DOCUMENTATION

PUMP TYPe: V8.5z

cOMmission No.: NM 81000047

serial No.: 105 480

technical documentation
documentation technique
dokumentation tecnico
dokumentation tcnico
Technische Dokumentation
Fon: +49 5724 390-0
Fax: +49 5724 390-290
info@bornemann.com
www.bornemann.com
 Screw Pump order no. / pos.
NM 81000047 / 2,0
Pumps and Systems
www.bornemann.com
V 8.5z - 103/2 / N page: 1
1.0 Project Data

:::::::
customer: CHRONOS SHIPPING CO. LTD 6 quantity 1
revision

7 delivery date 04.06.2010

Item:

8 customer-no. 352700
41 AKTI MIAOULI 9 expert Scheithauer
GR 185 35 PIRAEUS, GREECE 10 phone/fax 05724/390-2342 /
:

1 order-no. :::M/T"Asphalt Eagle", Hull 501 11 application Asphalt Cargo Pumps

:::
2 order-date 12.01.2010 12 final destination Greece
3 project-no. CP-BP-001 13 application code
4 position 14 serial-no.
5 project name Onomichi Dockyard 15 item-no. 1186
2.0 Performance Data
:

1/2 pumped liquid asphalt,

/3

operating points 1. 2. 3. operating points 1. 2. 3.

::::::::::

:::
guarantee guarantee
4 temperature (C) 0,0 148,0 170,0 14 6 capacity (m/h) 0,00 390,00 800,00

:
:
5 viscosity (mm/s) 0,00 3670 450 15 suction pressure (bar) 0,00 0,00 0,00
6 gravity (kg/dm) 0,000 0,950 0,920 16 discharge pressure (bar) 0,00 10,50 10,50

:
7 vapour pressure (bar) 17 diff. pressure (bar) 0,00 10,50 10,50

:
8 gas content (%) 18 6 speed (1/min-) 0 900 1800
9 solid content (%) 19 6 shaft power (kW) 0,00 216,00 398,00

:
10 particle size (mm) 20 motor power (kW)
11 pH-value 21 6 NPSH required (m) 0,00 4,50 5,31

:
12 condition (liqu./gas.) liquid 22 NPSH available (m)
13 11 remarks acc. to 2.15) suction head of min. -0,5 bar possible
3.0 Material Execution
::::::

:::::
1 pump casing P265GH (fabricated carbon steel) 7 bearing housing EN-GJL-250 s. t. ASTM A48 cl. 40
2 screws 1.4057 sim. to AISI 431 8 sealing housing 1.4057 sim. to AISI 431
3 shafts 1.4542 sim. to AISI 630 9 flat gaskets fiber composition, non asbestos
4 7 liner EN-GJS-400-15 s. to AISI 60-40-18 10 o-rings medium wett. FKM
5 intermediate flange P265GH (fabricated carbon steel) 11 non med. wetted seals NBR
:::::

6 remarks
:

4.0 Shaft Sealing

1 construction / function mechanical seal, single acting, throttle bush, steam quench 6 API-plan :
:

2 manufacturer Flowserve 7 piping CUSTOMER

:

3 type BXLS 8 piping execution

4 2 material code 5X4X (QQVGG) 9 quench / barrier fluid
5 2 remarks
:::::
::::::::

5.0 Bypass / Heating / Design / Bearings

1 bypass without handwheel 9 heating fluid data 6,0 bar 180,000 C
2 setting point 11,5 bar 10 bearing life time h
3 max. suction pressure 6 bar 11 additional execut. 1
4 casing design 22 bar, 300C 12 additional execut. 2
::

5 design data heating 16 bar, 250 C 13 10 measuring points 1 4x G1/2'' for Pt-100 at bearing casing
:

6 heating heating jacket S 14 10 measuring points 2 1x G 1/2'' fr Pt-100 at pump casing

7 heating fluid steam 15 -----------
8 remarks
6.0 Flanges / Connections
rule size press. rate position
::

1 suction
7 DIN 2634 DN 300 PN 25 left
2 discharge DIN 2634 DN 300 PN 25 right
::::

3 heating DIN 2635 DN 25 PN 25-40 pump casing

4 drain DIN 2633 G 1'' PN 25-40 bottom
5 quench
6 cooling -
7 flange options
8 remarks
issued: Livecchi / 15.01.2010 checked: Hormann / 15.01.2010 revised: Scheithauer / 22.03.2010 rev.: 11
 Screw Pump order no. / pos.

:
NM 81000047 / 2,0
Pumps and Systems V 8.5z - 103/2 / N page: 2

:::
www.bornemann.com
7.0 Installation / Rotation / Name Plate

:
1 installation vertical 5 rotation ccw

::
2 location 6 pos. of drive shaft opposite to bypass
3 area classification 7/8 name plate English / aluminium

:
:::

::
4 remarks
8.0 Accessories
1 base plate - 9 maker coupling -

:
2 executioncode 10 coupling type -
:

:
:

3 option base plate 1 11 coupling guard -

::
4 option base plate 2 12 cover for drive -
:::

5 drip pan - 13 instruments/options

6 mounting option 1 socket and lantern 14 spare parts
7 mounting option 2 15 electrical wiring
8 10 remarks

9.0 Drive
:::::

1 drive system 3-phase-motor 11 frequency (Hz) :

2 type 12 protection :

::::::
3 manufacturer 13 explosion proof
:

4/5 size/ mounting form / 14 insulation class

6 start 15 certificate
:

7 power (kW) x 16 supplied by customer

:

8 speed (1/min-) x 17 assembly customer

9 voltage (V) 18 part no. drive

:
:

10 remarks
:

10.0 Painting / Konservation

:

:
1 painting silver 5 intermediate coat -
:

:
2 surface preparation acc. to QSA 09032 6 final coat acc. to QSA 09032
:

3 primer coat acc. to QSA 09032 7 preservation acc. to QSA 09011 standard
::

4 remarks
: ::

11.0 Mill Certs / Testing

1 casing EN 10204-3.1 11 liner
:

2 shafts EN 10204-3.1 12 bearing housing

:

3 screws EN 10204-3.1 13 10 intermediate flange EN 10204-3.1

4 additional parts
Testing yes/no according to by pressure test medium
::::::

5 4 hydrostat. press. test yes EN 10204-3.1 GL 1,5 x pD water

6 10 performance test yes VDMA 24284 GL water
7 NPSH-test no
8 noise level test no
9 vibration test no
10 remarks
::

12.0 Documentation
:::::

1 language English 6 operation manual 1-fold

2 hydrostat. press. test 1-fold 7 9 mill certs 1-fold
:

3 performance test 1-fold 8 dimensional drawing 1-fold

4 documents to
5 remarks
::

::

13.0 Weights / Packing

::

1 pump kg 3 accessories kg 5 total gross kg

2 base plate kg 4 total net kg 6 packing
14.0 Remarks
1 10 - Gear housing with water cooling (Cooling coils inside)
Inlet/Outlet in G 1/2"

- mech. seals with throttle bushing for steam quensch, Connection in G 1/2"
(no piping)

issued: Livecchi / 15.01.2010 checked: Hormann / 15.01.2010 revised: Scheithauer / 22.03.2010 rev.: 11
Screw Pump

Original Operating Manual

W/V Series

Ausgabe:09/2009-Rev0-TDL

Joh.Heinrich Bornemann GmbH

Postfach 1162
D- 31676 Obernkirchen
Fon: +49 5724 390-0
Fax: +49 5724 390-290
info@bornemann.com
Table of contents

Table of contents
1 About this document ............................... 5 5.4.1 Specifying supports and flange
connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.1 Target groups ................................. 5
5.4.2 Specifying nominal diameters . . . . . . . . . . . . . . . 20
1.2 Other applicable documents ................ 6 5.4.3 Specifying pipe lengths . . . . . . . . . . . . . . . . . . . . . . 21
5.4.4 Optimizing changes in cross-section and
1.3 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . 6
direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.4 Technical terms ............................... 7 5.4.5 Avoiding excessive pressure . . . . . . . . . . . . . . . . 21
2 Safety ................................................. 8 5.4.6 Providing safety and control devices . . . . . . . 21
5.4.7 Making it possible to drain the pump . . . . . . . 22
2.1 Intended use .................................. 8
5.5 Connecting the pipes . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2 General safety instructions . . . . . . . . . . . . . . . . . . 8 5.5.1 Keeping the piping clean . . . . . . . . . . . . . . . . . . . . 22
2.2.1 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 5.5.2 Installing auxiliary piping . . . . . . . . . . . . . . . . . . . . . 22
2.2.2 Obligations of the operating company . . . . . . 9 5.5.3 Installing the suction pipe . . . . . . . . . . . . . . . . . . . . 22
2.2.3 Obligations of personnel . . . . . . . . . . . . . . . . . . . . . 9 5.5.4 Installing the pressure pipe . . . . . . . . . . . . . . . . . . 22
2.3 Specific hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 5.5.5 Installing the heating pipe (optional) . . . . . . . . 22
2.3.1 Explosion-hazard area . . . . . . . . . . . . . . . . . . . . . . . 9 5.5.6 Checking the stress-free pipe connec-
2.3.2 Hazardous pumped liquids . . . . . . . . . . . . . . . . . . 9 tions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.6 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 Layout and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 5.6.1 Connecting the motor . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 5.6.2 Checking the sense of rotation . . . . . . . . . . . . . . 23
3.1.1 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 5.6.3 Connecting the instruments . . . . . . . . . . . . . . . . . 23
3.1.2 Pump type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 5.7 Aligning the pump unit . . . . . . . . . . . . . . . . . . . . . . . 24
3.2 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5.7.1 Checking the alignment of the
coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Shaft seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 5.7.2 Aligning the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3.1 Mechanical seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3.2 Stuffing box packing . . . . . . . . . . . . . . . . . . . . . . . . . 13 5.8 Installing the coupling guard . . . . . . . . . . . . . . . . 25
3.3.3 Shaft seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.4 Auxiliary operating systems . . . . . . . . . . . . . . . . . 13 6.1 Putting the pump into service for the first
4 Transport, storage and disposal . . . . . . . . . . . . . . . . . . 14 time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.1.1 Identifying the pump type . . . . . . . . . . . . . . . . . . . . 26
4.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 6.1.2 Checking the stuffing box packing (if
4.1.1 Unpacking and inspection on delivery . . . . . . 14 present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.1.2 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 6.1.3 Checking the shutdown period . . . . . . . . . . . . . . 26
4.2 Treatment for storage . . . . . . . . . . . . . . . . . . . . . . . . 16 6.1.4 Removing the preservative . . . . . . . . . . . . . . . . . . 26
4.2.1 For storage times < 3 months . . . . . . . . . . . . . . . 16 6.1.5 Lubricating the bearing/gear box . . . . . . . . . . . . 26
4.2.2 For storage times > 3 months . . . . . . . . . . . . . . . 16 6.1.6 Installing the stuffing box packing . . . . . . . . . . . 26
6.1.7 Preparing auxiliary systems (if
4.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 available) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.4 Removing the preservative . . . . . . . . . . . . . . . . . . 17 6.1.8 Filling and bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1.9 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 6.1.10 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5 Setup and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 6.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1 Preparing the setup . . . . . . . . . . . . . . . . . . . . . . . . . . 18 6.2.1 Preparing operation . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1.1 Checking the ambient conditions . . . . . . . . . . . 18 6.2.2 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1.2 Preparing the installation site . . . . . . . . . . . . . . . 18 6.2.3 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1.3 Preparing the foundation and surface . . . . . . 18 6.3 Shutting down the pump . . . . . . . . . . . . . . . . . . . . . 29
5.1.4 Preparing the pump . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1.5 Installing the heat insulation (optional) . . . . . 18 6.4 Start-up following a shutdown period . . . . . . . 30
5.2 Setting up the pump unit . . . . . . . . . . . . . . . . . . . . . 19 6.5 Operating the stand-by pump . . . . . . . . . . . . . . . 30
5.2.1 Setting the pump unit on the founda- 7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2.2 Fastening the pump unit . . . . . . . . . . . . . . . . . . . . . 19 7.1 Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.3 Installing the motor and coupling . . . . . . . . . . . 20 7.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.3.1 Installing the coupling . . . . . . . . . . . . . . . . . . . . . . . . 20 7.2.1 Maintenance table . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.3.2 Setting up the motor . . . . . . . . . . . . . . . . . . . . . . . . . 20 7.2.2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.4 Planning the pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 7.3 Removing and installing the pump . . . . . . . . . . 34

2 W/V Series BA-2009.12 1000 98 118en

 Table of contents

7.3.1 Removing the pump . . . . . . . . . . . . . . . . . . . . . . . . . 34

7.3.2 Returning the pump to the manufac-
turer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.4 Repairing the pump . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.4.1 Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . 35

8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.1 Technical specifications . . . . . . . . . . . . . . . . . . . . . . 38
9.1.1 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.1.2 Sound pressure level . . . . . . . . . . . . . . . . . . . . . . . . 38
9.2 Lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.2.1 Oil/grease lubrication version . . . . . . . . . . . . . . . 38
9.2.2 Oil/oil lubrication version . . . . . . . . . . . . . . . . . . . . . 39
9.3 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.3.1 Gear oil, temperature of the pumped liquid
10300 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.3.2 Lubricating grease, temperature of the
pumped liquid 10150 C . . . . . . . . . . . . . . . . . . . . 40
9.3.3 Lubricating grease, temperature of the
pumped liquid 150300 C . . . . . . . . . . . . . . . . . . 40
9.4 Lubricant quantities . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.5 Preservatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.6 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.7 Document of compliance . . . . . . . . . . . . . . . . . . . . 42
9.8 Declarations according to EC machine
directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.8.1 Declaration of conformity according to EC
machine directives . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.8.2 Declaration of installation according to EC
machine directives . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

1000 98 118en BA-2009.12 W/V Series 3

Table of contents

List of figures List of tables

Fig. 1 Type plate (example) . . . . . . . . . . . . . . . . . . . . . . . . 10 Tab. 1 Target groups and their duties .............. 5
Fig. 2 Pump type code (example) . . . . . . . . . . . . . . . . . . 10 Tab. 2 Other applicable documents and their
purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fig. 3 W type layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tab. 3 Warnings and consequences of disregarding
Fig. 4 V type layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
them . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fig. 8 Limit for heat insulation . . . . . . . . . . . . . . . . . . . . . . 18
Tab. 4 Symbols and their meaning ................. 7
Fig. 10 Straight pipe lengths upstream and down-
Tab. 5 Technical terms and their meaning ......... 7
stream of the pump (recommended) . . . . . . . 21
Tab. 6 Filter for suction pipe mesh size per
Fig. 14 Oil level eyelet on the gear box housing or
operating phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Tab. 7 Measures to be taken if the pump is shut
Fig. 15 Airborne sound level diagram (source:
down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
VDI 3743) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Tab. 8 Measures depending on the behavior of the
Fig. 16 Overview of lubrication points, oil/grease
pumped liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
lubrication version . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Tab. 9 Maintenance intervals and mea-
Fig. 17 Overview of lubrication points, oil/oil
sures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
lubrication version . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Tab. 10 Measures for return . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Tab. 11 Antifriction bearings required bearing
play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Tab. 12 Malfunction/number assignment . . . . . . . . . . . . 36
Tab. 13 Troubleshooting list . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Tab. 14 Lubricants gear oil . . . . . . . . . . . . . . . . . . . . . . . . . 39
Tab. 15 Lubricating grease for pumped liquids at
10150 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Tab. 16 Lubricating grease for pumped liquids at
150300 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Tab. 17 Minimum amounts for grease lubrica-
tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Tab. 18 Minimum oil lubrication quantities . . . . . . . . . . . 40
Tab. 19 Preservatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Tab. 20 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Tab. 21 Document of compliance . . . . . . . . . . . . . . . . . . . . 42
Tab. 22 Declaration of conformity according to EC
machine directives . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Tab. 23 Declaration of installation according to EC
machine directives . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4 W/V Series BA-2009.12 1000 98 118en

 About this document

1 About this document

This manual:
Is part of the pump
Applies to the afore-mentioned W/V series
Describes safe and appropriate operation during all oper-
ating phases

1.1 Target groups

Target group Definition Duty
Operating company Keep this manual available at the site of
operation of the equipment, including for later
use.
Ensure that personnel read and follow the
instructions in this manual and the other
applicable documents, especially all safety
instructions and warnings.
Observe any additional rules and regulations
referring to the system.
Operator Trained or instructed by the pump Read, observe and follow this manual and
manufacturer the other applicable documents, especially all
safety instructions and warnings.
Qualified personnel, Years of professional experience or training Read, observe and follow this manual and
fitter in repairs, maintenance and inspection and the other applicable documents, especially all
maintenance of pumps safety instructions and warnings.
Familiar with operating the manufacturers
pump, putting it into service and subjecting
it to maintenance
Trained or instructed by the pump
manufacturer
Knowledge of all relevant regulations and
standards
Tab. 1 Target groups and their duties

1000 98 118en BA-2009.12 W/V Series 5

About this document

1.2 Other applicable documents

Document Purpose
1)
System documentation Technical documentation for the pump unit or system
1)
ATEX additional instructions Operation in explosion-hazard areas
Installing shaft seals (stuffing box packings) and Instructions for installing stuffing box packings and putting them into
putting them into service. service
1)
Spare parts lists Sectional drawing, part numbers, component designations
Declaration of conformity Conformity with standards, contents of the declaration of conformity
( 9.8 Declarations according to EC machine directives, Page 43).
Dimension drawings Flange loads
Pump data sheet Technical specifications, operating conditions, performance and
operating limits
1)
Repair instructions Repairing and installing the pump, including the mechanical seal
1)
WN 1024 Change in top height of screw pumps due to operating temperature
1)
Supplier documentation Technical documentation for parts supplied by subcontractors
1)
Additional instructions for the pump unit Technical documentation for the pump unit
Additional instructions for the pump system 1) Technical documentation for the pump system
Additional instructions for the sealing system 1) Technical documentation for the sealing system
1)
Additional instructions for the oil supply unit Technical documentation for the recirculating oil lubrication
Additional instructions for transport, storage and Guidelines for treatment for long-term storage for max. 36 months
treatment 1)
Tab. 2 Other applicable documents and their purpose
1) Included in the scope of delivery only if the pump was ordered accordingly. Can be subsequently ordered if necessary.

1.3 Warnings and symbols

Warning Risk level Consequences of disregard
Immediate acute risk Death, serious bodily harm
DANGER
Potential acute risk Death, serious bodily harm
WARNING
Potentially hazardous situation Minor bodily harm
CAUTION
Potentially hazardous situation Material damage
NOTE
Tab. 3 Warnings and consequences of disregarding them

6 W/V Series BA-2009.12 1000 98 118en

 About this document

Symbol Meaning
Safety warning sign
Take note of all information highlighted by the safety warning sign
and follow the instructions to avoid injury or death.

Instruction
1. , 2. , ... Multiple-step instructions
9 Precondition
Cross reference
Information, notes

Tab. 4 Symbols and their meaning

1.4 Technical terms

Term Meaning
API plan Design of the sealing system according to the American Petrol Institute
(API)
Auxiliary operating systems Systems for operating the pump
Contamination Poisoning or impurification with detrimental substances
Cavitation Creation and sudden dissolving of vapor bubbles in the pumped liquid
where the pressure of the liquid locally falls below its vapor pressure
Pump unit Pump with drive and base plate
Pump system Pump with drive, base plate and control unit
Quenching Sealing system at which the pressure of the quench medium is lower
than that of the pumped liquid. The seal is lubricated by the pumped
liquid.
The quench medium absorbs pumped liquid.
Quench medium Medium for quenching mechanical seals or shaft seals
Blocking Sealing system at which the pressure of the blocking medium is higher
than that of the pumped liquid. The seal is lubricated by the blocking
medium.
The pumped liquid absorbs blocking medium. The pumped liquid has
no contact to the atmosphere.
Blocking medium Medium for blocking mechanical seals
Flushing medium Medium for flushing the pump, seal chamber and sliding surfaces
Tab. 5 Technical terms and their meaning

1000 98 118en BA-2009.12 W/V Series 7

Safety

2 Safety
The manufacturer does not accept any liability caused by 2.2 General safety instructions
disregarding any of the documentation.
2.2.1 Product safety
The pump has been constructed according to the latest tech-
2.1 Intended use nology and recognized technical safety rules. Nevertheless,
operation of the pump can still put the life and health of the
Only use the pump to pump the agreed pumped liquids user or third parties at risk or damage the pump or other prop-
( pump data sheet). erty.
Adhere to the operating limits ( pump data sheet).
Only operate the pump if it is in perfect technical condition
Avoid running dry: and only use it as intended, remaining aware of safety and
risks, and in adherence to the instructions in this manual.
Make sure the pump is only operated with, and never
without, pumped liquid. Keep this manual and all other applicable documents com-
plete, legible and accessible to personnel at all times.
Avoid cavitation:
Fully open the suction-side valve during pump opera- Keep the information on the machine in a complete and
tion and do not use it to adjust the flow rate. legible condition.
Fully open the pressure-side valve during pump oper- Refrain from any procedures and actions that would pose
ation. a risk to personnel or third parties.
Avoid damage to the motor: In the event of any safety-relevant malfunctions, shut down
Note the maximum permissible number of times the the pump immediately and have the malfunction corrected
motor can be switched on per hour ( manufacturers by the personnel responsible.
specifications).
In addition to the entire documentation for the product,
Consult the manufacturer about any other use of the pump. comply with statutory or other safety and accident-preven-
tion regulations and the applicable standards and guide-
Prevention of obvious misuse (examples) lines in the country where the pump is operated.
Observe the operating limits of the pump with regard to
the temperature, pressure, viscosity, flow rate and speed
( pump data sheet).
When pumping liquids containing solids, adhere to the lim-
its for the proportion of solids and the grain size ( pump
data sheet).
When pumping liquids containing gas, adhere to the limits
for the proportion of gas ( pump data sheet).
Overpressure safety valves are not system safety valves.
Do not use the pump without overpressure safety valves or
an equivalent safeguard against exceeding the differential
pressure.
Do not use the overpressure safety valve to regulate the
flow rate or pressure.
Do not operate the pump while the pressure-side valve is
closed.

8 W/V Series BA-2009.12 1000 98 118en

 Safety

2.2.2 Obligations of the operating company 2.2.3 Obligations of personnel

Safety-conscious operation
Only operate the pump if it is in perfect technical condition
and only use it as intended, remaining aware of safety and
risks, and in adherence to the instructions in this manual.
Ensure that the following safety aspects are observed and
monitored:
Adherence to intended use
Statutory or other safety and accident-prevention reg-
ulations
Safety regulations governing the handling of haz-
ardous substances
Applicable standards and guidelines in the country
where the pump is operated
Make personal protective equipment available.
Qualified personnel
Make sure all personnel tasked with work on the pump
have read and understood this manual and all other appli-
cable documents, especially the safety, maintenance and
repair information, before they start any work.
Organize responsibilities, areas of competence and the
supervision of personnel.
Ensure that all work is carried out by specialist technicians
only:
Installation, initial start-up, repairs, maintenance
Work on the electrical and electronic equipment
Make sure that trainee personnel only work on the pump
under the supervision of specialist technicians.
Observe local safety regulations.
All directions given on the pump must be followed (and kept
legible), e.g. the arrow indicating the sense of rotation and
the markings for fluid connections.
Do not remove the safety guarding for hot, cold or moving
parts during operation.
Use personal protective equipment whenever necessary.
Only carry out work on the pump while it is not running.
Only carry out work on the pump after it has been com-
pletely depressurized.
Isolate the motor from its supply voltage and secure it
against being switched back on again when carrying out
any fitting or maintenance work.
Reinstall the safety equipment on the pump as required by
regulations after any work on the pump.
2.3 Specific hazards
2.3.1 Explosion-hazard area
( ATEX additional instructions).
2.3.2 Hazardous pumped liquids
Follow the safety regulations for handling hazardous
substances when pumping hazardous liquids (e.g. hot,
flammable, poisonous or potentially harmful) ( safety
data sheets).

Safety equipment Use personal protective equipment when carrying out any
work on the pump.
Provide the following safety equipment and verify its func-
tionality:
For hot, cold and moving parts: Safety guarding pro-
vided by the customer for the pump
For possible build up of electrostatic charge: ensure
appropriate grounding
If there is no overpressure safety valve in the system:
Provide suitable absolute pressure limiters in the sys-
tem
If there is no overpressure safety valve or blow-out
disk in the pump: Provide suitable differential pressure
safeguards on the pump

Warranty
Obtain the manufacturers approval prior to carrying out
any modifications, repairs or alterations during the warranty
period.
Only use genuine parts or parts that have been approved
by the manufacturer.
Spare parts lists and repair instructions are available on
request when not included in the scope of delivery.

1000 98 118en BA-2009.12 W/V Series 9

Layout and function

3 Layout and function

3.1 Label 3.1.2 Pump type code

3.1.1 Type plate

4 5 6 7 8 9 1
2
3
4
5
3 10
Fig. 2 Pump type code (example)
2 11 1 Series (W: horizontal, V: vertical)
1 12 2 Size
3 Order code
4 Installation length
zk: centered short version
Fig. 1 Type plate (example) z: centered long version
zi: centered version with internal bearing
1 Viscosity
5 Slope [mm]
2 Flow rate
3 Order number
4 Serial number
5 Differential pressure
6 Weight
7 Type
8 Motor speed
9 Max. admission pressure
10 Year of manufacture
11 Power consumption
12 Max. outlet pressure

10 W/V Series BA-2009.12 1000 98 118en

 Layout and function

3.2 Layout

7
6

1 2 3 4 5

Fig. 3 W type layout

1 Gear box housing 4 Bearing housing 7 Outlet flange
2 Pump casing 5 Top shaft
3 Suction branch 6 Circulation

1000 98 118en BA-2009.12 W/V Series 11

Layout and function

4
12

10 11
8

Fig. 4 V type layout

1 Motor 5 Bearing housing 9 Base plate
2 Motor shaft 6 Circulation 10 Outlet flange
3 Coupling 7 Pump casing 11 Suction branch
4 Top shaft 8 Gear box housing 12 Bell housing

12 W/V Series BA-2009.12 1000 98 118en

 Layout and function

3.3 Shaft seals 3.3.2 Stuffing box packing

The stuffing box packing must always leak slightly to carry
Only one of the following shaft seals can be used.
the frictional heat away.

3.3.3 Shaft seal ring

3.3.1 Mechanical seal
Shaft seal rings have functional leaks.
Mechanical seals have functional leaks.

Single-action mechanical seal ( pump data sheet, addi-

tional instructions for the sealing system). 3.4 Auxiliary operating systems
Double-action mechanical seal ( pump data sheet, addi- Layout and function of the auxiliary operating systems
tional instructions for the sealing system). ( manufacturers specifications, additional instructions
for the sealing system, system documentation).

1000 98 118en BA-2009.12 W/V Series 13

Transport, storage and disposal

4 Transport, storage and disposal

4.1 Transport
Weight specifications ( dimension drawings).

Transport with the base plate ( additional instructions for

the pump unit / pump system).

4.1.1 Unpacking and inspection on delivery

1. Unpack the pump/unit upon delivery and inspect it for visi-
ble transport damage.
2. Immediately report any transport damage to the transport-
ing company and manufacturer.
3. Dispose of packaging material according to local regula-
tions.

4.1.2 Lifting
The eyelets and attachment points for transport are marked
on the pump.

DANGER
Death or crushing of limbs caused by falling loads!
Use lifting gear appropriate for the total weight to be trans-
ported ( dimension drawings).
Fasten the lifting gear as shown in the following illustra-
tions. Fig. 5 Fastening lifting gear to horizontal pump
Fasten the lifting gear according to the marks on the pump.
For vertical pumps with motor, attach a safety rope to the
motor or motor lug to prevent the pump from overturning.
Do not stand under suspended loads.

NOTE
Material damage due to inappropriate transport
Do not lift the pump by the bearing housing or gear box
housing.
Make sure the pump unit is not distorted when lifting it.
Make sure that the lifting gear does not damage any
pipelines or units. Use a lifting frame, when necessary
( dimension drawings, additional instructions for the
pump unit / pump system).

Lift the pump/unit properly.

14 W/V Series BA-2009.12 1000 98 118en

 Transport, storage and disposal

Fig. 6 Fastening lifting gear to vertical pump

Fig. 7 Fastening lifting gear to pump with stool

1000 98 118en BA-2009.12 W/V Series 15

Transport, storage and disposal

4.2 Treatment for storage 4.3 Storage

Unless ordered elsewhere, all visible shaft parts and bare, Observe the measures for treatment for long-term storage
non-corrosive metal parts are treated with preservative for when storing for > 3 months ( additional instructions for
transport upon delivery. transport, storage and treatment).

NOTE NOTE
Material damage due to inappropriate treatment for stor- Material damage due to inappropriate storage!
age! Treat and store the pump properly.
Treat the pump properly, inside and outside, for storage.
Do not undo the seal flange from the mechanical seals. 1. Seal all openings with blank flanges, blind plugs or plastic
Do not apply preservative to non-metallic parts. covers.
2. Make sure the storage room meets the following condi-
4.2.1 For storage times < 3 months tions:
Dry
1. If present: remove the plastic covers from the suction and Frost-free
pressure sides. Vibration-free
2. Grease all visible, internal and external bare metal parts 3. Rotate the shaft once a month (by ca. 30).
with acid-free and resin-free grease ( 9.5 Preservatives,
4. Check the preservative once a month and renew it if nec-
Page 41).
essary.
3. Close the plastic covers on the suction and pressure sides.

4.2.2 For storage times > 3 months

Observe the measures for treatment for long-term storage
when storing for > 3 months ( additional instructions for
transport, storage and treatment).

16 W/V Series BA-2009.12 1000 98 118en

 Transport, storage and disposal

4.4 Removing the preservative 4.5 Disposal

Only necessary for pumps treated for storage. The pump and parts which come into contact with media
can be contaminated by poisonous or radioactive pumped
liquids to such an extent that cleaning is insufficient.

WARNING
Damage to health due to cleaning agents!
Use personal protective equipment when carrying out any
work with cleaning agents.
Do not inhale vapors from cleaning agents.
NOTE
High water pressure or spray water can cause material
damage!
Do not clean the pump with a water or steam jet.
NOTE
Damage to seals due to wrong cleaning agents!
Ensure the cleaning agent does not corrode the seals.
WARNING
Risk of poisoning and environmental damage by the
pumped liquid or oil!
Use personal protective equipment when carrying out any
work on the pump.
Prior to the disposal of the pump:
Collect and dispose of any escaping pumped liquid or
oil in accordance with local regulations.
Neutralize residues of pumped liquid in the pump.
Remove the preservative ( 4.4 Removing the preser-
vative, Page 17).
Remove the plastic parts and dispose of them in accor-
dance with local regulations.
Dispose of the pump in accordance with local regulations.

1. Choose the cleaning agent according to the application.

( 9.6 Cleaning agents, Page 41).
2. Remove the preservative using cleaning agent and a cloth
or operate the pump with cleaning agent.
3. Dispose of cleaning agents in accordance with local regu-
lations.
4. Check all external elastomer parts (O-rings, shaft seals) for
proper elasticity and replace them if necessary.

1000 98 118en BA-2009.12 W/V Series 17

Setup and connection

5 Setup and connection

Observe the measures for treatment for long-term storage
when storing for > 3 months ( additional instructions for
transport, storage and treatment).
For pumps in explosion-hazard areas ( ATEX additional
instructions).
Setup options:
With steel foundation frame ( dimension drawing,
additional instructions for the pump unit / pump sys-
tem).
Ensure that all work is carried out by specialist technicians
only:
Installation, initial start-up, repairs, maintenance
Work on the electrical and electronic equipment
NOTE
Material damage caused by dirt!
Do not remove any covers or transport plugs until immedi-
ately before connecting the pipes to the pump.
5.1 Preparing the setup
5.1.1 Checking the ambient conditions
Make sure the required ambient conditions are met
( pump data sheet).
5.1.4 Preparing the pump
1. If the pump is to be put into operation immediately after
setup and connection: remove the preservative prior to
setup ( 4.4 Removing the preservative, Page 17).
2. Take the measures required after long storage/shutdown
periods ( additional instructions for transport, storage
and treatment).
5.1.5 Installing the heat insulation (optional)
Only for pumps ordered accordingly.
Only necessary to maintain the temperature of the pumped
liquid ( pump data sheet).
NOTE
Material damage due to incorrect insulation!
Install heat insulation so that leaks can always be detected
safely.
NOTE
Material damage caused by overheating!
Install heat insulation only on the pump casing.
A

5.1.2 Preparing the installation site

Ensure the installation site meets the following conditions:
Pump freely accessible from all sides ( dimension
drawings)
Sufficient space for the installation/removal of the pipes
and for maintenance and repair work, especially for the
removal and installation of the pump and the motor
Pump not exposed to external vibrations (damage to
bearings)
Frost protection

5.1.3 Preparing the foundation and surface

Consult the manufacturer when installing with concrete
foundations.

Make sure the foundation and surface meet the following

conditions:
Level: Permitted deviation ( dimension drawings, Fig. 8 Limit for heat insulation
system documentation, additional instructions for the
Install the heat insulation correctly (in area A only). Do not
pump unit / pump system).
insulate the gear box housing and bearing housing.
Clean (no oil, dust or other impurities)
Observe the shaft offset for heated pumps
Capable of bearing the weight of the pump unit and all
( WN 1024).
operating forces
The pump is stable and cannot tip over

18 W/V Series BA-2009.12 1000 98 118en

 Setup and connection

5.2 Setting up the pump unit 5.2.2 Fastening the pump unit
The damping behavior is improved by filling the base plate
The pump may only be installed on a base plate (steel
with mortar grout (additional instructions for the pump unit
frame).
/ pump system).

1. Fill the anchoring holes with mortar grout.

NOTE 2. When the mortar grout has set, screw the base plate tight
Material damage due to distortion of the base plate! at three points with the appropriate torque.
Place the base plate on the foundation and fasten it as 3. Before tightening the remaining bolts, compensate for any
described below. unevenness in the surface using metal spacing shims next
to each bolt.
5.2.1 Setting the pump unit on the foundation 4. Fill the inside of the base plate with concrete, if intended.
Knock on the base plate to ensure that no cavities are cre-
Resources, tools and materials:
ated in the process.
Foundation bolts
Steel washers
Non-shrinking mortar grout
Spirit level
1. Lift the pump unit ( additional instructions for the pump
unit/ pump system) and ( 4.1 Transport, Page 14).
2. Attach the foundation bolts from below into the base plate
fixing holes.

Observe the manufacturers instructions when using adhe-

sive anchors.

3. Set the pump unit down on the foundation. When doing

so, sink the foundation bolts into the prepared anchoring
holes.

2 1 2 3

Fig. 9 Setup with foundation (schematic diagram)

4. Use steel washers to align the pump unit to the height and
system dimensions as described below:
Place a steel washer (2) to the left and right-hand side
of each foundation bolt (1).
If the distance between the anchoring holes is greater
than 750 mm, place additional steel washers (3) in the
middle, on each side of the base plate.
5. Make sure the steel washers lie flat against the base plate,
in full contact.
6. Use an integrated spirit level (laser alignment device) to
check end to end and side to side:
Permissible height deviation ( dimension drawings,
additional instructions for the pump system).
7. Repeat the procedure until the base plate is correctly
aligned.

1000 98 118en BA-2009.12 W/V Series 19

Setup and connection

5.3 Installing the motor and coupling 5.4 Planning the pipes
Only necessary if the pump unit is assembled on site. The parallel operation of pumps is only permitted with the
express consent of the manufacturer.

If the pump is delivered without base plate, provide a base
plate which securely prevents torsion and impermissible
vibrations during operation. Compensate the height for the
drive.
As a standard, the pump-side coupling half is already
installed with a transition fit.
NOTE
Material damage due to installation errors!
Keep the coupling halves properly aligned when slipping
them on.
Do not knock or hit any components of the pump or motor.
Do not shrink the coupling halves by heating them.
5.3.1 Installing the coupling
Consult the manufacturer for couplings with press fits.
5.4.1 Specifying supports and flange connections
NOTE
Material damage due to excessive forces and torques
exerted by the piping on the pump!
Do not exceed the permissible limits ( dimension draw-
ings).
If present: observe the manufacturers specifications for
the auxiliary systems.
1. Calculate the pipe forces, taking every possible operating
condition into account:
Cold/warm
Empty/full
Depressurized/pressurized
Positional changes of the flanges
2. Ensure the pipe supports have permanent low-friction
properties and do not seize up due to corrosion.
3. Provide suction-side and pressure-side bleeding.

1. For detailed information and special couplings, observe the 5.4.2 Specifying nominal diameters
manufacturers specifications. Keep the flow resistance in the pipes as low as possible.
2. Make sure both coupling halves have the same diameter.
3. Smear molybdenum disulfide (e.g. Molykote) on the shaft
end of the motor. 1. Observe the suction, pressure and auxiliary pipe dimen-
sions ( dimension drawing).
4. Insert the shaft key.
2. Make sure the nominal suction pipe diameter is not smaller
5. Slide on the motor-side coupling half until the shaft end is
than the nominal suction flange diameter.
flush with the coupling hub.
3. Make sure the nominal pressure pipe diameter is not
6. If present, tighten the grub screws on both coupling halves.
smaller than the nominal outlet flange diameter.
Observe the tightening torques ( manufacturers specifi-
cations).

5.3.2 Setting up the motor

Resources, tools and materials:
Metal spacing shims
1. Lift the motor ( manufacturers specifications).
2. Place the motor on the base plate.
3. Connect the coupling halves. Keep the prescribed gap
between the coupling halves ( dimension drawings).
4. Use suitable metal shims on the motor to align the end of
the motor shaft to the end of the pump shaft.
5. Screw in the motor bolts, but do not tighten them yet
( 5.7.2 Aligning the motor, Page 25).

20 W/V Series BA-2009.12 1000 98 118en

 Setup and connection

5.4.3 Specifying pipe lengths 5.4.5 Avoiding excessive pressure

WARNING
Risk of injury due to excessive pressure!
If there is no overpressure safety valve in the pump: Pro-
vide appropriate safety equipment (e.g. blow-out disk) in
the pressure pipe.

1. Observe the manufacturers specifications.

2. Make sure the factory setting of the safety equipment
A meets the requirements of the system.
3. Always feed the return flow of the safety equipment in the
safe (depressurized) area.

B 5.4.6 Providing safety and control devices

Avoid impurities
We recommend also using a filter in the suction pipe during
operation.

1. Provide a filter in the suction pipe according to the following

table:

Fig. 10 Straight pipe lengths upstream and downstream Operating Pump size Mesh size [mm]
of the pump (recommended) phase
A > 5 x DN Start-up phase All 1
B > 5 x DN during the initial
start-up, after
Maintain the recommended minimum values when maintenance
installing the pump. work etc.

Suction side: shorter pipes are possible but may restrict During operation Up to 5 2
the hydraulic performance. 6, 7 4
Pressure side: shorter pipes are possible but can result in
7T, 8 6
increased operating noise.
9, 10 8
5.4.4 Optimizing changes in Tab. 6 Filter for suction pipe mesh size per
cross-section and direction operating phase

1. Avoid abrupt changes of cross-section and direction along
the piping.
2. If several pumps are operated simultaneously and
gas-loaded pumped liquid is pumped:
Ensure the same pressure conditions for each pump
by laying the lines symmetrically.
Same cross sections and line lengths from the joint
supply line up to the pumps.
3. Make sure no cavitation can occur.
2. Provide differential pressure monitoring equipment to mon-
itor impurities:
Observe the permissible differential pressure of the fil-
ter ( manufacturers specifications)
Avoiding reverse running
1. Install relevant safety equipment (non-return valve) to
ensure the medium does not flow back when the pump is
switched off.
2. Distance from outlet flange to non-return valve < 2 m.

Avoid drainage
Route suction/pressure pipes and auxiliary pipes so that
the pump, blocking system and pipes will not drain when
the pump is not running.

1000 98 118en BA-2009.12 W/V Series 21

Setup and connection

Making provisions for isolating and shutting off pipes 5.5 Connecting the pipes
For maintenance and repair work, provide pipe connec-
Connections for suction, pressure, drainage and auxiliary
tions for flushing, bleeding, draining and inerting all rele- pipes ( dimension drawing).
vant pipe areas (customer installation).

1. Select shut-off devices that can be secured against acci-

dental opening.
2. Provide shut-off devices in the suction and pressure pipes.
3. Provide shut-off plates in the suction and pressure pipes.
Allowing measurement of the operating conditions
1. Provide pressure monitoring equipment in the suction and
pressure pipes.
As close as possible to the pump, while observing the
limit values ( pump data sheet) 5.5.1
2. Provide for pump-side temperature measurements.
5.4.7 Making it possible to drain the pump
Have a sufficiently large oil receptacle possible.
NOTE
Damage to pump, hoses or fittings during pressure tests
and flushing!
Do not subject the pump, hoses or fittings to impermissible
pressure when testing pressure or flushing.
If necessary, disconnect the pump, hoses and fittings from
the system beforehand.
Keeping the piping clean
NOTE
Material damage due to impurities in the pump!
Make sure no impurities can enter the pump.

1. Clean all piping parts and valves prior to assembly.

2. Ensure no flange seals protrude inwards.
3. Remove any blank flanges, plugs, protective foils and/or
protective paint from the flanges.

5.5.2 Installing auxiliary piping

Observe the manufacturers specifications for any auxiliary
operating systems which are present ( manufacturers
specifications, additional instructions for the sealing sys-
tem).

1. Install the auxiliary piping stress-free and sealed.

2. To avoid air pockets: run the pipes with a continuous
upward or downward slope to the pump.

5.5.3 Installing the suction pipe

1. Remove the transport plugs from the pump.
2. Install the suction pipe.
3. Make sure the flange seals do not protrude.
4. Fit the connection for filling the pump.
Make sure the connection size corresponds to the viscosity
of the pumped liquid.

5.5.4 Installing the pressure pipe

1. Remove the transport plugs from the pump.
2. Install the pressure pipe.
3. Make sure the flange seals do not protrude inwards.
4. If there is no overpressure safety valve in the system: Pro-
vide suitable absolute pressure limiters in the system.

5.5.5 Installing the heating pipe (optional)

1. Remove the transport plugs from the pump.
2. Install the fittings.
3. Install the heating pipe.
4. Make sure the flange seals do not protrude inwards.

22 W/V Series BA-2009.12 1000 98 118en

 Setup and connection

5.5.6 Checking the stress-free pipe connections 5.6 Electrical connection

Piping installed and cooled down
5.6.1 Connecting the motor
1. Disconnect the pipe connecting flanges from the pump.
2. Check whether the pipes can be moved freely in all direc- DANGER
tions within the expected range of expansion:
Nominal diameter < 150 mm: by hand Risk of death due to electric shock!
Nominal diameter > 150 mm: with a small lever Have all electrical work carried out by qualified electricians
3. Make sure the flange surfaces are parallel. only.
4. Reconnect the pipe connecting flanges to the pump. Isolate the motor from its supply voltage and secure it
5. Make sure the flange seals do not protrude. against being switched back on again prior to any work on
the electrical system.

1. Connect the motor according to the connection diagram.

2. Provide appropriate cable ducts.
3. Make sure no danger arises due to electric power.
4. Install an EMERGENCY STOP switch.

5.6.2 Checking the sense of rotation

If present, check the sense of rotation with a rotary field
measuring device.

DANGER
Risk of death due to rotating parts!
Use personal protective equipment when carrying out any
work on the pump.
Secure the shaft key from being thrown out when checking
the sense of rotation.
Keep an adequate distance to rotating parts.

NOTE
Material damage caused by dry running or incorrect sense
of rotation!
Uncouple the motor from the pump.

1. Switch the motor on and immediately off again.

2. Check whether the motors sense of rotation is the same
as that of the arrow on the pump.
3. If the sense of rotation is different:
Swap two phases ( 5.6.1 Connecting the motor,
Page 23).
4. Couple the motor to the pump again.

5.6.3 Connecting the instruments

Instrument connection ( additional instructions for the
pump system, system documentation).

1000 98 118en BA-2009.12 W/V Series 23

Setup and connection

5.7 Aligning the pump unit 2. Check the light gap towards the outer diameter using a
straightedge (1):
5.7.1 Checking the alignment of the coupling Position the straightedge across both halves of the
coupling.
Permissible deviations and dimensions ( manufacturers
Align the motor if there is a visible gap on the outer
specifications).
diameter ( 5.7.2 Aligning the motor, Page 25).
Check the alignment of the couplings ( manufacturers 3. Measure the gap with a feeler gauge (2):
specifications). Permissible gap ( dimension drawings)
Use the feeler gauge to measure the gap (A) between
the coupling halves.
NOTE Align the motor if the gap is too wide ( 5.7.2 Aligning
the motor, Page 25).
Material damage due to incorrect alignment of the cou-
pling!
Align the motor exactly to the pump if there is any vertical,
lateral or angular misalignment.
For detailed information and special couplings ( manu-
facturers specifications).

Checking the alignment of the coupling

Resources, tools and materials:
Feeler gauge
Straightedge
Dial gauge (for couplings with spacer piece)
Other suitable tools, e.g. laser alignment instrument
Manufacturers specifications
Fig. 12 Checking for lateral and vertical misalignment

DANGER
Risk of death due to rotating parts!
Isolate the motor from its supply voltage and secure it
against being switched back on again before all assembly
and maintenance work.
4. Check for any lateral or vertical misalignment using the dial
gauge:
Carry out the measurement as illustrated.
Align the motor if there is any lateral or vertical mis-
alignment ( 5.7.2 Aligning the motor, Page 25).
Permissible axial or radial deviation, measured on the
coupling front or circumference: ( manufacturers
specifications)

Fig. 13 Checking for angular displacement

5. Check the angular displacement with a dial gauge:
Carry out the measurement as illustrated.
2 If there is any angular displacement: align the motor
( 5.7.2 Aligning the motor, Page 25).

Fig. 11 Checking the alignment of the coupling

1. Measure in two planes at an angle of 90 on the circumfer-
ence of the coupling.

24 W/V Series BA-2009.12 1000 98 118en

 Setup and connection

5.7.2 Aligning the motor

Only necessary if the gap width or lateral, height or angular
misalignment is too small or large.

1. Align the motor so that the coupling halves are exactly in

line and fit shims if necessary.
2. Check the alignment.
3. Repeat the alignment procedure if there is still any vertical
misalignment.
4. Then tighten the motor bolts.

5.8 Installing the coupling guard

1. If the coupling guard is not pre-assembled upon delivery:
Install the coupling guard.
Adjust the coupling guard to the distance between the
motor and pump.
To do so, move the sliding piece in the outer part of the
coupling guard.
Screw the outer part and sliding piece together.
2. If a protective cover is used:
Make sure there is enough space between the protec-
tive cover and pump/motor for ventilation of the unit.

1000 98 118en BA-2009.12 W/V Series 25

Operation

6 Operation
For pumps in explosion-hazard areas ( ATEX additional
instructions).
For pumps as part of a pump unit or pump system ( addi-
tional instructions for the pump unit / pump system).
6.1.7 Preparing auxiliary systems (if available)
The manufacturer does not accept any liability for damage
caused by installing or using a third-party or unapproved
auxiliary system.

Sealing system
6.1 Putting the pump into service 1. Make sure the sealing medium is compatible with the
for the first time pumped liquid.
2. Identify the sealing system ( pump data sheet).
Ensure that all work is carried out by specialist technicians 3. Install the sealing system ( manufacturers specifi-
only: cations, additional instructions for the sealing system,
Installation, initial start-up, repairs, maintenance additional instructions for the pump system).
Work on the electrical and electronic equipment 4. Make sure the parameters required for the installed seal-
ing system are met ( pump data sheet, manufacturers
6.1.1 Identifying the pump type specifications).
Identify the pump type ( pump data sheet).
Overpressure safety valve
The pump versions vary e.g. with regard to the bearing Overpressure safety valves supplied by the manufacturer
lubrication, type of shaft seal and auxiliary operating sys- are pre-set.
tems.
Make sure the overpressure safety valve on the system
6.1.2 Checking the stuffing box packing (if present)
side meets the requirements of the pump.
Only necessary if the gland packings are not pre-assem-
bled. Heating/cooling of the casing (optional)
The top height of the top shaft may be changed through
Fit the stuffing box packings ( Installing shaft seals and
heating. In this case, the pump unit must be realigned
putting them into service).
( 5.7 Aligning the pump unit, Page 24).
6.1.3 Checking the shutdown period
1. Lay down the connections and install heating/cooling prop-
After downtimes > 1 year ( additional instructions for erly ( manufacturers specifications).
transport, storage and preservation).
2. Check the technical data of the heating/cooling medium
6.1.4 Removing the preservative ( order data sheet).
3. Bleed the heating/cooling.
Only necessary for pumps treated for storage.
4. For heating/cooling, ensure:
Required parameters ( system documentation,
Remove the preservative ( 4.4 Removing the preserva- pump data sheet, dimension drawings)
tive, Page 17). Difference in temperature between the heating medium
and pumped liquid < 50 C
6.1.5 Lubricating the bearing/gear box Switch on the pump heating at least 2 hours before
putting the pump into service.
Pumps with drive-side, grease-lubricated antifriction bear-
ings are ready for operation upon delivery. Recirculating oil lubrication
Pumps in Vshape are not pre-filled with oil upon delivery. 1. Identify the recirculating oil lubrication system
( pump data sheet).
Fill them with lubricating oil ( 7.2.2 Lubrication,
2. Install the recirculating oil lubrication system
Page 34).
( manufacturers specifications, additional instructions
for the oil supply unit, additional instructions for the pump
6.1.6 Installing the stuffing box packing
system).
This is only necessary when the stuffing box packing is not 3. Make sure the required operating parameters are met
already installed. ( manufacturers specifications, additional instructions
for the oil supply unit).
Install the stuffing box packing ( pump data sheet, addi-
tional instructions for the sealing system).

26 W/V Series BA-2009.12 1000 98 118en


6.1.8 Filling and bleeding
For flammable or explosive pumped liquids ( ATEX addi-
tional instructions).
Pump set up and connected properly
All connections stress-free and sealed
Suction-side and pressure-side valves closed
Drainage fittings closed
WARNING
Risk of injury and poisoning due to hazardous pumped
liquids!
Safely collect any leaking pumped liquid and dispose of it
in accordance with environmental rules and requirements.
NOTE
Material damage caused by dry running!
Make sure the pump is filled properly.
1. Open the suction-side valve completely.
2. Open the pressure-side valve completely.
3. Fill the pump and suction pipe with pumped liquid until
pumped liquid escapes without bubbles.
4. Ensure that no pipe connections are leaking.
1000 98 118en
Operation
6.1.9 Switching on
Pump set up and connected properly
Motor set up and connected properly
Motor exactly aligned with the pump
All connections stress-free and sealed
All safety equipment installed and tested for functionality
Pump prepared, filled and bled properly
If present: heating/cooling and pumped liquid at operating
temperature ( pump data sheet)
Auxiliary operating systems ready for operation and
switched on
DANGER
Risk of injury due to running pump!
Do not touch the running pump.
Do not carry out any work on the running pump.
DANGER
Risk of injury and poisoning due to pumped liquid spray-
ing out!
Use personal protective equipment when carrying out any
work on the pump.
NOTE
Bearing damage caused by overheating!
Open the leak drain if available.
Keep the cooling ribs clear.
Protect the pump against direct sunlight.
NOTE
Material damage caused by dry running!
Make sure the pump is filled properly.
NOTE
Risk of cavitation when throttling down the medium flow
rate!
Fully open the suction-side valve and do not use it to adjust
the flow rate.
Check the filter for contamination on a regular basis.
Maintain the viscosity of the pumped liquid in the specified
area ( pump data sheet).
NOTE
Material damage due to excessive pressure!
Do not operate the pump while the pressure-side valve is
closed.
BA-2009.12 W/V Series 27
Operation

1. Make sure the pumped liquid is at operating temperature 6.2 Operation

( pump data sheet).
2. Open the pressure-side valve completely. 6.2.1 Preparing operation
3. Open the suction-side valve completely. If necessary, carry out the following steps:
4. Switch on the motor and make sure it is running smoothly. With heating, switch on the pump heating at least
5. Make sure any temperature changes at pumps with hot two hours before putting the pump into service.
pumped liquids are below 2 K/min. Prepare the auxiliary operating systems
( 6.1.7 Preparing auxiliary systems (if avail-
6. After the first load under pressure and at operating temper-
able), Page 26).
ature, check that the pump is not leaking.
Fill and bleed the pump ( 6.1.8 Filling and bleeding,
7. Set a slight leak (drop) at the stuffing box packing if present. Page 27).
Make sure the pumped liquid is at operating tempera-
6.1.10 Switching off ture ( pump data sheet).

WARNING 6.2.2 Switching on

Risk of injury due to hot pump parts! Pump initially put into service properly
Use personal protective equipment when carrying out any Operation prepared properly
work on the pump.

1. Switch off the motor. Maintain the following functions if DANGER

present:
Supply of cold water until the operating temperature of Risk of injury due to running pump!
the pump is below 100 C Do not touch the running pump.
Sealing system Do not carry out any work on the running pump.
2. Close the suction-side and pressure-side valves. If possible: allow the pump to cool down before commenc-
3. If present and permitted for the process: switch off heating. ing work.
The pumped liquid must not solidify
4. Check the coupling alignment at operating temperature
and realign the motor if necessary ( 5.7.1 Checking the DANGER
alignment of the coupling, Page 24). Risk of injury and poisoning due to pumped liquid spray-
5. Check all tie bolts and tighten them if necessary. ing out!
Use personal protective equipment when carrying out any
work on the pump.

NOTE
Bearing damage caused by overheating!
Open the leak drain if available.

NOTE
Material damage due to cavitation when throttling down
the suction flow rate!
Fully open the suction-side valve and do not use it to adjust
the flow rate.

NOTE
Material damage caused by dry running!
Make sure the pump is filled properly.

NOTE
Material damage due to excessive pressure!
Do not operate the pump while the pressure-side valve is
closed.

28 W/V Series BA-2009.12 1000 98 118en

 Operation

1. Open the pressure-side valve completely. Pump is Measure

2. Open the suction-side valve completely.
...shut down Take measures according to
3. Switch on the motor and make sure it is running smoothly. for a prolonged the pumped liquid ( Table
4. Make sure any temperature changes at pumps with hot period 8 Measures depending on the
pumped liquids are below 2 K/min. behavior of the pumped liquid,
5. Set a slight leak (drop) at the stuffing box packing if present. Page 29).
Secure the pump against
6.2.3 Switching off accidental pressurization.
...emptied Close the suction-side and
NOTE pressure-side valves.
Material damage caused by voltage peaks! ...dismounted Provide shut-off plates in the
Only switch off the unit with the emergency-stop switch in suction and pressure pipes.
an emergency! Disconnect the electrical
connections and secure the
1. Switch off the motor. Maintain the following functions if motor against being switched on
present: again.
Supply of cold water until the operating temperature of
the pump is below 100 C ...put into Follow the storage instructions
Sealing system storage ( 4.3 Storage, Page 16).
2. Close the suction-side and pressure-side valves. Tab. 7 Measures to be taken if the pump is shut down
3. If present and permitted for the process: switch off heating.
The pumped liquid must not solidify Behavior of the Duration of shutdown
pumped liquid (depending on process)

6.3 Shutting down the pump Short Long

Solids Flush the Flush the
WARNING sedimenting pump. pump.

Risk of injury and poisoning due to hazardous pumped Solidifying/ Heat up Empty
liquids! freezing, or empty the pump,
non-corrosive the pump, containers
Use personal protective equipment when carrying out any
containers and pipes.
work on the pump.
and pipes.
Safely collect any leaking pumped liquid and dispose of it
in accordance with environmental rules and requirements. Solidifying/ Heat up Empty
freezing, or empty the pump,
Neutralize residues of pumped liquid in the pump.
corrosive the pump, containers
When disposing of the pump ( 4.5 Disposal, Page 17). containers and pipes.
and pipes. Apply
1. Take the following measures whenever the pump is shut
preservative
down:
to the pump,
containers
and pipes.
Remains liquid,
non-corrosive
Remains liquid, Empty
corrosive the pump,
containers
and pipes.
Apply
preservative
to the pump,
containers
and pipes.
Tab. 8 Measures depending on the behavior
of the pumped liquid

2. For further measures ( manufacturers specifications).

1000 98 118en BA-2009.12 W/V Series 29

Operation

6.4 Start-up following a shutdown period

1. Observe the manufacturers specifications ( additional
instructions for transport, storage and treatment, storage
and treatment).
2. Carry out all steps as for the initial start-up ( 6.1 Putting
the pump into service for the first time, Page 26).

6.5 Operating the stand-by pump

The parallel operation of pumps is only permitted with the
express consent of the manufacturer.
Operate the pump and stand-by pump alternately.

Stand-by pump filled and bled

Operate the stand-by pump at least once a week.

30 W/V Series BA-2009.12 1000 98 118en


7 Maintenance
For pumps in explosion-hazard areas ( ATEX additional
instructions).
Trained service technicians are available for fitting and
repair work. When requesting service, present a pumped
medium certificate DIN safety data sheet or document of
compliance ( 9.7 Document of compliance, Page 42).
Ensure that all work is carried out by specialist technicians
only:
Installation, initial start-up, repairs, maintenance
Work on the electrical and electronic equipment
7.1 Inspections
The inspection intervals depend on the operational strain
on the pump.
Automatic monitoring functions ( system documenta-
tion).
DANGER
Risk of injury due to running pump!
Do not touch the running pump.
Do not carry out any work on the running pump.
WARNING
Risk of injury and poisoning due to hazardous pumped
liquids!
Use personal protective equipment when carrying out any
work on the pump.
1. Check at appropriate intervals:
Temperature of antifriction bearings with metal cage
(alarm at 100 C, shutdown at 120 C)
Normal operating conditions unchanged
Coupling alignment and condition of elastic parts
Check the functionality of the safety equipment
( manufacturers specifications)
If present, make sure the blow-out disk is intact
( manufacturers specifications)
2. For trouble-free operation, always ensure the following:
No dry running
No leaks
No cavitation
Suction-side valves open
Pressure-side valves open
Unclogged and clean filters
Sufficient suction pressure
No unusual running noises or vibrations
No excessive leakage at the shaft seal
Check function of the auxiliary operating systems
1000 98 118en
Maintenance
7.2 Maintenance
Mechanical seals have functional leaks ( manufacturers
specifications).
Mechanical seals are subject to natural wear, which
strongly depends on the respective operating conditions.
Therefore, general statements regarding their service life
cannot be made.
The stuffing box packing must always leak (drop) slightly
to carry the frictional heat away.
Larger leaks in the initial hours of operation lessen during
the running-in period.
Maintenance intervals are reduced for more difficult oper-
ating conditions (e.g. switching on and off constantly, high
temperatures, low viscosities, aggressive ambient and
process conditions).
DANGER
Risk of death due to electric shock!
Have all electrical work carried out by qualified electricians
only.
DANGER
Risk of injury due to running pump!
Do not touch the running pump.
Do not carry out any work on the running pump.
Isolate the motor from its supply voltage and secure it
against being switched back on again before all assembly
and maintenance work.
Secure the pump against pressurization before all assem-
bly and maintenance work.
DANGER
Risk of death due to rotating parts!
Make sure the coupling guard is fitted after working on the
pump.
WARNING
Risk of injury and poisoning due to hazardous or hot
pumped liquids!
Use personal protective equipment when carrying out any
work on the pump.
Allow the pump to cool down before commencing work.
Make sure the pump is depressurized.
Empty the pump, flush (when necessary) and safely collect
the pumped liquid before disposing of it in accordance with
environmental regulations.
BA-2009.12 W/V Series 31
Maintenance

7.2.1 Maintenance table

Perform the maintenance work as specified in the following
table unless required otherwise by the operating mode.

Interval Sub-assembly (if Who2) Measure

present)
Hourly during the Blocking pressure B Check the filter and vent valve for dirt.1)
start-up phase system Check the blocking medium level.1)
Daily Stuffing box packing B Check the grease lubrication and top up the grease via
the grease nipple if necessary.
Weekly Gear box housing/ B Check the oil level.
bearing housing F Refill/change if necessary ( 7.2.2 Lubrication,
Page 34).
Mechanical seal B Check for leaks.
F In the event of major leaks:
Determine the leak intensity by counting the drops.
Consult the manufacturer.
Replace the bearing rings or elastomer parts
( 7.4 Repairing the pump, Page 35).
Stuffing box packing B If there is increased leakage: Gently tighten the
hexagon nuts on the stuffing box flange. 3)
F If there is a constant leak:
replace the stuffing box packing:
( 7.4 Repairing the pump, Page 35).
( manufacturers specifications)
Shaft seal rings B Check for leaks.
F In the event of major leaks:
Determine the leak intensity by counting the drops.
Consult the manufacturer.
Replace the shaft seal rings ( 7.4 Repairing the
pump, Page 35).
Drive unit F 1)
Check for wear.
Blocking pressure F Check the function.1)
system F Clean the filter and vent valve.1)
F
Top up the blocking medium if necessary.1)
F
If the blocking liquid is dirty:
Check the mechanical seal.
Heater F Check the function.1)
F Check for leaks.1)
Recirculating oil F Check the function.1)
lubrication F Check for leaks.1)
After the first Antifriction bearings F Refill/change if necessary ( 7.2.2 Lubrication,
250 operating hours, with oil lubrication Page 34).
at the latest after
3 months

32 W/V Series BA-2009.12 1000 98 118en

 Maintenance

Interval Sub-assembly (if Who2) Measure

present)
800 operating hours Antifriction bearings B Top up the grease via the grease nipple.
lubricated with grease
every 3000 operating Antifriction bearings F Refill/change if necessary ( 7.2.2 Lubrication,
hours, after 6 months with oil lubrication Page 34).
at the latest
Yearly Gear box housing/ F Replace the air release filter.
bearing housing
Tab. 9 Maintenance intervals and measures
1) ( manufacturers specifications, system documentation)
2) B = operator, F = expert
3) ( manufacturers specifications)

1000 98 118en BA-2009.12 W/V Series 33

Maintenance

7.2.2 Lubrication 7.3 Removing and installing the pump

Observe the order-specific documentation ( system doc-
Any warranty claims are rendered void if the pump is
umentation). opened by the customer during the warranty period.
If in doubt, the lubrication quantities specified there apply.

DANGER
NOTE
Risk of injury due to running pump!
Material damage due to incorrect lubrication! Do not touch the running pump.
Make sure the lubricant type is correct Do not carry out any work on the running pump.
( 9.3 Lubricants, Page 39).
Isolate the motor from its supply voltage and secure it
Make sure the lubricant quantity is correct against being switched back on again before all assembly
( 9.3 Lubricants, Page 39). and maintenance work.
Secure the pump against pressurization before all assem-
Changing the lubricating oil bly and maintenance work.
Change the lubricating oil

DANGER
1. Unscrew the oil drain and drain the lubricating oil, at oper- Risk of death due to electric shock!
ating temperature, into a suitable container.
Have all electrical work carried out by qualified electricians
2. Close the oil drain and refill with lubricating oil. only.

Topping up lubricating oil

Change the lubricating oil ( 9.2 Lubrication points, WARNING
Page 38). Risk of injury and poisoning due to hazardous or hot
pumped liquids!
Use personal protective equipment when carrying out any
work on the pump.
Empty the pump, safely collect the pumped liquid and dis-
pose of it in accordance with environmental regulations.
1 Allow the pump to cool down before commencing any work.
Make sure the pump is depressurized.
2
7.3.1 Removing the pump
Pump depressurized
Pump completely empty, flushed and decontaminated
Electrical connections disconnected and motor secured
against being switched on again
Pump cooled down
Fig. 14 Oil level eyelet on the gear box housing Coupling guard dismounted
or bearing housing On couplings with spacer piece: spacer piece removed
1 Maximum oil level Remove the pump from the system.
2 Minimum oil level

1. Open the oil filler plug.

2. Fill the gear box housing/bearing housing with lubricating
oil until the oil level in the oil level eyelet is within the spec-
ified range.
3. Screw in the oil filler plug with seal ring.
4. Check the oil level at the oil level eyelet and change it if
necessary.

34 W/V Series BA-2009.12 1000 98 118en

 Maintenance

7.3.2 Returning the pump to the manufacturer 7.4 Repairing the pump
Repair work is only carried out if the document of com-
Trained service technicians are available for fitting and
pliance is presented ( 9.7 Document of compliance,
repair work. When requesting service, present a pumped
Page 42).
medium certificate DIN safety data sheet or document of
compliance ( 9.7 Document of compliance, Page 42).
Pump removed
Repair instructions can be ordered with spare parts if car-
Pump cooled down rying out the repair work yourself.
Pump cleaned
All flanges and bores closed
1. Enclose a truthfully and fully completed safety certificate DANGER
when returning pumps or components to the manufacturer
( 9.7 Document of compliance, Page 42). Risk of injury due to running pump!
2. Take necessary measures, depending on the required Do not touch the running pump.
repair work, as listed in the table below when returning the Do not carry out any work on the running pump.
pump to the manufacturer. Isolate the motor from its supply voltage and secure it
against being switched back on again before all assembly
Repairs Measure for return and maintenance work.
...at the Flush the pump and
7.4.1 Ordering spare parts
manufacturers decontaminate it if it was
premises used for hazardous pumped 1. Have the following information ready to hand when order-
liquids. ing spare parts ( 3.1.1 Type plate, Page 10).
Return the complete pump Short designation of the pump
(not disassembled) to the Order number
manufacturer. Machine number / serial number
Submit the following details: Item number of the part ( spare parts lists) or TAG
Repair reason number ( manufacturers equipment list)
Operating conditions Designation
Quantity
With warranty Flush the pump and
2. Submit the required bearing play when ordering antifriction
claim at the decontaminate it if it was
bearings (do not use standard bearings):
manufacturers used for hazardous pumped
premises liquids.
Antifriction bearing Bearing play
Return the complete pump
(not disassembled) to the Groove ball bearing C3
manufacturer.
Cylindrical roller bearing C3
Submit the following details:
Information on the Angular ball bearing C4
course of events which
Four-point bearing normal
caused the damage
Operating conditions Tab. 11 Antifriction bearings required bearing play
Tab. 10 Measures for return

1000 98 118en BA-2009.12 W/V Series 35

Troubleshooting

8 Troubleshooting
If malfunctions occur which are not specified in the following
table or cannot be traced back to the specified causes, please
consult the manufacturer.
Possible malfunctions are identified by a number in the follow-
ing table. This number identifies the respective cause and rem-
edy in the troubleshooting list.

Malfunction Number
Pump not pumping 1
Pumping rate insufficient 2
Pumping rate excessive 3
Pump running roughly or very loud 4
Pump jammed 5
Pump leaking 6
Excessive motor power uptake 7
Tab. 12 Malfunction/number assignment

Malfunction number Cause Remedy

1 2 3 4 5 6 7
X X Excess play between: Repair or replace any worn parts.
Consult the manufacturer.
Conveyor screws
Conveyor screws and housing
X X Supply/suction pipe closed by valve Open the valve completely.
X X Pump not filled completely Fill pump completely ( 6.1.8 Filling and
bleeding, Page 27).
X X X Motor speed too low Increase the motor speed if speed control
is available.
X X X Supply/suction pipe, pump or filter blocked Clean the supply/suction pipe, pump or
or encrusted filter.
Check the mesh size of the filter and
change it, if necessary, after consulting the
manufacturer.
X X Uncontrolled opening of the safety valve Check the safety valve setting and adjust
it if necessary.
X X X Pump running in the wrong sense of rotation Check the drives sense of rotation and
correct if necessary ( 5.6.2 Checking the
sense of rotation, Page 23).
X X X X Pump very dirty Consult the manufacturer.
X X X X Pressure pipe blocked Clean the pressure pipe.
X X X X X X Tie bolts not tightened properly Tighten the tie bolts.
X X X X X X X The viscosity or temperature of Consult the manufacturer.
the pumped liquid is outside the
range specified for the pump
( pump data sheet)

36 W/V Series BA-2009.12 1000 98 118en

 Troubleshooting

Malfunction number Cause Remedy

1 2 3 4 5 6 7
X X Suction/pressure pipe cross-section too Increase the cross-section.
narrow Remove any encrustations from the
suction or pressure pipes.
X X Pumped liquid temperature too high: pump Lower the temperature.
is cavitating Adjust the speed.
Consult the manufacturer.
X X X Pressure-side valve not opened wide enough Open the pressure-side valve completely.
X X X Motor speed too high Reduce the motor speed if speed control
is available.
X Pump leaks Consult the manufacturer.
X Coupling elements worn Replace the coupling elements, check
Coupling not aligned properly the coupling alignment and correct
if necessary ( 5.7.1 Checking the
alignment of the coupling, Page 24).
X Insufficient oil in the gear box housing Fill with oil ( 7.2.2 Lubrication, Page 34).
X Insufficient oil in the bearing housing Fill with oil ( 7.2.2 Lubrication, Page 34).
X X Pipes distorted Check the pipes.
Connect the pipes without tension.
X X X Expansion of the inner pump parts due to Wait for the temperature equalization.
excess temperature
X X X Antifriction bearings/cogwheels defective Consult the manufacturer.1)
X X X Pump distorted Check the pipe connections and supports
and the pump attachment.
Check the coupling alignment.
Check the attachment of the support foot.
Check the foundation.
X X X Defective antifriction bearing in motor Consult the manufacturer.
Tab. 13 Troubleshooting list
1) Return the pump to the manufacturer if necessary

1000 98 118en BA-2009.12 W/V Series 37

Appendix

9 Appendix

9.1 Technical specifications 9.2 Lubrication points

Further technical specifications ( pump data sheet). 9.2.1 Oil/grease lubrication version

9.1.1 Ambient conditions

For operation under other ambient conditions ( pump 10 9
data sheet) or consult the manufacturer. 8

Temperature - max. 40 C, min. -10 C (or pump data

sheet) 7
Max. setup height above sea level of 1000 m
6
9.1.2 Sound pressure level
Measurements were taken in accordance with DIN 45635,
part 1. The emission values were measured under repro-
1 2 3 4 5
ducible conditions in accordance with DIN 45635, part 24.
The measurement is based on a single screw pump. The
specified sound values are approximate values. Fig. 16 Overview of lubrication points, oil/grease
lubrication version
y
100 1 Oil level sight glass
2 Oil drain plug
95 3 Gear box housing
4 Pump casing
90
5 Grease nipple
A
85 6 Bearing cover
7 Top shaft
80
8 Bearing housing
9 Bleeding
75
10 Oil filler plug
70

65

60 x
1 10 100 1000
Fig. 15 Airborne sound level diagram (source: VDI 3743)
x Power consumption [kW]
y Measuring surface airborne sound level LpA [dB]
A Variation

38 W/V Series BA-2009.12 1000 98 118en

 Appendix

9.2.2 Oil/oil lubrication version 9.3 Lubricants

The lubricant used is noted on a material trailer at the
pump.
11 10 9

NOTE
Material damage caused by using incompatible lubricants!
8 Only use one type of lubricant.

9.3.1 Gear oil, temperature of the pumped

liquid 10300 C
7
Manufac- Gear oil
turer
Types of mineral oil
1 2 3 4 5 6
Agip Blasia 150
Fig. 17 Overview of lubrication points, oil/oil Aral Degol BG 150
lubrication version
BP Energol GR-XP 150
1 Oil level sight glass on gear box housing
Elf Reductelf SP 150
2 Gear box housing
3 Oild drain screw on gear box housing Esso Spartan EP 150
4 Pump casing Fina Giran 150
5 Oild drain screw on bearing cap
Finke Aviaticon oil EP 150
6 Bearing cap
7 Oil level sight glass on bearing cap Fuchs Renolin CLP 150 PLUS
8 Top shaft Klber Klberoil GEM 1-150
9 Bearing cap oil filler / bleeding Mobil Mobilgear 629
10 Bleeding
Shell Omala oil 150
11 Oil filler on gear box housing
Total Carter EP 150
Synthetic oil
Finke Aviaticon Finkol PA 1501)
Tab. 14 Lubricants gear oil
1) Synthetic oil based on polyalphaolefin for continuous oper-
ation at temperatures down to 40 C, not mixable with min-
eral oil

1000 98 118en BA-2009.12 W/V Series 39

Appendix

9.3.2 Lubricating grease, temperature of the 9.4 Lubricant quantities

pumped liquid 10150 C

Size Approx. amount of grease [g]

Manufac- Lubricating grease Type of
turer saponification1) Initial fill Refill
Agip GR MU 3 Li 2.... 10 5
3.... 10 5
Aral Aralub HL 3
4.... 15 5
BP Energrease LS 3
5..... 20 5
Elf Epexa 3
6.... 901) 151)
Esso Beacon 3 602)
102)
Fina Marson L 3 7.... 110 15
Finke Aviaticon MZF 3 7T 190 30
Fuchs/DEA Renolit FWA 220 8.... 190 30
Klber Centoplex 3 9.... 180 40
Mobil Mobilux 3 10....
Shell Alvania grease R 3 Tab. 17 Minimum amounts for grease lubrication
Total Multis 1) Top shaft antifriction bearings
Tab. 15 Lubricating grease for pumped liquids at 10150 C 2) Antifriction bearings, driven shafts
1) Li = lithium
Size Oil quantity [l]
9.3.3 Lubricating grease, temperature of the W pump V pump
pumped liquid 150300 C
Gear box Bearing
housing housing
Manufac- 150300 C Type of
2.... 0,25
turer saponification1)
Agip GR NF G 3.... 0,4 1,0 0,3 0,7 0,7
4.... 0,4 0,2 1,0 0,8
Aral Aralub HTR 2 G
5.... 0,6 0,7 0,35 1,55
BP Energrease HTB 2 G
6.... 1,4 2,5 1,1 3,3
Elf Staterma MO 2 G
7.... 2,5 4,1 1,5 2,0 5,0 7,2
Esso Norva 275 G
7T, 4,1 ( Table 7,2
Fina Bentex 3 G oil/grease 17 Minimum
amounts
Finke Finkox AKF 2 Al for grease
Fuchs/DEA Renogel FHT 2 G lubrication,
Page 40).
Klber Petamo GHY443 PHS
7T, oil/oil 4,1 2,0
Mobil Mobiltemp 78 G
8.... 2,5 4,3 1,1 1,5 5,0 9,4
Shell Darina grease 2 G
9.... 11,0 16,0 5,5
Total Caloris 3 G
10.... 29,0 16,0
Tab. 16 Lubricating grease for pumped liquids
at 150300 C Tab. 18 Minimum oil lubrication quantities
1) Al = aluminum complex, G = gel grease, PHS = polyurea

40 W/V Series BA-2009.12 1000 98 118en

 Appendix

9.5 Preservatives

Manufac- Preservatives
turer
Oily Wax-type
Agip Rustia TI 10 W/20
Aral Reselin M 46
BP Energol LX 4
Elf Stockage
Esso Rust Ban 335
Fina Rusan 20
Finke Finkox RSO fluid Finkox RSO
fluid1)
Pharmawhite
W 002)
Fuchs/DEA Renolin MR 15
Klber Contrakor A40K Contrakor HW90
Mobil Mobilarma 524
Shell Ensis motor oil 10 W
Total Osyris HL 2
Valvoline Tectyl 5061)
Tab. 19 Preservatives
1) Contains solvent
2) Compatible with foodstuffs

9.6 Cleaning agents

Application area Cleaning agents

Other Benzine, wax solvents,
diesel, paraffin, alkaline
cleaners
Tab. 20 Cleaning agents

1000 98 118en BA-2009.12 W/V Series 41

Appendix

9.7 Document of compliance

Please copy this document and send it together with the
pump.

All industrial companies are obliged by statutory regulations to protect their employees, other people and the environment from
detrimental effects when handling hazardous substances.
Products and their components are therefore only repaired or inspected if the following declaration is submitted after being
filled out properly and completely and signed by an authorized and qualified specialist technician.
If safety precautions have to be taken by the operating company in spite of the product being completely emptied and cleaned,
the required information must be submitted. This document of compliance is part of the repair or inspection order.

We hereby declare that the returned device

Type: ________________________________________________

Serial no.: ________________________________________________

is free of substances that pose a risk to health. Special safety precautions are not necessary for subsequent
handling.
The pump has been completely emptied and thoroughly cleaned on the outside and inside prior to shipment
and delivery.

Last medium pumped by the pump: ________________________________________

The medium posed a risk to health: YES NO
The pump has been emptied by the operating company: YES NO
The pump has been thoroughly cleaned on the inside and outside by the YES NO
operating company:
The pump came into contact with hazardous substances: YES NO
If so: hazardous substance number according to the Ordinance on ________________________________________
Hazardous Substances
or
CAS registration number (chemical abstract service) ________________________________________

Company/ ________________________________________________
institute:

Street: ________________________________________________

Zip code, city: ________________________________________________

Phone: ________________________________________________

Name: ________________________________________________

Position: ________________________________________________

Date: ________________________________________________

Signature,
company ________________________________________________
stamp:
Tab. 21 Document of compliance

42 W/V Series BA-2009.12 1000 98 118en

 Appendix

9.8 Declarations according to EC

machine directives
9.8.1 Declaration of conformity according to
EC machine directives
The following declaration does not contain serial numbers
or signatures. The original declaration is delivered with the
respective pump.

Declaration of conformity
EC declaration of conformity according to
machine directive, appendix II A
We,
Joh. Heinr. Bornemann GmbH
Postfach 1162, 31676 Obernkirchen
Tel. +49 (0) 5724-390-0, Fax. +49 (0) 5724-390-290
hereby declare that the following machine adheres to the relevant EC directives detailed below:
Serial number
Designation W/V
Year of
manufacture

EC directives:

Machine directive (98/37/EC), valid until 12.28.2009

Machine directive (2006/42/EC), valid from 12.29.2009 onwards
Low-voltage directive (2006/95/EC)
EMC directive (2004/108/EC)

Applicable harmonized norms:

EN ISO 12100-1:2003
EN ISO 12100-2:2003
EN 809

Applicable harmonized norms for operation in explosion-hazard areas:

EN 13463-1
EN 13463-5
Dokumentation

Joh. Heinr. Bornemann GmbH

Postfach 1162
31676 Obernkirchen
Company stamp / signature: Company stamp / signature:

Technical Managing Director Head of Quality

Tab. 22 Declaration of conformity according to EC machine directives

1000 98 118en BA-2009.12 W/V Series 43

Appendix

9.8.2 Declaration of installation according to

EC machine directives
The following declaration is valid from 12.29.2009 onwards
(according to the EC machine directive 2006/42/EC).
The following declaration does not contain serial numbers
or signatures. The original declaration is delivered with the
respective pump.

Declaration of installation
EC declaration of installation according to
machine directive 2006/42/EC appendix II B

We,
Joh. Heinr. Bornemann GmbH
Postfach 1162, 31676 Obernkirchen
Tel. +49 (0) 5724-390-0, Fax. +49 (0) 5724-390-290
hereby declare that commissioning of the following pump is forbidden until it is proved that the machine where the pump is to
be installed adheres to the guidelines set in the directive (2006/42/EC):
Serial number
Designation W/V
Year of
manufacture

Applicable harmonized norms:

EN ISO 12100-1:2003
EN ISO 12100-2:2003
EN 809

Applicable harmonized norms for operation in explosion-hazard areas:

EN 13463-1
EN 13463-5
Dokumentation

Joh. Heinr. Bornemann GmbH

Postfach 1162
31676 Obernkirchen
Company stamp / signature: Company stamp / signature:

Technical Managing Director Head of Quality

Tab. 23 Declaration of installation according to EC machine directives

44 W/V Series BA-2009.12 1000 98 118en

Pumpen und Systemlsungen fr
Industrie, Umwelttechnik und Schiffbau

Pumps and Systems for Industry,

Environmental and Shipbuilding

www.bornemann.com

Durchgngige Kommunikation von der Good communication with our customers is an

Beratung bis zur Wartung prgt das
Bornemann-Qualittskonzept genauso wie
der kompetente Support und der schnelle
Service. Die professionelle Qualitt der
Betreuung wird durch Pumpenfachleute in
der Firmenzentrale und in fast 100
Bornemann-Tochtergesellschaften und
Vertretungen in aller Welt gesichert. Im
Bornemann-Schulungszentrum werden die
Mitarbeiter der Firma und der Vertretungen
regelmig und intensiv geschult, um immer
auf dem aktuellen Wissensstand zu sein.
important feature in Bornemanns Quality
Program, from inital project consultation to
maintenance. Professional support and fast
service are top priorities. Specialists in pumps
and systems located in our company
headquarters and in nearly 100 representatives
and agencies through the world provide
professional quality support on a local level. Our
employees and reprensentatives are trained at
our training center in order to stay current on
new technologies and provide the best support
available to our customers.

USA: Canada: Argentina: China: Singapore:

Bornemann Pumps Inc. Bornemann Inc. Canada Bombas Bornemann Pumps & Bornemann Pumps
P.O. Box 1769 320 441, 5th Avenue, S.W. Bornemann S.R.L. Systems (Tianjin) Co., Ltd. Asia Pte. Ltd.
Matthews, NC 28106 Calgary, Alberta Armenia 2898 Jinbin General Building No. 6 25 Intern. Business Park
USA Canada T2P 2V1 B1605CDP Munro No. 45 Muning Road German Centre, # 04-08
Prov. Buenos Aires TEDA, Tianjin Singapore 609916
Argentina Singapore
Fon:
Fon: +86 22 66297800 Fon:
Fon: Fon:
+1 704 8498636 Fax: +65 6 5616782
+1 403 6680552 +54 11 47568008
Fax: +86 22 25326799 Fax:
Fax: Fax:
+1 704 8498637 Info.cn@bornemann.com +65 6 5616784
+1 403 2624073 +54 11 47565541
Info.usa@bornemann.com Www.bornemann-cn.com Info.sg@bornemann.com
Info.cdn@bornemann.com Info.ar@bornemann.com