Seepex

seepex France SARL 1,Rue Pelloutier F-77183 Croissy Beaubourg Tel+33.1.64114450 Fax+33.1.64114469 [email protected] www.seepex.com

Operating and Assembly Instruction Progressive Cavity Pump 24h Helpline: www.seepex.com

Commission-no. 287754

Read instructions before beginning any work!

Original Instructions

Issue 13.02.2014

Type BN 200-6L

Always keep instructions handy on the worksite.

Index

1

.................................................................................................................................................... 1 Safety Safety.................................................................................................................................................... ....................................................................................................................................................1 1.1 General notes 1.2 Safety and warning notes 1.2.1 Warning notes 1.2.2 Danger symbols 1.2.3 Information symbols 1.3 Dangers that can be caused by the machine 1.4 Qualification of the personnel 1.5 Authorised people 1.5.1 Tasks and information for the owner/operators 1.5.2 Safety notes for maintenance, inspection and assembly work 1.6 Personal protective equipment 1.7 Safety and protective devices 1.8 Foreseeable misuse 1.9 Designated use 1.10 Warranty

2

Description of the pump ........................................................................................................................ 5 pump........................................................................................................................ ........................................................................................................................5 2.1 General description 2.2 Mode of action and pumping principle of the pump 2.3 Constructive design

3

Technical Data ...................................................................................................................................... 6 Data...................................................................................................................................... ......................................................................................................................................6 3.1 Data sheet ................................................................................................................................ 7 3.2 Characteristic Curves ............................................................................................................... 9 3.3 Declarations........................................................................................................................... 10

4

Transport, Intermediate storage, Disposal .......................................................................................... 11 Disposal.......................................................................................... ..........................................................................................11 4.1 Safety 4.2 Transport 4.2.1 Dimensions, weight and centre of gravity 4.2.2 Symbol 4.2.3 Lashing points (AP) for lifting devices 4.2.4 Unpacking the machine 4.3 Temporary storage/corrosion protection 4.4 Disposal

Index

5

Assembly / Installation ........................................................................................................................ 13 Installation........................................................................................................................ 5.1 Mounting tools / lifting gear 5.2 Space requirement 5.2.1 Dimension for stator replacement 5.2.2 Space requirement for service work 5.3 Assembly of the complete mounted pump 5.4 Power supply of the pump 5.5 Pipelines 5.5.1 Suction and pressure connection 5.5.2 Pipeline dimensions 5.5.3 Residue-free pipelines 5.5.4 Tension-free assembly 5.6 Dimensional Drawing............................................................................................................. 15

6

Commissioning / De-Commissioning .................................................................................................. 16 De-Commissioning.................................................................................................. ..................................................................................................16 6.1 Commissioning report............................................................................................................ 16 6.2 Measures before commissioning............................................................................................ 17 6.2.1 Checking pipelines 6.2.2 Protective devices on the pump 6.2.3 Electrical / hydraulic connections 6.2.4 Direction of rotation check 6.2.5 Additional devices - optional 6.3 Initial commissioning/repeated commissioning 6.3.1 Avoiding dry running of the pump 6.3.2 Pressure in the suction and pressure connection 6.4 De-commissioning 6.4.1 Switching off the pump 6.4.2 Emptying the pump 6.4.3 Dismantling the pump 6.4.4 Preservation/storage of the pump

7

....................................................................................................................................... 21 Maintenance Maintenance....................................................................................................................................... 7.1 Preventative measures 7.1.1 Pump down-time 7.2 Lubrication 7.2.1 Joint grease 7.3 Inspection

8

...................................................................................................... 23 Malfunctions, causes, rectification rectification......................................................................................................

Index

9

Pump Dismantling / Reassembly ........................................................................................................ 25 Reassembly........................................................................................................ ........................................................................................................25 9.1 Pump Dismantling / Reassembly........................................................................................... 25 9.1.1 Prepare the pump for dismantling 9.1.2 Dismantling 9.1.3 Reassembly 9.2 Rotating unit – individual parts .............................................................................................. 31 9.2.1 Dismantling 9.2.2 Rotating unit (RTE) - prepare individual parts for reassembly 9.2.3 Rotating unit (RTE) - individual parts - reassembly 9.3 Holding band - assembly........................................................................................................ 36 9.3.1 Prepare the holding band 9.3.2 Check the holding band 9.3.3 Assembling the holding band 9.3.4 Correct tension for the holding band (HBD) 9.3.5 Cant up the holding band 9.3.6 Shear the holding band 9.3.7 Check the holding band after assembly 9.5 Shaft Sealing .......................................................................................................................... 38 9.5.1 Safety 9.5.2 Application conditions and material version 9.5.3 Design 9.5.4 Commissioning 9.5.5 Monitoring during operation 9.5.6 Packing Ring - dismantling 9.5.7 Gland Packing – dismantling 9.5.8 Reassembly

10

Spare parts ......................................................................................................................................... 39 parts......................................................................................................................................... 10.1 Order template for spare parts............................................................................................... 40 10.2 Sectional drawing and parts list.............................................................................................. 42

11

Special tools ....................................................................................................................................... 45

12

Related documents ............................................................................................................................. 46 documents............................................................................................................................. .............................................................................................................................46 12.2 Technical Information............................................................................................................. 47

13

............................................................................................................................................. 49 Appendix Appendix............................................................................................................................................. .............................................................................................................................................49 13.1 Manufacturer's documents / suppliers 13.1.1 Gearbox ..................................................................................................................... 50 13.1.2 Motor ......................................................................................................................... 98 Subsidiaries

1 Safety 1.1

General notes ¾ Always keep the operating and maintenance instructions close by the machine. ¾ If problems cannot be solved with reference to the operating and maintenance instructions, please contact the manufacturer. Observe the following points in addition to these operating and maintenance instructions:

1.2

•

Prohibition, warning and mandatory signs, warning notes on the machine

•

Relevant laws and ordinances

•

Statutory provisions on accident prevention

•

Corresponding harmonised standards and regulations

Safety and warning notes ¾ Comply with safety and warning notes for safe and efficient use of the product. Signal words for specific dangers and (possible) consequences are explained below. These are supplemented by symbols (pictograms) if necessary.

1.2.1 Warning notes NOTICE Caution for machine! Possible danger. Material damage can occur. CAUTION Caution for people and machine! Possible danger. Minor injury or damage to property can occur. WARNING Warning for people! Possible danger. Death or serious injury can occur. DANGER Danger for people! Possible danger. Immediate risk of sever or fatal injury. 1.2.2 Danger symbols

Warning: Suspended load.

Ausgabe issue

Warning: Dangerous electrical voltage.

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1 Safety 1.2.3 Information symbols NOTICE

Ensure environmental protection.

Wear eye protection.

¾ Instruction to act/take measures • 1.3

List item

Dangers that can be caused by the machine seepex machines are built in accordance with the state of the art. Nevertheless, there is a residual risk, because the machine works with: •

Mechanical movements that pose a danger

•

Electrical voltages and currents

We have used design measures and applied safety technology to minimise the risk to the health of people posed by this danger. 1.4

Qualification of the personnel This handbook is intended for:

1.5

•

Owner

•

Operators

•

Setters

•

Maintenance personnel

Authorised people People authorised to undertake operation, set up and maintenance are instructed and trained specialists employed by the owner/manufacturer. Detailed technical knowledge is essential for performing any work on the machine.

The owner is responsible for: •

Personnel training

•

Compliance with safety regulations

•

Compliance with operating and maintenance instructions

The operator must: •

Have received instruction

•

Read and understood the relevant parts of the operating instructions before starting work

•

Know the safety devices and regulations

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1 Safety 1.5.1 Tasks and information for the owner/operators ¾ Regularly check and maintain the machine, replacing all parts in good time which no longer guarantee safe operation. ¾ It is essential to comply with the procedure described in the operating instructions for shutting down the machine. •

On completion of work, attach all safety and protective devices and make sure they are functioning.

1.5.2 Safety notes for maintenance, inspection and assembly work ¾ Do not work on the machine or system unless it is stationary and depressurised. ¾ Switch off the master switch and pull out the power plug before starting work on live components. ¾ Comply with the procedure for shutting down the machine as described in the Shut-down chapter. ¾ Decontaminate (de-toxify) machines that are used for pumping media that can be harmful to health. ¾ Refer to the Initial start-up chapter before repeated start-up of the machine. 1.6

Personal protective equipment ¾ Wear personal protective equipment and/or additional equipment for your own safety. ¾ Avoid/limit risks by the use of collective technical protective equipment or by organisational measures at work.

1.7

Safety and protective devices ¾ Prior to start-up, bolt seepex machines onto a concrete foundation so as to ensure stability. ¾ Starting and stopping devices must be clearly recognisable. Take appropriate measures to avoid defects.

1.8

•

No protective device is necessary for checking and/or setting the shaft seal.

•

Hot surfaces are identified with a danger symbol on the machine.

Foreseeable misuse Serious personal injury and damage to property can be caused by: •

Incorrect use

•

Incorrect installation or operation of the machine

•

Impermissible removal of necessary protective equipment

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1 Safety 1.9

Designated use •

Only use seepex machines if they are in perfect condition and in compliance with the operating and maintenance instructions.

•

Do not start up the machine unless the system in which the machine is installed is in accordance with the provisions of the applicable guidelines and statutory regulations.

•

Equivalent sustained sound pressure level at workplaces of operating personnel C75 dB (A). Cavitation-free operation of the machine and screwed connection to concrete foundation are essential.

•

seepex machines are components that are exclusively intended for pumping media in accordance with the technical data (→ chapter 3). Written approval must be obtained from the manufacturer before other media are pumped.

•

Refer to the information on the type plate and the operating instructions for technical data (→ chapter 3), and comply with them.

•

The operating instructions are assigned to the seepex machine based on the commission number.

Fig. 1-1 Similar illustration

1.10 Warranty •

Warranty in accordance with our terms and conditions of delivery and order confirmation.

•

It is a condition of the machine warranty that the machine must correspond to the listed operating instructions in accordance with the type plate/data sheet.

•

All wearing parts are excluded from the warranty.

•

These operating instructions are subject to copyright. Reproduction is not permitted and will be punished. Contravention will be pursued through the courts.

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2 Description of the pump 2.1

General description seepex pumps are members of the group of rotating displacement pumps. •

2.2

2.3

Characteristic features – Special configuration/arrangement of the rotor and stator pumping elements. – Motion sequence

Mode of action and pumping principle of the seepex pump •

Sealing bands are produced through geometric design/contact of both conveying elements.

•

Sealing bands ensure a perfect fit between the suction and pressure side. Result: – Increased pump suction. – Higher pressure build-up independent of speed possible.

Constructive design

No.

Designation

ANT

Drive

200

Lantern

307

Plug-in shaft

400

Coupling rod

SEA

Shaft seal

500

Suction casing

600

Rotor

RTE

Rotating unit

601

Stator

700

Pressure branch

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3 Technical data 3.1

Data sheet

3.2

Characteristic Curves

3.3

Declaration of conformity / declaration of incorporation

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sc Data Sheet

287754

seepex GmbH Postfach.PO Box 10 15 64 46215 Bottrop Scharnhölzstraße 344 46240 Bottrop Germany

Page 1

seepex order no. date

114986/2014 06.02.14

commission no. offer no.

customer purchase order no. project

MEURA S.A. 69563 3082 2 4 21

item/denomination

1 off

seepex progressive cavity pump

287754 500016126/1 001 1402004-14

Tel +49.2041.996-0 Fax +49.2041.996-400 [email protected] www.seepex.com

type BN 200 -6L /A6-A5-A5-R0-F1-X conveying product

G 208 BE0005

denomination rate of solids size of solids density composition remarks

Maische (Biermaische) no advice < 1 mm 1 - 1,1 kg/dm3 no advice

performance data

nom.

conveying capacity pump speed press in press. branch press in suct. branch differential pressure required drive power remarks

min 32,00 58

max 164,00 260 2,00 en charge +/-1 mCE bar 23,90 kW

viscosity pH-value temperature

flowable neutral 55-60°C

m3/h rpm bar operating torque starting torque

1730

Nm Nm

Tolerances according to seepex standards

technical pump data range size pressure stage

BN 200 6L

kind of install. direction of rot. pos. of branch

component lantern suction casing suction connection

material EN-JL-1040 (gci 25) 1.4408

design/option standard enlarged cross section and cleanouts on both sides DN 200 PN 10 EN 1092-1 (DIN 2542)

pressure branch pressure connection joint joint grease joint seal coupling rod rotor stator gland housing packing

1.4571

plug-in shaft special designs

Rechtsform GmbH HRB 9350 Gelsenkirchen

standard 30321 EPDM 1.4301 1.4301 EPDM 1.4408 K 41 1.4301

Geschäftsführender Gesellschafter: Ulli Seeberger

horizontal counter clockwise 1

DN 200 PN 10 EN 1092-1 (DIN 2632) standard standard with screw -0,9 (K) standard with seal cage ring, two buffer fluid connect. (F) drilled Ø60x100

7

sc Data Sheet

287754

seepex GmbH Postfach.PO Box 10 15 64 46215 Bottrop Scharnhölzstraße 344 46240 Bottrop Germany

Page 2

Tel +49.2041.996-0 Fax +49.2041.996-400 [email protected] www.seepex.com

general operating data kind of operation site of installation remarks

15 toutes les 1h30 indoor, dry

drive type make model mounting position flange dia output shaft

geared motor Getriebebau Nord SK62F-200LH/4 IMM1 350 mm 716/0700-002B4

type of adjustment speed transmitter speed indication special/accessories

frequency control

ratio

i= 5,290

output speed motor speed frequency

nom./ min- max 277/ 58- 260 rpm 1470/ rpm 50/ 11- 47 Hz

voltage rated frequency protection thermal class

400/690 50 IP55 F

electric motor nominal power nominal speed mounting position starting duty type special/accessories

30,0 kW 1470 rpm IM dir. at frequ. inv.

V Hz

with 3 PTC thermistors IE2-motor

Remarks: constant torque inverter required; min. starting torque to be 1.5 times of running torque!

painting execution colour remarks

standard RAL 5002

packing packing type marking

documentation dimensional drawing no. sectional drawing no. shaft sealing sect.view

262-A36/2000-A-003A4 062-002C1

operating manual

1 copy English copy

QA-documentation Quality Inspection Certificate DIN 55350-18-4.1.1 CE-sign

order desk phone

Rechtsform GmbH HRB 9350 Gelsenkirchen

Sabine Zanger 02041.996-0

Geschäftsführender Gesellschafter: Ulli Seeberger

sales engineer issue

Alexander Herde 13.02.14 / 12:03

8

R

9

EC declaration of conformity according to Machinery Directive 2006/42/EC, Annex II A

seepex GmbH Scharnhölzstraße 344 46240 Bottrop Postfach 10 15 64 46215 Bottrop PO Box 10 15 64 46215 Bottrop Germany Tel +49.2041.996-0 Fax +49.2041.996-400 [email protected] www.seepex.com

Manufacturer:

seepex GmbH

Address:

Scharnhölzstrasse 344 D-46240 Bottrop, Germany

We hereby declare that the following product Progressive cavity pump unit

Type:

BN 200-6L

Comm. no.:

287754

meets the provisions of the directive indicated above, including the modifications holding at the time of declaration. The product also meets all the provisions of the following directives: 2006/95/EC 2004/108/EC

Electrical equipment Electromagnetic compatibility

The following harmonised standards were applied: DIN EN ISO 12100 DIN EN ISO 13857 DIN EN 809

Safety of machinery Safety distances, upper and lower limbs Pumps and pump units for liquids

Responsible for documentation:

Bottrop,

Issue 03/2011 Issue 06/2008 Issue 10/2012

seepex GmbH Scharnhölzstraße 344 46240 Bottrop Tel +49 2041 996 - 0 Fax +49 2041 996 - 400 [email protected]

13.02.2014

i.V. Klemens Fockenberg Technology Manager seepex GmbH

Rechtsform: GmbH HRB 9350 Gelsenkirchen

Geschäftsführender Gesellschafter: Ulli Seeberger

i.V. Roland Hecker Quality Control Manager seepex GmbH

10

4 Transport, Intermediate storage, Disposal 4.1

Safety

CAUTION Damage to property/injuries due to incorrect transport Slight injury or damage to property can occur ¾ Comply with the safety notes and transport notes on the packaging. ¾ Use suitable means of transport, lifting devices and tools. ¾ Use protective equipment. 4.2

Transport

4.2.1 Dimensions, weights and center of gravity ¾ Note the dimensional drawing (→ chapter 5.6). 4.2.2 Symbols •

Meaning of symbol

Top

Fragile item

Against moisture Centre of gravity

Lashing points

protect

4.2.3 Sling points (AP) for lifting devices WARNING Warning of suspended load. Death of serious injury can occur. ¾ Use the lashing points (AP) for lifting divices. ¾ Note the centre of gravity (→ dimensional drawing, chapter 5.6). Lifting machine

Industrial trucks

4.2.4 Unpacking the machine ¾ Comply with the symbols and notices on the packaging. ¾ Remove the screwed connection between the machine and packaging. ¾ Remove the machine with a lifting machine/industrial truck. 4.3

Temporary storage/Corrosion protection •

All seepex machines have corrosion protection applied as standard prior to transport.

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4 Transport, Intermediate storage, Disposal NOTICE Damage to property if corrosion protection is missing Property damage can occur due to corrosion. ¾ Temporary storage must be in a dry, enclosed, frost-free room in order to provide protection against ambient influences. ¾ Contact seepex regarding the necessary corrosion protection for temporary storage. 4.4

Disposal NOTICE Environmental protection Material damage can occur. ¾ Drain the pumping medium and dispose of it in accordance with the regulations. ¾ Dispose of the machine with regard to its composition and existing regulations.

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5 Assembly / Installation 5.1

Mounting tools / lifting gear

CAUTION Pump falling over. Slight injury or damage to property can occur.  Adhere to the lifting tool’s starting point.  Pay attention to the dimensions, weight and centre of gravity of the pump.  Use suitable mounting tools/lifting gear. 5.2

Space requirement The required space should be determined by considering the following factors: •

Dimensions and weight.

•

Requisite transport and lifting equipment.

•

Pipe routing – dismantling (dimension for stator replacement).

5.2.1 Dimension for stator replacement (P)  Refer to the dimensional drawing.

5.2.2 Space requirement for service work

Provide a working area of approx. 1 m/ 40 inch width alongside the pump.

B

When changing the stator, provide suspension points above the stator and in front of the pressure branch.

C

For dismantling/assembly the drive, provide suspension points above the drive unit.

D

P

For dismantling/assembly of the suction casing/hopper, provide suspension points above the housing.

P

A A

A

A

Note the following measure:

B

B

D

C

B

Dimension for stator replacement.

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5 Assembly / Installation 5.3

Assembly of the complete mounted pump  Assemble according to technical data (chapter 3.).  Note the dimensional drawing. Tension-free mounting of the pump  Balance unevenness with suitable supports.. •

Applies to mounting on foundations/load-bearing elements.

•

Total areas of all pump bearing areas are resting on the surface.

Correct position of the drives •

All drives are set up ready for operation and mounted.

•

Correct displacements of the drive during transport/installation of the pump by adjusting/fixing the drive. CAUTION Safety protective devices. Slight injury or damage to property can occur.

 Connect safety protection devices and activate.

5.4

Power supply of the seepex pump DANGER Line voltage and line frequency Death or serious injury can occur.  Note the type plate on the pump.  Pay attention to manufacture’s directions (chapter 13.).  Pay attention to safety regulations.

5.5

Pipelines

5.5.1 Suction and pressure connection •

Refer to the dimensional drawing for position, nominal width and standard.

•

Note the direction of rotation/flow direction.

5.5.2 Pipeline dimensions •

Adhere to specifications regarding pressure in the pressure respectively suction connection.

•

Note technical data (chapter 3.).

•

Nominal width of suction pipe = nominal width of pump suction connection.

5.5.3 Residue-free pipelines NOTICE Damage to property through assembly residue. No claims under guarantee if violated.  Keep all pipelines free from foreign objects.  Remove weld spatter, screws, steel chips, etc. 5.5.4 Tension-free assembly  Assemble pipelines and other components in a tension-free manner on the pump. Ausgabe issue

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6 Commissioning / De-commissioning Master Copy 6.1

Commissioning report

Send commissioning report online to

From:

www.seepex.com\

Must be specified with every order! Commission:

Model:

Contact person: ............................................. Tel.: ................................................................

_________________________

_____________________

Fax: ............................................................... E-mail: ...........................................................

Germany

Customer Service:

Phone:+49 2041.996-231 Address of plant: Fax: +49 2041.996-431

seepex GmbH

.......................................................................

Postfach 10 15 64

Rest of

Phone:+49 2041.996-224 .......................................................................

D-46215 Bottrop

Europe

Fax: +49 2041.996-424

[email protected]

Outside

Phone:+49 2041.996-120 .......................................................................

Europe

Fax: +49 2041.996-432

....................................................................... .......................................................................

Delivery date: Date of installation: Assembly check carried out on: Please enter operational data: Conveying liquid: Temperature: Fuse level/motor protection or power consumption Frequency control

no yes

If yes: Supplied by seepex Supplied by customer Frequency: Speed: Power consumption:

________________________________

_______________________________________

Place, date

Signature / company stamp

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6 Commissioning / De-commissioning 6.2

Measures before commissioning ¾ Note the technical data (→ chapter 3.).

6.2.1 Checking pipelines ¾ Check flange screwed connections (SCH).

¾ Check threaded connections (G).

NOTICE Ensure the liquid can flow through without obstruction. Malfunction and/or irreparable damage to the pump. ¾ Open all shut-off elements before switching on the pump. 6.2.2 Protective devices on the pump DANGER Missing protective device. Danger of pulling in and crushing. ¾ Equip the pump with a protective device. Protective devices provided for preventing contact with surfaces or moving parts must be regarded as suitable if contact is not possible in a test involving a test finger, with regard to the penetration possibility, strength and shock resistance. ¾ Comply with national protection regulations. ¾ In pumps with an open suction flange/feed hopper, attach touch protection. These safety clearances protect those persons who are attempting to reach danger areas without additional help and under the conditions defined for various situations of reaching up, reaching under or reaching through In shaft seals, touch protection is only necessary if there are components on the rotating shaft. 6.2.3 Electrical/hydraulic connections DANGER Dangerous voltage. Death or serious injury can occur. ¾ Note safety regulations. ¾ Disconnect motor from all sources of energy. ¾ Secure electrical connections against restarting.

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6 Commissioning / De-commissioning 6.2.4 Direction of rotation check flow direction ¾ The pump direction of rotation determines the flow direction of the pumping medium. ¾ Note the direction of rotation arrow on the type plate. counter clockwise

clockwise

6.2.5 Additional devices - optional ¾ Refer to additional devices (→ chapter 12.1). 6.3

Initial commissioning/repeated commissioning ¾ Start up the pump. NOTICE Dry running of the pump. Malfunction and/or irreparable damage to the pump. ¾ Fill the suction casing with liquid in order to lubricate the pumping elements.

6.3.1 Avoid dry running of the pump NOTICE High temperature between rotor and stator. Stator material burned. Complete failure of the pump. ¾ Make sure that the suction-side conveying capacity does not cavitate. ¾ If this cannot be guaranteed on the machine side, assemble a seepex dry running protection (TSE). 6.3.2 Pressure in the suction and pressure connection CAUTION High pressure. Malfunction and/or irreparable damage to the shaft seal or pump. ¾ Maintain pressure in the suction connection in accordance with the technical data (→ chapter 3.). Recommendation: ¾ Assemble an oil-filled contact pressure gauge to monitor and deactivate the pump.

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6 Commissioning / De-commissioning 6.4

De-commissioning Protect the pump and additional devices against the following: •

Frost

•

Deposit of solids

•

Sedimentation from the liquid

•

Corrosion of parts that come into contact with the medium

6.4.1 Switching off the pump DANGER Dangerous voltage. Death or serious injury can occur. ¾ Note safety regulations. ¾ Disconnect motor from all sources of energy. ¾ Secure electrical connections against restarting. 6.4.2 Emptying the pump CAUTION Liquid draining out. Minor injury or damage to property can occur. ¾ Wear suitable protective clothing. ¾ Refer to the technical data (→ chapter 3.) for the corresponding configuration of the pump housing. To drain the pump: ¾ If the pump housing has screwed plugs, remove the screwed plugs. ¾ Drain using a connection branch (suction casing, pressure branch) if the pump housing is coated or the housing does not have screwed plugs. ¾ Drain the residual liquid from the pump housing. ¾ Drain the pipelines on the suction and pressure sides, or shut off behind the pump connections.

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6 Commissioning / De-commissioning 6.4.3 Removing the pump WARNING Risk of pump tipping or falling. Death or serious injury can occur. ¾ Support the drive unit to guarantee stability. Pipeline dismantling ¾ Remove flange bolts (SCH) and flange seals (DFL). with/without base plate ¾ Remove bolts (SCH) from the pump feet.

Pipeline dismantling ¾ Remove threaded connections (G). with/without base plate ¾ Remove bolts (SCH) from the pump feet.

6.4.4 Preservation/storage of the pump NOTICE Damage to property due to lack of corrosion protection. Property damage can occur due to corrosion. ¾ Contact seepex to discuss suitable preservation measures. – State the commission number of the pump.

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7 Maintenance 7.1

Preventive measures The maintenance personnel must have these operating instructions, follow them and also require corresponding qualifications.

DANGER Dangerous voltage. Death or serious injury can occur.  Note safety regulations.  Disconnect pump from all sources of energy.  Secure electrical connections against restarting. 7.1.1 Pump down-time NOTICE Pump down-time. Production failure due to wear.  Acquisition of a set of wearing parts and a set of gaskets. 7.2

Lubrication

No.

Denomination

Lubricant

Lubricant change in operating hours

Fill volume

1

Pin joint

seepex special grease 10000 h (30321)

147 cm3

2

Pin joint

seepex special grease 10000 h (30321)

147 cm3

3

Drive

Refer to manufacturer's documentation (chapter 13._)

Rotor/stator

Conveying medium

---

---

Shaft seal

Conveying medium

---

---

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7 Maintenance 7.2.1 Joint grease NOTICE Other grease types. Malfunction and/or irreparable damage to the joints or the pump.  Exclusively use seepex special grease. 7.3

Inspection Component

Interval

Joints

Every 10,000 operating hours Renew joint grease

Stator

Every week

Visual check for leaks

Shaft seal

Every week

Visual check for leaks

Drive unit

Every 3000 operating hours, at least every 6 months

Comply with manufacturer's documentation

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8 Malfunctions, causes, rectification Refer to technical data (chapter 3.) for application range of the pump.

X

X

X Static friction between sta- Apply lubricant (liquid soap) tor/rotor too great. between stator and rotor.

X

X X X

X X

X X X

X

X X X X

X

Rectification

Shaft seal is leaky

Premature stator wear

Motor gets too hot

Pump is loud when running

Pump seized / pump does not pump

Causes

Pump does not start up

Pressure head is not reached

Conveying capacity is not achieved

Pump pumping unevenly

Pump is not sucking

Malfunction

X

Incorrect direction of rotation.

Check direction of rotation and swap over motor connections if necessary.

Suction pipe or shaft seal leaking.

Eliminate leaks.

Suction head too great.

Check the suction head, if necessary increase pipe cross section on suction pipe and use a larger filter, open suction-side valve fully.

Viscosity of conveying product too great.

Check/adapt (data sheet).

Pump rotation speed incorrect.

Correct rotation speed (data sheet).

X X

Avoid air bubbles in the conveying product.

X

X X

X X

X X X

X

X

X X

X

X

Ausgabe issue

B / 11.09.2007

Dokument document

Pressure head too great.

Check pressure head with pressure gauge, reduce pressure head by using larger pressure pipe crossed section or shortening the pressure pipe.

Pump running partially/ completely dry.

Check there is adequate conveying product available on the suction side. Dry running protection DRP.

Check coupling.

If necessary, move pump in relation to drive, check wear on coupling gear, re-adjust coupling if necessary.

Rotation speed too low.

Increase rotation speed for low-viscosity media/large suction volume.

OM.REC.01e

Blatt sheet

1 (2)

23

8 Malfunctions, causes, rectification

X X

Rotation speed too high.

Reduce rotation speed for high-viscosity media, risk of cavitation.

X

Joint play too large.

Check mounting of coupling rod bushing.

Foreign objects in pump.

Dismantle pump, remove foreign bodies, replace defective parts.

X

X

X

X X

X

Stator/rotor worn.

Dismantle pump and renew defective parts.

X

X

X X

Joint parts worn.

Renew joint parts, use seepex pin joint grease.

X

X

X

X

Suction pipe blocked.

Clean the suction pipe.

X X

X X

Temperature of pumping liquid too high.

Check temperature, use an undersize rotor.

X

X

X X

X

X X

Shaft seal is leaky

X

Premature stator wear

Rectification

Motor gets too hot

Causes

Pump is loud when running

Pump seized / pump does not pump

Pump does not start up

Pressure head is not reached

Conveying capacity is not achieved

Pump pumping unevenly

Pump is not sucking

Malfunction

X

X Gland packing too firm/ worn.

Loosen packing gland or tighten. Renew unusable packing rings.

X

X X

X

X

X

X X Sedimentation/gumming of Rinse through and clean solids when pump station- the pump immediately. ary.

X

X X

X X Conveying product hardHeat the pump. ens when the temperature drops below a certain limit.

X X

Solid content and/or grain size too great.

X X

X

Stator swollen and unable to withstand conveying product. X Bearings in pump drive housing or drive unit defective.

Reduce pump speed, install screen with permitted mesh width. Increase liquid proportion.

Select a suitable stator material, use an undersize rotor. Renew bearings.

X Mechanical seal defective. Check sliprings and Orings for wear/resistance, renew if necessary.

Ausgabe issue

B / 11.09.2007

Dokument document

OM.REC.01e

Blatt sheet

2 (2)

24

9 Dismantling / Reassembly 9.1

Pump Dismantling/Reassembly Range: BN Size: 05-24 bis 300-6L

9.1.1 Preparing the pump for dismantling DANGER Dangerous voltage. Death or serious injury can occur.  Note safety regulations.  Disconnect motor from all sources of energy.  Secure electrical connections against restarting.  Empty pipelines.  Allow pipelines to cool down.  Remove pipeline connections (suction side/pressure side).  Note decommissioning (chapter 6.4).

9.1.2 Dismantling WARNING Risk of pump tipping or falling. Death or serious injury can occur.  Fasten the lantern (200) to secure the pump.

9.1.2.1 Pressure branch (700) - Dismantling  Prop up stator (601) with a support (S).  Remove screw fitting (604, 606).  Remove pressure branch (700).  Remove tie bolt (602).

Ausgabe issue

E / 19.08.2013

Dokument document

OM.MAI.02e

Blatt sheet

1 (6)

25

9 Dismantling / Reassembly 9.1.2.2 Stator (601) - Dismantling  Raise/move splash ring (310).  Remove the plug-in shaft pin (309).  Insert tool (WS).  Turn tool (WS) upwards.

Tool (W2/chain wrench)  Add lubricant (GM) to the opening on pressure branch side between the rotor (600) and the stator (601).  Turn the stator (601) in the “leftt” rotating direction and remove. – Use tool (W2).  Prop up the rotor (600) with support (S). 9.1.2.3 Suction casing (500) - Dismantling  Put a protective cover (SH) on the rotor (600).  Prop up rotor (600) with a support (S).  Remove screw fitting (506, 507, 509).  Remove suction casing (500) and casing gasket (501).  Remove tool (WS).

9.1.2.4 Rotating unit (RTE) - Dismantling

Tool (W10/dismantling tool)

Tool (W9/mounting lever)

with flush connection  Remove the flush connection (SSÜ) on the shaft seal casing (SEA).

Ausgabe issue

E / 19.08.2013

Dokument document

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Blatt sheet

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26

9 Dismantling / Reassembly  Assemble tool (W10/dismantling tool).

 Pull the rotating unit (RTE) with shaft seal (SEA) off from the output shaft of the drive (ANT). – Use tool (W9/mounting lever).

 Dismantle tool (W10/dismantling tool).

 Pull off the splash ring (310).  Pull off the shaft seal casing (SEA). – Note dismantling shaft seal (chapter 9.4). without flush connection  Assemble tool (W10/dismantling tool).

 Pull the rotating unit (RTE) with shaft seal (SEA) off from the output shaft of the drive (ANT). – Use tool (W9/mounting lever).

 Dismantle tool (W10/dismantling tool).

Ausgabe issue

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Dokument document

OM.MAI.02e

Blatt sheet

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27

9 Dismantling / Reassembly  Pull off the splash ring (310).  Pull off the shaft seal casing (SEA). – Note dismantling shaft seal (chapter 9.4). 9.1.2.5 Rotor (600), coupling rod (400), plug-in shaft (307) - Dismantling  Joint (G) dismantling note rotating unit individual parts (chapter 9.2).

9.1.2.6 Lantern (200)/drive (ANT) - Dismantling CAUTION Falling or tilting drive. Slight injury can occur.  Secure the drive (ANT).  Remove the screw fitting (210, 212, 213).  Remove the drive (ANT).

9.1.3 Reassembly WARNING Risk of pump tipping or falling. Death or serious injury can occur.  Fasten the lantern (200) to secure the pump.

9.1.3.1 Lantern (200)/drive (ANT) - Reassembly  Clean the flange bearing surfaces (FLS), bolt circle (ZD) and the output shaft of the drive unit (ANT).  Mount the drive (ANT) to the lantern (200) with screw fittings (210, 212, 213).

Ausgabe issue

E / 19.08.2013

Dokument document

OM.MAI.02e

Blatt sheet

4 (6)

28

9 Dismantling / Reassembly 9.1.3.2 Rotor (600), coupling rod (400), plug-in shaft (307) - Reassembly  Joint (G) reassembly note rotating unit individual parts ( chapter 9.2).

9.1.3.3 Rotating unit (RTE) - Reassembly  Slide on shaft seal casing (SEA). – Note reassembly shaft seal ( chapter 9.4).  Moisten splash ring (310) and plug-in shaft (307) with antiseize graphite petroleum.  Slide splash ring (310) onto plug-in shaft (307). – Observe fitting position of splash ring (see lettering).  Apply antiseize graphite petroleum to the output shaft of drive (ANT).  Slide on rotating unit (RTE).

with flush connection  Mount the flush connection (SSÜ).

9.1.3.4 Suction casing (500) - Reassembly  Put a protective cover (SH) on the rotor (600).  Prop up rotor (600) with a support (S).  Push on the casing gasket (501).  Mount and align the suction casing (500) with screw fitting (506, 507, 509). – Use spirit level (W).  Remove the protective cover (SH). 9.1.3.5 Stator (601) - Reassembly  Insert tool (WS).  Turn tool (WS) down.

Ausgabe issue

E / 19.08.2013

Dokument document

OM.MAI.02e

Blatt sheet

5 (6)

29

9 Dismantling / Reassembly

Tool (W2/chain wrench)  Moisten outer surface of the rotor (600) with lubricant (GM).  Moisten inner surface of the stator (601) with lubricant (GM).  Prop up stator (601) with support (S).  Turn stator (601) in the “right” rotating direction and slide onto rotor (600). – Use tool (W2).  Remove tool (WS).  Slide in plug-in shaft pin (309).

 Pay attention to the position of the splash ring (310).  Insert the splash ring collar at a distance of 0.5 mm from the lantern (200).

9.1.3.6 Pressure branch (700) - Reassembly  Prop up stator (601) with a support (S).  Insert tie bolts (602) loosely into the suction casing (500).

 Push pressure branch (700) on to the stator (601).  Insert tie bolts (602) loosely in the pressure branch (700).  Remove the support (S).  Mount screw fitting (604, 606).  Tighten tie bolts (602) equally.

Ausgabe issue

E / 19.08.2013

Dokument document

OM.MAI.02e

Blatt sheet

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30

9 Dismantling / Reassembly 9.2

Rotating unit individual parts

9.2.1 Dismantling 9.2.1.1 Holding band (406, 407) - dismantling CAUTION Danger of injury. Parts might be thrown out.  Wear safety glasses.  Detach holding band loop (SCL). – Use suitable tool (WH).  Push out parts of holding band loop (SCL).  Remove holding band (406, 407).  Pull back universal joint sleeve (405).

9.2.1.2 Retaining sleeve (401) - dismantling  Knock back retaining sleeve (401). – Use suitable tool (WM).

9.2.1.3 Detach joint Tool (W5/drift)

 Eject coupling rod pins (402).

Ausgabe issue

D / 30.08.2012

Dokument document

OM.PJT.02e

Blatt sheet

1 (5)

31

9 Dismantling / Reassembly  Bend (A) the coupling rod (400). Knock guide bushing (403) out with tool (W5).

 Remove coupling rod (400).

9.2.2 Rotating unit (RTE) - prepare individual parts for reassembly 9.2.2.1 Rotor (600)  Remove any damage.  Clean rotor (600). Tool (W4/assembly mandrel)  Press in guide bushings (403) (depth = 2/3). – Use tool (W4).

9.2.2.2 Coupling rod (400)  Clean the coupling rod (400).  Examine bore head for wear. – If wearing is detected on the bore head, replace the coupling rod (400).

Ausgabe issue

D / 30.08.2012

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OM.PJT.02e

Blatt sheet

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32

9 Dismantling / Reassembly 9.2.2.3 Plug-in shaft (307)  Remove any damage.  Clean rotor (600). Tool (W4/assembly mandrel)  Press in guide bushings (403) (depth = 2/3). – Use tool (W4).

9.2.3 Rotating unit (RTE) - individual parts - reassembly NOTICE Malfunction of the joints. Malfunction and/or destruction of joints.  Replace coupling rod pins (402) and guide bushings (403) jointly. 9.2.3.1 Coupling rod (400) - reassembly  Slide the universal joint sleeve (405) and holding bands (406, 407) onto coupling rod (400).  Fit the diameter and width of the holding band of the universal joint sleeve.  Fill the joint head with seepex joint grease. Rotor (600)  Insert coupling rod pins (402).  Slide on retaining sleeve (401).  Connect rotor/coupling rod.

Tool (W5/drift)

 Slide in the coupling rod pins (402).  Knock the guide bushings (403) in. – Use tool (W5).

Ausgabe issue

D / 30.08.2012

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OM.PJT.02e

Blatt sheet

3 (5)

33

9 Dismantling / Reassembly Plug-in shaft (307)  Insert coupling rod pins (402).  Slide on retaining sleeve (401).  Connect plug-in shaft/coupling rod.

Tool (W5/drift)

 Slide in the coupling rod pins (402).  Knock the guide bushings (403) in. – Use tool (W5).

9.2.3.2 Retaining sleeve (401) - reassembly Tool (W4/assembly mandrel)  Knock back retaining sleeve (401). – Use tool (W4).

Rotor (600) unhardened material  Secure retaining sleeve (401) in a displaced manner (2x180°). – Use suitable tool (WK).

Rotor (600) hardened material  Secure retaining sleeve (401) in a displaced manner (2x180°). – Use suitable tool (WK).

Ausgabe issue

D / 30.08.2012

Dokument document

OM.PJT.02e

Blatt sheet

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34

9 Dismantling / Reassembly 9.2.3.3 Universal joint sleeve (405) - reassembly  Moisten the surface of coupling rod (400) / inner surface of universal joint sleeve (405) with joint grease (maintenance  chapter 7.).  Slide on universal joint sleeve (405).  Remove air from the inside of the joint. – Use suitable tool (WS).

 Assemble the holding band. – Holding band assembly (chapter 9).

Ausgabe issue

D / 30.08.2012

Dokument document

OM.PJT.02e

Blatt sheet

5 (5)

35

9 Dismantling / Reassembly 9.3

Holding band - assembly

9.3.1 Prepare the holding band  Only use prefabricated double-band holding bands may. 9.3.2 Check the holding band •

Bent-over holding band (HBD) is in contact with holding band loop (SCL) to avoid damaging universal joint sleeve.

 Press on holding band (HBD) using tool (WZ) if necessary.

9.3.3 Assemble the holding band

 Use tool (W3/mounting tool)  Feed holding band into tool (W3).  Hold ends of holding band with the eccentric lever (EX).  Turn the crank (KU) until the holding band is strained and lies against the holding band loop (SCL).  Carefully pull the holding band together until it is in contact with the circular groove of universal joint sleeve. 9.3.4 Correct tension of holding band (HBD) Correct The holding band (HBD) has drawn in the out shape of the universal joint sleeve and is firmly seated.

Incorrect The holding band (HBD) is too loose, can slip off.

Incorrect The holding band (HBD) is too tight, universal joint sleeve will be damaged/sheared off.

Ausgabe issue

D / 05.08.2013

Dokument document

OM.HBD.01e

Blatt sheet

1 (2)

36

9 Dismantling / Reassembly 9.3.5 Cant up the holding band  Swivel mounting tool (W3) approx. 60° upwards.  Loosen crank (KU) by a half turn.  Swivel cutting lever (SH) forward until the pressure piece is lying behind the holding band loop (SCL).

9.3.6 Shear the holding band (material: 1.4301; 1.4401)  Hit the cutting lever (SH) with the inside of your hand. – Cant up and shear the end of the holding band behind the loop (SCL). – Carefully straighten up the holding band (HBD) if it rises up on the sheared side.

NOTICE Universal joint seal damage. Pin joint grease can emerge.  Avoid hammering or striking. 9.3.7 Check the holding band after assembly  The holding band must lie in the groove of the universal joint sleeve.  Replace the holding band if the holding band slips back through the loop.

Ausgabe issue

D / 05.08.2013

Dokument document

OM.HBD.01e

Blatt sheet

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37

Shaft SealingDesign Gland Packing seepex Code F 1. Safety for Shaft Sealings (in compliance with DIN EN 809)

2.3 Buffer Fluid Connection

Sufficient precautions must be taken to prevent the emergence into the atmosphere of any leakage constituting a hazard due to its toxicity, explosiveness or combustibility. The leakage must be disposed of at a safe location. Always pay due regard to the applicable national standards and specifica-tions. 2. Shaft Sealing

Prior to commissioning the relevant shutoff organs must be opened. The buffer fluid pressure must be set to a level at least 0.5-1 bar above the pressure requiring to be sealed off. Any liquid can be used as buffer fluid as long as it does not endanger the corrosion resistance of the parts it comes into contact with and is compatible with the conveying medium. The buffer fluid must be free from solids and not prone to deposits.

2.1 Operating Conditions The permissible operating conditions and material combination are matched with the particular application in each case and are indicated in the data sheet of the associated pump. 2.2 Design • 5 packing rings • 1 seal cage ring • 2 connections The volume of buffer fluid is reduced vor vacuum operation. The frictional heat is carried off through secound connection. The buffer fluid prevents the conveying medium from penetrating the packing, assures that lubrication takes place between packing and shaft and reduces wear

associated operating instructions OM.SEA.01e Ausgabe issue

A / 22.02.1995

Dokument document

OM.SEA.Fe

Blatt sheet

1 (1)

38

10 Spare parts 10.1 Spare parts list 10.2 Sectional drawing and parts list

Ausgabe issue

B / 29.03.2011

Dokument document

OM.SZG.02e

Blatt sheet

1 (1)

39

10 Spare parts Version for copying 10.1 Spare parts list

Type: BN 05-24 to 300-6L

Spare parts can be ordered online or requested from www.seepex.com\ Request

Sender:

Order

Must be included in every order or enquiry! Commission:

Type:

Contact: ......................................................... Tel.: ................................................................

_________________________ _______________________

Fax: ............................................................... E-mail: ...........................................................

Customer service:

Germany

Tel +492041.996-231

Delivery address:

Fax +492041.996-431 .......................................................................

seepex GmbH Postfach 10 15 64

Rest of Europe

Tel +492041.996-224

.......................................................................

Fax +492041.996-424 .......................................................................

D-46215 Bottrop

[email protected] Outside Europe Tel +492041.996-120

.......................................................................

Fax +492041.996-432 ....................................................................... No.

Quantity Component

Material

Comment

Minor set of wearing parts 301

1

Set of packing rings

311

1

Rinse ring

330

1

Mechanical seal

601

1

Stator

according to data sheet (chapter 3.1) according to data sheet (chapter 3.1)

Major set of wearing parts 301

1

Set of packing rings

according to data sheet (chapter 3.1)

307

1

Plug-in shaft

330

1

Mechanical seal

400

1

Coupling rod with coupling rod bushings

402

2

Coupling rod pin

403

4

Guide bushing

405

2

Universal joint sleeve

406

2

Holding band, large

407

2

Holding band, small

600

1

Rotor

601

1

Stator

according to data sheet (chapter 3.1)

__________________________________

_______________________________________

Place, date

Signature / company stamp

Ausgabe issue

E / 19.08.2010

Dokument document

OM.WPS.02e

Blatt sheet

1 (2)

40

10 Spare parts Version for copying No.

Quantity Component

Material

Comment

Set of gaskets 301

1

Set of packing rings

according to data sheet (chapter 3.1)

310

1

Splash ring

according to data sheet (chapter 3.1)

330

1

Mechanical seal

501

1

Casing gasket

503

3

Sealing ring

511

2

O-ring/cleaning cover

517

2

Sealing ring

706

1

Sealing ring

Plug-in shaft & shaft seal 301

Set of packing rings

according to data sheet (chapter 3.1)

307

Plug-in shaft

309

Plug-in shaft pin

310

Splash ring

according to data sheet (chapter 3.1)

330

Mechanical seal

according to data sheet (chapter 3.1)

Coupling rod & joint parts 400

Coupling rod with coupling rod bushings

401

Retaining sleeve

402

Coupling rod pin

403

Guide bushing

405

Universal joint sleeve

406

Holding band, large

407

Holding band, small

401-407

Complete set of joint parts

Conveying elements 600

Rotor

601

Stator

Miscellaneous parts 501

Casing gasket

098

Pin joint grease

1 cartridge = 300 g (approx. 315 cm³) Grease quantity according to maintenance (chapter 7._)

__________________________________

_______________________________________

Place, date

Signature / company stamp

Ausgabe issue

E / 19.08.2010

Dokument document

OM.WPS.02e

Blatt sheet

2 (2)

41

Stückliste Parts List Liste des pièces

Stck. 1 2 1 4 4 4 1 6 1 2 2 1 1 1 1 2 2 4 2 2 2 2 1 1 3 3 4 4 4 2 2 8 2 2 1 1 4 8 8 1 1 1 1

°) °) °) °) °)

Pos. 200 202 203 210 211 212 213 300 301 302 303 304 307 309 310 400 401 402 403 404 405 406 407 500 501 502 503 506 507

DE Baureihe BN Schnittzeichnung Nr. 062-002_1 Benennung Stck. / Pos. Laterne Halbrundkerbnägel Typenschild 6kt-Schraube 6kt-Schraube Federring 6kt-Mutter Stopfbuchsgehäuse Packungsring Stopfbuchsbrille Hammerschraube 6kt-Mutter Steckwelle Steckwellenbolzen Spritzring Kuppelstange Gelenkhülse Kuppelstangenbolzen Führungsbuchse Kuppelstangenbuchse Manschette Halteband Halteband Sauggehäuse Sauggehäusedichtung Verschlussschraube Dichtring 6kt-Schraube Fächerscheibe

EN Range BN sectional drawing no. 062-002_1 denomination Qty. / Item lantern round head grooved pins type plate hexagon bolt hexagon bolt spring washer hexagon nut gland housing packing ring packing gland gland bolt hexagon nut plug-in shaft plug-in shaft pin splash ring coupling rod retaining sleeve coupling rod pin guide bushing coupling rod bushing universal joint sleeve holding band holding band suction casing casing gasket screwed plug sealing ring hexagon bolt fan type lock washer

509 510 511 512 516 517 600 601 602 604 606 607 700 705 706

6kt-Mutter Reinigungsdeckel Dichtung 6kt-Schraube Verschlussschraube Dichtring Rotor Stator Spannschraube 6kt-Mutter Scheibe Stützbock Druckstutzen Verschlussschraube Dichtring

hexagon nut cleanout gasket hexagon bolt screwed plug sealing ring rotor stator tie bolt hexagon nut washer trestle pressure branch screwed plug sealing ring

Ausgabe issue

C / 29.10.02

Dokument document

SL.062.002def

FR Série BN plan no. 062-002_1 désignation Qté. / Poste lanterne rivet plaque signalitique vis vis rondelle frein écrou boitier de presse étoupe tresses fouloir vis de fouloir écrou arbre à broche cheville pour arbre à broche bague de projection barre d'accouplement douille d'articulation axe d'articulation douille de guidage chemise d'axe manchette collier de serrage collier de serrage carter d'aspiration étanchéité du carter d'aspiration bouchon de vidange joint d'étanchéité vis rondelle à dents chevauchantes extérieures écrou couvercle de nettoyage étanchéité vis bouchon de vidange joint d'étanchéité rotor stator tirant écrou rondelle pied bride de refoulement bouchon de vidange joint d'étanchéité

Blatt sheet

1 (2)

43

Stückliste Parts List Liste des pièces

DE Baureihe BN Schnittzeichnung Nr. 062-002_1 Benennung Stck. Pos. Stck. / Pos. 098 seepex Gelenkfett Typ und Füllmenge: Betriebs- und Montageanleitung entnehmen Verschleißteile und Dichtungen: Betriebs- und Montageanleitung entnehmen Werkzeuge: Betriebs- und Montageanleitung entnehmen versetzt gezeichnet °) Option

Ausgabe issue

C / 29.10.02

EN Range BN sectional drawing no. 062-002_1 denomination Qty. / Item seepex joint grease type and filling quantity: see operating and assembly instruction Wear parts and sealings: see operating and assembly instruction Tools: see operating and assembly instruction drawn displaced option

Dokument document

SL.062.002def

Blatt sheet

FR Série BN plan no. 062-002_1 désignation Qté. / Poste seepex graisse d' articulations sommaire pour type et quantité: voir instructions de montage et de fonctionnement pièces d'usure et étanchéités: voir instructions de montage et de fonctionnement Outils: voir instructions de montage et de fonctionnement plan separé option

2 (2)

44

11 Special tools Version for copying Spare parts can be ordered online or requested from

Sender:

www.seepex.com\

Must be specified with every order! Commission:

Mark tool!

Contact: ......................................................... Tel.: ................................................................

__________________________

X

Fax: ............................................................... E-mail: ...........................................................

Customer service:

Germany

Delivery address:

Fax +492041.996-431 .......................................................................

seepex GmbH Postfach 10 15 64

Tel +492041.996-231

Rest of Europe

Tel +492041.996-224

.......................................................................

Fax +492041.996-424 .......................................................................

D-46215 Bottrop

[email protected] Outside Europe Tel +492041.996-120

.......................................................................

Fax +492041.996-432 ....................................................................... For installation of:

Packing gland

Stator

Coupling rod bushings

Tool no. Denomination:

W1

W2

Packing lever

Order no.

W14

Chain pipe wrench + replacment chain

Pressing tool

KRZ

PWZ

PKZ

For installation of:

Rotating unit Holding band

Tool no. Denomination:

W3

Plug-in shaft

W5

W10

Assembly mandrel

Drift

Dismantling tool

MHB

MTD

DHS

AZV

For installation of:

Denomination:

W4

Joint

Mounting tool

Order no.

Tool no.

Joint

General W9 Mounting lever

Order no.

MHL

Ausgabe issue

A / 21.09.2006

Dokument document

OM.STO.02e

Blatt sheet

1 (1)

45

12 Related documents 12.1 Additional components 12.2 Technical information 12.3 Manufacturer's documents shaft seal

Ausgabe issue

B / 12.01.2010

Dokument document

OM.ZUG.01e

Blatt sheet

1 (1)

46

Electrical Connection of Frequency Inverters

Dokument / document TI.FRU.01e Ausgabe / issue B / 07.01.08 Blatt / sheet 1 (2)

1.0

Connection of the drive motor to a frequency inverter NOTICE  Heed the technical information and information in the manufacturer’s operating instructions when installing and commissioning the frequency inverter.  Perform the connection of the frequency inverter and motor in accordance with the table.  An incorrect motor connection causes considerable reduction in motor performance. The pump may possibly not start, or it might cause the drive to overheat. Details motor type place (nominal motor voltage / circuit arrangement) 230 V ▲ / 400 V Y 230 V ▲ / 400 V Y 400 V ▲ / 690 V Y

1.1

Line voltage of the frequency inverter

Output voltage of the frequency inverter

Motor connection

1 x 230 V AC 3 x 400 V AC 3 x 400 V AC

3 x 0 to 230 V 3 x 0 to 400 V 3 x 0 to 400 V

Delta Star Delta

Y

▲

Standard three phase current squirrel cage motors with PTC thermistors Delta connection (▲) W2

U1

L1

U2

V1

Star connection (Y) W2

V2

U1

W1

L2

L3

PTC

Motor terminal board 1.2

▲

U2

V1

L1

V2

W1

L2

L3

PTC

Motor terminal board

Self ventilated and force ventilated motors  Do not load self ventilated motors with nominal torque in the lower speed range (up to approx. 20Hz.). - Motor ventilation does not provide adequate cooling.  Self ventilated motors must be equipped with a PTC temperature monitoring device for speed control by means of a frequency inverter.  Force ventilated motors may be loaded with nominal torque for the complete speed range.  Connect force ventilators to a separate terminal board on the fan cover.  Heed type plate details of the force ventilator or see separate terminal connection diagram.

1.3

Setting up the frequency inverter  The power output of the frequency inverter must correspond to the motor power. - Where applicable the power of the inverter can be customised to the motor rating by adjusting the parameters.  The pump requires a higher torque to start (breakaway torque). - This required torque can only be achieved by frequency inverters, which make 1.5 times the rated current for the motor available for at least 30s. - The operating torque is approximately constant throughout the whole speed range where the conveying pressure remains constant.  Head the following frequency inverter characteristic curves (Item 1.3.1, 1.3.2). - The quadratic characteristic curve, which is frequently designated the pump and ventilator characteristic curve, is not suitable for progressive cavity pumps

47

Electrical Connection of Frequency Inverters

Dokument / document TI.FRU.01e Ausgabe / issue B / 07.01.08 Blatt / sheet 2 (2)

1.3.1

Linear voltage / frequency characteristic curve up to mains frequency U [%] 100 50

½ f mains = 50/60 Hz)

(f 1.3.2

f mains

f

Mains

Linear voltage / frequency characteristic curve up to levels above the mains frequency U [%] 100 50

½ f mains (f 1.3.3

f mains

f max.

f

= 50/60 Hz)

mains

Linear voltage / frequency characteristic curve with the installation of a magnetic bias (StartBoost)  If problems arise when starting the pump which make a higher breakaway torque necessary, these should be resolved by the adjustment of a magnetic bias. In the case of the magnetic bias the drive is supplied with current by the frequency inverter at just 0Hz. NOTICE Magnetisation current set too high Damage to the motor due to overheating.  Heed the frequency inverter manufacturer’s instructions when setting the magnetic bias.

U [%]

f mains

f max.

f

(f mains= 50/60 Hz)

48

13 Appendix 13.1 Manufacturer's documents / suppliers •

available

Ausgabe issue

B / 19.06.2008

Dokument document

OM.MDS.01e

Blatt sheet

1 (1)

49

Intelligent Drivesystems, Worldwide Services

GB

B1000

Operating and Assembly Instructions for Gear Units and Geared Motors

DRIVESYSTEMS 50

51

Contents

1. Notes ................................................................................................................................. 4 1.1 General information ........................................................................................................ 4 1.2 Safety and information symbols ...................................................................................... 4 1.3 Correct use...................................................................................................................... 4 1.4 Safety information ........................................................................................................... 5 1.5 Other documents............................................................................................................. 6 1.6 Disposal .......................................................................................................................... 6 2. Description of gear units ................................................................................................ 7 2.1 Type designations and gear unit types ........................................................................... 7 2.2 Name plate ...................................................................................................................... 8 3. Assembly instructions, storage, preparation, installation .......................................... 9 3.1 Storing the gear unit ........................................................................................................ 9 3.2 Long-term storage ........................................................................................................... 9 3.3 Transporting the gear unit ............................................................................................. 10 3.4 Preparing for installation ............................................................................................... 10 3.5 Installing the gear unit ................................................................................................... 11 3.6 Fitting hubs on the gear shafts...................................................................................... 12 3.7 Fitting push-on gear units ............................................................................................. 13 3.8 Fitting shrink discs ........................................................................................................ 15 3.9 Fitting the covers ........................................................................................................... 16 3.10 Fitting a standard motor .............................................................................................. 17 3.11 Retrospective paintwork.............................................................................................. 18 3.12 Fitting the cooling coil to the cooling system .............................................................. 19 4. Commissioning .............................................................................................................. 20 4.1 Checking the oil level .................................................................................................... 20 4.2 Activating the automatic lubricant dispenser ................................................................ 20 4.3 Operation with lubricant cooling .................................................................................... 21 4.4 Running-in time for the worm gear unit ......................................................................... 21 4.5 Checklist........................................................................................................................ 21 5. Service and maintenance.............................................................................................. 22 5.1 Service and maintenance intervals ............................................................................... 22 5.2 Service and maintenance work ..................................................................................... 22 6. Appendix......................................................................................................................... 26 6.1 Versions and maintenance ........................................................................................... 26 6.2 Torque values ............................................................................................................... 38 6.3 Troubleshooting ............................................................................................................ 38 6.4 Lubricants...................................................................................................................... 39 6.5 Lubricant quantities ....................................................................................................... 41

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1. Notes 1.

Notes

1.1 General information Read the Operating Manual carefully prior to performing any work on or putting the gear unit into operation. Strict compliance with the instructions in this Operating Manual is essential. Getriebebau NORD accepts no liability for damage to persons, materials or assets as a result of the non-observance of this Operating Manual, operating errors or incorrect use. General wearing parts, e.g. radial seals are excluded from the warranty. If additional components are attached to or installed in the gear unit (e.g. motor, cooling system, pressure sensor etc.) or components (e.g. cooling system) are supplied with the order, the operating instructions for these components must be observed. If geared motors are used, compliance with the Motor Operating Manual is also necessary. If you do not understand the contents of this Operating Manual or additional operating instructions, please consult Getriebebau NORD!

1.2 Safety and information symbols Please always observe the following safety and information symbols!

Danger! Risk of fatalities and injury

Attention! Machine may be damaged

Note! Useful information

1.3 Correct use These gear units generate a rotational movement and are intended for use in commercial systems. The gear unit must only be used according to the information in the technical documentation from Getriebebau NORD.

Danger! Use in explosion hazard areas is prohibited. Strict compliance with the technical data on the rating plate is essential. The documentation must be observed. Appropriate safety measures must be taken for applications where failure of a gear unit or geared motor may result in injury.

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B1000-GB-0713

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1. Notes 1.4 Safety information All work including transportation, storage, installation, electrical connection, commissioning, servicing, maintenance and repair must be performed only by qualified specialist personnel. It is recommended that repairs to NORD Products are carried out by the NORD Service department.

Danger! Installation and maintenance work must only be performed when gear units are at a standstill and have cooled down. The drive must be isolated and secured to prevent accidental start-up. CAUTION! Depending on the operating conditions, the temperature of the gear unit may exceed 60°C. Danger of burns! Protection against accidental contact may need to be installed. Tighten the drive elements or secure the parallel key before switching on.

Danger! Only use the eyebolts attached to the gear unit for transport. No additional loads may be attached. Transportation aids and lifting gear must have an adequate load-bearing capacity. If geared motors have an additional eyebolt attached to the motor, this must also be used. Avoid pulling the eyebolts at an angle. The thread of the eyebolt must be fully screwed in. Observe all safety information, including that provided in the individual sections of this Operating Manual. All national and other regulations on safety and accident prevention must also be observed.

Danger! Serious physical and property damage may result from inappropriate installation, nondesignated use, incorrect operation, non-compliance with safety information, unauthorised removal of housing components or safety covers and structural modifications to the gear unit.

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1. Notes 1.5 Other documents Further information may be obtained from the following documents: - Gear unit catalogues (G1000, G2000, G1011, G1012, G1034, G1035) - Operating and maintenance instructions for the electric motor - if applicable, operating instructions for attached or supplied options

1.6 Disposal Observe the current local regulations. In particular, lubricants must be collected and disposed of correctly. Gear unit components:

Material:

Toothed wheels, shafts, rolling bearings, parallel keys, locking rings, …

Steel

Gear unit housing, housing components, …

Grey cast iron

Light alloy gear unit housing, light alloy gear unit housing components, …

Aluminium

Worm gears, bushes, ...

Bronze

Radial seals, sealing caps, rubber components,…

Elastomers with steel

Coupling components

Plastic with steel

Flat seals

Asbestos-free sealing material

Gear oil

Additive mineral oil

Synthetic gear oil (rating plate code: CLP PG)

Polyglycol-based lubricants

Cooling spiral, embedding material of the cooling spiral, Copper, epoxy, yellow brass screw fittings

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B1000-GB-0713

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2. Description of Gear Units 2.

Description of gear units

2.1 Type designations and gear unit types Helical gear units SK 11E, SK 21E, SK 31E,SK 41E, SK 51E (single-stage) SK 02, SK 12, SK 22, SK 32, SK 42, SK 52, SK 62N (2-stage) SK 03, SK 13, SK 23, SK 33N, SK 43, SK 53 (3-stage) SK 62, SK 72, SK 82, SK 92, SK 102 (2-stage) SK 63, SK 73, SK 83, SK 93, SK 103 (3-stage) NORDBLOC helical gear units SK 320, SK 172, SK 272, SK 372, SK 472, SK 572, SK 672, SK 772, SK 872, SK 972 (2-stage) SK 273, SK 373, SK 473, SK 573, SK 673, SK 773, SK 873, SK 973 (3-stage) SK 072.1, SK 172.1, SK 372.1, SK 572.1, SK 672.1, SK 772.1 SK 872.1, SK 972.1 (2-stage) SK 373.1, SK 573.1, SK 673.1, SK 773.1, SK 873.1, SK 973.1 (3-stage) Standard helical gear units SK 0, SK 01, SK 20, SK 25, SK 30, SK 33 (2-stage) SK 010, SK 200, SK 250, SK 300, SK 330 (3-stage) Parallel shaft gear units SK 0182NB, SK 0282NB, SK 1282, SK 2282, SK 3282, SK 4282, SK 5282, SK 6282, SK 7282, SK 8282, SK 9282, SK 10282, SK 11282 (2-stage) SK 1382NB, SK 2382, SK 3382, SK 4382, SK 5382, SK 6382, SK 7382, SK 8382, SK 9382, SK 10382, SK 11382, SK 12382 (3-stage) Bevel gear units SK 92072, SK 92172, SK 92372, SK 92672, SK 92772 SK 92072.1, SK 92172.1, SK92372.1, SK 92672.1, SK 92772.1, SK 93072.1, SK 93172.1, SK 93372.1, SK93672.1, SK 93772.1 (2-stage) SK 9012.1, SK 9016.1, SK 9022.1, SK 9032.1, SK 9042.1, SK 9052.1, SK 9062.1, SK 9072.1, SK 9082.1, SK 9086.1, SK 9092.1, SK 9096.1 (3-stage) SK 9013.1, SK 9017.1, SK 9023.1, SK 9033.1, SK 9043.1, SK 9053.1 (4-stage) Contrate worm gear unit SK 02040, SK 02050, SK 12063, SK 12080, SK 32100,SK 42125 (2-stage) SK 13050, SK 13063, SK 13080, SK 33100, SK 43125 (3-stage) MINIBLOC worm gear units SK1 S32, SK1 S40, SK 1S50, SK 1S63, SK 1SU... SK 1SM31, SK 1SM40, SK 1SM50, SK 1SM63 (single-stage) SK 2S32NB, SK 2S40NB, SK 2S50NB, SK 2S63NB, SK 2SU…, SK 2SM40, SK 2SM50, SK 2SM63 (2-stage) UNIVERSAL worm gear units SK 1SI31, SK 1SI40, SK 1SI50, SK 1SI63, SK 1SI75, SK 1SIS31,…, SK 1SIS75, SK 1SID31,…, SK 1SID63, SK 1SMI31,…, SK 1SMI75, SK 1SMID31,…, SK 1SMID63, SK 1SIS-D31,…, SK 1SIS-D63 (single-stage), SK 2SMID40, SK2SMID50, SK2SMID63, SK 2SID40,…, SK 2SID63 (2-stage)

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B1000-GB-0713

Versions / Options A V L Z F X XZ XF AL 5

Foot mounting with solid shaft Hollow shaft version Solid shaft version Solid shaft both sides Drive flange B14 Output flange B5 Foot mounting Base and output flange B14 Base and output flange B5 Reinforced axial drive bearings Reinforced output shaft (Standard helical gear unit) V Reinforced drive shaft (Standard helical gear unit) D Torque support K Torque console S Shrink disc VS Reinforced shrink disc EA Hollow shaft with internal spline G Rubber buffer VG Reinforced rubber buffer R Back stop B Fixing element H Covering cap as contact guard H66 Covering cap IP66 VL Reinforced bearings VL2 Agitator design VL3 Drywell agitator design IEC Standard motor mounting NEMA Standard motor mounting W With free drive shaft VI Viton radial seals OA Oil expansion vessel OT Oil level tank SO1 Synthetic oil ISO VG 220 CC Casing cover with cooling spiral DR Spring Loaded Breather H10 Modular contrate pre-stage /31 Worm pre-stage /40 Worm pre-stage

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2. Description of Gear Units Double gear units consist of two single gear units. They are to be treated as per the instructions in this Manual, i.e. as two individual gear units. Type designation of double gear units: e.g. SK 73/22 (consisting of single gears SK 73 and SK 22)

2.2 Name plate

Figure 2-1: Name plate (example)

Explanation of the Name Plate

-8-

1

Matrix – Barcode

2

NORD gear unit type

3

Operating mode

4

Year of manufacture

5

Serial number

6

Rated torque of gear unit output shaft

7

Drive power

8

Weight according to ordered version

9

Overall gear unit ratio

10

Installation orientation

11

Rated speed of gear unit output shaft

12

Lubricant type, viscosity and quantity

13

Customer’s part number

14

Operating factor

B1000-GB-0713

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3. Assembly instructions, storage, preparation, installation 3.

Assembly instructions, storage, preparation, installation Please observe all of the general safety information in Section 1.4, 1.3 and in the individual sections.

3.1 Storing the gear unit For short-term storage before commissioning, please observe the following: x

Store in the fitting position (see Section 6.1) and secure gear units against falling

x

Lightly grease bare metal housing surfaces and shafts

x

Store in dry rooms

x

Temperature must not fluctuate beyond the range of –5 oC to +50 oC

x

Relative humidity less than 60%

x

No direct exposure to sunlight or UV light

x

No aggressive, corrosive substances (contaminated air, ozone, gases, solvents, acids, alkalis, salts, radioactivity etc.) in the immediate vicinity

x

No vibration or oscillation

3.2 Long-term storage Note! For storage or standstill periods in excess of 9 months, Getriebebau NORD recommends the long-term storage option. With the long-term storage option and the use of the measures listed below, storage for up to 2 years is possible. As the actual influences on the unit greatly depend on the local conditions, these times should only be regarded as guide values. Conditions of the gear unit and storage area for long-term storage prior to commissioning: x

Store in the fitting position (see Section 6.1) and secure gear units against falling

x

Transportation damage to the external paint must be repaired. Check that a suitable rust inhibitor is applied to the flange bearing surfaces. If necessary apply a suitable rust inhibitor to the surfaces.

x

Gear units with the long-term storage option are completely filled with lubricant or have VCI corrosion protection agents added to the gear oil. (See label on gear unit)

x

The sealing band in the vent plug must not be removed during storage. The gear unit must remain sealed tight.

x

Store in a dry place.

x

In tropical regions, the drive unit must be protected against damage by insects

x

Temperature must not fluctuate beyond the range of –5 oC to +40 oC

x

Relative humidity less than 60%

x

No direct exposure to sunlight or UV light

x

No aggressive, corrosive substances (contaminated air, ozone, gases, solvents, acids, alkalis, salts, radioactivity etc.) in the immediate vicinity

x

No vibration or oscillation

Measures during storage or standstill periods x

If the relative humidity is 35 0.5 S When connecting a lead to the external ground, the minimum cross-section must be 4 mm2.

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6. Motors for use in Zone 21 and Zone 22 6.6 Maintenance The voltage must always be switched off and secured against being switched on again! Attention! Higher temperatures than the maximum permitted surface temperature of the housing may be present inside the motor. The motor must therefore never be opened in hazardous dust atmospheres! The motors must be checked and tested regularly for functional safety! The applicable national standards and regulations must be complied with! Unpermitted high dust deposits > 5 mm may not be allowed to build up! If functional safety cannot be ensured, the motor may not be operated! When the ball bearings are replaced, the rotary shaft seals must also be replaced. FKM rotary shaft seals as specified by Getriebebau NORD must be used. Ensure that they are fitted correctly! The rotary shaft seals must be lubricated on the external rings and on the seal lips. If an explosion protected gear is flanged dust-tight to the motor, an NBR rotary shaft seal can be used on the drive side of the motor if the gear oil temperature does not exceed 85°C. Only original parts may be used as spare parts with the exception of standardised, commercially available and equivalent parts. This also applies in particular to seals and connection components. Parts for terminal boxes or spare parts for external grounding must be ordered as per the spare parts list in the operating instructions. The functionality of seals, rotary shaft seals and cable glands must be regularly checked! Maintaining dust protection for the motors is of paramount importance for explosion protection. Maintenance must be implemented by qualified personnel in a specialist workshop with suitable equipment. We urgently recommend that general overhauls are implemented by NORD Service.

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7. IE2-ATEX Motors for use in Zone 21 and Zone 22 ATTENTION! Section 7 of these operating instructions applies as a supplement for IE2-ATEX motors for Zone 21 and Zone 22 as per EN 60079-0 and DIN EN 60079-31. Please disregard Section 6 for these motors. 7.1 General information The following information applies additionally or especially to motors in categories 2D and 3D! The motors are suitable for use in Zone 21 (category 2D) or Zone 22 – non-conductive dusts (category 3D) according to their designation. Type addition: Zone 21: 2D e.g.: 80 L/4 2D TF Zone 22: 3D e.g: 80 L/4 3D TF The designation is as follows:

0102

II 2 D Ex tb IIIC T125°C Db for Category 2 (Zone 21)* II 3 D Ex tc IIIB T125°C Dc for Category 3 (Zone 22, non-conducting dust)*

* the details of the surface temperature may deviate from 125°C and may be obtained from the name plate If the motor is attached to a gear unit, the EX labelling of the gear unit must also be observed! 7.1.2 Impact test As per 26.4.2 of EN 60079-0 (2009 version), motors for Category 3D are subjected to an impact test with 4J. 7.2 Safety information The increased danger in areas with inflammable dust demands the strict observation of the general safety and commissioning information. Explosive concentrations of dust may cause explosions if ignited by hot or sparking objects. Such explosions may cause serious or fatal injuries to persons or severe material damage. It is absolutely essential that the persons responsible for the use these motors and frequency inverters in explosion hazard areas are trained in their correct use. 7.3 Commissioning information / Field of application If the motors are required for use with frequency inverters, this must be stated in the order. The motors must be protected against overheating with suitable monitoring equipment! The thickness of dust deposits must not exceed 5 mm! The motors are designed for the voltage and frequency range B of EN 60034 Part 1. Motors for use in Zone 21 and Zone 22, with labelling TF may be thermally monitored via the built-in PTC in combination with a suitable triggering device as the sole protection. Electrical equipment for use in areas with combustible dust comply with the standards DIN EN 60079-0, EN 60079-31 and DIN EN 60034. The valid version of the standard can be seen from the EEC Declaration of Conformity. The degree of explosion hazard determines the zone categorisation. The operator / employer is responsible for the assignment of zones (RL 1999/92/EEC) If the certification is supplemented with an "X" the special conditions in the EEC prototype certification and/or the relevant documentation must be observed. The use of standard motors which are not certified for explosion hazard areas in explosion hazard areas is prohibited. The terminal box cover is covered on one side with a very thin film of grease. This grease film prevents the seal from adhering to the frame of the terminal box and must not be removed. This grease film must also be applied using a suitable grease, if the seal is replaced.

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7. IE2-ATEX Motors for use in Zone 21 and Zone 22 The terminal box seal is glued into the cover of the terminal box cover. Please only use an original seal when replacing the seal. If the terminal box is opened during installation, maintenance, repair, troubleshooting or overhaul, the terminal box cover must be re-fitted after the work is complete. There must be no dirt on the surface of the seal or the sealing surface of the terminal box frame. The screws for the terminal box cover must be tightened with a torque according to the following table. Tightening torques for terminal box cover screws Thread

Tightening torque [Nm]

M4

0.8 to 1.2 1.2 to 1.8 1.5 to 2.5 3.0 to 5.0

M5 M6 M8

7.3.1 Electrical Connection The electrical connections of the terminal board are protected against twisting. The voltage supply to the terminal board must be made by means of suitable ring terminals. The ring terminals are installed between the two brass washers below the lock washer. The nuts must be tightened with a torque according to the table below. The contact pressure is permanently maintained by means of the specified torque and the lock washer. In addition, twisting of the ring terminals of the voltage supply is prevented. The connection elements are corrosion-proof. Torques for Electrical Rated thread diameter Tightening torque [Nm] M1.6 0.09-0.12 M3 0.35-0.5 M4 0.8-1.2 M5 1.8-2.5 M6 2.7-4.0 M8 5.5-8.0 M10 9.0-13.0 M12 16.0-20.0 M16 36.0-40.0

Electrical connection:

Brass nut

r

Lock washer Brass washer Brass washer Brass nut

A

Brass washer Ring terminal Brass washer Brass thread with collar Mechanical protection against twisting

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7. IE2-ATEX Motors for use in Zone 21 and Zone 22 7.3.2 Cable and wiring glands In Zone 21, the cable entries must be authorised for Ex areas (protection class minimum IP 66) and must be secured against accidental loosening. Unused apertures must be sealed with authorised plugs (minimum protection class IP 66). As delivered, the motors are equipped with a blank screw cap and a plastic cap. The plastic cap must be replaced with a certified cable gland. For Zone 22, the cable glands must as a minimum correspond to the protection type specified on the name plate. Unused openings must be closed with plugs, which as a minimum correspond to the protection class of the motor and the requirements of EN 60079-0. The cable glands and blank plugs must be suitable for a temperature of at least 100°C. The motor must not be opened under hazardous atmospheres to connect the electrical cables or for any other work. The voltage must always be switched off and secured against being switched on again before opening the motor! The motors are equipped with cable glands according to the following overview. Assignment of Cable Glands to Motor Size Cable glands for standard motors Type

Number Thread

Number Thread

Cable glands for brake motors

Number Thread

Type

Number Thread

Number Thread

Number Thread

63

2

M20x1.5

63

4

M20x1.5

2

M12x1.5

71

2

M20x1.5

71

4

M20x1.5

2

M12x1.5

80

2

M25x1.5

80

4

M25x1.5

2

M12x1.5

90

2

M25x1.5

90

4

M25x1.5

2

M12x1.5

100

2

M32x1.5

100

4

M32x1.5

2

M12x1.5

112

2

M32x1.5

112

4

M32x1.5

2

M12x1.5

132

2

M32x1.5

132

4

M32x1.5

2

M12x1.5

2

M16x1.5

M40x1.5

160/ 180/..X

2

M40x1.5

2

M12x1.5

2

M16x1.5

160/ 180/..X

2

2

M12x1.5

2

M16x1.5

180/

180/

200/..X

2

M40x1.5

2

M12x1.5

2

M16x1.5

200/..X

2

M40x1.5

2

M12x1.5

2

M16x1.5

200

2

M40x1.5

2

M12x1.5

2

M16x1.5

200

2

M40x1.5

2

M12x1.5

2

M16x1.5

If the motor is supplied with a certified cable gland, the clamping nuts of the cable gland must be tightened to the torque specified in the following table. Cable gland M20x1.5 M25x1.5 M32x1.5 M40x1.5

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Clamping nut tightening torque [Nm] 6 8 12 16

B1091-GB-3212

-15112

7. IE2-ATEX Motors for use in Zone 21 and Zone 22 7.3.3 Permissible Ambient Temperature Range The permissible ambient temperature range for all motors is -20°C...+40°C. A greater ambient temperature range of -20°C...+60°C is permissible with motors for operation in Zones 21 and 22. This does not however apply with the option brake and external fans! In this case, the rated power must be reduced to 72% of the value stated in the catalogue. If the maximum ambient temperature is between +40°C and +60°C, the power output should be inversely linearly interpolated between 100% and 72%. In this case thermal protection of the motor by means of a thermistor sensor is essential. The motor connection cables and the cable glands must be suitable for temperatures of at least 100°C. 7.3.4 Painting Motors for Zone 21 and Zone 22 are provided with suitable painting ex-works. Subsequent painting may only be carried out after consultation with Getriebebau NORD or a workshop which is approved for the repair of explosion protected motors. Compliance with the valid standards and regulations is mandatory. 7.3.5 IEC-B14 Motors The B14 flanged bearing plate must be covered with a protective foil which must be removed before the motor is fastened in place. All four fixing screws, even if not required, must be screwed into the flanged bearing plate! The fixing screw threads must be inserted with a sealant, e.g. Loctite 242. The maximum screw-in depth in the bearing plate is 2 x d. If the end of the shaft faces upwards, e.g. version IMV3, IMV6, a cover must be provided by the operator / installer, which prevents foreign bodies from falling into the fan cover of the motor (see DIN EN 60079-017, item 17). This must not obstruct the fan from cooling the motor. If the end of the shaft faces downwards, e.g. versions IMV1, IMV5, motors for Zone 21 and Zone 22 are provided with a protective cover on the fan cover. A hand wheel on the second end of the shaft is not permitted for versions with the "shaft end downwards". Unless otherwise specified for operating modes and tolerances in the test certificate or name plate, electrical machinery is designed for continuous operation and normal infrequent start-ups where insignificant start-up heating occurs. The motors may only be used for the type of operation stated on the name plate. The installation instructions must be strictly observed.

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7. IE2-ATEX Motors for use in Zone 21 and Zone 22 7.4 Structure and method of use The motors are self-cooling. Rotary shaft seals are fitted both on the drive side (DS) and on the ventilation side (VS). Motors for Zone 21 and Zone 22 have metal fans. Motors with brakes for Zone 22 (Category 3D, non-conducting dust) have a special plastic fan. The motors are produced as protection class IP55, optionally protection class IP 66, (Zone 22 – non-conducting dust) or IP66 (Zone 21). Under normal operating conditions, the surface temperature does not exceed the surface temperature stated on the name plate. 7.5 Minimum cross section of bonding conductors Minimum cross-section of the associated Cross-section of phase conductor in inground lead SP in mm2 stallation S in mm2 S 16 S 16 < S 35 16 S > 35 0.5 S When connecting a lead to the external ground, the minimum cross-section must be 4 mm2. 7.6 Maintenance The voltage must always be switched off and secured against being switched on again before opening the motor! Attention! Higher temperatures than the maximum permitted surface temperature of the housing may be present inside the motor. The motor must therefore never be opened in hazardous dust atmospheres! The motors must be checked and tested regularly for functional safety! The applicable national standards and regulations must be complied with! Unpermitted high dust deposits > 5 mm may not be allowed to build up! If functional safety cannot be ensured, the motor may not be operated! When the ball bearings are replaced, the rotary shaft seals must also be replaced. FKM rotary shaft seals as specified by Getriebebau NORD must be used. Ensure that they are fitted correctly! The rotary shaft seals must be lubricated on the external rings and on the seal lips. If an explosion protected gear is flanged dust-tight to the motor, an NBR rotary shaft seal can be used on the drive side of the motor if the gear oil temperature does not exceed 85°C. Only original parts may be used as spare parts with the exception of standardised, commercially available and equivalent parts. This also applies in particular to seals and connection components. Parts for terminal boxes or spare parts for external grounding must be ordered as per the spare parts list in the operating instructions. The functionality of seals, rotary shaft seals and cable glands must be regularly checked! Maintaining dust protection for the motors is of paramount importance for explosion protection. Maintenance must be implemented by qualified personnel in a specialist workshop with suitable equipment. We urgently recommend that the general overhaul is carried out by NORD Service.

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8. Options for motors used in Zone 22 8.1 Option inverter operation ATEX NORD motors for Zone 22 are suitable for inverter operation due to their insulation system design. Because of the variable rpm range, temperature monitoring with PTC resistors or temperature monitors is necessary. For safe engineering and application, comply with the engineering guideline "Operation of ATEX motors with frequency inverters", No. 605 2101. The engineering guideline provides information about the necessary requirements for inverter operation and about the permitted rpm ranges. 8.2 Option external fan Motors with the additional designation F (e.g. 80S/4 3D F) are equipped with an external fan and must be monitored via the integrated temperature sensor. Attention! The motor may only be operated together with the external fan! A failure of the external fan can lead to the motor overheating and therefore endanger property/persons. Comply with the operating instructions for the external fan! The power supply for the external fan is provided independently via the external fan terminal box. The external fan power supply must be identical to the voltage rating given on the name plate. The external fans must be protected against overheating with suitable monitoring equipment! The IP protection classes of the external fan and motor may be different. The lower IP protection class applies to the drive unit. The cable glands must as a minimum correspond to the protection type specified on the name plate. Unused openings must be closed with plugs, which as a minimum correspond to the protection class of the motor. External fans and motors for use in hazardous areas have an Ex designation as per guideline 94/9 EC. This designation must be present on the external fan and on the motor. If the designations of the external fan and the motor differ, the lowest designated explosion protection applies to the entire drive. The maximum specified temperature given in the surface temperature data for the individual components applies for the entire drive unit In this case, it may be necessary to take into account any gears that may be present. Contact Getriebebau NORD if there are any doubts. If any component in the entire drive does not have an Ex designation, then the entire drive may not be operated in an Ex area. 8.3 Option return stop Motors with the additional designation RLS (e.g. 80S/4 3D RLS) are equipped with a return stop. Motors with return stops have an arrow marking the direction of rotation on the ventilation cover. The arrow points in the rotation direction of the motor. It must be ensured, when connecting the motor and during motor control, that the motor can only operate in the rotation direction, e.g. by means of a rotary field test. Switching the motor to the blocked rotation direction, i.e. incorrect rotation direction, can lead to damage. Return stops operate without wear from a speed of ca. 800 1/min.. Return stops must not be operated at speeds under 800 l/min to prevent unpermitted heating and rapid wear of the return stop. This must be taken into account for motors with a frequency of 50 Hz and poles ! 8, and for motors with frequency inverters. 8.4 Option brake Motors with the additional designation BRE (e.g. 80S/4 3D BRE 10) are equipped with a brake and must be monitored via the integrated temperature sensor. If the temperature sensor of one of the components (motor or brake) is triggered, the entire drive must be securely shutdown. The motor and brake PTC's must be switched in series. Attention! The brake DC voltage supply must be implemented via a rectifier located in the motor terminal box or via a directly supplied voltage. The brake voltage shown on the name plate must be complied with. The power supply lines must not be laid in a cable together with the temperature sensor circuit. The brake functionality must be checked before start-up. There should be no grinding noises, as this could lead to unpermitted excessive heating.

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9. Spare parts drawing and spare parts list

Item No. 900 902 902.1 902.2 904 905 906 907 907.1 907.2 908 908.1 909 910 911 911.1 911.5 912 912.1 913 913.1 913.2 916 916.1 916.2

Description Rotor with shaft End shield at drive end Cheese-head screw Hexagon nut Shaft seal Bearing at drive end Ball bearing shim Terminal box frame Chassis connection terminal wire clamp Oval-head screw Terminal box lid Cheese-head screw Terminal box frame gasket Terminal box lid gasket Terminal board Cheese-head screw Spring lock washer Mini-terminal Oval-head screw Spacer Cheese-head screw Spring lock washer Stator with winding Equipotential bonding terminal Spring pin

www.nord.com

B1091-GB-3212

Item No. 918 924 924.1 924.2 924.3 929 932 932.1 932.2 933 939 940 940.1 940.2 941 942 947 948 952 953 955 956 980 988 989 989.1

Description Key Screw-on foot (BG 100-132) Hexagon bolt Spring lock washer Hexagon nut Bearing at ventilation end End shield at ventilation end Cheese-head screw Hexagon nut Shaft seal Fan Fan hood Oval-head screw Countersink screw B3 Key Circlip Circlip Clamping bush Cable gland Blind plug Blind plug Protective roof Ring seal Name plate Oval-head screw

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10. Conformity declaration

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10. Conformity declaration

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10. Conformity declaration

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10. Conformity declaration Getriebebau NORD GmbH & Co. KG

Rudolf-Diesel-Str. 1, D-22941 Bargteheide, Germany Telephone: +49 (0) 4532-401-0 Fax: +49 (0) 4532-401-555 http://www.nord.com

EC Declaration of Conformity According to Directive 94/9/ EEC Annex VII

We, Getriebebau Nord GmbH & Co. KG hereby declare that the surface-cooled three-phase asynchronous motors with squirrel cage rotor Type:

SK 80*H/4 3D, SK 90*H/4 3D, SK 100*H/4 3D, SK 112*H/4 3D, SK 132*H/4 3D, SK 160*H/4 3D, SK 180*H/4 3D, SK 200XH/4 3D * Power code (e.g. S, M, L, A)

comply with the following regulations: 94/9/EG Directive for the harmonisation of statutory regulations of member states for devices and protective systems for proper use in explosion hazard areas

Applied harmonised standards: EN 60079-0: 2009 EN 60079-31: 2009

Initial labelling was carried out in 2011.

Bargteheide, 19.08.2011

U. Küchenmeister: Manager

www.nord.com

i.V. F. Wiedemann Head of Motors Division

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NORD DRIVESYSTEMS GROUP

www.nord.com/locator

Getriebebau NORD GmbH & Co. KG Rudolf-Diesel-Straße 1 22941 Bargteheide, Germany Fon +49 (0) 4532 / 289 - 0 Fax +49 (0) 4532 / 289 - 2253 [email protected], www.nord.com Member of the NORD DRIVESYSTEMS GROUP

DRIVESYSTEMS 121

Mat.-Nr. 6051302/3212

Headquarters:

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seepex GmbH Scharnhölzstr 344 46240 Bottrop Postfach 10 15 64 46215 Bottrop Germany Tel +49.2041.996-0 Fax +49.2041.996-400 [email protected] www.seepex.com

Great Britain

Austria

Belgium

Denmark

seepex UK Ltd. 3 Armtech Row Houndstone Business Park Yeovil Somerset BA22 8RW Tel +44.1935.472376 Fax +44.1935.479836 [email protected]

seepex GmbH Vertriebsbüro Österreich Obermüllergasse 18 3003 Gablitz Tel +43.2231.61085 Fax +43.2231.6108520 [email protected]

seepex GmbH Bureau België Industriezone Klein Gent-Link 21 Welvaartstraat 14-1 bus 15 2200 Herentals Tel +32.14.501471 Fax +32.14.501461 [email protected]

seepex Nordic A/S Krakasvej 7C 3400 Hillerød Tel +45.49.192200 Fax + 45.49.193200 [email protected]

France

Hungary

Irland

Italy

seepex France SARL 1, Rue Pelloutier 77183 Croissy Beaubourg Tel +33.1.64114450 Fax + 33.1.64114489 [email protected]

seepex GmbH Magyarországi iroda Hecskó Tamás okl.vill.mérn. Éva utca 5. 7632 Pécs Tel +36.205806134 Fax +36.72952587 [email protected]

seepex UK Ltd. Branch Office Ireland 29 Lackenfune Dungarvan Co. Waterford Tel +353.860450439 [email protected]

seepex Italia S.r.l. Via Alberto da Giussano 23 20145 Milano (MI) Tel +39.02.36569360 Fax +39.02.92877855 [email protected]

Poland

Sweden

Spain

The Netherlands

seepex GmbH Przedstawicielstwo w Polsce ul. Romana Maya 1 61-371 Poznan Tel +48.61.6469270 Fax +48.61.6469271 [email protected]

seepex Nordic A/S Hamndalsvägen 58 61633 Åby Tel +46.1166940 Fax +46.1166941 [email protected]

seepex GmbH Officina de Representación en España C/Copenhague, 12 Edif. Tifan Oficina 207 28232 La Rozas Madrid Tel +34.91.6361353 Fax +34.91.6409371 [email protected]

seepex GmbH Bureau Nederland Visbystraat 13 7418 BE Deventer Tel +31.570.516644 Fax +31.570.516077 [email protected]

Russia

USA

China

India

seepex Ltd. Ugreshskaya Str. 2 Bldg. 7 115088 Moscow Tel +7.495.2874830 Fax +7.495.2874830 [email protected]

seepex Inc. 511 Speedway Drive Enon Ohio 45323 Tel +1.937.8647150 Fax + 1.937.8647157 [email protected]

seepex Pumps (Shanghai) Co., Ltd. Xuanzhong Rd. 399, Building 13 Nanhui Industrial Area 201300 Shanghai Tel +86.21.38108888 Fax +86.21.38108899 [email protected]

seepex India Pvt. Ltd. Office No. 305. Raheja Arcade Building Sector 11, C.B.D. Belapur Navi Mumbai 400614 Tel +91.22.40240434/35 Fax +91.22.40240436 [email protected]

Japan

Malaysia

Australia

seepex Japan Co., Ltd. 5-2-44 Onna, Atsugi-shi, Kanagawa-ken, 243-0032 Tel +81.46.2595931 Fax +81.46.2595941 [email protected]

seepex (M) Sdn. Bhd. 59-1, Jalan PJU 1/37 Dataran Prima 47301 Petaling Jaya Selengor Darul Ehsan Tel +60.3.78806951/53 Fax +60.3.78806959 [email protected]

seepex Australia Pty. Ltd. Unit 3, 4 Bounty Close Tuggerah Business Park NSW 2259 Tel +61.2.43554500 Fax +61.2.43554022 [email protected]

More seepex sales partnes in Europe, America, Asia, Africa and Oceania you willl find on our website.

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