeachtung dieser Betriebsanleitung mit Failure to adhere to these operating instructions
ihren Sicherheitshinweisen kann sowohl eine and the safety notes they contain may not only
Gefährdung für Personen als auch für die Um- endanger the safety of personnel but also cause
welt und die Anlage zur Folge haben. Dies kann damage to the environment and the machine.
zum Verlust jeglicher Schadensersatzansprü- This will render any claims for damages invalid.
che führen.

Im einzelnen kann die Nichtbeachtung folgende Specifically, failure to adhere to these instruc-
Gefährdungen nach sich ziehen: tions can entail the following dangers:

- das Versagen wichtiger Teile der Anlage - Failure of important parts of the machine
- das Auslaufen umweltgefährdender Stoffe - Leakage of environmentally harmful sub-
- Tod oder schwere Körperverletzung durch stances
elektrische bzw. mechanische Einwirkungen - Severe or fatal physical injury due to electri-
cal or mechanical energy

1.5 SICHERHEITSBEWUSSTES ARBEITEN / SAFE WORKING PRACTICES

Die in dieser Montage- und Betriebsanleitung The following must be adhered to: safety notes
aufgeführten Sicherheitshinweise, die beste- contained in these installation and operating
henden nationalen Vorschriften zur Unfallver- instructions; national regulations in place gov-
hütung sowie eventuelle interne Arbeits-, Be- erning accident prevention; any in-house, works
triebs- und Sicherheitsvorschriften des Betrei- and safety instructions issued by the owner.
bers, sind zu beachten.

1.6 SICHERHEITSHINWEISE FÜR DEN BETREIBER/BEDIENER / SAFETY INSTRUCTIONS FOR THE

OPERATOR
Beim Betrieb elektrischer Wärmegeräte können Certain parts of these electrical preheating units
bestimmte Teile dieser Geräte unter gefährli- may be live (carrying dangerous voltage levels)
chen Spannungen stehen und die Oberfläche . and the surface may be at a high temperature
hohe Temperaturen erreichen. Eine Gefährdung during operation. Appropriate precautions must
ist durch dementsprechende Vorkehrungen be taken to preclude any dangers. To this end,
auszuschliessen. Hierzu sind wie in Abschnitt as stated in the SAFE WORKING PRACTICES section,
SICHERHEITSBEWUSSTES ARBEITEN angeführt die the relevant accident prevention regulations and
einschlägigen Unfallverhütungsvorschriften und directives issued by the local power utility must
die Vorschriften der örtlichen Energieversor- be adhered to.
gungsunternehmen zu beachten.

1.7 SICHERHEITSHINWEISE FÜR WARTUNG-, INSPEKTIONS UND MONTAGEARBEITEN / SAFETY

INSTRUCTIONS FOR MAINTENANCE, INSPECTION AND INSTALLATION
Der Betreiber hat dafür zu sorgen, dass alle The owner must ensure that all maintenance,
Wartungs- Inspektions- und Montagearbeiten inspection and installation work is performed by
von autorisiertem und qualifiziertem Fachperso- authorised and qualified technical personnel.
nal ausgeführt werden, das sich durch einge- These personnel must have read the installation
hendes Studium der Montage- und Betriebsan- and operating instructions in order to acquire
leitung ausreichend informiert hat. the requisite knowledge.
Grundsätzlich sind Arbeiten am Gerät oder Mo- Never work on the unit or the module unless:
dul nur zulässig wenn:

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Landsberger Str. 367-369 P.O.Box 210466 Tel: +49-89-546779-0
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- die Stromzufuhr unterbrochen ist - The electrical power supply is switched off
- alle Medium Zu- und Abläufe abgesperrt - All fluid inlets and outlets are sealed
sind - The system has been depressurised
- das System drucklos gemacht ist

Unmittelbar nach Abschluss der Arbeiten müs- All safety and protection equipment must be
sen alle Sicherheits- und Schutzeinrichtungen returned to its correct position and restored to a
wieder in ihre ordnungsgemässe Position ge- functional condition immediately after work has
bracht bzw. in Funktion gesetzt werden. finished.
Für die Wiederinbetriebnahme sind die im Ab- Refer to the points listed in the COMMISSIONING
schnitt INBETRIEBNAHME aufgeführten Punkte zu section when taking the unit back into operation.
beachten.

1.8 UNZULÄSSIGE VERWENDUNG / NON-DESIGNATED USE

Die Betriebssicherheit des gelieferten Geräts The operational safety of the unit or module is
oder Moduls ist nur bei bestimmungsgemässer only guaranteed provided it is operated in ac-
Verwendung entsprechend Abschnitt cordance with the designate use as defined in
BESCHREIBUNG der Betriebsanleitung gewähr- the DESCRIPTION section of these operating
leistet. Die in den technischen Daten angege- instructions. The limit values given in the techni-
benen Grenzwerte dürfen auf keinen Fall über- cal data must under no circumstances be ex-
schritten werden. ceeded.

1.9 NORMEN UND VORSCHRIFTEN / STANDARDS AND REGULATIONS

Anstelle der in dieser Anleitung genannten, in When using the unit outside the area of validity
Europa gültigen Industrienormen und Bestim- of the industrial standards and directives listed
mungen (z.B. in Europa DIN,VDI,VDE) müssen in this manual (e.g. in Europe: DIN, VDI, VDE),
bei einer Verwendung außerhalb deren Gel- the equivalent and pertinent directives in force
tungsbereiches die im Anwenderland gültigen in the area of use must be observed.
einschlägigen Vorschriften beachtet werden.

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2 ALLGEMEIN / GENERAL

2.1 BESCHREIBUNG / DESCRIPTION

Das Aggregat ist ausgelegt um wässrige Medi- The unit is designed to heat up aqueous media
en mit Hilfe von elektrischer Energie zu erwär- by means of electrical energy and to maintain
men und mittels eines Reglers auf der ge- the required temperature by means of a regu-
wünschten Temperatur zu halten. Eine einge- lator. A built-in pump forces the medium through
baute Pumpe drückt das Medium durch den the continuous-flow heating battery, while a
Durchlauferhitzer, dabei verhindert eine Rück- non-return flap on the unit's outlet prevents the
schlagklappe am Auslauf des Aggregats die medium flowing through opposite to the pump-
Durchströmung entgegen der Förderrichtung. ing direction. The pump and the heating battery
Die Pumpe und der Erhitzer sind elektrisch so are wired up electrically so the heating battery
verschaltet, daß ein Betrieb des Erhitzers ohne cannot be operated without the pump. A safety
Pumpe verhindert wird. Ein Sicherheitstempe- temperature limiter protects the heating battery
raturbegrenzer schützt den Erhitzer vor thermi- against thermal overload.
scher Überbelastung.

Wässrige Medien: Aqueous media:

- Kühlwasser - Cooling water
- Heizungswasser mit einer Qualität gem. - Heating water
VDI 2035 - Drinking water
- Trinkwasser - Fluid, not aggressive and not explosive
- Dünflüssige, nicht-aggressive und nicht- media without mineral oil, stable or long fi-
explosive mineralölfreie Medien ohne feste bre
oder langfasrige Bestandteile

Sollte das Gerät für andere als hier angegebene If the unit is designed for media other than those
Medien ausgelegt sein, so ist dies im, listed here, then this is recorded in the
TECHNISCHE DATEN angegeben. TECHNICAL DATA.

ACHTUNG ! IMPORTANT!
Der Erhitzer darf nur betrieben werden, Do not operate the heating battery at tem-
wenn die Betriebstemperatur die Siedetem- peratures above the boiling temperature of
peratur des durchströmenden Mediums bei the medium under atmospheric pressure!
Atmosphärendruck nicht übersteigt !

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2.2 HAUPTBESTANDTEILE / MAIN COMPONENTS

2.2.1 DRUCKBEHÄLTER / PRESSURE VESSEL (1)

Druckbehälter mit Ein- und Austrittsflansch, Pressure vessel with inlet and outlet flange,
Entleeranschluß, Standfüße sowie Muffe für das drainage connection, legs and sleeve for the
Sicherheitsventil. safety valve.
Standardmäßig ist der Druckbehälter aus Stahl- As standard, the pressure vessel is manufac-
blech gefertigt, das mediumseitig Schutzlackiert tured from sheet steel which has a protective
ist. Edelstahl als Behältermaterial ist auf Anfra- coating on the side exposed to the medium.
ge möglich, die ist im TECHNISCHE DATEN ver- Optionally, high-grade steel is available as a
merkt. material for the vessel. If used, this is indicated
Außen ist der Druckbehälter mit einem lackier- in the TECHNICAL DATA.
ten oder verzinkten Isoliermantel versehen, der Externally, the pressure vessel is equipped with
den Wärmeverlust reduziert. Maße sind dem a painted or galvanised insulating jacket in order
Anhang 1 zu entnehmen. to reduce heat losses. Refer to Appendix 1 for
dimensions.

2.2.2 HEIZBATTERIE / HEATING BATTERY (2)

Der Heizeinsatz ist je nach Gesamtleistung des The heating unit is equipped with a suitable
Geräts mit einer der Leistung entsprechenden number of tubular heating elements depending
Anzahl an Rohrheizkörpern bestückt. Diese sind on the overall power of the unit. These are
durch Gewindenippel in einen Heizflansch ein- screwed into a heating flange by means of
geschraubt und in der Anschlusszarge zu Lei- threaded nipples. They are connected to output
stungstufen verschaltet. stages in the connection frame.

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2.2.3 PUMPE / PUMP (3)

Bei er Pumpe handelt es sich um eine einstufi- The pump is a single-stage centrifugal pump
ge Kreiselpumpe mit oberflächengekühlten with a surface-cooled asynchronous motor. It is
Asynchronmotor in Inline-Bauweise mit gegen- installed inline with connection flanges on oppo-
überliegenden Anschlußflanschen gleicher site ends having the same nominal width.
Nennweite. The pump shaft is sealed against the housing
Die Pumpenwelle ist zum Gehäuse mit einer by means of a stressed slipring seal. It is con-
nicht-entlasteten Gleitringdichtung abgedichtet nected to the motor via a rigid coupling. The
und mit dem Motor über eine starre Kupplung pump head unit (motor, bell housing and impel-
verbunden. Der Pumpenkopf (Motor, Laterne ler) can be removed for service purposes with-
und Laufrad) lassen sich ohne Ausbau der out removing the pump.
Pumpe für Servicearbeiten demontieren.

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2.2.4 SCHALTSCHRANK / SWITCH CABINET (4)

Der Schaltschrank enthält sowohl die Absiche- The switch cabinet contains the circuit breakers
rung der Heizelemente und der Pumpe durch for protecting the heating elements and the
automatische Sicherungen, als auch deren pump as well as the controlgear for the break-
Ansteuerung. ers.
Durch einen Hauptschalter kann das komplette The entire module can be switched on and off
Modul EIN/AUS-geschaltet werden. Die Steuer- using a master switch. The control voltage is
spannung wird durch einen Transformator auf converted to 230 V by a transformer. Indicator
230V konvertiert. Meldelampen zeigen die Be- lamps signal the operating states.
triebszustände an. Refer to the wiring diagram in Appendix 3 for
Die genaue Funktionsweise ist dem Schaltplan details of the functions.
im Anhang 3 zu entnehmen.

2.2.5 RÜCKSCHLAGKLAPPE / NON-RETURN FLAP (5)

Um einen Mediumstrom gegen die Laufrichtung A non-return flap is installed in the outlet of the
der Pumpe zu verhindern ist im Auslauf des water preheating module in order to prevent
Wasservorwärmmoduls eine Rückschlagklappe medium from flowing in the opposite direction to
eingebaut. Dabei handelt es sich um eine Ein- the pump operation. It is a clamp-type fitting
klemmarmatur mit elastischer Dichtung. with a flexible seal.

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Landsberger Str. 367-369 P.O.Box 210466 Tel: +49-89-546779-0
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E-mail: [email protected]
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2.2.6 SICHERHEITSVENTIL (OPTIONAL) / SAFETY VALVE (OPTIONAL) (6)

Das Sicherheitsventil kann zusätzlich bestellt The safety valve is available as an option and
und am Wasservorwärmaggregat angebaut can be fitted on the water preheating unit. Oth-
werden. Andernfalls kann für den nachträgli- erwise, it can be retrofitted by means of the
chen Anbau die am Gerät vorhandene An- connection sleeve provided on the unit.
schlußmuffe verwendet werden.

ACHTUNG ! IMPORTANT!
Jeder für sich absperrbare Behälter oder Any sealable container or any sealable con-
jede für sich absperrbare Behältergruppe tainer group must be fitted with a spring-
muß mit einem federbelasteten, nicht ab- loaded, non-sealable safety valve which
sperrbaren Sicherheitsventil versehen wer- closes reliably after blowing off.
den, das nach dem Abblasen wieder zuver-
lässig schließt.

Sicherheitsventil Typ MSV-W, federbelastet Safety valve type MSV-W, spring-loaded

- Oberteil und Innenteil - Top and inner parts

aus Messing made of brass
- Durch Linksdrehung - Turn the knurled nut to
der Rändelmutter ist vent valve
das Ventil anlüftbar - Seal is resistant
- Die Membrane ist bis against ageing up to
140°C hitze und alte- 140 °C operating tem-
rungsbeständig perature
- Die Feder ist korrosi- - Corrosion-free spring
onsgeschützt

(auf der Zeichnung: unten) (In drawing: pointing down)

Anschlußgröße Eingang: Inlet size:

G ¾“ G ¾“
(auf der Zeichnung: links) (In drawing: pointing left)

Vergrößerter Austritt: Outlet (large socket):

G 1“ G 1“

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2.2.7 TEMPERATURREGLER / TEMPERATURE CONTROLLER

Als Standardausstattung ist im Wasservorwär- An electromechanical controller ATHF-2 is in-
maggragat ein elektromechanischer Regler stalled in the water preheating unit as standard
ATHF-2 eingebaut. Dieser schaltet bei Errei- equipment. This trips when the set temperature
chen der eingestellten Temperatur. Nach absin- is reached. The thermostat switches back to its
ken der Temperatur um den Betrag der Schalt- initial position when the temperature drops by
differenz schaltet der Thermostat wieder in sei- more than the hysteresis value. The setpoint
ne Ausgangsstellung. Der Sollwert ist am Reg- temperature can be set on the controller using a
ler durch einen Schraubendreher einstellbar. screwdriver. It is located either in the switch
Dieser befindet sich entweder im Schaltschrank cabinet or in the connection compartment for
oder im Anschlußraum des Erhitzers.(siehe the heating battery (look for label "regulator
Aufkleber „Regler/Begrenzer ... innen“) Der limiter inside"). The temperature range is shown
Temperaturbereich entspricht der Skala unter on the scale below the adjusting knob.
dem Einstellknopf.
Bild Regler
Sonderausstattung: Special equipment:
- Elektronischer 2-Punktregler mit Tempera- - Electronic 2-point controller with tempera-
turanzeige (1) ture display (1)
- Elektronischer Mehrstufenregler mit Soll- - Electronic multi-stage controller with set-
und Istwertanzeige (2) point and actual value display

(1) (2)
Betriebsanleitungen im Anhang. See Appendix for operating instructions.

2.2.8 SICHERHEITS-TEMPERATUR-BEGRENZER / SAFETY TEMPERATURE LIMITER ATHF-70

Der Sicherheits-Temperatur-Begrenzer schaltet ATHF-70 trips if the pre-set temperature is
bei Erreichen der eingestellten Temperatur, reached. The thermostat does not switch back
behält jedoch den Schaltzustand auch bei Ab- to its normal position if the temperature falls
sinken der Temperatur unter den eingestellten back below the pre-set value. To reset the
Grenzwert bei. Die Betriebsbereitschaft des thermal safety cut-out, press the red button in
Gerätes wird durch Betätigung des Wiederein- the switching cabinet or the terminal box located
schaltknopfes im Schaltschrank oder Anschluß- on the head of the heater (look for label "regu-
raum des Erhitzers wiederhergestellt.(siehe lator limiter inside"). The temperature setting
Aufkleber „Regler/Begrenzer ... innen“) Eine can be adjusted by turning the knob above the
Beschädigung des Meßsystems ( Fühler und scale. This scale represents the maximum set-
Kapillare) bewirkt sofort den ausgelösten ting range.
Schaltzustand (Selbstüberwachung). Der Aus-
lösewert ist am Regler einstellbar. Der Tempe-
raturbereich entspricht der Skala unter dem
Einstellknopf.

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de01a.doc
 ELWA Elektrowärme München A.Hilpoltsteiner GmbH & Co KG
Landsberger Str. 367-369 P.O.Box 210466 Tel: +49-89-546779-0
80687 München 80674 München Fax: +49-89-546779-10
E-mail: [email protected]
 Document: 04-71-FB-033
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OPERATING INSTRUCTIONS Page: 13 of: 23 KA

3 MONTAGE / INSTALLATION
Das Wasser-Vorwärme-Aggregat muß durch The water preheating set must be installed by
einen sachkundigen Facharbeiter, entspre- qualified personnel according to our operating
chend unserer Betriebsanleitung und unter Be- manual and by observing the pertinent regula-
achtung der einschlägigen Bestimmungen und tions.
Vorschriften montiert werden. The operating manual should be read carefully
Vor Beginn der Montagearbeiten und vor der and thoroughly before beginning the installation
ersten Inbetriebnahme ist die Betriebsanleitung work and before the initial start-up. All damages
in allen Teilen gründlich zu lesen. Alle Schäden, occurring because this instruction had not been
die durch Nichtbeachtung dieser Anweisung duly noted will not be covered by the works
entstehen, fallen nicht unter die Werksgarantie. guarantee.

Die für die Montage nötigen Abmessungen, Refer to the drawing in Appendix 1 for the di-
sowie Anschlußmasse sind in der Zeichnung mensions and connection sizes required for
Anhang 1 zu entnehmen. installation.

Das Modul ist verspannungsfrei auf ebenem Install the module on a flat, level base and
Untergrund zu montieren! ensure that no connections are under
stress!

3.1 ROHRLEITUNGEN / PIPING SYSTEM

Alle Rohrleitungen müssen sauber gereinigt Make sure the piping system is clean and no
(spülen) und spannungsfrei montiert werden. connections are under stress. Ensure sufficient
Bei der Montage ist genügend Freiraum für space for repair and maintenance work (e.g.
Reparatur- und Wartungsarbeiten (z.B. Heiz- heater removal).
körperausbau) vorzusehen. Tighten flange connections to the appropriate
Beim Verschrauben der Flanschverbindungen torque.
ist das passende Drehmoment zu berücksichti- The inlet and outlet are identified by a blue and
gen. red sticker with a direction arrow. Never mix
Zulauf und Ablauf sind durch einen blauen und them up.
roten Aufkleber mit Richtungspfeil gekenn-
zeichnet und dürfen keinesfalls vertauscht wer-
den.
ACHTUNG ! IMPORTANT!
Verspannungen oder Verunreinigungen der Stress on the pipe connections or dirt in the
Rohrleitungen können zu Schäden am Mo- pipes can lead to damage to the module!
dul führen!

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 ELWA Elektrowärme München A.Hilpoltsteiner GmbH & Co KG
Landsberger Str. 367-369 P.O.Box 210466 Tel: +49-89-546779-0
80687 München 80674 München Fax: +49-89-546779-10
E-mail: [email protected]
 Document: 04-71-FB-033
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OPERATING INSTRUCTIONS Page: 14 of: 23 KA

3.2 ELEKTRISCHER ANSCHLUß / ELECTRICAL CONNECTION

Die Betriebsspannung und die Netzfrequenz The operating voltage and the mains frequency
müssen mit den Angaben auf dem Hersteller- must accord to the data on the manufacturer’s
schild übereinstimmen. Das Zuleitungskabel ist plate. The incoming supply cable must be sized
entsprechend dem Gesamtanschlußwert zu and fused in accordance with the total con-
bemessen und abzusichern. Je nach Netzsy- nected load.
stem ist vor dem Anschluß der elektrischen Before connecting the unit to the power supply,
Zuleitung das Gerät an der gekennzeichneten the equipment must be earthed at the marked
Erdungsklemmme unter Beachtung der jeweili- earthing terminal paying regard to the appropri-
gen Vorschriften zu erden. ate regulations.
Grundsätzlich sind die Vorschriften des Netzbe-
treibers zu berücksichtigen.

3.3 DREHRICHTUNG DER PUMPE / PUMP (DIRECTION OF ROTATION)

Durch die Drehrichtung der Welle wird die För- The direction of rotation of the shaft determines
derrichtung der Pumpe bestimmt, d.h. sie muß the pumping direction of the pump, i.e. check it
mit den Pfeilen auf der Haube der Pumpe ver- against the arrows on the pump hood. Swap
glichen werden. Stimmt die Drehrichtung nicht over two phases to correct the direction of rota-
mit den Pfeilen überein, so muß durch Vertau- tion if the direction of rotation does not corre-
schen von 2 Phasen die richtige Drehrichtung spond to the arrows.
hergestellt werden.

ACHTUNG ! IMPORTANT!
Falsche Drehrichtung kann zu Schäden an The wrong direction of rotation can lead to
der Pumpe führen! damage to the pump!

4 INBETRIEBNAHME / COMMISSIONING
Für die Inbetriebnahme des Wasservorwär- Note the following points concerning taking the
maggregats sind folgende Schritte zu beachten: water preheating unit into operation:

- Anlage mit Medium befüllen und entlüften - Fill unit with water and bleed it
- Regler auf gewünschten Sollwert einstellen, - Adjust the controller to the required set-
jedoch nicht höher als Betriebstemp. max. point, but not above "Operating Temp.
(siehe TECHN. DATEN) max."(see TECHNICAL DATA)
- Der Begrenzer ist auf einen Wert 20 °C - The limiter has to be adjusted to a setpoint
über dem Regler-Sollwert einzustellen. 20 °C above the controller setpoint.
- Hauptschalter einschalten ⇒ Pumpe läuft - Turn on main switch ⇒ pump in operation
- Wenn Stufenschaltern vorhanden Heizlei- - If selector switches are fitted, use them to
stung mittels dieser(I = ein,0 = aus) vor- select the heating power (I = on, 0 = off).
wählen

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 ELWA Elektrowärme München A.Hilpoltsteiner GmbH & Co KG
Landsberger Str. 367-369 P.O.Box 210466 Tel: +49-89-546779-0
80687 München 80674 München Fax: +49-89-546779-10
E-mail: [email protected]
 Document: 04-71-FB-033
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OPERATING INSTRUCTIONS Page: 15 of: 23 KA

5 WARTUNG, SERVICE UND REPARATUR / MAINTENANCE, SERVICE AND REPAIR

ACHTUNG ! IMPORTANT!
Vor Arbeiten am Gerät: Before working on the unit:
Zu- und Ablauf absperren, Stromzufuhr un- Shut off the inlet and outlet, switch off the
terbrechen und gegen Wiedereinschalten electrical power supply and take measures
sichern! to prevent it from being switched back on!

5.1 ERHITZER / HEATER

Je nach Betriebsart und Beschaffenheit des Depending on the type of operation and on the
Mediums muß der Erhitzer in kürzeren oder degree of contamination of the fluid the heater
längeren Intervallen gründlich gereinigt werden. has to be thoroughly cleaned in longer or
Schlamm, der sich im unteren Bereich des Be- shorter intervals. Sludge deposited in the bot-
hälters abgesetzt hat, kann in der Regel mit tom region of the pressure vessel can be
geeigneter Reinigungsflüssigkeit über Zulauf washed out with suitable liquids via drain socket
und Entleermuffe ausgespült werden. Feste and feed pipes. Solid deposits in the pressure
Ablagerungen im Behälter und zwischen den vessel and between heating pockets or heating
Heiztaschen bzw. Heizkörpern können nur nach elements can only be removed after disassem-
Ausbau des Heizeinsatzes entfernt werden. Um bling the heating insert. In order to avoid dam-
Schäden an den Rohrflächen zu vermeiden, age to the tube surfaces they should not be
sollte die Reinigung nicht mechanisch, sondern cleaned mechanically but with suitable solvents
mittels geeigneter Lösungsmittel bekannter of well-known manufacturers.
Hersteller vorgenommen werden.

ACHTUNG ! IMPORTANT!
Reinigungs- oder Lösungsmittel nur auf der Do not spill liquid cleaner or solvents on the
Druckbehälterseite des Heizflansches an- heating flange surface.
wenden.

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 ELWA Elektrowärme München A.Hilpoltsteiner GmbH & Co KG
Landsberger Str. 367-369 P.O.Box 210466 Tel: +49-89-546779-0
80687 München 80674 München Fax: +49-89-546779-10
E-mail: [email protected]
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5.1.1 AUSBAU-EINBAU DES HEIZEINSATZES / REMOVING HEATING INSERT

Stromzufuhr unterbrechen, Zu- und Ablauf ab- Turn off power, shut off inlet and outlet and
sperren, Behälter entleeren, Zargendeckel ab- drain pressure vessel. Remove top of terminal
nehmen, elektrische Anschlüsse am Klemm- box, disconnect wiring from terminal strip, with-
steg lösen, Zuleitungen aus den Kabeleinfüh- draw cables through the cable glands, unlock
rungen nehmen, Arretierungen lösen und Fühler and remove sensors of controllers and thermal
von Regler bzw. Begrenzer aus den Tauchroh- cut-outs from immersion tubes (make sure not
ren ziehen (auf Kapillare achten - nicht knicken to damage the capillaries), then pull off terminal
!), anschließend Zarge abziehen. Flanschbefe- box. Remove flange mounting bolts, lift heating
stigungsschrauben lösen und herausdrehen, insert by means of the provided forcing bolts
Heiz-einsatz mittels Druckschrauben (werkseitig and withdraw it from the vessel.
vorgesehen) abheben und aus dem Behälter
ziehen. Behälter und Heizeinsatz sind nun gut Pressure vessel and heating insert are now
zugänglich und können ebenso wie die easily accessible and can be cleaned incl. the
Flanschdichtflächen gereinigt werden. Über- sealing surfaces of the flange. Check the heat-
prüfen Sie Heizkörper, Regler, Begrenzer, An- ing elements, the temperature controller, the
schlußklemmen und die gesamte Verdrahtung thermal safety cut-out, the terminals and the
auf Funktion. Defekte Teile sind zu erneuern. entire wiring. Faulty parts must be exchanged.
Die Vorgehensweise für den Ausbau eines Hei- For exchange instructions heating elements see
zelements folgt. following chapter.
Zusammenbau und Wiederinbetriebnahme Reassemble the heater in reverse order, using
erfolgen in umgekehrter Reihenfolge unter Ver- new flange gaskets
wendung einer neuen Flanschdichtung

5.1.2 AUS- UND EINBAU DER HEIZELEMENTE / REMOVING HEATING ELEMENTS

- Heizkörperverbindungen entfernen. - Remove heating element connections.
- Sechskantmutter lösen - Undo nuts
- Heizkörper nach unten herausziehen. - Remove heating element.

Wiedereinbau in umgekehrter Reihenfolge unter Reassemble unit in reverse order using new
Verwendung neuer Dichtungen gaskets.

Beim Einbau mit Gabelschlüssel gegenhalten um ein Verfor-

men des Heizkörpers zu verhindern.
For fitting hold with spanner to prevent a deformation of the
heating element.

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 ELWA Elektrowärme München A.Hilpoltsteiner GmbH & Co KG
Landsberger Str. 367-369 P.O.Box 210466 Tel: +49-89-546779-0
80687 München 80674 München Fax: +49-89-546779-10
E-mail: [email protected]
 Document: 04-71-FB-033
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OPERATING INSTRUCTIONS Page: 17 of: 23 KA

5.2 SCHALTSCHRANK / SWITCH CABINET

Die Schaltanlage bedarf keiner besonderen The control cabinet does not need special
Wartung und Pflege. maintenance.

5.3 PUMPE / PUMP

ACHTUNG ! CAUTION !
Eine detaillierte Betriebsanleitung des Pum- More detailed instructions by the pump
penherstellers liegen am Gerät vor !! manufacturer are available in the control box
of the unit
Die Pumpe und der Motor sind wartungsfrei. Pump and motor do not require maintenance. If
Wird die Pumpe für längere Zeit entleert, sollten the pump is drained for a longer period of inac-
einige Tropfen Silikonöl auf die Welle zwischen tivity, apply a few drops of silicone oil to the
Laterne und Kupplung gespritzt werden. Da- shaft between the motor bell housing and the
durch wird ein Verkleben der Dichtungsflächen coupling to prevent the seals from sticking to-
verhindert. gether.

5.3.1 SERVICE / SERVICE

Bei eventueller Serviceanforderung bei Grund- If Grundfos is requested to service the pump,
fos muß unbedingt vor dem Versand der Pum- Grundfos must be contacted supplying details
pe mit Grundfos Kontakt aufgenommen werden. about the pumped liquid and other operation
Informationen über Fördermedium usw. müssen details before the pump is returned for service.
vorliegen, da Grundfos sonst die Annahme der Possible costs of returning the pump are paid
Pumpe verweigern kann. Eventuelle Versand- by the customer.
kosten gehen zu Lasten des Absenders.

\\LINUXELWA\amann\BEDA
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 ELWA Elektrowärme München A.Hilpoltsteiner GmbH & Co KG
Landsberger Str. 367-369 P.O.Box 210466 Tel: +49-89-546779-0
80687 München 80674 München Fax: +49-89-546779-10
E-mail: [email protected]
 Document: 04-71-FB-033
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5.3.2 PUMPENWELLE JUSTIEREN / SHAFT ADJUSTMENT

Wurde der Motor während der Montage oder If the motor has been removed during installa-
bei einer Reparatur der Pumpe entfernt, muß tion or repair of the pump, the pump shaft must
die Pumpenwelle nach der Montage wie folgt be adjusted after the pump is reassembled.
justiert werden. Dabei ist darauf zu achten, daß Ensure that the shaft pin is correctly fitted in the
der Zylinderstift korrekt in der Pumpenwelle pump shaft.
montiert ist.

- Kupplungsschutz mit einem Schraubenzieher - Remove the coupling covers using a

entfernen screwdriver
- Innensechskantschrauben in die Kupplung - Fit the hexagon head bolts in the coupling.
einsetzen
Do not tighten.
- Kupplung bzw. Pumpenwelle mit einem Schrau-
benzieher in Richtung Motor heben, so daß die - Lift coupling and the pump shaft as far as
possible towards the motor using a screw-
Pumpenwelle die Motorwelle berührt 
driver until the pump shaft touches the mo-
- Innensechskantschrauben in der Kupplung mit
tor shaft. 
5 Nm (0,5 kpm) anziehen ‚
- Tighten the bolts to approximately 5 Nm
- Prüfen, ob der Abstand zwischen den Kupp-
lungshälften auf beiden Seiten gleich ist. (0.5 kpm) ‚
- Innensechskantschrauben in der Kupplung - Check the coupling parts on both sides for
paarweise entsprechend folgender Werte an- equal clearance.
ziehen: M6x20: 13Nm (1,3kpm) / M8x25 -31Nm - Tighten the bolts (one side at a time) to the
(3,1kpm) ‚ torque stated below: M6x20: 13Nm (1.3kpm) /
- Kupplungsschutz montieren
M8x25 -31Nm (3.1kpm) ‚
- Fit the coupling covers

Für Doppelpumpen kann ein Blindflansch ge- Twin-head pumps: If one pump requires serv-
liefert werden, um die zweite Pumpe während ice, a blind flange can be supplied to keep the
einer Reparatur zu betreiben other pump running

\\LINUXELWA\amann\BEDA
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 ELWA Elektrowärme München A.Hilpoltsteiner GmbH & Co KG
Landsberger Str. 367-369 P.O.Box 210466 Tel: +49-89-546779-0
80687 München 80674 München Fax: +49-89-546779-10
E-mail: [email protected]
 Document: 04-71-FB-033
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OPERATING INSTRUCTIONS Page: 19 of: 23 KA

6 STÖRUNGSÜBERSICHT / TROUBLESHOOTING

6.1 ERHITZER / HEATER

Erhitzer kommt nicht auf Soll-Temperatur Heater does not reach setpoint tempera-
ture
- Sicherung einer oder mehrerer Heizstufen - Fuse blown in one or more heating ele-
ausgelöst ments
- Steuersicherung ausgelöst - Control fuse blown
- Regler zu niedrig eingestellt - Controller set too low
- Regler defekt - Controller defective
- Heizkörper defekt - Heating element defective
- Durchfluß unterbrochen - Throughflow blocked
- Begrenzer ausgelöst - Limiter has tripped
- Keine Stromzufuhr - No electrical power supply
- Erhitzer verschmutzt - Heater dirty

6.2 SCHALTSCHRANK / SWITCH CABINET

Störungslampe leuchtet Fault lamp lights
- Sicherheitstemperaturbegrenzer hat aus- - Safety temperature limiter has tripped
gelöst - Motor protection switch on the pump has
- Motorschutzschalter der Pumpe hat ausge- tripped
löst

6.3 PUMPE / PUMP

Motor läuft nicht Motor does not run when started
- Keine Stromzufuhr am Motor - Supply failure
- Sicherung durchgebrannt oder Sicherungs- - Fuse blown or automatic circuit breaker
automat ausgelöst tripped
- Motorschutz hat ausgelöst - Motor protection tripped
- Schütz defekt - Contactor fault
- Steuersicherung durchgebrannt oder Siche- - Control fuse blown or automatic circuit
rungsautomat ausgelöst breaker tripped
- Motor defekt - Motor fault
Motorschutz löst beim Einschalten aus Motor protection cuts out when
pump is started
- Sicherung durchgebrannt oder Sicherungs- - Fuse blown or automatic circuit breaker
automat hat ausgelöst tripped
- Motorschutzschalter defekt - Motor protection fault
- Kabelverbindung lose oder defekt - Cable connection loose or faulty
- Motorwicklung defekt - Motor winding defective
- Pumpe mechanisch blockiert - Pump mechanically blocked
- Motorschutzschalter falsch eingestellt - Overload setting too low

Motorschutz löst gelegentlich aus Motor protection cuts out occasionally

- Motorschutzschalter falsch eingestellt - Overload setting too low
- Netzspannungsschwankungen - Supply voltage periodically too high or low
- Differenzdruck über Pumpe zu gering - Differential pressure across pump too low

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 ELWA Elektrowärme München A.Hilpoltsteiner GmbH & Co KG
Landsberger Str. 367-369 P.O.Box 210466 Tel: +49-89-546779-0
80687 München 80674 München Fax: +49-89-546779-10
E-mail: [email protected]
 Document: 04-71-FB-033
BETRIEBSANLEITUNG Version/Date: 01 vom 2001-03-08
OPERATING INSTRUCTIONS Page: 20 of: 23 KA

Motorschutz ok, aber Pumpe läuft nicht Motor protection ok, but pump does not run
- Keine Stromzufuhr am Motor - Check voltage supply
- Sicherung durchgebrannt oder Sicherungs- - Fuse blown or automatic circuit breaker
automat hat ausgelöst tripped
- Schütz defekt - Contactor fault

Pumpleistung schwankt Pump capacity not constant

- Saugleitung zu eng - Pump inlet pressure too low
- Saugleitung/Pumpe verschmutzt - Suction pipe / pump partly blocked
- Pumpe saugt Luft - Air in suction line

Pumpe läuft, keine Förderleistung Pump is running but does not deliver
- Saugleitung/Pumpe verstopft - Suction pipe/pump blocked
- Rückschlagventil blockiert - Non-return flap blocked in closed position
- Saugleitung undicht - Leakage in suction line
- Luft in Saugleitung/Pumpe - Air in suction line
- Motor falsche Drehrichtung - Motor rotates in wrong direction

Pumpe dreht nach Abschalten rückwärts Pump turns in reverse when switched off
- Saugleitung undicht - Leakage in suction line
- Rückschlagventil defekt/blockiert - Non-return flap blocked/faulty

Undichtigleit an der Wellendichtung Leakage on shaft seal

- Falsche Höhenstellung der Pumpewelle - Incorrect pump shaft position
- Wellendichtung defekt - Shaft seal defective

Geräusche Noise
- Kavitation - Pump is cavitating
- Falsche Höhenstellung der Pumpenwelle - Incorrect pump shaft position
- Fremdkörper in der Pumpe - Blocking parts in pump

\\LINUXELWA\amann\BEDA
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 ELWA Elektrowärme München A.Hilpoltsteiner GmbH & Co KG
Landsberger Str. 367-369 P.O.Box 210466 Tel: +49-89-546779-0
80687 München 80674 München Fax: +49-89-546779-10
E-mail: [email protected]
 Document: 04-71-FB-033
BETRIEBSANLEITUNG Version/Date: 01 vom 2001-03-08
OPERATING INSTRUCTIONS Page: 21 of: 23 KA

7 TECHNISCHE DATEN / TECHNICAL DATA

Typ Wasservorwärmaggregat Type: Water preheating unit KVE
Anschlußleistung Connected load 7,5 - 108 kW
Mögliche Betriebsspannungen Availible operating voltages 380-690V 50/60Hz
Betriebsdruck (max.) Operating pressure (max.) 10 bar
Betriebstemperatur (max.) Operating temp. (max.) 95 °C
Medium Medium wässrige Medien
Aqueous media
Pumpe Pump 11-13m³/h / 4,7-11,1bar
Schutzklasse Protective standard IP 54

Die gerätespeziefischen Daten können dem Typenschild oder den angehängten Zeichnungen ent-
nommen werden.
For project-specific data please refer to manufacturers plate at module or attached drawings.

\\LINUXELWA\amann\BEDA
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 ELWA Elektrowärme München A.Hilpoltsteiner GmbH & Co KG
Landsberger Str. 367-369 P.O.Box 210466 Tel: +49-89-546779-0
80687 München 80674 München Fax: +49-89-546779-10
E-mail: [email protected]
 Document: 04-71-FB-033
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OPERATING INSTRUCTIONS Page: 22 of: 23 KA

8 ERSATZTEILE / SPARE PARTS

8.1 ERSATZTEILLISTE / SPARE PARTS LIST

Fabr.-Hersteller-Nr. / Serial No.: .....................................

Ersatzteilbestellung:
Diese Seite kopieren, die Seriennummer des Geräts eintragen, gewünschten Ersatzteile
markieren und an die u.a. FAX-Nummer senden.
Ordering spare parts:
Copy this sheet, enter serial No, mark spare parts and send to FAX number (see below).
Stck/
1. Elektrodurchlauferhitzer Electric flow heater Qty.
Heizbatterie komplett verdrahtet Heating insert completely wired
Heizkörper einzeln Heating element single
Heizflanschdichtung Flange gasket
Anschlußklemmsteg komplett Terminal strip, complete
Anschlußklemme einzeln Single terminal
Erdungsklemme einzeln Single earth terminal
Kabeleinführungen Cable gland
Anschlußflansch-Dichtung Coupling flange gasket
Stck/
2. Schaltschrank Switch cabinet Qty.
Die Bezeichnug ist am jeweiligen Bauteil angebracht Parts are marked with labels
Schaltschrank komplett Switch cabinet complete
F0 Steuersicherung Control fuse
F1-4 Heizstufensicherung Fuses for heating elements
F7 Motorsicherung / Motorschutzschalter Motor fuses / Motor starter
F6 Überstromauslöser Overcurrent trip
F10+11 Steuersicherung „primär“ + „secundär“ Control fuses "primary" & "secondary"
H0 Signallampe „Störung“ Signal lamp "fault"
H1-4 Signallampe „Erhitzer“ Signal lamp "heater"
H7 Signallampe „Pumpe“ Signal lamp "pump"
K0 Hilfsschütz Contactor
K1-4 Leistungsschütz Contactor
K7 Leistungsschütz Contactor
K10 Relaiskoppler Interface relay
Q0 Hauptschalter Main switch
S1-4 Stufenschalter Selector switch
S10 Steuerschalter Control switch
S20 Temperaturbegrenzer Temp. controller
S21 Temperaturregler Temp. limiter
T0 Steuertrafo Control transformer
Kabeleinführungen Cable glands

\\LINUXELWA\amann\BEDA
NL\KVE\TEXTE\KVE-
de01a.doc
 ELWA Elektrowärme München A.Hilpoltsteiner GmbH & Co KG
Landsberger Str. 367-369 P.O.Box 210466 Tel: +49-89-546779-0
80687 München 80674 München Fax: +49-89-546779-10
E-mail: [email protected]
 Document: 04-71-FB-033
BETRIEBSANLEITUNG Version/Date: 01 vom 2001-03-08
OPERATING INSTRUCTIONS Page: 23 of: 23 KA

Stck/
3. Pumpe Pump Qty.
Pumpe komplett mit Motor Pump incl. motor
Motor einzeln Motor only
Dichtungssatz Gasket service kit

Stck/
4. Rückschlagklappe Non-return flap Qty.

Rückschlagklappe Non-return flap

Gegenflansche Counter flange
Stck/
5. Sonderausstattung Special equipment Qty.

Sicherheitsventil Safety valve

Thermometer Thermometer
Manometer Manometer

8.2 ERSATZTEILBEVORRATUNG / STOCK OF SPARE PARTS

Wir empfehlen folgende Mindestreserve an We suggest to stock a minimum of spare parts
Ersatzteilen je Erhitzer zu bevorraten: for each heater:
- 1 Heizflanschdichtung - 1 pce. flange gasket
- 1 Temperaturregler - 1 pce. temp. controller (no. 5)
- ca 1/3 der Gesamtanzahl Heizkörper - about 1/3 of the heating elements
- Dichtungssatz für Pumpe - Pump gasket service kit

\\LINUXELWA\amann\BEDA
NL\KVE\TEXTE\KVE-
de01a.doc
 ELWA Elektrowärme München A.Hilpoltsteiner GmbH & Co KG
Landsberger Str. 367-369 P.O.Box 210466 Tel: +49-89-546779-0
80687 München 80674 München Fax: +49-89-546779-10
E-mail: [email protected]
 Dokument: Konform_o_PED
HERSTELLERERKLÄRUNG Version: 04 / 2007-10-16
MANUFACTURER DECLARATION
without PED Page: 1 / 1 Thanner

im Sinne der EG-Maschinenrichtlinie in accordance with EU Machinery Directive

98/37/EG 98/37/EU
Hiermit erklären wir, daß es sich bei dieser Lieferung We hereby declare that this delivery (see below
um die nachfolgend bezeichnete, jedoch following details) is to be handled as incomplete
unvollständige Maschine handelt, und daß ihre equipment and is not allowed to be put into use
Inbetriebnahme solange untersagt ist, bis festgestellt until the equipment has been declared to conform
wurde, daß die Maschine den Bestimmungen der with rules of the appropriate EU Machinery
EG-Maschinenrichtlinie entspricht und daß bei unten Directive and that the products with pressure
genannten Geräten mit Druckbehältern die Richtlinie vessel listed below not according to EU-Directive
über Druckgeräte ( 97/23/EG) nicht zutreffend ist: Pressure Equipment ( 97/23/EG).
Ö Konformitäts-Bewertungsverfahren Ö Conformity Assessment Procedures
Ö “gute Ingenieurpraxis“ Ö “sound engineering practice“
Angewandte harmonisierte EN ISO 12100-1/-2 Harmonised and national EN ISO 12100-1/-2
und nationale Normen, DIN EN 12828, standards applied, in particular: DIN EN 12828,
insbesondere: DIN 4753 AD 2000 DIN 4753 AD 2000
EN 287-1; EN 288 EN 287-1; EN 288
Produkt: Typ: Product: Type:
Elektro - 4600, 4700, KDE, 400, Electric Flow Heater 4600, 4700,KDE, 400,
Durchlauferhitzer ROE, RWE ROE, RWE
Elektro – Heizbatterien 800, 4600 Electric Heating Battery 800, 4600
Viskositäts - Viscosity Transmitter
EVM-2 / EVM-3 EVM-2 / EVM-3
Meßwertgeber
Aggregate / Module KVE, KVES, KVD, KVT, Sets / Moduls KVE, KVES, KVD,
SVE, DKW KVT, SVE, DKW
Heizkörper lose Rillenflach, Mikanit, „N“ Heating element single flat tube, mikanit, “N”
Raumheizgeräte 7500, 7600, room heating moduls 7500, 7600
Sondergeräte Special Moduls

ERKLÄRUNG ÜBER KONFORMITÄT DECLARATION OF CONFORMITY

Hiermit erklären wir, daß das oben genannte We hereby declare that the products fulfils the
Produkte mit den Anforderungen folgender Normen requirements of the following standards and
und Richtlinien regulations of the directive
EG-Niederspannungsrichtlinie DIN EN 60204-1 EU Low -Voltage Equipment DIN EN 60204-1
(2006/95/EG): DIN EN 60335 Directive (2006/95/EU) DIN EN 60335
DIN EN 60519 DIN EN 60519
DIN 31000 DIN 31000
DIN 57727 DIN 57727
DIN VDE 0100 DIN VDE 0100
EG-Richtlinie DIN EN 50081-2 EU-Directive DIN EN 50081-2
Elektromagnetische DIN EN 61000-6-2 Electromagnetic Compatibility DIN EN 61000-6-2
Verträglichkeit (2004/108/EG) IEC 801-2 (2004/108/EU) IEC 801-2
ENV 50140 ENV 50140
ENV 50141 ENV 50141
übereinstimmt und damit den Bestimmungen and therefore corresponds to the regulations of the
entspricht. directive.

München, 2007-10-16

Geschäftsführender Inhaber ( oder Vertretung )

Managing director and company owner ( or representativ )

ELWA ” ELWA Elektrowärme München A.Hilpoltsteiner GmbH & Co KG

Landsberger Str. 367-369 P.O.Box 210466 Tel: +49-89-546779-0
80687 München 80674 München Fax: +49-89-546779-10
E-Mail: [email protected]
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 3 x 35 A
18,55 kW
3/ PE/ 440-460V
60 Hz

35 A
18 kW 0,55 kW
 Engine Adjusting Valve C5.05.09.09.15.00
-

Engine Adjusting Valve

en / 25.02.2004 FD000518 1/10

Electrically Operated MOV - 81
Control Valves
Electrical Motor Drive
MOV - S - 81
MOV - 3 - 81
Types Technical Data
Single-seat valve in straight-way form Overall length: according to DIN 3300
Type MOV-81
Dimension sheet EK-413 Flanges: PN 10 DIN 2532
PN 16 DIN 2533
Seat valve in straigth-way form PN 25 DIN 2544
with noise attenuating cone PN 40 DIN 2545
Type MOV-S-81
Dimension sheet EK-413 Operating pressures: according to DIN 2401
Three-way valve
Type MOV-3-81 Differential in accorddance with tables
Dimension sheet EK-414 pressures: EK-413 and EK-414

Positioning ratio: 1:50

Construction
Positioning - normal
Straight-way valves up to DN 200 with shrunk seats, beginning speed: 25mm/min; 50mm/min possible
with DN 250 with screwed seats
cone characteristics linear or equi-percentage different Kv values Strokes: DN 15- 50 25 mm
are possible at equal nominal width DN 65- 100 35 mm
DN 125-175 50 mm
three-way valves with screwed-in double-seat bushes with linear DN 200 58 mm
characteristics of flow and disk cones DN 250-350 65 mm
inserted stuffing-box flanges
Installing position: vertical to horizontal
cast housing
driven by spur gearing with linear actuator Electrical data: according tables „electrical Drive Data“

4 drive sizes, having different positioning forces are available

Additional Equipment
E-motors for 50 or 60 HzAC and three-phase voltages
Soft seal in the cone
drives with emergency manual operation and mechanical cone with multi-hole sleeve
position display
ribbed stuffing-box
drive covered with steel cover spindle sealing by bellows W. No. 1.4571

General
The motor valves are used as electrically operated continuous
Materials control elements (control valves) and as on-off controller for the
control of gaseous and liquid agents. The control is established
Valve housing: PN10/16 GG20 by means of two-point or three-point controllers as a function of
PN25/40 GS-C-25 temperature, pressure, quantity etc. or manually with push-
othermaterials, such as special steel cast, button or switch.
chromium-nickel steel, gun metal, bronze,
etc. and hard rubber lining on request
Construction and Operation
Valve seats: W. No. 1.4401
for three-way valves DN 65-200 -Straight-way valves in single-seat construction.
W. No. 1.4410 or bronze G Sn Bz 10 Dimension sheet EK-413
other materials on request with cooling rib assembly or bellows sealing, respectively.
Dimension sheet EK-425
Valve conel: W. No. 1.4401
for straight-way valves DN 125-350 - Three-way valves.
and three-way valves DN 250-350 Dimension sheet EK-414
W. No. 1.4410 or bronze G Sn Bz 10 with cooling rib assembly or bellows sealing, respectively.
other materials on request Dimension sheet EK-419
Valve spindle: W.-Nr. 1.4401 or bronze AlBz 10Ni
other materials on request - 4 different drives (1.2 kN; 4.5 kN; 12 kN; 24 kN) are optionally
available to meet the operational requirements.
Stuffing-box PTFE, silkyam (reinforced)
packing: orpure graphite The switching-off at the end position is established for
straightway valves in the closing position torque-dependent,
Housing: steel casting GS-C-25 and in
the opening position travel dependent, with an additional limit Electrical and technical drive data
switch, being torque dependent, wired in parallel, for three-way
valves in both end positions, torque dependent. Data for The motors are designed for intermittent
regulating duty S4 acc. to VDE 530 with a relative
In addition, a further free travel dependent limit switch with operation: duty cycle of 30%.
switch-over contact is provided. switching frequencymax.600/h
The valve position is indicated by a pointer at the drive spindle minimum pulse duration: 250 ms
and a scale at the housins. minimum pulse pause: 40ms

For the analog remote transmission of the valve position, the Electrical at the terminal via cable sorewings
installation of 2 potentiometers is possible. wiring: according to DIN 89280

In addition, a further travel dependent limit switch can be Power supply: normally
installed. The built-in electro motor (a) drives the linear actuator 230 V- 50 or. 60 Hz, single-phase-AC,
via a spur gear. In the last gear (b) of the geartrain, a bushing with or
internal thread is shrunk in, which runs in ball bearings. In this 380 V- 50 or. 60 Hz three-phase current
thread runs the upper part of the push-rod (d), provided against other supply voltages on request
torsion by a key and groove. Type of protection: DIN 40050 · IP 65
When the gear is driven, the push-rod and the valve spindle Allowable ambient temperature: - 20 to + 60°C
performs a push / pullmotion, depending on direction of rotation.
Limit switch: torque dependent switches max. 230 V
On power failure, the final control element can manually be ohmic loadmax.10A
actuated. inductive loadmax.5A
The gear ist dustproof separated from the electrical components travel dependent switchesmax.230V
in an aluminium pressure housing. Terminals, motor, limit switch ohmic loadmax.5A
and potentiometers are easily accessible by removing of the inductive loadmax.3A
steel cover electric bulb max. 1 A
Potentiometer: max. 50 V, 100 mA

Motor data
Positioning time mm/min 25 50 25 50 30 60
Voltage Volt
single-phase
three-phase three-phase
AC current
400 V 50 Hz 440 V 60 Hz
230 V 50 Hz
Drive 1,2 kN
Rated current mA 29 15 14,3
Power consumption Watt 6,6 9,9 9,35
Power output Watt 2,4 3,1 3,1
Rotational speed motor U/min 500 500 600

Positioning time mm/min 25 50 25 50 30 60

Voltage Volt
single-phase
three-phase three-phase
AC current
400 V 50 Hz 440 V 60 Hz
Drive 4,5 kN 230 V 50 Hz
Rated current mA 135 160 110 80 100 100
Power consumption Watt 28 32 35 32 35 45
Power output Watt 5,3 12 10 16 12 19
Rotational speed motor U/min 1350 2700 1350 2700 1620 3240

Positioning time mm/min 25 50 25 50 30 60

Voltage Volt
single-phase
three-phase three-phase
AC current
400 V 50 Hz 440 V 60 Hz
Drive 12 kN 230 V 50 Hz
without brake Rated current mA 320 700 210 290 220 265
Power consumption Watt 60 130 75 120 80 138
Power output Watt 22 72 28 63 28 85
Rotational speed motor U/min 1300 2750 1300 2750 1600 3300

Positioning time mm/min 25 50 25 50 30 60

Voltage Volt
single-phase
three-phase three-phase
AC current
400 V 50 Hz 440 V 60 Hz
Antrieb 24 kN 230 V 50 Hz
without brake Rated current mA 660 930 400 700 342 640
Power consumption Watt 145 206 163 337 180 370
Power output Watt 67 110 75 215 88 235
Rotational speed motor U/min 1350 2700 1350 2750 1560 3300
Connection Diagrams The pipes have thouroughly to be cleaned prior to assembling,
in order to prevent a later damage to the seats and cones.
AC 2/2 way valve RTA-264
3/2 way valve RTA-265 The installation of a dirt tr,ap in front of each control valve is
strongly recommended.
Three-phase 2/2 way valve
current: linear actuator 1,2 + 4,5 kN RTA-264/3 On mounting of straight-way and angle valves pay attention to
linear actuator 12 + 24 kN RTA-264/4 the direction of arrow on the valve housing.

3/2 way valve Mix and partitioning valves are provided with the figures 1,2 and
linear actuator 1,2 + 4,5 kN RTA-265/3 3 on their connecting flanges. Observe the correct installation in
linear actuator 12 + 24 kN RTA-265/4 accordance with piping diagram.1 is always the joint
connection, whereas to 2 and 3 the incoming or leaving part
Installation streams are connected.
"These actuator valves shall be mounted with the drive towards The wiring and connecting of the electrical circuitry has to be
the top. For any other position ask before ordering." performed in accordance with the regulations for the installation
of power plants and with the respective wiring diagrams.

Start-up and
Adjustment instructions
For start-up of the valve place the drive by means of the hand
wheel (e) in the middle of the positioning travel, switch on power
and give shortACpulses to the drive; watch whether the push rod
(d) moves into the correct direction. Otherwise, exchange the
motor connections at the terminal strips 2 + 3.

Drive 1.2 kN and 4.5 kN

Operate manually only with the motor at standstill.
For this purpose press the bolt (f) mounted below at the drive
housing with the hexagonal head into the housing until the spring
lever (h) engages into the notch of the bolt. Hereby rotate the
handwheel (e) a little bit. On rotating of the handwheel ciockwise,
the push spindle is extended rotating ccw draws the spindle in.
On pressing of spring lever (h) in the direction of the valve shaft
the bolt jumps out on its own and the drive is switched back to
motor drive.

Drive 12 kN and 24 kN
Change over to hand-operating:
Push hand disengaging lever into direction -1- (at the time turn
hand wheel slightly if necessary), then swivel hand disengaging
lever above the hexagon screw into direction -2-.
Now hand operating position is locked.
Change over to motor drive:

Swivel hand disengaging lever into direction - 3 - and release. All

further engaging proceedings will occur automatically with
starting up of themotor.
Figure travel dependent switch and message devices

With the end position reached with extended push spindle, the
two slotted levers (1) are parallel. A'ter loosening of the nut, the
carrier bolt (7) can be moved into the slot of the lever allowing the
stroke of the drive to be adjusted by means of the auxiliary scale.
After this being done, re-fasten the bolt. In this position, the
potentiometers (5) (in case there are any) have to be in the end
position. They can be adjusted by rotating the slider.
After that move the drive by the required travel for 2/2 valves or
the possible travel for 3/2-way valves in the opposite direction the
potentiometer will then turn into the other end position.
For the adjustment of the travel dependent limit switch "S 3" for
the limiting of the travel in the position open, the knurled head nut
(4) has to be loosened. Adjust the cam washer (4) to make the
switch shut off. The second built-in travel dependent switch "S 4"
and another possible "S 5" may freely be adjusted inbetween the
two end positions. Re-fasten the knurled head nut after the
switches being adjusted.
The switches provided for the end positioning are factory
adjusted. The torques of the load dependent switches are fixed
and can not be changed.

1 Slotted levers; the lower one is marked for the set travel
2 Travel-dependent switches
3 Knurled nut
4 Cam disks
5 Potentiometer for position indication
6 Scale for setting the travel
7 Connection bolt

Maintenance

Valve assembly Drive

Re-fasten the screws and flange connections at the housing after Grease the drive at normal operating conditions every three
start-up of the installation as the sealings are settling a bit at the years, at higher loads after approx. 200 000 double strokes with
beginning. The maintenance of the stuffing-box is also important. "Fett Klüber Structoris P 00" or a similar grease.
In case of leakage, the stuffing-box gland has to be fastened at
once. If this is no longer possible, the stuffing-box has to be re-
packed.
Take care to use the right material, depending on the agent, the
temperature etc. Keep the part of the spindle being in contact with
the stuffing-box always clean and grease at regular intervals with
a suitable grease. If the sealing surfaces at the seat and the cone
are damaged by dirt or foreign particles, no longer giving a tight
seat, they can be ground with a fine emery paste. With valves
having PTFE inserts in the cone, the latter can easily be replaced.

The above information and our technical advice for application in word, in writing and by tests
are given to the best knowledge. They shall be applied, however, only as hints without
obligation, also with reference to any protective rights of third parties. The advice does not
relieve you from examining our advisory hints and our products by yourself with regard to their
suitability for the intended procedures and purposes. Application and use of our products and
those products manufactured by you on the basis of our technical advice for application are
beyond our possibilities of control and, therefore, exclusively belong to your responsibility. The
sale of our products is subject to our General Terms and Conditions of Sale and Delivery.

Ausgabe/EDITION 06/02

Pleiger Maschinenbau Postfach 32 63 ( +49 / (0) 2324 398-0

GmbH & Co KG D-58423 Witten Fax +49 / (0) 2324 398-380
 Plate Heat Exchangers C5.05.09.40.02.20
Description

Plate Heat Exchangers

Description

en / 20.03.2013 FD048624 1/79

General Operation Manual
Gasketed Plate Heat Exchangers

engineering for a better world GEA Heat Exchangers

 Pl ate H eat Exchanger
General Operating Instructions

Version: 1.5, 2012-01-03

1
General Operating Instructions 1.5 | 2012-01-03
We enj oy w ork i ng f or you

1 We enjoy w orking f or you

Within the GEA H eat Exchangers Segment of the international GEA Group,
GEA PH E Systems is responsible for plate heat exchanger technologies.
Strong individual companies: GEA Ecoflex, GEA WTT, GEA PH E Systems
A sia Pacific and GEA PH E Systems N A w ith production locations in
Germany, USA and India manufacture gasketed, fully w elded and brazed
plate heat exchanges for w orldw ide distribution, covering almost all indus-
trial applications. Our GEA EcoServe service organisation provides quick
and competent maintenance and spare parts service throughout the w orld
w ith customer service centers in many countries.

With GEA PH E Systems you put the technical edge of one of the leading
manufacturers of plate heat exchangers (PH E) w orldw ide to good use
These operating instructions are your personal guide explaining design,
function, installation, operation, maintenance, troubleshooting, transport
and repairs to you in an easy-to-understand and clear manner. The present
operating instructions in particular aim at avoiding possible hazards or
damage right from the beginning. This is w hy all employees w orking w ith
the PH E should have access to these operating instructions at any time.

If any questions remain unansw ered, your GEA PH E Systems Sales Office or
the Central Service Dept. w ill be glad to help you.
A dditional technical information is available for specific applications.

Please take note of the rear cover of these operating instructions! You can
find the address of your Sales Office there.

Responsible for content:

GEA Ecoflex GmbH
Karl-Schiller-Str. 1-3
D-31157 Sarstedt
Germany

2
 Content

Co n t en t
1 We en j o y w o r k i n g f o r y o u .......................................................................... 2
2 A b o u t t h ese o p er at i n g i n st r u ct i o n s ......................................................... 5
2.1 Scope of validit y of t hese operat ing inst ruct ions..................................... 6
2.2 Represent at ion of inf ormat ion .................................................................. 7
2.2.1 Warnings ........................................................................................ 7
2.2.2 Symbols........................................................................................... 8
2.2.3 Abbreviat ions ................................................................................. 8
2.2.4 Draw ings and f igures..................................................................... 8
3 Im p o r t an t saf et y i n f o r m at i o n ................................................................... 9
3.1 Hazards on t he PHE.................................................................................... 9
3.2 Int ended use ............................................................................................. 10
3.3 Personnel qualif icat ion ............................................................................ 11
3.4 Obligat ions of operat ing company ......................................................... 12
3.5 Personnel prot ect ive equipment ............................................................. 13
3.6 Addit ional prot ect ive equipment ............................................................ 13
3.7 Warrant y ................................................................................................... 14
4 Descr i p t i o n o f f u n ct i o n .............................................................................. 14
5 Ov er v i ew an d d escr i p t i o n ......................................................................... 15
5.1 Basic st ruct ure ........................................................................................... 15
5.2 Ident if icat ion ............................................................................................ 16
5.3 Frames ....................................................................................................... 18
5.3.1 Fit t ing t he piping ......................................................................... 19
5.3.2 Tensioning bolt s and pre-t ensioning bolt s................................. 20
5.3.3 Fit t ing t he HE plat es in t he f rame .............................................. 20
5.4 HE plat es ................................................................................................... 22
5.5 HE plat e and f rame gasket s..................................................................... 22
6 Set t i n g u p an d co n n ect i n g PHEs ............................................................. 24
6.1 Inspect ing t he PHE upon delivery............................................................ 25
6.2 Transport ing t he PHE t o it s place of inst allat ion .................................... 26
6.3 Put t ing up a horizont al PHE at t he place of inst allat ion ....................... 26
6.4 Relocat ing an upright PHE....................................................................... 29
6.4.1 Slinging t he PHE at a beam and at shackles .............................. 32
6.4.2 Slinging t he PHE at bolt -on lif t ing plat es................................... 33
6.4.3 Slinging t he PHE at w eld-on lif t ing lugs .................................... 34
6.4.4 Slinging t he PHE at t he f ront w it h round slings ........................ 35
6.4.5 Slinging t he PHE at t he side w it h round slings .......................... 36

3
General Operating Instructions 1.5 | 2012-01-03
Content

6.5 Set t ing up and connect ing PHEs ............................................................. 37

6.5.1 Space requirement at t he place of inst allat ion ......................... 40
6.5.2 Removing and disposing of t ransport packaging ..................... 41
6.5.3 Inst allat ion of piping ................................................................... 41
7 Co m m i ssi o n i n g , d eco m m i ssi o n i n g , o p er at i o n .................................. 42
7.1 Commissioning ......................................................................................... 44
7.2 Operat ion ................................................................................................. 45
7.3 Decommissioning ..................................................................................... 46
7.3.1 Short -t erm decommissioning ...................................................... 46
7.3.2 Long-t erm decommissioning ...................................................... 46
7.4 Disposal ..................................................................................................... 47
8 M ai n t en an ce .................................................................................................. 48
8.1 Frame maint enance ................................................................................. 49
8.2 Cleaning HE plat es w hile PHE is closed .................................................. 49
8.2.1 CIP cleaning .................................................................................. 49
8.2.2 Reverse f lushing cleaning met hod ............................................. 50
8.3 Preparat ory measures f or opening t he PHE........................................... 51
8.4 Opening t he PHE...................................................................................... 53
8.4.1 Opening a PHE w it h C f rame ...................................................... 54
8.4.2 Opening a PHE w it h a B f rame ................................................... 57
8.5 Removing t he HE plat es f rom t he PHE ................................................... 58
8.5.1 Removing HE plat es f rom a C f rame .......................................... 59
8.5.2 Removing HE plat es f rom a B f rame .......................................... 60
8.6 Cleaning HE plat es w hile PHE is open .................................................... 61
8.6.1 M anual cleaning of HE plat es..................................................... 61
8.6.2 Chemical cleaning of HE plat es .................................................. 62
8.7 Replacing HE plat e gasket s ..................................................................... 63
8.8 Replacing t he f rame gasket s ................................................................... 64
8.9 Inst alling t he HE plat es and closing t he PHE.......................................... 64
8.9.1 Preparat ory measures f or inst alling t he HE plat es .................... 64
8.9.2 Inst alling HE plat es in PHE w it h a C f rame ................................ 65
8.9.3 Inst alling HE plat es in PHE w it h a B f rame ................................ 67
8.9.4 Tensioning and t est ing t he HE plat e pack ................................. 68
9 Tr o u b l esh o o t i n g ........................................................................................... 70
9.1 Out put def icit ........................................................................................... 70
9.2 Leaks ......................................................................................................... 71
10 Tech n i cal t er m s ............................................................................................. 73

4
 A bout these operati ng i nstructi ons

2 About t hese operat ing inst ruct ions

The present operating instructions contain important information required
for safe and proper installation, transport, commissioning, operation, main-
tenance, dismounting and troubleshooting of your PH E.
➔ Read these operating instructions thoroughly and completely before
w orking w ith the PH E.
➔ Keep these operating instructions so that they are accessible for all users
at any time.
➔ If you pass the PH E on to third parties, please include these operating
instructions and all other documents included in the scope of supply.

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A bout these operati ng i nstructi ons

2.1 Scope of validit y of t hese operat ing

inst ruct ions
These operating instructions apply to all gasketed PH E manufactured and
delivered by GEA PH E Systems. The designation of your PH E can be found
on its rating plate - see chapter “ 5.2 Identification” (page 16).
Desi g n at i o n s o f g ask et ed PHE m ad e b y GEA PHE Sy st em s

PH E type Designation
Concitherm CT 187 CT 193
Free-flow FA 159 FA 161 FA 184 FA 192
N 40
N F 350
LWC – Laser-Welded Cassettes LWC 100 T LWC 100 M LWC 100 X
LWC 150 S LWC 150 L
LWC 250 S LWC 250 L
LWC 350 S LWC 350 M
NH N H 250 S N H 250 M N H 250 L
N H 350 S N H 350 M N H 350 L
NT N T 50 T N T 50 M N T 50 X
N T 100 T N T 100 M N T 100 X
N T 150 S N T 150 L
N T 250 S N T 250 M N T 250 L
N T 350 S N T 350 M N T 350 L
N T 500 T N T 500 M N T 500 X
NX N X 100 X N X 150 X N X 250 L
Safetytherm VT 10 VT 20 VT 40
VA RITH ERM VT 04 VT 10 VT 20
VT 405 VT 40
VT 805 VT 80
VT 1306 VT 130 VT 180
VT 250 VT 2508

6
 A bout these operati ng i nstructi ons

2.2 Represent at ion of inf ormat ion

2.2.1 Warnings
In this document, w arnings precede requests for action involving a hazard
for persons or objects. These w arnings are structured as follow s:

SIGNA L WORD

Ty p e o f h azar d
Consequences
➔ Protective measures

■ Warni ng symbol – Points out to mortal danger or danger of injury.

■ Si gnal w ord – Indicates the seriousness of the hazard (see table below ).
■ Type of hazard – Designates the type and source of the hazard.
■ Consequences – Describes possible consequences w hen failing to observe
the information.
■ Protecti ve measures – Indicates how the hazard can be avoided. You
must absol utel y compl y w i th these protective measures!

War n i n g si g n , M ean i n g acc. t o A NSI Z535.6-2006

si g n al w o r d

Identifies a danger w hich w ill certainly result in death

DA NGER or serious bodily injury w hen failing to avoid the
danger.
Identifies a danger w hich can result in death or serious
WA RNING bodily injury w hen failing to avoid the danger.

Identifies a danger w hich can result in slight to medium

CA UTION bodily injury w hen failing to avoid the danger.

Identifies possible material damage. The PH E or the

NOTICE surroundings may suffer damage w hen failing to avoid
this danger.

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A bout these operati ng i nstructi ons

2.2.2 Symbols

Sy m b o l M ean i n g

This symbol appears besides paragraphs that provide you w ith useful or
important information for the correct handling of the PH E. This informa-
tion helps you to avoid problems and makes handling the PH E easier.
➔ Identifies a request for action w ithin a warning. A ct accordingly in order
to avoid a danger.
➔ Identifies a request for a specific action/step.
When such requests follow one another, you do not have to follow a
specific order for these actions.
1. Identifies a specified order of steps to be taken.
2. Carry out these steps exactly in the order as specified.

✔ Identifies the result of a series of steps taken.

This information describes the new condition of the PH E after you have
carried out all steps correctly.
➥ Identifies a supplementary information w ith a direct relation to the
previous request for action.
■ Identifies a list.

2.2.3 Abbreviat ions

A b b r ev i at i o n M ean i n g

PH E Plate H eat Exchanger

H E plate H eat exchanger plate

2.2.4 Draw ings and f igures

The draw ings used in these operating instructions are exemplary. M any
details are show n in a simplified manner. The actual conditions of an indi-
vidually manufactured PH E cannot be reflected here. You find binding
view s and dimensions of the PH E delivered to you in the technical docu-
mentation supplied.

8
 I mportant saf ety i nf ormati on

3 Import ant saf et y inf ormat ion

The PH E has been manufactured in accordance w ith the state of the art and
the recognized safety rules. The PH E can still be the origin of hazards to
persons and material assets if you
■ fail to observe this chapter,
■ fail to observe the w arnings in these operating instructions,
■ fail to use the PH E in accordance w ith the intended use.

➔ For this reason, please read this chapter attentively. It contains important
information and obligations. It concerns your health and the troublefree
operation of the PH E.

3.1 Hazards on t he PHE

■ The PH E is heavy. Should it tip over or fall dow n during transport,
persons may be killed or seriously injured.
Transport the PH E to its intended position w ith the transport packaging
if possible. Use sufficiently dimensioned lifting equipment exclusively for
handling the PH E at the place of installation. N ever stand under
suspended loads and keep other persons aw ay.
■ Upright PH Es have a high center of gravity and may tip over.
Put up a PH E delivered in a horizontal position only directly before it is
installed. Secure the upright PH E against tipping over by bolting it to the
ground. If possible, remove the lifting devices used only after the PH E
has been fastened to the ground.
■ The use of dangerous flow media (explosive, flammable, caustic, toxic)
involves danger of chemical burns, fire burns or intoxication.
Wear suitable protective clothing w hen w orking on the PH E. Ensure that
the PH E is depressurized and empty prior to opening.
■ When opening the PH E, sharp-edged H E plates may fall out.
Keep H E plates from falling out by having them secured by another
person.

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I mportant saf ety i nf ormati on

■ The flow media may be colder than 0 °C and hotter than +50 °C. This is
w hy PH Es involve the danger of frostbites and burns.
Protect persons by a protection against accidental contact and install
warning signs relating to frostbites and burns.
■ A cutting hazard exists on burrs, threads and the H E plates.
Wear protective equipment at all times w hen w orking on the PH E.

3.2 Int ended use

The PH E is a component intended for permanent installation in a plant or a
machine. It serves for heat transmission from a heat-emitting flow medium
to a heat-absorbing flow medium.
We recommend that you put the PH E into operation only after checking if
the plant or machine into w hich the PH E has been integrated meets the
applicable national regulations, safety rules and standards.

The PH E is a technical equipment and not intended for private use. It is basi-
cally designed for mostly stationary use.

The PH E w as designed and built specifically for the operating conditions

you have specified. The operating conditions are documented in the tech-
nical documentation:
■ min./max. allow ed pressure
■ min./max. allow ed temperature
■ flow rates
■ type and composition of the flow media
■ additional loads if allow ed
➔ Deviating from these allowed operating conditions w ill void the
warranty and the operating permit. The same applies to unauthorized
essential modifications on the PH E.
➔ Please contact your GEA PH E Systems Sales Office for checking such
requirements and the modifications w hich may become necessary.

10
 I mportant saf ety i nf ormati on

The intended use also includes:

■ observing the present operating instructions and the technical documen-
tation included in the delivery..
■ that the plate heat exchanger is in technically flaw less condition, i.e. it
show s no apparent defects, e.g. loose or missing tensioning bolts, leaks
due to defective H E plates and/or frame gaskets.
■ compliance w ith the national and international law s, decrees, regulations,
guidelines and other rules in force at the place of installation, e.g. occupa-
tional safety and accident prevention regulations, even if those are not
mentioned in these operating instructions.

3.3 Personnel qualif icat ion

Persons entrusted w ith setting-up, transportation, installation, commis-
sioning, operation, dismounting or maintenance of the PH E must have the
follow ing know ledge:
■ Basic mechanical know ledge,
■ know ledge of the plant and/or machine into w hich the PH E is integrated,
■ know ledge of the associated technical terms.

To ensure operational safety, such activities may be carried out only by a

suitable specialist or by a trained person supervised by a specialist.
A specialist is a person w ho, in view of his technical training, the know ledge
and experience gathered and his know ledge of the relevant regulations, can
■ assess the w ork entrusted to him,
■ identify possible hazards and
■ take suitable safety precautions.

A specialist must comply w ith the relevant technical rules, e.g. the accident
prevention regulations.

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I mportant saf ety i nf ormati on

3.4 Obligat ions of operat ing company

The operating company is responsible for the safe operation of the PH E.

Ensuring saf e operat ion

A s the operating company you must ensure that:
■ the PH E is operated only according to the intended use (see chapter 3.2)
■ there w ill be no w ear of certain PH E components due to unfavourable
ambient conditions.
Un f av o u r ab l e am b i en t co n d i t i o n s

Component Unfavourable ambient conditions

Gasket – A ggressive gases and/or aggressive aerosols in the
materials surrounding air
– Effects of UV radiation (e.g. sunlight)
– Extreme ambient temperatures
M etal – A ggressive gases and/or aggressive aerosols in the
components surrounding air
– H umidity

■ all maintenance operations/inspections are carried out at regular inter-

vals. The time intervals have to be fixed as a function of area of use, the
flow media, the risk potentials and the regulations applicable for opera-
tion.
■ that the personnel regularly inspects the PH E for leaks. These must be
repaired w ithout delay if required.

Training of personnel
A s the operating company, you must regularly train your personnel in these
subject-matters:
■ Observing and use of the operating instructions and of legal provisions,
■ use of the plate heat exchanger in line w ith the intended use,
■ observing the operating instructions in force at the operating company,
■ behaviour in an emergency.

12
 I mportant saf ety i nf ormati on

3.5 Personnel prot ect ive equipment

To protect yourself against injuries, you have to:
■ w ear solid gloves, protective clothing and safe shoes as w ell as a hard hat
and eye or face protection if required w hile w orking on the PH E (espe-
cially w hen using explosive, flammable, caustic or toxic flow media).

3.6 Addit ional prot ect ive equipment

When using hazardous f low media

When using explosive, flammable, caustic or toxic flow media, you have to
fit additional protective equipment in order to protect persons against inju-
ries.
■ Fit a tray w ith a sufficient volume beneath the PH E for collecting its
entire content. This tray must be made of a material resisting the flow
media permanently.
■ Fit a splash guard in order to avoid persons and objects being sprayed
w ith flow media in case of a leaky H E plate pack.
■ Provide earthing w hen handling explosive and flammable media.

When using cold f low media

When the temperature of a flow medium is below 0 °C, you must fit the
follow ing safety equipment:
■ an insulation in order to prevent freezing up of the PH E,
■ a protection against accidental contact in order to avoid frostbites of
persons,
■ w arning signs indicating the low temperatures to persons.

When using hot f low media

When the temperature of a flow medium is above +50 °C, you must fit the
follow ing safety equipment:
■ a protection against accidental contact in order to avoid burns of persons,
■ w arning signs indicating the high temperatures to persons.

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D escri pti on of f uncti on

3.7 Warrant y
The w arranty applies to the delivered PH E version exclusively and w ill
cease to be valid if the PH E if incorrectly installed or not used in line w ith its
intended use.

4 Descript ion of f unct ion

Serially arranged profiled H E plates w ith flow openings form a pack of flow
gaps inside the PH E. The flow media flow through every other flow gap
involved in heat exchange in different directions.

Single-pass or mult i-pass PHE

Single-pass PH Es are normally used. In a single-pass PH E, all incoming and
outgoing pipes are connected to the fixed plate, i.e. on the same side.

Fig. 4 a – Pat h of f low media in a single-pass PHE

Small temperature differences betw een the flow media may call for multi-
pass PH E. In this case, the connecting piping is on the fixed and on the loose
plate, i.e. on both sides.

Fig. 4 b – Pat h of f low media in a mult i-pass PHE

14
 Overvi ew and descri pti on

5 Overview and descript ion

5.1 Basic st ruct ure

The basic structure of a PHE is show n below . The specific design depends on
the application.

4
1

5
2
6

3 7

10

Fig. 5.1 a – Component s of a gasket ed PHE

No . Co m p o n en t No . Co m p o n en t

1 Top beam 6 H E plates

2 Piping connections 7 Bottom guide beam

3 Fixed plate 8 H E plate gasket

4 Column 9 H exagon nut on tensioning bolt

5 Loose plate 10 Tensioning bolt

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Overvi ew and descri pti on

14
The H E plate pack consists of individual
embossed H E plates w ith the associated
H E plate gaskets.
13
The H E plate gaskets seal the flow media
11
tow ards one another and the environment.
For further details see chapter “ 9.2 Leaks”
(page 71).
12
The number and the arrangement of H E
plates depends on the requirements speci-
fied in the order.
13

14
Fig. 5.1 b – Const it uent s of a HE plat e

Nr . Co m p o n en t Nr . Co m p o n en t

11 Embossed H E plate profile 13 Leakage spaces

12 H E plate gasket 14 Round gasket sections

5.2 Ident if icat ion

Every PH E manufactured by GEA PH E Systems has a rating plate. This
plate is fitted on the outside of the PH E fixed plate.
It usually provides information about:

■ PH E type ■ Dry equipment w eight

■ Serial no. ■ Year of construction
■ Permitted pressure levels ■ Tensioning dimensions
■ Permitted temperatures a max. and a min.

■ Test pressures ■ M anufacturer

■ Capacities

16
 Overvi ew and descri pti on

The rating plate also provides additional project-related information.

Execut ion of rat ing plat es

Example of a rating plate in accordance w ith A SM E and the European Pres-
sure Vessel Directive 97/23/EC:

Fig. 5.2 a – Example of a PHE rat ing plat e Fig. 5.2 b – Example of a rat ing plat e f or
in t he scope of validit y of A SM E PHE subject t o CE marking regulat ions

Enclosed document at ion

Each PH E is delivered w ith a dimension sheet and/or an assembly draw ing
and a circuit diagram.

The di mensi on sheet and/or the assembly draw ing include, among others,
the outer dimensions as w ell as type, size and position of the piping connec-
tions.

The ci rcui t di agram show s the specific arrangement of the H E plates, their
type, the material used as w ell as the material thickness and indicates the
gasket material and the part nos.

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5.3 Frames
PH E made by GEA PH E Systems are available in various application-
specific frame versions. The basic versions are the C and B designs, w ith the
B design being used above all for longer plate packs. Variants of these
designs are marked by further abbreviations.

2F 1F 2F 1F

3F 4F 3F 4F

Fig. 5.3 a – C f rame w it h column Fig. 5.3 b – PHE w it h a B f rame

Part icular execut ion det ails

Special stainless steel versions are employed in foodstuff and
pharmaceutical applications and may include intermediate plates for
separating the individual sections.
Some frames are equipped w ith
height-adjustable bases [1].
2F 1F

1 1 3F 4F

Fig. 5.3 c – Version w it h bases

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 Overvi ew and descri pti on

5.3.1 Fit t ing t he piping

The piping may be connected to the fixed plate, the loose plate and the inter-
mediate plate. Please take the position and type of connections from your
dimension sheet, circuit diagram or the assembly draw ing.

The piping connections on the fixed plate and on the loose plate are consist-
ently numbered according to the follow ing pattern:
Fixed plat e
2F 1F
When view ing the fixed plate from the
outside, the numbering of connections
1F–4F is continuous and anti-clockw ise.

3F 4F

Fig. 5.3.1 a – Fixed plat e connect ions 1F–4F

Loose plat e

1L 2L When view ing the loose plate from the

outside, the numbering of connections
1L-4L is continuous and clockw ise.

4L 3L

Fig. 5.3.1 b – Loose plat e connect ions 1L–4L

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5.3.2 Tensioning bolt s and pre-t ensioning bolt s

A ll PH E frames include at least four
1
tensioning bolts [1]. On PH E w ith more
than four tensioning bolts per side, two
2 tensioning bolts per side are usually
longer than the others. These are referred
1 to as pre-tensioning bolts [2] and serve for
pre-tensioning the H E plate pack. See also
2 chapter “ 8.9.4 Tensioning and testing the
H E plate pack” (page 68).
1

Fig. 5.3.2 – Longer pre-t ensioning bolt s (f rom f ive pairs of t ensioning bolt s)

5.3.3 Fit t ing t he HE plat es in t he f rame

Depending on the PH E frame type, the H E plates are fitted in the frame in
different w ays.

C f rames
In C frames, the H E plates stand on the low er round carrier bar [2]. The
upper round bar [1] ensures guiding. See chapter “ 8.4 Opening the PH E”
(page 53).
VT a.o. 1 NT a.o. 1

2 2
Fig. 5.3.3 a – HE plat e f or C-f rames of VT and NT series

20
 Overvi ew and descri pti on

B f rames
The H E plates are suspended directly from the top beam [1] or from a
special suspension rail [2] fitted below the top beam in B frames. The
bottom connecting bar [3] ensures guiding.

Variant 1 Top beam [1] w ithout

1
any additional suspen-
sion rail

This variant applies to

all PH E not mentioned
under variants 2 and 3.

3
Fig. 5.3.3 b – Variant 1: Top beam (1) w it hout any addit ional suspension rail

Variant 2 Top beam [1] w ith

1
2 special suspension rail
[2]

This variant applies to

VT 20, 40, 405, 80 and
805 PH Es and to FA 161
and FA 184 PH Es.

3
Fig. 5.3.3 c – Variant 2: Top beam (1) w it h special suspension rail (2)

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Variant 3 Top beam[1] w ith

1
special suspension rail
[2] w ithout any addi-
2 tional guide rail

This variant applies to

N T 500, VT 130, 1306,
1309, 250 and 2508
PH Es and to FA 192
and CT 193 PH Es.

3
Fig. 5.3.3 d – Variant 3: Top beam (1) w it h suspension (2)

5.4 HE plat es
The H E plate material is selected to meet the customer’s requirements
(e.g. pressure, temperature, media, operating mode).

M at er i al ab r asi o n o n HE p l at es
In some special applications, H E plate material abrasion caused by the
media used is a typical process.
M aterial abrasion may result in functional failure of the H E plates and
in mixing of the flow media.

5.5 HE plat e and f rame gasket s

The H E pl ate gask et material is selected to meet the customer’s require-
ments (e.g. pressure, temperature, media, operating mode).

H E plate gaskets made of elastomers are available in various materials and

designs (e.g. H E plate gaskets for tw o openings). The H E plate gasket mate-
rial is clearly marked by a color marking.

22
 Overvi ew and descri pti on

M ost H E plate gaskets are fixed w ithout glue, using a mechanical joint on
the H E plate. A s an alternative, the H E plate gaskets can also be glued.

The type of gasket used betw een the H E plate pack and the frame compo-
nents depends on the frame type. Tw o types of f rame gask ets can be distin-
guished:
■ Gasket rings positioned in a groove.
■ Rubber mouldings covering the entire connection opening and providing
a sealing effect – tow ards the H E plate pack and the connected piping
flange – on both sides.

M at er i al ch an g es o f g ask et s
H E plate and frame gaskets may lose their initial properties due to
external environmental influences and the flow media used. This may
cause leaks and damage.

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Setti ng up and connecti ng PH Es

6 Set t ing up and connect ing PHEs

DANGER DANGER

Dan g er t o l i f e Dan g er t o l i f e i f i n co rrect

i f t h e l o ad sl i p s! sl i n g i n g eq u i p m en t i s u sed !
Always transport the Nev er use steel hawsers or
PHE horizontally.
Nev er transport the PHE Use only undamaged
using the tensioning bolts. round slings.

CAUTION
Dam ag e t o
co n n ect i o n n o zzl es!
Nev er
equipment to the
connection nozzles.

Dam ag e t o t h e h eat
ex ch an g er p l at es!
Nev er transport the

Always transport the

PHE suspended.

24
 Setti ng up and connecti ng PH Es

6.1 Inspect ing t he PHE upon delivery

If you notice damage to an item at delivery in spite of careful packaging,

please be sure to note the extent and type of the damage in the transport
documents and have a receipt for this signed by the deliverer.

Transport variant s
The completely assembled PH E is packed either horizontally or vertically,
depending on the execution. The piping connections are plugged.
■ PH E delivered i n a hori zontal posi ti on are fastened on pallets w ith the
fixed plate facing dow n to enable safe transportation.
■ PH E delivered i n an upri ght posi ti on are frequently fixed on w ooden
boards or pallets.

Specif ic t ransport at ion f eat ures

■ The height-adjustable bases of the BC frame are substituted by transport
bases. The bases are enclosed w ith the PH E.
■ The PH E may be filled w ith dried gas at an excess pressure of 1 bar max.
CA UTION! Before removing the transport flanges, relieve the excess
pressure on the associated bleed valve.
➔ Check if all nuts of tensioning bolts are firmly tightened. Should the nuts
have come loose during transportation, tension the H E plate pack to the
tensioning dimension a max. (see rating plate). If required, contact your
GEA PH E Systems Sales Office.

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Setti ng up and connecti ng PH Es

6.2 Transport ing t he PHE t o it s place of

inst allat ion

WA RNING

M o r t al d an g er d u e t o h i g h w ei g h t o f PHE
The use of unsuitable or unsafe means of transport may cause very serious
accidents.
➔ If possible, put up a PH E delivered in horizontal position only at its
place of installation - See chapter “ 6.3 Putting up a horizontal PH E at the
place of installation” (page 26).

Transport ing a PHE delivered in horizont al posit ion

➔ Leave the transport straps unchanged. Transport the PH E laying horizon-
tally on the pallet to its place of installation w ith a fork lift truck.
➥ Put up the PH E only there as described in chapter “ 6.3 Putting up a hori-
zontal PH E at the place of installation” (page 26).

Transport ing a PHE delivered in upright posit ion

A PH E delivered in upright position must be suspended during transport to
its final position.

6.3 Put t ing up a horizont al PHE at t he place of

inst allat ion

WA RNING

Dan g er o f i n j u r y w h en p u t t i n g u p t h e h o r i zo n t al PHE
Fitting of round slings, lifting and tipping of the PH E involves danger of
serious injuries.
➔ Fasten the lifting equipment so that it w ill not come loose from the PH E.
➔ Do not tilt the PH E jerkily.
➔ Wear sturdy gloves, safety shoes and a safety helmet.

26
 Setti ng up and connecti ng PH Es

1. Remove all transport straps [1] from

the PH E and the pallet.

Fig. 6.3 a – Removing all t ransport st raps

2. Put a round sling [2] around the

upper tensioning nuts [3] of the fixed
plate on both sides.
➥ Guide the round sling upwards so
that it goes around the top tensioning
bolts on the loose plate on both sides
3
and suspend the sling in a crane hook.
2

Fig. 6.3 b – Fit t ing round slings

3. Slow ly lift the PH E from the pallet

beyond its point of gravity. Ensure
that the round sling alw ays fits safely
around the top tensioning bolts.

Fig. 6.3 c – Lif t ing t he PHE slow ly beyond t he point of gravit y

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Setti ng up and connecti ng PH Es

4. Slow ly low er the PH E dow n to the

edge of the fixed plate or on the PH E
bases. A lign the PH E and move it to
its final position at the place of instal-
lation.

Fig. 6.3 d – Low ering t he PHE slow ly

DA NGER

M o r t al d an g er b y PHE f al l i n g o v er
Some PH E types may fall over very easily
due to their high centre of gravity.
➔ A fter putting up the PH E, bolt the
PH E dow n at the place of installation
or anchor the PH E at a temporary
location before removing the lifting
equipment.

5. A fter putting up the PH E, bolt the

PH E dow n at the place of installation
or anchor the PH E at a temporary
location before removing the lifting
equipment.
6. Remove the round slings and other
aids only after that.
✔ The PH E is now put up.

Fig. 6.3 e – Anchoring a PHE on t he f loor

28
 Setti ng up and connecti ng PH Es

6.4 Relocat ing an upright PHE

DA NGER

M o r t al d an g er b y PHE f al l i n g o v er
Some PH E types may fall over very easily due to their high centre of gravity.

➔ Leave the PH E bolted dow n to w ooden boards until it has been trans-
ported to its final place of installation.
➔ Loosen the PH E from the w ooden boards only after it is held by lifting
equipment.
➔ Ensure that the floor of the installation site is sufficiently large, level and
able to support the load.
➔ Bolt the PH E dow n at the place of installation as planned.
M o r t al d an g er b y PHE f al l i n g d o w n
The PH E may fall dow n if you fix lifting equipment incorrectly or use
improperly dimensioned lifting equipment.

➔ A lw ays fix the lifting equipment as described in the follow ing chapters.
➔ N ever fix the lifting equipment at the PH E tensioning bolts.

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➔ N ever fix the lifting equipment at the piping connections.

➔ Use undamaged and sufficiently long round slings exclusively as lifting
equipment on tensioning nuts.
➔ N ever use chains or steel ropes as lifting equipment w ith shackles w hen
the lifting equipment touches the PH E directly.
➔ Before transporting the PH E, ensure that the
lifting equipment can carry the w eight of the
PH E reliably.

M o r t al d an g er b y PHE f al l i n g d o w n
Persons can be killed by the high w eight of a PH E
falling dow n.
➔ N ever stand underneath suspended loads.
➔ Keep persons that are not involved out of the
hazard area.
➔ Do not grab the lifting equipment after the
PH E has been lifted.

The suspended PH E may be easily set sw inging.

Round slings may slip off of the tensioning nuts.
➔ When selecting the round slings, bear in mind
that the point of gravity of the PH E is not in
the center, but closer to the fixed plate
➔ Lift a PH E carefully in order to avoid lateral
sw inging movements.

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 Setti ng up and connecti ng PH Es

NOTICE

Dam ag e o f PHE d u e t o i n co r r ect l i f t i n g

The H E plates w ill be damaged if you apply a fork lift truck directly at the
bottom of the H E plate pack.
➔ N ever lift the PH E at the bottom of the H E plate pack.

If you fix lifting equipment at the piping connections, these may be bent,
may break off or tear off.
➔ N ever fix the lifting equipment at the piping connections.
➔ A lw ays fix the lifting equipment as described in chapters 6.4.1 to 6.4.5.

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6.4.1 Slinging t he PHE at a beam and at shackles

a b
Fig. 6.4.1 a – Fast ening t he f irst short er round sling
Fig. 6.4.1 b – Fast ening t he second longer round sling

Applying t he slings
1. Fasten a round sling to shackles fitted in both shackle bores in the fixed
plate [a].
2. Place another round sling over the top beam and around the top outside
pairs of tensioning nuts [b ] at the loose plate.

Sel ect i n g t h e r i g h t r o u n d sl i n g s
When using two round slings, tw o different lengths are needed!

Lif t ing
3. Slow ly lift the PH E until the round slings are evenly tensioned and the
PH E is almost horizontal.

Low ering
4. Slow ly lower the PH E dow n above the prepared place of installation and
avoid jerky floor contact.

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 Setti ng up and connecti ng PH Es

6.4.2 Slinging t he PHE at bolt -on lif t ing plat es

a b
Fig. 6.4.2 a – Fast ening t he f irst short er round sling
Fig. 6.4.2 b – Fast ening t he second longer round sling

Applying t he slings
1. Fix a round sling to a shackle fitted in the hole in the plate bolted to the
fixed plate [a]. (chains and steel ropes are permitted only if they do not
directly touch the PH E. Otherw ise the PH E may be damaged.)
2. Fix another round sling to a shackle fitted in the hole in the plate bolted
to the column [b ].

Sel ect i n g t h e r i g h t r o u n d sl i n g s
When using two round slings, two different lengths are needed!

Lif t ing
3. Slow ly lift the PH E until the round slings are evenly tensioned and the
PH E is almost horizontal.

Low ering
4. Slow ly low er the PH E dow n above the prepared place of installation and
avoid jerky floor contact.

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6.4.3 Slinging t he PHE at w eld-on lif t ing lugs

Fig. 6.4.3 – Fast ening round slings t o shackles f it t ed in lif t ing lugs

Applying t he slings
1. Fasten one round sling to shackles fitted to one lifting lug each. (chains
and steel ropes are permitted only if they do not directly touch the PH E.
Otherw ise the PH E may be damaged.)

Lif t ing
2. Slow ly lift the PH E until the round slings are evenly tensioned and the
PH E is almost horizontal.

Low ering
3. Slow ly lower the PH E dow n above the prepared place of installation and
avoid jerky floor contact.

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 Setti ng up and connecti ng PH Es

6.4.4 Slinging t he PHE at t he f ront w it h round slings

a b

Fig. 6.4.4 a – Fast ening t he round sling t o t he f ixed plat e

Fig. 6.4.4 b – Fast ening t he round sling t o t he loose plat e over t he t op beam

Applying t he slings
1. A pply the round sling around the upper outside pairs of tensioning nuts
[a] at the fixed plate - w ith tensioning nuts projecting only a little, the
round sling must be applied completely around the fixed plate.
2. Place another round sling around the top outside pairs of tensioning
nuts [b ] at the loose plate.

Sel ect i n g t h e r i g h t r o u n d sl i n g s
When using two round slings, two different lengths are needed!

Lif t ing
3. Slow ly lift the PH E until the round slings are evenly tensioned and the
PH E is almost horizontal.

Low ering
4. Slow ly low er the PH E dow n above the prepared place of installation and
avoid jerky floor contact.

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6.4.5 Slinging t he PHE at t he side w it h round slings

➔ Choose this type of transportation if the fastening methods described in

the previous chapters are not provided or impossible.

Fig. 6.4.5 – Applying round slings lat erally around t he t op out side pairs of t ensioning nut s

Applying t he slings
1. A pply a sufficiently long round sling or two equally long round slings
around the top outside pairs of tensioning nuts on both sides of the PH E.

Lif t ing
2. Slow ly lift the PH E until the round slings are evenly tensioned and the
PH E is almost horizontal.

Low ering
3. Slow ly lower the PH E dow n above the prepared place of installation and
avoid jerky floor contact.

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 Setti ng up and connecti ng PH Es

6.5 Set t ing up and connect ing PHEs

DA NGER

M o r t al d an g er b y PHE f al l i n g o v er
Some PH E types may fall over easily due to their high centre of gravity.

➔ Leave the PH E bolted dow n to w ooden boards until it has been trans-
ported to its final place of installation.
➔ Loosen the PH E from the w ooden boards only after it is held by lifting
equipment.
➔ Ensure that the floor of the installation site is sufficiently large, level and
able to support the load.
➔ Bolt the PH E dow n at the place of installation as planned.
M o r t al d an g er b y PHE f al l i n g d o w n
The PH E may fall dow n if you fix lifting equipment incorrectly or use
improperly dimensioned lifting equipment.

➔ A lw ays fix the lifting equipment as described in the follow ing chapters.
➔ N ever fix the lifting equipment at the PH E tensioning bolts.
➔ N ever fix the lifting equipment at the piping connections.

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Setti ng up and connecti ng PH Es

➔ Use undamaged and sufficiently long round slings exclusively as lifting

equipment on tensioning nuts.
➔ N ever use chains or steel ropes as lifting equipment w ith shackles w hen
the lifting equipment touches the PH E directly.
➔ Before transporting the PH E, ensure that the lifting equipment can carry
the w eight of the PH E reliably.
M o r t al d an g er b y PHE f al l i n g d o w n
Persons can be killed by the high w eight of a
PH E falling dow n.
➔ N ever stand underneath suspended loads.
➔ Keep persons that are not involved out of
the hazard area.
➔ Do not grab the lifting equipment after the
PH E has been lifted.

The suspended PH E may be easily set sw inging.

Round slings may slip off of the tensioning nuts.
➔ When selecting the round slings, bear in
mind that the point of gravity of the PH E is
not in the center, but closer to the fixed
plate.
➔ Lift a PH E carefully in order to avoid lateral
sw inging movements.

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 Setti ng up and connecti ng PH Es

WA RNING

Dan g er o f i n j u r y d u e t o h azar d o u s f l o w m ed i a
If you w ish to use hazardous flow media (e.g. explosible, flammable, caustic,
toxic, under high pressure, very hot or very cold) w hen operating the PH E,
ensure that the safety accessories below are provided and/or fitted:

Req u i r ed saf et y Pr o p er t y o f f l o w m ed i a
accesso r i es
Hi g h l y ex p l o si v e Fl am m ab l e Un d er h i g h p r essu r e

Collecting tray x x
Splash guard x x x
Earthing tab x x
Insulation
Warning sign

Req u i r ed saf et y Pr o p er t y o f f l o w m ed i a
accesso r i es
Ver y co l d Ver y h o t Cau st i c, t o x i c, h azar d o u s
t o t h e en v i r o n m en t

Collecting tray x
Splash guard x
Earthing tab
Insulation x x
Warning sign x1 x2

1
Surface temperature below 0° C

2
Surface temperature above + 50° C

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WA RNING

Dam ag e t o PHE d u e t o f r eezi n g o f f l o w m ed i a

➔ Ensure that the temperature w ill not drop below the freezing tempera-
ture of the flow media used in all setting-up and operating conditions.

A s a function of the future operating conditions and of the permanent place

of use, the PH E may have to be retrofitted.

6.5.1 Space requirement at t he place of inst allat ion

Ensure sufficient free space around

the PH E. This makes access to the
PH E and maintenance work easier.
The specified reference values for
at least ent ire the free space required are guide-
lengt h of PHE line values and are recommended
by GEA PH E Systems.
They enable sufficient access to the
PH E.

Fig. 6.5.1 a – Only f or C f rames: Recommended spacing f rom f ixed plat e

w idt h

1.5 x w idt h 1L 2L 1.5 x w idt h

4L 3L

Fig. 6.5.1 b – Recommended lat eral spacing f rom HE plat e pack

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 Setti ng up and connecti ng PH Es

6.5.2 Removing and disposing of t ransport packaging

➔ Remove the transport packaging as far as provided.
➔ Leave the transport covers on the piping connections unless you install
the piping straightaway.
➔ PH E may be filled w ith dry compressed air or inert gases at an excess
pressure of 1 bar max. in order to avoid ingress of moisture.

NOTICE

Red u ci n g t h e ex cess p r essu r e

If the PH E w as delivered w ith a compressed-air or inert gas filling, the
excess pressure must be reduced before you can loosen the flanges.
➔ Before loosening the flanges, reduce the excess pressure on the associ-
ated valve.

➔ In case of PH Es w ith a seaworthy packaging, remove the desiccant packs

provided in the manifold channels w ithout damaging them.
➔ Dispose of the transport packaging according to the regulations appli-
cable to you.

6.5.3 Inst allat ion of piping

WA RNING

Hazar d d u e t o d eact i v at ed saf et y eq u i p m en t

When deactivating safety equipment for installation, maintenance or
commissioning w ork, you have to ensure that this produces no hazard to
persons and material assets.
➔ Observe the instruction manual of the plant or machine in question
w here the PH E is integrated.

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NOTICE

Dam ag e t o p i p i n g co n n ect i o n s an d t o PHE d u e t o ex cessi v e

f o r ces an d t o r q u es
When excessive forces and torques are transmitted on the PH E connections
through the piping, the piping connections and/or the PH E may be
damaged.
➔ You can take the forces and torques permitted for your PH E from the
technical documentation.
➔ Ensure that the forces and torques transmitted from the piping to the
PH E connections are not too high.

Fl ex i b l e p i p i n g co n n ect i o n s
Realise the piping connections at the loose plate and on intermediate
plates flexibly so that the tensioning dimension of the H E plate pack
can be adjusted between a max. and a min.

7 Commissioning, decommissioning, operat ion

WA RNING

Dan g er o f i n j u r y d u e t o h azar d o u s f l o w m ed i a
If you use hazardous flow media (e.g. explosible, flammable, caustic, toxic,
under high pressure, very hot or very cold) and the PH E becomes leaky,
persons can be sprayed w ith flow medium and become injured.
➔ Tension the H E plate pack of the
PH E to the fixed values of tensioning
dimension a min. < a < a max.
See chapters “ 10 Technical terms”
a
(page 73), “ 5.2 Identification”
(page 16) and “ 8.9 Installing the H E
plates and closing the PH E”
(page 64).
➔ If you use hazardous flow media, ensure that an anti-splash guard is
provided. This splash guard may only be removed after the PH E has
adapted to its ambient pressure and temperature.

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 Commi ssi oni ng, decommi ssi oni ng, operati on

NOTICE

Dam ag e t o HE p l at es b y ex cessi v e t i g h t en i n g
When the H E plate pack is tensioned to less than tensioning dimension
a min., the H E plates are damaged. The PH E may become leaky and flow
media can escape.
➔ N ever tension to less than tensioning
dimension a min.
➔ Ensure that the tensioning dimension
a of the H E plate pack is alw ays a
w ithin the permitted value range
a min. < a < a max. (see explanation
of rating plate, starting on page 16).

En v i r o n m en t al d am ag e
d u e t o l eak s
➔ When using environmentally
hazardous media, ensure that these can be reliably collected in case of a
PH E leak (e.g. collecting trays and suction equipment) and cannot
pollute the environment
Dam ag e t o PHE b y su d d en p r essu r e r i se (l i q u i d h am m er ) o r
su d d en p r essu r e d r o p (cav i t at i o n h am m er )
When the flow velocity of a flow medium changes, a liquid hammer or a
cavitation hammer may occur. This can damage the PH E and flow media
can escape.
➔ A lw ays open or close the valves of the piping connected to the PH E slow ly.
➔ A void sudden condensation of gases by suitable process control.
Dam ag e t o PHE d u e t o f r eezi n g o f f l o w m ed i a
➔ Ensure that the temperature w ill not drop below the freezing tempera-
ture of the flow media used in all setting-up and operating conditions.
Leak s w h en p u t t i n g m u l t i -st ag e PHE i n t o an d o u t o f o p er at i o n
When putting multi-stage PH Es into and out of operation and failing to
pressurize or relieve all sections evenly, the tensioning dimension may be
exceeded in individual sections. This may produce leaks.
➔ Ensure that w hen putting multi-stage PH Es into and out of operation, all
sections must be pressurized or relieved evenly.

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7.1 Commissioning
Initial commissioning of the PH E is to follow the conditions below :

➔ Before starting PH E commissioning, ensure

– that all required components of the PH E have been completely
installed,
– that all piping connections are firmly connected w ith the PH E,

– that the tensioning dimension a of the H E plate pack is alw ays w ithin
the permitted value range a min. < a < a max. (see explanation of
rating plate, starting on page 16),
– that no residues from previous processes (e.g. cleaning media) are
present inside the PH E w hen putting the unit back into operation.

➔ Ensure that operating conditions are so

– that liquid hammers and cavitation hammers are avoided,

– that the PH E is not operated w ith unpermitted flow media, pressure or

temperature levels.
➔ When integrating the PH E into your plant, ensure that the PH E is vented.

Co m m i ssi o n i n g at v er y l o w am b i en t t em p er at u r es
If you w ish to commission or re-commission the PH E at very low
ambient temperatures, GEA PH E Systems recommends to heat up the
PH E slow ly to the operating temperature, using the flow media.
➔ Bring the PH E to the operating temperatures of the tw o circuits by
means of the flow media at low pressure.
➥ In this process, cold leaks may occur briefly due to the low elas-
ticity of the gaskets. These w ill disappear as soon as the operating
temperature has been reached.

Co m m i ssi o n i n g o f m u l t i -st ag e PHE

Ensure that w hen commissioning multi-stage PH E, all sections must be
pressurized or relieved evenly.

Rem o v i n g f au l t s d u r i n g co m m i ssi o n i n g
If faults appear during PH E commissioning, please refer to chapter “ 9
Troubleshooting” (page 70).

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 Commi ssi oni ng, decommi ssi oni ng, operati on

7.2 Operat ion

CA UTION

Danger of injury due t o f ailure of HE plat e gasket s

Operation at unpermitted pressure and temperature levels and w ith unper-
mitted media may cause direct functional failure of the H E plate gaskets.
H azardous media may escape at high pressure and possibly high or low
temperatures and cause personal injury.
➔ A lw ays respect the permitted values specified on the rating plate.

NOTICE

M at er i al d am ag e d u e t o u n p er m i t t ed o p er at i n g co n d i t i o n s
When operating the PH E under conditions for w hich it is not designed,
damage may result.
➔ Carry out visual inspections of the PH E at regular intervals during oper-
ation. If the PH E is leaky, service or repair it.
➔ Ensure that the PH E is not operated w ith unpermitted flow media, pres-
sure or temperature levels. The permitted minimum and maximum
values are specified on the rating plate, see „ Identification“ (Seite 16).
➔ A void liquid hammers and cavitation hammers.

Rem o v i n g f au l t s d u r i n g o p er at i o n
If faults appear during PH E operation, please refer to chapter “ 9 Trou-
bleshooting” (page 70).

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7.3 Decommissioning

NOTICE

Dam ag e d u e t o h azar d o u s f l o w m ed i a
If you use hazardous or environmentally incompatible flow media and these
leak during standstill, damage may result.
➔ Ensure that no flow media can escape during the standstill phase.
Dam ag e o f PHE d u e t o f r eezi n g
Freezing of flow media may cause damage w hen de-commissioning the unit.
➔ Ensure that the flow media remaining inside the unit cannot freeze, e.g.
by draining or heating.

7.3.1 Short -t erm decommissioning

➔ Ensure that no flow media can escape during the standstill phase.

7.3.2 Long-t erm decommissioning

NOTICE

Co r r o si o n o f HE p l at es
Flow media remaining inside the PH E during extended standstill periods
may cause corrosion of the H E plates.
➔ Drain the flow media completely.
➔ Flush the PH E and the H E plates and let the PH E dry w ell.
➔ Plug the piping connections to be used w ith blind plugs in order to
avoid ingress of moisture or dirt into the PH E during standstill.
➔ Take care of protected storage until the unit is put back into operation.

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 Commi ssi oni ng, decommi ssi oni ng, operati on

7.4 Disposal
Upon request, GEA PH E Systems w ill take care of disposing of your PH E.
The PH E w ill be dismounted, transported aw ay and disposed of properly by
our employees against payment of the expenses incurred.

Di sp o sal o f p ar t s p o l l u t ed b y co n t am i n an t s
If PH Es or parts thereof are contaminated, GEA PH E Systems cannot
take care of the disposal. In this case, disposal of the PH E is the respon-
sibility of the operating company.

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M ai ntenance

8 M aint enance
➔ Prepare a time schedule for regular maintenance w ork in order to enable
reliable unit operation.

Pr i o r t o PHE m ai n t en an ce
Prior to PH E maintenance, we recommend that you contact your GEA
PH E Systems Sales Office (see rear cover).
Process-related deposits on the H E plates
■ affect heat transfer betw een the flow media,
■ increase the pressure loss,
■ can cause or accelerate corrosion on the H E plates.

The application in question w ill dictate

■ the necessity,
■ the type and
■ the frequency of PH E cleaning.

H ard dirt such as deposits on the surface of H E plates w hich cannot be

removed by a CIP process (see page 49) can be successfully treated by
manual cleaning and/or open chemical baths.

WA RNING

Dan g er o f i n j u r y w h en car r y i n g o u t w o r k d u r i n g o p er at i o n
When w orking on the PH E during operation, you may be injured and the
PH E may be damaged.
➔ A lw ays put the PH E out of operation prior to maintenance w ork, see
chapter “ 7.3 Decommissioning” (page 46).

48
 M ai ntenance

8.1 Frame maint enance

Carry out simple maintenance w ork yourself at regular intervals:
➔ Clean the outside of the PH E frame, especially the beams, rails and bars.
➔ Grease the guide rails of B frames (see page 67).
➔ Rew ork paint damage on the PH E frame.

Fr am e m ai n t en an ce
Detailed information about frame maintenance is available from your
GEA PH E Systems Sales Office (see rear cover).

8.2 Cleaning HE plat es w hile PHE is closed

Pr i o r t o cl ean i n g t h e HE p l at es
Prior to cleaning of H E plates w hile the PH E is closed, we recommend
that you contact your GEA PH E Systems Sales Office (see rear cover).

8.2.1 CIP cleaning

In the CIP cleaning process (“ Cleaning in place” ), a cleaning medium flow s
through the PH E instead of the flow media. The deposits are removed by the
dissolving pow er of the cleaning medium and by the mechanical effect of the
turbulent flow .

WA RNING
Dan g er o f i n j u r y d u e t o ag g r essi v e cl ean i n g m ed i a
The use of aggressive cleaning media involves a poisoning hazard and
danger of chemical and possibly thermal burns.
Ensure the follow ing:
➔ that you have been instructed in the handling before starting CIP
cleaning and have a safe command of all w ork steps.
➔ that you alw ays w ear suitable protective clothing w hile w orking w ith
aggressive cleaning fluids.
➔ that the cleaning medium you use is completely removed from the PH E
after the cleaning process is complete.

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M ai ntenance

NOTICE

M at er i al d am ag e d u e t o ex ceed i n g p er m i t t ed v al u es
The rating plate of your PH E specifies the permitted values, e.g. for pressure
and temperature. When these values are exceeded during PH E cleaning, the
PH E may be damaged.
➔ Ensure that all permitted values specified on the rating plate are
respected in the cleaning process as w ell.

Dam ag ed HE p l at es an d HE p l at e g ask et s d u e t o ag g r essi v e

cl ean i n g m ed i a
Chemical cleaning processes may attack the H E plate and gasket material
and cause leaks.
➔ A lw ays use cleaning media that do not attack the H E plate and gasket
material.
➔ Choose a suitable temperature and do not let the cleaning media take
effect for an unnecessarily long time.
➔ A lw ays comply w ith the safety regulations and follow the recommenda-
tions of the cleaning media producers.

En v i r o n m en t al d am ag e d u e t o ag g r essi v e cl ean i n g m ed i a
When aggressive cleaning media are discharged into the environment, envi-
ronmental damage may result.
➔ Collect the cleaning agent you have used completely so that it cannot be
discharged into the environment.
➔ H ave the cleaning agent you have used disposed of in an environmen-
tally compatible w ay.

8.2.2 Reverse f lushing cleaning met hod

Cleaning by reverse flushing is a possible alternative to CIP cleaning.
Reverse flushing is employed w hen the flow media contain coarse dirt parti-
cles plugging the manifold channels. The dirt particles are removed from the
PH E by briefly reversing the flow direction.

50
 M ai ntenance

8.3 Preparat ory measures f or opening t he PHE

WA RNING

Dan g er o f i n j u r y
M aintenance w ork on the PH E involves danger of injury.
For this reason, alw ays observe the follow ing rules:
➔ Wear suitable protective equipment at all times.
➔ H azardous flow media (caustic, toxic, flammable, explosive etc.) present
a severe danger of injury for the operator and bystanders. Ensure that
the regulations for flow media are follow ed during all w ork.
➔ When opening a pressurized and/or filled PH E, the flow media may
escape in an uncontrolled w ay. This is a danger of injury for the opera-
tors and bystanders. Ensure that the PH E is at the ambient pressure
level.
➔ When using hot or very cold flow media there is a danger of burns or,
respectively, frostbites. Before starting maintenance w ork, alw ays ensure
that the PH E has reached ambient temperature.
➔ Drain the PH E, ensuring that the media contained inside are reliably
collected.

Fr am e t y p es C o r B
Before starting w ork, establish w hich frame type (C or B) has been
delivered w ith the PH E, using the enclosed documentation.
Follow the work steps in chapters 8.4 to 8.5 and 8.9 for the relevant
frame type C or B.

1. Stop operation of the PH E.

2. Slow ly close the valves of the incoming and outgoing lines and relieve
the PH E pressure until ambient pressure is reached.
3. Wait for the PH E to reach the ambient temperature level.
4. Drain the PH E, ensuring that the content of the PH E is collected.
5. Remove any provided insulation and/or splash guards.

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M ai ntenance

6. The tensioning bolt nuts on the loose plate must be accessible.

If required, remove all piping connected to the loose plate.
The loose plate must be freely movable tow ards the column.
7. Clean the tensioning bolt threads.
➥ This removes dirt and avoids
jamming-up of the nuts.

Fig. 8.3 a – Cleaning t he t hreads

8. A pply a little grease to the visible

threads of the tensioning bolts.
➥ This makes slackening off the
tensioning bolt nuts easier later.

Fig. 8.3 b – Greasing t he t ensioning bolt nut s

9. M ark the H E plate pack w ith a diag-

onal strip of paint on the side in order
to know the correct order of H E plates
w hen reinstalling.

Fig. 8.3 c – Lat eral marking of HE plat e pack by a st rip of paint

52
 M ai ntenance

10. Be sure to w rite dow n the current

tensioning dimension “ a” of the H E
plate pack.
a

Fig. 8.3 d – M easuring t he t ensioning dimension bet w een f ixed and loose plat e

8.4 Opening t he PHE

WA RNING

Dan g er o f i n j u r y f r o m m o v ab l e l o o se p l at e
There is a high bruising hazard w hen relocating/moving the loose plate.
➔ Secure the loose plate against unexpected movements (e.g. on board of
ships).

CA UTION

Dan g er o f i n j u r y o n sh ar p ed g es, t h r ead s

an d b u r r s
Both the H E plates and threads or burrs on the
PH E may have sharp edges that may cause cuts.
➔ Wear protective gloves w hen w orking on the
PH E and/or w ith the H E plates.

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Figure ref erence f or chapt ers 8.4 t hrough 8.9

The PH E components are referred to as follow s in the chapters below :
1 = H E plate(s)
2 = Fixed plate
4 5
3 = Loose plate
3 6
4 = Tensioning bolts
5 = Top beam
2 7 6 = Safety stop
7 = Column
1

Fig. 8.4 – C f rame w it h saf et y st op

8.4.1 Opening a PHE w it h C f rame

➔ WA RNING! Prior to opening, the preparatory measures described in
chapter 8.3 must be carried out.

The draw ings below show a CL frame (w ith column).

The handling of CS frames (w ithout column) is identical.

M ost C frames have a safety stop at the end of the top beam. This safety stop
limits the travel of the loose plate.
➔ WA RNING! A lways carry out the maintenance work described below
w ith at least two persons.

Po si t i o n o f saf et y st o p
The position of the safety stop [5] depends on the size and the number
of H E plates. If you have any questions, please contact your GEA PH E
Systems Sales Office (see rear cover).
➔ When opening C frames w ithout a safety stop, proceed in a similar w ay
as described for C frames w ith a safety stop.

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 M ai ntenance

WA RNING

A s soon as the tensioning bolts have been slackened off, there is danger of
H E plates coming loose from their guiding, falling out laterally and causing
serious injury.
➔ A bsolutely comply w ith the procedure described below .

1. Remove all tensioning bolts except for

the four tensioning bolts show n.
2. Slacken off the nuts of the four
1 3 remaining tensioning bolts at the
loose plate.
➥ Proceed evenly in small steps alter-
natingly (1–2–3–4) and diagonally
(1–2 and 3–4) in order to avoid over-
4 2 loading specific tensioning bolts and
the loose plate.

Fig. 8.4.1 a – Slackening of f t ensioning bolt s (diagram)

6 3. Remove the nuts of the remaining

tensioning bolts [4] on the loose plate
side [3].
4 WA RNING! There is a bruising
3
hazard w hen relocating/moving the
loose plate. Push the loose plate [3]
up to next to the safety stop[6].
4

Fig. 8.4.1 b – Pushing t he loose plat e next t o t he saf et y st op

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4. N ow push the H E plates[1] tow ards

2
the loose plate on t he bot t om beam
[2] and tow ards the fixed plate [3] at
1
the top beam.
➥ N ow the H E plates must be saf el y
held by the fixed plate.

Fig. 8.4.1 c – Set t ing HE plat es at an angle and let t ing t hem rest against t he f ixed plat e t op

6 5. M ark the position of the safety stop

[6]. N ow slide the safety stop [6] up
to column [7].

Fig. 8.4.1 d – Pushing t he loose plat e next t o t he saf et y st op

6. Push the loose plate [3] up to next to

the column [7].
➥ In this process, the second person
3 safeguards the H E plate pack against
7
slipping.
✔ The PH E is open.
➥ To continue, see “ 8.5.1 Removing H E
plates from a C frame” (page 59).

Fig. 8.4.1 e – Pushing t he loose plat e next t o t he saf et y st op

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8.4.2 Opening a PHE w it h a B f rame

➔ WA RNING! Prior to opening, the preparatory measures described in
chapter 8.3 must be carried out.
1. Clean the visible areas of the top
beam.
➥ This improves the movability of the
H E plates.

Fig. 8.4.2 a – Cleaning t he t op beam

2. If short tensioning bolts are provided,

first slacken off the nuts of these
tensioning bolts.
1 3 3. Slacken off the nuts of the long
tensioning bolts (pre-tensioning
bolts).
➥ Proceed evenly in small steps alternat-
ingly (1-2-3-4) and diagonally (1-2
and 3-4) in order to avoid overloading
4 2
specific tensioning bolts and the loose
plate getting w edged.

Fig. 8.4.2 b – Slackening of f t ensioning bolt s (diagram)

4. Remove the short tensioning bolts [4].

4

Fig. 8.4.2 c – Removing t he short t ensioning bolt s

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5. Remove the remaining long

tensioning bolts [4] (pre-tensioning
bolts).
4

Fig. 8.4.2 d – Removing t he long t ensioning bolt s (pre-t ensioning bolt s)

8.5 Removing t he HE plat es f rom t he PHE

WA RNING

Dan g er o f f al l i n g o v er w h en st ack i n g HE p l at es
When stacking removed H E plates too high, these stacks may fall over. This
may injure you and other persons and damage H E plates.
➔ N ever stack H E plates any higher than:
- 60 H E plates for Varit herm/NT
- 30 cassettes for LWC
- 30 H E plates for Freist rom / Concit herm / Saf et yt herm

NOTICE

Dam ag e o f HE p l at es b y i m p r o p er st o r ag e
When the H E plates including the associated H E plate gaskets are not prop-
erly handled and stored, damage may result that causes PH E leaks.
➔ Ensure that H E plates are not damaged by transport and storage.
Observe the max. stacking height (page 60) and the instructions w ithin
the defined w ork steps.

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Do cu m en t i n g t h e o r d er o f HE p l at es
Document the order of H E plates upon removal, using the circuit
diagram included in the technical documentation.

HE p l at es st i ck i n g t o o n e an o t h er
If necessary, loosen sticking H E plates from one another w ithout
damaging the H E plate gaskets in this process.

8.5.1 Removing HE plat es f rom a C f rame

1. Observe chapter “ 5.3.3 Fitting the H E plates in the frame” (page 20). This
chapter describes how the H E plates are held in the frame.
2. CA UTION! H ave the H E plates
secured against unw anted move-
ments by another person.
1 Remove the H E plates one by one.
➥ Push one H E plate [1] at a time
towards the loose plate [3].
➥ Tilt this H E plate and remove it later-
3 ally from the guide.

Fig. 8.5.1 a – Removing HE plat es one by one

3. WA RNING! Do not exceed the

permitted stacking height (page 58).
1 Stack the H E plates [1] on a clean and
level surface.

Fig. 8.5.1 b – St acking HE plat es horizont ally

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8.5.2 Removing HE plat es f rom a B f rame

Observe chapter “ 5.3.3 Fitting the H E plates in the frame” (page 20). This
chapter describes how the H E plates are held in the frame.
1. The H E plates must not fall out. If
required, have the open H E plate
pack secured by a second person.
3 Push the loose plate [3] up to next to
the column [7].

Fig. 8.5.2 a – Pushing t he loose plat e next t o t he column

5 2. For removing, sw ing out one H E plate

[1] at a time laterally and remove
them one by one from the top beam
1 guide rail [5].
➥ Some Varitherm top beams allow
sw inging out to one si de only. See
Figure 5.3.3 (page 21).

Fig. 8.5.2 b – Removing HE plat es one by one

3. WA RNING! Do not exceed the

permitted stacking height (page 58).
1 Stack the H E plates [1] on a clean and
level surface.

Fig. 8.5.2 c – St acking HE plat es horizont ally

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8.6 Cleaning HE plat es w hile PHE is open

Pr i o r t o cl ean i n g t h e HE p l at es
Prior to cleaning of H E plates w hile the PH E is open, we recommend
that you contact your GEA PH E Systems Sales Office (see rear cover).

8.6.1 M anual cleaning of HE plat es

WA RNING

Dan g er o f i n j u r y d u e t o ag g r essi v e cl ean i n g m ed i a

The use of aggressive cleaning media involves a poisoning hazard and
danger of chemical and possibly thermal burns.
Ensure the follow ing:
➔ that you have been instructed in the handling of the aggressive cleaning
media prior to the cleaning process and have a safe command of all
w ork steps.
➔ that you alw ays w ear suitable protective clothing w hile w orking w ith
aggressive cleaning fluids.
➔ that the cleaning medium you use is completely removed from the H E
plates after the cleaning process is complete.

NOTICE

Dam ag e b y cl ean i n g t o o l s
H ard cleaning tools (e.g. brushes w ith metal bristles) can damage the metal
surface of the H E plates and cause corrosion. Damaged H E plate gaskets
may cause leaks.
➔ N ever use hard cleaning tools.
➔ A lw ays proceed carefully w hen cleaning in order to avoid damage to H E
plates and plate gaskets. Ensure that no particles w ill end up beneath the
H E plate gaskets as this may cause leaks.

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1. When removing coarse dirt, use a

high-pressure cleaner nozzle for
loosening the particles before starting
the actual cleaning process.
CA UTION! The high-pressure
cleaning jet may accidentally remove
the H E plate gaskets.

Fig. 8.6.1 a – Cleaning aw ay dirt f rom t he HE plat e w it h a high-pressure jet cleaner

2. N ow clean each H E plate on both

sides w ith running, w arm w ater and a
sof t brush.

Fig. 8.6.1 b – Cleaning of a HE plat e w it h a sof t brush under running w at er

8.6.2 Chemical cleaning of HE plat es

NOTICE

Dam ag ed HE p l at e g ask et s d u e t o ag g r essi v e cl ean i n g ag en t s

Chemical cleaning processes may attack the H E plate gasket material and
cause leaks.
➔ A lw ays use cleaning agents that do not attack the H E plate gasket mate-
rial.
➔ Choose a suitable temperature and do not let the cleaning agents take
effect for an unnecessarily long time.
➔ A lw ays comply w ith the safety regulations and follow the recommenda-
tions of the cleaning agent producers.

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 M ai ntenance

NOTICE

Co r r o si o n d u e t o ch l o r i d e-co n t ai n i n g cl ean i n g ag en t s
Chlorides in the cleaning agent used reduce the corrosion resistance of
nickel-chromium and nickel-chromium-molybdenum steel grades (including
Hast elloy, Incoloy and Inconel).
➔ Dilute the cleaning liquid only w ith chloride-free or low -chloride w ater
of low hardness.

➔ Select the cleaning agent as a function of the dirt to be removed and of

the resistance of H E plates and gasket materials..
1. Clean the H E plates according to the w orking instructions by the
cleaning agent producer.
2. A lw ays flush the cleaned H E plates w ith a sufficient amount of clean
w ater prior to reinstalling them.
3. Check both sides of the H E plate if any dirt has remained on the plate.
4. Remove particles on and beneath the H E plate gaskets, e.g. using a soft
brush.

8.7 Replacing HE plat e gasket s

You can take the type of fastening of H E plate gaskets from the technical
documentation of the plate heat exchanger. The H E plate gaskets may be
glued or fixed w ithout glue.

We recommend that you replace all H E plate gaskets at the same time.
A lw ays use original GEA PH E Systems H E plate gaskets exclusively.

Co n t act i n g t h e GEA PHE Sy st em s Sal es Of f i ce

Contact your GEA PH E Systems Sales Office for replacing the H E plate
gaskets of your PH E. The contact addresses can be found on the rear
cover.

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8.8 Replacing t he f rame gasket s

The type of gasket used betw een the H E plate pack and the frame compo-
nents depends on the frame type.

Co n t act i n g t h e Sal es Of f i ce
Contact your GEA PH E Systems Sales Office for replacing the frame
gaskets of your PH E. The contact addresses can be found on the rear
cover.

8.9 Inst alling t he HE plat es and closing t he PHE

➔ Observe the work steps detailed in chapter “ 3.1 H azards on the PH E”
(page 9), before installing the H E plates and closing the PH E.

8.9.1 Preparat ory measures f or inst alling t he HE plat es

NOTICE

Leak y PHE d u e t o o l d HE p l at e o r f r am e g ask et s

If you reuse used H E plate gaskets and frame gaskets or replace only part of
them, the PH E may leak.
➔ Perform a visual inspection to see if replacement is needed.
➔ Replace used H E plate gaskets and used frame gaskets (sealing rings or
rubber mouldings) alw ays for the entire PH E at the same time.
Leak y PHE d u e t o d am ag ed HE p l at e an d f r am e g ask et s
H E plate gaskets and frame gaskets (sealing rings or rubber mouldings) are
easily damaged.
➔ H andle H E plate and frame gaskets w ith care.

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 M ai ntenance

➔ Carry out the four steps below for al l PH E:

1. Ensure that the H E plate gaskets and the H E plates are free of foreign
objects and dirt. Clean them if required.
2. Check if the H E plate gaskets properly fit in the grooves of the H E
plates.
3. Clean the sealing faces of the frame gaskets.
4. Clean the threads of the tensioning bolts and the tensioning nuts and
apply a little grease.

8.9.2 Inst alling HE plat es in PHE w it h a C f rame

➔ First carry out the work steps described in chapter “ 8.9.1 Preparatory
measures for installing the H E plates” (page 64).
1. Before installing the H E plates, insert
tw o tensioning bolts [4] on both sides
4 as a safeguard.
Install the H E plates in the PH E frame
in the correct order.

Fig. 8.9.2 a – Leaving t ensioning bolt s in t he PHE as a saf eguard

2 2. A lw ays install the H E plates [1] so

1 that they are slightly tilted and rest
firmly against the fixed plate [2] at the
1 top.
➥ H ave the H E plate pack secured by
another person.

Fig. 8.9.2 b – Rest ing HE plat es against t he f ixed plat e t op af t er inst allat ion

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3. Push the loose plate [3] next to the

H E plate pack.
3

Fig. 8.9.2 c – Pushing t he loose plat e next t o t he HE plat e pack and insert ing t he t ensioning
bolt s

4. Insert the remaining tensioning bolts

6
[4].
4 5. Fix the safety stop[6] at the position
marked before the PH E w as opened
4 ➥ Do not yet tighten the H E plate pack.
➥ Continue w ith chapter “ 8.9.4
4 Tensioning and testing the H E plate
pack” (page 68).

Fig. 8.9.2 d – Pushing t he loose plat e next t o t he HE plat e pack and insert ing t he
t ensioning bolt s

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 M ai ntenance

8.9.3 Inst alling HE plat es in PHE w it h a B f rame

➔ First carry out the work steps described in chapter “ 8.9.1 Preparatory
measures for installing the H E plates” (page 64).
1. Clean the H E plate suspension beam
[5] and apply a little grease.
5

Fig. 8.9.3 a – Applying grease along t he beam

2. Install the H E plates [1] in the PH E

5
frame in the correct order.
➥ Sw ing one H E plate at a time laterally
into the H E plate suspension of beam
1 [5]. Push the H E plates towards the
fixed plate one by one.

Fig. 8.9.3 b – Inst alling t he HE plat e int o t he f rame

3. Push loose plate [3] next to the H E

plate pack [1] and insert all tensioning
3
bolts.
➥ Do not yet tighten the H E plate pack.
➥ Continue in the next chapter 8.9.4.

Fig. 8.9.3 c – Pushing t he loose plat e next t o t he complet e HE plat e pack

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8.9.4 Tensioning and t est ing t he HE plat e pack

NOTICE

Dam ag e t o HE p l at es b y ex cessi v e t i g h t en i n g
When tensioning the H E plate pack beyond the value permitted by
tensioning dimension a min., the H E plates w ill be damaged and the PH E
may leak.
➔ Tension the H E plate pack of the
PH E w ithin the fixed values
a min. < a < a max.
a

1. Check if the H E plates have been

properly installed.
➥ To do this, use the diagonal strip of
paint you have applied before
opening the PH E.

Fig. 8.9.4 a – Diagonal st rip of paint as an aid f or checking t he order

2. Check if all H E plates have been

correctly installed (no reverted instal-
lation).
➥ When all H E plates are properly
installed, the H E plate pack usually
show s a continuous honeycomb
pattern (left).

Fig. 8.9.4 b – Lat eral honeycomb pat t ern of correct ly inst alled HE plat es

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 M ai ntenance

3. Determine the necessary tensioning dimension a.

➥ The necessary t ensioning dimension a is:
– in case of complete replacement of H E plate gaskets: the a max. speci-
fied on the rating plate a max.
– if the plates w ere merely cleaned and no H E plate gaskets w ere
replaced: the tensioning dimension a taken dow n before opening the
PH E.
– in case the number of H E plates has changed: the new tensioning
dimension a max. w hich can be taken from the enclosed circuit
diagram and the new rating plate.
4. Tighten the tensioning bolts to the necessary tensioning dimension a in
small steps alternatingly (see 8.4.1 and 8.4.2) and diagonally.
5. Carry out a leakage test prior to putting the unit into operation again.
H ere the test pressure must be equal to the max. permitted pressure
specified on the rating plate and must be applied to the PH E on all sides
at the same time.
✔ N ow the H E plate pack is tensioned again and tight.
➔ Refer to chapter „Troubleshooting“ (Seite 70) w hen leaks occur.

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9 Troubleshoot ing
Pr i o r t o r em o v i n g f au l t s
You should contact your GEA PH E Systems Sales Office (see rear cover)
before removing faults in order to avoid improper work on the PH E
and its consequences.

9.1 Out put def icit

Fau l t Reaso n Rem ed y

Reduced heat transfer Deposits on the H E plates Clean H E plates - see

chapters 8.6 (page 61) and
8.2 (page 49)
Change of operating H ave PH E design w ith
mode, flow media etc. as new operating data
compared w ith the design checked by GEA PH E
case Systems
Excessive pressure loss Plugging of manifold flow Clean H E plates - see
gaps obstructs flow chapters 8.6 (page 61) and
8.2 (page 49)
Incorrect installation of H E Check installation order
plates obstructs flow by means of circuit
diagram
Change of operating H ave PH E design w ith
mode, flow media etc. as new operating data
compared w ith the design checked by GEA PH E
case Systems

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 Troubl eshooti ng

9.2 Leaks
Fau l t Reaso n Rem ed y

Leaks between the H E Incorrect tensioning Check correct tensioning

plates - flow media escape dimension of PH E dimension according to
from the H E plate pack rating plate data
Excessive operating Check operating pressure
pressure according to rating plate
data
Excessive / insufficient Check operating tempera-
operating temperatures tures according to rating
plate data
H E plate gaskets are not Open the PH E and correct
properly seated the seat of H E plate
gaskets
H E plate gaskets are soiled Open the PH E and clean
the H E plate gaskets
H E plate gaskets either Open the PH E and replace
defective or hardened the H E plate gaskets
Leaks between H E plates Incorrectly seated H E Open the PH E and correct
and frames, reinforcement plate and frame gaskets seat of plate and frame
plates and intermediate gaskets
plates
H E plate and frame Open the PH E and clean
gaskets are soiled the H E plate and frame
gaskets
H E plate and frame Open the PH E and replace
gaskets are defective the H E plate and frame
gaskets

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Troubl eshooti ng

Fau l t Reaso n Rem ed y

Leaks between frame Excessive load of frame Reduce connecting loads

connection and pipework connection from pipework to permitted values
Gasket improperly seated Slacken off frame connec-
tion and correct gasket
seat
Dirty gasket Slacken off frame connec-
tion and clean the gasket
Defective gasket Slacken off frame connec-
tion and replace the gasket
Flange connection is not Check gasket and
sufficiently tightened retighten connection
evenly if required
Damaged H E plates Excessive tightening of H E Replace defective H E
plate pack (tensioning plates
dimension below a min.)
Corrosion of H E plate Check design of PH E
material regarding flow media,
contact GEA PH E Systems
Damaged H E plates at the Incorrect earthing w hen Replace defective H E
beginning or at the end of welding on special connec- plates
the PH E tions to open frame
connecting pipes

72
 Techni cal terms

10 Technical t erms

Ter m M ean i n g

B frame A particularly sturdy frame version permitting a high

number of H E plates.
Bottom guide beam Component serving for bottom guiding of H E plates
and of the loose plate.
Particularity: In C frames, the H E plates stand on and
are supported by this beam.
C frame A compact PH E frame design. In a C frame, the possible
number of H E plates is lower than in a corresponding B
frame.
CIP process (Cleaning In A cleaning process in w hich the flow channels of the
Place) unopened PH E are flushed w ith specific cleaning
media.
Column A fixed frame component to w hich the top beam and
the bottom beam are attached.
Connection Piping connections provided on the fixed plate and
(pipe connection) possibly on the loose plate. Depending on the applica-
tion, the piping connections may be executed in
different ways (industrial version, rubber moulding,
metal lining, flange nozzle etc.).
EcoLoc A glueless fastening system for H E plate gaskets.
Fixed plate The basic component of a frame. The fixed plate is a
non-movable frame plate. N ormally, the pipes are
connected to this component.
Flow media The term for the media involved in the heat transfer in
the PH E.
Frame gaskets Provide sealing of frame plates in the pipework
connecting area. Versions as gasket ring (sealing on one
side) or rubber moulding (sealing on both sides).
Frame plates The fixed and loose plate of a PH E frame.

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Techni cal terms

Ter m M ean i n g

Gasket groove Continuous recess stamped into the H E plate in w hich

the H E plate gaskets are installed. When installing H E
plate gaskets by gluing, the glue is applied here.
Gasket ring Provides single-sided sealing of frame plates in the
pipework connecting area. Gasket rings are located in a
gasket groove.
H E plate gaskets A n elementary component for sealing the flow gap
between the H E plates towards the environment and
the leakage space. There are H E plate gaskets for glued
and for glueless fastening (LocIn, EcoLoc) to the H E
plates.
H E plate pack The collective term for all of the H E plates located
between the frame plates, including the H E plate
gaskets.
H E plates A n elementary component that keeps the flow media
separated from each other and transfers the heat.
H eader channel The flow channel of the outgoing medium formed by all
passage openings of the H E plates.
Insulation A n insulating layer provided around the H E plate pack.
GEA PH E Systems recommends an insulation at high
and low operating temperatures.
Intermediate plate A component inside the H E plate pack. The interme-
diate plate has lateral piping connections for multi-
stage PH E designs.
Leakage space A rea around the gasket eyes (see page 22).
LocIn A glueless fastening system for some types of H E
plates.
Loose plate A movable frame plate suspended at the frame top
beam. This frame plate serves for tensioning the H E
plate pack.
The loose plate may have piping connections.
M anifold channels The flow channel of the incoming medium formed by
all passage openings of the H E plates.

74
 Techni cal terms

Ter m M ean i n g

M etal lining Lining of the frame plates in the area of piping connec-
tions. The material used (stainless steel grades, tita-
nium, etc.) depends on the application.
M ulti-pass PH E A special PH E design w ith internal deflections of the
flow media. The design of multi-pass PH E always
results in piping connections on the loose plate.
M ulti-stage PH E A special PH E version w ith more than 2 flow media
(use of intermediate plates). This version combines
more complex heat transfer tasks in one single PH E
(heating and cooling, e.g. in food applications).
PH E Short form of the term “ Plate H eat Exchanger ” .
Rating plate A plate fitted on the fixed plate and indicating the basic
technical data of the PH E.
Reinforcement plate A component inside the H E plate pack. The reinforce-
ment plate has no piping connections and is used for
special multi-pass PH E designs.
Reverse flushing A cleaning process in w hich the flow direction is
reversed at regular intervals. This flushes dirt out of the
PH E.
Rubber moulding A positive lining (elastomer) of the frame plates in the
piping connecting area. It serves for sealing towards
both the H E plate pack and the connected piping.
Single corner Component of the intermediate plate in the H E plate
(single pipe corner) pack. This intermediate plate is used for realizing multi-
stage PH E variants. The single corners are used for
connecting additional pipes/media (especially for food
applications).
Single-pass PH E The standard version of a PH E w ith two flow media.
The connections are usually located on the fixed plate.
Splash guard A n protective guard provided around the H E plate
pack. GEA PH E Systems recommends fitting a splash
guard w hen using hazardous media as a general rule.
The splash guard can be included in the order.
Suspension (of loose The suspension of the loose plate on the top beam
plate) (normally using a moving roller). This suspension
enables relocating the loose plate on the top beam.

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Techni cal terms

Ter m M ean i n g

Tensioner Consists of tensioning bolt, tensioning nut and thrust

washers/washers. The H E plate pack is tensioned
between the frame plates by means of several
tensioners.
Tensioning dimension a Dimension relating to the unpressurized (!) PH E. The
a max. / a min. H E plate pack between the frame plates must be
tensioned to this dimension. The H E plate pack may be
damaged if the actual tensioning dimension is below
the specified a min. value. The tensioning dimension
must be measured at the tensioning bolts.
Top beam The component located at the top between the fixed
plate and the column and on w hich the H E plates and
the loose plate are suspended.
Particularity: In C frames the top beam has a guiding
function of the H E plates.

76
Excellence Passion Integrity Responsibility GEA-versity

GEA Group is a global mechanical engineering company with multi-billion euro sales and operations
in more than 50 countries. Founded in 1881, the company is one of the largest providers of
innovative equipment and process technology. GEA Group is listed in the STOXX Europe 600 Index.

© GEA PHE Systems. All rights reserved. 05/2012 – PR-2011-0000-DE

GEA Heat Exchangers

GEA PHE Systems
Karl-Schiller-Str. 1-3, 31157 Sarstedt, Germany
Phone: +49 5066 601 0, Fax: +49 5066 601 104
[email protected], www.gea-phe.com
 Oil Mist Detector C5.05.11.02.03.07
-

Oil Mist Detector

en / 25.09.2013 FD049241 1/71

 Version 2.0, 01/2013

VISATRON®
Oil Mist Detectors
VN115/87plus
VN116/87plus
VN215/87plus
Operation Manual
Part-No. 11078

IACS UR M67 type approved

Operation Manual VISATRON® series VN87plus 01/2013
Page 2

About this Manual

This operation manual was designed to answer your questions concerning the
handling, operation and maintenance of the Oil Mist Detector (OMD) VISATRON®
series VN87plus. It contains no details about repairs.

The operating instructions are applicable for:

VN115/87plus
VN116/87plus
VN215/87plus

Should you encounter any interruption or breakdown of your VISATRON® series

OMD device during operation, please contact your local representative (refer to
FKDSWHUµ6HUYLFH3DUWQHUV¶RU Schaller Automation, Industrielle
Automationstechnik GmbH & Co. KG directly. The repair of OMD devices should be
carried out by Schaller Automation directly or by a repair center dedicated and
authorized by Schaller Automation. You can expect safe and reliable operation of
your OMD only when the device is operated in accordance with this manual.

Please take note of the following:

x Please read this manual thoroughly and acquaint yourself with the correct
installation, operation and maintenance of your VISATRON® series VN87plus
device.
x Installations of the VISATRON® series VN87plus devices have to be in
accordance to the IACS UR M10 if applicable.
x Use the VISATRON® series VN87plus devices only for the purpose described in
the operation manual.
x Incorrect maintenance and handling errors may cause possible device failure or
an unsafe operating environment.
x The VISATRON® series VN87plus devices may only be used by authorised staff.
x This operation manual must be available at the place of installation at all times.

Terms and conditions of sale

The standard terms and conditions of sale of SCHALLER AUTOMATION shall apply to
all VISATRON® and related products.

SCHALLER AUTOMATION Industrielle Automationstechnik GmbH & Co. KG warrants

that under proper use, handling and maintenance OMD VISATRON® series
VN87plus is free from defects in material, design and/or workmanship. Claims of
buyers/operators, in particular compensation for damage, which does not arise at
OMD VISATRON® series VN87plus itself or for natural wear and tear of consumable
supplies, e.g. filters etc., are excluded. SCHALLER AUTOMATION Industrielle
Automationstechnik GmbH & Co. KG is not responsible for defects, which arise as a
result of:

a) natural wear and tear, improper commissioning, improper use/handling, use of

unsuitable power supply, welding processes on the engine as well as non-

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 3

observance of commissioning, installation, operating and service instructions as

given in this Operation Manual
b) components and design other than the OMD VISATRON® series VN87plus
c) alterations or modifications of the OMD VISATRON® series VN87plus carried
out by the buyer/operator or third parties without written authorization of
SCHALLER AUTOMATION Industrielle Automationstechnik GmbH & Co. KG
d) incorrect combination of devices and/or components or operation of devices
and/or components which are not certified to be compatible or not permitted by
the manufacturer - SCHALLER AUTOMATION Industrielle Automationstechnik
GmbH & Co. KG

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 4

Safety instructions

The series VN87plus devices are manufactured according to the high quality
standards of SCHALLER AUTOMATION and must pass stringent factory tests. In
order to keep the device in a smooth and problem free operation, the user has to
take note of the safety hints and warnings. In the instruction manual they are
marked with the following symbols.

Used symbols

CAUTION! Do not ignore the text in this box. Personnel

safety can be endangered or the device can be damaged.

WARNING! The marked text contains important information.

The marked text contains only a hint for faster processing.

CAUTION! Unplug the OMD during welding processes

on the engine.

Reset of Oil Mist Alarms

CAUTION!
Ensure that the oil mist concentration inside the
engine has fallen under the Lower Explosion Level
(LEL) before acknowledging an oil mist alarm by
pressing the Oil-Mist-Alarm button. Otherwise you
risk an oil mist explosion!

Follow the instructions of engine builder, ship yard

and ship owner!

Use a monitoring device at a safe location (e.g. ECR)

to check for the actual oil mist concentration. At an
Oil Mist Alarm, Schaller Automation strongly
recommends to approach the engine only after
indicated oil mist concentration (LED chain) has
lowered to half of its bar indication (VISATRON®-
device and Remote Indicator II).

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 5

EC Declaration of Conformity

We, the manufacturer

SCHALLER AUTOMATION
Industrielle Automationstechnik GmbH & Co. KG
Industriering 14
D-66440 Blieskastel
Germany
Tel.: 06842 / 508-0
Fax: 06842 / 508-260

declare on our own responsibility, that the product:

Kind of equipment: Oil Mist Detector

Type-designation: VISATRON® VN115/87plus

VISATRON® VN116/87plus
VISATRON® VN215/87plus

to which this declaration relates exclusively used for the detection and signalizing of oil mist
in diesel aggregates and complies with the following EG-directives

Machinery directive 2006/42/EG

EMC directive 2004/108/EC

is in compliance with following standards:

EN ISO 4414
EN 60529
EN 55022
EN 61000-part 6-1 till 6-4
EN ISO 12100
CSPRI 16-1
CSPRI 16-2
CSPRI 16-4
IACS UR M67

A technical documentation is completely available. The operating manual

according to the oil mist detectors is available in the original version.

D-66440 Blieskastel, 2012/08/02

Stephan Schaller
- Managing Director -

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 6

Table of Contents

1 Introduction and functional overview ............................... 8

2 Installation instructions .................................................. 13
2.1 Mechanical installation ........................................................ 13
2.1.1 Basics .................................................................................13
2.1.2 Pipe dimensions ...................................................................17
2.1.3 Installation of pipe siphons ....................................................18
2.1.4 Installation of the siphon block connection units .......................20
2.1.5 Suction funnels in the crankcase compartment ........................21
2.1.6 Pipe arrangement at valve box (VN215/87plus system only) .....22
2.1.7 Compressed air connection ....................................................23
2.2 Electrical installation ........................................................... 24
2.2.1 VISATRON® series VN87plus device .......................................24
2.2.2 Connection of monitoring devices ...........................................27
2.2.3 Schematic electrical wiring diagram ........................................29
3 Commissioning ................................................................ 30
3.1 Adjusting or checking the suction pressure ......................... 30
3.2 Filling of siphon blocks VN280plus of VN215/87plus system
with oil ................................................................................ 31
3.3 Filling of siphon blocks VN180 for VN115/87plus and
VN116/87plus system with oil ............................................. 33
3.4 Filling of pipe siphons for VN115/87plus and VN116/87plus
system with oil .................................................................... 34
3.5 Adjusting the sensitivity of the OMD .................................... 35
3.6 Commissioning check list ..................................................... 36
4 Operating instructions ..................................................... 37
4.1 Display ................................................................................. 37
4.2 Reset of Oil Mist Alarms ....................................................... 39
5 Troubleshooting .............................................................. 40
5.1 Clean fresh air bores ............................................................ 41
5.2 Clean infrared (IR-) filter..................................................... 41
5.3 Exchange air filters in the measuring head .......................... 42
5.4 Exchange air filter in pressure regulator unit ...................... 42

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 7

5.5 Exchange measuring head ................................................... 43

5.6 Exchange bellows and suspension-system........................... 45
5.7 Measuring head fuses .......................................................... 47
5.8 Check for earth fault problem .............................................. 48
6 Maintenance procedures ................................................. 50
7 Functional test ................................................................ 51
7.1 On board test ....................................................................... 51
7.2 Factory test at engine builder with smoke generator on
VN115/87plus and VN116/87plus installations ................... 53
7.3 Additional pressure measurement on VN115/87plus and
VN116/87plus installations ................................................. 54
7.4 Factory test at engine builder with fog machine on
VN115/87plus, VN116/87plus and VN215/87plus ............. 56
8 Optional Spare Parts and Accessories ............................. 58
9 Technical data ................................................................. 65
10 Service Partners .............................................................. 70

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 8

1 Introduction and functional overview

The newly developed VISATRON® series VN87plus Oil Mist Detector (OMD) from
SCHALLER AUTOMATION protects large diesel engines against oil mist explosion,
caused by spontaneously occurring oil mist. It is part of a safety system that
secures the life and health of the operating staff and prevents heavy damages to
the engine.

SCHALLER AUTOMATION developed this device to meet the IACS UR M10.

It is not possible to directly monitor all potential sources of oil mist inside a large
diesel engine. There are main bearings, large end bearings, pistons, liners, sliders,
pumps, camshaft bearings, chains, gears or even tools left behind from installation
± all of these parts could produce oil mist e.g. in case of lubrication problems.
Therefore the philosophy of SCHALLER AUTOMATION is that only OMD-systems can
securely prevent oil mist explosions by detecting the primary origin of danger: the
oil mist itself.

The VISATRON® series VN87plus OMD-system uses the approved wear-free suction
system to continuously extract the atmosphere of the crankcase compartments and
other engine locations. The system works actively and is not simply waiting for oil
mist clouds. This ensures proper reaction times from the beginning of oil mist
generation to an oil mist alarm.

To avoid false alarms, caused by splash oil, the suction system makes use of
Schaller's special suction funnels working independent of the rotation sense of the
engine. Additional draining components ensure correct working under all operating
conditions. This includes the application in power plants as well as on vessels with
their static or dynamic inclinations. False alarms initiated by condensing water
vapour are prevented by an integrated heater inside the measuring head housing.

The OMD-system consists of following parts:

x VISATRON® series VN87plus oil mist detector

x Protection cover
x Suction system including pressure regulator
x Monitoring device (optional)

Three different types of the VISATRON® series VN87plus oil mist detectors are
available (see Figure 1):

x VN115/87plus
x VN116/87plus
x VN215/87plus

All devices have a measuring head (2) which includes the optical measuring track
under the control cover (3) and a display to give the user all important information
for normal operations conditions. The measuring head is mounted on a vibration
protected base plate.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 9

The negative pressure for the suction system is generated by an air jet pump (1)
working with the Venturi principle. The electrical interface is integrated within a
socket housing (5). The mating plug contains the Oil-Mist-Alarm button. The device
can be connected directly to the engine safety system. The interface includes two
Oil-Mist-Alarm outputs, a Pre-Alarm output and a Ready signal.

VN115/87plus VN116/87plus VN215/87plus

Figure 1: Types of VISATRON® series VN87plus

VN115/87plus
The suction system is connected to the common "Connecting Box" (4). This type of
oil mist detector is able to detect an oil mist development, without identifying the
location of the oil mist source inside the engine.

VN116/87plus
The suction system is connected to the "Valve Box 116" (4). This type of oil mist
detector is able to detect an oil mist development, indicating in the valve box
window the left or right side of the detector with the highest oil mist concentration.

VN215/87plus
The suction system is connected to the "Valve Box 215" (6). This type of oil mist
detector is able to detect an oil mist development, indicating in the valve box
window the compartment with the highest oil mist concentration.

In normal operation mode all models sample the atmosphere of the engine at all
suction points in parallel through the suction system to the measuring head. Upon
detection of an oil mist alarm the models VN116 and VN215 start an additional
search run to determine the location of the highest oil mist concentration. The
reaction time to an alarm is totally independent of the search run.

All devices offer two alarm levels.

The Main-Alarm level can be adjusted with a switch at the rear side of the
measuring head.
The Pre-Alarm will be activated at fix 70% of the Main-Alarm level.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 10

To keep the optical track clean all models use clean scavenging air in front of the
filter glasses. This air is derived from the compressed air driving the air jet pump.

The devices can be ordered as single OMD device or integrated in a mounting unit.
In this case the scope of supply includes an additional pressure regulator unit and a
protection cover.

Protection cover

Pressure
regulator unit

Figure 2: VISATRON® VN116/87plus oil mist detector with protection cover and
pressure regulator unit

The suction system always requires a so called 'suction funnel' (see page 21, Fig.
19) at each suction point. This prevents the system against incoming splash oil.
During normal operation mode of an engine the OMD sucks out a small
concentration of oil mist which was generated by blow-by or mechanical spraying.
This oil mist may fall out in the suction pipes and must be drained out the pipes.
Ideally, drainage flow back ends inside the HQJLQH¶Vcrankcase.

Figure 3:
Optional Siphon block VN180 optional Siphon block VN280plus optional Pipe siphon

The best method on a VN115/87plus and VN116/87plus installation to drain the

system is to use pipe siphons. Also recommended is the use of siphon blocks.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 11

On 2-stroke engines the crankcase and the combustion chambers are separated by
stuffing boxes, which let the crankcase be nearly free of blow-by. Therefore it's also
possible to use the suction funnel as draining device. In this case it is necessary to
mount the suction pipes with an inclination of greater than 6°.

To become independent from fast changes of the engine room air pressure, it is
recommended that the output of the air jet pump is blown back into the crankcase.
If the air is blown into the engine room, SCHALLER AUTOMATION offers an optional
oil separator which should be mounted directly to the output of the pump.

Figure 4: Optional Oil separator for air outlet

Remote monitoring devices:

The OMD device can be connected to Schaller's monitoring devices Remote
Indicator II to monitor the oil mist concentration and the status of the OMD device
from a safe location as requested by IACS UR M10. The connection to the
monitoring devices is realized by a RS485 two-wire bus.

Figure 5: Optional Remote Indicator II

Additionally Schaller realized an integration of the VISATRON® devices into ship

automation systems (e.g. Mega-Guard of Praxis Automation).

Thus, the series VN87plus is a further contribution to safety at sea. Our goal is to
avert damage to assets, personnel and the environment.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 12

Important features of the series VN87plus compared to the series VN87

x Heater is integrated into the measuring head, no external connector

x Scavenging air is integrated into the measuring head, connecting hose same
as supplied before
x Pre-alarm interface available, threshold is fixed to 70% of main-alarm level
x Serial interface for monitoring devices is integrated
x Additional error codes
x Switch for the adjustment of the main-alarm level is placed on the rear side
of the measuring head, no disassembly of the electronic module furthermore
necessary
x Switch for the adjustment of the bus device address is available on the rear
side
x Easier access to the wire break resistors on the rear side
x Optional 4 -20 mA output of the relative opacity data

And finally very important

No changes of the base plate mechanical interface (or the
measuring head) compared to the series VN87. So, base
plate of VN115/87 is interchangeable with VN115/87plus,
VN215 with VN215/87plus, etc.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 13

2 Installation instructions

2.1 Mechanical installation

2.1.1 Basics
There are multiple potential sources of oil mist inside an engine. These are for
example defective main bearings, connecting rod bearings as well as piston
seizures, chains and covers of pumps. For each of these individual sources you
could determine the "optimum" suction point. The result would be a vast number of
holes to be distributed over the entire engine. To find out a safe and economic
solution to monitor oil mist SCHALLER AUTOMATION recommends the OMDEA-test
(Oil Mist Detection Efficiency Approval). In each case the following rules are
recommended.

CAUTION! Do not ignore the warnings. The safety of persons

can be endangered

Following rules are recommended by SCHALLER AUTOMATION:

x Use at least one suction point per compartment.

x Use always the long version of the suction funnels. This makes the
installation independent from the rotation sense of the engine.
x At least one suction point per chain drive or gear drive is necessary.
x Avoid the splash oil disk of the crankshaft bearings.
x Select points in the upper area of the crankcase, as oil mist tends to rise
upwards!
x The detection unit has to be placed above the suction points.
x Installation Rules: in general avoid U-bends or kinks in the tubing system.
o VN115/116 with pipe siphons: Mount one pipe siphon at each end of
the horizontal header pipes, place the pipes a little bit above the
suction points and connect the pipes and the engine wall connections
with flexible tubes.
o VN115/116 with siphon blocks: Use one siphon block at each
compartment.
o VN215 with siphon block: Use one siphon per compartment. If a
suction point is placed above the detection unit e.g. at the camshaft
use a pipe siphon at the lowest point of the pipe to avoid an oil pocket,
which could clog the pipe.
o VN215 without draining components: The pipes have to be mounted
with an angle greater than 6° inclination.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 14

x If possible mount the device on the engine side opposite to the crankcase
relief valves, to reduce danger to the crew during a damage situation.
x If possible place the VISATRON® detection unit in the center of the engine to
avoid long pipe runs.
x Select only suction points which allow the use of long suction funnels. In this
case the installation side is independent from the rotation sense of the
engine. Installations without any suction funnels are not allowed.
x If recommended by engine builder, determine an additional suction point at
the camshaft bed.
SCHALLER AUTOMATION recommends a final test procedure per engine
type called OMDEA (Oil Mist Detection Efficiency Approval).

According to the IACS unified requirement M10 the installation drawings have to be
approved from engine builder and SCHALLER AUTOMATION. The installations have
to be executed in compliance with these drawings and the contents of this manual.

The following figures show typical installation arrangement on a 6 cylinder engine.

Example of an VISATRON VN115/87plus installation on a 6-cyl. engine

with engine wall connections (oil draining through pipe siphons)

recommended:
manoeuvre
side
suction point

engine wall
connection

flexible hose exhaust

engine wall engine wall engine wall engine wall engine wall engine wall
pipe connection connection connection connection connection connection
pipe
siphon siphon
additional suction points, e.g.:
chain/gear-case
thrust bearing

compartment 1 compartment 2 compartment 3 compartment 4 compartment 5 compartment 6

Figure 6: Recommendation for best VN115/87plus OMD installation

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 15

Example of an VISATRON VN115/87plus installation on a 6-cyl. engine

with siphon blocks (oil draining through siphon blocks)

recommended:
manoeuvre
side
suction point

optional
engine wall
connection
exhaust
siphon- siphon- siphon- siphon- siphon- siphon-
block block block block block block
VN180 VN180 VN180 VN180 VN180 VN180

additional suction points, e.g.:

chain/gear-case
thrust bearing
compartment 1 compartment 2 compartment 3 compartment 4 compartment 5 compartment 6

Figure 7: Alternative installation of VN115/87plus OMD

Example of an VISATRON VN116/87plus installation on a 6-cyl. engine

with engine wall connections (oil draining through pipe siphons)

recommended:
manoeuvre
side
suction point

engine wall
connection

flexible hose
exhaust
engine wall engine wall engine wall engine wall
pipe connection connection connection connection
pipe
siphon siphon
additional suction points, e.g.:
chain/gear-case
thrust bearing

compartment 1 compartment 2 compartment 3 compartment 4 compartment 5 compartment 6

Figure 8: Recommendation for best VN116/87plus OMD installation

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 16

Example of an VISATRON VN116/87plus installation on a 6-cyl. engine

with siphon blocks (oil draining through siphon blocks)

recommended:
manoeuvre
side
suction point

engine wall
exhaust connection

siphon- siphon- siphon- siphon- siphon- siphon-

block block block block block block
VN180 VN180 VN180 VN180 VN180 VN180

additional suction points, e.g.:

chain/gear-case
thrust bearing
compartment 1 compartment 2 compartment 3 compartment 4 compartment 5 compartment 6

Figure 9: Alternative installation of VN116/87plus OMD

Example of an VISATRON VN215/87plus installation on a 6-cyl. engine

with siphon blocks (oil draining through siphon blocks)

recommended:
manoeuvre
side
suction point

exhaust
siphon- siphon- siphon- siphon- siphon- siphon-
block block block block block block
VN280-1 VN280-2 VN280-3 VN280-4 VN280-3 VN280-2 engine wall
connection
additional suction points, e.g.:
chain/gear-case
thrust bearing

compartment 1 compartment 2 compartment 3 compartment 4 compartment 5 compartment 6

Figure 10: Recommendation for best VN215/87plus OMD installation

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 17

Example of an VISATRON VN215/87plus installation on a 6-cyl. engine

with inclined suction pipes (oil draining through suction funnels)

recommended:
manoeuvre
side
suction point
pipe inclination >6°

exhaust

engine wall engine wall engine wall engine wall engine wall engine wall
connection connection connection connection connection connection engine wall
connection

additional suction points, e.g.:

chain/gear-case
thrust bearing
compartment 1 compartment 2 compartment 3 compartment 4 compartment 5 compartment 6

Figure 11: Alternative installation of VN215/87plus OMD

2.1.2 Pipe dimensions

x For VN115 and VN116 standard applications:

o Seamless steel pipes: 22 mm outer diameter, 2 mm wall thickness
o Flexible hoses: inner diameter not less than 6 mm

x For VN215 standard applications:

o Seamless steel Pipes: 14 mm outer diameter, 2 mm wall thickness
or, if 14 mm is not available
o Seamless steel Pipes: 13,71 mm (known as1 /4-inch pipes, schedule
no. 40, 0.540 inch outer diameter, 0.088 inch wall thickness)

The length of exhaust air pipe (outlet of the venturi injector) should be limited to
max. 4m. If a longer tube is required, please contact Schaller Automation. The
inner diameWHUKDVWREH•PPU-bends and kinks are forbidden.

All installation solutions must have written agreements by SCHALLER AUTOMATION

as required by IACS UR M10.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 18

2.1.3 Installation of pipe siphons

Figure 12: Pipe siphon

x Mount the engine wall connection into the G3/4" thread with 110 Nm torque
x Put the pipe siphon in the hole
x Fix the clamping nut
x Fill the pipe siphon with oil (see chapter 'commissioning')
x Fix the flexible tube on the top fitting

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
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x
Figure 13: Pipe siphon at engine wall Figure 14: Image of pipe siphon

Crank case atmosphere

Header pipe
Flexible hose from
suction point
Oil

Flexible hose
to pipe siphon

Figure 15: Oil draining principle

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
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2.1.4 Installation of the siphon block connection units

Figure 16: Connection unit

Consider the following points:

x Take note of the drilling template (made of paper, included with the
connection units)
x Drill through
x Seal all threads with 'Loctite 572'
x Max. torque = 30 Nm

OKAY Wrong alignment Wrong angles Wrong distance

Figure 17: Side view

x Avoid wrong alignment, wrong angles and incorrect distances (see Figure 17)
x Insert the suction funnel from the crankcase side into the siphon block, align
it in a vertical position (see Figure 18) with the opening at the bottom
and fix the small clamping nut.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
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2.1.5 Suction funnels in the crankcase compartment

The suction funnels have to be fitted in such a way that flooding by splashing
bearing oil or returning piston cooling oil is avoided (see Figure 18).

CAUTION! Make sure funnels do not interfere with rotating or

moving parts of the engine.

Figure 18: Different types of suction funnels

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
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Operation Manual VISATRON® series VN87plus 01/2013
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2.1.6 Pipe arrangement at valve box (VN215/87plus system only)

5 6
4 7
3 8
2 9
1 10

1 2 3 4

5 6 or 5 6
4 7 4 7
3 8 3 8
2 9 2 9
1 10 1 10

1 2 3 4 5 1 2 3 4 5

5 6
4 7
3 8
2 9
1 10

1 2 3 4 5 6

5 6 or 5 6
4 7 4 7
3 8 3 8
2 9 2 9
1 10 1 10

1 2 3 4 5 6 7 1 2 3 4 5 6 7

5 6
4 7
3 8
2 9
1 10

1 2 3 4 5 6 7 8

Figure 19: Pipe arrangement for 4 to 8 suction points

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
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5 6 or 5 6
4 7 4 7
3 8 3 8
2 9 2 9
1 10 1 10

1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9

5 6
4 7
3 8
2 9
1 10

1 2 3 4 5 6 7 8 9 10

Figure 20: Pipe arrangement for 9 and 10 suction points

CAUTION! Other arrangements are not valid. Unused

connection points (see Figure 19 and Figure 20, marked dark
grey) have to be closed by supplied rubber plugs.

2.1.7 Compressed air connection

If the SAB pressure regulator (see Figure 21) is used connect the compressed air
supply at the NTP/BSP/G1/4A fitting. Do always connect OMD to engine's control air
system, pressure range 2 - 15bar. A dry and clean air with low humidity/oil
contamination is of high importance.

Fine pressure
regulator Throttle block

Air inlet

Air outlet
Air flow Air filter

Figure 21: Pressure regulator unit

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
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2.2 Electrical installation

2.2.1 VISATRON® series VN87plus device

The electrical terminal is inside the socket housing (see Figure 22) on the base
plate of the VISATRON® device. The pin assignment is specified in Figure 25. The
cable entry points are located on either side.

Fixing screws
of terminal
board

Cable entry
Cable entry

Figure 22: Socket housing

According to the pin assignment of Figure 25 connect the VISATRON® device to the
24 Volts power supply. The supply voltage can be potential free or not. The earth
connection between the OMD and the engine is carried out by the fixings screw of
the base plate or protection cover.

Additionally connect one alarm relay output to the safety system of the engine. As
specified by the classification societies the 'Alarm' relay must be connected either to
the shutdown or to the slow-down input.

During normal operation the alarm relay is switched off. In case of an oil mist alarm
the relay is switched on. To monitor this output, a wire break resistor is installed
(between pin 7 and 8 and between 15 and 16 as shown in Figure 25).

To replace the wire break resistors the measuring head has to be dismounted. The
resistors (see Figure 24) are located on the rear side under the plastic cover (see
Figure 23). The plastic cover can be removed via the screws. Do not forget to write
the resistor value on the plastic cover with a permanent marker.

Also placed on the rear side two jumpers are available to select the interface mode:
RS485 bus or 4- 20mA output of the relative opacity at pin 11 and 13.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 25

Plastic cover

Jumper to select the

RS485 interface or
Fixing screws of the 4 -20 mA output
plastic cover

Current values
of wire break
resistors

Security seal

Figure 23: Rear side of measuring head

Second 'Alarm' output and 'Ready' output must be connected to separate channels
on YHVVHO¶VRUSRZHUSODQW¶Valarm monitoring system. The 'Ready' relay is switched
on when OMD is in correct operation (see Figure 25).

Wire break resistors

Figure 24: Wire break resistors

The optional pre-alarm output can be used to initiate either a pre-warning signal or
slow-down signal. The pre-alarm relay is switched on when the oil mist
concentration has risen up to 70% of the Oil Mist alarm level. Please note that
depending on the characteristics of an oil mist occurrence, the time between 'Pre-
alarm' and 'Main Alarm' could be only a fraction of a second.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
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Shown is non-operated relay condition

Description Pin Description
24 Volts DC + 1 9 'Pre-alarm' relay
24 Volts DC GND 2 10 'Pre-alarm' relay
'Ready' relay closed 3 11 RS485 B (opt. 4 - 20 mA -)
'Ready' relay open 4 12 Reserved, do not use
'Ready' relay common 5 13 RS485 A (opt. 4 - 20 mA +)
'Alarm' 1 relay closed 6 14 'Alarm' 2 relay closed
'Alarm' 1 relay open 7 15 'Alarm' 2 relay open
'Alarm' 1 relay common 8 16 'Alarm' 2 relay common

Figure 25: Pin assignment

- We recommend to connect 'Alarm' 1 to the alarm system and 'Alarm' 2 to

the safety system.
- Alarms 1 and 2 are getting switched simultaneously by same relay.
- The relay outputs are potential-free.
- In case of a High Oil Mist Alarm, contacts 7 and 8 as well as 15 and 16
are closing
- ,QFDVHGHWHFWRUJRHVLQWRµ5($'<¶-Mode, contacts 4 and 5 are closing
- In case Pre-Alarm is activated, contacts 9 and 10 are opening. Pre-Alarm
will be switched as soon as 70% of High Oil Mist Alarm level is reached.

Power supply 18 ± 31.2 Volts DC, max. 2 A

Nominal voltage 24 Volts DC
Relay Outputs Max. 60 Volts DC, 1 A
Internal fuse 2 A semi time lag

Table 1: Electrical specification

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
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2.2.2 Connection of monitoring devices

As required by IACS UR M10 the OMD device can be connected to Schaller's remote
monitoring devices Remote Indicator II to monitor the oil mist concentration and
the OMD status from a safe location.

The connection to the monitoring devices is accomplished via a RS485 two-wire

bus. In case of a Remote Indicator II the connection is only a two point link. The
bus system at the OMD device must be terminated by the resistor. It is integrated
in the terminator (see Figure 26), which is supplied with the monitoring device.

The used communication cable must be twisted pair and shielded. We recommend
LAPPKABEL UNITRONIC-FD CP (TP) plus UL-CSA, AWG20. The total bus length is
limited to 400 m. The VISATRON® device cable entry (see Figure 26) at the
VISATRON® device is designed for cable diameter between 7.5 and 10.0 mm.

Figure 26: Cable entry and bus-terminator on the bottom side of the VISATRON®
device

The connection between the OMD device and the monitoring device for standard
applications is shown in the following wiring diagram (see Figure 27)

WARNING! The shield must be connected directly at the

cable grommet.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
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Operation Manual VISATRON® series VN87plus 01/2013
Page 28

Monitoring device

Terminator

13 11 2 1

ł ł ł ł

Figure 27: Wiring diagram to connect Remote Indicator II

The monitoring device is the bus master and the OMD devices are the slaves. It's
necessary to adjust different bus addresses at each slave device. Normally the first
OMD device gets the address '1' and so on. The switch is on the rear side of the
measuring head (see Figure 28).

Address switch

Figure 28: Bus address switch at the rear side of the measuring head

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
 Operation Manual VISATRON® series VN87plus 01/2013
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2.2.3 Schematic electrical wiring diagram

Engine room

VN87plus

Ready and alarm signals

Engine control room

Engine safety system

Optional 4 ± 20 mA
link

RS485 2-wire-bus

Remote Indicator II

Alarm monitoring system

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 30

3 Commissioning

CAUTION! Unplug the OMD during welding processes

on the engine.

3.1 Adjusting or checking the suction pressure

The suction pressure must be set by adjusting the pressure regulator when the
engine is at standstill. Make sure ventilation of the engine room is in operation.

No need to touch
Setscrew throttle-block for
pressure setting.
Pressure setting
Counter-nut by setscrew on
left side only!

Figure 29: Pressure regulator unit

WARNING! Adjust 60 mm WC negative pressure.

After adjustment, remove U-tube pressure gauge and screw
in the previously removed plug.

CAUTION! A pressure setting much higher than 60 mm WC

negative pressure may cause a change in detecting
sensitivity and can impact the functionality of the siphon
blocks.

x Connect a U-tube manometer at inspection cover (see Figure 30).

(U-tube manometer is included in the service box, available as an option).
x Switch on compressed air supply with inlet pressure in a range from 2 to 15
bar (before connecting the OMD the first time check the pressure).
x If the negative suction pressure is already adjusted to 60 mm WC within a
tolerance of ±5 mm remove the U-tube manometer and finish the procedure.
x Otherwise loosen counter-nut.
x Turn setscrew until the negative pressure is only 60 mm WC.
x Tighten counter-nut.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
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Operation Manual VISATRON® series VN87plus 01/2013
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Figure 30: U-tube manometer connected to OMD control cover

x Remove U-tube manometer

3.2 Filling of siphon blocks VN280plus of VN215/87plus system with oil

x Press the pump lever of the filling pump (see Figure 32) as many times until
first oil drops come out.
x Unscrew the lower siphon block plug (see Figure 31).
x Insert filling pump nozzle.

Siphon block for 5

connecting tubes.

Open filling screw to There are blocks also

push in pump nozzle for 4, 3, 2 and 1
connecting tubes

Figure 31: Siphon block VN280plus for 5 connecting tubes (5 holes on its side)

pump nozzle

Figure 32: Filling pump

x Press the black nipple into the block¶VORZHUVFUHZKROHVHHFigure 32).

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
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Operation Manual VISATRON® series VN87plus 01/2013
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x Pumps nozzle is equipped with 5 marks for max. 5-hole siphon block
x Push in the nozzle to the first mark next to the nozzles tip (see Figure 33).

First mark

Further
Marks on
Pump
nozzle

Figure 33: Marks on the nozzle

x Fill in 12 pump strokes, then push in the nozzle ca. 10mm to the next mark
and repeat filling in oil with 12 pump strokes
x Repeat procedure at all marks until the nozzle reaches stop at the rear plate.
At a siphon for 5 connecting tubes you will reach stop at 5th mark, at siphons
for e.g. 2 connecting tubes, stop will come after 2nd mark, etc.

CAUTION! Do not fill with more than 12 strokes per

siphon. The excess oil may flow in the suction tubes.
Additionally the excess oil can remove the required oil in the
siphon by a physical suction effect through the draining
channel.

The number n of internal siphons is equal to the number of

pipe connections. This means, that the pump has to be used
n times at varying positions.

x Close the threaded hole with the plug (a small amount of oil coming out does
not impact the functionality).
x Clean the outer siphon block.
x Continue with the next block.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
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3.3 Filling of siphon blocks VN180 for VN115/87plus and VN116/87plus

system with oil

x Press the pump lever of the filling pump (see Figure 35) as many times until
first oil drops are coming out.
x Unscrew the lower siphon block plug (see Figure 34).
x Insert filling pump nozzle (see Figure 36).

Oil input

Figure 34: Siphon block VN180

Fitting

Lock nut

Figure 35: Filling pump

x Screw in the fitting of the filling pump.

x Press the nozzle to stop position.
x Tighten the lock nut.
x Fill the siphon with 8 strokes.

CAUTION! Do not fill with more than 8 strokes. The excess

oil may flow in the suction tubes. Additionally the excess oil
can remove the required oil in the siphon by a physical
suction effect through the draining channel.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
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Figure 36: Filling pump inserted and fixed in the siphon block

x Remove the filling pump.

x Close the threaded hole with the plug (a small amount oil coming out does
not impact the functionality.
x Clean the siphon block.
x Continue with the next block.

3.4 Filling of pipe siphons for VN115/87plus and VN116/87plus system

with oil

Fitting to
flexible hose
and oil input

Figure 37: Pipe siphon

x Remove flexible hose

x Fill in 70ml lubrication oil
x Fix flexible hose again

CAUTION! Do not fill in more than 70ml; the excess oil can
remove the required oil in the siphon by a physical suction
effect through the draining channel.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 35

3.5 Adjusting the sensitivity of the OMD

The detector determines the oil mist concentration by an optical measurement. The
calculated values have the unit 'opacity'. 100% opacity means that no light is
transmitted through the oil mist sample. This is equivalent to a complete white
wall.
The LEL (Lower Explosion Level) is equal to 47mg/l oil mist concentration in air at a
temperature of 25 °C. IACS UR M67 rules do request that OMD¶V do indicate an oil
mist alarm latest at approx. 2.5mg/l. The lesser sensitivity level of all VN/87plus
20'¶VOHYHOVWLOOHQVXUHVDQ2LO0LVt Alarm at oil mist concentrations inside the
engine of <2.5mg/l. This complies fully with the requirements given by the IACS
UR M67.

Position Relative VN115 alarm Relative VN116/VN215 alarm

level in opacity level in opacity

3 1.5% 1.6%
4 2.0% 2.4%
5 3.0% 3.7%
6 5.0% 5.5%

Table 2: Sensitivity switch position and corresponding oil mist alarm level

CAUTION! Standard switch position 3 or 4 normally is

sufficient for all sorts of engines. In case, sensitivity level
needs to get switched to 5 or 6 (less sensitive), it is
mandatory that person changing it does inform Schaller
Automation about that in writing: [email protected].

The sensitivity of the VISATRON® oil mist detector can be adjusted by a switch on
the rear side of the measuring head (see Figure 38).

Sensitivity
Switch

Figure 38: Sensitivity switch at rear side of measuring head

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
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3.6 Commissioning check list

Mechanical check
Are all suction pipes installed as specified in the installation Ŀ\HVĿQR
drawing?
Are all fittings fastened and tight? Ŀ\HVĿQR
On VN215/87plus installation: Is the arrangement of the pipes Ŀ\HVĿQR
at the valve box correct?
On VN215/87plus installation: Are all un-used openings at the Ŀ\HVĿ no
valve box closed?
On installations with siphon blocks: Are all siphon blocks filled Ŀ\HVĿQR
with oil and all un-used openings closed?
On installations with pipe siphon: Are all siphons filled with oil? Ŀ\HVĿQR
On installations with oil separator: Is the separator filled with Ŀ\HVĿQR
oil?
Is the negative pressure at the measuring head adjusted to 60 Ŀ \HVĿQR
mmWC?
Adjusted negative pressure mmWC

Electrical check
Is the power supply connected to the terminal and is the Ŀ \HVĿQR
voltage within the specified range?
Measured supply voltage Volts
Is the monitoring device installed? Ŀ \HVĿQR
Are the µAlarm¶ and µReady¶ signals connected to the engine Ŀ \HVĿQR
control and safety system?
Are the correct wire break resistors installed Ŀ\HVĿQR
Value of wire break resistor kOhm
Is the correct interface mode at pin 11 and 13 selected? Ŀ\HVĿQR

Functional check
On vessels perform the on-board test with test plate. Test Ŀ\HVĿQR
positive?
At engine factory perform smoke test. Test positive? Ŀ\HVĿQR
On VN115/87plus installations, as an alternative to the smoke Ŀ\HVĿQR
test, measure the negative pressure at the end of the suction
pipes. Values as specified?

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 37

4 Operating instructions

4.1 Display

After power-on LED 1 is blinking for 30 seconds. The device will show the following
display.

Error
Code

Oil Mist 14
13
Alarm
12
11
10
..9
..8
Test ..7
..6
..5
..4
..3
Ready ..2
1
Opacity

VN 1 15 / 87 plu s
SN 50 0 70 0 91 2 3

Figure 39: Normal display mode

In case of a high oil mist concentration the LED bar goes up and at 70 % opacity
compared to the adjusted alarm level the 'Oil-Mist Alarm' LED switches on. At
100% opacity, compared to the alarm level, the 'Oil-Mist Alarm' LED starts blinking.
If the opacity later goes down, later the alarm condition will be stored.

Error
Code

Oil Mist 14
13
Alarm 12
11
10
..9
Blinking ..8
Test ..7
..6
..5
..4
..3
Ready ..2
1
Opacity

VN 1 15 / 87 plu s
SN 50 0 70 0 91 2 3

Figure 40: Example of an oil mist alarm state

The opacity is shown in the right LED bar. If highest LED is switched on the opacity
has reached / exceeds the Oil Mist Alarm level.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
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Error Blinking
Code

Oil Mist 14
13
Alarm 12
11
10
..9
..8
Test ..7
..6
..5
..4
..3
LED off Ready ..2
1
Opacity

VN 1 15 / 87 plu s
SN 50 0 70 0 91 2 3

Figure 41: Device not ready, example of 'Negative pressure too low'

If a device internal error or a system failure occurs the diagnostics system shows
the failure condition by a blinking LED on the LED bar. The error codes are shown in
Table 3. A detected oil mist alarm is displayed at this time with the 'Test' LED. In
this case the alarm relay or shutdown relay is not switched on.

Blinking LED on display Series VN87plus device failures

14 Negative pressure/airflow too low
13 Optical sensor dirty
12 Voltage of internal battery too low
11 Ambient temperature too low (<0°C)
10 Ambient temperature too high (>70°C)
9 Electronics temperature too low (<0°C)
8 Electronics temperature too high (>75°C)
7 Reset button defective
6 Supply voltage too high
5 Switch for adjusting sensitivity defective
4 Optical sensor defective
3 Airflow-sensor defective
2 Electronic module defective
1 Blinking: Startup phase

Table 3: Error codes

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 39

4.2 Reset of Oil Mist Alarms

CAUTION!
Ensure that the oil mist concentration inside the
engine has fallen under the Lower Explosion Level
(LEL) before acknowledging an oil mist alarm by
pressing the Oil-Mist-Alarm button. Otherwise you risk
an oil mist explosion!

Follow the instructions of engine builder, ship yard

and ship owner!

Use a monitoring device at a safe location (e.g. ECR)

to check for the actual oil mist concentration. At an Oil
Mist Alarm, Schaller Automation strongly recommends
to approach the engine only after indicated oil mist
concentration (LED chain) has lowered to half of its
bar indication (VISATRON®-device and Remote
Indicator II).

The alarm condition can be reset only by pressing the Oil-Mist-Alarm RESET button.

Figure 42: Oil-Mist-Alarm RESET button

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 40

5 Troubleshooting

Error Description remedy Chapter

14 Negative pressure / 1. Adjust suction pressure 3.1 page 30
airflow too low 2. Exchange air filters 5.3 page 42
3. Clean fresh air bores 5.1 page 41
4. Check suction system
5. Exchange bellows 5.6 page 45
6. Exchange measuring head 5.5 page 43
13 Optical sensor dirty 1. Clean infrared filter 5.2 page 41
12 Voltage of internal 1. Exchange measuring head 5.5 page 43
battery too low
11 Ambient temperature too 1. Remove ambient cooling
low (<0°C) components
10 Ambient temperature too 1. Remove or turn away ambient
high (>70°C) heating components
2. Install metal heat shields
against radiation
9 Electronics temperature 1. Remove ambient cooling
too low (<0°C) components
8 Electronics temperature 1. Remove or turn away ambient
too high (>75°C) heating components
2. Install metal heat shields
against radiation
7 Reset button defective 1. Eliminate blocking
2. Exchange Measuring head 5.5 page 43
6 Supply voltage too high 1. Measure supply voltage
2. Exchange measuring head 5.5 page 43
5 Switch for adjusting 1. Exchange measuring head 5.5 page 43
sensitivity defective
4 Optical sensor defective 1. Clean infrared filter 5.2 page 41
2. Exchange measuring head 5.5 page 43
3 Airflow-sensor defective 1. Exchange measuring head 5.5 page 43
2 Electronic module 1. Exchange measuring head 5.5 page 43
defective
All LED off 1. Measure supply voltage
2. Activate Self-repair of
Polyfuse 5.7 page 40
3. Replace measuring head fuse 5.7 page 40
4. Check for earth fault problem 5.8 page 48
5. Exchange measuring head 5.5 page 43

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 41

5.1 Clean fresh air bores

Fresh air bore

Needle of right
chamber

Figure 43: Cleaning of fresh air bore in the left and the right chambers

5.2 Clean infrared (IR-) filter

CAUTION! Dirty IR-filter glass may cause a loss of sensitivity

of the device. Clean filters acc. maintenance plan (page 50)

Cleaning
fluid

IR-
filter Cotton
glass stick

Figure 44: Cleaning of IR-Filter glass in the left and the right chamber

WARNING! Use only cleaning fluids for optical components as

delivered in the service box.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 42

5.3 Exchange air filters in the measuring head

Circlip
pliers for
Seeger
rings
Fresh air
filters

Figure 45: Exchange of the air filters

WARNING! Do not try to clean the filters, use always new

ones.

5.4 Exchange air filter in pressure regulator unit

Lock screw

Figure 46: The air filter is behind the lock screw of the throttle block

WARNING! Switch off the compressed air supply during the

maintenance work. After the exchange re-check the negative
suction pressure.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 43

5.5 Exchange measuring head

Scavenging air
fitting

Figure 47: Step 1 is to open the scavenging air fitting

Additionally on
VN116 and VN215
Measuring head units:
main connector Valve box connector

Figure 48: Step 2 is to unplug the connectors

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 44

Fixing
screws

Figure 49: Step 3 is to unscrew the measuring head

To mount the new measuring head execute the 3 steps in reverse order.

WARNING! Check the values of the wire break resistors or in

case of doubt use the old ones.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 45

5.6 Exchange bellows and suspension-system

Step 1 is to dismount the measuring head.

Rubber gasket

Figure 50: Step 2 is to press out the 4 rubber gaskets with a blunt tool and
finally to remove the carrier plate

Upper spring/
insulation-
system

Figure 51: Step 3 is to exchange the suspension-system if necessary

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 46

Upper bellow
of the suction
channel

Fixing screws

Figure 52: Step 4 is to exchange the 2 bellows if necessary. The bellow is

secured by a ring which is fixed by two screws.

Dismounted
rubber sealing
before start of
assembly

Figure 53 Step 5 is to pull out the gaskets before the carrier plate is mounted

To finish the assembly execute the first 2 steps in reverse order.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 47

5.7 Measuring head fuses

Fuse II

Figure 54 Fuse on the rear side of the measuring head

The device has two internal fuses. The first is located in the main connector of the
measuring head. This LVDµVHOI-UHSDLULQJ¶IXVHZKLFKSURWHFWVWKHILOWHUFLUFXLWLQWKH
connector.

To reset this fuse, unplug the main connector and wait 5 minutes before you plug
it again.

WARNING! Unplug the main connector during the exchange

of the fuse.

,IDOO/('¶VUHPDLQoff exchange the 2A semi lag fuse II at the rear side of the
measuring head (see Figure 54).

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 48

5.8 Check for earth fault problem

Measure
Measure contact contact of Pin
of Pin No. 7 No. 8 against
against ground. ground.
If short circuit: If short circuit:
problem is outside problem is
the Oil Mist outside the Oil
Detector, maybe in Mist Detector,
cabling system maybe in
cabling system

Measure
resistance
between Pin
8 and plug
earthing pin.
If short
circuit:
Measure measuring
Measure resistance head has to
resistance between Pin be replaced
between Pin 7 & 8. Must
7 and plug be 33 kOhm
earthing pin. or due to
If short wire break
circuit: resistor
measuring
head has to
be replaced

Figure 55 isolation of earth fault problem

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 49

In case DOO/('¶VUHPDLQRIIGHVSLWHfuses are ok, perform check as shown in Figure

56. Often it happens during welding work around the engine or in engine room that
electrical current of high energy passes through detector and its electrical wiring.

As a result, possible bursts and peaks may cause damage inside the measuring
head. In that case, only a replacement of the measuring head helps.

WARNING!
Unplug the main connector during welding work around the
engine or in engine room!

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 50

6 Maintenance procedures

CAUTION! Maintenance work has to be done when engine is

stopped.

Quarterly or after 2000 operating hours, whatever comes first

1 Check negative pressure in the measuring head: See chapter 3.1
page 30
under 55 mmWC Æ adjust pressure
between 55 mmWC and 65 mmWC Æ okay
between 65 mmWC and 85 mmWC Æ adjust pressure
over 85 mmWC Æ check pressure regulator unit
2 Clean infrared filters in the measuring head See chapter 5.2
page 41
3 Clean fresh air bores in the measuring head See chapter 5.1
page 41
4 Exchange air filters in the measuring head See chapter 5.3
page 42
Half-yearly or after 4000 operating hours, whatever comes first
5 Perform quarterly maintenance procedure 1 - 4
6 Exchange air filter in pressure regulator unit See chapter 5.4
page 42
Yearly or after 8000 operating hours, whatever comes first
7 Perform half-yearly maintenance procedure 5 - 6
8 Clean suction system with compressed air. See chapter 3
ATTENTION, do not forget to refill siphons! page 31/32
9 Check the bellows and the suspension-system between
measuring head and base plate, check the scavenging
air outlet behind the control cover (see Figure 44) by
feeling the air stream to control scavenging air system
10 Perform functional test with test glass See chapter 7.1
page 51
Bi-yearly or after 16000 operating hours, whatever comes first
11 An inspection of the entire OMD installation onboard has to be executed by
service staff being trained and authorized for this job by Schaller Automation
12 Perform functional test of entire OMD system with See chapter 7.2
smoke Page 53
Additional every 5 years or 40000 operating hours, whatever comes first
13 Exchange suspension-system and bellows See chapter 5.6
page 45

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 51

7 Functional test

7.1 On board test

Attention: Before starting the on board test execute the

procedures as specified in the maintenance schedule. The
pipe system has to be clean and if used all siphons have to
be filled with oil (refer to chapter 2.1.3.)

Using the test plate set, included in this manual folder, you can easily test the
functionality of the VISATRON® oil mist detectors and their connection to the
safety system of the engine. The set can also be ordered separately under Part.-No.
270453. It consists of the following parts:

A B
x Test plate (A)
x Test glass (B)
x Working instruction

Attention: You will stop or slow down the engine.

Test procedure step by step:

Step 1 Open the latches of the OMD control cover

and flip the cover to the left side.

Step 2 Press the test plate onto the openings.

Ensure that the openings are completely
covered. Now the device starts to create the
negative suction pressure again.

Step 3 Wait for the 'Ready'-LED on the display.

Step 4 Insert the test glass into the slot of the test
plate. The glass simulates oil mist and
generates an oil mist alarm.

Step 5 Wait for the 'Alarm'-LED. At this comes on, the

engine has to stop or to enter the slow down

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 52

mode.
Step 6 Remove the test plate and put it together with
the test glass back into the bag.
Step 7 Close the control cover carefully.
Step 8 Wait for the 'Ready'-LED.
Step 9 Press the Oil-Mist-Alarm RESET button to
acknowledge the alarm state and enter the
normal monitoring mode.

If LED14 is blinking and the Oil-Mist-Alarm RESET button is

pressed the OMD device enters a test mode. In this test
mode the LED bar displays the measured opacity. After
pressing the Oil-Mist-Alarm RESET button again the OMD
device exits the test mode and LED14 is blinking again.

If applicable perform an additional pressure measurement to check the tightness of

the suction system as described in chapter 7.3. Instead of an electronic gauge you
can use the U-pipe manometer of the service box.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 53

7.2 Factory test at engine builder with smoke generator on

VN115/87plus and VN116/87plus installations

Both installation types can be verified by a smoke test. Due to vessels not normally
having the equipment and SCHALLER AUTOMATION recommends this procedure
only for the factory test by using the SCHALLER smoke generator (see Figure 56).
If a smoke generator is available on a vessel this test can be also performed,
however, in this case observe the following warning.

Attention: Before starting the on board test execute the

procedures as specified in the maintenance schedule. The
pipe system has to be clean and if used all siphons have to
be filled with oil refer to chapter 2.1.3.

A test of the entire OMD system (incl. tubing system) can be done only at standstill
of the engine. The crankcase service covers must be opened first. Put a small
amount of smoke fluid (see Chapter 'Accessories') into the reservoir and switch on
the generator for a few seconds until the storage tank is completely filled with
smoke. This is important so that the tank can provide sufficient smoke to complete
the search run of a VN116/87plus installation to determine the correct engine side.
The last step is to hold the flexible hose directly into the suction funnels until an oil
mist alarm is indicated.

Storage tank

Reservoir
Flexible hose

Figure 56: SCHALLER AUTOMATION smoke generator, see 'Accessories'

If it's not possible to open the service covers a functional test can be preformed
without testing the suction funnels.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 54

In this case the flexible hose has to be pressed over the opening under the lock
screws of the siphon blocks as seen in Figure 57 or has to be pressed over the open
header pipe end after removing the lock nut.

Lock screw

Figure 57: Test inlet on the siphon blocks VN180

Attention: In case of siphon block VN180 installation you

have to test all compartments and the additional suction
points at running engine.

7.3 Additional pressure measurement on VN115/87plus and

VN116/87plus installations

Perform the functional and smoke test as shown in the previous chapters 'On board
test' and µ)DFWRU\WHVWZLWKVPRNHJHQHUDWRU¶.

Adapter

17 mm nut

19 mm nut

Figure 58: Manometer (not scope of Figure 59: Manometer (not scope of
supply) connected to siphon supply) connected to
block VN180 header pipe

Then carry out a pressure measurement at the end of the suction system. The
engine including the oil pump must be at standstill.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 55

Attention: You will only measure correct values with engine

and lube oil pump at standstill.

On a VN115/87plus and VN116/87plus installation the tightness of the suction

system can be determined by a pressure measurement at the outer siphon blocks
or at the end of the header pipes.

This siphon block has an additional fitting for a manometer (see Figure 58). To
remove the 17 mm lock nut you have to counter the 19 mm nut with a jaw wrench.

The pressure measurement procedure can also performed at the end of the 22 mm
diameter suction pipes which are delivered from SCHALLER AUTOMATION. These
pipes have also fittings for the manometer at the pipe end (see Figure 59).

Use only a digital manometer with a differential measuring method. On completion

do not forget to lock all openings.

The minimal negative pressure values are defined in Table 4. They are only valid if
a negative pressure of 60 mm WC is adjusted at the measuring head.

VN115/87plus >6.5 mmWC

VN116/87plus, VN215/87plus >1.5 mmWC

Table 4: Minimal pressure values at the end left and right of the suction tubing
system

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 56

7.4 Factory test at engine builder with fog machine on all installations

This test includes the indication of an oil mist alarm as well as the indication of the
affected compartment. Instead of the above mentioned smoke generator you have
to use the more powerful fog machine (see Figure 60) with a fog bag with adapter
(see Figure ).

Figure 60: optional Fog machine Figure 61: optional Fog bag adapter

This equipment guarantees a constant fog concentration during the test and due to
high density no influence of the additionally sucked in crankcase atmosphere.

Due to the increasing request of the ship owners and classification societies to test
the OMD-system at running engines SCHALLER AUTOMATION recommends now
following procedure.

The first test must be performed at standstill to secure, that the engine is well
protected by the OMD system. If it is not possible to open the service covers or if it
is not possible to access the suction funnels, e.g. on large 2-stroke engines, a
functional test can be preformed alternatively using a special connection on the
siphon block or respectively on the T-engine wall connection.

Fill the fog bag completely with fog and close the adapter with the yellow cap. The
next step is to press the flexible hose of the fog bag adapter over the opened plug
at the side of the siphon blocks as seen in Figure 62 or over the open tube end at
T-engine wall connections. Do not remove the hose until an oil mist alarm is
indicated and the search run to indicate the affected compartment is finished. The
plugs can be countered by an 11 mm jaw wrench to open or close the lock screw.

Attention: Let in fog at sampling points of all compartments

including chain/gear drive.

The second test can be performed on request at running engine using the plugs of
the siphon block or the T-engine-wall connection to induce the fog.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 57

Lock screws

Figure 62: Test fog inlet on the siphon blocks

A wrong compartment indication (VN215/87plus) can be

caused either by:
x Empty fog bag: Æ Repeat the test with a full bag or
x Empty siphon block Æ Drain all siphon blocks of the
affected side completely by opening the 4 screws on
the front side and refill the siphons again

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 58

8 Optional Spare Parts and Accessories

Part-No. Part-No. Description Quantity

new old per OMD
150993 11079 Service box 1
11651 11651 Measuring head VN115/87plus; 33k; RS485; 1
sensitivity level 4 *
11751 11751 Measuring head VN116/87plus; 33k; RS485; 1
sensitivity level 4 *
10851 10851 Measuring head VN215/87plus; 33k; RS485; 1
sensitivity level 4 *
270399 10727 Control cover measuring head series VN87plus 1
devices
11752 11752 Valve box VN116/87plus 1
10852 10852 Valve box VN215/87plus 1
365206 10002 Air filter for pressure regulator unit 1
365197 10042 Scavenging air filter (10 pcs.) 2
270090 10035 Bottle with cleaning fluid 1
190003 10135 Cleaning needle 1
452176 10036 Cotton buds to clean IR-filters (min. 10 pcs.) 1
200548 10046 U-pipe manometer 1
270502 Manometer adapter for siphon block VN180 1
270089 10040 Bottle with slacked water 1
270493 10053 Manometer adapter for control cover 1
330721 10405 Gasket for valve box 1
360132 10406 Sealing for oil draining in valve box 1
360133 10407 Sealing for suction channel in valve box 1
310526 10087 Fuse cap 1
436551 10973 Semi lag fuses 3.15A (10 pcs.) 1
350001 10409 Clamp plate VN215 valve box connection 2
365193 10023 Bellow of suction Channel 2
365198 10041 Circlip for scavenging air filter (10 pcs.) 2
360079 10411 Rubber insert for valve box pipe connection 2
VN215
360194 10412 Rubber plugs for unused valve box 3
connections
200175 11004 Main connector socket 1
270303 10726 Scavenging air hose 1

Table 5: Optional Spare parts

* Other versions are also available on enquiry.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 59

Part-No. new Part-No. old Description

150993 11079 Service box series VN87plus
151055 11000 Commissioning box series VN87plus
180062 11078 Manual DVD series VN87plus
151072 10001 Pressure regulator unit with input throttle
270888 10753 Protection cover
150938 11163 Oil separator for air outlet
150939 11164 Pipe siphon
150929 10140 Siphon block VN280 1 connection
150931 10142 Siphon block VN280 2 connection
150932 10143 Siphon block VN280 3 connection
150933 10144 Siphon block VN280 4 connection
150934 10145 Siphon block VN280 5 connection
150930 10141 Siphon block VN280 1 connection with manometer fitting
271544 10160 Mounting plate VN280
270409 11062 Oil pump VN280
340115 10091 Blind plug VN280
150260 10013 Siphon block VN180
150166 10612 Siphon block VN180 with manometer fitting
270504 10089 Mounting plate VN180
270371 10062 Oil pump VN180
340375 10640 Blind plug VN180
150740 10353 Smoke generator, 230 Volts
151067 11089 Smoke generator, 110 Volts
451209 10097 Smoke fluid
151167 11049 Fog machine complete
450137 11052 Fog fluid
270453 11072 Test-plate kit
150998 11506 Monitoring device Remote Indicator II
230140 11503 Bus-cable 10m for monitoring devices
Depends on Suction funnel
engine type
Depends on Engine wall connection
engine type

Table 6: Optional Accessories

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 60

Figure 63: Optional Service box 150993

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 61

Item Description Quantity For spares

01 Hex key 5 mm L-shape 1 See table 5
02 Fuse 2A semi time lag 10 See table 5
03 Scavenging air filters 6 See table 5
04 Seeger circlip rings 4 See table 5
05 Rubber plugs for unused valve box 3 See table 5
connections
06 Sealing for oil draining valve box 1 See table 5
07 Screwdriver 3 mm 1 See table 5
08 Bellow of suction channel 2 See table 5
09 Sealing for suction channel in valve box 2 See table 5
10 Bottle with slacked water 1 See table 5
11 Bottle with cleaning fluid 1 See table 5
12 Sealing for oil draining in connection box 1 See table 5
VN115
13 Clamp plate VN215 valve box connection 2 See table 5
14 Suspension elements bottom 2 See table 5
15 Suspension elements top 2 See table 5
16 Air filter for pressure regulator unit 1 See table 5
17 Manual series VN87plus in English 1 See table 5
18 U-pipe manometer 1 See table 5
19 Philips screwdriver 1 See table 5
20 Screwdriver 4 mm 1 See table 5
21 Hex key 4 mm with handle bar 1 See table 5
22 Hex key 6 mm L-shape 1 See table 5
23 Double jaw wrench 14/17 mm 1 See table 5
24 Gasket for valve box 1 See table 5
25 Manometer adapter for siphon block 1 See table 5
VN180
26 Rubber plate for VN215 valve box 2 See table 5
connection
27 Circlip pliers for Seeger rings 1 See table 5
28 Cotton buds to clean IR-filters 5 See table 5
29 Cleaning needle 1 See table 5
30 Manometer adapter for control cover 1 See table 5
31 7mm combination wrench 1 See table 5

Table 7: Contents of optional service box series VN87plus 150993

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 62

Figure 64: Optional Commissioning box 151055

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 63

Item Description Quantity For Spares

01 Test glass and test plate 1 See table 5
02 Working instruction 1 See table 5
03 Manometer adapter for control cover 1 See table 5
04 Manual CD 1 See table 5
05 Air filter for pressure regulator unit 2 See table 5
06 Seeger circlip rings 2 See table 5
07 Fresh air filters 6 See table 5
08 Cotton buds to clean IR-filters 5 See table 5
09 Cleaning needle 1 See table 5
10 U-pipe manometer 1 See table 5
11 Bottle with slacked water 1 See table 5
12 Bottle with cleaning fluid 1 See table 5

Table 8: Contents of optional commissioning box series VN87plus 151055

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
 Operation Manual VISATRON® series VN87plus 01/2013
Page 64

Driving Air Conditioning (Part No. 272213)

VISATRON VN/87plus

x For longer lasting air filter VISATRON Oil Mist Detection In case of a non-optimal driving
lifetime systems of VN/87plus series are air quality to the oil mist
known as being reliable and detector, this kit may help you
x Longer TBO
trustworthy safety systems to getting rid of failing OMD
x Makes independ of onboard measuring heads, being
protect your engine from
air quality crankcase explosions. indicated eg. by failure LED No.
x Easy retrofit 14, negative pressure/airflow to
As an Option: Nevertheless, in order to reduce low.
x Automatic de-oiling/-watering maintenance cost and to ensure a It helps you also avoiding
maximum availability time, some trouble with clogged air filters
upgrade kits are available. in measuring head and
pressure reducer.

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 65

9 Technical data

Mechanical data
Dimensions See drawings (Figure to Figure )
Weight VN115/87plus 7.5 kg
VN116/87plus 9.4 kg
VN215/87plus 9.6 kg
Display LED-bar with 14 LED's
1 green Ready LED
1 red High Oil Mist Alarm LED
1 red Test LED
Suction pipes VN115/87plus ø 22 x 2 x max. 9m
VN116/87plus ø 22 x 2 x max. 9m
VN215/87plus ø 14 x 2 x max. 9m
Pipe connections VN115/87plus 2 x G3/4
VN116/87plus 2 x G1/2 or G3/4
VN215/87plus 10 x ø 14
Venturi injector connections In NTP/BSP/G1/2A
Out NTP/BSP/G3/4A
Pressure reducer connections In NTP/BSP/G1/4A
Out NTP/BSP/G1/4A
Air pressure Pressure reducer inlet 2 ± 15 bar
Air jet pump inlet max. 500 mbar
Negative pressure in measuring head - 60 mm WC or ± 6 mbar
Air consumption Depends on the suction system (max.
2,5 m3/h)
Electrical data
Power supply 18 Volts ± 31.2 Volts DC, max. 2A
Nominal voltage 24 Volts DC
Relay Outputs 2 x 'High Oil Mist Alarm'
1 x 'Ready'
1 x 'Oil Mist Pre-Alarm'
(max. 60 Volts DC, 1A)
Cable entry 2 x M25
Communication interface to monitoring 2 wire RS485, galvanically isolated
device (opt. 4-20 mA, galvanically isolated)

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 66

Communication cable recommendation LAPPKABEL UNITRONIC-FD CP (TP) plus

UL-CSA, 2 x 2 x AWG20, max 400 m
length, 7.5-10.0mm Ø
Environmental conditions
Operating temperature 0 - +70 °C
Storage temperature -25 ± +80 °C
Max. vibrations 4 g (25-100Hz)
Relative humidity up to 95%
Protection class IP54
Approval of classes
Type approved for closed areas,
designed for installation on combustion
engines, environmental category D (GL),
IACS UR M67 conform, list of type
approvals see www.schaller.de

Table 9: Technical data

Figure 65: Mechanical dimensions of VN115/87plus: side view

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 67

Figure 66: Mechanical dimensions of VN115/87plus: top view

Figure 67: Mechanical dimensions of VN116/87plus: side view

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 68

Figure 68: Mechanical dimensions of VN116/87plus: top view

Figure 69: Mechanical dimensions of VN215/87plus: side view

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 69

Figure 70: Mechanical dimensions of VN215/87plus: top view

Figure 71: Drilling template of the OMD base plate

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
Operation Manual VISATRON® series VN87plus 01/2013
Page 70

10 Service Partners

Schaller Automation maintains a worldwide network of service partners in following

countries:

Australia
Brazil
Canada
Chile
China
Denmark
Germany
Greece
Italy
Japan
Korea
Netherlands
Norway
Poland
Singapore
Spain
Taiwan
Turkey
United Arabian Emirates
United Kingdom
United States of America

For an up-to-date list of our representatives including address and contact details
please visit our website:

www.schaller.de

or call our technical support centre at the German headquarter:

Tel. +49 6842 508 0

SCHALLER AUTOMATION D-66440 Blieskastel / Saarland / Germany / Industriering 14 / P.O Box 1280
Industrielle Automationstechnik GmbH & Co. KG Tel. +49(0)6842-508-0 / Fax -260 / eMail: [email protected] / www.schaller.de
 Flange - Coupling - RATO C5.05.12.13.06.30
(Vulkan)

M25

Flange - Coupling - RATO

(Vulkan)

en / 21.01.2014 FD049647 1/92

Operating Manual
VULKAN RATO R

Customer: Caterpillar Motoren GmbH & Co. KG

Contract number.: Ktr. 271 283

Consignment number.: 311303508

Drawing number: 1G2620R127

Part list: 1G262TR127-C

Read the operating instructions before starting work!

 VULKAN Kupplungs- und Getriebebau
Bernhard Hackforth GmbH & Co. KG
©
Heerstrasse 66
44653 Herne

Tel.: +49 (0) 2325 / 922-0

Fax.: +49 (0) 2325 / 711 10

E-mail: [email protected]
Internet: www.vulkan.com

0000000859
001
3.9.13

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Operating Manual VULKAN RATO R

Table of contents

Table of contents

1 General

1.1 Information about the operating manual............................................... 6

1.2 Explanation of symbols ........................................................................ 6
1.3 Limitation of liability .............................................................................. 7
1.4 Copyright .............................................................................................. 7
1.5 Spare parts........................................................................................... 8
1.6 Limitation of liability .............................................................................. 8
1.7 Customer service ................................................................................. 8

2 Safety

2.1 Responsibility of the owner .................................................................. 9

2.2 Personnel requirements ....................................................................... 10
2.3 Intended use ........................................................................................ 11
2.4 Personal protective equipment............................................................. 12
2.5 Special dangers.................................................................................... 13
2.6 Behaviour in the event of danger or accident....................................... 18
2.7 Environmental protection...................................................................... 18

3 Technical data

3.1 General information.............................................................................. 19

3.2 Coupling designation............................................................................ 19
3.3 Consignment number ........................................................................... 19

4 Structure and function

4.1 Mode of operation ................................................................................ 21

4.2 Structure of the coupling ...................................................................... 21
4.3 Identification ......................................................................................... 23

5 Transport, packaging, and storage

5.1 Safety instructions for transport............................................................ 24

5.2 Symbols on the packaging ................................................................... 24
5.3 Delivery status...................................................................................... 25
5.4 Transport inspection............................................................................. 25
5.5 Packaging ............................................................................................ 26
5.6 Preservation ......................................................................................... 27
5.6.1 Preservation with Metacorin ................................................................. 27

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Table of contents

5.6.2 Preservation of VCI .............................................................................. 31

5.6.3 Preservation with Rolimeco.................................................................. 33
5.6.4 Table Metacorin/VCI/Rolimeco............................................................. 34
5.7 Transport .............................................................................................. 35

6 Assembly

6.1 Safety assembly ................................................................................... 39

6.2 Installation of the coupling.................................................................... 41
6.2.1 Mount hub on the output side............................................................... 41
6.2.2 Mounting the membrane assembly ...................................................... 47
6.2.3 Alignment ............................................................................................. 48
6.2.4 Mounting the elastic part ...................................................................... 51
6.2.5 Concluding tasks and final inspection .................................................. 53

7 Faults

7.1 Safety faults ......................................................................................... 54

7.2 Fault table ............................................................................................ 55
7.3 Fault correction tasks ........................................................................... 57
7.4 Start-up after a corrected fault.............................................................. 58

8 Maintenance

8.1 Safety maintenance.............................................................................. 59

8.2 Maintenance schedule ......................................................................... 61
8.3 Maintenance tasks ............................................................................... 63
8.4 Tightening torques................................................................................ 69
8.5 Measures after successful maintenance .............................................. 69

9 Dismantling

9.1 Safety dismantling ................................................................................ 70

9.2 Dismantling sequence .......................................................................... 74
9.2.1 Dismounting the elastic part ................................................................. 74
9.2.2 Dismounting the diaphragm assembly ................................................. 75
9.2.3 Dismounting the hub on the driven side ............................................... 76
9.3 Disposal................................................................................................ 80

10 Appendix

10.1 Abbreviations of the technical data ...................................................... 81

10.1.1 Technical data ...................................................................................... 82

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Table of contents

10.2 Drawing ................................................................................................ 83

10.3 Parts list................................................................................................ 86
10.4 Delivery status...................................................................................... 89

11 Index

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Operating Manual VULKAN RATO R

1 General

1 General

1.1 Information about the operating manual

This assembly manual provides important instructions for handling the
VULKAN RATO R. The prerequisite for safe work is compliance with all
specified safety instructions and handling instructions.
In addition the applicable local accident prevention regulations and gen-
eral safety regulations must be complied with for the specific area of im-
plementation of the VULKAN RATO R.
The operating manual must be carefully read prior to starting any task!
The operating manual is a component of the product and must be kept in
the vicinity of the coupling where it is available to personnel at all times.
If the VULKAN RATO R is provided to a third party then this operating
manual must also be provided.
The illustrations in this manual are provided for better presentation of the
described material; these illustrations are not necessarily true to scale
and may deviate slightly from the actual version of the VULKAN RATO R.
The position numbers used in the illustrations and steps correspond to
the position numbers of the drawing in the Appendix.
This assembly manual corresponds to requirements of DIN 82079. It is
subject to an ongoing review process. Subject to changs and errors.

1.2 Explanation of symbols

Safety instructions are indicated by symbols in this operating manual.
The safety instructions are introduced by signal words that express the
scope of the hazard.
The safety instructions must be strictly complied with, you must act pru-
dently to prevent accidents, personal injury, and material damage.

CAUTION!

... indicates a possible dangerous situation that can result in minor injury
if it is not avoided.

WARNING!

... indicates a possible dangerous situation that can result in death or

serious injury if it is not avoided.

DANGER!

... indicates a directly dangerous situation that will result in death or seri-
ous injury if it is not avoided.

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1 General

Prohibitory!

Note!
i ... indicates useful tips and recommendations, as well as information for
efficient and trouble-free operation.

1.3 Limitation of liability

All information and instructions in this operating manual have been pro-
vided under due consideration of applicable guidelines, the current state
of technology, as well as our many years of experience.
The manufacturer assumes no liability for damage due to:

• Failure to comply with the instructions in the operating manual

• Non-intended use
• Deployment of untrained personnel
• Unauthorized conversions
• Technical changes
• Use of non-approved spare parts

The actual delivery condition can vary from the explanations and graphic
representations provided in this manual in the case of special versions, if
supplemental order options are desired, or on the basis of the latest tech-
nical changes. The agreed obligations in the delivery contract, the gener-
al terms and conditions, as well as delivery conditions of the
manufacturer, and the statutory regulations valid at the time the contract
was concluded, apply.

1.4 Copyright
Treat this operating manual with confidentiality. It has been exclusively
prepared for personnel working with the VULKAN RATO R coupling. Pro-
vision of the operating manual to third-parties without written consent
from the manufacturer is prohibited.

Note!
i The content, texts, drawings, graphics, and other presentations are pro-
tected by copyright and are subject to commercial property rights Any
improper use is punishable.

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1 General

Duplication in any form - including excerpts - as well as exploitation and/

or communication of the content are not permitted without a written dec-
laration of consent from the manufacturer. Actions to the contrary make
damage compensation mandatory. We reserve the right to enforce addi-
tional claims.

1.5 Spare parts

WARNING!

Incorrect or defective spare parts can cause damage, malfunction, or

total failure; they can also impair safety.
Therefore:
• Only use manufacturer's original spare parts.
Spare parts Order via authorized dealers or directly from VULKAN cus-
tomer service. See section "Customer service" for the contact address.
Specify the following information when ordering spare parts:

• Order number or consignment number

• Drawing number
• Parts list number

1.6 Limitation of liability

The warranty terms are included in the manufacturer's terms and condi-
tions.

1.7 Customer service

Our customer service organization is available for technical information.
The responsible contact is always available at the following contact ad-
dress:

Customer service:
VULKAN Kupplungs- und Getriebebau B. Hackforth GmbH & Co. KG
Heerstrasse 66
44653 Herne Germany
Tel.:+49 (0) 2325 / 922-0
Fax:+49 (0) 2325 / 711 10
Mobile: +49 (0) 178 / 8 922 179

In addition our employees are always interested in new information and

experiences associated with the application that could be valuable for the
improvement of our products.

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2 Safety

2 Safety

2.1 Responsibility of the owner

The VULKAN RATO R coupling is used in commercial operation. Conse-
quently the owner of the VULKAN RATO R coupling is subject to legal in-
dustrial safety obligations.
In addition to the industrial safety instructions in this operating manual,
generally valid safety and accident protection guidelines, and environ-
mental protection guidelines must be heeded and complied with for the
area of implementation of the VULKAN RATO R coupling.
The following particularly applies in this regard:

• The owner must inform himself of applicable occupational health and

safety regulations, and in a hazard analysis identify other hazards
that may exist at the installation site of the coupling due to the special
work conditions. The owner must convert this information relative to
hazards into operating instructions for operation of the coupling.
• The owner must ensure during the entire implementation period of
the coupling that the operating instructions created by the owner cor-
respond to the current state of legislation, and if necessary the owner
must adapt these operating instructions.
• The owner must clearly regulate and specify responsibilities for
installation, operation, maintenance, and cleaning.
• The owner must ensure that all employees who handle the coupling
have read and understood the operating manual. In addition, cus-
tomer must train personnel and inform personnel of the hazards at
regular intervals.
• The owner must attach a distance protection fixture in the form of a
coupling protector before commencing operation of the system.
• The owner must provide the required protective equipment for per-
sonnel.

Moreover the owner is responsible for ensuring that the coupling is al-
ways in technically faultless condition; consequently the following ap-
plies:

• The owner must ensure that the maintenance intervals described in

this operating manual are complied with.
• The owner must have all safety devices inspected regularly for func-
tion and for completeness.

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2 Safety

2.2 Personnel requirements

Qualifications

WARNING!

Danger of injury due to insufficient qualification!

Improper handling can cause serious injury or material damage.
Therefore:
• Only have activities performed by personnel who are qualified to per-
form these activities.
The following qualifications are cited in the operating manual for the vari-
ous activity areas.

• Instructed person is a person who has been instructed by the owner

relative to the tasks assigned to him and the possible dangers asso-
ciated with improper behaviour.
• Qualified personnel are personnel who, due to their qualified training,
skills, and experience, as well as knowledge of the applicable regula-
tions, are capable of executing the tasks assigned to them and of
recognizing possible hazards and avoiding them on their own.

Only persons from whom it can be expected that they reliably execute
their work are considered as personnel. Persons whose capability to re-
act is impaired, for instance through drugs, alcohol, or medication, are
not approved.

• Comply with age-specific and job-specific regulations that are appli-

cable at the installation site when selecting personnel.
Unauthorized persons

WARNING!

Danger for unauthorized persons!

Unauthorized persons who do not satisfy the requirements described
here are not aware of the hazards in the work area.
Therefore:
• Keep unauthorized persons away from the work area.
• If in doubt, speak to these persons and instruct them to leave the
work area.
• Interrupt work as long as unauthorized persons are in the work area.

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Operating Manual VULKAN RATO R

2 Safety

2.3 Intended use

The coupling is a highly elastic, all-round ductile coupling for use in ship
main drives, ship auxiliary drives, ship compressor drives, ship pump
drives, and ship blower drives. It has been especially developed for a par-
ticular application case and can only be used for a different application af-
ter consultation with the manufacturer.

WARNING!

Danger due to non-intended use!

Any use that extends beyond intended use and/or other use of the cou-
pling can cause hazardous situations.
Therefore:
• Only use the coupling as intended.
• Only place the coupling in service after complete assembly in accord-
ance with the instructions in this operating manual.
• Strictly comply with all instructions in this operating manual.
• Particularly refrain from the following uses of the coupling. They are
considered as non-intended use:
• Use outside of the originally intended application case.
• Overloading the coupling by exceeding the limit values specified in
the technical data.
• Use of a coupling that does not bear an Ex designation, and thus is
not designed for use in explosive atmospheres, in the Ex area.
Claims of any type due to damage arising from non-intended use are ex-
cluded.
The owner is solely liable for all damage in the case of non-intended use.

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Operating Manual VULKAN RATO R

2 Safety

2.4 Personal protective equipment

Wearing of personal protective equipment is required for work, to mini-
mize health hazards.

• When performing the task always wear the personal protective equip-
ment that is required for the task.
• Follow the instructions that have been posted in the work area.

Always wear the following during all tasks:

• Protective work clothing is tight-fitting work clothing with low resist-

ance to tearing, with tight sleeves, and without projecting parts. It is
primarily used to protect against entanglement by moving machine
parts. Do not wear rings, chains, or other jewellery.

• Hard hat to protect against falling and flying parts and materials.

• Safety footwear for protection against heavy falling parts and slipping
on slippery surfaces.

Special protective equipment is required when executing special tasks.

Special reference is made to this equipment in the specific sections of
this manual. This special protective equipment is explained below:

• Light respiratory protection for protection against harmful dusts.

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2 Safety

• Protective goggles to protect eyes from flying parts and liquid

splashes.

• Protective gloves to protect hands from friction, abrasion, puncture

wounds, or deeper injuries, as well as from contact with hot surfaces.

• Chemical-resistant protective gloves to protect hands from aggres-

sive substances. Check protective gloves for leaks prior to use.
Clean the gloves before pulling them off; store them in a well-venti-
lated location.

2.5 Special dangers

Residual risks that have been determined based on a risk assessment
are cited below.
Follow the safety instructions listed here and the warning instructions in
the other sections of this manual to reduce health hazards and to avoid
dangerous situations.

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2 Safety

WARNING!

Life-threatening hazard - High elastic forces!

The rubber elements and the membrane can accumulate extreme quanti-
ties of energy when they are deflected. Sudden loosening of obstructions
can cause high energy movements of coupling parts, and in the process
cause life-threatening injury.
Therefore:
• Prior to working on the coupling ensure that it is force-free and that
the resilient elements are not deflected.
• For tasks that require deflection of resilient elements only employ the
work methods described in this manual. Only use tools and clamping
devices that are designed for high forces.
• Only specialized personnel familiar with the installation should select
the thrust bearing required for deflection of the membrane assem-
blies.

WARNING!

Life-threatening hazard - High dead weight!

The coupling has an extremely high dead weight. A life-threatening haz-
ard due to crushing exists if the coupling rolls off or falls down.
Therefore:
• Always safeguard the coupling against rolling off.
• Carefully supervise the lifting processes and transport.
• Only use the transport methods described in the "Transport" section.
• Secure the coupling parts that will be loosened against falling, before
loosening any threaded joints.
• Physical lifting processes involving a reference weight in excess of
25 kg should only be executed with two persons.

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Operating Manual VULKAN RATO R

2 Safety

WARNING!

Life-threatening danger and danger of material damage due to incom-

plete or incorrect assembly!
If there is a mechanical failure of components and incomplete or incorrect
assembly, coupling parts can be thrown out at high speed due to rotation.
This poses a life-threatening hazard and danger of material damage.
Therefore:
• Only place the coupling in service after complete assembly in accord-
ance with the instructions in this operating manual.
• Only operate the coupling within the protective fixture described in
the "Assembly" section. This protective fixture must be installed by
the owner.
• After working on the coupling, ensure that all bolt connections are
firmly tightened in accordance with the specified tightening torques
(see drawing).

CAUTION!

There is a danger of stumbling due to fouling and loose objects!

Fouling and loose objects on the ground pose slipping and stumbling
hazards and can cause severe injuries.
Therefore:
• Always keep the work area clean.
• Remove objects that are not being used.
• Mark stumbling hazards clearly.
• Make provisions for good lighting.

CAUTION!

Material damage if configured incorrectly!

If the coupling is configured incorrectly then extremely high dynamic
forces can be transferred to the shafts and to the adjacent machine com-
ponents and they could be damaged.
Therefore:
• Prior to installation ensure that all characteristic values specified for
the application in the "Technical data" section are correct.
• Only use the coupling in the application for which the coupling is orig-
inally designed by the manufacturer.

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2 Safety

CAUTION!

Contact with Vulkan Coating LP poses a health hazard!

Due to its pH value the LP coating can cause irritation if there is repeated
or sustained skin contact.
Therefore:
• Comply with the instructions in the manufacturer's safety data sheet.
• Avoid spills and formation of mist.
• If ingested summon a physician immediately. Thoroughly rinse
mouth out with water.
• Avoid contact with skin and eyes:

When working wear chemical-resistant protective gloves and protec-

tive goggles with side protection.

After work wash thoroughly and use skin-care cream.

• After skin contact wash immediately with lots of water and soap.
• If there is eye contact rinse immediately and thoroughly with water.
Seek medical attention.
• If the substance splashes on clothing, immediately remove the
affected garments.
Remove contamination in the work area in a proper and environmen-
tally responsible manner.
Do not allow droplets to get into waterways.
• Do not eat, drink, or smoke when working with the substance.

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2 Safety

WARNING!

There is a fire hazard and explosion hazard posed by highly flammable

corrosion-protection fluid and fumes!
Liquid corrosion protection and its outgassing, when combined with air,
form an explosive mixture and can cause serious or fatal injuries if
ignited.
Therefore:
• Do not smoke in the work area when unpacking the coupling and
removing the corrosion preventative.
• Do not handle open flame or ignition sources.
• Ensure measures that prevent electrostatic charging.
• Have fire extinguishers (CO2, powder or foam) on hand.
• Do not extinguish with a water jet; water mist is suitable.
• Initiate safety measures to prevent the accumulation of flammable
fumes in lower positioned areas or enclosed areas.
• Stop work immediately if there is a fire. Leave the danger zone until it
is safe to resume work.

WARNING!

Toxic hazard if fumes or aerosols are inhaled or if the corrosion preventa-

tive is ingested!
Corrosion preventative contains harmful components that can result in
poisoning and skin irritations. Repeated contact can cause skin dryness
and cracking.
Therefore:
• Comply with the instructions in the manufacturer's safety data sheet.
• Only unpack the coupling in well-ventilated areas.
• Only use the corrosion preventative in well-ventilated areas.
• If inhaled get the person affected to fresh air immediately. Seek med-
ical attention.
• If ingested summon a physician immediately. Thoroughly rinse
mouth out with water.
• Avoid contact with skin and eyes:
When working wear chemical-resistant protective gloves and protec-
tive goggles with side protection.
After work wash thoroughly and use skin-care cream.
• If there is skin or eye contact rinse immediately and thoroughly with
water. Seek medical attention.
• Do not eat, drink, or smoke when working with the substance.

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2 Safety

CAUTION!

Material damage if stored incorrectly!

Incorrect storage of the elastic elements can cause irreversible deforma-
tion of the elastomer. The consequence is uncontrolled torsional oscilla-
tion that can destroy the elastic element.
Therefore:
• Store the elastic element horizontally.
• Do not stress the elastic element axially, e.g. by stacking additional
weights.
• Do not set up the elastic element diagonally or on one side.

2.6 Behaviour in the event of danger or accident

Preventative measures

• Always be prepared for accidents or fire!

• Keep first-aid supplies (first-aid kits, blankets etc.) and fire extin-
guishers close at hand.
• Familiarise personnel with accident alarms, first-aid kits, and rescue
equipment.
• Keep access routes clear for rescue vehicles

Measures in the event of accident

• Immediately activate the emergency stop.

• Initiate first-aid measures.
• Get people out of the danger zone.
• Inform those responsible at the implementation site.
• Alert emergency medical services.
• Keep rescue routes clear.

2.7 Environmental protection

CAUTION!

Environmental hazard due to incorrect handling!

Incorrect handling of environmentally hazardous substances, particularly
improper disposal, can cause significant environmental damage.
Therefore:
• Always comply with the following warnings.
• If environmentally harmful substances should inadvertently get into
the environment, initiate suitable measures immediately. If in doubt
notify the responsible municipal authority about the damage.

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Operating Manual VULKAN RATO R

3 Technical data

3 Technical data

3.1 General information

Technical data, dimension drawing and parts list are provided in the Ap-
pendix. Additional technical data is provided in the VULKAN RATO-R
product catalog.

3.2 Coupling designation

example:

Fig. 3-1

• a : Assembly
• b : Rigidity
• c : Number of rows
• d : Model
• e : 0 = without torsional limit device
• f : 1 = with torsional limit device
• g : Series

3.3 Consignment number

The consignment number is on the outer diameter of the driven-side hub
(5). It has been stamped on.

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3 Technical data

Fig. 3-2

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Operating Manual VULKAN RATO R

4 Structure and function

4 Structure and function

4.1 Mode of operation

The VULKAN RATO R coupling is a highly elastic, rubber ring element
coupling that is ductile on all sides. All connecting elements are posi-
tioned in such a way that there is no backlash Play-free torque transmis-
sion and the large rubber cross-section guarantee good damping of
structure-borne noise and effective electrical insulation. Good heat dissi-
pation is ensured via vent openings.

4.2 Structure of the coupling

Hub
The hub (5) is the machine element that is used to anchor the coupling on
the driven shaft. Depending on the version (--> see drawing in Appendix)
it is pre-bored, has a feather key groove as carrier element, or it is shrink-
fit onto the shaft via a pull-on device and hydraulic support (oil press fit).

Fig. 4-1

Membrane assembly:
The membrane assembly consists of multiple circular membranes of
steel plates. These are connected on the outer diameter (A) with the elas-
tic part, and they are connected with the hub on the inner diameter (B).
The spring deflection of the membranes enables angular and axial dis-
placement.

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4 Structure and function

Fig. 4-2

The elastic element is the basic element of the coupling. The elastic part
of the coupling is comprised of two elastic elements (example: 3-row
elastic part, see figure).
The elastic part is used to tune torsional vibration behaviour and to com-
pensate radial shaft displacement. The elastic part cannot compensate
axial and angular displacement.

Fig. 4-3

Safety Gear
The 2-and 3-row Couplings have safety gears.
They avoid that parts will be ejected during a break of the flexible ele-
ment.
The safety gear is an assembly of washers (40 optional), bushes (46),
screws (47)and nuts (48 optional) and is assembled in axial direction of
the element

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4 Structure and function

47 46 48
47

40 40 46

Fig. 4-4

4.3 Identification
During the manufacturing process of the coupling the individual delivery
assemblies were precisely matched to each other. Consequently the po-
sition of the components is not random. When mounting the coupling pay
attention to the markings on the connection parts. When replacing an
elastic element it must be re-inserted at the correct position. Consequent-
ly each elastic element is marked on the interface.

E F G H
A B C D

Fig. 4-5

In view X the fitting holes for connection of the other assemblies are
marked with a notch A until D.
In view Y the fitting holes for connection of the other assemblies are
marked with two markings E until H.
This ensures that these modules are not assembled in 180° misalign-
ment.

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5 Transport, packaging, and storage

5 Transport, packaging, and storage

5.1 Safety instructions for transport

WARNING!

Life-threatening danger due to suspended loads!

When lifting loads there is a life-threatening hazard due to falling parts or
parts swinging out of control.
Therefore:
• Never step under suspended loads.
• Comply with the instructions concerning the intended attachment
points.
• Do not attach on projecting machine parts or on the eyes of installed
components. Ensure that the sling gear is securely seated!
• Only use approved hoists and sling gear with sufficient bearing
capacity.
• Do not use rope and straps that are torn or frayed.
• Do not place ropes and straps on sharp edges and corners; do not
knot or twist ropes and straps.

WARNING!

Danger of falling due to eccentric center of gravity!

Packages can have an eccentric center of gravity. If attached incorrectly
the packages can tip and cause life-threatening injuries.
Therefore:
• Note the markings on the packages.
• Attach the crane hook in such a manner that it is located above the
center of gravity.
• Carefully lift and see if the load tips. If necessary change the attach-
ment.

5.2 Symbols on the packaging

Attachment point
Only place sling gear (attachment chain, lifting strap) at the points
marked with this symbol.

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5 Transport, packaging, and storage

Fig. 5-1

Weight, attached load

Indicates the weight of packages. Handle the marked package in accord-
ance with its weight.

Fig. 5-2

5.3 Delivery status

The coupling is delivered in partially-assembled status for easier assem-
bly. See the delivery drawing in the Appendix for the precise delivery sta-
tus.

5.4 Transport inspection

Check delivery immediately upon receipt to ensure that delivery is com-
plete, and to identify any transport damage.
Proceed as follows if there is apparent external damage:

• Do not accept the delivery or only accept it with reservation.

• Note the extent of transport damage on the transport documents or
on the transport company's delivery ticket.
• Submit a complaint.

Note!
i Report any defect as soon as it is detected. Claims for damage compen-
sation can only be enforced during the applicable periods for giving
notice of lack of conformity.

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5 Transport, packaging, and storage

5.5 Packaging
About the packaging
Individual packed goods are packaged according to the expected trans-
port conditions. Environmentally-friendly materials have been used exclu-
sively for the packaging. Packaging should protect the specific
components from transport damage, corrosion, and other damage until
assembly. Consequently do not destroy the packaging and only remove it
just before assembly.

Fig. 5-3

Fig. 5-4

Handling packaging materials

Dispose of packaging materials in accordance with the respectively valid
statutory regulations and local guidelines.

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5 Transport, packaging, and storage

CAUTION!

Improper disposal causes environmental damage!

Packaging materials are valuable raw materials and in many cases they
can be reused, or they can be effectively treated and recycled.
Therefore:
• Dispose of packaging materials in an environmentally responsible
manner.
• Comply with locally applicable disposal guidelines. If necessary,
commission a specialized company to dispose of packaging.

5.6 Preservation

5.6.1 Preservation with Metacorin

CAUTION!

Material damage due to improper removal of the corrosion preventative!

Mechanical removal of the corrosion preventative (e.g. with abrasive
agents or tools) can damage surfaces and fit.
Therefore:
• Use a suitable solvent or alkaline cleaning agents.

CAUTION!

Corrosion preventatives are hazardous to water!

This substance is toxic and should not get into the soil, water, or drainage
systems.
Therefore:
• Do not dispose of with household waste.
• Dispose of in accordance with government agency regulations.
• If the substance is inadvertently released then it must be dammed in
and bound with absorbing agents. Do not use spark-forming auxiliary
materials to dam-in; do not add absorbing agents (e.g. sand, dirt, or
universal binders).

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WARNING!

Fire hazard due to spark-producing auxiliary material!

When handling corrosion preventative there is a fire hazard due to spark-
ing.
Therefore:
• Do not use metallic and spark producing tools.

WARNING!

Toxic hazard if fumes or aerosols are inhaled or if the corrosion preventa-

tive is ingested!
Corrosion preventative contains harmful components that can result in
poisoning and skin irritations. Repeated contact can cause skin dryness
and cracking.
Therefore:
• Comply with the instructions in the manufacturer's safety data sheet.
• Only unpack the coupling in well-ventilated areas.
• Only use the corrosion preventative in well-ventilated areas.
• If inhaled get the person affected to fresh air immediately. Seek med-
ical attention.
• If ingested summon a physician immediately. Thoroughly rinse
mouth out with water.
• Avoid contact with skin and eyes:
When working wear chemical-resistant protective gloves and protec-
tive goggles with side protection.
After work wash thoroughly and use skin-care cream.
• If there is skin or eye contact rinse immediately and thoroughly with
water. Seek medical attention.
• Do not eat, drink, or smoke when working with the substance.

CAUTION!

Solvents are a health hazard!

Solvents are harmful and can damage mucous membranes.
Therefore:
• Only use substantially solvent-free agents.
• Wear chemical-resistant protective gloves and protective goggles.
• Only use solvents in well-ventilated areas.

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5 Transport, packaging, and storage

CAUTION!

Material damage due to solvent!

Solvents can damage the rubber elements!
Therefore:
• Do not bring the rubber elements into contact with solvents.

Preservation of steel and cast parts with Metacorin 835 and Meta-
corin 850

The following types of steel parts are generally protected against corro-
sion with the corrosion preventative METACORIN 835/850:
For steel and cast parts on surfaces and stamped images treated to finish
dimension
Metacorin 835 offers sufficient protection in case of:

• dry indoor storage: more than 12 months

• outdoor storage under a roof: 6 months

The layer thickness of the preservation agent is 4 - 6 µm.

Metacorin 850 offers sufficient protection in case of:

• dry indoor storage: more than 12 months

• outdoor storage under a roof: 4 months

The layer thickness of the preservation agent is 5 - 8 µm.

Cleaning
To clean off the Metacorin 835 corrosion preventative film we recom-
mend spraying or immersing in an aqueous-alkaline solution.
The cleaning process should generally be supplemented by mechanical
cleaning.

Note!
i Always use lint-free cloths for cleaning.

VULKAN uses METACLEAN 772 for this purpose.

This is an aqueous cleaner with good anti-corrosion protection for 2-3
days.
AVILUB METACLEAN 772 and AVILUB METACORIN 835/850 can be
purchased from the manufacturer Bantleon.

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5 Transport, packaging, and storage

www.bantleon.de

Note!
i The connection surfaces and bores are preserved with corrosion prevent-
ative or the coupling is packed in VCI foil.
Before installing the coupling, use cleaner to clean surfaces that have
been treated with corrosion preventative.

Note!
i Comply with the safety data sheets for Metacorin and VCI foil (www.ban-
tleon.de).
Example for Metacorin:

Fig. 5-5

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5.6.2 Preservation of VCI

CAUTION!

Health hazard due to contact with VCI foil!

VCI coil contains harmful components. Repeated or longer skin contact
can dissolve skin fat and cause dermatitis.
Therefore:
• Comply with the instructions in the manufacturer's safety data sheet.
• Avoid contact with skin and eyes.
• Apply suitable skin protection cream prior to working on elastic ele-
ments.
• When working wear chemical-resistant protective gloves and protec-
tive goggles with side protection.
• After work wash thoroughly and use skin-care cream.
• After eye contact thoroughly rinse eyes for approximately 15 minutes.
Seek medical care immediately.
• After skin contact wash immediately with water and soap.
• Do not eat, drink, or smoke when working with the substance.

CAUTION!

VCI foil is slightly hazardous to water!

VCI foil has an irritating effect. It is slightly hazardous to water and should
not get into drainage systems, surface water or ground water.
Therefore:
• Comply with the instructions in the manufacturer's safety data sheet.
• If it penetrates into drainage systems, bodies of water, or soil, notify
the responsible authorities immediately.
• Dispose of in accordance with government agency regulations.

Note!
i Do not treat elastomers and rubber parts with the corrosion preventative.
Preservation of elastomer will void the warranty.

Preservation with VCI 126 foil

As additional transport packaging VULKAN prefers Cortec VCI-126 foils
(manufactured by Bantleon: www.bantleon.de). For medium- and large-
sized components, entire sets are used.

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5 Transport, packaging, and storage

These sets include:

• ready-made Cortec-VCI covers cut to size for the particular compo-

nent,
• Cortec-VCI foil pre-cut for the bottom,
• VCI dispenser in the form of impregnated Cortec-VCI-PUR foam,
• Small parts are packaged in VCI-126 continuous foil or in VCI bags
and other VCI-126 foil products. It may be necessary to supplement
this with pre-cut VCI foam.

Note!
i The VCI foil used by VULKAN is PE foil with the VCI additive as vapour-
phase inhibitors. The inhibitors emerge from the foil in the form of vapour,
saturate the enclosed air space and adhere to the bare metal surfaces as
invisible, monocular films.
They can also reach hard-to-access areas.
When used as specified, they provide protection of 2-5 years with an air-
tight seal.
Do not allow the VCI foil to become damaged!
If the VCI foil is not replaced immediately after being damaged, VULKAN
will assume no liability for any adverse effects on the coupling as a result
of corrosion!

Note!
i Comply with the safety data sheets (www.bantleon.de).

• The VCI foil fulfils the requirements of the standard TRGS 615, para-
graph 5.1.
• The VCI foil is reusable and recyclable. Dispose of in landfill (house-
hold trash) or by burning.

Fig. 5-6

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5 Transport, packaging, and storage

5.6.3 Preservation with Rolimeco

Preservation of membrane assemblies with Rolimeco 397

Rolimeco forms an elastic and permanent film that adheres to the sur-
face.
This film provides protection against moisture and salt water and is stable
in the temperature range from -40°C to 100°.
Rolimeco is suitable for preservation for transport (including transport by
sea) and for long-term preservation.
Do not remove the Rolimeco protective film, since this can cause the
components to corrode.
The single parts of the membranes are completely preserved with
Rolimeco.

Note!
i Comply with the safety data sheets (www.rolith.de).

Fig. 5-7

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5 Transport, packaging, and storage

5.6.4 Table Metacorin/VCI/Rolimeco

Overview of corrosion protection with Metacorin/VCI

Standard Standard Standard Additional cor-

corrosion pro- rosion protec-
corrosion pro- corrosion pro-
tection tection tection tion
Steel and cast Vulcanised Membrane Steel, cast and
assemblies up vulcanised
parts up to 6 steel and cast
to steel and cast
months parts up to 4
(stored out- months 6 months parts > 12
doors under a (stored out- (stored out- months
doors under a (stored indoors
roof) doors under a
roof) roof) in a dry room)

Parts in VCI foil

See freight over- Metacorin 835, Metacorin 850, Rolimeco 397, or aluminium
seas, tropical dry layer thick- dry layer thick- dry layer thick- foil; inside with
and sub-tropical ness min. 4 µm / ness min. 5 µm / ness min. 4 µm / VCI foam dis-
regions max. 6 µm max. 8 µm max. 6 µm penser, if neces-
sary

Metacorin 835, Metacorin 850, Rolimeco 397, Parts in VCI foil;

Intercontinental dry layer thick- dry layer thick- dry layer thick- inside with VCI
shipping points ness min. 4 µm / ness min. 5 µm / ness min. 4 µm / foam dispenser,
max. 6 µm max. 8 µm max. 6 µm if necessary

Metacorin 835, Metacorin 850, Rolimeco 397,

within dry layer thick- dry layer thick- dry layer thick-
Parts in VCI foil
Europe ness min. 4 µm / ness min. 5 µm / ness min. 4 µm /
max. 6 µm max. 8 µm max. 6 µm

Short hauls, Metacorin 835, Metacorin 850, Rolimeco 397,

domestic, bor- dry layer thick- dry layer thick- dry layer thick-
Not necessary!
dering states per ness min. 4 µm / ness min. 5 µm / ness min. 4 µm /
carrier max. 6 µm max. 8 µm max. 6 µm

Tbl. 5-1

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5 Transport, packaging, and storage

5.7 Transport

Transporting pallets with the crane

Packages that are attached to pallets can be transported with a crane un-
der the following conditions:

• Crane and lifting gear must be designed for the weight of the pack-
ages.
• The operator must be authorized to operate the crane.

Attachment:

• Attach ropes, straps or multi-point suspensions to the pallet accord-

ing to the illustration and ensure that they cannot slip.
• Ensure that the packages cannot be damaged by the sling gear. Use
other sling gear if necessary.
• If there is an eccentric centre of gravity ensure that the pallet cannot
tip.
• Start the transport.

Fig. 5-8

Transporting pallets with the forklift

Packages that are attached to pallets can be transported with a forklift
under the following conditions:

• The forklift must be designed appropriately for the weight of the

transport units.
• The operator must be authorized to operate the forklift.

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5 Transport, packaging, and storage

Attachment

• Drive the forklift with the forks between or under the spars.
• Drive in the forks until they protrude on the opposite side.
• If there is an eccentric centre of gravity ensure that the pallet cannot
tip.
• Lift the package and start the transport.

Fig. 5-9

The coupling components (delivery assemblies) can be transported with

a crane under the following conditions:

• Crane, hoists, and attachment gear must be designed for the weight
of the coupling components.
• The operator must be authorized to operate the crane.

Attachment:
Transporting assemblies with a crane:

• Attach rope or straps on the attachment points of the coupling parts.

• Ensure that the coupling hangs straight; pay attention to possible
eccentric center of gravity.
• Start the transport.

CAUTION!

Using the wrong sling gear can damage the rubber body.
The rubber body can be damaged if looped with rope.
Therefore:
• Never place rope around the rubber body for attachment.
• Only use the intended attachment points.

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5 Transport, packaging, and storage

Hub
Horizontal transport
Screw two eye bolts (A) offset by 180° into the tapped bores of the hub
(5) until the collar rests on the hub.
Use a shackle or self-closing hook to fasten the hub to the eye bolts, and
connect it with the hoist.
Use suitable shackles in accordance with DIN EN 13889 and suitable eye
bolts in accordance with DIN EN 580.

A
1

Fig. 5-10

Vertical transport
Use a shackle to fasten the hub to the marked bore (--> arrow) and con-
nect with the hoist.
Use suitable shackles according to DIN EN 13889.

Fig. 5-11

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5 Transport, packaging, and storage

10

Fig. 5-12

Connect the membrane assembly (10) with a shackle at the marked bore
(see arrow) with a suitable lifting gear. Use shackles according DIN EN
13889.

Fig. 5-13

Attach the flexible element via a textile load sling (arrow) and connect it to
the hoisting unit. Use suitable load slings in accordance with DIN EN
1492.

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6 Assembly

6.1 Safety assembly

DANGER!

Life-threatening danger if restarted without authorization!

When installing there is danger of the energy supply being switched on
without authorization. This poses a life-threatening hazard for persons in
the danger zone.
Therefore:
• Prior to starting the tasks switch off all energy supplies and safeguard
them from being switched on again.
• If combustion motors supply the motive power then the safety
instructions and the instructions for switching off and safeguarding
against restart in the assembly manuals provided by the manufactur-
ers must be complied with.

WARNING!

Life-threatening hazard - High elastic forces!

The rubber elements and the membrane can accumulate extreme quanti-
ties of energy when they are deflected. Sudden loosening of obstructions
can cause high energy movements of coupling parts, and in the process
cause life-threatening injury.
Therefore:
• Prior to working on the coupling ensure that it is force-free and that
the resilient elements are not deflected.
• For tasks that require deflection of resilient elements only employ the
work methods described in this manual. Only use tools and clamping
devices that are designed for high forces.
• Only specialized personnel familiar with the installation should select
the thrust bearing required for deflection of the membrane assem-
blies.

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6 Assembly

WARNING!

Life-threatening hazard - High dead weight!

The coupling has an extremely high dead weight. A life-threatening haz-
ard due to crushing exists if the coupling rolls off or falls down.
Therefore:
• Always safeguard the coupling against rolling off.
• Carefully supervise the lifting processes and transport.
• Only use the transport methods described in the "Transport" section.
• Secure the coupling parts that will be loosened against falling, before
loosening any threaded joints.
• Physical lifting processes involving a reference weight in excess of
25 kg should only be executed with two persons.

WARNING!

Life-threatening danger due to suspended coupling parts!

When lifting coupling parts a life-threatening hazard is posed by such
parts falling or swinging out of control.
Therefore:
• Never step under suspended coupling parts.
• Comply with the instructions concerning the intended attachment
points.
• Do not attach sling gear to projecting machine parts or to the lugs of
attached components; ensure that the sling gear is firmly seated.
• Only use approved hoists and sling gear with sufficient bearing
capacity.
• Do not use rope and straps that are torn or frayed.
• Do not place ropes and straps on sharp edges and corners; do not
knot or twist ropes and straps.

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6 Assembly

WARNING!

There is an injury hazard due to swinging coupling parts during the lifting
process!
Coupling parts can swing to the side and cause life-threatening injury
when they are lifted from and lowered to the floor.
Therefore:
• When lifting and lowering do not position yourself in the direct vicinity
of the coupling parts and maintain a safety distance.
• Look for safe possibilities of avoiding this hazard when lifting and
lowering.
• Carefully lift and observe the behaviour of the suspended load.
• Comply with the instructions concerning the intended attachment
points.
• Do not attach sling gear to projecting machine parts or to the lugs of
attached components; ensure that the sling gear is firmly seated.
• Only use approved hoists and sling gear with sufficient bearing
capacity.
• Do not use rope and straps that are torn or frayed.
• Do not place ropes and straps on sharp edges and corners; do not
knot or twist ropes and straps.

6.2 Installation of the coupling

6.2.1 Mount hub on the output side.

Mounting the hub - oil pressure connection

Working with the oil injection method is safe if the following hazard warn-
ings are complied with.

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6 Assembly

DANGER!

Life-threatening danger due to hydraulic energy!

Hydraulic energy can cause severe or fatal injuries.
If individual components are damaged hydraulic fluid can escape under
high pressure.
Therefore:
• Only have trained, skilled personnel perform work on the hydraulic
equipment.
• Only use hydraulic tools and accessories that are suitable and
approved for these pressures.
• Do not change pressure settings to exceed the maximum specified
values.
• Prior to starting activities check the hydraulic system for leaks.
• Prior to dismounting all connections, ensure that the entire hydraulic
system is de-pressurized. Completely de-pressurize the existing
pressure accumulator.
• Ensure that the pump and the pipe are completely filled with oil.
• Wear protective goggles.
• Wear protective gloves.
• Wear personal protective equipment.
• Avoid skin contact with oil.

Mounting the hub

1. Deburr shaft and clean again.
2. Screw two threaded rods (A) and (B) into the tapped bores of the hub
as guides.

Fig. 6-1

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6 Assembly

3. Attach a hand-operated chain hoist to the bore via a shackle (see ar-
row) and take it into the crane.
4. Select the bore so that the left and right guiding aids are at the some
height.
5. Use suitable shackles in accordance with DIN EN 13889.
6. Clean and dry shaft.
7. Press the hub with light pressure onto the conical shaft.

Fig. 6-2

8. Push hub onto the shaft (C) until the conical surfaces are close togeth-
er, without exerting force. Measure the control dimension “X” from this
position at three points over the circumference.

Fig. 6-3

9. Remove the guide aids.

10. Screw the hollow press element (2) against the hub (1) hand tight via
the threaded rod (3).

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1 2

Fig. 6-4

11. Remove screw plug from the connection (A) from the hub (1)
12. Connect the hydraulic unit (3000 bar) on the hub (1).
13. Connect the hydraulic hand pump (1600 bar) on the hollow pressing
element (2).
14. Attach a dial gauge to check the push-on distance.

A B

Fig. 6-5

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Note!
i The push-on distance is specified on the drawing and is stamped on the
facing side of the hub.
The push-on distance "X" must be maintained, example: 13.3 + 1.2 mm

13,3 + 1,2 mm

13,3 + 1,2 mm

Fig. 6-6

Note!
i Read the separate operating manual provided by the manufacturer of the
hollow pressing element and for the hydraulic supply.

Note!
i A separate hydraulic pump must be used for each threaded connection.

Note!
i For expanding, only use a clean oil with the prescribed viscosity. Oil
specification: ISO VG 46 (44 cSt at 40°C) (Mobil DTE25). The oil must
not contain any EP (Extreme Pressure) additives.
15. To expand the hub (1) (connection A), oil is injected between the taper
surfaces, until it escapes at the facing sides of the hub.
16. Through incremental coordinated alternate increase of the push-on
pressure on the hollow pressing element (2) (connection B), and of the
expansion pressure on the hub (1) (connection A) the hub is pushed
onto the shaft.

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6 Assembly

Note!
i During the push-on process the expansion pressure must not exceed 100
bar/3 min. Avoid punctiform overshooting of the permissible yield
strength.

Note!
i If the needle deflection on the dial gauge is not uniform, or if there is an
unexpected increase of the axial mounting force, there is danger of mate-
rial friction (oil film is not uniformly applied).
In this case, pull off the hub again and check shaft / hub for damage.
If there is no damage pull the hub on again.
Use oil with a higher viscosity!

Note!
i Under normal conditions 2000 bar expansion pressure (A) is not
exceeded!
In special cases higher pressures are necessary!
17. If the hub (1) is in the target position, discharge the expansion pres-
sure from the hub (1), (connection A).
18. Maintain the push-on pressure on the hollow pressing element (2),
(connection B), for at least 1.5 hours.
19. After the holding time, slowly discharge the push-on pressure on the
hollowing pressing element (2) (connection b).
20. Unscrew the nut from the hollow pressing element, until a gap of 3-5
mm between the hub (1) and hollow pressing body (2) occurs.
21. Strike the hub with a rubber hammer.

Note!
i Execute the hammer blows opposite to the push-on direction!

22. If the hub (1) remains in the intended position, the mounting process
was successful.
23. Remove hydraulic connections (A, B) from the shaft (1) and from the
hollowing pressing element (2).
24. Screw the screw plug into connection A of the hub (1).
25. Dismount the hollow pressing element.

Note!
i For a taper of 1:15 or steeper, an axial safeguard of the hub must be pro-
vided by the system manufacturer!
26. Measure control dimension “X” to check the push-on distance.

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Note!
i Wait 24 hours before operating the oil pressure connection at the full
rated motor speed.
This is necessary to ensure that the pressure fluid has escaped out of the
fit joint.
ª The hub is mounted.

6.2.2 Mounting the membrane assembly

1. Attach a manual chain hoist using a shackle on the marked bore hole
(see arrow) and connect to the crane.
2. Use suitable shackles according to DIN EN 13889.
3. Position the membrane assembly (10) in front of the hub (5).

10

Fig. 6-7

4. Slide the membrane assembly (10) onto the hub (5).

5 B

A
10

Fig. 6-8

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Note!
i Insert the bolt heads (B) into the bore holes (A) on the hub (5) provided
for this purpose.
5. Bolt the membrane assembly (10) with fastening elements (22), (35)
and (36) onto the hub (5), hand tight.

10

35
36 22

Fig. 6-9

6. Use a torque wrench to tighten the fastening elements with the pre-
scribed torque (for tightening torque, see installation drawing in the
Appendix).

6.2.3 Alignment
To align the system, the following prerequisites must be fulfilled:

• The hub must be mounted.

• The elastic part should not be installed yet.
• The preservation agent applied to the connecting surfaces must be
completely removed.

Note!
i The tolerance values specified here are for operation in warmed-up con-
dition.
If alignment is only possible in cold condition then the specified tolerance
values cannot be used.
System-specific thermal expansion must be determined by the system
engineer and these values must be used.
Contact the manufacturer for further information.
After installation of the elastic part, the alignment must be checked in
warmed-up condition.
Alignment principles

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The more accurate the alignment, the more effective the compensation of
operational misalignments by the coupling.
The VULKAN RATO R couplings are capable of compensating for signifi-
cant displacement of the connected machines without forfeiting service
life.

CAUTION!

Improper alignment can cause system damage!

In case of excessive misalignments, high forces can be transferred to the
adjoining machine parts.
Therefore:
• Make sure the system is aligned correctly.
• If the tolerances specified here are exceeded, do not operate the sys-
tem. Coordinate additional measures with the manufacturer.
Radial alignment

1. Determine the dimension Xr1.

2. Turn hub and shaft 180° and determine the dimension Xr2.
3. Turn hub and shaft 90° and determine the dimension Xr3.
4. Turn hub and shaft 180° and determine the dimension Xr4.
5. Determine the value ∆Xr according to the formula below:

2 2
§ X − X r1 · § X r 3 − X r 4 ·
∆X r = ¨ r 2 ¸ +¨ ¸
© 2 ¹ © 2 ¹

Fig. 6-10

Axial alignment

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1. Determine the dimension Xa1.

2. Turn hub and shaft 180° and determine the dimension Xa2.
3. Turn hub and shaft 90° and determine the dimension Xa3.
4. Turn hub and shaft 180° and determine the dimension Xa4.
5. Determine the value ∆Xa according to the formula below:

X a1 + X a 2 + X a 3 + X a 4
∆X a = − Xa
4

Fig. 6-11

Angular alignment

1. Determine the dimension Xw1.

2. Turn hub and shaft 180° and determine the dimension Xw2.
3. Turn hub and shaft 90° and determine the dimension Xw3.
4. Turn hub and shaft 180° and determine the dimension Xw4.
5. Determine the value Xw according to the formula below:

2 2
§ X − X w1 · § X w3 − X w 4 ·
∆X w = ¨ w 2 ¸ +¨ ¸
© 2 ¹ © 2 ¹

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Fig. 6-12

Alignment: alignment tolerances

The determined ∆values must be within the tolerances specified below. In
case the values are not within the tolerances, the elements of the system
must be re-aligned. If this is not successful, please contact the manufac-
turer.

∆Xr (mm)
Assembly flexible mounted/ ∆Xa (mm) ∆Xw (mm)
rigid mounted

1,0 -2+1,0 /
G261R ± 0,5 0,35
1,0 ±0,5

Tbl. 6-1

6.2.4 Mounting the elastic part

1. Connect the flexible element (1) (see chapter "Transport") and attach
to the crane.
2. Press the flexible element (1) into the centring device of the flywheel.
3. Screw the flexible element (1) to the flywheel hand-tight using the fas-
tening elements (20), (61).

Fig. 6-13

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4. Slacken the lifting gear and unscrew the shackles.

5. Use a torque wrench to tighten the fastening elements (20), taking the
prescribed tightening torque into account.
6. Turn the drive side or driven side until the markings of the fitting holes
on the flexible element (see chapter "Markings") align with the mark-
ings on the membrane assembly. In this case, "align" means offset
3.5°, since two bore holes offset by 180° serve as the marking.

3,5°

Fig. 6-14

7. Insert the two cylinder pins (55) with two bushings (A) offset 180° into
the fitting holes provided.

55

Fig. 6-15

8. Insert the fastening elements (16), (19) and (28) each with one bush
(A), through the flexible element (1) and the membrane assembly
(10). Lightly tighten the fastening elements.
9. Use a torque wrench to tighten the fastening elements, complying with
the prescribed torque (for tightening torque see drawing in the Appen-
dix).
10. Remove the two cylinder pins (55) and replace with fastening ele-
ments (16), (19) and (28). Firmly tighten the fastening elements to the
specified tightening torque.

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Fig. 6-16

6.2.5 Concluding tasks and final inspection

Concluding tasks and final inspection

1. Tighten all threaded connections with a torque wrench in compliance
with the specified torque (see Tightening torques).
2. Perform a final alignment check (see "Alignment").
3. Ensure that the owner has attached a distance protection fixture in the
form of a coupling protector before commencing operation of the sys-
tem (see chapter "Owner's responsibility").
ª This concludes assembly of the coupling.

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7 Faults

7 Faults

7.1 Safety faults

Possible fault causes and the tasks to correct these faults are described
in the following section.
If faults occur more frequently, the maintenance intervals must be short-
ened to correspond to actual system load.
Contact the manufacturer if there are faults that cannot be corrected by
following the instructions below (see "Customer service").
Personnel

• The maintenance and troubleshooting tasks described here should

only be performed by experts with special training, or exclusively by
the manufacturer. Special reference will be made to the requirement
for personal protective equipment or the requirement for experts with
special training in the description of the specific fault.
Personal protective equipment
Wear the following protective equipment for all troubleshooting tasks:

• Protective work clothing

• Hard hat
• Safety footwear
• Protective gloves

Note!
i The warnings in this section make special reference to additional protec-
tive equipment that is required for certain tasks.

WARNING!

Danger of injury due to improper fault correction!

Improper fault correction can cause serious injury or property damage.
Therefore:
• Prior to starting the tasks ensure that there is adequate free space for
assembly.
• Ensure order and cleanliness at the installation location! Parts and
tools that are lying loose or on top of each other are accident haz-
ards!
• If components have been removed, ensure that they are properly re-
installed, that all fastening elements are re-installed, and that all
threaded connections are tightened with the specified bolt-tightening
torque.

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DANGER!

Life-threatening danger if restarted without authorization!

When correcting faults there is danger of the power supply being
switched on without authorization. This poses a life-threatening hazard
for persons in the danger zone.
Therefore:
• Prior to starting the tasks switch off all energy supplies and safeguard
them from being switched on again.
• If combustion motors supply the motive power then the safety
instructions and the instructions for switching off and safeguarding
against restart in the assembly manuals provided by the manufactur-
ers must be complied with.
Behaviour in case of a fault:

1. For faults that pose an imminent hazard for personnel or assets, exe-
cute the emergency stop function immediately.
2. Determine the cause of the fault.
3. If correction of the fault requires work in the danger zone, switch off
the device and safeguard it against being restarted.
4. Inform the responsible parties at the implementation site of the fault
without delay.
5. Have authorized, specialized personnel correct the fault or correct it
yourself depending on the type of fault.

Note!
i The fault table provided below lists personnel who are authorized to cor-
rect the fault.
Possible fault causes and the tasks to correct these faults are described
in the following section.
If faults occur more frequently, the maintenance intervals must be short-
ened to correspond to actual system load.
Contact the manufacturer if there are faults that cannot be corrected by
following the instructions below (see "Customer service").

7.2 Fault table

Fault Possible cause Fault correction Corrected by

Execute maintenance
Cracks in the elas- Maintenance interval
and eliminate crack Specialist
tomer exceeded
formation

Service life limit Replace flexible ele-

Specialist
exceeded ment

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Fault Possible cause Fault correction Corrected by

Improve ventilation
Inadequate ventila-
and eliminate crack Specialist
tion of the coupling
formation

Check the alignment

Faulty alignment and eliminate crack Specialist
formation

Only operate the cou-

pling in the pre-
Overload scribed load range Specialist
and eliminate crack
formation

Reapply surface pro-

Inadequate surface
tection and eliminate Specialist
protection
crack formation

Noise in operation Faulty alignment Alignment check Specialist

Faulty installation of Check the radial

flexible element or deflection and correct Specialist
diaphragm assembly installation faults

Elastomer detaches Replace flexible ele-

Specialist
from the metal ment

Increased bearing
Faulty alignment Alignment check Specialist
forces

Faulty installation of Check the radial

flexible element or deflection and correct Specialist
diaphragm assembly installation faults

Elastomer detaches Replace flexible ele-

Specialist
from the metal ment

Destruction of a Maintenance interval Replace flexible ele-

Specialist
flexible element exceeded ment

Service life limit Replace flexible ele-

Specialist
exceeded ment

Eliminate block and

Block in the unit replace flexible ele- Specialist
ment

Replace flexible ele-

Propeller contact Specialist
ment

Short circuit in gener- Replace flexible ele-

Specialist
ator operation ment

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Fault Possible cause Fault correction Corrected by

Out-of-phase synchro-
Replace flexible ele-
nization in generator Specialist
ment
operation

Tbl. 7-1

Note!
i For couplings with race safeguard, if the elastic element is destroyed,
brief emergency operation of the system is possible (see "Race safe-
guard"). You must replace the elastic element as quickly as possible.

7.3 Fault correction tasks

Venting the coupling

• Execution only by a specialist assigned by the owner.

• To prevent unnecessary and impermissible warming of the elastic
elements, a suitable coupling protection element (e.g. perforated
plate) with appropriate ventilation cross-sections must be selected.
• Ensure that applicable standards for separating spacing protection
fixtures are complied with.

Alignment check

• Execution only by a specialist.

• Special tools required

1. Radial measuring device

2. Axial measuring device
3. Angle measuring device

The alignment process is described in detail in the "Alignment" chapter.

Correcting crack formation

• Execution only by a specialist.

1. Check for surface cracks (see chapter "Checking for surface

cracks").
2. Grind the surface cracks (see "Grinding surface cracks").
3. Apply surface protection (see "Applying surface protection").

Replacing the surface protection

• Execution only by a specialist.

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1. The process for replacing the surface protection of the coupling is

described in detail in the chapter "Applying surface protection"
Replacing the elastic part

• Execution only by a specialist.

1. Dismount the elastic part (see "Dismounting the elastic part”).

2. Mount new elastic part (see "Mounting the elastic part”).
3. Perform final inspection (see "Concluding tasks and final inspec-
tion").

7.4 Start-up after a corrected fault

After correcting the fault and before switching on, perform the following
steps:

1. Check all previously loosened threaded unions for firm seat.

2. Ensure that all previously removed protective devices and covers
have been properly installed.
3. Ensure that all tools, materials, and other equipment have/has been
removed from the work area.
4. Clean the work area and remove any substances that may have
escaped, such as liquids, processing material, or similar items.
5. Ensure that all system safety devices are again functioning properly.
6. Owner-installed emergency stop devices, if present, must be reset.
7. Ensure that no one is in the danger zone.

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8 Maintenance

8 Maintenance

8.1 Safety maintenance

Personnel

• The maintenance and troubleshooting tasks described here should

only be performed by experts with special training, or exclusively by
the manufacturer. Special reference will be made to the requirement
for personal protective equipment or the requirement for experts with
special training in the description of the specific fault.
Personal protective equipment
Wear the following protective equipment for all troubleshooting tasks:

• Protective work clothing

• Hard hat
• Safety footwear
• Protective gloves

DANGER!

Life-threatening danger if restarted without authorization!

When correcting faults there is danger of the power supply being
switched on without authorization. This poses a life-threatening hazard
for persons in the danger zone.
Therefore:
• Prior to starting the tasks switch off all energy supplies and safeguard
them from being switched on again.
• If combustion motors supply the motive power then the safety
instructions and the instructions for switching off and safeguarding
against restart in the assembly manuals provided by the manufactur-
ers must be complied with.

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8 Maintenance

WARNING!

Danger of injury due to improperly executed maintenance tasks!

Improper maintenance can cause serious injury or material damage.
Therefore:
• Prior to starting the tasks ensure that there is adequate free space for
assembly.
• Ensure order and cleanliness at the installation location! Parts and
tools that are lying loose or on top of each other are accident haz-
ards!
• If components have been removed, ensure that they are properly re-
installed, that all fastening elements are re-installed, and that all
threaded connections are tightened with the specified bolt-tightening
torque.
Vulkan Coating LP
Vulkan Coating LP is applied on the rubber surfaces as a protective coat-
ing after sanding out cracks. This substance is a minor water hazard and
should not get into the soil, water, or waterways.
Unintended release
If the substance is unintentionally released, then it must be taken up with
liquid binding material (e.g. sand, universal binder, silica gel, acid binder,
or sawdust).
Disposal
Disposal must be executed in accordance with government agency regu-
lations.
Empty packaging so that it is scraped clean and dripless. Then recycle in
compliance with the national and governmental regulations.

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8 Maintenance

CAUTION!

Contact with Vulkan Coating LP poses a health hazard!

Due to its pH value the coating can cause irritation if there is repeated or
sustained skin contact.
Therefore:
• Comply with the instructions in the manufacturer's safety data sheet.
• Avoid spills and formation of mist.
• If ingested summon a physician immediately. Thoroughly rinse
mouth out with water.
• Avoid contact with skin and eyes:
• When working wear chemical-resistant protective gloves and protec-
tive goggles with side protection.
• After work wash thoroughly and use skin-care cream.
• After skin contact wash immediately with lots of water and soap.
• If there is eye contact rinse immediately and thoroughly with water.
Seek medical attention.
• If the substance splashes on clothing, immediately remove the
affected garments. Remove contamination in the work area in a
proper and environmentally responsible manner. Do not allow drop-
lets to get into waterways.
• Do not eat, drink, or smoke when working with the substance.

8.2 Maintenance schedule

Maintenance schedule
Maintenance tasks are described in the sections below that are required
for optimal and trouble-free operation.
If increased wear is detected during regular inspections, then reduce the
required maintenance intervals according to the actual indications of
wear.
Contact the manufacturer, (see the service address on page 2) if you
have questions concerning maintenance tasks and intervals.

Interval Maintenance task To be performed by:

Elastic part: Visual

annually inspection for surface Specialist
cracksSpecialist

Elastic part: Check sur-

Specialist
face cracks

Elastic part: Inspection

for irreversible defor- Specialist
mation

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8 Maintenance

Interval Maintenance task To be performed by:

Alignment check Specialist

Check for crack growth

(only after cracks have Specialist
formed)

Check play in bearing

bush of support mem- Specialist
brane (optional)

Visual inspection for

cracks on the steel Specialist
parts

Visual inspection for

surface cracks
Annually after a repair
Check play in bearing Specialist
has been carried out
bush of support mem-
brane

Check protective coat-

Specialist
ing

Check play in bearing

bush of support mem- Specialist
brane (optional)

In case of damage or
Grind surface cracks Specialist
malfunction

Apply surface protec-

Specialist
tion

Dismantle the elastic

part (after a defect has Specialist
been determined)

Check play in bearing

bush of support mem- Specialist
brane (optional)

Tbl. 8-1

Damage or malfunction due to:

• Propeller contact
• Short circuit in generator operation
• Faulty synchronization in generator operation
• Regulator oscillation
• Emergency shut-off

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8 Maintenance

8.3 Maintenance tasks

• Execution only by a specialist.

• Special tools required:

1. Caliper gauge
2. Depth gauge

Checking for surface cracks

1. Remove the coupling protection installed by the owner.
2. To determine the depth of the crack in the interior diameter, the elastic
element must be removed (section "Dismantling the elastic part").
3. Use the caliper gauge and depth gauge to measure the crack depth
"X" on the inner and outer diameter of the elastic element.

Y X

4. Compare the measured value with the maximum permissible values

in the table below.
5. The cracks must be sanded internally within the permissible values for
the crack depth, (chapter "Sanding surface cracks").
6. If the maximum permissible crack depths are exceeded then the elas-
tic element must be replaced.

Permissible crack depths

Model Depth X (mm) Depth Y* (mm)

G2610R 9.3 15.8

Tbl. 8-2

* Cracks in the area of the outer diameter / inner diameter free from
cracks
Sand surface cracks

• Execution only by a specialist.

• Additionally required protective equipment:

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8 Maintenance

1. Protective goggles.
2. Protective gloves
3. Light respiratory protection

• Required special tools

1. Belt sander

WARNING!

Inhaled rubber dusts, can result over the long term in irritations of the res-
piratory system, lung damage or other health impairments. Skin contact
can result in sensitivity.
Therefore:
• Wear personal protective equipment for sanding and subsequent
cleaning tasks.

CAUTION!

Material damage due to sharp edges and non-circular cavities!

Sharp edges and non-circular cavities (A) can cause further crack forma-
tion and can destroy the flexible element.
Therefore:
• Smooth surface cracks so that they are round.
• Do not sand any sharp edges.

CAUTION!

Material damage due to excess temperatures when sanding!

Excess temperatures result in hardening of the rubber and a change in
rigidity.
Therefore
• For the concluding treatment the surface temperature should not
exceed 70°C.
If the crack depths of the dismounted and measured flexible element are
within the permitted tolerances, smooth the cracks.

1. Use a belt sander (A) or (B) and three different grades of grit (fine, me-
dium, coarse) to smooth the cracks into a trough shape. To use the belt
sander, comply with the instructions in the separate operating manuals
supplied by the belt sander manufacturers.

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8 Maintenance

Fig. 8-1

2. Execute the concluding sanding step with the fine-grit sanding belt.

Fig. 8-2

3. Clean the flexible element so that it is free of grease, oil and talcum
powder. This ensures that the surface protection that will subsequently
be applied will bond.
4. Apply surface protection on the entire rubber surface (--> chapter
“Applying surface protection”).

• Execution by a specialist.
• Additionally required protective equipment:

1. Protective goggles
2. Chemical-resistant protective gloves

• Required tools - brass brush

• Required processing material - Vulkan Coating LP
• The rubber surfaces must be treated with this protective coating after
grinding out cracks, or they must be treated in the appropriate main-
tenance interval.

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8 Maintenance

Note!
i This treatment extends the service life of the coupling. Aging of the elas-
tomer, particularly through oxidation with atmospheric oxygen is slowed.

Protective coating for dismantled elastic elements

1. If the rubber surfaces are in good condition without micro cracks,

then carefully clean these surfaces with a brass brush.
2. If micro cracks are present then the surfaces must be processed with
a belt sander (see chapter "Sanding surface cracks").
3. Thoroughly clean surfaces of grinding dust. When using compressed
air the quality class must be at least class 322 in accordance with
DIN ISO 8573-1.
4. Use a brush to apply the first protective coat on all sides, thin, and
full-coverage on the rubber surface.
5. Allow the protective coating to dry for 60 minutes, and thoroughly
ventilate the work area.
6. Use a brush to apply the second protective coat on all sides, thin, and
full-coverage on the rubber surface.
7. Allow the protective coating to dry for at least 60 minutes, and thor-
oughly ventilate the work area.
8. Install the elastic element (see chapter "Mounting the elastic part").

Note!
i Oil, grease, or condensation residues on the rubber surface reduce the
bond of the protective coat.

CAUTION!

Material damage due to premature re-commissioning of the coupling!

The protective coating can detach or new cracks can form in the protec-
tive coating if the device is re-commissioned prematurely.
• Wait for at least an hour after the last protective coat is applied before
re-commissioning the coupling.

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Protective coating for installed elastic elements

1. Remove the coupling protection.

2. If the outer rubber surfaces are in good condition without micro
cracks, then carefully clean these surfaces with a brass brush.
3. If micro cracks are present then the outer surfaces must be proc-
essed with a belt sander (see chapter "Sanding surface cracks").
4. Thoroughly clean surfaces of grinding dust. When using compressed
air the quality class must be at least class 322 in accordance with
DIN ISO 8573-1.
5. Use a brush to apply the first protective coat, thin and full-coverage
on the external rubber surface.
6. Allow the protective coating to dry for 60 minutes, and thoroughly
ventilate the work area.
7. Use a brush to apply the second protective coat on all sides, thin, and
full-coverage on the rubber surface.
8. Allow the protective coating to dry for at least 60 minutes, and thor-
oughly ventilate the work area.
9. Re-attach the coupling protection.

Fig. 8-3

Note!
i Oil, grease, or condensation residues on the rubber surface reduce the
bond of the protective coat.

CAUTION!

Material damage due to premature re-commissioning of the coupling!

The protective coating can detach or new cracks can form in the protec-
tive coating if the device is re-commissioned prematurely.
• Wait for at least an hour after the last protective coat is applied before
re-commissioning the coupling.

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8 Maintenance

Alignment check

• Execution only by a specialist

• Required special tools: Radial measuring device, axial measuring
device, angle measuring device

Alignment of the RATO coupling is described in detail in the chapter

“Aligning”.

Inspection for permanent deformation

• Execution only by a specialist.

• Special tools required: Caliper gauge and protractor

1. Remove the coupling protection installed by the owner.

2. Turn the coupling until the lip is visible and easily accessible.

Fig. 8-4

3. Measure the irreversible deformation "S" on the lip.

Fig. 8-5

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8 Maintenance

4. Compare the measured value with the maximum permissible value.

This value is listed below.
5. If the maximum permissible crack depths are exceeded, replace the
flexible segment (see chapter "Dismantling the flexible element").

Permissible irreversible deformation

Model S (mm)

G2610 50

Tbl. 8-3

8.4 Tightening torques

The bolt tightening torque for all fastening elements of the coupling is
specified on the drawing in the Appendix.

8.5 Measures after successful maintenance

Execute the following steps after concluding maintenance tasks and be-
fore switching the system on:
1. Check all previously loosened threaded unions for firm seat.
2. Ensure that all previously removed protective devices and covers
have been properly installed.
3. Ensure that all tools, materials, and other equipment have/has been
removed from the work area.
4. Clean the work area and remove any substances that may have es-
caped, such as liquids, processing material, or similar items.
5. Ensure that all system safety devices are again functioning properly.
6. Owner-installed emergency stop devices, if present, must be reset.
7. Ensure that no one is in the danger zone.

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9 Dismantling

9 Dismantling

9.1 Safety dismantling

Note!
i The fault table provided below lists personnel who are authorized to cor-
rect the fault.

• Only trained, specialized personnel should perform dismantling work.

• If the customer so desires the dismantling process can also be exe-
cuted by Vulkan employees.

Wearing of personal protective equipment is required for work, to mini-

mize health hazards.

• Follow the instructions that have been posted in the work area.
Always wear the following during all dismantling tasks:

• Protective work clothing is tight-fitting work clothing with low resist-

ance to tearing, with tight sleeves, and without projecting parts. It is
primarily used to protect against entanglement by moving machine
parts. Do not wear rings, chains, or other jewellery.

• Hard hat to protect against falling and flying parts and materials.

• Safety footwear for protection against heavy falling parts and slipping
on slippery surfaces.

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• Protective gloves to protect hands from friction, abrasion, puncture

wounds, or deeper injuries, as well as from contact with hot surfaces.

Note!
i The warnings make special reference to additional protective equipment
that is required for certain tasks.

DANGER!

Life-threatening danger if restarted without authorization!

When installing there is danger of the energy supply being switched on
without authorization. This poses a life-threatening hazard for persons in
the danger zone.
Therefore:
• Prior to starting the tasks switch off all energy supplies and safeguard
them from being switched on again.
• If combustion motors supply the motive power then the safety
instructions and the instructions for switching off and safeguarding
against restart in the assembly manuals provided by the manufactur-
ers must be complied with.

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9 Dismantling

WARNING!

Danger of injury due to improper dismantling!

Stored residual energy, sharp-edged components, points, and corners on
and in the coupling, or on the necessary tools can cause serious injuries.
Therefore:
• Prior to starting the tasks ensure that there is adequate free space for
assembly.
• Ensure order and cleanliness at the installation location! Parts and
tools that are lying loose or on top of each other are accident haz-
ards!
• Handle open, sharp-edged components carefully.
• Dismantle components properly. Pay attention to the high dead
weight of some of the components. If necessary use lifting equipment
that is suitable and approved for the weight.
• Secure the components so that they do not fall down or fall over.
• Consult with the manufacturer if there are questions.

WARNING!

Life-threatening hazard - High elastic forces!

The rubber elements and the membrane can accumulate extreme quanti-
ties of energy when they are deflected. Sudden loosening of obstructions
can cause high energy movements of coupling parts, and in the process
cause life-threatening injury.
Therefore:
• Prior to working on the coupling ensure that it is force-free and that
the resilient elements are not deflected.
• For tasks that require deflection of resilient elements only employ the
work methods described in this manual. Only use tools and clamping
devices that are designed for high forces.
• Only specialized personnel familiar with the installation should select
the thrust bearing required for deflection of the membrane assem-
blies.

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WARNING!

Life-threatening danger due to suspended loads!

When lifting loads there is a life-threatening hazard due to falling parts or
parts swinging out of control.
Therefore:
• Never step under suspended loads.
• Comply with the instructions concerning the intended attachment
points.
• Do not attach on projecting machine parts or on the eyes of installed
components. Ensure that the sling gear is securely seated!
• Only use approved hoists and sling gear with sufficient bearing
capacity.
• Do not use rope and straps that are torn or frayed.
• Do not place ropes and straps on sharp edges and corners; do not
knot or twist ropes and straps.

WARNING!

There is an injury hazard due to swinging coupling parts during the lifting
process!
Coupling parts can swing to the side and cause life-threatening injury
when they are lifted from and lowered to the floor.
Therefore:
• When lifting and lowering do not position yourself in the direct vicinity
of the coupling parts and maintain a safety distance.
• Look for safe possibilities of avoiding this hazard when lifting and
lowering.
• Carefully lift and observe the behaviour of the suspended load.
• Comply with the instructions concerning the intended attachment
points.
• Do not attach sling gear to projecting machine parts or to the lugs of
attached components; ensure that the sling gear is firmly seated.
• Only use approved hoists and sling gear with sufficient bearing
capacity.
• Do not use rope and straps that are torn or frayed.
• Do not place ropes and straps on sharp edges and corners; do not
knot or twist ropes and straps.

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9 Dismantling

9.2 Dismantling sequence

9.2.1 Dismounting the elastic part

1. Unscrew the fastening elements (16), (19) and (28) and remove the
bushes (A).
2. Attach the flexible element (1) (see chapter "Transport").
3. Slightly raise via the manual chain hoist until there is tension.

Fig. 9-1

4. Remove the fastening elements (20) and (61) from the flexible ele-
ment (1) and flywheel.

Fig. 9-2

5. Lift the elastic part (1) from the system and put it down at a safe spot
where there is sufficient space.
6. Slacken the hoist and unscrew the load slings.
ª The elastic part is disassembled.

Disassembly safety gear

Remove the safety gear from the ealstic element.
Remove the fastening elements (46,47, 40optional, 48 optional).

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Operating Manual VULKAN RATO R

9 Dismantling

Insert the safety gear and fastening elements into the new elastic ele-
ment.

47 46 48
47

40 40 46

Fig. 9-3

9.2.2 Dismounting the diaphragm assembly

1. Attach a manual chain hoist using a shackle on the marked bore hole
(see arrow) and connect to the crane.
2. Use suitable shackles according to DIN EN 13889.
3. Slightly raise via the manual chain hoist until there is tension.

Fig. 9-4

4. Unscrew the fastening elements (22), (35) and (36) from the hub(5).
5. Pull the membrane assembly (10) off of the hub (5) and remove it from
the system.
6. Place the membrane assembly (10) to the side at safe location where
there is sufficient space.
7. Slacken the lifting gear and unscrew the shackles.

75/92
Operating Manual VULKAN RATO R

9 Dismantling

10

35
36 22

Fig. 9-5

9.2.3 Dismounting the hub on the driven side

Dismounting the hub oil pressure connection

WARNING!

Life-threatening danger due to pressed-on joining parts and parts under

tension when pulling off the hub!
If the pull-off device slips, or due to abrupt detachment of the hub from
the shaft, there is danger of life-threatening injuries.
Therefore:
• Use suitable hollow pressing elements that ensure the axial travel
limitation of the hub after detaching.
• If in doubt contact the manufacturer.

76/92
Operating Manual VULKAN RATO R

9 Dismantling

WARNING!

Life-threatening danger due to hydraulic energy!

Hydraulic energy can cause severe or fatal injuries. If individual compo-
nents are damaged hydraulic fluid can escape under high pressure.
Therefore:
• Only have trained, skilled personnel perform work on the hydraulic
equipment. Only use hydraulic tools and accessories that are suita-
ble and approved for these pressures.
• Do not change pressure settings to exceed the maximum specified
values.
• Prior to dismounting all connections, ensure that the entire hydraulic
system is de-pressurized. Completely de-pressurize the existing
pressure accumulator.
• Wear protective gloves.
• Wear protective goggles.
• Wear personal protective equipment.
• Avoid skin contact with oil.
1. Attach a hand-operated chain hoist to the bore via a shackle (see ar-
row) and take it into the crane.
2. Use suitable shackles in accordance with DIN EN 13889.
3. Lift slightly with the manual chain hoist until slightly tensioned.

Fig. 9-6

4. Note the maximum push-on dimensions (X) stamped on the facing

side of the hub (1).
5. Mount the hollow pressing element (2) on the hub (1) (see the sepa-
rate operating manual provided by the manufacturer of the hollow
pressing element).

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Operating Manual VULKAN RATO R

9 Dismantling

1 2

Fig. 9-7

6. Connect the hydraulic supply for the expansion pressure on the hub
(1) (connection A) and for the hollow pressing element (2) (connection
B) (see the separate operating manual provided by the manufacturer
for the hollow pressing element and for the hydraulic supply).

A B

Fig. 9-8

Note!
i A separate hydraulic pump must be used for each threaded connection.

78/92
Operating Manual VULKAN RATO R

9 Dismantling

Note!
i For expansion, only use a clean oil with the prescribed viscosity. Oil
specification: ISO VG 46 (44 cSt at 40°C) (Mobil DTE25). The oil must
not contain any EP (Extreme Pressure) additives.
7. Loosen the fastening element (D) until the piston (F) is extended by
the dimension X+4 mm to the hollow pressing element (E).
8. Slightly tighten the fastening element (D).
9. Increase the mounting pressure on the hollow pressing element (2)
(connection B) to 100 bar and thus position the hollow pressing ele-
ment on the hub (1).

1 2 X +4mm

F
E

Fig. 9-9

10. Charge the hub (1) (connection B) with pressure for expanding until
the pressure on connection B visibly increases on the manometer
(see the separate operating manual provided by the manufacturer of
the hollow pressing element and the hydraulic supply).

Note!
i Increase the expansion pressure at a maximum rate of 100 bar every 3
minutes, in order not to locally exceed the permissible elongation value.

Note!
i Under normal conditions 2000 bar expansion pressure (A) is not
exceeded!
In special cases higher pressures are necessary!

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Operating Manual VULKAN RATO R

9 Dismantling

Note!
i If the hub does not release at the maximum expansion pressure, then
maintain the pressure for 1 h.
Uniformly heat the hub to 150°C and attach an additional pull-off device.
Use oil with a different viscosity!
11. Slowly discharge the pressure in the hollow pressing element (2) (con-
nection B). In this process maintain the expansion pressure in the hub
(1) (connection A) through constant re-pumping, until the hub is de-
tached from the conical seat.
12. Completely discharge the pressure in the hollow pressing element (2)
(connection B). Ensure that the pressure in the hollow element is com-
pletely reduced.
13. Completely discharge the pressure on the hub (1) (connection A). En-
sure that the pressure is completely reduced.
14. Dismount the hollow pressing elements (2) and hydraulic supplies
(connection A and B) (see separate operating manual provided by the
manufacturer for the hollow compact and for the hydraulic supply).
15. Take the hub off of the shaft and set it down at a safe place,
ª The hub is dismounted.

9.3 Disposal
If a return or disposal agreement has not been concluded, then recycle
dismantled components: if a return or disposal agreement has not been
concluded, then recycle dismantled components:

• Dispose of rubber mixtures in accordance with governmental guide-

lines.
• Sort and dispose of the remaining components in accordance with
material condition
• Remove fuels and auxiliary materials, as well as residual processing
materials and dispose of these items in an environmentally responsi-
ble manner.

CAUTION!

Improper disposal causes environmental damage!

Lubricants and other auxiliary materials are subject to treatment as spe-
cial waste and can cause environmental damage if they are disposed of
improperly.
Therefore:
• Only specialized companies should dispose of lubricants and other
auxiliary materials.
Local municipal authorities or specialized disposal companies provide in-
formation on environmentally responsible disposal.

80/92
Operating Manual VULKAN RATO R

10 Appendix

10 Appendix

10.1 Abbreviations of the technical data

Abbreviation Description

TKN Nominal Torque

TK max.1 Maximum Torque1

TK max.2 Maximum Torque2

∆Tmax. Maximum Torque Range

TKW Permissible Vibratory Torque

PKV50 Permissible Power Loss 50°C

PKV50, 1h Permissible Power Loss 50°C / 1h

nK max. Maximum Rotational Speed

∆Ka Permissible Axial Shaft Displacement

Permissible Radial Coupling Displace-

∆Kr‘
ment / See List Technical Data

Permissible Angular Coupling Dis-

∆Kw‘
placement

Crdyn Radial stiffness

CT dyn Dynamic Torsional Stiffness

Ψ Relative Damping

Cax Axial Stiffness

Cw Angular Stiffness

Axial Reaction Force 1.0mm Deflec-

Fax1.0
tion

Tbl. 10-1

81/92
 Technical Data for RATO R Coupling
Size G262TR Blech Drawing-No.: 1G2620R127

Rubber qual. TR
T KN kNm 40,0
T K max.1 kNm 53,5
T K max.2 kNm 180,0
' T max kNm 64,0
T KW kNm 12,00
P KV50 kW 1,06
n K max min -1 2000
'Ka mm 6,0
'Kr´ mm 9,0
F ax1,0 kN 0,4
C rdyn kN/mm 3,0
nominal warm
C T dyn-total kNm/rad 176,0 123,2
rel . Damping < 1,13 0,79

The guide lines according to "EXPLANATION OF TECHNICAL

DATA" have to be considered
http://www.vulkan.com/vulkan_couplings/downloads.htm

VULKAN
Technische Daten
Kupplungs- und Getriebebau
BLANCO-RATO-R3 Druckdatum: 03.09.2013
 Production Partslist

Manuf.Product 1G262TR127-C Date 03.09.2013

Rato R Page 1
Drawing 1G2620R127 printed by BUNK

Pos. Quant. Part Number Description Dimensions Material Remark DM

1 1 EG262T002R Flex. Part G262TR St/Gummi

5 1 4G27K0095M-C Hub FM 434 X 178.562 X 309 42CrMo4+QT EN10083-1

10 1 2G27K2000M-C MEMBR.ASSEMBLY

16 32 7033616000 DISC FM 27 X 16.2 X 4.5 42CrMo4+QT EN10083-1

19 32 7000116080 HEXAGON BOLT M 16 X 80 10.9 931M

20 32 7000116070 HEXAGON BOLT M 16 X 70 10.9 931M

22 24 7000124080-C HEXAGON BOLT M 24 X 80 10.9 931M

28 32 7020116000 Hex Nut M 16 10 934

35 24 7033624000 Disc FM 39 X 24.2 X 4.5 42CrMo4+QT EN10083-1

36 24 7019124000 Hex Nut M 24 10 DINEN24032

40 12 7033612000 Washer FM 20 X 12.1 X 4.5 42CrMo4+QT EN10083-1

46 6 3G27K80000 Bush FM 24 X 13.5 X 69 42CrMo4+QT EN 10083-1 EN 10083-1

47 6 7000112100 HEXAGON BOLT M 12 X100 10.9 931M

48 6 7020112000 Hex Nut M 12 10 934

55 2 7042617080 Cylinder Bolt 17 X 80 C45 PASSUNG h8

61 32 4G26K3004M-C Bush FM 35 X 17.5 X 26.25 42CrMo4+QT EN10083-1

99 32 7020116000 Hex Nut M 16 10 934

 Production Partslist

Manuf.Product EG262T002R Date 03.09.2013

Flex. Part Page 1
Drawing EG2620002R printed by BUNK

Pos. Quant. Part Number Description Dimensions Material Remark DM

1A 1 EG26RT004R Flex. Element St/Gummi

1B 1 EG26RTR003 Flex. Element St/Gummi

2 30 7001116040 HEXAGON BOLT M 16 X 40 10.9 933M

3 30 7020116000 Hex Nut M 16 10 934

4 60 7033616000 DISC FM 27 X 16.2 X 4.5 42CrMo4+QT EN10083-1

5 30 7033316100 DISC FM 30 X 17.2 X 4 42CrMo4V VERG.17200

6 2 7006116040-C HEX FITTEDBOLT M 16 X 40 10.9 610 JS6

7 2 7020116000 Hex Nut M 16 10 934

8 2 7033316100 DISC FM 30 X 17.2 X 4 42CrMo4V VERG.17200

9 4 7033716000 Disc FM 27 X 17.2 X 4.5 siehe Zeichnung

10 32 3G27K3000M-C BUSH FM 35 X 17,5 X 31,25 42CrMo4+QT EN10083-1 EN 10083-1

 Production Partslist

Manuf.Product 2G27K2000M-C Date 03.09.2013

MEMBR.ASSEMBLY Page 1
Drawing printed by BUNK

Pos. Quant. Part Number Description Dimensions Material Remark DM

1 2 3G27K2000M-C MEMBRANE FM 793X334X1,5 50CRV4

2 4 3G27K7000M-C DISTANCE DISC. FM 301,2X95,2X6 50CrV4+QT EN 10083-1

3 96 3G27K60000 DISTANCE DISC. FM 34 X 25.5 X 0.25 CuSn6 F55

4 12 3G27G10000 Spacer Sheet FM 304.8 X 97.7 X 0.25 CuSn6 F55

5 32 3G27K4000M-C Collared Bush FM 35 X 17 X 15 42CrMo4+QT EN10083-1 EN 10083-1

6 32 3G27K5000M-C DISC FM 35 X 25 X 6 42CrMo4+QT EN10083-1 EN 10083-1

7 8 7010006012 SOCK HD SCREW M 6 X 12 8.8 912M

Operating Manual VULKAN RATO R

11 Index

11 Index

A Intended use 11
Accident 18
Alignment 49 L
Alignment - prerequisites 48 Liability 7
Alignment - radial 49 Limitation of liability 7
Assembly drawing 83, 84, 85
Assembly Manual 6 M
Assembly parts list 86, 87, 88 Maintenance schedule table 62
Attachment 24, 35, 36 Maintenance tasks 63
Marking 19
B Measures after maintenance 69
Behaviour in case of a fault 55 Membrane assembly 21

C O
Coating LP 60 Operating manual 7, 9
Concluding tasks and final inspection 53
Consignment number 19 P
Contact 8 Personal protective equipment 12
Copyright 7, 8 troubleshooting 54, 59
Corrosion preventative 27 Personnel;troubleshooting 54, 59
Corrosion protection 17, 17, 28 Personnel requirements 10
Customer service 8 Preservation 29, 31, 33, 34

D S
Dangers 13 Safety assembly 39, 71
Danger zone 18 Safety instructions 6
delivery status 25, 89 Solvents 28
Disposal 80 Spare parts 8
Disposal of packaging 26 Startup after troubleshooting 58
Storage 18
E Symbols on the packaging 24
Elastic forces 14, 39, 72
Environmental protection 18 T
Explanation of symbols 6 Technical data 82
Explosion hazard 17 Tightening torques 69
Transport crane 35
F Transport forklift 35
Faults 54, 55 Transport inspection 25
Fire 18 Transport of single components
Fire extinguishers 17 prerequisites 36
Fire hazard 17 Troubleshooting 57, 57
First-aid 18
U
H Unauthorized persons 10
Hub 21
V
I VCI foil 31, 31
Incorrect configuration 15

90/92
Operating Manual VULKAN RATO R

11 Index

W
Warranty 8

91/92
 Engine Adjusting Valve C5.05.13.09.15.00
-

Engine Adjusting Valve

en / 22.11.2000 FD020145 1/10

Electrically Operated MOV - 81
Control Valves
Electrical Motor Drive
MOV - S - 81
MOV - 3 - 81
Types Technical Data
Single-seat valve in straight-way form Overall length: according to DIN 3300
Type MOV-81
Dimension sheet EK-413 Flanges: PN 10 DIN 2532
PN 16 DIN 2533
Seat valve in straigth-way form PN 25 DIN 2544
with noise attenuating cone PN 40 DIN 2545
Type MOV-S-81
Dimension sheet EK-413 Operating pressures: according to DIN 2401
Three-way valve
Type MOV-3-81 Differential in accorddance with tables
Dimension sheet EK-414 pressures: EK-413 and EK-414

Positioning ratio: 1:50

Construction
Positioning - normal
Straight-way valves up to DN 200 with shrunk seats, beginning speed: 25mm/min; 50mm/min possible
with DN 250 with screwed seats
cone characteristics linear or equi-percentage different Kv values Strokes: DN 15- 50 25 mm
are possible at equal nominal width DN 65- 100 35 mm
DN 125-175 50 mm
three-way valves with screwed-in double-seat bushes with linear DN 200 58 mm
characteristics of flow and disk cones DN 250-350 65 mm
inserted stuffing-box flanges
Installing position: vertical to horizontal
cast housing
driven by spur gearing with linear actuator Electrical data: according tables „electrical Drive Data“

4 drive sizes, having different positioning forces are available

Additional Equipment
E-motors for 50 or 60 HzAC and three-phase voltages
Soft seal in the cone
drives with emergency manual operation and mechanical cone with multi-hole sleeve
position display
ribbed stuffing-box
drive covered with steel cover spindle sealing by bellows W. No. 1.4571

General
The motor valves are used as electrically operated continuous
Materials control elements (control valves) and as on-off controller for the
control of gaseous and liquid agents. The control is established
Valve housing: PN10/16 GG20 by means of two-point or three-point controllers as a function of
PN25/40 GS-C-25 temperature, pressure, quantity etc. or manually with push-
othermaterials, such as special steel cast, button or switch.
chromium-nickel steel, gun metal, bronze,
etc. and hard rubber lining on request
Construction and Operation
Valve seats: W. No. 1.4401
for three-way valves DN 65-200 -Straight-way valves in single-seat construction.
W. No. 1.4410 or bronze G Sn Bz 10 Dimension sheet EK-413
other materials on request with cooling rib assembly or bellows sealing, respectively.
Dimension sheet EK-425
Valve conel: W. No. 1.4401
for straight-way valves DN 125-350 - Three-way valves.
and three-way valves DN 250-350 Dimension sheet EK-414
W. No. 1.4410 or bronze G Sn Bz 10 with cooling rib assembly or bellows sealing, respectively.
other materials on request Dimension sheet EK-419
Valve spindle: W.-Nr. 1.4401 or bronze AlBz 10Ni
other materials on request - 4 different drives (1.2 kN; 4.5 kN; 12 kN; 24 kN) are optionally
available to meet the operational requirements.
Stuffing-box PTFE, silkyam (reinforced)
packing: orpure graphite The switching-off at the end position is established for
straightway valves in the closing position torque-dependent,
Housing: steel casting GS-C-25 and in
the opening position travel dependent, with an additional limit Electrical and technical drive data
switch, being torque dependent, wired in parallel, for three-way
valves in both end positions, torque dependent. Data for The motors are designed for intermittent
regulating duty S4 acc. to VDE 530 with a relative
In addition, a further free travel dependent limit switch with operation: duty cycle of 30%.
switch-over contact is provided. switching frequencymax.600/h
The valve position is indicated by a pointer at the drive spindle minimum pulse duration: 250 ms
and a scale at the housins. minimum pulse pause: 40ms

For the analog remote transmission of the valve position, the Electrical at the terminal via cable sorewings
installation of 2 potentiometers is possible. wiring: according to DIN 89280

In addition, a further travel dependent limit switch can be Power supply: normally
installed. The built-in electro motor (a) drives the linear actuator 230 V- 50 or. 60 Hz, single-phase-AC,
via a spur gear. In the last gear (b) of the geartrain, a bushing with or
internal thread is shrunk in, which runs in ball bearings. In this 380 V- 50 or. 60 Hz three-phase current
thread runs the upper part of the push-rod (d), provided against other supply voltages on request
torsion by a key and groove. Type of protection: DIN 40050 · IP 65
When the gear is driven, the push-rod and the valve spindle Allowable ambient temperature: - 20 to + 60°C
performs a push / pullmotion, depending on direction of rotation.
Limit switch: torque dependent switches max. 230 V
On power failure, the final control element can manually be ohmic loadmax.10A
actuated. inductive loadmax.5A
The gear ist dustproof separated from the electrical components travel dependent switchesmax.230V
in an aluminium pressure housing. Terminals, motor, limit switch ohmic loadmax.5A
and potentiometers are easily accessible by removing of the inductive loadmax.3A
steel cover electric bulb max. 1 A
Potentiometer: max. 50 V, 100 mA

Motor data
Positioning time mm/min 25 50 25 50 30 60
Voltage Volt
single-phase
three-phase three-phase
AC current
400 V 50 Hz 440 V 60 Hz
230 V 50 Hz
Drive 1,2 kN
Rated current mA 29 15 14,3
Power consumption Watt 6,6 9,9 9,35
Power output Watt 2,4 3,1 3,1
Rotational speed motor U/min 500 500 600

Positioning time mm/min 25 50 25 50 30 60

Voltage Volt
single-phase
three-phase three-phase
AC current
400 V 50 Hz 440 V 60 Hz
Drive 4,5 kN 230 V 50 Hz
Rated current mA 135 160 110 80 100 100
Power consumption Watt 28 32 35 32 35 45
Power output Watt 5,3 12 10 16 12 19
Rotational speed motor U/min 1350 2700 1350 2700 1620 3240

Positioning time mm/min 25 50 25 50 30 60

Voltage Volt
single-phase
three-phase three-phase
AC current
400 V 50 Hz 440 V 60 Hz
Drive 12 kN 230 V 50 Hz
without brake Rated current mA 320 700 210 290 220 265
Power consumption Watt 60 130 75 120 80 138
Power output Watt 22 72 28 63 28 85
Rotational speed motor U/min 1300 2750 1300 2750 1600 3300

Positioning time mm/min 25 50 25 50 30 60

Voltage Volt
single-phase
three-phase three-phase
AC current
400 V 50 Hz 440 V 60 Hz
Antrieb 24 kN 230 V 50 Hz
without brake Rated current mA 660 930 400 700 342 640
Power consumption Watt 145 206 163 337 180 370
Power output Watt 67 110 75 215 88 235
Rotational speed motor U/min 1350 2700 1350 2750 1560 3300
Connection Diagrams The pipes have thouroughly to be cleaned prior to assembling,
in order to prevent a later damage to the seats and cones.
AC 2/2 way valve RTA-264
3/2 way valve RTA-265 The installation of a dirt tr,ap in front of each control valve is
strongly recommended.
Three-phase 2/2 way valve
current: linear actuator 1,2 + 4,5 kN RTA-264/3 On mounting of straight-way and angle valves pay attention to
linear actuator 12 + 24 kN RTA-264/4 the direction of arrow on the valve housing.

3/2 way valve Mix and partitioning valves are provided with the figures 1,2 and
linear actuator 1,2 + 4,5 kN RTA-265/3 3 on their connecting flanges. Observe the correct installation in
linear actuator 12 + 24 kN RTA-265/4 accordance with piping diagram.1 is always the joint
connection, whereas to 2 and 3 the incoming or leaving part
Installation streams are connected.
"These actuator valves shall be mounted with the drive towards The wiring and connecting of the electrical circuitry has to be
the top. For any other position ask before ordering." performed in accordance with the regulations for the installation
of power plants and with the respective wiring diagrams.

Start-up and
Adjustment instructions
For start-up of the valve place the drive by means of the hand
wheel (e) in the middle of the positioning travel, switch on power
and give shortACpulses to the drive; watch whether the push rod
(d) moves into the correct direction. Otherwise, exchange the
motor connections at the terminal strips 2 + 3.

Drive 1.2 kN and 4.5 kN

Operate manually only with the motor at standstill.
For this purpose press the bolt (f) mounted below at the drive
housing with the hexagonal head into the housing until the spring
lever (h) engages into the notch of the bolt. Hereby rotate the
handwheel (e) a little bit. On rotating of the handwheel ciockwise,
the push spindle is extended rotating ccw draws the spindle in.
On pressing of spring lever (h) in the direction of the valve shaft
the bolt jumps out on its own and the drive is switched back to
motor drive.

Drive 12 kN and 24 kN
Change over to hand-operating:
Push hand disengaging lever into direction -1- (at the time turn
hand wheel slightly if necessary), then swivel hand disengaging
lever above the hexagon screw into direction -2-.
Now hand operating position is locked.
Change over to motor drive:

Swivel hand disengaging lever into direction - 3 - and release. All

further engaging proceedings will occur automatically with
starting up of themotor.
Figure travel dependent switch and message devices

With the end position reached with extended push spindle, the
two slotted levers (1) are parallel. A'ter loosening of the nut, the
carrier bolt (7) can be moved into the slot of the lever allowing the
stroke of the drive to be adjusted by means of the auxiliary scale.
After this being done, re-fasten the bolt. In this position, the
potentiometers (5) (in case there are any) have to be in the end
position. They can be adjusted by rotating the slider.
After that move the drive by the required travel for 2/2 valves or
the possible travel for 3/2-way valves in the opposite direction the
potentiometer will then turn into the other end position.
For the adjustment of the travel dependent limit switch "S 3" for
the limiting of the travel in the position open, the knurled head nut
(4) has to be loosened. Adjust the cam washer (4) to make the
switch shut off. The second built-in travel dependent switch "S 4"
and another possible "S 5" may freely be adjusted inbetween the
two end positions. Re-fasten the knurled head nut after the
switches being adjusted.
The switches provided for the end positioning are factory
adjusted. The torques of the load dependent switches are fixed
and can not be changed.

1 Slotted levers; the lower one is marked for the set travel
2 Travel-dependent switches
3 Knurled nut
4 Cam disks
5 Potentiometer for position indication
6 Scale for setting the travel
7 Connection bolt

Maintenance

Valve assembly Drive

Re-fasten the screws and flange connections at the housing after Grease the drive at normal operating conditions every three
start-up of the installation as the sealings are settling a bit at the years, at higher loads after approx. 200 000 double strokes with
beginning. The maintenance of the stuffing-box is also important. "Fett Klüber Structoris P 00" or a similar grease.
In case of leakage, the stuffing-box gland has to be fastened at
once. If this is no longer possible, the stuffing-box has to be re-
packed.
Take care to use the right material, depending on the agent, the
temperature etc. Keep the part of the spindle being in contact with
the stuffing-box always clean and grease at regular intervals with
a suitable grease. If the sealing surfaces at the seat and the cone
are damaged by dirt or foreign particles, no longer giving a tight
seat, they can be ground with a fine emery paste. With valves
having PTFE inserts in the cone, the latter can easily be replaced.

The above information and our technical advice for application in word, in writing and by tests
are given to the best knowledge. They shall be applied, however, only as hints without
obligation, also with reference to any protective rights of third parties. The advice does not
relieve you from examining our advisory hints and our products by yourself with regard to their
suitability for the intended procedures and purposes. Application and use of our products and
those products manufactured by you on the basis of our technical advice for application are
beyond our possibilities of control and, therefore, exclusively belong to your responsibility. The
sale of our products is subject to our General Terms and Conditions of Sale and Delivery.

Ausgabe/EDITION 06/02

Pleiger Maschinenbau Postfach 32 63 ( +49 / (0) 2324 398-0

GmbH & Co KG D-58423 Witten Fax +49 / (0) 2324 398-380