Operating Instruction PDF

SIHISuperNova Programme
Range: ZLND
Volute casing pump complying with EN 733 / DIN 24255*
PUMP DESCRIPTION: ______________________________
SERIAL NUMBER: ____________________
Operating instructions
Translation of the original instructions
Safety issues Chapter 1

Intended application Chapter 2
Planning the installation Chapter 3
Unpacking, storage, handling Chapter 4
Installing the pump Chapter 5
Start up and shut down Chapter 6
Maintenance, dismantling and assembly Chapter 7
Troubleshooting Chapter 8
Technical data Chapter 9
Connections, dimensions, sectional drawing Chapter 10
Additional instructions: M1S Annex I
Additional instructions: N1S, NFS Annex II
Declaration of conformity. Example Annex III
ATEX information Annex IV
Regulation EU 547/2012 Annex V
*
With certain exceptions see Technical Catalogue
Attention: Both the pump and/or the pump set must be installed and commissioned by qualified technical
personnel only and these installation, commissioning and operating instructions must be strictly observed.
Failure to do so could result in:
danger to you and your colleagues,
the pump or the pump unit may be damaged,
Note that the manufacturer is not liable for damages resulting from failure to observe these instructions.
Please be aware of your responsibility to your colleagues when working on the pump or the pump set!
Safety instructions marked with included in this Operating Instructions and in the
Supplementary Operating Instructions, which must be attached to this Operating Instruction, have to
be considered in particular when operating this pump in potentially explosive atmospheres!
In the search to improve continuously its products,

For local contact details:
Sterling Fluid Systems reserves the right to modify its (Sterling Fluid Systems BV) 2012
www.sterlingsihi.com
products at any time without prior notice.
Safety issues Page 1 of 3 Chapter 1
1. Safety
This operating manual gives basic instructions, 1.2 Qualification and training of
which must be observed during installation, personnel
operation and maintenance of the pump. It is The personnel responsible for operation,
therefore imperative that this manual is read by maintenance, inspection and assembly must be
the responsible personnel / operator(s) prior to adequately qualified. The scope of responsibility
assembly and commissioning. It must always be and supervision of the personnel must be exactly
kept available at the site of pump installation. defined by plant management. If the staff do not
It is not only the general safety instructions have the necessary knowledge, they must be
contained in this chapter Safety which must be trained and instructed. This task may be
observed, but also the specific information performed by the machine manufacturer or
provided in the other chapters. supplier on behalf of the plant management.
Moreover, plant management must ensure that
1.1 Identification of safety the contents of the operation instructions are fully
symbols in the operating understood by plant operators and other relevant
instructions personnel such as maintenance staff.
Safety symbols are given in these operating
instructions. Non compliance with these would 1.3 Hazards in case of non
affect safety and are identified by the following compliance with safety
symbol instructions
Non compliance with the safety instructions may
result in risk to personnel as well as to the
environment and the pump/pump set and result in
Danger symbol as per DIN 4844-W9 the loss of any right to claim damages.
(ISO 3864 - B.3.1) For example, non-compliance may result from, or
lead to, the following:
Or in case of danger of electric current with: failure of important functions of the pump/pump
set/plant
failure of specified procedures of maintenance
and repair
exposure of people to electrical, mechanical
Danger symbol as per DIN 4844 W-8 and chemical hazards
(ISO 3864 - B.3.6) danger to the environment owing to hazardous
The word substances being released.
ATTENTION
1.4 Compliance with regulations
relating to safety at work
identifies those safety regulations where non-
When operating the pump the safety instructions
compliance may pose a danger to the pump and
contained in this manual, the relevant national
its function. It is imperative that the appropriate
accident prevention regulations and any other
safety information is attached to the pump/pump
service and safety instructions issued by plant
set, for example:
management must be observed.
an arrow indicating the direction of rotation
symbols indicating fluid connections
the identification plate
and that these are kept legible.

1.5 Safety instructions relating to 1.7 Safety instructions for the use in
operation areas with explosion hazard
If high or low temperature pump/pump set
components involve hazards, steps must be
taken to avoid accidental contact.
Guards for moving parts (e.g. couplings) must
not be removed from the pump/pump set while
in operation. In this section information is given for operation in
Any leakage of hazardous (e.g. explosive, areas where an explosion hazard exists.
toxic, hot) fluids (e.g. from the shaft seal) must
be drained safely so as to prevent any risk to
1.7.1 Complete pump sets
persons or the environment. Statutory If the pump is combined with other mechanical or
regulations are to be complied with. electrical components in one set, the category of
Hazards from electricity are to be avoided by the complete unit will correspond, based upon the
the user (see for example the VDE- Directive 94/9/EC, only to that category with which
specifications and the bye-laws of the local all of its components comply.
power supply utilities).
Note:
1.6 Safety instructions relevant for These comments are of particular importance
maintenance, inspection and when pumps, which conform to a given category
assembly work of Directive 94/9/EC, are powered by a driver
It is the plant manegements responsibility to which is not in the same category.
ensure that all maintenance, inspection and Although the pump may bear the Ex sign, the set
assembly work is performed by authorized should not be used in areas with an explosion
personnel who have adequately familiarised hazard when the motor is not classified for this
themselves with the subject matter by studying application.
this manual in detail. This means that plant management personnel
Any work on the machine must only be performed should always check that all elements of the set
when it is at a standstill. It is imperative that the comply with the Directive 94/9/EC.
procedure for shutting down the machine
described in this manual is followed.
1.7.2 Execution of coupling guards
Pumps and pump sets, which convey hazardous Coupling guards that are to be used in areas with
media, must be decontaminated. an explosion hazard, have to fulfil one of the
On completion of the work all safety and following criteria:
protective guards must be re-installed and made consist of non-sparking material, e.g. brass.
operative again. Prior to re-starting the machine, if they consist of sparking material, e.g. steel
the instructions listed under first commissioning sheet, they must be designed in such a way
are to be observed. that the rotating parts will not come in contact
with any part of the guard if errors, that could
be foreseen, are committed by the user, e.g if
a person steps on the guard.

1.7.3 Monitoring technical modifications are only undertaken with Sterling

parameters Fluid Systems written agreement.
When using pumps in areas with an explosion
risk, the operator must check the following
parameters regularly:
leakage of shaft seals
bearing temperature
that the pump is always filled with liquid during
operation
that the pump does not operate against a
closed valve for any length of time.
The operator must ensure that pumps, which
show evidence of abnormal operation, are
switched off and not started again until the cause
of the abnormal operation has been eliminated.
1.7.4 Avoiding external damage

In areas with a risk of explosion the operator must
ensure that the pumps and or pump set is not
subjected to external impacts e.g by heavy
objects.
1.8 Unauthorized alterations and

production of spare parts
Modifications may be made to the pump/pump set
only after consultation with,and written approval
from, the manufacturer. Using spare parts and
accessories authorized by the manufacturer are in
the interests of safety. Use of other parts may
exempt the manufacturer from any liability.
1.9 Unauthorized mode of operation

The reliability of the pump/pump set can only be
guaranteed if it is used in the manner intended
and in accordance with the instructions of this
manual. The specified limit values must under no
circumstances be exceeded.
1.10 Warranty / guarantee

Sterling Fluid Systems guarantee satisfactory
operation if:
the pump is installed and operated in
compliance with these instructions and in
operating conditions approved by Sterling Fluid
Systems

Intended application Page 1 of 3 Chapter 2
2. Application
The pump is to be used only for the operating 2.3 Construction and mode of
conditions stated by the customer and confirmed operation
by the supplier. Guarantee is assumed within the ZLND pumps are horizontal, single-stage volute
scope of the Sterling Fluid Systems conditions casing pumps with nominal outputs and flange
of sale. dimensions meeting EN 733 / DIN 24255. Their
Appropriate application and operating conditions back pull out construction allows the disassembly
are contained in the attached data sheets. of the complete bearing unit towards the drive
side without removing the pump casing from the
pipework.
2.1 Warning of misuse ZLND pumps are preferably used when pure or
turbid liquids, not containing solid particles, are to
be handled.
Impurities up to a grain size of 3 mm can be
handled, but shorten the service life.
The pump may only be used for the

application(s) stated. Otherwise hazards for
people and environment may arise.
ATTENTION
Do not exceed fluid density stated.

Otherwise, there is a the danger of motor
overload.
The pump must not be operated beyond its
characteristic curve otherwise there is a
danger of cavitation and motor damage.
2.2 Accessories
The accessories included in the scope of supply
are indicated in the delivery note or in the order
confirmation. The corresponding operating and
installation instructions are also indicated in the
Annex relating to accessories.
If it is intended to mount other accessories on the
pump or on the pump set, please inform the
manufacturer in advance in order that appropriate
technical advice can be given.

2.4 Description
Type
size Hydraulic + Bearing Shaft seal Material design Casing gasket
A First hydraulic 041: Self-sealed, uncooled packing rings 0B: Cast iron GG25
B Second hydraulic 2: confined flat
D Double volute 052: Uncooled packing rings, external seal 0C: Cast iron GG25, gasket of EWP
liquid Bronze G-CuSn10 impeller 210 material
B27:WC/Carbon, EPDM 0E: Cast iron GG25,

B Two ball bearings
Stainless steel 1.4408 4: confined flat
ZLND greased for life (2Z)
BJ3,C23,AF3,AX3,AY3,A93:SiC/Carbon, EPDM impeller gasket of PTFE
C Two ball bearings oil
032125 lubricated BJS,C2S,AFS, AXS,AYS,A9S: SiC/ SiC, Viton 1B: Ductile cast iron
to S One double row angular GGG40.3, cast iron GG25
300500 contact bearing plus one ball BJJ,C2J,AFK,AXK,AYK,A9K: SiC/Carbon, Viton impeller
bearing, grease lubricated
T One double row ball M1S,N1S,NFS: SiC/ SiC, Viton 4B: Stainless steel 1.4408
bearing plus ball bearing, oil
lubricated
Alternatively
A or B 032160, 032200 Alternatively Alternatively
A 032125 to 200315, 250315 041, 052, B27, BJ3, C23, AF3, AX3, AY3, A93,
D 200400 to 300500 BJS, C2S, AFS, AXS, AYS, A9S, BJJ, C2J, 0B, 0C, 0E, 1B, 4B 2, 4
AFK, AXK, AYK, A9K, M1S, N1S, NFS
Alternatively B, C, S or T
Codes AX3, AXS, AXK: are equivalent to AF3, AFS, AFK respectively plus quench
Codes AY3, AYS, AYK: are equivalent to AF3, AFS, AFK respectively plus heating
Codes A93, A9S, A9K: are equivalent to AF3, AFS, AFK respectively plus external flushing
Code B27: this execution is only valid for water up to 140 degrees.

Example of a pump designation: 2.5 Shaft sealing

Depending on the application, different shaft
1-3 4 5-7 8-10 11 12 13-15 16-17 18 sealing executions are offered (see 2.4)
ZLND 125 250 A C 041 0B 2 a stuffing box with lantern ring (executions
041, 052, and optionally 051) or mechanical
Casing gasket
seals according to EN12756 are utilised in the
Construction following cases:
Shaft sealing if the pump draws from a suction line,
Bearings:B,C,S, or T if the pump is fed by a feed line with a
Hydraulic: A/B/D pressure of less than 0.5 bar or
if the pumped liquid is at or near its boiling
Impeller size
point.
Nominal discharge Provision of the sealing liquid is as follows:
041: Internal self sealing ISO 5199 plan 01
052: External self sealing ISO 5199 plan 08
Pump series
051: External self sealing ISO 5199 plan 09
Mechanical seal: ISO 5199 plan 02. API plan
11
Mechanical seal execution plus external
flushing: ISO 5199 plan 08, API plan 32.
Mechanical seal execution plus quench: ISO
5199 plan 09. API plan 62.
ATTENTION
Section 2.4 does not contain the codes for all

variations of mechanical seals. Where the code is
not included or replaced by QQQ, consult the
relevant data sheet of the mechanical seal
supplier (e.g. special execution of the mechanical
sealing in a back to back position).

Planning the installation Page 1 of 2 Chapter 3
3.0 Planning the installation
3.1 Piping system Ensure that air pockets cannot be created.

Unequal nominal widths of the suction branch and
suction line must be compensated by eccentric
ATTENTION
transition pieces.
Note the arrows on the pump branches

indicating the direction of flow. Flow straightener
Choose nominal widths of the pipelines

according to the nominal widths of the pump
branches or larger ones with the
corresponding reductions.
Flange sealing must not protrude on the
inside.
Ensure that the pipework is clean before
installing of the pump. Connection of eccentric pipe transitions
Support the pipework in order to avoid
distortions at the pump components (risk of It is recommended that a filter is installed in front
damage to pump components) of the pump with a filter surface of at least 3 times
Avoid abrupt changes of cross section and the pipe cross section (approx. 100 meshes/cm).
direction.
Where different diameter pipework is to be The suction opening of the suction line should be
used, connection should be by eccentric well below the liquid level, and a strainer should
transition pieces. This will avoid the formation be used.
of air pockets in the pipework. The strainer must be far enough from the bottom
For difficult pumping on the suction side, to to avoid excessive inlet losses, which could impair
stabilise the flow, a pipe length 15 times the pumping performance. It is advisable to check that
diameter of the suction branch should be there is no leakage.
installed before the suction branch. 7
The flow rate in the suction line or inflow line, 6
must not exceed 2 - 3 m/s. 3 1 2

4
4
3.1.1 Suction line / inflow line

See the sketches below for the optimum layout of 1 Eccentric reducer ( suction line ) or
pump installation for flow and suction lift concentric reducer ( feed line )
operation. 5
2 Shut-off valve
3 Suction line
4 Bend
Pump installation 5 Foot valve with suction strainer
6 Check valve
7 Regulating valve
positive suction head operation suction lift operation

Planning the installation Page 2 of 2 Chapter 3
A shut-off valve should be installed in the feed

line. It must be closed for maintenance work.
It should be installed in order to avoid air pockets
forming in the spindle cap, i.e. with the spindle in
a horizontal position or pointing vertically
downward.
3.1.2 Discharge line

For flow regulation, a valve must be installed
behind the pump. If non-return valves are used,
they should close smoothly. Pressure shocks
must be avoided.
3.1.3 Inlet and outlet connections

The various connecting points are shows in the
drawings. (See Annex, Chapter 10, point 10.1).
3.1.4 Pressure control

For consistent control of pressure, it is advisable
to install in the pipework a measuring point in front
of, and behind the pump.
3.2 Electrical connections

For the drive motor a mains connection is required
which complies with the European Regulations
and Directives for the Standards in Industry and
with the instructions of the local power supply
utilities of the country concerned.

Unpacking, storage, handling Page 1 of 2 Chapter 4
4. Unpacking, storage, handling 4.4 Handling

The pump or pump set must be lifted and handled
4.1 Safety measures as shown in the following sketches.
Never stay below the suspended load.

Keep a safe distance while the load is being
transported.
Use only approved lifting appliances, which
are in good condition.
Adjust the length of the lifting appliances in
such a way that the pump and/ or the pump
set, is suspended horizontally. Pump without motor
Do not use the eyebolts on the pump

components for lifting the assembled pump or
the complete set.
Do not remove documents, which are
attached to the pump.
Do not remove the protection covers from the
pump suction/discharge. Otherwise, there
may be a risk of contamination.
4.2 Unpacking
Before unpacking, a visual check of the packing is
recommended. If transport damage is visible, the
Pump set
extent should be noted on the receipt or on the
delivery note. Potential claims must be lodged
immediately with the carriers or the insurance
4.5 Protection against corrosion
In general, a protective coating is only applied to
company.
the following executions: OB, OC and OE.
4.3 Interim storage
If the pump or the pump unit is not installed
4.5.1 Removal of protective coating
To remove the protective coating, the pump
immediately after delivery, it must be stored free
should be filled and drained several times using
from vibration in a dry room.
appropriate agents, e.g. solvent naphtha, diesel
oil or alkaline detergent. Flush with water, if
necessary.
The pump must be installed and started up
immediately afterwards.

products at any time without prior notice
Unpacking, storage, handling Page 2 of 2 Chapter 4
4.5.2 Renewing corrosion protection

If the pump has been supplied with a protective
coating and has to be stored, a new protective
coating should be applied after six months.
For suitable protective coatings, contact Sterling
Fluid Systems.

Installing the pump Page 1 of 3 Chapter 5
5. Installing the pump

5.4.3 Base, foundation
5.1 Requirements The pump must be installed on a flat floor or
The pump and the pump set, must have been foundation free from vibration. In case of doubt
unpacked and handled as described in Chapter 4. use vibration dampening feet.
The pump set must be correctly mounted on the
5.2 Use of trained staff foundations. To avoid distortion of the pump set
Only appropriately trained staff must undertake and/or the foundation, parallel shims must be
the work described in this chapter. used between the base plate and foundation.
5.3 Safety measures Prior to installing, checks should be made with

regard to:
- Possible damage to the pump or the

pump set that may occur in transit.
Connect the pipework carefully to prevent the - Ease of running ( check that the shaft is
pumped liquid escaping during operation and free to rotate by hand ).
endangering operating personnel. - The foundation dimensions.
Ensure that the suction or inflow line, and the
discharge line are closed by valves. The following preparatory work must be carried
Ensure that all electrical connections are out before to placing the pump:
dead. Otherwise, there is a risk of electric
shock. - Roughen and clean foundation surface.
Pay attention to relevant internal plant - Remove shuttering/cores from the anchor
regulations. holes.
Avoid accidental contacts with hot - Blow the anchor holes clean.
components. - Check the position and dimensions of
the anchor holes against the arrangement
ATTENTION drawing.
Remove the protective coating by following 5.4.4 Installation of the set

the instructions of Chapter 4. Otherwise there The complete set mounted on the base plate must
is a danger of contamination . be placed on the foundation with its foundation
(rag) bolts hanging below the baseplate.
5.4 General information 5.4.5 Space required

The space required for the pump set is set out in
5.4.1 Assembly tools the foundation plan or installation drawing.
Special tools are not required for assembly and Ensure easy access to the shut-off and regulation
installation. valves as well as to any measuring instruments.
5.4.2 Permissible ambient conditions

The ambient temperature can be from -20 C to
+60 C. The atmospheric humidity should be as
low as possible in order to avoid corrosion.

5.4.6 Position If other manufacturers couplings are used, follow

In principle the ZLND pumps are installed the manufacturers instructions. After installation
horizontally. on the foundation and connecting the pipework,
the coupling alignment must be checked and re-
aligned, if necessary. Moreover, after reaching the
operating temperature the alignment of the
coupling must be checked again.
The coupling requires a guard that meets DIN
31001 in order to avoid accidental contact during
operation.
In any event, the operating instructions of the
coupling manufacturer must be followed, since the
coupling is a component incorporated by Sterling
5.5 Motor Fluid Systems.
Before assembly check the direction of rotation of
the motor (indicated by an arrow on the pump ruler
casing). If this is not possible the direction of
rotation of the complete unit can only be checked
only if the pump is filled.
In any event, the operating instructions of the
motor manufacturer must be followed, since the
motor is generally incorporated by STERLING
FLUID SYSTEMS into the pump set.
5.6 Alignment of the set

The following is required a = a1 and b = b1
Place shims under the base plate on both sides of
the foundation bolts, 10 mm from the base plate
edge. Use a spirit level to align the set.
5.8 Checking before installation
If necessary, place shims between the foundation
Before installing the pump on the plant, the
bolts to prevent the base plate from sagging. Care
following points must be checked:
should be taken to minimize distortion of the base
1. Is the electrical current to the drive motor
plate during installation. The location of the driver
switched off?
must not be higher than that of the pump. The
2. Are suction and discharge lines emptied and
max. deviation from the shaft centre line is 0.1
closed by valves?
mm.
3. Is it possible to rotate the pump easily by
The foundation bolts should be embedded in
hand (for this purpose turn the fan of the
concrete using quick-setting grout.
motor or the coupling)?
4. Have the latest internal/plant instructions been
5.7 Coupling
observed?.
Install the coupling avoiding hard blows, if
necessary in warm condition. Arrange the pump
and motor on a level base. The shaft ends must
be aligned exactly. The distance between each
half of the N-EUPEX B ( FLENDER ) coupling
must be 2 - 3 mm (see fig.).

5.9 Mounting the pump and

installation into pipework
The following instructions must be carried out:
1. Remove the protective covers from the pump

flanges and the auxiliary pipework
connections.
2. Correctly insert the flange seals.
3. Connect the suction or feed line.
4. Connect the discharge line.
The pump must be aligned with the pipework. The

pipework must be supported so that distortion
cannot occur when connecting the pump.
5.10 Final work

The following final steps must be undertaken:
1. Check the tightness of the connecting flanges.

2. Check for easy running of the pump (for that
purpose turn the motor fan or the coupling).
3. Check the coupling alignment.
4. Install the coupling guard.
5.11 Hydrostatic pressure test

When subjecting the piping system to a
hydrostatic pressure test, exclude the pump from
the pressure test.
If it is not possible to test the pipework without the
pump, ensure that foreign material cannot enter
the pump.
The max. permissible pressure for a

pressure test is 1,3 times the nominal
pump pressure.
The nominal pump pressure is indicated
in the technical data sheet.

Start-up and shut-down Page 1 of 3 Chapter 6
6. Start-up and shut-down

operations
6.1 Requirements If there is no bypass line, do not run the

The pump or the pump set, must be installed acc. pump with the control valve closed for any
to the instructions of Chapter 5. length of time.
Safety measures should be taken by the
6.2 Use of trained staff end user to ensure (for example by
Only appropriately trained staff must carry out the means of a relief valve) that the
work described in this chapter. permissible pump casing pressure is not
exceeded during operation
6.3 Safety measures If water up to 140C is being pumped end
user must ensure that pressure is at least
0,5bar above the vapour pressure of the
hot water. Water quality see chapter 9
Repeat the alignment of the coupling at
operating temperature. Re-align the pump
Electrical connections must be made or the motor, if necessary.
according to the European Regulations and
Directives for the Standards in Industry and in
compliance with the instructions of the local 6.4 Electrical connection
power supply utilities of the country The motor must be connected at set out in the
concerned. circuit diagram in the terminal box.
Only appropriately authorized personnel may
carry out this work. 6.5 Checks before switching-on
Before switching on the pump unit, the following
ATTENTION points should be checked:
1. is all pipework connected and are the unions
Fill the pump correctly; otherwise the shaft tight?
seal could be destroyed. 2. is the pump including the pipework filled
Fill the supply lines correctly. properly?
Check the direction of rotation only when the 3. is the shut-off valve in the discharge line
pump is filled. closed?
Fill the pump slowly if hot media are being 4. is the shut-off valve in the suction line
pumped in order to avoid distortions or heat completely opened?
shock. 5. is the motor ready for operation?
When handling explosive, toxic, hot, 6. is the direction of rotation of the motor
crystalline or corrosive media, ensure that correct?
there is no risk to people or the environment. (check by running the motor for a short time)
Control the output at constant speed at the 7. is the coupling aligned exactly?
discharge side only. The valve at the suction 8. has the shaft seal been installed?
side must always be completely open during 9. are the supply lines, if any, to the shaft seal
operation to avoid the risk of cavitation. open?
10. in the case of oil lubrication - has the bearing
housing been correctly filled with oil?

Sterling Fluid Systems reserves the right to modify (Sterling Fluid Systems) 2012
its products at any time without prior notice.
11. is the gland finger slightly tight?. 6.7 Switching frequency
Size Permissible number of

starts equally spaced
per hour
032125,032160, 032200, 032250,
040125, 040160, 040200, 040250,
050125, 050160, 050200, 065125,
065160, 065200, 065250, 080160, 15
080200, 080250,100160,
100200, 100250, 100315,
125200, 150200, 150250
040315, 050250, 050315, 065315,
080315, 080400, 100400,
125250, 125315, 125400,
Fasten gland nuts
150315, 150400, 150500, 8
200250, 200315, 200400,
200500, 250300, 250315,
250400, 250500, 300400, 300500
6.6 Start-up operation

For starting proceed as follows:
1. open fully the valve on the suction side 6.8 Special instructions
2. close the valve on the discharge side During operation the following points must be
3. switch on the motor observed:
4. check the pressure gauges at the pressure - control the speed and the delivery head
measuring points - ensure that the pump runs without vibration
If the pumping pressure does not increase - control the liquid level in the suction line and/or
consistently with increasing speed, switch off the inflow tank
motor again and vent the pump one more. - control the bearing temperature (max.
5. After reaching operating speed, regulate the temperature 100 C)
operating point of the pump by adjusting the - control the pressure in the supply lines according
valve in the discharge line (see technical data to the following limits:
for permissible range of operation). External flushing:
6. For running in the packing, the gland should Impeller size 125
be tightened only slightly (even in the case of Buffer pressure = pW + 0,5 bar
considerable leakage initially). After approx. Rest of impeller sizes:
30 minutes tighten the gland to such an extent Buffer pressure = pW + H + 2,5 bar

3
that it leaks only slightly. Check it several Flow = 0,1 0,2 m /h
times, until leakage from the packing is about pW = suction pressure, in bar
20 to 40 drops a minute. In extreme operating H = differential pressure of pump, in bar
conditions and high temperatures this rate
may be higher. Quench
Maximum pressure = 4 bar
Pumping against a closed valve in the discharge Heating
line is permitted only if a minimum output via a Maximum pressure = 4 bar, with
bypass line is guaranteed. water steam to 140 C

- shaft seal
Executions with stuffing box:
For correct operation of the shaft seal a slight
leakage (20 - 40 drops per minute) is essential. If
the leakage is reduced too much by retightening When handling explosive, toxic, hot, crystalline or
the packing, it will be destroyed. corrosive media, ensure that people and the
If the pump is equipped with code 052 or code environment are not endangered. Even if the
051, the supply lines to the stuffing box have to be pump has been drained using the threaded plug
open before the pump is started. 90.30, residues can remain in the pump. For
Executions with mechanical seal: transport, the pump must be free from any
During running-in slight leakage may occur. If the dangerous material. In case of extended periods
pump is equipped with an external flush, quench out of service, protect the pump against corrosion.
or heating, the flush, quench or heating supply
has to be switched on before the pump is started.
The mechanical seal must be allowed to cool
before the next re-start.
ATTENTION
For executions with stuffing box: If the leakage

increases considerably and cannot be adjusted by
retightening the gland, the packing is worn and
must be replaced by a new one.
For executions with mechanical seal: If the initial
leakage does not disappear within 5 minutes of
operation, stop the pump, dismantle the seal and
check for damage of the seal faces and auxiliary
sealing.
6.9 Shutting-down
Before shutting down close the valve on the
discharge side.
After shutting down, all valves may be closed. The
valves of the auxiliary pipework connections,
(quench, heating, external flush, code 052, code
051), have to be closed in the last place.
If there is a risk of very low ambient temperatures,
remove the pump and then drain it using the
threaded plug 90.30.

Maintenance, dismantling and assembly Page 1 of 10 Chapter 7
7. Maintenance, dismantling and grease nipple

assembly
7.1 Requirements
The pump or the pump set must have been shut
down in the manner described in Chapter 6.
7.2 Use of trained staff

Only appropriately trained and skilled staff should Grease lubrication:
undertake the work described in this chapter.
The bearings receive their first engreasing at the
supplier plant.
Only authorised personnel must undertake
electrical work associated with maintenance of the Grease amount per ball bearing:
pump/pump set. bearing housing 55: (shaft end diameter at the
driving side 50 mm) 30 gramme
7.3 Safety measures bearing housing 65: (shaft end diameter at the
driving side 60 mm) 40 gramme
lubrication low activity middle and high

intervals activity
for grease n 1500 1/min 1500 < n 3000 1/min
For explosive, toxic, hot, crystalline as well as lubrication every 5000 hours every 2500 hours
at the latest after 12 months
different pumping media ensure that people
and the environment are not endangered.
Flush the pump with clean liquid before After about 10000 hours of activity or the latest
dismantling. after two years, the bearings have to be
The working place for disassembly or disassembled, washed and refilled with grease.
assembly must be clean. Under extremely unfavourable circumstances (wet
Before reinstallation, the pump must be free of or dusty environment or high temperatures of the
any dangerous material. environment) the lubrication intervals have to be
chosen considerably shorter.
For renewing or adding lubrication grease, only
7.4 Maintenance and inspection lithium soap bearing grease have to be utilised
The pump requires only limited maintenance. (e.g. Mobilux 2, Shell Aero Grease 16, Esso
Unirex N3).
7.4.1 Bearing with grease lubrication
The pumps with bearing brackets 25, 35 and 45 7.4.2 Bearing with oil lubrication
use an antifriction bearing, lubricated for service The pump is supplied empty (no oil). Before the
life, on the drive side and on the pump side. initial start up, pour oil into the oil inlet hole until
The pumps with bearing brackets 55 and 65 must the oil level reaches the mark on the dipstick.
be greased through grease nipples 63.60.

and/or if there is danger of contamination, the oil

Oil filling
should be renewed about every six months.
Oil properties:
Operating Ambient temp.
temp. of < 0C
bearing up
to 80C
n1500 n>1500
rpm rpm
Type of lubrication CL68 CL46 CL22

DIN 51517
Kinematic viscocity 61.2 to 41.8 to 19.8 to
2
at 50C in mm /s 74.8 50.8 24.2
Oil drainage Constant level oiler
Neutralisation figure Maximum 0.15 mg KOH/g
t Ash ( as Ash Oxide ) Maximum 0.02% weight
As an additional accessory, it is possible to Water content Maximum 0.1% weight
connect a constant level oiler. In this case, the Suitable motor oil SAE 20 and 20W SAE 10W
bearing support must be filled with oil through the
oil inlet hole, until the oil is visible in the screw-in
Oil quantities:
elbow, the oil reservoir having been removed.
Bearing Bracket Oil ( litre )
Subsequently the oil reservoir should be filled with
25 0.22
oil and put into its correct position.
35 0.38
The bearing housing will be supplied with oil from
45 0.57
the constant level oiler with the correct amount as
55 1.50
long as there is oil in the reservoir.
65 2.00
See sketch of oiling system below
1. Oil reservoir
2. Screw-in elbow ATTENTION
3. Fill in oil here
The lubricating oil must be extremely pure,
4. Never fill with oil here, always use the oil inlet
resistant to ageing, must have good viscosity-
hole.
temperature behaviour, good water separating
properties and corrosion protection.
7.4.3 Stuffing box

If leakage makes it necessary, the packing rings
should be retightened. After extended periods and
frequent retightening, the packing rings gradually
lose their shape and elasticity. We therefore
recommend replacing the packing material at
Oil change intervals regular intervals. As a typical indication, after an
If the bearings are new, change the oil after about operating time of approx. 2500 hours or when the
200 hours and subsequently annually. These gland has been retightened by approximately half
intervals only apply if the bearing temperature the width of a packing ring.
does not exceed 50 C. If the bearing temperature Repacking
during operation is above 50 C but below 80 C When repacking, the stuffing box rings used up,

as well as, the lantern ring are to be removed 7.4.5 Drive motor
carefully from the shaft seal chamber. The shaft The drive motor must be maintained according to
and shaft protection sleeve must not be damaged. the instructions of the manufacturer.
Otherwise perfect sealing cannot be guaranteed
and the shaft sleeve would then need replacing.
If the pump is installed, cut soft packing rings 7.5 Dismantling
diagonally, bend them in a spiral shape, position
them on the pump shaft and bend them carefully 7.5.1 Preparation for the dismantling
into a ring form.
Push the packing rings as well as the lantern ring Proceed as follows:
by means of the gland into the shaft seal disconnect power to the motor
chamber. The cut joints should be staggered by drain the plant, at least within the pump area,
180. Tighten the nuts at the gland steadily until i.e. between the valves on the suction- and
resistance is felt when rotating the pump shaft by discharge side
hand. Remove the gland again and fasten the if necessary, disconnect any measuring
nuts slightly. If the pump is removed in order to probes or control devices and remove them
carry out repacking, it is useful to push the drain liquid from the pump by means of the
packing rings in the delivered condition, that drain plug
means closed over the shaft sleeve. dismantle shaft seal supply lines, if any.
If oil lubricated bearings are used, drain the oil
Lantern ring
from the bearing housing.
the pump casing must not be detached from
the pipe union
remove motor mounting bolts and move the
motor so that there is sufficient space to
remove the back pull out unit. When using a
Packing rings
spacer coupling repositioning of the motor is
not necessary.
7.4.4 Mechanical seal dismantle guard coupling, pump feet and
The mechanical seal should have little or no coupling.
visible leakage. Where there is considerable
leakage, check the mechanical seal. To do this, it 7.5.2 Replacement parts
is necessary to dismantle the rotating part(s). The item numbers necessary for ordering spare
parts are provided in the component parts list in
43.30 16.10
the Annex.
7.5.3 Dismantling the pump
For executions with bearing housings 25,35

and 45.
50.40 21.10

10.20 40.00 90.10 16.10 40.05 45.10 90.23 45.70 52.40 91.40
46.10 45.80 92.01 45.20 90.21 55.40 92.01
90.30
Design with a mechanical seal
1. Mark the position of the parts in relation to 1. Detach the distance ring 50.40.
each other by a coloured pencil or a scribing 2. Remove the rotating part of the mechanical
tool. seal 43.30.
2. Remove the hexagonal screws 90.10. 3. Remove the Allen head screws 91.40 and
3. Remove the back pull out unit from the volute detach the casing cover 16.10.
casing 10.20.
50.40 43.30 16.10 91.40
90.13 68.10 92.20 23.00 94.01
68.10 90.13
4. Remove flat gasket 40.00.

5. Remove hexagonal screws 90.13 and remove
protective screen 68.10. Design with quench (AX3, AXS, AXK)
6. Loosen impeller nut 92.20. Detach the cover 16.50, O-ring 41.23 and lip
7. Remove impeller 23.00 and key 94.01. seals 42.11.
16.10 41.23 42.11 16 .50

Design with stuffing box
1. Remove the Allen head screws 91.40 and
detach the casing cover 16.10.
1. Detach hexagonal nuts 92.01 and studs
90.21.
2. Loosen hexagonal screws 90.23 and detach
packing housing 45.10 and gland 45.20 with
the pressure ring 45.70.
3. Detach packing ring 46.10 and lantern ring
45.80. Design with heating (AY3, AYS, AYK)
4. Detach the shaft sleeve 52.40. Detach the cover 16.50, O-rings 41.22 and
41.23.

16.10 41.22 41.23 16. 50 5. Pull out complete shaft 21.00 with both ball
bearings 32.10 and support washers for ball
bearing 50.50 if any.
6. Remove ball bearings 32.10 and support
washers for ball bearing 50.50.
32.10 50.50 21.00 50.50 32.10
4. Remove the static part of the mechanical seal

43.30 and pin 56.10.
For executions with bearing housings 55 and
43.30 16.10 56.10 65:
90.80
10.20 90.20 40.00 92.00 92.06
90.30 50.20 56.00
1. Mark the position of all parts with a colour pen

or scribing tool in order to be able to
Bearing design B, C or 2:
reassemble the pump correctly.
1. Release hexagonal screws 90.11, remove
2. Unscrew hexagonal nuts 92.00.
V-seal 42.20 in case of grease lubrication,
3. Withdraw pull out assembly from the volute
dismantle bearing cover 36.00 and flat gasket
casing 10.20. Withdraw the flat gasket 40.00.
40.02. Remove the lip seal 42.10 if pump is oil
The wear ring 50.20, if it is necessary can be
lubricated.
removed.
2. Release the thrower 50.70
3. Undo hexagonal screws 90.12, remove 92.20
93.00 40.03 23.00 94.01 16.10 90.22 92.02
washer 93.01 and dismantle the pump foot
18.30.
4. For oil lubricated pumps, remove the oil dip
stick 91.60 and remove the constant level
oiler (CLO) 63.80 if any.
50.70 42.20 42.10 33.00 91.60 40.02 42.10 36.00 90.11 42.20 94.00
4. Loosen impeller nut 92.20 and helicoil 93.00.

18.30 93.01 90.12
5. Remove impeller 23.00, key 94.01 and flat
gasket 40.03. Unscrew hexagonal nuts 92.02
and detach the casing cover 16.10.
Design with a stuffing box:

Bearing design S or T:
1. Remove hexagonal nuts 92.01 and studs 1. Release the thrower 50.70
90.21. 2. Release hexagonal screws 90.11 and 90.14,
2. Detach the gland 45.20, the packing ring dismantle bearing covers 36.00, 36.01 and flat
46.10 and the lantern ring 45.80. gaskets 40.02. Remove the lip seals 42.10.
3. Detach shaft sleeve 52.40 and flat gasket 3. Release hexagonal screws 90.12, remove
40.01. washer 93.01 and dismantle the pump foot
4. Detach the pin 56.00 and then, the wear ring 18.30.
50.21 4. For oil lubricated pumps, remove the plug
67.20 and the constant level oiler (CLO) 63.80
16.10 90.22 46.10 45.80 45.20 40.01 52.40
if any.
90.14 36.01 63.60 42.10 40.02 50.70 33.00 93.21 40.02 42.10 36.00 63.60 94.00 90.11
18.30 93.01 90.12
56.00 50.21 90.21 55.40 92.01

5. Pull out complete shaft with both ball bearings
32.10 and 32.11 and circlip 93.21.
Design with a mechanical seal:
1. Loosen hexagonal screws 90.24 and withdraw
32.11 21.00 93.21 32.10
the mechanical seal cover 47.10 with the flat
gasket 40.06, static part of the mechanical
seal 43.30 with pin 56.10.
2. Remove the shaft sleeve 52.30 with the
distance ring 50.40, the rotating part of the
mechanical seal 43.30 and the flat gasket
40.01.
3. Loosen grub screw 56.00.
7.6 Post dismantling activities
4. Detach the pin 56.00 and then, the wear ring
50.21.
7.6.1 Hints on cleaning.
40.01 52.30 50.40 43.30 16.10 90.22 40.06 47.10 Clean all parts.
Clean the clearances and sealing surfaces
with an appropriate liquid.
7.6.2 Points to be checked

The following pump components, if installed, must
be checked:
Mechanical seal : If the running faces are
damaged or worn, replace the mechanical
seal.
56.00 50.21 56.10 90.24

32.10 50.50 21.00 50.50 32.10
Shaft and shaft sleeve : Check the shaft

within the stuffing box. If the shaft has worn
badly and is grooved, a new shaft or shaft
sleeve should be used.
Clearances : The difference in diameter
between impeller clearance area and casing
or cover clearance area should be 0.3 mm to 3. Insert the shaft assembly into the bearing
0.5 mm. In the case of excessive wear in the housing from the drive end towards non-drive
clearance area, wear rings must be installed. end.
Radial seal ring : If the radial seal ring is 4. Attach the bearing cover 36.00, with its radial
damaged, it must be replaced. seal inserted, if it is oil lubricated, and the flat
gasket 40.02;( the lip of the radial seal ring
7.7 Assembly should point towards the non drive end). Then
fasten hexagonal screws 90.11. In case of
7.7.1 Tightening torque grease lubrication, mount the V- seals 42.20
When tightening the bolts the following torques in the shaft and lean one against the bearing
must be used: housing 33.00. Insert the key 94.00.
5. Insert the oil dip stick 91.60 and the CLO
63.80 if any.
Thread M8 M10 M12 M16 M20 M24 M30 M36
50.70 42.20 42.10 33.00 91.60 40.02 42.10 36.00 90.11 42.20 94.00
Torque 12 25 40 90 175 300 500 700
Nm Nm Nm Nm Nm Nm Nm Nm
7.7.2 Pump assembly 18.30 93.01 90.12
Proceed as follows:
6. Fasten pump foot 18.30 and insert the thrower
Bearing design B, C or 2 :
50.70.
For executions with bearing housings 25,35
and 45:
For executions with stuffing box:
1. Prior to installing bearings, the support
washer for ball bearing 50.50 must be
7. Position the shaft sleeve 52.40 on the shaft.
replaced, (only bearing housing 25). Install
8. Insert the packing housing 45.10 with the
ball bearings (use new ball bearings, if
gasket 40.05 in the casing cover 16.10.
necessary). Before installation, the ball
9. Install one of the packing rings 46.10 in the
bearings must be heated to 80C in an oil
packing housing, the lantern ring 45.80 and
bath.
then, the remaining packing rings.
(Only bearing design C or 2).
10. Fasten hexagonal screws 90.23 , fix the studs
2. For a pump with oil lubrication, using a tool,
90.21 and hexagonal nuts 92.01.
press lip seal 42.10 in the bearing housing
33.00. When lip seals are used, the lip should
point towards the drive end.

16.10 40.05 45.10 90.23 45.70 52.40
16.10 41.23 42.11 16 .50
46.10 45.80 92.01 45.20 90.21 55.40 92.01
11. Finally, install the pressure ring 45.70 and the

gland 45.20. Fix the washer 55.40 and the
Attach the cover 16.50 and casing cover 16.10.
following hexagonal nuts 92.01.
12. Adjust the stuffing box as described in 16.10 1 6 . 50
Chapter 7.4.3.
For executions with mechanical seal:
7. Insert the static part of the mechanical seal

43.30, with the pin 56.10 if any, in the casing
cover 16.10.
43.30 16.10 56.10
Design with heating (AY3, AYS, AYK)

Insert the O-rings 41.22 and 41.23 in the cover
16.50.
16.10 41.22 41.23 16. 50
Design with quench (AX3, AXS, AXK)

Insert the lip seals 42.11 and the O-ring 41.23 in
the cover 16.50.
Attach the cover 16.50 and casing cover 16.10.

16.10 16.50
Bearing design S or T :
For executions with bearing housings 55 and
65:
Carry out the following steps:
1. Fit the shaft unit.
2. If the shaft is to be fitted with new bearings,
they should be heated in an oil bath to a
temperature of 80 C before assembling. First,
install the ball bearing 32.11, then the circlip
93.21 and finally ball bearing 32.10. Make
sure that the bearing is pressed home against
the shoulders of the shaft.
8. Attach the bearing housing 33.00 and the 3. If the lip seals have been removed, they must
casing cover 16.10. be exchanged. The lip seals should be fitted
9. Insert the rotating part of the mechanical seal into the bearing cover with a bush, pressing
43.30 and the distance ring 50.40. on the external ring of the oil seals. The lips
10. Insert the key 94.01, impeller 23.00 and should point towards the bearing after
tighten the impeller nut 92.20. Attach the installation. Pay attention to the bearing
protective screens 68.10 with the hexagonal covers to avoid fitting them incorrectly.
screws 90.13.
32.11 21.00 93.21 32.10
90.13 68.10 92.20 23.00 94.01 50.40 43.30 16.10 33.00 91.40
68.10 90.13
11. Insert the gasket 40.00 between the pull out

unit and volute casing. Tighten hexagonal 4. Install the bearing cover of the pump side with
screws 90.10. the flat gasket 40.02 and the grease nipple
63.60 if any.
10.20 40.00 90.10
5. When fitting the rotating unit in the bearing
housing 33.00, the circlip 93.21 must be
inserted in the groove in the bearing housing.
6. Insert the bearing cover 36.01 with the flat
gasket 40.02 and the grease nipple 63.60 if
any.
7. Mount the plug 67.20, the oil level sight glass
64.20 and the constant level oiler ( CLO )
90.30 63.80, where oil lubrication is used.
8. Fasten pump foot 18.30 and insert the thrower
50.70.

90.14 36.01 63.60 42.10 40.02 50.70 33.00 93.21 40.02 42.10 36.00 63.60 94.00 90.11
40.01 52.30 50.40 43.30 16.10 90.22 40.06 47.10
18.30 93.01 90.12
For executions with stuffing box:
9. Mount the shaft sleeve 52.40 on to the shaft 56.00 50.21 56.10 90.24
unit.
12. Join the casing cover 16.10, the bearing
10. In the casing cover, insert one of the packing
housing 33.00 and fasten hexagonal nuts
rings 46.10, the lantern ring 45.80, the
92.02.
remaining packing rings and finally the gland
45.20. 92.20
93.00 40.03 23.00 94.01 16.10 90.22 92.02
11. Fix the studs 90.21, the washers 55.40 and

the nuts 92.01. Adjust the stuffing box as
described in Chapter 7.4.3.
12. Mount the wear rings 50.21 with grub screws
56.00.
16.10 90.22 46.10 45.80 45.20 40.01 52.40
Finally:
13. Insert the flat gasket 40.01, keys 94.01,
impeller 23.00 and flat gasket 40.03.
14. Tighten the impeller nut 92.20 with the helicoil
93.00.
15. Insert the wear ring 50.20 with grub screws
56.00 and then, insert studs 90.20.
56.00 50.21 90.21 55.40 92.01 16. Insert flat gasket 40.00 between the unit and
the volute casing 10.20. Tighten hexagonal
For executions with mechanical seal: nuts 92.00.
9. Install the mechanical seal cover 47.10 with
the mechanical seal stationary part 43.30 and
its pin 56.10 if any, then place the flat gasket
40.06 and hexagonal screws 90.24.
10. Insert the shaft sleeve 52.30 with the rotating
part of the mechanical seal 43.30 and the
distance ring 50.40.
11. In the casing cover 16.10, insert the wear ring
50.21 with grub screws 56.00 and the studs
90.22.

Troubleshooting Page 1 of 1 Chapter 8
8. Help in case of trouble
8.1 Use of trained staff

Trouble shooting must be undertaken only by appropriately trained personnel.
8.2 Symptoms, causes and remedies
Symptom Cause Remedy

Output too low - Back pressure too high. Check the plant for contamination.
Regulate anew the operating point.
- Pump or pipework, resp., not completely Vent and fill the pump as well as the
filled. suction or inflow line.
- Suction lift too high or positive suction Check the liquid levels, open the shut-off
head too low. valves on the suction side.
Clean the filters and dirt traps installed on
the suction side.
- Sealing gap too large because of wear. Replace worn parts.
- Wrong direction of rotation. Change the motor connection.
- Casing or suction line leaks. Replace the casing seal.
Check the flange connections.
Pump does not prime or only - Pump casing, shaft seal, foot valve or Replace the casing seal.
suction line leaks. Check the shaft seal.
intermittently
Check the flange connections..
the suction side.
- Loose or jammed parts in the Open and clean the pump.
pump.
Pump leaks - Casing bolts not correctly Check the tightening torque of the casing
tightened. bolts.
- Mechanical seal leaks. Check the seal surfaces and elastomere of
the mechanical seal. In case of damages
exchange mechanical seal.
- Stuffing box leaks. Check the condition of the stuffing box. If
possible, retighten the stuffing box, if not,
replace it.
- Seals defective. Replace the seals.
Temperature of the pump - Pump or pipework not completely filled. Vent and fill the pump as well as the
suction line or inflow line.
increases
the suction side.
- Stuffing box overtightened. Loosen the stuffing box.
- Pump is run against closed valve. Open the shut-off valve on discharge side.
Pump runs noisily - Pump or pipework not completely filled. Vent and fill the pump as well as the
suction line or inflow line.
the suction side.
- Pump is not properly levelled or is Check the pump installation
distorted.
- Foreign material in the pump. Dismantle and clean the pump.
Motor protection switch - Pump is not properly levelled or is Check the pump installation.
distorted.
switches off.
- Operating conditions outside of Refer to pump operating conditions stated
performance range of pump. in technical data.
- Loose or jammed parts in the pump. Open and clean the pump.

Technical data Page 1 of 3 Chapter 9
9. Technical Data Flanges:

For technical information about the pump or pump Material design 4B: Complies with DIN 2543
set, which is not described in this chapter, see the PN16.
specific data sheet. Note that data relating to a Material design 0B, 0C, 0E, 1B: DIN 2533 PN16 /
1)
specific order may conflict with information 2532 PN10
provided here. In any such case, the order Flanges drilled according to ANSI 150 can be
specific information will override data provided in supplied.
1)
the general technical documentation. 200250
Pressure component operating limits:
Direction of rotation:
Material Temperature Pressure Sizes Clockwise seen from the drive end of the pump.
-40C to 120C 16 bar All Materials of construction, and of shaft seals:
4B
120C to 170C 14 bar All See Chapter 2.4.
16 bar 032125 to 150400
-20C to 120C
0B/0C/0E/1B
10 bar 200250 to 300500 Vibrations:
14 bar 150500
14 bar 032125 to 080315
ZLND range pumps comply with VDI 2056 and
120C to 170C
9 bar 80400 to 300500 ISO 5199 Class K for pumps with a driving power
8 bar 150500
of up to 15 kW and Class M with a driving power
of more than 15 kW
Shaft sealing operating limits:
Noise levels:
The noise levels of the pump comply with the
Shaft sealing execution Temperature Directive 001/30 - 1992 of the EUROPUMP
range Commission.
041, 052 -40C to + 110C
B27 -20C to + 140C The following table provides approximate values:
BJ3, BJS, BJJ -20C to + 120C
AF3, AX3, AY3, A93, -30C to +150C
AFS,AXS,AYS,A9S, AFK,AXK,AYK,A9K -20C to + 180C
M1S -20C to + 180C LWA (dB)
C23, C2S, C2J -40C to + 150C

N1S, NFS -50C to + 180C
ATTENTION
All indicated operating limits are not valid

for all liquids which can be pumped. See P (kW)
technical data or delivery note.

pump without motor
Shaft sealing execution B27 only
Note that additional noise can be generated by:
configuration valid for water up to 140C,
the driver.
water quality has to be in accordance to
a possible misalignment of the coupling.
VdTV 1466; additional requirement: O2
pipework (note: the larger the pipe diameter,
(oxygene) < 0,02 mg/l.
the lower the pipe noise).
Flange locations:
Axial suction flange, discharge flange radially
upwards.

Technical data Page 2 of 3 Chapter 9
Permissible branch forces and moments:
Values according to ISO/DIN 5199 Class II

(1997) Annex B, Family N 2 for mounting on
sheet metal baseplates and frames without
grouting for pumping temperatures up to 110 C
and up to 120 C for grouted baseplates / frames.
Material execution 0B / 0C / 0E:
DN Fy Fz Fx F My Mz Mx M
flanges (N) (N) (N) (N) (Nm) (Nm) (Nm) (Nm)
32 400 500 440 780 360 420 520 760
40 400 500 440 780 360 420 520 760
50 540 660 600 1040 400 460 560 820
Top branch z-Axis
65 820 1000 900 1580 460 520 640 940

80 820 1000 900 1580 460 520 640 940
100 1080 1340 1200 2100 500 580 700 1040
125 1620 2000 1800 3140 700 820 1000 1460
150 1620 2000 1800 3140 700 820 1000 1460
200 2160 2680 2400 4180 920 1060 1300 1920
250 2700 3340 2980 5220 1260 1460 1780 2620
300 3220 4000 3580 6260 1720 1980 2420 3560
50 600 540 660 1040 400 460 560 820
65 900 820 1000 1580 460 520 640 940
End branch x-Axis
80 900 820 1000 1580 460 520 640 940

100 1200 1080 1340 2100 500 580 700 1040
125 1800 1620 2000 3140 700 820 1000 1460
150 1800 1620 2000 3140 700 820 1000 1460
200 2400 2160 2680 4180 920 1060 1300 1920
250 2980 2700 3340 5220 1260 1460 1780 2620
300 3580 3220 4000 6260 1720 1980 2420 3560
350 4180 3760 4660 7300 2200 2540 3100 4560
Material execution 1B:

Multiply by = 1,296; which is the relationship of
E modules between GGG-40.3 and GG-25
Material execution 4B:
Multiply by = 1,536; which is the relationship of
E modules between 1.4408 and GG-25.

Techical Data Page 3 of 3 Chapter 9
Maximum permissible speeds at 50 Hz:
Max. speed Max. speed Max. speed Max speed

Size rpm Size rpm Size rpm Size rpm
032125 032160 032250 0403154) 0503154)
032200 040125 040250 0653154) 0803154) 150500 200315
040160 040200 3600 050250 3000 080400 100315 1800 200400 200500 1500
050125 050160 065250 100400 125250 250300 250315
050200 065125 080250 125315 125400 250400 250500
065160 0652001) 1002502) 150200 1502503) 300400 300500
0801601) 080200 1252002) 150315 150400
100160 100200 200250
For material specification 4B:the max. speed changes to : 1) 3000 rpm 2)

1800 rpm 3)
1500 rpm
4)
In material specification 0E and 4B max. speed 3000 rpm
Operating range:
(Continuous operation)
Sizes
032125 to 080400
100315 to100400
0,3 Qopt < Q < 1,1 Qopt
125315 to 125400
150250 to 150500
100160 to 100250
125200 to 125250
0,5 Qopt < Q < 1,1 Qopt
150200
200500 to 300500
0,7 Qopt < Q < 1,2 Qopt 200250 to 200400
This operating range is applicable if waterlike liquids are pumped. If liquids having distinctly different physical
properties are handled, it may be necessary to narrow the permissible operating range.
See the specific performance curve for more details.

Connections, dimensions, sectional drawing Page 1 of 15 Chapter 10
10. Connections, dimensions, sectional drawing

10.1 Connections
Connections for bearing brackets 25, 35 and 45.
1)
Only for Impellers 125
um1 : Pressure gauge. Only available on request uk1 : Quench Inlet

um2 : Pressure gauge. Only available on request uk2 : Heating Inlet
ue : Drainage uk3 : 051 Inlet (Stuffing box)
ueo : Oil drainage uk4 : 052 External sealing (Stuffing box)
ufo : Oil filling uk5 : External Flushing
uAL : Drainage for leakage. Threaded hole only available on request uk6 : Quench Outlet
us : Sensor uk7 : Heating Outlet
9A : Quench liquid outlet (tandem arrangement) uk8 : 051 Outlet (Stuffing box)
9E : Quench liquid inlet (tandem arrangement) 11A : Sealing liquid outlet (back to back arrangement)
11E : Sealing liquid inlet (back to back arrangement)
Size um1 um2 ue ueo ufo uAL us uk1 uk2 uk3 uk4 uk5 uk6 uk7 uk8 9A 9E 11A 11E
0321251)
032160
032200
032250
0401251)
040160
040200 G 1/4
040250
040315
0501251)
050160
050200 G 1/8
050250
050315
1)
065125
065160
065200
065250
065315 G 1/4 G 1/4 15.65 13 M8 G 1/4 G 1/8 G 1/4
080160
080200
080250
080315
080400 G 1/4
100160
100200 G 3/8
100250 G 1/8
100315
100400 G 1/4
125200
G 1/8
125250
125315
G 1/4
125400
150200
G 1/8
150250
150315
150400 G 1/4
200250
Drawings are indicative only.

Connections for bearing brackets 55 and 65
um1 : Self sealing connection um3 : Pressure gauge connection

um2 : Pressure/vacuum gauge. Only available on request uk3 : 051 Inlet (Stuffing box)
ue : Drainage uk4 : 052 External sealing (Stuffing box)
ueo : Oil drainage uk8 : 051 Outlet (Stuffing box)
ufo : Oil filling umo : Oil level control
uAL : Drainage for leakage uk9 : 041 inlet (Stuffing box)
Size um1 um2 ue ueo ufo uAL um3 uk3 uk4 uk8 umo uk9
150500
200315
200400
200500
250300
250315 G1/4 G1/2 G1/2 G1/4 20 G1/2 G1/2 G1/4 G1/4 G1/4 G3/4 G1/4
250400
250500
300400
300500

10.2 Table of Dimensions
All dimensions in mm
Size BB Pump dimensions Foot dimensions End shaft
DN2 DN1 a f h1 h2 b c m1 m2 n1 n2 s1* s2* w x d1 l t u
032125 25 32 50 80 360 112 140 50 15 100 70 190 140 M12 M12 260 100 24 50 27 8
032160 25 32 50 80 360 132 160 50 15 100 70 240 190 M12 M12 260 100 24 50 27 8
032200 25 32 50 80 360 160 180 50 15 100 70 240 190 M12 M12 260 100 24 50 27 8
0322501) 25 32 50 100 360 180 225 65 15 125 95 320 250 M12 M12 260 100 24 50 27 8
040125 25 40 65 80 360 112 140 50 15 100 70 210 160 M12 M12 260 100 24 50 27 8
040160 25 40 65 80 360 132 160 50 15 100 70 240 190 M12 M12 260 100 24 50 27 8
040200 25 40 65 100 360 160 180 50 15 100 70 265 212 M12 M12 260 100 24 50 27 8
040250 25 40 65 100 360 180 225 65 15 125 95 320 250 M12 M12 260 100 24 50 27 8
0403151) 35 40 65 125 470 225 250 65 18 125 95 345 280 M12 M12 340 100 32 80 35 10
050125 25 50 65 100 360 132 160 50 15 100 70 240 190 M12 M12 260 100 24 50 27 8
050160 25 50 65 100 360 160 180 50 15 100 70 265 212 M12 M12 260 100 24 50 27 8
050200 25 50 65 100 360 160 200 50 15 100 70 265 212 M12 M12 260 100 24 50 27 8
050250 25 50 65 100 360 180 225 65 15 125 95 320 250 M12 M12 260 100 24 50 27 8
0503151) 35 50 65 125 470 225 280 65 17 125 95 345 280 M12 M12 340 100 32 80 35 10
065125 25 65 80 100 360 160 180 65 15 125 95 280 212 M12 M12 260 100 24 50 27 8
065160 25 65 80 100 360 160 200 65 15 125 95 280 212 M12 M12 260 100 24 50 27 8
065200 25 65 80 100 360 180 225 65 15 125 95 320 250 M12 M12 260 140 24 50 27 8
065250 35 65 80 100 470 200 250 80 15 160 120 360 280 M16 M12 340 140 32 80 35 10
065315 35 65 80 125 470 225 280 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
080160 25 80 100 125 360 180 225 65 15 125 95 320 250 M12 M12 260 140 24 50 27 8
080200 35 80 100 125 470 180 250 65 15 125 95 345 280 M12 M12 340 140 32 80 35 10
080250 35 80 100 125 470 200 280 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
080315 35 80 100 125 470 250 315 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
1)
080400 45 80 125 125 530 280 355 80 18 160 120 435 355 M16 M12 370 140 42 110 45 12
1001601) 35 100 125 125 470 200 280 80 18 160 120 360 280 M16 M12 340 140 32 80 35 10
100200 35 100 125 125 470 200 280 80 18 160 120 360 280 M16 M12 340 140 32 80 35 10
100250 35 100 125 140 470 225 280 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
100315 35 100 125 140 470 250 315 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
100400 45 100 125 140 530 280 355 100 18 200 150 500 400 M20 M12 370 140 42 110 45 12
1252001) 35 125 150 140 470 250 315 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
125250 35 125 150 140 470 250 355 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
125315 45 125 150 140 530 280 355 100 18 200 150 500 400 M20 M12 370 140 42 110 45 12
125400 45 125 150 140 530 315 400 100 18 200 150 500 400 M20 M12 370 140 42 110 45 12
1)
150200 35 150 200 160 470 280 400 100 20 200 150 550 450 M20 M12 340 140 32 80 35 10
1502501) 35 150 200 160 470 280 400 100 20 200 150 500 400 M20 M12 340 140 32 80 35 10
150315 45 150 200 160 530 280 400 100 18 200 150 550 450 M20 M12 370 140 42 110 45 12
150400 45 150 200 160 530 315 450 100 18 200 150 550 450 M20 M12 370 140 42 110 45 12
1)
200250 45 200 200 160 590 280 400 100 22 200 150 500 400 M20 M12 430 180 42 110 45 12
1)
Transnorm pump sizes, not included in DIN 24255 / EN 733. Flanges drilled according to ANSI 150 on request.
*Holes for bolts of the dimensions indicated.

Table of Dimensions
All dimensions in mm
Size BB Pump dimensions Foot dimensions End shaft
DN2 DN1 a f h1 h2 b c m1 m2 n1 n2 s1* s2* w x d1 l t u
1505001) 55 150 200 180 670 400 500 100 22 200 150 640 540 M20 M16 489 180 50 115 53.5 14
2003151) 55 200 250 200 670 355 450 100 22 200 150 550 450 M20 M16 489 180 50 115 53.5 14
2004001) 55 200 250 180 670 355 500 100 22 200 150 550 450 M20 M16 489 180 50 115 53.5 14
2005001) 3) 55 200 250 200 670 425 560 100 22 200 150 660 560 M20 M16 489 180 50 115 53.5 14
2503001) 55 250 300 305 655 425 550 120 28 240 190 700 600 M20 M16 474 180 50 115 53.5 14
2503151) 55 250 300 250 670 375 560 120 28 240 190 620 520 M20 M16 489 180 50 115 53.5 14
2504001) 65 250 300 250 720 400 600 120 29 240 190 700 600 M20 M16 508 180 602) 145 64 18
1) 2)
250500 65 250 300 250 720 450 670 120 32 240 190 750 650 M20 M16 508 180 60 145 64 18
3004001) 65 300 350 300 720 425 670 120 30 250 190 760 660 M24 M16 508 180 602) 145 64 18
3005001) 65 300 350 300 720 480 670 140 32 250 190 840 720 M24 M16 508 180 602) 145 64 18
1)
Transnorm pump sizes, not included in DIN 24255 / EN 733. Flanges drilled according to ANSI 150 on request.
2)
For these sizes the clearance corresponds to M6.
3)
Discharge flange 12 x threaded drillings/M20 (only for PN 16 flanges).
*Holes for bolts of the dimensions indicated.
Flange connections to DIN 2501 PN 16 DIN 2501 PN 10

DN2/DN1 32 40 50 65 80 100 125 150 200 250 300 350 400 100 125 150 200
D 140 150 165 185 200 220 250 285 340 405 460 520 580 220 250 285 340
k 100 110 125 145 160 180 210 240 295 355 410 470 525 180 210 240 295
d2 x number 18x4 18x4 18x4 18x4 18x8 18x8 18x8 22x8 22x12 26x12 26x12 26x16 30x16 18x8 18x8 22x8 22x8

10.3 Parts list
When ordering spare parts give the following

information: position number, the complete pump
designation and the serial number, which can be
found on the nameplate fixed to the pump.
Pos. Nr. Description Pos. Nr. Description
10.20 Volute casing 56.10 Pin

10.200 Casing plug 63.60 Grease nipple
10.201 Hexagonal screw 63.80 Constant level oiler
10.202* O-ring 64.20 Oil level sight glass
16.10 Casing cover 67.20 Plug
16.50 Cover 68.10 Protection screen
18.30 Pump foot 70.30 Pipe
21.00* Shaft 73.10 Compression nut
23.00* Impeller 73.11 Screw connection
32.10* Ball bearing 90.10 Hexagonal screw
32.11* Ball bearing 90.11 Hexagonal screw
33.00 Bearing housing 90.12 Hexagonal screw
36.00 Bearing cover 90.13 Hexagonal screw
36.01 Bearing cover 90.14 Hexagonal screw
40.00* Flat gasket 90.20 Stud
40.03* Flat gasket 90.23 Hexagonal screw
40.05* Flat gasket 90.24 Hexagonal screw
40.07* Flat gasket 90.30 Threaded plug
41.22* O-ring 90.34 Threaded plug
41.23* O-ring 90.41 Grub screw
41.24* O-ring 90.80 Hexagonal screw
42.10* Lip seal 91.40 Allen head screw
42.11* Lip seal 91.41. Allen head screw
42.20* V seal 91.60 Dip stick
43.30* Mechanical seal 92.00 Hexagonal nut
45.10 Packing housing 92.06 Hexagonal nut
45.20 Gland 92.20* Impeller nut
45.70* Pressure ring 93.00* Helicoil
45.80* Lantern ring 93.01 Washer
46.10* Packing ring 93.21* Circlip
47.10* Mechanical seal cover 94.00* Key
47.11* Mechanical seal cover 94.01* Key
50.20* Wear ring 94.02* Key
50.21* Wear ring 99.99 Plastic plug
50.40* Distance ring
50.50* Support washer for ball bearing * Recommended spare parts
50.70* Thrower
52.30* Shaft sleeve
52.40* Shaft sleeve
55.40 Washer
56.00 Grub screw

ZLND 032125 to 200250 AB

MECHANICAL SEALS, 0B 2
68.10
10.20 23.00 50.40 40.00 43.30 16.10 90.13 32.10 50.50 33.00 36.00 42.20 21.00
Mechanical seal code

B271)/BJ3/BJS/BJJ
92.20 94.01 90.30 90.10 91.40 50.70 18.30 93.01 90.12 90.11 94.00
Mechanical Seal Mechanical Seal

code AF3/AFS/AFK code C23/C2S/C2J
10.20 23.00 50.40 43.30 40.00 16.10 56.10 10.20 23.00 50.40 43.30 40.00 16.10

code AX3/AXS/AXK code AY3/AYS/AYK
10.20 23.00 50.40 43.30 40.00 16.10 99.99 41.23 56.10 42.11 16.50 10.20 23.00 50.40 43.30 40.00 16.10 99.99 41.23 41.22 56.10 16.50
Mechanical Seal
code A93/A9S/A9K
10.20 23.00 50.40 43.30 40.00 16.10 99.99 56.10
1)
Not available for size 080400, 100400, 125315, 125400, 150315, 150400, 200250.

ZLND 032125 to 200250 AC/A2

68.10
10.20 23.00 50.40 43.30 40.00 16.10 90.13 42.10 32.10 50.50 63.80 91.60 40.02 36.00 21.00

B271)/BJ3/BJS/BJJ
92.20 94.01 90.30 90.10 91.40 50.70 33.00 63.81 90.31 18.30 93.01 90.12 90.11 94.00

code AF3/AFS/AFK code C23/C2S/C2J
10.20 23.00 50.40 43.30 40.00 16.10 56.10 10.20 23.00 50.40 43.30 40.00 16.10

code AX3/AXS/AXK code AY3/AYS/AYK
10.20 23.00 50.40 43.30 40.00 16.10 99.99 41.23 56.10 42.11 16.50 10.20 23.00 50.40 43.30 40.00 16.10 99.99 41.23 41.22 56.10 16.50
Mechanical Seal
code A93/A9S/A9K
10.20 23.00 50.40 43.30 40.00 16.10 99.99 56.10
1)
Not available for size 080400, 100400, 125315, 125400, 150315, 150400, 200250.

ZLND 032125 to 200250 AB

STUFFING BOX, 0B 2
68.10
10.20 23.00 52.40 40.00 16.10 40.05 90.23 45.70 45.20 90.13 32.10 50.50 33.00 36.00 42.20 21.00
Stuffing box code

041
92.20 94.01 90.30 45.10 46.10 45.80 92.01 90.10 91.40 55.40 90.21 50.70 18.30 93.01 90.12 90.11 94.00
Stuffing box
code 052
10.20 52.40 45.80 40.00 99.99 92.01 45.70 55.40

23.00 45.10 16.10 40.05 46.10 45.20 90.21

ZLND 032125 to 200250 AC/A2

STUFFING BOX, 0B 2
90.23 45.20 68.10 32.10 63.80

10.20 23.00 52.40 40.00 16.10 40.05 45.70 90.13 42.10 50.50 91.60 40.02 36.00 21.00
Stuffing box code

041
92.20 94.01 45.10 46.10 45.80 92.01 91.40 90.21 33.00 63.81 90.31 18.30 93.01 90.12 90.11 94.00
90.30 90.10 55.40 50.70
Stuffing box
code 052
10.20 52.40 45.80 40.00 99.99 92.01 45.70 55.40

23.00 45.10 16.10 40.05 46.10 45.20 90.21

ZLND 200315 to 300500 and 150500 AS

40.03 23.00 43.30 90.80 73.10 90.22 73.11 50.70 33.00 32.10 36.00 94.00
10.20 50.40 16.10 90.34 40.00 92.06 41.10 70.30 92.02 41.11 47.10 36.01 93.21 63.60 21.00

BJ3/BJS/BJJ
40.01 90.30 90.24 90.14 18.30 90.12 90.11

92.20 94.01 50.20 50.21 52.30 90.20 40.06 32.11 93.01 40.02 42.10
93.00 56.00 56.00 92.00
Shaft seal Shaft seal

Code AF3/AFS/AFK Code C23/C2S/C2J
50.40 23.00 40.00 73.11 47.10 56.10 50.40 23.00 40.00 73.11 47.10 52.30
10.20 43.30 16.10 40.06 41.11 90.24 52.30 10.20 43.30 16.10 40.06 41.11 90.24

ZLND 200315 to 300500 and 150500 AT/A2

40.03 23.00 73.11 90.80 73.10 90.22 50.70 67.20 93.21 90.11 94.00
10.20 50.40 16.10 41.11 90.34 40.00 92.06 41.10 70.30 92.02 47.10 90.14 32.11 33.00 32.10 21.00

BJ3/BJS/BJJ
40.01 90.30 43.30 90.24 36.01 64.20 18.30 90.12 36.00

92.20 94.01 50.20 50.21 52.30 90.20 40.06 90.31 63.80 93.01 40.02 42.10
93.00 56.00 56.00 92.00
Shaft seal Shaft seal

Code AF3/AFS/AFK Code C23/C2S/C2J
50.40 23.00 40.00 73.11 47.10 56.10 50.40 23.00 40.00 73.11 47.10 52.30
10.20 43.30 16.10 40.06 41.11 90.24 52.30 10.20 43.30 16.10 40.06 41.11 90.24

ZLND 200315 to 300500 and 150500 AS

STUFFING BOX, 0B 2
40.03 23.00 73.11 90.80 73.10 90.22 50.70 33.00 32.10 36.00 94.00
10.20 45.80 16.10 41.11 90.34 40.00 92.06 41.10 70.30 92.02 45.20 36.01 93.21 63.60 21.00
Stuffing box code 041
40.01 46.10 90.14 18.30 90.12 90.11

92.20 94.01 50.20 90.30 50.21 52.40 90.20 55.40 90.21 32.11 93.01 40.02 42.10
93.00 56.00 56.00 92.00 92.01
Shaft seal
Code 052
45.80 23.00 40.00 55.40 90.21

10.20 46.10 16.10 90.33 45.20 92.01 52.40

ZLND 200315 to 300500 and 150500 AT/A2

STUFFING BOX, 0B 2
40.03 23.00 73.11 90.80 73.10 90.22 50.70 67.20 93.21 90.11 94.00
10.20 45.80 16.10 41.11 90.34 40.00 92.06 41.10 70.30 92.02 45.20 90.14 32.11 33.00 32.10 21.00
Stuffing box code 041
40.01 90.30 46.10 36.01 64.20 18.30 90.12 36.00

92.20 94.01 50.20 50.21 52.40 90.20 55.40 90.21 90.31 63.80 93.01 40.02 42.10
93.00 56.00 56.00 92.00 92.01
Shaft seal
Code 052
45.80 23.00 40.00 55.40 90.21

10.20 46.10 16.10 90.33 45.20 92.01 52.40

ZLND 032125 to 200250 AB

MECHANICAL SEALS 0B 4
Shaft seal M1S
Shaft seal N1S

ZLND 032125 to 200250 AB

DOUBLE MECHANICAL SEAL 0B 4
Shaft seal NFS

Additional instructions: M1S Page 1 of 2 Annex I
Multiple mechanical seal in tandem The following rules should be observed when
arrangement mounting the mechanical seal:
Extreme care and cleanliness.
1 Description Take care not to damage the seal faces and the O-
The shaft is sealed by two balanced single-acting rings.
reversible mechanical seals acc. to EN 12750 (old Clean the shaft and the seat ring seat in the
DIN 24960) in tandem arrangement, (see general discharge casing and carefully remove any
drawing). deposits.
2 Seal size / materials 1. Insert the static part of the mechanical seal
43.32, with the pin 56.10 , in the mechanical
mechanical seal mechanical seal seal cover, insert gasket 40.08.
Bearing inboard, 43.31 outboard, 43.32 2. Push mechanical seal cover towards bearing
bracket seal seal bracket
material material
size size 3. The rotating part of the mechanical seal 43.32
25 KU024S Q12Q1VGG KU024S Q12Q1VGG must be fixed to the shaft.
GNZ GNZ 4. Insert the O-ring 41.24 in the mechanical seal
35 KU032S Q12Q1VGG KU032S Q12Q1VGG cover 47.11.
GNZ GNZ 5. Insert the mechanical seal cover 47.11 in the
45 KU045S Q12Q1VGG KU045S Q12Q1VGG casing cover 16.10.
GNZ GNZ
seal cover.
3 Disassembly
7. Mount casing cover 16.10 on the bearing
bracket, fasten Allen head screws 91.40.
1. Dismantling the pump as described in the
8. Mount mechanical seal cover 47.10 in the
operating instructions, section 7.5.3.
casing cover, fasten Allen head screws 91.41.
2. Unscrew impeller nut 92.20 and remove
9. Insert rotating part of the mechanical seal 43.31
impeller.
and the distance ring 50.40
3. Detach the distance ring 50.40.
10 Proceed with pump assembly as described in
4. Remove the rotating part of the mechanical seal
the operating instructions, section 7.7.2.
43.31 (inboard).
5 Liquid quench
91.41, detach the casing cover 16.10.
6. Push mechanical seal cover 47.10 towards
If the pump is equipped with a double-acting
bearing bracket.
mechanical seal in tandem arrangement, the shaft
7. Detach the casing cover 16.10.
seal chamber needs to be flushed with liquid from
8. Remove the rotating part of the mechanical seal
an external source.
43.32 (outboard).
The flushing liquid must be free of solid particles, it
9. Remove mechanical seal cover 47.10 from the
should not crystallise and must it be compatible with
shaft.
liquid handled.
This system must also remove the heat generated
4 Assembly
al the mechanical seal.
Reassembly the pump as described in the
operating instructions, section 7.7.

Additional instructions: M1S Page 2 of 2 Annex I
6 General drawing and list of components
Fig. 6-1 Mechanical seal in tandem arrangement
Part n Part designation

16.10 Casing cover
40.08 Flat gasket
41.24 O-ring
43.31 Mechanical seal (inboard)
43.32 Mechanical seal (outboard)
47.10 Mechanical seal cover
50.40 Distance ring
56.10 Pin
91.40 Allen head screw
9A Quench liquid outlet G 1/4
9E Quench liquid inlet G 1/4

Additional instructions: N1S, NFS Page 1 of 4 Annex II
Multiple mechanical seal in tandem The following rules should be observed when
arrangement mounting the mechanical seal:
Extreme care and cleanliness.
1 Description Take care not to damage the seal faces and the O-
The shaft is sealed by two unbalanced single-acting rings.
reversible mechanical seals acc. to EN 12750 (old Clean the shaft and the seat ring seat in the
DIN 24960) in tandem arrangement, (see general discharge casing and carefully remove any
drawing). deposits.
2 Seal size / materials 1. Insert the static part of the mechanical seal
mechanical seal mechanical seal seal cover, insert gasket 40.08.
Bearing inboard, 43.31 outboard, 43.32 2. Push mechanical seal cover towards bearing
bracket seal seal bracket
material material
size size 3. The rotating part of the mechanical seal 43.32
25 KU024S Q1Q1VGG KU024S Q1Q1VGG must be fixed to the shaft.
M7N M7N 4. Insert the O-ring 41.24 in the mechanical seal
35 KU032S Q1Q1VGG KU032S Q1Q1VGG cover 47.11.
M7N M7N 5. Insert the mechanical seal cover 47.11 in the
45 KU045S Q1Q1VGG KU045S Q1Q1VGG casing cover 16.10.
M7N M7N 6. Insert the static part of the mechanical seal
3 Disassembly seal cover.
1. Dismantling the pump as described in the bracket, fasten Allen head screws 91.40.
operating instructions, section 7.5.3. 8. Mount mechanical seal cover 47.10 in the
2. Unscrew impeller nut 92.20 and remove casing cover, fasten Allen head screws 91.41.
impeller. 9. Insert rotating part of the mechanical seal 43.31
3. Detach the distance ring 50.40. and the distance ring 50.40
4. Remove the rotating part of the mechanical seal 10 Proceed with pump assembly as described in
43.31 (inboard). the operating instructions, section 7.7.2.
91.41, detach the casing cover 16.10. 5 Liquid quench
6. Push mechanical seal cover 47.10 towards
bearing bracket. If the pump is equipped with a double-acting
7. Detach the casing cover 16.10. mechanical seal in tandem arrangement, the shaft
8. Remove the rotating part of the mechanical seal seal chamber needs to be flushed with liquid from
43.32 (outboard). an external source.
9. Remove mechanical seal cover 47.10 from the The flushing liquid must be free of solid particles, it
shaft. should not crystallise and must it be compatible with
liquid handled.
4 Assembly This system must also remove the heat generated
Reassembly the pump as described in the al the mechanical seal.

Fig. 6-1 Mechanical seal in tandem arrangement

16.10 Casing cover
40.08 Flat gasket
41.24 O-ring
50.40 Distance ring
56.10 Pin
9A Quench liquid outlet G 1/4
9E Quench liquid inlet G 1/4

The following rules should be observed when

Multiple mechanical seal in back to mounting the mechanical seal:
back arrangement Extreme care and cleanliness.
Take care not to damage the seal faces and the O-
1 Description rings.
Clean the shaft and the seat ring seat in the
The shaft is sealed by two unbalanced single-acting
discharge casing and carefully remove any
reversible mechanical seals acc. to EN 12750 (old
deposits.
DIN 24960) in back to back arrangement, (see
general drawing).
2 Seal size / materials
seal cover, insert gasket 40.08.
2. Push mechanical seal cover towards bearing
mechanical seal mechanical seal
bracket
Bearing inboard, 43.31 outboard, 43.32
3. The rotating parts of the mechanical seal 43.32
bracket seal seal
material material and 43.31 must be fixed to the shaft.
size size
4. Insert the mechanical seal cover 47.11 with the
25 KU024S Q1Q1VGG KU024S Q1Q1VGG
gasket 40.07 and O-ring 41.24 in the casing
M7N M7N
cover 16.10.
M7N M7N
seal cover.
M7N M7N
6. Fasten hexagonal screws 90.23.
3 Disassembly bracket, fasten Allen head screws 91.40.
8. Mount mechanical seal cover 47.10 in the
1. Dismantling the pump as described in the casing cover, fasten Allen head screws 91.41.
operating instructions, section 7.5.3. 9. Insert the distance ring 50.40
2. Unscrew impeller nut 92.20 and remove 10. Proceed with pump assembly as described in
impeller. the operating instructions, section 7.7.2.
3. Detach the distance ring 50.40.
4. Loosen the Allen head screws 91.40 and 91.41. 5 Sealing liquid
5 Push mechanical seal cover 47.10 towards
bearing bracket. If the pump is equipped with a double-acting
6 Detach the casing cover 16.10. mechanical seal in back to back arrangement, the
7. Remove the rotating part of the mechanical seal shaft seal chamber needs to be sealed with liquid
43.31 (inboard). from an external source.
8. Remove the rotating part of the mechanical seal The sealing liquid must be free of solid particles, it
43.32 (outboard). should not crystallise and must it be compatible with
9. Remove mechanical seal cover 47.10 from the liquid handled.
shaft. This system must also remove the heat generated
4 Assembly al the mechanical seal.
Reassembly the pump as described in the


Fig. 6-2 Mechanical seal in back to back arrangement

16.10 Casing cover
40.07 Flat gasket
40.08 Flat gasket
41.24 O-ring
50.40 Distance ring
56.10 Pin
90.23 Hexagonal screw
11A Sealing liquid outlet G 1/8
11E Sealing liquid inlet G 1/4

Declaration of conformity. Example Page 1 of 1 Annex III

ATEX information Page 1 de 11 Annex IV
Supplementary operating instructions in accordance to EC directive 94/9/CE (ATEX)

for the use in potentially explosive atmospheres of the following pumps types,
manufactured by Sterling Fluid Systems (Spain), S.A. type:
ZLN, ZLK and ZLI (Industrial pumps)

ULN (Self Priming Pumps)
ZTN, ZTK and ZTI (Thermal Oil Pumps)
ZHN, ZDN, ZEN and ZLI (Hot Water Pumps)
These supplementary operating instructions give only general instructions for the use of pumps in
conditions that need explosion protection. The operating instructions of the specific pump must be
taken into consideration as well.
Contents Page
1 General objective 2
2 Safety issues 2
2.1 Identification of safety symbols in these operating instructions 2
2.2 Compliance with regulations 2
2.3 Qualification and training of personnel 3
2.4 Safety instructions for maintenance, inspection and installation work 3
3 Instructions concerning pump and accessories 3

3.1 General 3
3.2 Pump pressure containment components 3
3.3 Coupling and coupling guard 3
3.4 Belt drive 3
4 Instructions concerning installation and start-up of pump sets 3

4.1 Coupling 3
4.2 Connection to power supply 3
4.3 Earthing 4
4.4 Belt drive 4
5 Instructions concerning operation and maintenance 4

5.1 Unauthorized modes of operation 4
5.2 Explosion protection 4
5.3 Pump filled and vented 4
5.4 Marking 4
5.5 Fluid pumped 5
5.6 Checking of direction of rotation (see also pump specific operating manual) 5
5.7 Pump operating mode 5
5.8 Temperature limits 5
5.9 Maintenance 7
6 Additional instructions for couplings in ATEX pump sets 7

6.1 Limitations 7
6.2 Storage 7
6.3 Installation 7
6.4 Mounting coupling parts 8
6.5 Alignment 8
6.6 Fixing the coupling on the shaft 9
6.7 Operation 9
6.8 Maintenance 9
6.9 Figures 10

Sterling Fluid Systems reserves the right to modify (Sterling Fluid Systems BV) 2012
1 General Objective
Pumping systems can be operated in hazardous areas. It is the obligation of the operator to define the zone
and to select the pump with the correct category for this zone.
The pump installation and operation must take into account the Operating Instructions that are described in
these supplementary operating instructions. They contain important information for safe and reliable pump
operation in hazardous areas. This information plus all information given for all components of the system
(e.g. the operating instructions for the pump) are of vital importance to avoid risks.
These supplementary operating instructions do not take into account national or local regulations; the
operator must ensure that such regulations are strictly observed by all, including the personnel in charge of
the installation.
For any further information or instructions exceeding the scope of this manual or in case of damage, please
contact Sterling Fluid Systems nearest customer service.
2 Safety issues
These supplementary operating instructions contain fundamental information concerning all actions with
pumping systems, when operated in hazardous areas like: installation, inspection, operation, monitoring and
maintenance. Therefore these and all other instructions related to safety must be known and available with
easy access to all personnel involved in the above stated actions.
Not only must the general safety instructions established in this chapter on Safety issues be complied with,
but also the safety instructions outlined under specific headings as well as the safety instructions contained
in the specific operating manual of the specific pump.
2.1 Identification of safety symbols in these instructions

In these supplementary operating instructions, the safety instructions related to explosion protection are
marked with:
The sign
is used to highlight safety instructions where non-compliance may pose a damage to the pump and its
functions.
2.2 Compliance with regulations

It is imperative to comply with the safety instructions contained in these supplementary operating
instructions, the operating instructions of the pump type concerned, the relevant national and international
explosion protection regulations, health and safety regulations and the operators own internal work,
operation and safety regulations.
Ex symbol relates to additional requirements, which must be complied with when the pump is operated
in hazardous areas.
In addition the following must be observed:
If pumps / units are located in hazardous areas, it is imperative to make sure that the correct category
of pump and equipment is selected and that unauthorised modes of operation are prevented. Non-
compliance may result in first: increased risk of explosion and second: the specified temperature limits might
be exceeded.
Non-compliance with these safety instructions may also result in the loss of any rights to claim damages.
Non-compliance may also result in hazards to persons by explosion.

2.3 Qualification and training of personnel

The personnel responsible for or involved in the installation, the operation, maintenance and inspection of
the pump and the unit must be adequately qualified to carry out these works in hazardous areas.
The scope of responsibility and supervision of the personnel must be exactly defined by plant management.
If the staff does not have the necessary knowledge, they must be trained and instructed. The pump
manufacturer or supplier on behalf of the plant management may perform this task. Moreover, plant
management must ensure that the contents of the operation instructions are fully understood by plant
operators and other relevant personnel such as maintenance staff.
2.4 Safety instructions for maintenance, inspection and installation work

The operator is responsible to assure that all installation work, inspection, operation and maintenance must
be carried out by authorized and qualified specialist personnel, which is thoroughly familiarized with the
pump operating instructions and these supplementary operating instructions.
If necessary, additional explosion protection regulations must be considered.
3 Instructions concerning pump and accesories

3.1 General
Pumps and accessories for installations in hazardous areas must comply with the relevant category of
mechanical and electrical equipment.
Some details are pointed out below:
3.2 Pump pressure containment components
For handling inflammable fluids, the pump pressure containment components must be made of ductile
material.
3.3 Coupling and coupling guard

The accident prevention regulations require, that pump drive must not be operated without a coupling guard.
If a customer specifically decides, not to include a coupling guard in our delivery, then the operator must
provide such coupling guard himself. The coupling must be selected and sized in accordance with the
instructions of the coupling manufacturer. It is important to make sure that the materials selected for coupling
and coupling guard are non-sparking in the event of mechanical contact. Sterling Fluid Systems scope of
supply meets this requirement.
In hazardous areas coupling guards must be of non-sparking material, whereby the coupling material
must be considered.
3.4 Belt drive

Belts must include some electrically conductive material.
4 Instructions concerning installation and start-up of pump sets

In addition to the normal installation instructions, the specific criteria for explosion protection are listed below:
4.1 Coupling
The coupling must be installed, started-up and operated in accordance with the operating instructions
of the coupling manufacturer. Misalignment of the coupling may result in inadmissible temperatures at the
coupling and motor bearings. It has to be ensured that the coupling halves are correctly aligned at all times.
4.2 Connection to power supply
Only a properly trained electrician must effect connection to the power supply. The available main
voltage must be checked against the data on the motor rating plate and an appropriate start-up method must
be selected.

Sterling Fluid Systems strongly recommends using a motor protection device (motor protection switch)
In hazardous areas, compliance with national and local regulations form and additional requirement
for electrical connections.
4.3 Earthing
To eliminate risks due to electrostatic charging, pump set must be earthed directly or through an
earthing line.
4.4 Belt drive
Belt-driven pump sets must always be earthed. The condition of the belts must be checked regularly.
5 Instructions concerning operation and maintenance

5.1 Unauthorized modes of operation
The warranty related to the operating reliability and safety of the unit supplied is only valid if the equipment is
used in accordance to its designated use as described in the following sections of this supplementary
operating manual and the specific pump operating manual. The limits stated in the data sheet must not be
exceeded under any circumstances.
Any operation of the pump outside the permissible operating range and any unauthorized modes of
operation may result in the specific temperature limits being exceeded (see section 5.8).
5.2 Explosion protection
If pumps / units are installed in hazardous areas where compliance with EC directive 94/9/EC is
required, the measures and instructions given in the following sections 5.3 to 5.9 must be carried out with no
excuse, to ensure explosion protection.
5.3 Pump filled and vented

Especially dry running of a pump results in friction and non-allowed temperature rise. Therefore precautions
have to be taken to prevent dry running.
It is necessary that the system of suction and discharge lines and thus the wetted pump parts
including seal chamber and auxiliary systems are completely filled with fluid to be handled at all time during
pump operation, so that and explosive atmosphere is prevented.
If the operator cannot warrant this condition, appropriate monitoring devices must be used.
Improper installation (e.g. vertical installation) may impair the self-venting properties of the seal chamber, so
that gas bubbles may be collected in the pump and cause the mechanical seal to run dry.
High negative pressure on the suction side (e.g. due to clogged suction-side strainers or low system
pressure) may result in air intake at the shaft seal forming gas bubbles in the pump. This may also cause the
mechanical seal to run dry. Suitable monitoring facilities shall be installed, if necessary.
For design inherent reasons, however, it is not always possible to exclude the existence of a certain
residual volume not filled with liquid after the pump has been filled prior to start of operation. However, once
the motor is started up the pumping effect will immediately fill this volume with pumped fluid.
It is imperative to make sure that seal chambers and auxiliary seal systems are properly vented
from air and filled with liquid.
5.4 Marking
The Ex marking on the pump only refers to the pump part, i.e. the coupling and motor must be
considered separately. The coupling must have an EC Declaration of Conformity and the EC marking. The
driver must be treated separately
Example of marking on the pump part: CE Ex II 2 G c T1 - T5
The safety instructions published in section 5.8 must be complied with.
5.5 Fluid pumped
Abrasive particles in the fluid handled may erode the casing walls to such and extent that fluid may
escape. When handling inflammable media, it has to be ensured that the fluid does not contain any abrasive
particles, or that the pump is regularly checked with respect to erosion.
5.6 Checking of direction of rotation (see also pump specific operating manual)
If the explosion hazard also exists during the installation phase, the direction of rotation must never be
checked by starting up the unfilled pump unit, even for a short period, to prevent temperature increases
resulting form contact between rotating and stationary components. If it is possible to fill the pump, the
direction of rotation must be checked with the pump / motor coupling removed.
5.7 Pump operating mode
Make sure that the pump is always started up with the suction-side shut-off valve fully open and the
discharge-side shut-off valve slightly open. However, the pump can also be started up against a closed
swing check valve. Only after the pump has reached full rotational speed shall the discharge-side shut-off
valve be adjusted to comply with the duty point.
Pump operation with closed shut-off valves in the suction and / or discharge pipes is not permitted. In
this case, there is a risk of the pump casing reaching a high surface temperature after a very short time, due
to a rapid temperature rise in the pumped fluid inside the pump. Additionally, the resulting rapid pressure
build-up inside the pump may cause excessive stresses on the pump materials and even cause it to burst.
The minimum flows indicated in the relevant pump operating manuals refer to water and water-like liquids.
Longer operation periods with these liquids and at the flow rates indicated will not cause and additional
increase in the temperature on the pump surface. However, if the physical properties of the fluids handled
are different from water, it is essential to check if and additional heat build-up may occur and if the minimum
flow rate must therefore be increased.
The calculation formula below can be used to check if an additional heat build-up may lead to a dangerous
temperature increase at the pump surface.
To = Tf +
= ((g * H) / (c * ))*(1 - )
c Specific heat of liquid [J / kg K]

g Acceleration due to gravity [m2/s]
H Pump head [m]
Tf Temperature of pumped fluid [ C]
To Temperature of casing surface [ C]
Pump efficiency [-]
Temperature difference [ C]
5.8 Temperature limits
In normal pump operation, the highest temperature is to be expected on the surface of the pump
casing, at the shaft seal, at the bearing areas and at the pump shaft end in close coupled executions.
Unless the pump is equipped with an additional heating facility, the surface temperature at the pump casing
will correspond to the temperature of the fluid handled, assuming that the pump surface is freely exposed to
the atmosphere.

In any case, responsibility for compliance with the specified fluid temperature (operating temperature) lies
with the plan operator. The maximum permissible fluid temperature depends on the temperature class to be
complied with.
The following limits for the maximum permissible temperature must be observed for the individual
temperature classes as per EN 13463-1 given below (temperature increase in the shaft seal area, if any, has
been taken into consideration):
Temperature class Permissible Max. Permissible fluid

as per EN 13463-1: surface temperature for compliance
temperature with temperature class
T5 100 C 80 C
T4 135 C 115 C
T3 200 C 180 C
T2 300 C 280 C
T1 450 C Temperature limit of the pump
The permissible operating temperature of the pump in question is indicated in the technical data. If the pump
is to be operated at a higher temperature, the technical data are missing or if the pump is part of a pool of
pumps, the maximum permissible operating temperature must be requested from the pump manufacturer.
Because of the very close contact between pumps and motors in close coupled design (ZLK and ZLI
Industrial pumps; ZTK and ZTI, Thermal Oil Pumps; and ZLI, Hot Water Pumps), there is a thermal influence
between pump and motor.
Especially for motors with protection type EExe (increased safety) the possibility that the declaration of
conformity losses its validity exits, as for the EC type examination an ambient temperature of 40 C is taken
as a basis. This admissible ambient temperature could be exceeded in the area of the motor flange when
pumping hot liquids.
In the event of fluid temperature above 80 C, the temperature category of the unit / set is determined by the
pump not by the motor.
The motor is usually rated for continuous operation at the data indicated in the technical data.
Frequent motor start-ups may result in increased surface temperature at the motor. Contact motor
manufacturer, if necessary.
Based on ambient temperature of max. 40 C and assuming that the pump unit is properly serviced and
operated and that the surfaces in the bearing area are freely exposed to the atmosphere, compliance with
temperature class T4 is warranted for surfaces in the area of rolling element bearings.
If temperature class T5 (100 C) and T6 (85 C) have to be compliance with, special measures may have to
be taken with regard to bearing temperature. In such cases and if ambient temperatures are higher, contact
the manufacturer.
Operators errors or malfunctions may result in substantially higher temperatures. Please refer to section 5.1
in this context.
Mechanical seals may exceed the specified temperature limits if run dry. Dry running may not only
result from an inadequately filled seal chamber, but also from excessive gas content in the fluid pumped.
Pump operation outside the specified operating range may also result in dry running. Shaft seals shall be
regularly checked for leakage.
The above stated and also stated in other paragraphs related to the mechanical seal, is also
applicable for any shaft sealing execution (i.e. packing rings, lip seal rings,)
It has to be verified, that V-rings are properly fitted to the shaft. Only proper contact should exist
between the sealing lip and the shaft.

5.9 Maintenance
Only a pump set, which is properly operated and maintained in perfect technical conditions, will give
safe and reliable operation. This also applies to the reliable function of the rolling element bearings whose
actual lifetime largely depends on the operating mode and operating conditions.
Regular checks of the lubricant and the running noises will prevent the risk of excessive temperatures as a
result of bearings running hot or defective bearing seals.
The correct function of the shat seal must be checked regularly.
Any auxiliary systems installed must be monitored, if necessary, to make sure they function correctly.
Static sealing elements shall be regularly checked for leakage.
The coupling guard and any other guards of fast rotating components must be regularly checked for
deformation and sufficient distance from rotating elements.
Regularly verify the correct position and the status of plastic components exposed to the atmosphere.
It is strongly recommended to draw up a maintenance schedule, which includes the above-mentioned

points.
In case of repair, only original Sterling Fluid Systems spare parts must be used, which comply with
the corresponding EC Directives.
6 Additional instructions for couplings in ATEX pump sets
The following instructions for couplings need especially to be followed for pump sets which are manufactured
in conformity with Directive 94/9/EC for operations as category 2G equipment in hazardous areas.
6.1 Limitations
Only the coupling type BDS and HDS are released for pump sets in conformity with 94/9/EC.
These couplings are designed to be operated according to the following parameters:

- Max. 25 starts per hour.
- Daily operating cycle up to 24 h.
- Operation within the specified alignment.
- Temperature range -30C a +80C in the immediate vicinity of the coupling.
6.2 Storage
If coupling parts are stored as spare parts, the storage area must be dry and free from dust. The flexible
elements must not be stored with chemicals, solvents, motor fuels, acids, etc Furthermore they should be
protected against light, in particular sunlight and bright artificial light with high ultraviolet content.
The storage area must not contain any ozone-generating equipment, e.g. fluorescent light sources, mercury
vapour lamps, high voltage electrical equipment. Damp storage areas are unsuitable. Ensure that no
condensation occurs. The most favourable atmospheric humidity is below 65%.
6.3 Installation
Type B and H couplings shall never be operated in pump sets category 2G.
The flexible elements are delivered in different materials and are then differently coloured or marked with
stripes in different colours. Only elements of one type must be used in one coupling.
When assembling a pump set with a coupling, the fits of the bores and shafts must be checked. See table
6.C.1

Table 6.C.1 Tolerances for coupling fit
Coupling
Nominal Shaft
Fit bore
diamenter tolerance
tolerante
Shaft tolerance
according to 50 mm k6
H7
DIN 748/1
> 50 mm m6
Failure to observe these instructions may result in breakage of the coupling. Danger from flying
fragments! The coupling then becomes and explosion hazard.
6.4 Mounting coupling parts

Before beginning installation, shaft ends and coupling part must be carefully cleaned. Before cleaning the
coupling parts with solvent the flexible elements must be removed.
If necessary, heating the coupling parts (to max 150 C) will facilitate fitting. With temperatures over 80 C
the flexible elements must be removed form the coupling parts before heating.
Coupling parts must be fitted with the aid of suitable equipment to avoid damaging the shaft bearings
through axial joining forces. Always use suitable lifting equipment.
Shaft ends must not project from the inner sides of the hub. Axial security is effected by means of the set
screw.
Tighten the set screws with a tightening torque in accordance with the table 6.C.3.
Failure to observe these instructions may result in breakage of the coupling. Danger from flying
fragments! The coupling then becomes and explosion hazard.
After fitting the coupling parts onto the shafts the flexible elements, if previously removed must be fitted.
Previously heated coupling parts must make cooled down again to a temperature below +80 C. It must be
ensured that the flexible elements are of identical size and colour or have identical marking.
Move together the pump set components to be coupled.
Danger of squeezing!
6.5 Alignment
Couplings connect shaft ends of the driver and the pump. The alignment of shaft ends needs to be adjusted
within the following tolerances.
The errors of alignment are differentiated into:
- Axial misalignment: the allowable difference between maximum and minimum axial gap S between
maximum and minimum axial gap S between the two coupling halves is given Table 6.C.2.
- Angular misalignment: this can usefully be measured as the difference in the gap dimensions S = Smax
Smin. The allowable values are given in Table 6.C.2, depending on coupling size and speed.

- Radial misalignment is the radial offset between the shaft centres. The allowable values are the same S
values like for the angular misalignment given in Table 6.C.2.
The method to adjust the alignment is:
- First correct the angular misalignment.

- Then correct the axial gap.
- Then correct the radial misalignment.
The useful tools are a feeler gauge and a ruler as shown in figure 6.C.2.
Table 6.C.2 Alignment dimensions
Coup. Axial Angular and radial misalignment

type gap S max. in mm
BDS S at speed
750 1000 1500 2000 3000
mm 1/min 1/min 1/min 1/min 1/min
76 24 0,25 0,2 0,2 0,15 0,15
88 24 0,25 0,2 0,2 0,15 0,15
103 24 0,25 0,25 0,2 0,2 0,15
118 24 0,3 0,25 0,2 0,2 0,15
135 24 0,3 0,25 0,25 0,2 0,15
152 24 0,35 0,3 0,25 0,2 0,2
172 26 0,4 0,35 0,3 0,25 0,2
194 26 0,4 0,35 0,3 0,25 0,2
218 26 0,45 0,4 0,3 0,3 0,2
245 26 0,5 0,4 0,35 0,3 0,25
6.6 Fixing the coupling on the shaft

For fixing the coupling parts on the shaft there are set screws, which need to be locked with the following
torque depending on coupling size:
Table 6.C.3 Torque for set screws
Size 76 88 103 118 135 152

Torque Nm 4 4 4 4 8 8
Size 172 194 218 245
Torque Nm 15 25 25 25
6.7 Operation
If any irregularities are registered during operation (vibrations of noise) the pump set is to be switched off
immediately. Determine the cause of the fault using the fault list in Chapter 8. This list contains possible
faults, their reasons and successful actions.
If the analysis is not possible then contact the Sterling Service.
6.8 Maintenance
Regular control of the torsional backlash is necessary to prevent.

The torsional backlash has to be measured in the following way: One coupling part is rotated against the
other with no torque to a stop. Then this position of the two coupling halves is marked (se figure 6.C.3). Then
the coupling parts are rotated into the other direction as far as possible without torque. The distance between
both marks is the backlash measure Sb. The maximum values for this measure are given in Table 6.C.4 by
coupling size. If this measure is exceeded, then the flexible elements need to be exchanged.
The flexible elements must be replaced in sets (all elements of one coupling at once, independent of the
individual wear). Only identically marked flexible elements must be used. Only spare parts from the original
equipment manufacturer are allowed for replacement
Table 6.C.4 Torsional backlash measure
Size 76 88 103 118 135 152 172

Sb
7,0 5,0 7,0 9,0 10,5 11,5 9,0
mm
Size 194 218 245
Sb
8,0 7,0 6,5
mm
6.9 Figures:
Figure 6.C.1 Measures for checking alignment
Smax Smax
Smin Smin
S = Smax - Smin
Figure 6.C.2 Checking of alignment
Ruler

Figure 6.C.3 Measurement of torsional backlash
Sb

Regulation EU 547/2012 Page 1 of 4 Annex V
Supplementary operating instructions in accordance to regulation EU 547/2012 in

order to implement Directive 2009/125/EC, regarding eco-design requirements for
water pumps:
ZLN, ZLK and ZLI
Contents Page
1 Introduction 2
2 MEI
2.1 Definition 2
2.2 Calculation 2
2.3 Pump values 3
2.4 Requirements 3
3 Efficiency
3.1 General overview 4
3.2 Curves 4
4 Efficient operation 4
5 End of life 4
6 Web side information 4

1 Introduction
For energy saving reasons all rotodynamic water pumps from types ZLND, ZLKD and ZLIC in future have to
fulfil eco-design requirements with respect to pump efficiency. The measure for the quality of a pump in
respect to efficiency is the Minimum Efficiency Index (MEI).
EU 547/2012 implement Directive 2009/125/EC regarding eco-design requirements for the placing on the
market of rotodynamic water pumps for pumping clean water, including where integrated in other products.
Annex contains all relevant documentation about mentioned pumps related to information requirements
include in ErP standard.
2 MEI
2.1. Definition
Minimum Efficiency Index (MEI) could be defined as the measure for the quality of a pump in respect to
efficiency. It is a dimensionless scale and related to best efficiency point (BEP), part load (PL) and overload
(OL) conditions (0,75 x QBEP and 1,1 x QBEP). It is only valid for full impeller diameter at rated speed. The
higher this value is, the better is pump in respect to efficiency and as lower is its energy consumption and
CO2 emission.
2.2. Calculation
The MEI-value for a particular pump size is calculated considering four parameters:
a) Flow rate at BEP (QBEP).
b) Specific speed (ns), which refers to the specific impeller shape (from radial type at the lowest
values to axial at the highest ones)
QBEP
ns = n 3/4 [rpm]
H BEP
where QBEP [m/s], HBEP [m] and n [rpm].
c) A constant (C), which quantifies the differences in efficiency for different pump types (end suction,
in-line,) and speed.
d) Required minimum efficiency at best efficiency point ( BEP )min requ . The formula is as follows:

( BEP )min requ = 88,59 x + 13,46 y 11,48 x 2 0,85 y 2 0,38 x y CPump Type, rpm
Where,
x = ln (ns)
y = ln (Q)
ln = natural logarithm
3
Q = flow (m /h)
ns = specific speed (rpm)
C = constant which depends on the pump type, nominal speed and MEI value. It could be found below table.
2.3. Pump values
MEI-value of each pump is indicated in the nameplate as follows:
MEI [x, xx ]
It should be mentioned that the benchmark for highest efficiency water pump is MEI 0,7
2.4. Requirements
MEI requirements for next years will be the following ones:
a) Starting point in 2013: MEI 0,1

b) Updated value in 2015: MEI 0,4

3 Efficiency
3.1. General overview
a) The minimum required pump efficiency has to be at least equal or higher than that one indicated by the
specific MEI value.
b) Hydraulic pump efficiency is indicated in the nameplate in the format: % [--,-]
c) The efficiency of a pump with a trimmed impeller is usually lower than one of a pump with the full impeller
diameter. The trimming of the impeller will adapt the pump to a fixed duty point, leading to reduced energy
consumption. The minimum efficiency index (MEI) is based on the full impeller diameter.
3.2. Curves
Pump efficiency has a maximum at ns values in the range between 40 50. It decreases for higher and
lower ns values, especially leading to very low values at ns 10 rpm.
Requirements for pumps grow with increasing MEI, i.e. pumps have to reach higher efficiencies with
increasing MEI-values.
Benchmark efficiency graphs are permanently available under www.europump.org/efficencycharts
4 Efficient operation
The operation of this water pump with variable duty points may be more efficient and economic when
controlled, for example, by the use of a variable speed drive that matches the pump duty to the system.
5 End of life
End of life pump treatment is a very important issue to fulfil eco-design requirements. The procedure to
dismantle the pump is described in chapter 7 of the Instruction Manual document. In general, once pump has
been dismantled, metallic parts come back to the foundry and for the rest of components, the recycling
process follow the recommendation of our suppliers.
6 Web side information
This information is also available at www.sterlingsihi.com

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SIHISuperNova Programme

Safety issues Chapter 1

In the search to improve continuously its products,

In the search to improve continuously its products,

In the search to improve continuously its products,

1.7.3 Monitoring technical modifications are only undertaken with Sterling

1.7.4 Avoiding external damage

1.8 Unauthorized alterations and

1.9 Unauthorized mode of operation

1.10 Warranty / guarantee

In the search to improve continuously its products,

The pump may only be used for the

Do not exceed fluid density stated.

In the search to improve continuously its products,

B27:WC/Carbon, EPDM 0E: Cast iron GG25,

In the search to improve continuously its products,

Example of a pump designation: 2.5 Shaft sealing

Section 2.4 does not contain the codes for all

In the search to improve continuously its products,

3.0 Planning the installation

3.1 Piping system Ensure that air pockets cannot be created.

Note the arrows on the pump branches

Choose nominal widths of the pipelines

must not exceed 2 - 3 m/s. 3 1 2

3.1.1 Suction line / inflow line

positive suction head operation suction lift operation

In the search to improve continuously its products,

A shut-off valve should be installed in the feed

3.1.2 Discharge line

3.1.3 Inlet and outlet connections

3.1.4 Pressure control

3.2 Electrical connections

In the search to improve continuously its products,

4. Unpacking, storage, handling 4.4 Handling

Never stay below the suspended load.

Do not use the eyebolts on the pump

In the search to improve continuously its products,

4.5.2 Renewing corrosion protection

In the search to improve continuously its products,

5. Installing the pump

5.3 Safety measures Prior to installing, checks should be made with

- Possible damage to the pump or the

Remove the protective coating by following 5.4.4 Installation of the set

5.4 General information 5.4.5 Space required

5.4.2 Permissible ambient conditions

In the search to improve continuously its products,

5.4.6 Position If other manufacturers couplings are used, follow

5.6 Alignment of the set

In the search to improve continuously its products,

5.9 Mounting the pump and

1. Remove the protective covers from the pump

The pump must be aligned with the pipework. The

5.10 Final work

1. Check the tightness of the connecting flanges.

5.11 Hydrostatic pressure test

The max. permissible pressure for a

In the search to improve continuously its products,

6. Start-up and shut-down

6.1 Requirements If there is no bypass line, do not run the

In the search to improve continuously its products,

11. is the gland finger slightly tight?. 6.7 Switching frequency

Size Permissible number of

6.6 Start-up operation