Sulzer Pumps Finland Oy Product Specification: General

Sulzer Pumps Finland Oy Description A33-100
Serial Number 100117418

PRODUCT SPECIFICATION Reference no. 219505/000010
Time of delivery/EXW 13.11.2013
Date printed 26.08.2014 Page 1
Customer
Puerto Impala Barrancabermeja S.A. Metron SA
COLOMBIA 45, Dimitriou Rigou str
COLOMBIA GR-19018 MAGOULA
Cust. Order e-mail
Cust. PO line Equipment P-08 A
Country code CO Id
GENERAL
Product design: SI, mm-dimensioned structure Quality requirement: 2006/42/EC
Quality requirement: EN ISO 5199:2002, 9001:2008 Quality requirement: Atex 94/9/EC, Ex II 2 G c T4
Version: Version 14 Material of construction: 41 / J0265 / ASTM A890 3A
Pump type: A, Process Pump Performance tests: ISO 9906 / HI 14.6 Gr 2B
Performance tests: Vibration test, ISO 5199 Performance tests: Bearing temp. test (30 min)
Product category: Pump product Material and NDT tests: Material test EN 10204-2.2
Product scope: Pump Product scope: Drive unit
Product scope: Assembly Product scope: Documents
Structural tests: Hydrost. Pressure Test, 30 min Pump scope: Wet end
Pump scope: Sealing unit Pump scope: Bearing unit
Inside surface treatment: Standard surface treatment Drive unit scope: Drive motor
Outside surface treatment: Standard, Corrosivity C4 [NZ] Assembly scope: Sealing water equipment
Assembly scope: Coupling unit Assembly scope: Baseplate
Classification: B, Pre-engineered
____________________________________________________________________________________________________
PROCESS DATA
Mill: PUERTO IMPALA BARRANCABERMEJA Temperature: 35,0 C
Process: All Other Indust.or Commer.App Viscosity: 1,0 mm2/s
Pumping: NAPHTHA NPSH available: 5,1 m
Units: SI Capacity Q (l/sec): 55,5 l/sec
Pumped liquid: CRUDE OIL, NAPHTHA Head H: 54,0 m
Density: 650,0 kg/m3
____________________________________________________________________________________________________
PUMP
Pump Classification: B, Pre-engineered Seal. unit elastomer material: (94) PTFE, Teflon
Pump size: 33-100 Sealing unit gasket material: (83) Klinger SIL C-4430
Impeller type: Open 1 Shaft seal material: Sealing/Thrust:SiC/SiC-SiC/SiC
Impeller number: 916274 Shaft seal fluid: BF, Barrier sealing fluid
Impeller holes: Balance holes Mechanical seal type: FD27, John Crane, JCS2P
Impeller diameter: 340,0 mm Sealing unit connections: No Temperature measuring C48
Impeller max.diameter: 400,0 mm Sealing unit equipment: 683, Stainless steel guards
Impeller min. diameter: 320,0 mm Su.inside surface treatment: Standard surface treatment
Sideplate cutting grooves: Not included in the delivery Su.outside surface treatment: Standard,1xEP Top coat (prim.
Sulzer Pumps Finland Oy Contact Person Tatu Pykalainen

Agent Sales LBU Order 0000219505
PO Box 66 LBU Position 000010
48601 KOTKA Reference no. 219505/000010
Telephone +358 (0)10 234 3333
Telefax +358 (0)10 234 3331
Customer
Cust. Order e-mail
Country code CO Id
Volute case material: (41) A890 3A Sealing unit color shade: Standard, NCS 1700
Impeller material: (41) A890 3A Adapter size: 33
Sideplate material: (41) A890 3A Support foot size: H 162,5
Flange drilling: ASME B16.5-2009 CLASS 150 Shaft size: Shaft 3, D42
Wet end connections: Yes Wet end drain. C40, bottom Wet end connections: Yes Disharge pipe C27
Wet end connections: No Pressure measuring C36 Wet end connections: No Temperature measuring C48
Bearing lubrication type: Oil splash Wet end o-ring material: (93) FKM, Fluorocarbon
Bearing housing material: Cast Iron We.inside surface treatment: Standard surface treatment
Shaft material: 33 / S0400 / EN1.4460 / SS2324 We.outside surface treatment: Standard,1xEP Top coat (prim.
Bearing unit connections: No Temperature measuring C48 Wet end color shade: Standard, NCS 1700
Bearing unit equipment: 640, Lubrication equipment Sealing unit size: Sealing unit 33
Lubrication eq. installation: Left side, Seen from D-end Shaft size: Shaft 3, D50
Bu.outside surface treatment: Standard,1xEP Top coat (prim. Sealing unit type: MS21, Integrated Double, Open
Bearing unit color shade: Standard, NCS 1700 Case cover material: (41) A890 3A
Pump type designation: A33-100 Case cover cutting grooves: Not included in the delivery
Dimensional drawing of Pump: P12396
____________________________________________________________________________________________________
WET END PERFORMANCE
Operational Point: Standard range Efficiency water: 71,0 %
Variable rotational speed: No Capacity Q: 55,5 l/sec
Pump synchronous speed: 1.800 rpm Head H: 54,0 m
Pump rotational speed: 1.760 rpm NPSH required: 2,1 m
Characteristic curve: K18493 Pump power P: 26,9 kW
Capacity Q water: 55,5 l/sec Rated power P: 26,9 kW
Head H water: 54,0 m Efficiency: 71,0 %
NPSH required water: 2,1 m Motor synchronous speed: 1.800 rpm
Pump power water P: 42,2 kW Motor power: 35,00 kW
Rated power P water: 42,2 kW
____________________________________________________________________________________________________
DRIVE MOTOR
Motor standard: IEC, Standard frame size Motor frequency: 60 Hz
Motor mounting: Foot Motor power kW: 35,00 kW
Motor Supplier: Pump supplier Motor frame material: Cast Iron
Motor manufacturer: ABB Motors Motor type: M3KP, Flameproof "Ex de"

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Customer
Cust. Order e-mail
Country code CO Id
Motor environment: Explosion proof Motor nominal voltage: 480 VD

Motor protection: IP55 Motor IEC code: 200M55
Motor efficiency class: Not definied by standard Motor variable speed: No
Motor synchronous speed: 1.800 rpm Motor special features: 002, Restamping volt. freq.
____________________________________________________________________________________________________
ASSEMBLY
Assembly Classification: B, Pre-engineered Coupling guard material: Aluminum
Drive type: Direct drive Co.guard surface treatment: Standard,1xEP Top coat
Sealing unit size: Sealing unit 33 Co.guard color shade: Standard, NCS 0582-Y09R
Sealing unit type: MS21, Integrated Double, Open Pump mounting size: 34, H280 L370 B400/ 150
Shaft seal fluid: BF, Barrier sealing fluid Motor IEC mounting size: IEC 200M42-55
Sealing water equipment type: 760P2, Sealing water eq. Baseplate type: Type STD
Pump shaft dimension: 42 x 110 mm Baseplate material: Steel
Motor synchronous speed: 1.800 rpm Baseplate equipment: 918, Foundation screw, Grouted
Motor power kW: 35,00 kW Baseplate surface treatment: Hot galvanizing
Motor shaft dimension: 55 x 110 mm Dim. drawing of Assembly: P30543
Coupling type: Elastic type Rex Viva VS
____________________________________________________________________________________________________
DOCUMENTS
Documents Classification: B, Pre-engineered End user language for book: EN, English
Certificates: Hydraulic performance Certificates: Hydrostatic test
Certificates: Vibration Certificates: Bearing temperature
Certificates: Material test (EN 2.2 / EN3.1) Certificates: Outside surface treatment
Remarks
Viscosity 0,31cP

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PART LIST Reference no. 219505/000010
Customer Instructions
D01.31 1 PART LIST, BEARING UNIT N31024EN
D02.01 1 DIMENSIONAL DRAWING, PUMP P12396EN
D02.02 1 DIMENSIONAL DRAWING, DRIVE MOTOR P12465EN
D02.03 1 DIMENSIONAL DRAWING, ASSEMBLY P30543EN
D02.11 1 DIMENSIONAL DRAWING, WET END CONNECTIONS P12447EN
D02.12 1 Dimensional drawing P02184EN
D02.21 1 DIM.DRAW.,SEAL.UNIT CONNECT. P12459EN
D02.31 1 DIM. DRAW., BEARING UNIT CONNECT. P30572EN
D02.61 1 DIMENSIONAL DRAWING, FOUNDATION SCREW P12525EN
D03.11 1 CHARACTERISTIC CURVE K18493EN
D04.01 1 SECTIONAL DRAWING, PUMP N15579EN
D04.03 1 SECTIONAL DRAWING, ASSEMBLY N30766EN
D04.11 1 SECTIONAL DRAWING, WET END N15583EN
D04.21 1 SECTIONAL DRAWING, SEALING UNIT N16117EN
D04.25 1 SECTIONAL DRAWING, GUARDS N30338EN
D04.31 1 SECTIONAL DRAWING, BEARING UNIT N31011EN
D04.32 1 SECTIONAL DRAWING, LUBRICATION EQUIPMENT N31320EN
D04.41 1 SECTIONAL DRAWING, SEALING WATER EQ. N31549EN
D04.51 1 SECTIONAL DRAWING, COUPLING UNIT N31039EN
D04.61 1 SECTIONAL DRAWING, BASEPLATE N30768EN
D04.62 1 SECTIONAL DRAWING, FOUNDATION SCREW N15634EN
D05.00 1 INSTRUCTION, CONTENTS N31566EN
D05.01 1 INSTRUCTION, INTENDED USE N31567EN
D05.02 1 INSTRUCTION, SAFETY INSTRUCTIONS N31568EN
D05.03 1 INSTRUCTION, HOISTING AND TRANSPORT. N31569EN
D05.04 1 INSTRUCTION, COMMISSIONING N31570EN
D05.05 1 INSTRUCTION, INSTALLATION N31571EN
D05.06 1 INSTRUCTION, OPERATION N31572EN
D05.07 1 INSTRUCTION, PREVENTIVE MAINTENANCE N31573EN
D05.08 1 INSTRUCTION, CORRECTIVE MAINTENANCE N31574EN
D05.09 1 INSTRUCTION, SPARE PARTS RECOMM. N31575EN
D05.21 1 INSTRUCTION, SHAFT SEAL C10151EN
D05.43 1 INSTRUCTION, SEALING WATER EQUIPMENT C10150EN
D05.51 1 INSTRUCTION, COUPLING, REX VIVA C10014EN
D05.81 1 ATEX INSTRUCTION, DRIVE MOTOR C10080EN
D06.02 1 QUALITY OF CONFORMITY N15715EN
D07.01 1 MATERIAL CERTIFICATE N15716EN
D07.012 1 Hydrostatic pressure test certificate N05670EN_100117418
D07.014 1 Vibration test report N30186EN_100117418
D07.015 1 Inspection record, Bearing temperature N30238EN_100117418

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D07.02 1 Performance Certificate N04386EN_100117418
D07.022 1 CERTIFICATE EN10204-2.1 N30527EN
D07.09 1 CERTIFICATE, SURFACE TREATMENT N31223EN
Connections
C20.21 CON-C20 1 SEALING LIQUID INLET ISO 7/1-Rp 3/8
C20.41 CON-C20 1 SEALING LIQUID INLET 3/8"
C21.21 CON-C21 1 SEALING LIQUID OUTLE ISO 7/1-Rp 3/8
C27.11 CON-C27 1 DISCHARGE PIPE CONN. ISO 7/1-Rp 3/8
C40.11 CON-C40 1 DRAINING OF PUMP ISO 7/1-Rp 3/8
C42.31 CON-C42 1 OIL FILLING ISO 7/1-Rp 1/2
C43.31 CON-C43 1 DRAINING OF LUBRICAT ISO 7/1-Rp 1/2
Parts
102.11 9165890141-C 1 VOLUTE CASE A33-100 (41) A890 3A
Material and NDT tests: Material test EN 10204-2.2
Flange drilling: ASME B16.5-2009 CLASS 150
Wet end connections: Yes Wet end drain. C40, bottom
We.inside surface treatment: Standard surface treatment
We.outside surface treatment: Standard,1xEP Top coat (prim.
102V 9165830141-1 1 VOLUTE CASE CASTING A33-100 (41) A890 3A
135.11 9167850141-1 1 SIDEPLATE O A33-100 (41) A890 3A
161.21 9177260141-1 1 CASE COVER M A33 (41) A890 3A
1705.31 93580801BA 1 CONNECTOR D13 - R1/2 (BA) EN 1.4404
183.31 2837740152 1 SUPPORT FOOT H 162,5 (52) A48 CL 30 B
210.31 2837880133-1 1 SHAFT 3 (33) SS2324
230.11 9162740141-C 1 IMPELLER OB 400 B39 Z5 A33-100 (41) A890 3A
Material and NDT tests: Material test EN 10204-2.2
Structural tests: Hydrost. Pressure Test, 30 min
Impeller diameter: 340,0 mm
Impeller max.diameter: 400,0 mm
Impeller min. diameter: 320,0 mm
We.inside surface treatment: Standard surface treatment
320.31 G433000311 1 ANTIFRICTION BEARING NUP311 ECJ
320.32 G325007312 2 ANTIFRICTION BEARING 7312 BECBM
330.31 9319310153 1 BEARING HOUSING A3 (53) A48 CL 35 B
339.31 A3-33913-1 1 BEARING UNIT A 13/ 3
344.31 931357015H 1 ADAPTER A33 (5H) A395 60-40-18
360.31 9174700152-1 1 BEARING COVER 3 (52) A48 CL 30 B
400.21 E805420883 1 GASKET 420(-3/-4)/405(-1/-2)X0,5 (83) Klinger SIL-4430
411.21 ED211015V5 1 SEAL RING DDG100M10-V7BBH

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411.31 ES22152179 2 SEAL RING DIN 7603 - A 15X21X1.5 - CU (79) Cu
412.11 E143893N93 1 O-RING 389,3X5,7 (93) FKM
412.12 E11801339F 3 O-RING 13,3X2,4 SMS1586 (9F) FFKM
412.14 E113016194 1 O-RING 16,1X1,6 SMS1586 (94) PTFE
412.21 E11B039294 1 O-RING 39,2X3 SMS1586 (94) PTFE
412.31 E11B124591 1 O-RING 124,5X3 SMS1586 (91) NBR
412.32 E11B074591 2 O-RING 74,5X3 SMS1586 (91) NBR
412.34 E140120991 1 O-RING 12X2 (91) NBR
412.35 E140120991 1 O-RING 12X2 (91) NBR
412.36 E140120991 1 O-RING 12X2 (91) NBR
423.31 9268270131 2 LABYRINTH RING A3 (31) SS2303
433.21 FD27150017 1 MECHANICAL SEAL JCS2P-50-QRMQ-309064
507.31 EL1205506M 2 DEFLECTOR 9RB 55 (6M) AISI304/NBR
554.11 B310017037 16 WASHER ISO 7089-16-200 HV-A4 (37) A4 ISO3506
554.23 B380006437 1 WASHER 6,4 DIN 9021 (37) A4 ISO3506
554.61 B31002101K 4 WASHER ISO 7089-20-200 HV (1K) S+Z EN10025
556.61 918711091K 4 RISER BLOCK IEC200-225 150 X 100 X25 (1K) S+Z EN10025
559.61 9194740032 4 SHIM IEC200-280 (32) SS2333
571.21 9267240132 1 CLAMP A1-A6 (32) SS2333
633.31 935818017C 1 OILER SULZER A13 (7C) AlSi
638.31 GH7CC0201K 1 CONSTANT LEVEL OILER ADAMS 7963/200 (1K) S+Z EN10025
640.31 9358930100 1 LUBRICATION EQUIPMEN SULZER A13 OL
642.31 GH3630006D 1 SIGHT GLASS ELESA 1161 HE.26 (6D) Al (aluminium)
644.31 9182250112 1 OIL RING A3 (12) Fe P01 EN10130
672.31 GH55305000 1 VENTING DEVICE EV 1028-14-00 R 1/2
683.21 93322101BG 1 GUARD A33 (BG) EN 1.4301
683.22 93322101BG 1 GUARD A33 (BG) EN 1.4301
683.23 93745501BG 1 GUARD A1-A3 T (BG) EN 1.4301
685.51 2840320111 1 GUARD END D250/D95,S4 (11) S235JRG2 EN10025
686.51 931288017A 1 GUARD JACKET D250 L330 (7A) EN-AW5754 (AlMg3)
686.52 384476017A 1 GUARD JACKET D250, L165 (7A) EN-AW5754 (AlMg3)
718.31 93580401BA 1 PIPE CONNECTION 12X1,5X45 (BA) EN 1.4404
730.31 9183470134 1 PIPE FITTING RP 1/4 X 45 (34) SS2343
800 80005-C 1 MOTOR ABB
Motor standard: IEC, Standard frame size

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Motor mounting: Foot
Motor Supplier: Pump supplier
Motor manufacturer: ABB Motors
Motor environment: Explosion proof
Motor protection: IP55
Motor efficiency class: Not definied by standard
Motor synchronous speed: 1.800 rpm
Motor frequency: 60 Hz
Motor power kW: 35,00 kW
Motor frame material: Cast Iron
Motor type: M3KP, Flameproof "Ex de"
Motor nominal voltage: 480 VD
Motor IEC code: 200M55
Motor variable speed: No
Motor special features: 002, Restamping volt. freq.
840.51 KA34042055 1 COUPLING VS150-R-FBH D42H7/D55H7 DIN6885
REX VIVA VS 150-R FBH d1/d2=42H7/55H7+ISO R773 (SFS2636)
860.51 KA24S00000 1 COUPLING PART HIGH SPEED RING SET VS150 (2H) C45 EN10083-2
861.51 KA24H04200 1 COUPLING HUB FBH 150 D42H7+ KEY WAY JS9 (2H) C45 EN10083-2
861.52 KA24H05500 1 COUPLING HUB FBH 150 D55H7+ KEY WAY JS9 (2H) C45 EN10083-2
869.51 KA24F00000 1 FLEXIBLE PART REX VIVA VS150
890.61 931106011K 1 BASEPLATE STD4 PM34 IEC200M42-55 (1K) S+Z EN10025
897.61 918914014C 4 ALIGNMENT BLOCK IEC160 - 225 (4C) A743 CF-8
901.11 A121164539 16 HEXAGON HEAD SCREW M16X45 ISO4017 (39) A4-80 ISO3506
901.61 A12120501E 4 HEXAGON HEAD SCREW M20X50 ISO4017 (1E) 8.8 ZnK ISO898
903.11 CC14040034 1 THREADED PLUG ISO 7/1-R 3/8 SCC101 (34) SS2343
903.32 CC14050034 1 THREADED PLUG ISO 7/1-R 1/2 SCC101 6-KANTAKART (34) SS2343
903.36 CC14050034 1 THREADED PLUG ISO 7/1-R 1/2 SCC101 6-KANTAKART (34) SS2343
909.11 9168630233 3 ADJUSTING SCREW M12X35 (33) SS2324

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914.11 3842750333 1 CAP SCREW, SOCKET HD M16X40 (33) SS2324
914.31 A611040639 1 CAP SCREW, SOCKET HD M4X6 ISO4762 (39) A4-80 ISO3506
914.51 A611103539 3 CAP SCREW, SOCKET HD M10X35 ISO4762 (39) A4-80 ISO3506
920.11 B111120039 3 NUT M12 ISO4032 (39) A4-80 ISO3506
920.51 B222704030 3 NUT M10 - PTROM-1040 (30) SS
923.31 GA11001210 1 BEARING NUT KM12 (10) S EN10025
931.31 GC10001210 1 LOCK WASHER MB12 (10) S EN10025
932.51 B710001030 3 RETAINING RING 10 - DIN471 (30) SS
940.31 B810807015 1 KEY B-12X8X70 ISO/R 773 (15) CK45K DIN1652
970 WCA0210832 1 SIGN 100X21X0,8 MM (32) SS2333
970.31 WK3095227A 2 SIGN SULZER LOGO L95 W22 (6D) Al (aluminium)
971.01 93265001BG 1 NAME PLATE CENTRIF PUMP KOTKA (S0708) EN 1.4301
975.51 SS00050802 1 WARNING SIGN
Guard adjustment, in english
976.31 SS0006M002 1 MANDATORY ACTION SIG EN
Oil refilling
976.51 SS0006M021 1 MANDATORY ACTION SIG
Coupling alignment
982.01 SS0011Z434 1 ATEX SIGN II 2 G C T4 (34) SS2343
DRMO.8 A-DRMO13-C 1 DRIVE MOTOR A 13
Units: SI
Temperature: 35,0 C
Quality requirement: 2006/42/EC
Motor standard: IEC, Standard frame size
Motor mounting: Foot
Motor Supplier: Pump supplier
Motor manufacturer: ABB Motors
Motor environment: Explosion proof
Motor protection: IP55
Motor efficiency class: Not definied by standard
Motor synchronous speed: 1.800 rpm
Motor frequency: 60 Hz
Motor power kW: 35,00 kW
Motor frame material: Cast Iron
Motor type: M3KP, Flameproof "Ex de"
Motor nominal voltage: 480 VD
Motor IEC code: 200M55
Motor variable speed: No
Motor special features: 002, Restamping volt. freq.
Separate Delivered Parts
760.43 CEP309072038 1 SEALING WATER EQUIPM SAFESIPHON10 309072

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APPLICATION 2
918.61 AP11203213 3 FOUNDATION SCREW M20X320 SAP100 (13) S355J0 EN10025
Reference standard: DIN 529 FORM C
Thread lenghth (b) = 120mm
920.61 B11120001J 6 NUT M20 ISO4032 (1J) 8 ZnK ISO898
975.31 SS00050202 2 WARNING SIGN
Corrosive / Irritating liquid

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EC Declaration of Conformity
as defined by EC machinery directive 2006/42/EC, Annex IIA
Manufacturer: Sulzer Pumps Finland Oy

Pajatie 75, 48600 KOTKA, Finland
Contact person: Director Technology & Innovation and Engineering

Jukka-Pekka Peri
Sulzer Pumps Finland Oy
PL 66, 48601 Kotka, Finland
herewith declares that
Centrifugal pump, type: A33-100
Serial number: 100117418
is in conformance with directive 2006/42/EC (machinery directive) and where applicable following other EC directives 2004/108/EC
(electromagnetic compatibility) and 2006/95/EC (low voltage). Harmonized standard EN 809 has been applied to the design and
manufacture of the product.
The manufacturer further declares that the product in question is in conformance with directive 94/9/EC (ATEX) and is suitable for use in
potentially explosive atmospheres where the requirement is equipment group II G, equipment category 2 or 3,
temperature category T1, T2, T3 or T4. Harmonized standards EN 13463-1 and EN 13463-5 have been applied to the design and
manufacture of the product.
The technical documentation referred to in Annex VIII of Directive 94/9/EC has been delivered to the following notified body: TV-SD
Product Service GmbH, identification number 0123.
KOTKA 26.08.2014
Ilkka Sinisalo
Head Operations BU Water
This declaration only concerns the machine as it was brought to the market. This declaration does not cover parts added to the machine by
the end user afterwards and/or operations carried out on the machine by the end user.
COPYRIGHT SULZER PUMPS FINLAND OY

Series 2.15 Page
ISO
BEARING UNIT AHLSTAR September 2011 H
Part list Oil lubrication
SPP id: Version 13 > / 110901 / Replaces 110811 / en / N31024 / 3 / Page 1 (2)
Part list of bearing unit (BEUN.3) items for spare part sales purposes. Adapter, support foot, lubrication equipment
and associated parts not included in the delivery.
BEUN.3 ITEM Shaft size Size / Dimensions

A1-BEUN13OL-1 1 Bearing unit A13 OL/ 1
CONFIGURATION
A, Process Pump
APP, Process Pump
A, APP, NPP, WPP,
Pump type NPP, Non-clogging Pump
EPP
WPP, Wear resistant Pump
EPP, Hot liquid Pump
Quality of conformity
Quality requirement ISO
EN ISO 5199:2002, EN ISO 9001:2000
Tests EN22 Material test EN 10204:2004-2.2
Support foot and associated parts
SFP
Bearing unit parts Not included in the delivery
exclusion Adapter and associated parts
ADP
Not included in the delivery
Bearing lubrication type OS Oil splash
Bearing housing material CI Cast iron
Shaft material 33 33 / S0400 / EN1.4460 / SS2324
Bearing unit connection N48 No Temperature measuring C48
Bearing unit equipment - Not included in the delivery
Bu. outside surface Standard, 1xEP Top coat (ZN)
PA
treatment Atmospheric corrosivity category C4
Bu. color shade ST Standard color shade (NCS 1700)
Specialities of Bearing unit - Not included in the delivery
PARTS
Parts Description Quantity
D01.31 PART LIST OF BEARING UNIT (BEUN.3) 1
D02.31 DIM.DWG BEARING UNIT CONNECT. 1
D04.31 SECT.DWG BEARING UNIT 1
C42.31 CONN. OIL FILLING 1
C43.31 CONN. DRAINING OF LUBRICATION (shaft size 2, 3, 4, 5, 6, 7) 1
ORIGINAL INSTRUCTION COPYRIGHT SULZER PUMPS FINLAND OY

Series 2.15 Page
ISO
BEARING UNIT AHLSTAR September 2011 H
Part list Oil lubrication
Parts Description Quantity

339.31 Bearing unit Unfinished 1
210.31 SHAFT 1
320.32 ANTIFRICTION BEARING 1
320.32 ANTIFRICTION BEARING 2
330.31 BEARING HOUSING 1
360.31 BEARING COVER 1
412.31 O-RING 1
412.32 O-RING 2
412.33 O-RING (Shaft size 7) 2
423.31 LABYRINTH RING 2
507.31 DEFLECTOR 2
554.31 WASHER 4
644.31 LUBRICATION RING 1
901.31 HEXAGONAL SCREW 4
903.37 THREADED PLUG (Shaft size 7) 1
923.31 BEARING NUT 1
931.31 LOCK WASHER 1
672.31 VENTING DEVICE 1
903.32 THREADED PLUG (Shaft size 2, 3, 4, 5, 6, 7) 1
903.33 THREADED PLUG 2
940.31 KEY 1
970.31 SIGN 2
975.31 WARNING SIGN 2
976.31 MANDATORY ACTION SIGN 1

Series 2.15 Page
DIMENSIONS ISO
DIMENSIONAL DATA AHLSTAR September 2011 D
General Arrangement Bare Pump ISO Units
SPP id: Version 13 > / 110901 / Replaces 110524 / en / P12396 / 3
Product scope: Pump (PUMP.0)

Pump type: A, Process Pump
Pump size: 31-100 33-125
Drilling of flanges according to P02184
Dimensions in mm
DIMENSIONS
Pump size DN1 DN2 A H1 H2 B M1 M2 N1 N2 S1 K1 J kgm2 Weight kg
31-100 125 100 140 225 280 87 160 120 373 315 19 22 0,098 160
31-125 150 125 140 250 355 87 160 120 373 315 19 19 0,12 175
31-150 200 150 160 280 375 112 200 150 470 400 24 20 0,17 205
32-65 100 65 125 225 280 87 160 120 373 315 19 22 0,078 165
32-80 125 80 125 250 315 87 160 120 373 315 19 22 0,110 170
32-100 125 100 140 250 315 75 160 120 390 315 19 20 0,14 180
32-125 150 125 140 280 355 112 200 150 470 400 24 20 0,19 190
33-80 125 80 125 280 355 87 160 120 427 355 19 23 0,160 210
33-100 125 100 140 280 355 112 200 150 470 400 24 20 0,20 220
33-125 150 125 140 315 400 112 200 150 470 400 24 20 0,27 235

Series 2.15 Page
DIMENSIONS ISO
General Arrangement Motor ISO Units
Product scope: Drive motor (DRMO)

Motor standard: IEC motor
Dimensions in mm
DIMENSIONS OF FRAME DIMENSIONS OF SHAFT
IEC D F
A B C H K E GA
code Nominal Tolerance Nominal Tolerance
71 M 112 90 45 71 M6 14 j6 30 5 h9 16
80 M 125 100 50 80 M8 16 j6 40 5 h9 18
90 S 140 100 56 90 M8 18 j6 40 6 h9 20.5
90 L 140 125 56 90 M8 19 j6 40 6 h9 21.5
100 S 160 112 63 100 M10 22 j6 50 6 h9 24.5
100 L 160 140 63 100 M10 24 j6 50 8 h9 27
112 S 190 114 70 112 M10 28 j6 60 8 h9 31
112 M 190 140 70 112 M10 32 k6 80 10 h9 35
112 L 190 159 70 112 M10 38 k6 80 10 h9 41
132 S 216 140 89 132 M10 42 k6 110 12 h9 45
132 M 216 178 89 132 M10 48 k6 110 14 h9 51.5
132 L 216 203 89 132 M10 55 m6 110 16 h9 59
160 S 254 178 108 160 M12 60 m6 140 18 h9 64
160 M 254 210 108 160 M12 65 m6 140 18 h9 69
160 L 254 254 108 160 M12 70 m6 140 20 h9 74.5
180 S 279 203 121 180 M12 75 m6 140 20 h9 79.5
180 M 279 241 121 180 M12 80 m6 170 22 h9 85
180 L 279 279 121 180 M12 85 m6 170 22 h9 90
200 S 318 228 133 200 M16 90 m6 170 25 h9 95
200 M 318 267 133 200 M16 95 m6 170 25 h9 100
200 L 318 305 133 200 M16 100 m6 210 28 h9 106
225 S 356 286 149 225 M16 110 m6 210 28 h9 116
225 M 356 311 149 225 M16
225 L 356 356 149 225 M16 DIMENSIONS OF TYPE:
250 S 406 311 168 250 M20 IEC code A AB AC ADL ADR B
250 M 406 349 168 250 M20
250 L 406 406 168 250 M20 C H HA HC HD L K
280 S 457 368 190 280 M20
280 M 457 419 190 280 M20
280 L 457 457 190 280 M20 D F
E GA
315 S 508 406 216 315 M24 Nominal Tolerance Nominal Tolerance
315 M 508 457 216 315 M24
315 L 508 508 216 315 M24
355 S 610 500 254 355 M24
355 M 610 560 254 355 M24
355 L 610 630 254 355 M24
400 S 686 560 280 400 M30
400 M 686 630 280 400 M30
400 L 686 710 280 400 M30
450 L (1 800 1000 250 450 M36 1) Dimensions according to motor manufacturer ABB.

Series 2.15 Page
DIMENSIONS ISO
General Arrangement Pump + Motor + Baseplate ISO Units
Product scope: Assembly (ASSE.0)

Pump type and size: A33-100
Motor standard: IEC motor, IEC
Drive type: Direct drive, DD
Baseplate type: Baseplate for pump and motor, STD
Pump mounting size: 34
250 285
140 530 140 DN100
DN125
110 12
355
45
280
42k7
105
Moment of inertia
0.20 kgm2 (without coupling)
Drilling of flanges according to P02184
Dimensions in mm
DIMENSIONS
Weight kg
IEC-Motor (1 IEC-Motor (2 H L(1 L1 L2 L3 L4 S B2 B3 K2 K3 (3
100L28 112M28 405 1100 1420 50 1335 25 20 770 700 10 100 285
112M28 132S3238 405 1125 1420 50 1335 30 20 770 700 10 100 285
132S3238 160M4255 405 1250 1420 50 1335 40 20 770 700 10 100 290
132M3238 160M4255 405 1250 1420 50 1335 40 20 770 700 10 100 290
160M4255 180M4255 405 1400 1420 50 1335 45 20 770 700 10 100 290
160L4255 180M4255 405 1445 1420 50 1335 45 20 770 700 10 100 290
180M4255 200M4255 455 1470 1630 75 1520 55 25 770 700 11 150 325
180L4255 200M4255 455 1510 1630 75 1520 55 25 770 700 11 150 325
200M4255 225S6075 455 1570 1630 75 1520 70 25 770 700 11 150 345
200L4255 225M6075 455 1600 1630 75 1520 70 25 770 700 11 150 345
225S4255 250S6075 455 1600 1630 75 1520 80 25 770 700 11 150 345
225S6075 250S6075 455 1625 1630 75 1520 80 25 770 700 11 150 345
225M4255 250S6075 455 1620 1630 75 1520 80 25 770 700 11 150 345
225M6075 250S6075 455 1650 1630 75 1520 80 25 770 700 11 150 345
250S6075 280S6075 455 1630 1900 75 1790 90 25 770 700 11 150 355
250M6075 280S6075 455 1670 1900 75 1790 90 25 770 700 11 150 355
280S6075 315S8095 490 1835 1900 75 1790 100 25 770 700 11 150 370
280M6075 315S8095 490 1890 1900 75 1790 100 25 770 700 11 150 370
315S6075 355S6075 545 1935 2200 90 2075 115 30 770 700 14 180 470
315M6075 355S6075 545 2045 2200 90 2075 115 30 770 700 14 180 470
315L6075 355S6075 545 2100 2200 90 2075 115 30 770 700 14 180 470
355S6075 400M8095 590 2200 2200 90 2075 130 30 770 700 14 180 520
355M6075 400M8095 590 2275 2200 90 2075 130 30 770 700 14 180 520
355L6075 400M8095 590 2525 2200 90 2075 130 30 770 700 14 180 520
1. Primary motor
2. Max IEC-motor size, which can be installed on baseplate. Motor fixing holes are not drilled.
3. Weight without coupling and motor.

Series 2.15 Page
DIMENSIONS ISO
Wet end connections ISO Units
SPP id: Version 13 > / 110901 / Replaces101209 / en / P12447 / 5
Pump scope: Wet end (WEEN.1)

Pump size: 31-100 33-125
Dimensions in mm
CONNECTIONS
C27.11 (ISO 7/1 - Rp 3/8) C36.11 (ISO 7/1 - Rp 3/8) C36.12 (ISO 7/1 - Rp 3/8)
Pump size
X Y Z X Y Z X Y Z
31-100 61 229 -12 -115 0 135 -63 229 -12
31-125 73 290 0 -95 0 102 -75 290 0
31-150 88 310 0 -130 0 175 -93 310 0
32-65 39 235 -5 -100 0 115 -37 235 -5
32-80 46 265 0 -100 0 135 -50 265 0
32-100 57 270 0 -116 0 135 -64 270 0
32-125 72 300 0 -115 0 153 -75 300 0
33-80 47 310 -10 -100 0 135 -49 310 -10
33-100 60 300 -10 -121 0 135 -63 301 -10
33-125 73 335 0 -115 0 153 -73 335 0
CONNECTIONS
C40.11 (ISO 7/1 - Rp 3/8) C40.12 (ISO 7/1 - Rp 3/8) C48.11 (M8)
Pump size
X Y Z X Y Z X Y Z
31-100 0 -221 0 -56 -187 0 91 145 -84
31-125 0 -243 0 -66 -213 0 91 145 -84
31-150 0 -270 0 -84 -236 0 91 145 -84
32-65 0 -211 0 -34 -195 0 72 162 -94
32-80 0 -225 0 -48 -195 0 72 162 -94
32-100 0 -240 0 -52 -215 0 72 162 -94
32-125 0 -260 0 -66 -230 0 72 162 -94
33-80 0 -251 0 -45 -230 0 69 157 -157
33-100 0 -270 0 -55 -240 0 69 157 -157
33-125 0 -293 0 -63 -260 0 69 157 -157

Series Page
DIMENSIONAL DATA DIMENSIONS ISO
Flange drillings ISO, EN, JIS and ASME August 2013 D00a
SPP id: 130802 / Replaces 130515 / en / P02184 / 9 / Page 1 (4)
d
DN
Dimensional data
Flange drillings
ISO
ISO 7005-1:2011
ISO 7005-2:1988 n x d1
ISO 7005-1:2011 choose either EN 1092-1:2007+A1:2013 or ASME B 16.5:2009

ISO 7005-1:1992 EN 1092-1:2007+A1:2013 PN10, PN16, PN25 and PN40 drilling dimensions are the same as in the
corresponding pressure class in the ISO standard. ASME B16.5:2009 class 300 and class 600
drilling dimensions correspond to PN50 and PN110 dimensions in the ISO standard.
Please take a note that ISO 7005-1:1992 has been replaced by ISO 7005-1:2011.
ISO 7005-2 ISO 7005-2 ISO 7005-2 ISO 7005-2 ISO 7005-2
PN10 PN16 PN25 PN40 PN50
DN d d1 n d d1 n d d1 n d d1 n d d1 n
25 85 14 4 85 14 4 85 14 4 85 14 4 89 18 4
32 100 19 4 100 19 4 100 19 4 100 19 4 98.5 18 4
40 110 19 4 110 19 4 110 19 4 110 19 4 114.5 22 4
50 125 19 4 125 19 4 125 19 4 125 19 4 127 18 8
65 145 19 4 145 19 4 145 19 8 145 19 8 149.5 22 8
80 160 19 8 160 19 8 160 19 8 160 19 8 168 22 8
100 180 19 8 180 19 8 190 23 8 190 23 8 200 22 8
125 210 19 8 210 19 8 220 28 8 220 28 8 235 22 8
150 240 23 8 240 23 8 250 28 8 250 28 8 270 22 12
200 295 23 8 295 23 12 310 28 12 320 31 12 330 26 12
250 350 23 12 355 28 12 370 31 12 385 34 12 387.5 29.5 16
300 400 23 12 410 28 12 430 31 16 450 34 16 451 32.5 16
350 460 23 16 470 28 16 490 34 16 510 37 16 514.5 32.5 20
400 515 28 16 525 31 16 550 37 16 585 40 16 571.5 35.5 20
500 620 28 20 650 34 20 660 37 20 670 43 20 686 35.5 24
600 725 31 20 770 37 20 770 40 20 795 49 20 813 42 24
700 840 31 24 840 37 24 875 43 24
800 950 34 24 950 40 24 990 49 24
900 1050 34 28 1050 40 28 1090 49 28
1200 1380 40 32 1390 49 32 1420 56 32

Series Page
Flange drillings ISO, EN, JIS and ASME August 2013 D00b
d
DN
EN
EN 1092-1:2007+A1:2013
n x d1
EN 1092-2:1997
EN 1092-1 EN 1092-1 EN 1092-1 EN 1092-1 EN 1092-1 EN 1092-1

PN10 PN16 PN25 PN40 PN63 PN100
DN d d1 n d d1 n d d1 n d d1 n d d1 n d d1 n
25 85 14 4 85 14 4 85 14 4 85 14 4 100 18 4 100 18 4
32 100 18 4 100 18 4 100 18 4 100 18 4 110 22 4 110 22 4
40 110 18 4 110 18 4 110 18 4 110 18 4 125 22 4 125 22 4
50 125 18 4 125 18 4 125 18 4 125 18 4 135 22 4 145 26 4
65 145 18 8 145 18 8 145 18 8 145 18 8 160 22 8 170 26 8
80 160 18 8 160 18 8 160 18 8 160 18 8 170 22 8 180 26 8
100 180 18 8 180 18 8 190 22 8 190 22 8 200 26 8 210 30 8
125 210 18 8 210 18 8 220 26 8 220 26 8 240 30 8 250 33 8
150 240 22 8 240 22 8 250 26 8 250 26 8 280 33 8 290 33 12
200 295 22 8 295 22 12 310 26 12 320 30 12 345 36 12 360 36 12
250 350 22 12 355 26 12 370 30 12 385 33 12 400 36 12 430 39 12
300 400 22 12 410 26 12 430 30 16 450 33 16 460 36 16 500 42 16
350 460 22 16 470 26 16 490 33 16 510 36 16 525 39 16 560 48 16
400 515 26 16 525 30 16 550 36 16 585 39 16 585 42 16 620 48 16
500 620 26 20 650 33 20 660 36 20 670 42 20 705 48 20 760 56 20
600 725 30 20 770 36 20 770 39 20 795 48 20 820 56 20
700 840 30 24 840 36 24 875 42 24 900 48 24 935 56 24
800 950 33 24 950 39 24 990 48 24 1030 56 24 1050 62 24
900 1050 33 28 1050 39 28 1090 48 28 1140 56 28 1170 62 28
1200 1380 39 32 1390 48 32 1420 56 32 1460 62 32 1530 78 32
EN 1092-2 EN 1092-2 EN 1092-2 EN 1092-2 EN 1092-2

PN10 PN16 PN25 PN40 PN63
DN d d1 n d d1 n d d1 n d d1 n d d1 n
25 85 14 4 85 14 4 85 14 4 85 14 4
32 100 19 4 100 19 4 100 19 4 100 19 4
40 110 19 4 110 19 4 110 19 4 110 19 4 125 23 4
50 125 19 4 125 19 4 125 19 4 125 19 4 135 23 4
65 145 19 4 145 19 4 145 19 8 145 19 8 160 23 8
80 160 19 8 160 19 8 160 19 8 160 19 8 170 23 8
100 180 19 8 180 19 8 190 23 8 190 23 8 200 28 8
125 210 19 8 210 19 8 220 28 8 220 28 8 240 31 8
150 240 23 8 240 23 8 250 28 8 250 28 8 280 34 8
200 295 23 8 295 23 12 310 28 12 320 31 12 345 37 12
250 350 23 12 355 28 12 370 31 12 385 34 12 400 37 12
300 400 23 12 410 28 12 430 31 16 450 34 16 460 37 16
350 460 23 16 470 28 16 490 34 16 510 37 16 525 41 16
400 515 28 16 525 31 16 550 37 16 585 41 16 585 44 16
500 620 28 20 650 34 20 660 37 20 670 44 20
600 725 31 20 770 37 20 770 41 20 795 50 20
700 840 31 24 840 37 24 875 44 24
800 950 34 24 950 41 24 990 50 24
900 1050 34 28 1050 41 28 1090 50 28
1200 1380 41 32 1390 50 32 1420 57 32

Series Page
Flange drillings ISO, EN, JIS and ASME August 2013 D00c
d
DN
JIS
JIS B 2220:2012
JIS B 2239:2004 n x d1
JIS B 2220 JIS B 2220 JIS B 2220 JIS B 2220 JIS B 2220 JIS B 2220
10K 16K 20K 30K 40K 63K
DN d d1 n d d1 n d d1 n d d1 n d d1 n d d1 n
25 90 19 4 90 19 4 90 19 4 95 19 4 95 19 4 100 23 4
32 100 19 4 100 19 4 100 19 4 105 19 4 105 19 4 110 23 4
40 105 19 4 105 19 4 105 19 4 120 23 4 120 23 4 130 25 4
50 120 19 4 120 19 8 120 19 8 130 19 8 130 19 8 145 23 8
65 140 19 4 140 19 8 140 19 8 160 23 8 160 23 8 175 25 8
80 150 19 8 160 23 8 160 23 8 170 23 8 170 23 8 185 25 8
100 175 19 8 185 23 8 185 23 8 195 25 8 205 25 8 220 27 8
125 210 23 8 225 25 8 225 25 8 230 25 8 250 27 8 265 33 8
150 240 23 8 260 25 12 260 25 12 275 27 12 295 33 12 305 33 12
200 290 23 12 305 25 12 305 25 12 320 27 12 345 33 12 360 33 12
250 355 25 12 380 27 12 380 27 12 390 33 12 410 33 12 430 39 12
300 400 25 16 430 27 16 430 27 16 450 33 16 470 39 16 485 39 16
350 445 25 16 480 33 16 480 33 16 495 33 16 515 39 16 530 46 16
400 510 27 16 540 33 16 540 33 16 560 39 16 570 39 16 590 46 16
500 620 27 20 660 33 20 660 33 20
600 730 33 24 770 39 24 770 39 24
700 840 33 24
800 950 33 28
900 1050 33 28
1200 1380 39 32
JIS B 2239 JIS B 2239 JIS B 2239

10K 16K 20K
DN d d1 n d d1 n d d1 n
25 90 19 4 90 19 4 90 19 4
32 100 19 4 100 19 4 100 19 4
40 105 19 4 105 19 4 105 19 4
50 120 19 4 120 19 8 120 19 8
65 140 19 4 140 19 8 140 19 8
80 150 19 8 160 23 8 160 23 8
100 175 19 8 185 23 8 185 23 8
125 210 23 8 225 25 8 225 25 8
150 240 23 8 260 25 12 260 25 18
200 290 23 12 305 25 12 305 25 12
250 355 25 12 380 27 12 380 27 12
300 400 25 16 430 27 16 430 27 16
350 445 25 16 480 33 16 480 33 16
400 510 27 16 540 33 16 540 33 16
500 620 27 20 660 33 20 660 33 20
600 730 33 24 770 39 24 770 39 24
700 840 33 24
800 950 33 28
900 1050 33 28
1200 1380 39 32

Series Page
Flange drillings ISO, EN, JIS and ASME August 2013 D00d
d
DN
ASME
ASME B 16.1:2010
ASME B 16.5:2009
ASME B 16.47:1996 n x d1
ASME B 16.1 ASME B 16.1

Class 125 Class 250
DN d d1 n d d1 n
25 79 16 4 89 19 4
32 89 16 4 98 19 4
40 98 16 4 114 22 4
50 121 19 4 127 19 8
65 140 19 4 149 22 8
80 152 19 4 168 22 8
100 191 19 8 200 22 8
125 216 22 8 235 22 8
150 241 22 8 270 22 12
200 299 22 8 330 25 12
250 362 25 12 387 29 16
300 432 25 12 451 32 16
350 476 29 12 514 32 20
400 540 29 16 572 35 20
500 635 32 20 686 35 24
600 749 35 20 813 41 24
700
800
900 1086 42 32 1168 57 32
1200 1422 42 44 1543 57 40
ASME B 16.5 ASME B 16.5 ASME B 16.5 ASME B 16.5

Class 150 Class 300 Class 400 Class 600
DN d d1 n d d1 n d d1 n d d1 n
25 79 16 4 89 19 4 89 19 4 89 19 4
32 89 16 4 98 19 4 98 19 4 98 19 4
40 98 16 4 114 22 4 114 22 4 114 22 4
50 121 19 4 127 19 8 127 19 8 127 19 8
65 140 19 4 149 22 8 149 22 8 149 22 8
80 152 19 4 168 22 8 168 22 8 168 22 8
100 191 19 8 200 22 8 200 25 8 216 25 8
125 216 22 8 235 22 8 235 25 8 267 29 8
150 241 22 8 270 22 12 270 25 12 292 29 12
200 299 22 8 330 25 12 330 29 12 349 32 12
250 362 25 12 387 29 16 387 32 16 432 35 16
300 432 25 12 451 32 16 451 35 16 489 35 20
350 476 29 12 514 32 20 514 35 20 527 38 20
400 540 29 16 572 35 20 572 38 20 603 41 20
500 635 32 20 686 35 24 686 41 24 724 44 24
600 749 35 20 813 41 24 813 48 24 838 51 24
ASME B 16.47 ASME B 16.47 ASME B 16.47 ASME B 16.47
Class 150 Class 300 Class 400 Class 600
700 864 35 28 940 44 28 940 51 28 965 54 28
800 978 41 28 1054 51 28 1054 54 28 1080 60 28
900 1086 41 32 1168 54 32 1168 54 32 1194 67 28
1200 1422 41 44 1372 51 32 1403 60 28 1461 73 32
a

Series 2.15 Page
DIMENSIONS ISO
Sealing unit connections ISO Units
Pump scope: Sealing unit (SEUN.2)

APP, Process Pump
NPP, Non-clogging Pump
Sealing unit type: Standard integrated mechanical seal, MS11, MS12, MS21
Dimensions in mm
CONNECTIONS
C20.21 C21.21 C22.21 C41.21
C48.21 (M8)
Sealing unit size (ISO 7/1 - Rp 3/8) (ISO 7/1 - Rp 3/8) (ISO 7/1 - Rp 3/8) (ISO 7/1 - Rp 1/8)
X Y Z X Y Z X Y Z X Y Z X Y Z
10 -321 0 -55 -321 0 55 -315 60 0 -321 0 -55 -357 39 67
11 -290 0 -55 -290 0 55 -315 60 0 -290 0 -55 -357 39 67
20 -393 0 -57 -393 0 57 -421 60 0 -393 0 -57 -464 40 69
21 -398 0 -57 -398 0 57 -421 62 0 -398 0 -57 -464 40 69
22 -399 0 -57 -399 0 57 -423 62 0 -399 0 -57 -468 50 87
23 -399 0 -57 -399 0 57 -423 62 0 -399 0 -57 -468 50 87
31 -417 0 -67 -417 0 67 -441 72 0 -417 0 -67 -485 55 95
32 -420 0 -67 -420 0 67 -433 72 0 -420 0 -67 -487 15 114
33 -418 0 -68 -418 0 68 -433 72 0 -418 0 -68 -481 75 130
41 -551 0 -70 -551 0 70 -574 75 0 -551 0 -70 -594 46 -80
42 -547 0 -70 -547 0 70 -559 77 0 -547 0 -70 -604 68 -117
43 -547 0 -70 -547 0 70 -570 75 0 -547 0 -70 -600 46 -80
44 -547 0 -70 -547 0 70 -562 77 0 -547 0 -70 -610 75 -130
51 -659 0 -86 -659 0 86 -686 91 0 -659 0 -86 -722 75 -130
52 -659 0 -86 -659 0 86 -660 91 0 -659 0 -86 -689 75 -130
53 -659 0 -86 -659 0 86 -691 91 0 -659 0 -86 -722 75 -130
54 -659 0 -86 -659 0 86 -691 91 0 -659 0 -86 -700 125 -217
55 -659 0 -86 -659 0 86 -691 91 0 -659 0 -86 -722 75 -130
60 -788 0 -92 -788 0 92 -819 100 0 -788 0 -92 -845 75 -130
61 -777 0 -94 -777 0 94 -803 105 0 -777 0 -94 -837 75 -130
62 -783 0 -92 -783 0 92 -809 99 0 -783 0 -92 -837 75 -130
63 -781 0 -92 -781 0 92 -811 100 0 -781 0 -92 -837 75 -130
71 -867 0 -106 -867 0 106 -892 117 0 -867 0 -106 -920 105 -182
72 -867 0 -106 -867 0 106 -892 117 0 -867 0 -106 -920 105 -182

Series 2.15 Page
DIMENSIONS ISO
Bearing unit connections ISO Units
Pump scope: Bearing unit (BEUN.3)

APP, Process Pump
EPP, Hot liquid Pump
Bearing lubrication type: Grease, GR
Oil splash, OS
Dimensions in mm
CONNECTIONS
C41.31 C41.31
C42.31
Bearing unit (wet end side) (motor drive side)
(ISO 7/1 Rp 1/2)
size (ISO 7/1 Rp 1/8) (ISO 7/1 Rp 1/8)
X Y Z X Y Z X Y Z
1 -200.75 80.9 12.5 -85.75 69.9 12.5 -152.75 70 0
2 -294.75 89.1 10 -117.75 83.9 10 -228.75 90.1 0
3 -308 116.4 10 -149 104 10 -235 116.5 0
4 -391.5 127.3 10 -157.5 116.1 10 -297.5 127.8 0
5 -490.75 157.6 10 -191.75 143.6 10 -361.75 158.1 0
6 -606.5 183.5 10 -224.5 178.5 10 -435.5 184 0
7 -715 249 15 -274 200 15 -480 204 0
CONNECTIONS
C48.31 C48.32
C43.31
Bearing unit (M10x1-10) (M10x1x-10)
size Size
X Y Z X Y Z X Y Z
(ISO 7/1 -)
1 -152.75 -72 52 R 1/4 -199.75 61.3 51.4 -111.75 69.9 12.5
2 -244.25 -89.5 0 R 1/2 -296.75 67.4 56.6 -147.75 85.9 14.5
3 -235 -115.5 0 R 1/2 -308 108.1 39.4 -187.5 110.1 0
4 -298.5 -126 0 R 1/2 -391.5 117.5 42.8 -197 120.2 0
5 -391.75 156.5 0 R 1/2 -490.75 143.8 52.3 -238.75 147.6 0
6 -435.66 -184 0 R 1/2 -606.5 169.1 61.6 -281.5 181.1 0
7 -480 -220 0 R 1/2 -715 232 85 -338 203 0

Series 2.15 Page
DIMENSIONS ISO
Grouted foundation screw ISO Units
Assembly scope: Baseplate (BAPL.6)

Baseplate type: Baseplate for pump and motor
Baseplate equipment: Foundation screw / grouted, 918G
Dimensions in mm
DIMENSIONS
D S L E~ Umin U2min
M16 20 250 100 200 160
M20 25 320 125 250 200
M24 30 400 125 300 240
M30 36 450 160 400 300

AHLSTAR A33-100 (125-100-400)
Characteristic Curve K18493
COPYRIGHT SULZER PUMPS FINLAND OY
SPP id: Version 13 > / 110901 / Replaces 050101 / en / K18493 / 2
Impeller type: Open1 / 916274 B39 Z5

Pump rotational speed: 1760 rpm
IMPELLER DIA
d2 (mm)
400
397.5
395
392.5
390
387.5
385
382.5
380
377.5
375
372.5
370
367.5
365
362.5
360
357.5
355
352.5
350
347.5
345
342.5
340
337.5
335
332.5
330
327.5
325
322.5
320
0.5
d2

Series 2.15 Page
CROSS SECTION
CROSS SECTION DRAWINGS AHLSTAR September 2011 C
Pump
SPP id: Version 13 > / 110901 / Replaces 050101 / en / N15579 / 2
Product scope: Pump (PUMP.0)


Series 2.15 Page
CROSS SECTION
CROSS SECTION DRAWINGS AHLSTAR November 2013 C
Assembly
Product scope: Assembly (ASSE.0)

APP, Process Pump
WPP, Wear Resistant Pump
Pump mounting size: 11, 12, 13, 21, 22, 23, 24, 25, 26, 31, 32, 33, 34, 35, 41, 42, 43, 44, 45, 46, 47, 48, 49, 4A,
51, 52, 53, 54, 55, 56, 57, 58, 59, 5A, 5C, 5D, 5E, 5F, 5G, 5H, 61, 62
Original CAD drawing number is 941013

Series 2.15 Page
CROSS SECTION
Wet end
Pump scope: Wet end (WEEN.1)

Impeller type: Open, O
Special open, SO
*) Not with pump sizes 7.

Series 2.15 Page
CROSS SECTION
Sealing unit

APP, Process Pump
Sealing unit type: Standard integrated double mechanical seal, MS21
Shaft seal fluid: Quench sealing fluid, QF
Barrier sealing fluid, BF

Series 2.15 Page
CROSS SECTION
Guards

APP/APT, Process Pump
NPP/NPT, Non-clogging Pump
WPP/WPT, Wear resistant Pump
Sealing unit equipment: Guards, 683

Series 2.15 Page
CROSS SECTION
CROSS SECTION DRAWINGS AHLSTAR June 2012 C
Bearing unit

APP, Process Pump
EPP, Hot Liquid Pump
Bearing unit type: Oil splash lubrication, OS
*Antifriction bearing type:

A1-A6, upper view
A7, lower view
**Parts only on shaft size 7
***Not included on shaft size 1

Series 2.15 Page
CROSS SECTION
CROSS SECTION DRAWINGS AHLSTAR September 2011 C
Lubrication equipment

Bearing unit equipment: Lubrication equipment, 640

Series 2.15 Page
CROSS SECTION
Sealing water equipment
Assembly scope: Sealing water equipment (SWEQ.4)

APP, Process Pump
Sealing water equipment: Seal pot, connected to gas network, 760P2
Shaft seal fluid: Barrier sealing fluid, BF
Sealing unit type: Standard integrated double mechanical seal, MS21
Cartridge double mechanical seal on the shaft without shaft sleeve, MS41
Cartridge double mechanical seal on the shaft sleeve, MS42

Series 2.15 Page
CROSS SECTION
Coupling unit
Assembly scope: Coupling unit (COUN.5)

Coupling type: Elastic type, CT1, CT7

Series 2.15 Page
CROSS SECTION
Baseplate
Product scope: Baseplate (BAPL.6)

APP, Process Pump
Pump mounting size: 11, 12, 13, 21, 22, 23, 24, 25, 26, 31, 32, 33, 34, 35, 41, 42, 43, 44, 45, 46, 47, 48, 49, 4A,
51, 52, 53, 54, 55, 56, 57, 58, 59, 5A, 5C, 5D, 5E, 5F, 5G, 5H, 61, 62

Series 2.15 Page
CROSS SECTION
Grouted foundation screw
Assembly scope: Baseplate (BAPL.6)

Baseplate type: Baseplate for pump and motor
Baseplate equipment: Foundation screw / grouted, 918G

SERIES 2.15
SPP id: 131130 / Replaces 130131 / en / N31566 / 5
AHLSTAR
PROCESS PUMPS
Installation, operation and maintenance instruction
Intended use
Safety instructions
Hoisting and transportation
Commissioning
Installation at the site
Operation
Preventive maintenance
Corrective maintenance
Spare parts recommendation

Series 2.15 Page
INSTRUCTIONS ISO
USER'S MANUAL AHLSTAR November 2013 G
Documents & Dates
SPP id: 131130 / Replaces 130131 / en / N31566 / 5 / Page 2 (2)
Installation, operation and maintenance instruction
G ISO Cover
N31566 Nov - 13
G ISO Table of contents
G ISO N31567 Intended use Nov - 13
G ISO N31568 Safety instructions Nov - 13
G N31569 Hoisting and transportation Jun - 12
G N31570 Commissioning Sep - 11
G ISO N31571 Installation at the site Nov - 13
G ISO N31572 Operation Jun - 12
G ISO N31573 Preventive maintenance Nov - 13
G ISO N31574 Corrective maintenance Sep - 11
G ISO N31575 Spare parts recommendation Sep - 11

SERIES 2.15
AHLSTAR
PROCESS PUMPS
Intended use
1 General
2 Document identification
3 Type designation
4 Parts number designation
5 Nameplate designation
6 Capacity and head
7 Decommissioning

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INSTRUCTIONS ISO
Intended use
1 General
WARNING
The pump and its accessories may only be used for the purpose for which they have been supplied.
The intended use is given in the order specification and in the following instructions concerning the main pumping
parameters and mechanical durability. If the intended use changes, the user must make sure that the pump can be
used in the new application and, if necessary, obtain the manufacturers permission for the change.
Table 1, Intended use in the process

Application data: Sources:
Pumped liquid and its properties (chemicals, solids, Product specification (under Process data)
consistency, temperature etc.)
Main pumping parameters (capacity, head, speed etc.) Product specification (under Process data) and nameplate of
the pump
Other necessary process data Product specification (under Process data)
Table 2, Delivery and design

Delivery and design data: Sources:
Product scopes (modules) Product specification
Product size Product specification and nameplate of the pump
Other design alternatives (impeller type and size, materials, Product specification
lubrication, flange drillings, shaft sealing type etc.)
Dimensions (pump, accessories, flanges etc.) Dimensional drawings
Weights and mass moments of inertia (bare pump, pump + Dimensional drawings
baseplate etc.)
Connections (lubrication, shaft seal, drainage etc.) Location shown in the parts list and in the sectional drawings
and dimensional drawings. Moreover, connections having
importance in view of safety have been marked on the
product.
Part details (maximum impeller diameter, bearing types, Parts list (under heading Parts)
fastener sizes etc.)
This instruction set covers the process pump with the supplementary accessories included in the delivery. All
supplied instructions are found in the parts list under the heading Customer instructions.
Before commissioning, the operating staffs have to be instructed in the guidelines for correct and safe operation of
the product as stated in these instructions. This product must be serviced by qualified personnel who are familiar
with the design and operation of this product and the system with the essential safety aspects involved. The scope of
responsibilities and supervision of the personnel must be exactly defined by the plant operator.
Our guarantee will be valid only if the installation, operation, maintenance and repairs of this pump are carried out in
accordance with these instructions. The plant operator is to make sure that the contents of these instructions are
fully understood by the operating personnel.
To assure a steady start-up, supervision or service from an authorized manufacturer representative is
recommended. During operation, periodic inspections should be made to assure safe operation under the prevailing
conditions.

Series 2.15 Page
INSTRUCTIONS ISO
Intended use
Any modification may be made to the product only after consultation with the manufacturer. Using spare parts and
accessories authorized by the manufacturer is a relevant safety aspect. Only genuine spare parts which are in
accordance with the original delivery (in the parts list) are to be used. Use of other parts may exempt Sulzer from
any liability.
If any assistance regarding the product or its instructions is required, please contact our local representative for a
quick supply of the information you need.
The enclosed instructions regarding a possible long-term storage (more than 3 months) must be observed.
All customer instructions regarding this product and its main components are also available in an electronic format
for viewing and printing (depending on the end users software & hardware). If electronic format is needed, please
contact our local representative for further information.
If the delivery includes customer instructions or other information in an electronic format which can be
edited, we are only responsible for the contents of paper versions of these instructions and other
information supplied by us.
Keep these instructions at the place of operation for further reference!
2 Document identification
Sulzer product number
Series 2.15 Page

INSTRUCTIONS
Identification of Sulzer document
September 2011 G
Page number when the document has more than one

page (total number of pages)
Document version number
Document identification number
Language of the document
The date when this document was done previously (when needed)
The date when this document was done or updated
Product version number
Sulzer Pumps Finland Oy identification

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INSTRUCTIONS ISO
Intended use
3 Type designation
A 4 3 - 250 - LM
A P P
LM = LM design liquid ring pump / mechanical seal

GM = GM design gas separator / mechanical seal
GS = GS design gas separator / static seal
S = S design liquid ring pump / mechanical seal
R = R design air separating pump / mechanical seal
Nominal diameter of discharge (mm) = 250 mm
Except the markings:
8S nominal diameter of discharge = 80 mm
10S nominal diameter of discharge = 100 mm
10P nominal diameter of discharge = 100 mm
Sealing unit size = 43
Shaft size = 4
Hydraulic construction
A = Standard process pump (mm-dimensioned structure)
APP = Standard process pump (mm-dimensioned structure)
EPP = Hot liquid pump (mm-dimensioned structure)
NPP = Non-clogging pump (mm-dimensioned structure)
WPP = Wear resistant pump (mm-dimensioned structure)
4 Parts number designation
4.1 Part numbers of modules

The delivery may include the entire pump product (PUPR.0) and/or pump spare parts. The installation-ready pump
unit is divided into the following modules: pump (PUMP.0), assembly (ASSE.0), drive unit (DRUN.0), measuring
instrumentation (MEIN.0), external degassing system (DESY.0) and documents (DOCU.0).
The pump (PUMP.0) is divided into the following modules: wet end (WEEN.1), sealing unit (SEUN.2) and bearing
unit (BEUN.3). The assembly is divided into the following modules: sealing water equipment (SWEQ.4), coupling unit
(COUN.5) and baseplate (BAPL.6). The drive unit (DRUN.0) is divided into two parts: motor (DRMO) and frequency
converter (FRCO). Documents are divided into two categories: documents supplied with the delivery and documents
supplied separately.
4.2 Part numbers of parts, connections and documents

Parts, which have part numbers consisting of a three/four-digit number plus two digits after a dot. The first digit after
the dot shows the number of the delivery unit or module in question, while the second digit distinguishes parts of the
same type from each other.
In the part number, the first digit after the dot is determined by the module. For instance, o-ring 412.11. If the module
has many parts with the same name, the second digit after the dot distinguishes the parts from each other. For
instance, 412.12 is the second o-ring in the wet end (WEEN.1).
Connections, which have part numbers consisting of the initial letter C, a two-digit number plus two digits after a dot.
The first digit after the dot shows the number of the delivery unit or module in question, while the second digit
distinguishes connections of the same type from each other.
Documents, which have part numbers consisting of the initial letter D, a two-digit number plus two digits after a dot.
The first digit after the dot shows the number of the delivery unit or module in question, while the second digit
distinguishes documents of the same type from each other.

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INSTRUCTIONS ISO
Intended use
5 Nameplate designation
The following nameplates have been attached to the volute casing (102.11) of each pump:
Nameplate (971.01), showing the pumps identification data and flow properties. Fig. 1.
Patent nameplate, showing the patents protecting the product. Fig. 2.
ATEX nameplate (982.01), if the product is designed for use in potentially explosive environments. Fig. 3 and
Fig. 4.
1 3
2 4
7 6 5
Marking:
1 Pump type 5 Speed of rotation (rpm)
2 Serial No. = Job No. 6 Space for customer Pos. No.
3 Head (m) 7 Year of manufacture
4 Capacity flow (l/s)
Fig. 1
MADE UNDER ONE OR MORE OF

THE FOLLOWING US PATENTS:
NOS. 4,863,353
4,594,052
OTHER PATENTS PENDING
Fig. 2
0123 II 2 G c T3
c = The protection class used is constructional safety
T3 = Temperature class, indicates the maximum surface temperature
(200C)
Ex = Explosion protection marking
II = Equipment group
2 = Equipment category
G = The equipment is used in explosive atmospheres caused by gases, vapours or mists
CE marking and the mark of the notified body.
0123 = TV Product service, Mnchen
Fig. 3
II 3 G c T3
c = The protection class used is constructional safety
T3 = Temperature class, indicates the maximum surface temperature (200C)
Ex = Explosion protection marking
II = Equipment group
3 = Equipment category
G = The equipment is used in explosive atmospheres caused by gases, vapours or mists
Fig. 4

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INSTRUCTIONS ISO
Intended use
6 Capacity and head
The pump is always dimensioned according to the pumping values (flow, head) stated in the nameplate (971.01) of
the pump. Flow and head values that can be reached with the specific impeller diameter and operating speed are
given in the characteristic curve of the pump. The operating point on the curve can be changed by adjusting the
pumping system resistance e.g. by throttling the flow with the valve in the discharge piping. If the impeller diameter
or the rotational speed of the pump is changed, then the operating point will move totally to another head-flow curve.
The pump must not be used at other operating points without the following verifications:
When the pump was selected in the original operating point, all factors affecting the mechanical durability
(e.g pressure and temperature limits) and pump design (pump, impeller type, shaft sealing and lubrication
etc.) were carefully considered. All these factors are to be checked also in the new operating point.
The pump could temporarily operate even with the discharge valve closed. For continuous operation, a
minimum flow is still required. The required suction head (NPSH required) curve presented in the
characteristic curve always starts from the point of the minimum continuous flow allowed.
The suction properties of the system (NPSH available) and drive motor power are always to be checked in a
new operating point.
The efficiency of a pump is a relevant factor when estimating the lifetime costs of the pump. Therefore its
influence on the power need must be checked.
The characteristic curve enclosed is always based on tests with clean water. Other types of pumped liquid
can change the head, flow or power need values radically. These factors were recognized when the pump
was originally selected and they must be considered also in the new operating point.
7 Decommissioning
Sulzer Pumps products are designed so that their service would be as easy as possible by replacing worn or
damaged parts with new, original Sulzer spare parts. Parts can also be re-used after reconditioning them at Sulzer
Customer Support Service Centers. Sulzer Customer Support Service Centers must be used in the assessment of
re-use and reconditioning. If you need additional instructions or guidance, please contact our representative.
The materials used in Sulzer Pumps products are disclosed in the parts list supplied with the product.
At the end of the life cycle of a product or its parts, the appropriate materials and parts must be recycled or disposed
of using methods which are acceptable in terms of environmental protection and which conform to local legislation
and regulations. If a product or its part contains environmentally harmful substances, they must be removed and
disposed of by following valid regulations.
Packaging materials must be recycled or disposed of using methods which are acceptable in terms of environmental
protection and which conform to local legislation and regulations.
Make sure that hazardous substances are disposed of safely and that the personnel use appropriate personal
protective equipment. Safety considerations must always meet the requirements of valid regulations.

SERIES 2.15
AHLSTAR
PROCESS PUMPS
5 mm
MAX
0.2 in
Safety instructions
1 General
2 Safety of machinery
3 Definitions
4 Essential safety aspects
5 Ignition hazard assessment
6 Safety signs affixed to the product
7 Operating situations affecting product safety
8 Balance and vibration
9 Wet end

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INSTRUCTIONS ISO
USER'S MANUAL AHLSTAR May 2014 G
Safety instructions
1 General
This product is designed and tested for safe and reliable operation in the application for which it is specified and
sold. Remember, a pump is a piece of equipment with pressure containing parts and rotating elements which can
cause a hazard. Therefore, all the safety measures in the instructions are to be followed strictly. Personal injuries
may result if the instructions are not observed and followed.
It is not only the general safety instructions contained under this main heading Safety instructions which are to be
observed, but also the specific safety information presented in other instructions relating to this delivery, relevant
national safety regulations or any other safety information issued by the plant operator.
The exact and detailed process and application data is relevant for the safe and reliable operation of the product.
Special environmental conditions at the place of installation should always be checked between the end user and
manufacturer. Such conditions are e.g.
Abnormal temperature
High humidity
Corrosive atmospheres
Pressure fluctuations
Falling below the minimum permissible flow, dry running
Explosive and/or fire risk zones
Dust, sandstorms
Earthquakes
Special safety measures are also needed when the type of liquid to be pumped is e.g. the following:
Flammable
Corrosive, abrasive
Poisonous
Crystallizing
Solid containing
Gas containing
Non-compliance with the safety and specific operating instructions may produce a risk to the personnel as well as to
the environment, e.g.
Failure of important functions of the pump and/or plant
Failure of specific procedures of maintenance and repair
Exposure of people to electrical, mechanical and chemical hazards
Endangering the environment owing to hazardous substances being released

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Safety instructions
2 Safety of machinery
2.1 General
Our delivery does not include the design of the operating environment of the machine, nor the power circuits, control
circuits and controls for the machine required in the operation of the machine. However, the European Machinery
Directive 2006/42/EC on safety of machines and/or corresponding national legislation of the country where the
machine is used are mandatory in terms of essential health and safety requirements related to the operation of the
process.
We require that the Customer has taken into account the essential requirements laid down in this instruction when
designing, purchasing and starting up the process control systems, other controls and equipment related to the
machine. Some of these requirements also concern the personnel in charge of the operation of the machine.
As far as the above is applicable, the Customer must also ensure that the valid legislation on electrical safety (such
as low-voltage directive) or electromagnetic compatibility of equipment (EMC directive) is followed.
During the operation of the machine, valid occupational safety legislation of the country where the machine is used
must also be followed.
2.2 Essential health and safety requirements
2.2.1 General remarks
2.2.1.1 Definitions
When necessary, the potential danger zones related to the machine and its operating environment, persons exposed
within the danger zone and all operator groups of the machine must be specified jointly between the Customer and
the Manufacturer, for example for the purpose of introductory training arranged for the operators of the machine.
2.2.1.2 Principles of safety integration
As a machine manufacturer, we have, in accordance with the contents of the delivery, followed the Machinery
Directive and/or the national legislation of the country where the machine is used in order to ensure safety
integration.
The installation, operating and safety instructions supplied with the machine must be followed on receipt of the
machine, in installing it at the point of operation and in its operation. Prior to final start-up, it must be ensured that the
machine, its controls and other equipment related to a safe use of the machine fulfill the requirements laid down in
the Machinery Directive and/or in national safety legislation.
2.2.1.3 Materials and products
The products related to the use of the machine (liquids transferred in the process) must not endanger the exposed
persons' safety or health. The process where the machine is used must be designed so that the use of liquids
causes no hazard.
2.2.1.4 Lighting
Maintenance areas necessary for the regular inspections of the machine must be provided with appropriate lighting.
2.2.1.5 Design of machinery to facilitate its handling
The environment of the machine must be designed so that, in order to facilitate the handling of the machine or its
various components, standard lifting gear can be attached above the machine if necessary. The environment must
be designed so that the various components can be handled safely in other respects as well. The handling and lifting
instructions supplied with the machine must be absolutely followed.

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Safety instructions
2.2.2 Controls
2.2.2.1 Control and stopping devices
The controls of the machine must be safe and constructed in a way that will prevent a dangerous situation arising.
When designing the controls, the specified requirements laid down in the Machinery Directive and/or in the national
legislation of the country where the machine is used must be absolutely followed in terms of controls, starting
devices, stopping devices (including emergency stop devices) and selection of control and operating modes for the
machine and combinations of machinery.
The controls of the machinery must be designed so that fluctuations in energy supply or failures in the control circuit
do not lead to dangerous situations. The interactive software used in the controls between the operator and the
machine must be user-friendly.
2.2.3 Protection against mechanical hazards
2.2.3.1 Stability
Our delivery includes the appropriate accessories for securing the machine to the foundations. The installation
instructions supplied with the machine must be absolutely followed in order to ensure sufficient stability of the
machine/combination of machinery.
2.2.3.2 Risk of break-up during operation
The piping and hoses connected to the machine must be able to withstand the anticipated internal and external
stresses, and they must be firmly secured and protected against all loading and stress.
The instructions concerning the purpose of the machine, limitations of use, allowable flange forces and support of
piping, supplied with the machine, must be absolutely followed. During operation, there is always a risk of rupture in
the piping connected to the machine (risk of high-pressure/hot/harmful liquid spray) if the supplied instructions are
violated.
2.2.3.3 Risk due to falling or ejected objects
Necessary precautions must be taken to prevent risks from falling or ejected objects (e.g. tools used during
installation).
2.2.3.4 Risks due to sharp edges or angles
Due to the purpose and design of the machine, its parts have sharp edges and/or angles. During installation and
maintenance, the instructions supplied with the machine must be followed, and the appropriate personal protective
equipment must be used.
2.2.3.5 Risks related to variations in the rotational speed
The instructions supplied with the machine show the intended rotational speed of the machine and its maximum
rotational speed limits. The selection and adjustment of rotational speed must be performed so that these
instructions are adhered to.
2.2.3.6 Prevention of risks related to moving parts
The fixed guards used for preventing risks related to moving parts in the machine must be absolutely kept in place
while the machine is running. If a guard is not included in the delivery, it must be ensured prior to start-up that the
rotating parts are provided with guards in accordance with the valid legislation. If rotating parts of the machine seize
accidentally during operation, the machine must be stopped immediately and the cause of the fault must be
ascertained in accordance with the instructions supplied with the machine.

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Safety instructions
2.2.4 Protection against other hazards
2.2.4.1 Electricity supply
The electrical drives of the machine must be designed, constructed and equipped so that all hazards of an electrical
nature can be prevented. The specific rules and valid legislation in force related to electrical equipment must be
absolutely followed. The electrical equipment related to a machine conforming to the Machinery Directive must fulfil
the detailed requirements laid down in standard EN 60204-1:2006.
2.2.4.2 Static electricity
The build-up of potentially dangerous electrostatic charges in the machine and its auxiliary equipment must be
prevented or restricted.
2.2.4.3 Errors of fitting
Errors made when fitting parts of the machine can be a source of risk. For this reason, the instructions supplied with
the machine must be absolutely followed during the installation and repairs of the machine.
Faulty liquid and electrical connections can also be a source of risk. With liquid connections, the instructions
supplied with the machine must be followed. Faulty electrical connections must be made impossible by the design,
or information on the risk must be given on cables and connectors.
2.2.4.4 Extreme temperatures
If necessary, the machine must be provided with warnings concerning high surface temperatures. In these cases,
additional steps should be taken to eliminate any risk of injury caused by contact with or proximity to machinery
parts. Maintenance requires the heating of some parts prior to installation. Carefulness is imperative during
installation, and appropriate personal protective equipment must be used during installation.
2.2.4.5 Fire and explosion
Exact and detailed information on the process and the purpose for which the machine is used are essential in terms
of safe operation of the machine. The specific circumstances prevailing at the point of use must always be checked
between the Customer and Manufacturer when the machine is being selected.
With equipment intended for use in potentially explosive atmospheres (ATEX), see section 5 (Ignition hazard
assessment.
2.2.4.6 Noise and vibration
The instructions supplied with the machine provide information on the emission of airborne noise and on the
balancing of rotating parts of the machine. The data given must be taken into account and necessary steps must be
taken in order to eliminate any risks caused by noise or vibration in accordance with the circumstances prevailing at
the point of use.
2.2.4.7 Radiation
The instructions supplied with the machine provide information on the emission of radiation potentially involved in the
measuring equipment of the machine. The operators of the machine must absolutely follow the safety instructions
concerning the use of this equipment.
2.2.4.8 Emissions
The instructions supplied with the machine provide information on the control of leakages in the immediate proximity
of the machine. If necessary, the following steps must be taken to eliminate harmful emissions involved in the
process:

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Safety instructions
account of the emissions and their potential consequences (e.g. possibility of fire, appropriate extinguishing
equipment)
preventing exposure of operators
controlled containment and evacuation of emissions
cleaning of emissions and machinery
appropriate personal protective equipment and warnings
2.2.4.9 Slipping, stumbling and falling
When installing, servicing and repairing the machine, the instructions supplied with the machine, safety instructions
applicable at the point of use and sufficient care and attention must be followed in order to prevent any slipping,
stumbling or falling.
2.2.5 Maintenance
2.2.5.1 Machinery maintenance
The maintenance and repair instructions supplied with the machine must be absolutely followed. The instructions
specify separately which measures require stopping and potential draining of the machine. Appropriate personal
protective equipment as required by the work performed must always be used, e.g.:
hearing protectors
eye protectors
breathing protectors
safety gloves, safety footwear, protective clothing
When servicing and repairing the machine, principles of ergonomics (avoiding excessive use of muscular power,
utilization of lifting gear, lifting positions, lighting of the area, cleanliness etc.) must also be taken into account.
2.2.5.2 Access to operating position and servicing points
Where the location design for the machine is not included in the delivery, steps must be taken to situate the machine
at the point of operation in a manner that enables safe maintenance and repairs of the machine. Provision of
sufficient maintenance space around the machine must be taken into account in the design of the operating
environment.
2.2.5.3 Isolation of energy sources
The controls of the machine must be designed so that they include clearly identified devices that can be used to
isolate the machine from all energy sources. These devices must be capable of being locked if reconnection of
energy could endanger exposed persons. After the energy is cut off, it must be possible to dissipate any energy
remaining or stored in the process (e.g. discharging pressure) without risk to exposed persons.
2.2.5.4 Operator intervention
The controls of the machine must be designed so that the need for operator intervention is limited.
2.2.5.5 Cleaning of (internal) parts of machine
The potential cleaning of the machine must take place in accordance with the instructions supplied with the machine
and the safety instructions applicable at the point of use so that cleaning can be carried out as safely as possible.

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Safety instructions
2.2.6 Indicators
2.2.6.1 Information and warning devices
When designing the controls of the machine, the specified requirements laid down in the Machinery Directive and/or
national legislation of the country where the machine is used must be absolutely followed in terms of information and
warning devices used on the machine.
2.2.6.2 Warning of residual risks
The safety warnings related to the machine must be kept clean under all circumstances, and the warnings must be
renewed when necessary. All operators of the machine must be warned of the residual risks involved in electricity or
the controls in accordance with specified requirements laid down in the Machinery Directive and/or national
legislation of the country where the machine is used.
2.2.6.3 Marking and instructions
The marking and instructions for the machine must be drawn up in accordance with the Machinery Directive and/or
national legislation of the country where the machine is used. Steps must be taken to ensure that the marking and
instructions for other equipment related to a safe use of this machine conform to valid legislation.
In particular, it must be ensured that the point of use is provided with instructions for emergencies, such as:
how to give alarm
location of rescue and fire extinguishing equipment
availability of first aid and necessary first aid equipment
3 Definitions
The following words are used in the instructions to indicate issues which require special attention.
WARNING
There is a risk of personal injury if the instruction is not adhered to.
CAUTION
There is a risk of damaging or destroying the product or equipment if the instruction is not adhered to.
NOTE
Is used in the text for highlighting necessary information or requirements which are essential to
observe.

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Safety instructions
4 Essential safety aspects
All of the following relevant safety aspects are to be instructed to the operators and maintenance personnel before
putting the product into service.
General
The product is meant only for the purpose for which it is sold - never operate beyond the intended use
described in these instructions.
Personal injuries may occur if personal protective equipment is not used when servicing the product.
Pump units which convey hazardous media must be decontaminated before beginning any maintenance
work.
If there is a possibility that the pump or the pipeline contains explosive gases or vapours, it must be
ventilated carefully before working on the pump.
If there is a possibility that there are explosive gases or vapours in the atmosphere surrounding the pump,
the pumps environment must be ventilated carefully before working on the pump.
External heat must not be used when dismantling the pump, as any liquid, gas, vapour or their combination
that remains in the pump may explode.
All safety devices (e.g. coupling and shaft sealing guards) must be correctly installed before starting. For
explosive areas, guards with a non-sparking material are to be used.
Wet end
If there is a possibility of a dangerous return flow after the shutdown of the pump, a nonreturn device shall be
installed in the outlet piping.
The pump must be sufficiently filled with the pumped liquid before starting (with the exception of liquid ring
pumps (-LM, -S), air separating pumps (-R) and pumps equipped with a gas separator (-GM, -GS)).
The pump must run above the minimum recommended flow and never dry (with the exception of liquid ring
pumps (-LM, -S), air separating pumps (-R) and pumps equipped with a gas separator (-GM, -GS)).
The suction valve must be open during operation.
If leakage of harmful or dangerous substances can occur - prepare proper means for a safe waste removal.
The parts in contact with the pumped liquid can be dangerously hot.
Sealing unit
The product must always be equipped with a shaft sealing system compatible with the pumped liquid.
The parts in contact with the pumped liquid can be dangerously hot.
Bearing unit
For delivery, the bearing housing of the pump has been emptied of oil. Remember to refill it before starting.
There is no protection against contact in the shaft seal area.
Drive motor
Always stop the drive unit before beginning any repair work on the pump. Make sure that the motor cannot
be started by any means accidentally during the repairs.
The correct rotating direction of the drive unit must be checked before starting and the pump must rotate
freely (with coupling spacer removed).

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Safety instructions
Coupling unit
The coupling must be properly aligned before starting.
Baseplate
The pump baseplate must be properly installed before starting.
5.1 General
1 Description of use
Group II category 2 Ex II 2 G c T1, T2, T3 and T4: The equipment is a centrifugal pump designed for use in
environments in which the release of flammable materials will give rise to a zone 1 potentially explosive
atmosphere (zone in which explosive atmospheres caused by mixtures of air and gases, vapours or mists
are likely to occur occasionally during normal operation). The pump is designed for pumping various liquids
in the process industry.
Group II category 3 Ex II 3 G c T1, T2, T3 and T4: The equipment is a centrifugal pump designed for use in
environments in which the release of flammable materials will give rise to a zone 2 potentially explosive
atmosphere (zone in which explosive atmospheres caused by mixtures of air and gases, vapours or mists
are likely to occur occasionally during normal operation). The pump is designed for pumping various liquids
in the process industry.
2 Construction
The pump is horizontally mounted and has a single-stage end-suction design. The pump shaft is mounted on
antifriction bearings so that the bearing at the impeller end carries radial loads, while the bearings at the
clutch end carry mainly axial loads. The pump is made from cast iron (for non-corroding liquids) or acid-
resistant steel (for corroding liquids). The pump easily passes the required mechanical tests described in EN
13463-1. There are no light metal or plastic parts that need consideration, or other relevant restrictions as
described in EN 13463-1.
The pumps design is such that it will not leak even in the event of a foreseeable malfunction. In normal
operation, the pump contains the liquid being pumped. In a self-priming design, the pump is filled with air or
a mixture of air and, for example, vapours or mists when the pump starts and before it is filled with the liquid
that is to be pumped. This is a planned function and does not compromise the functioning of the pump. The
pump is sealed either by a single-acting or double-acting slide ring seal or a dynamic seal, depending on the
operating conditions. If a slide ring seal is used, the sliding faces are lubricated by either the liquid that is
being pumped or an external sealing liquid.
The pump mounting has been designed to withstand the expected loads and vibration caused by the pump.
The installation, operation and maintenance instructions include details of the support required by the pipes.
The ignition hazard assessment according to 5.2 of EN 13463-1 + AC identifies that, because of its
construction and on the basis of testing (temperature classification and shock resistance tests), no ignition
sources exist in normal operation, during scheduled maintenance or repairs.
The table below lists all potential ignition sources that can be detected on the basis of experience, assesses
the measures applied to prevent the source becoming effective and specifies the ignition protection methods
used. This ignition hazard assessment document is placed in the manufacturers technical file.

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Safety instructions
4 Marking with regard to ignition protection

EN 13463-1 requires the equipment to be marked with the symbol(s) of the ignition protection used. In this
particular case, the pump complies with EN 13463-1 and EN 13463-5 and the symbol c will therefore be
included in the marking.
5.2 Group II category 2 (Ex II 2 G c T1, T2, T3 and T4)

Potential ignition source (1)
Measures applied to prevent the Ignition
Normal Expected Rare malfunction source becoming effective (2) protection used
operation (1a) malfunction (1b) (1c)
Assembly
Electrostatic Electrostatic charging is not possible, as EN 13463-1 + AC
discharge from the pump has no exposed plastic parts. 7.4
the pumps Metal parts are attached to each other so
external that there are no differences in potential. EN 13463-1 + AC
surfaces and 11.
subsequent
arcing There is no ignition source. EN 13463-5 c
The pump is The design rotation speed for the pump is EN 13463-5 c
driven at excess indicated on a label attached to the pump
speed and is body.
therefore
damaged.
Accumulation of All air or gas mixtures are discharged EN 13463-1 + AC
an explosive from the pump when liquid enters. 15.
mixture of gases The pump is so designed that gases or
or air in the air cannot accumulate outside the pump. EN 13463-5 c
pump
There is no ignition source. IOM
The clutch cover The clutch cover is designed so that EN 13463-5 c
makes contact there is sufficient clearance to prevent
with the clutch contact between the rotating clutch and
and causes the clutch cover.
frictional arcing
or heat There is no ignition source.
The clutch cover The strength of the clutch cover has been EN 13463-1 + AC
is deformed checked by shock resistance tests. 13.3.2
because of a
shock so that the
clutch makes
contact with the
clutch cover,
which causes
frictional heat or
arcing. There is no ignition source.
Clutch The clutch is Clutch breakage The installation, operation and EN 13463-5 c 8
aligned or because of a rare maintenance manual contains
installed malfunction, such instructions on the installation and IOM
incorrectly, which as jamming, a alignment of the clutch.
leads to clutch material defect in
breakage and the clutch or
arcing. excessive pipe
strain on the pump.
Not considered. There is no ignition source.

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions

Bearings
Overheating of A bearing breaks The bearings are dimensioned for EN 13463-5 c 6
bearings and overheats continuous operation at rated values. The
installation, operation and maintenance IOM
manual contains instructions on the
maintenance and condition monitoring of
bearings. The pump has vibration
measurement fittings through which the
condition of the bearings can be
monitored.
There is no ignition source.

Insufficient Oil-lubricated bearings have a sight glass EN 13463-5 c 6
lubrication of for monitoring the oil level.
bearings, which The installation, operation and IOM
leads to their maintenance manual contains
overheating instructions on the lubrication of bearings.

Overheating of The installation, operation and EN 13463-5 c 6
grease-lubricated maintenance manual contains
bearings because instructions on correct lubrication to IOM
of excessive prevent the overheating of bearings.
grease
Ingress of water or The installation, operation and EN 13463-5 c 6
other impurities into maintenance manual contains
the bearings, which instructions on the maintenance and IOM
leads to insufficient condition monitoring of bearings. Failure
lubrication, bearing caused by the ingress of water is shown
failure and the as increased vibration of the bearings,
overheating of which can be detected during condition
bearings monitoring. The pump has vibration
monitored.

The metal part of The rotating ring is protected with the EN 13463-5 c
the bearings shock-resistant clutch cover at the drive
rotating ring rubs end. The rotating ring at the impeller end
against the labyrinth is located inside a socket, which is
static seal and arcs extremely unlikely to be subjected to
or overheats; a shocks.
shock on a metal
part deforms the Does not apply to categories 2 and 3.
rotating ring.
Rotary shaft seals
Failure of the Rotary shaft seals must always be EN 13463-1 + AC
sealing face of a selected on a case-by-case basis, 15.
mechanical seal depending on the liquid to be pumped
lubricated with the and process conditions. The installation, EN 13463-5 c
liquid being operation and maintenance manual
pumped due to contains instructions on the condition IOM
insufficient monitoring of seals.
lubrication, which
leads to seal
overheating. There is no ignition source.

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions

Failure of the Rotary shaft seals must always be EN 13463-1 + AC
sealing face of a selected on a case-by-case basis, 15.
mechanical seal depending on the liquid to be pumped
lubricated with and process conditions. The installation, EN 13463-5 c
external sealing operation and maintenance manual
liquid due to contains instructions on the condition IOM
insufficient monitoring of seals.
lubrication, which
leads to seal
overheating. There is no ignition source.
Load-bearing parts
The impeller makes Does not apply to categories 2 and 3. EN 13463-5 c 5.3
contact with the
side plate, sealing
ring or the casing
cover, which leads
to the overheating
of the pumps
external surface. There is no ignition source.
A solid object Does not apply to categories 2 and 3. EN 13463-1 + AC
blocks the gap 15.
between the
impeller and the IOM
side plate or the
casing cover, which
leads to the
overheating of the
pumps external
surface. There is no ignition source.
The pump runs The installation, operation and EN 13463-1 + AC
against a closed maintenance manual contains instruction 15.
valve for a long on the control and monitoring of
time, which leads operation. Long-term running against a IOM
to pump breakage closed valve is prohibited.
and overheating.
Components
Clutch The clutch delivered meets the EN 13463-1 + AC
requirements of the ATEX Directive.

Electric motor The motor delivered meets the Ex requirements

Sealing liquid The sealing liquid equipment delivered EN 13463-1 + AC
equipment meets the requirements of the ATEX
Directive.

Repairs
The pump is The installation, operation and EN 13463-1 + AC
repaired in the maintenance manual contains 15.
presence of an instructions on the ventilation of the
explosive mixture. premises in which repairs are carried out. IOM

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions

An explosive The installation, operation and EN 13463-1 + AC
mixture remains in maintenance manual contains 15.
the pipeline. instructions on the ventilation of the
pipeline that is connected to the pump. IOM
IOM = Installation, Operation and Maintenance manual
5.3 Group II category 3 (Ex II 3 G c T1, T2, T3 and T4)

Assembly
Electrostatic Electrostatic charging is not possible, as EN 13463-1 + AC
discharge from the pump has no exposed plastic parts. 7.4
the pumps Metal parts are attached to each other so
external that there are no differences in potential. EN 13463-1 + AC
surfaces and 11.
subsequent
arcing There is no ignition source. EN 13463-5 c
Accumulation of All air or gas mixtures are discharged EN 13463-1 + AC
an explosive from the pump when liquid enters. 15.
mixture of gases The pump is so designed that gases or
or air in the air cannot accumulate outside the pump. EN 13463-5 c
pump
There is no ignition source. IOM
The clutch cover The clutch cover is designed so that EN 13463-5 c
makes contact there is sufficient clearance to prevent
with the clutch contact between the rotating clutch and
and causes the clutch cover.
frictional arcing
or heat There is no ignition source.
Bearings
Overheating of A bearing breaks The bearings are dimensioned for EN 13463-5 c 6
bearings and overheats continuous operation at rated values. The
installation, operation and maintenance IOM
manual contains instructions on the
maintenance and condition monitoring of
bearings. The pump has vibration
monitored.

Load-bearing parts
Components
Clutch The clutch delivered meets the EN 13463-1 + AC

Electric motor The motor delivered meets the Ex requirements

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions

Sealing liquid The sealing liquid equipment delivered EN 13463-1 + AC
equipment meets the requirements of the ATEX
Directive.
IOM = Installation, Operation and Maintenance manual
6 Safety signs affixed to the product
The following warnings and informative signs concerning the essential safety aspects are permanently fixed on the
product. Safety signs must always be observed and kept clean and legible in any operating condition. The user must
always check that the symbols or items presented in those are understood by all user groups before putting the
product into service.
Wet end
Item no. 975.11. Hot surface, do not touch (to be fixed when the temperature of the pumped liquid is > 60C)
Sealing unit
ATTENTION!
This product is equipped with a
mechanical seal.
Do not run or rotate the seal dry!
Please read carefully through the
instructions for the product and
the mechanical seal before
commissioning.
4-941349-06
Item no. 976.21. Do not run or rotate the seal dry

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions
Bearing unit
Item no. 975.31. Splashing of corrosive or irritative substances (this sign is delivered unattached and it is to be
attached to both sides of the adapter if necessary)
Coupling unit
Item no. 976.51. Coupling alignment values
5 mm
MAX
0.2 in
Item no. 975.51. Coupling guard jacket to be adjusted during assembly
7 Operating situations affecting product safety
The following inadequate operating situations always have consequences which have an immediate effect on the
product safety and therefore they are not allowed in any operating conditions with this product.
Table 1, Typical inadmissible operating situations

Cause: Consequence:
Discharge valve not opened. Inadmissible pressure increase
Inlet pressure or piping system resistance incorrectly estimated when the pump
was originally selected.
The pump is operated at too high a rotational speed.
Discharge valve not opened. High temperatures (Wet end)
Discharge valve throttled too much.
Properties of the pumped liquid incorrectly estimated when the pump was
originally selected.

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions
Cause: Consequence:
Gland packing tightened too much. High temperatures (Sealing unit)
Adequate sealing water service neglected.
- Sealing water pump not started
- Sealing water valve not opened
- Sealing water equipment incorrectly adjusted
- Quality of the sealing water does not match our requirements.
Inlet pressure incorrectly estimated when the pump was originally selected.
Pump is not properly filled with the pumped liquid.
- Suction valve not opened
- Suction tank not properly filled
- Suction piping resistance or air tightness improperly checked
Pump lubrication carried out inadequately. High temperatures (Bearing unit)
- Oil/grease filling neglected
- Oil/grease quality incorrectly selected
- Relubrication carried out inadequately
Pump washdown carried out inadequately (sprayed water enters the bearing
unit).
Properties of the pumped liquid incorrectly estimated when the pump was
originally selected.
8 Balance and vibration
The pump is normally balanced in accordance with grade G 6.3 of ISO 1940, in special cases with grade G 2.5 of
ISO 1940. Vibration does not exceed the vibration severity limits given in Table 2 when measured at the
manufacturers test facilities. These values are measured radially at the bearing housing at rated speed and flow
when operating without cavitation.
A pump equipped with a specially designed impeller may exceed the limits given in Table 2.
Table 2, Max. r.m.s values of vibration velocity

Shaft centerline height H1
Pump installation
225 mm > 225 mm
Pump on a grouted baseplate or on a concrete baseplate 3 mm/s 4.5 mm/s
Pump on a baseplate without grouting 4.5 mm/s 7.1 mm/s
9 Wet end
9.1 Admissible forces and moments on pump flanges

Forces and moments acting on the pump flanges due to pipe loads can cause misalignment of the pump and driver
shafts, deformation and overstressing of the pump casing, or overstressing of the fixing bolts between the pump and
baseplate.
This is a simple method for checking that loads transmitted to a pump by its piping remain within acceptable limits.
This is done by comparing the loads (forces and moments) calculated by the piping designer, with the maximum
values allowed on the flanges, as a function of their size and the installation conditions.
The basic values given in Table 3 are applicable to each of the pump flanges, respecting the sign convention of the
three axes through the flange. The values can be applied simultaneously in all directions with positive or negative
signs, or separately on each flange (suction and discharge).

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions
WARNING
The basic values mentioned in Table 3 should be multiplied by: 0.15 white iron, 0.35 cast iron, 0.45
carbon steel and 0.7 stainless steel. The values mentioned in the table apply to pumps equipped with
a grouted baseplate or a concrete baseplate. A baseplate installed with machine feet should be
multiplied by 0.25.
x
z
Fig. 1
Table 3, Basic values of forces and moments

Top branch z-axis
Diameter DN Force (N) Moment (Nm)
Fy Fz Fx F* My Mz Mx M *
32 850 1050 900 1650 750 850 1100 1600
40 1000 1250 1100 1950 900 1050 1300 1900
50 1350 1650 1500 2600 1000 1150 1400 2050
65 1700 2100 1850 3300 1100 1200 1500 2200
80 2050 2500 2250 3950 1150 1300 1600 2350
100 2700 3350 3000 5250 1250 1450 1750 2600
125 3200 3950 3550 6200 1500 1900 2100 3050
150 4050 5000 4500 7850 1750 2050 2500 3650
200 5400 6700 6000 10450 2300 2650 3250 4800
250 6750 8350 7450 13050 3150 3650 4450 6550
300 8050 10000 8950 15650 4300 4950 6050 8900
350 9400 11650 10450 18250 5500 6350 7750 11400
400 10750 13300 11950 20850 6900 7950 9700 14300
500 13450 16600 14950 26050 10250 11800 14450 21300
600 16150 19900 17950 31250 14400 16600 20200 29900
700 18800 23880 21540 37500 17280 19920 24240 35880
End branch x-axis

32 900 850 1050 1650 750 850 1100 1600
40 1100 1000 1250 1950 900 1050 1300 1900
50 1500 1350 1650 2600 1000 1150 1400 2050

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions
End branch x-axis

65 1850 1700 2100 3300 1100 1200 1500 2200
80 2250 2050 2500 3950 1150 1300 1600 2350
100 3000 2700 3350 5250 1250 1450 1750 2600
125 3550 3200 3950 6200 1500 1900 2100 3050
150 4500 4050 5000 7850 1750 2050 2500 3650
200 6000 5400 6700 10450 2300 2650 3250 4800
250 7450 6750 8350 13050 3150 3650 4450 6550
300 8950 8050 10000 15650 4300 4950 6050 8900
350 10450 9400 11650 18250 5500 6350 7750 11400
400 11950 10750 13300 20850 6900 7950 9700 14300
500 14950 13450 16600 26050 10250 11800 14450 21300
600 17950 16150 19900 31250 14400 16600 20200 29900
700 21540 18800 23880 37500 17280 19920 24240 35880
*F and M are the vector sums of the forces and moments.
When all of the applied loads do not attain the maximum values allowed, one of these loads may exceed the normal
limit, provided that the following supplementary conditions are satisfied:
- any component of a force or of a moment shall be limited to 1.4 times the maximum allowed value;
- the actual forces and moments acting on each flange are governed by the following formula:
2 2
F actual M
actual 2
F M
max .allow . max .allow .
Under the maximum allowance forces and moments, the lateral displacement of the shaft end, relative to the fixed
point in space should not exceed the values indicated in Table 4.
Table 4, Lateral displacement

Shaft-end diameter (mm) Displacement (mm) *
< 30 0.15
31 to 40 0.20
> 40 0.25
* The displacement values given are for reference in checking the stiffness of the pump and its supports and are not the same
as the alignment requirements.
9.2 Sound level charts

Noise emission values are stated according to ISO 4871 and the essential requirements in the Machinery Directive
2006/42/EC.
The noise values are given in accordance with standard EN12639.
Sound power levels have been determined according to EN ISO 9614 Part II using sound intensity measurements.
It is not possible to measure all different pump applications. Therefore, some values have been determined by
calculations based on measurements with similar pumps and Europumps Guide 001/30/E, Forecasting the Airborne
Noise Emission of Centrifugal Pumps.
LpA = A-weighted sound pressure level, dB re 20 Pa, at the relevant working station.
LwA = A-weighted sound power level, dB re 1 pW, if A-weighted sound pressure level exceeds 85 dB.

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions
Open, special open, low flow and vortex impellers

Table 5, Sound pressure level LpA / open impellers (dB)
Pump Pump rot. speed (rpm)
Pump size
types 3550 2950 1760 1480 1180 980 880 740 710 590 510 495 445
10-32 A <70 <70 <70 <70
10-50 A <70 <70 <70 <70
10-65 A <70 <70 <70 <70
11-32 A <70 <70 <70 <70 <70
11-40 A <70 <70 <70 <70 <70
11-50 A 72 <70 <70 <70 <70
20-65 A <70 <70 <70 <70
20-80 A <70 <70 <70 <70
21-65 A 75 <70 <70 <70
21-80 A 77 73 <70 <70 <70
21-100 A 75 <70 <70 <70
22-32 A <70 <70 <70 <70 <70
22-40 A 74 <70 <70 <70 <70 <70 <70
22-50 A 76 73 <70 <70 <70 <70 <70
22-65 A 79 75 <70 <70 <70 <70 <70
22-80 A 81 77 <70 <70 <70 <70 <70
23-40 A 75 <70 <70 <70 <70 <70
23-50 A 77 <70 <70 <70 <70 <70
31-100 A 83 79 <70 <70 <70 <70 <70
31-125 A 81 73 <70 <70 <70 <70
31-150 A 75 <70 <70 <70 <70
32-65 A 72 <70 <70 <70 <70
32-80 A 72 <70 <70 <70 <70
32-100 A 74 <70 <70 <70 <70
32-125 A 76 72 <70 <70 <70
33-80 A 74 72 <70 <70 <70 <70
33-100 A 76 74 <70 <70 <70 <70
33-125 A 79 76 72 <70 <70 <70
41-200 A 81 78 74 71 <70
41-300 A 80 77 73 72 <70
41-400 A 80 77 73 72 <70
42-150 A 79 75 71 <70 <70
42-200 A 81 78 74 71 <70
43-250 A 88 85 81 78 76 73 72 <70
43-350 A 86 82 79 77 74 73 <70
43-500 A 86 82 79 77 74 73 <70
44-150 A 81 78 74 71 <70 <70
44-200 A 84 81 77 71 72 <70
51-250 A 90 87 83 80 78 75 74 71
51-300 A 88 84 81 79 76 75 72
51-400 A 89 85 82 80 77 73 73
51-500 A 89 85 82 80 77 76 73
53-100 A 86 83 79 76 74 71 70 <70
53-150 A 90 87 83 80 78 75 74 77
53-200 A 89 85 82 80 77 76 73
53-250 A 91 87 83 82 79 78 75
53-300 A 88 85 83 80 79 76
53-400 A 88 85 83 80 79 76

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Safety instructions

Pump size
types 3550 2950 1760 1480 1180 980 880 740 710 590 510 495 445
55-100 A 88 84 81 79 76 75 72
55-200 A 92 88 85 83 80 79 76
55-250 A 90 87 85 82 81 78
55-300 A 91 88 86 83 82 79
60-500 A 92 89 86 84 81 80 77
60-600 A 92 89 86 84 81 80 77
63-400 A 90 88 85 84 81
63-500 A 91 89 85 85 82
63-600 A 92 90 86 86 82
63-700 A 92 90 86 86 82
71-250 A 90 86 83 80 80 79 77 77
71-300 A 86 84 81 80 79 77 77
71-400 A 88 86 84 83 82 79 79
71-500 A 90 89 85 85 84 81 81
71-600 A 91 89 86 86 85 84 81
72-300 A 88 84 84 82 81 79 79
72-400 A 89 85 85 85 81 81 79
72-500 A 87 86 85 84 83 81
72-600 A 89 88 86 85 85 84
Table 6, Sound power level LwA / open impellers (dB)

Pump size
types 3550 2950 1760 1480 1180 980 880 740 710 590 510 495 445
43-250 A 96 93
43-350 A 94
43-500 A 94
51-250 A 98 95
51-300 A 96
51-400 A 97 93
51-500 A 97 93
53-100 A 94
53-150 A 98 95
53-200 A 97 93
53-250 A 99 95
53-300 A 96 93
53-400 A 96 93
55-100 A 96
55-200 A 100 95 93
55-250 A 98 95 93
55-300 A 99 96 94
60-500 A 100 97 94
60-600 A 100 97 94
63-400 A 98 96 93
63-500 A 99 98 95 95
63-600 A 100 98 94 94
63-700 A 100 98 94 94
71-250 A 104 102
71-300 A 102
71-400 A 104 102
71-500 A 105 104
71-600 A 105 104 101 101

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions

Pump size
types 3550 2950 1760 1480 1180 980 880 740 710 590 510 495 445
72-300 A 103
72-400 A 104 102 101 99
72-500 A 103 102 100
72-600 A 104 104 101 99 99
Closed impellers
Table 7, Sound pressure level LpA / closed impellers (dB)
Pump rot. speed (rpm)
Pump size Pump types
3550 2950 1760 1480 1180 980 880 740 710 590
11-32 APP <70 <70 <70 <70 <70
11-40 APP <70 <70 <70 <70 <70
11-50 APP 72 <70 <70 <70 <70
21-50 NPP 71 <70 <70 <70 <70 <70
21-65 APP 75 <72 <70 <70 <70
21-80, 8S APP 77 74 <70 <70 <70
21-80 NPP 75 <70 <70 <70 <70
22-40 APP 75 71 <70 <70 <70 <70 <70
22-50 APP, WPP 76 73 <70 <70 <70 <70 <70
22-50 NPP 76 <70 <70 <70 <70 <70
22-65 APP 79 75 <70 <70 <70 <70 <70
22-80, 8S APP 81 78 <70 <70 <70 <70 <70
22-80 NPP <70 <70 <70 <70 <70
23-50 APP, WPP 77 <70 <70 <70 <70 <70
31-65 EPP 81 78 <70 <70 <70
31-100, 10S APP 83 80 71 <70 <70 <70 <70
31-100 EPP 84 81 <72 <70 <70 <70 <70
31-100 NPP <71 <70 <70 <70 <70
31-125, 10P APP 82 72 <70 <70 <70 <70
31-150 APP 75 72 <70 <70 <70
32-65 APP 79 71 <70 <70 <70 <70
32-80, 8S APP, WPP 81 <70 <70 <70 <70 <70
32-80 NPP 74 71 <70 <70 <70
32-100, 10S APP, WPP 82 74 71 <70 <70 <70
32-100 NPP 76 73 <70 <70 <70
32-125, 10P APP 85 73 73 <70 <70 <70
32-200 EPP 77 74 <70 <70
33-80 NPP 79 76 <72 <70 <70 <70 <70
33-100, 10S APP, WPP 74 74 <70 <70 <70 <70
33-100 NPP 80 77 73 70 <70 <70 <70
33-125, 10P APP, WPP 79 76 <72 <70 <70 <70
41-150 EPP 77 74 <70 <70 <70
41-200 APP 80 77 72 <70 <70
41-200 EPP 79 76 72 <70 <70
41-300 APP 82 79 75 72 <70
42-150 APP 79 76 71 <70 <70
42-150 EPP 80 78 73 71 <70
42-150 NPP 79 76 72 <70 <70
42-200 APP 81 78 74 71 <70
42-200 EPP 83 80 76 72 <70
42-200 NPP 80 77 73 70 <70

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Safety instructions

3550 2950 1760 1480 1180 980 880 740 710 590
42-250 EPP 85 82 78 75 71
43-100 EPP 81 78 74 71 72
43-150 EPP 84 81 77 74 72
43-250 APP 85 82 78 75 73 <70
43-300 APP 83 79 76 74 <70
44-150 APP, WPP 81 78 74 71 74 <70
44-150 NPP 83 80 76 73 71 <70 <70
44-200 APP, NPP, WPP 84 81 77 74 <70 <70
51-250 APP 88 85 81 78 76 73 72
51-300 APP 87 83 80 78 74 73
52-350 APP 84 81 79 76 75
52-350 EPP - 81 - 76
52-400 APP 88 85 82 80 78
53-100 APP, EPP, WPP 85 82 78 75 73 70 <70
53-150 APP, WPP 87 84 80 77 75 72 71
53-200 APP, EPP, WPP 89 86 82 79 77 74 73
53-250 APP, WPP 88 84 81 79 76 75
53-250 EPP 88 85 81 78 75 73 72
53-250 NPP 81 83 77 78
53-300 APP 89 85 82 80 77 76
53-300 EPP 90 87 83 80 78 75 74
54-300 EPP 84 84 79 79
54-400 APP, WPP 87 87 82 82 78 78
54-500 APP 91 88 86 83 83 79
54-500 EPP 86 85 82 80 78 76
55-100 APP 90 87 83 80 78 75
55-200 APP 89 85 82 80 77 76 73
55-250 APP 91 87 84 82 79 78 75
55-300 APP, EPP, WPP 89 86 84 81 80 77
61-600 EPP 92 91 87 86 83
Table 8, Sound power level LwA / closed impellers (dB)

3550 2950 1760 1480 1180 980 880 740 710 590
51-300 APP 95 83
53-200 APP, EPP, WPP 94 82
53-250 APP, WPP 89 96 84
53-300 APP 97 85
54-400 APP, WPP 90 95
54-500 APP 91 96
55-100 APP 90 95 83
55-200 APP 97 85
55-250 APP 99 87
55-300 APP, EPP, WPP 89 94
61-600 WPP 100 100 95 95

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions
Open, special open and low pulse impellers

Table 9, Sound pressure level LpA / open impellers (dB)
3550 2950 1760 1480 1180 980 880 740 710 590
11-32 APP <70 <70 <70 <70 <70
11-40 APP <70 <70 <70 <70 <70
11-50 APP 72 <70 <70 <70 <70
21-65 APP 75 <70 <70 <70 <70
21-80, 8S APP 77 73 <70 <70 <70
22-32 APP, WPP <70 <70 <70 <70 <70
22-40 APP 74 <70 <70 <70 <70 <70 <70
22-50 APP, WPP 76 73 <70 <70 <70 <70 <70
22-65 APP 79 75 <70 <70 <70 <70 <70
22-80, 8S APP 81 77 <70 <70 <70 <70 <70
23-40 APP 75 <70 <70 <70 <70 <70
23-50 APP, WPP 77 <70 <70 <70 <70 <70
31-65 EPP 72 <70 <70 <70 <70
31-100, 10S APP 83 79 <70 <70 <70 <70 <70
31-100 EPP 72 <70 <70 <70 <70
31-125, 10P APP 81 73 <70 <70 <70 <70
31-150 APP 75 <70 <70 <70 <70
32-65 APP 72 <70 <70 <70 <70
32-80, 8S APP, WPP 72 <70 <70 <70 <70
32-100, 10S APP, WPP 74 <70 <70 <70 <70
32-100 EPP 77 74 <70 <70
32-125, 10P APP, WPP 76 72 <70 <70 <70
33-100, 10S APP, WPP 76 74 <70 <70 <70 <70
33-125, 10P APP 79 76 72 <70 <70 <70
41-150 EPP 77 74 <70 <70 <70
41-200 APP 79 76 72 <70 <70
41-200 EPP 80 77 72 70 <70
41-300 APP 82 79 74 <70 <70
42-150 APP 79 75 71 <70 <70
42-150 EPP 79 76 72 70 <70
42-200 APP 81 78 74 71 <70
42-200 EPP 83 80 75 73 71
42-250 EPP 84 81 75 74 71
43-100 EPP 81 78 74 71
43-150 EPP 84 81 77 74 72
43-250 APP 85 82 78 75 73 70
43-300 APP 83 79 76 74 71
44-150 APP, WPP 81 78 74 71 <70 <70
44-200 APP, WPP 84 81 77 74 72 <70
51-250 APP 88 84 80 77 76 72 <70
51-300 APP 86 82 79 77 74 73
52-350 APP 84 81 79 76 75
52-400 APP 87 84 82 79 78
53-100 APP, EPP, WPP 85 82 78 75 73 70 <70
53-150 APP, WPP 87 84 80 77 75 72 <70
53-200 APP, WPP 89 86 82 79 77 74 73
53-200 EPP 85 81 78 77 73 72
53-250 APP, WPP 88 84 80 79 75 75

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions

3550 2950 1760 1480 1180 980 880 740 710 590
53-250 EPP 83 78 76 73 71 <70
53-300 APP 89 85 82 80 77 76
53-300 EPP 85 81 78 76 73 72
54-400 APP, WPP 90 87 85 82 82 78
54-500 APP 87 86 82 82 78
54-500 EPP 86 83 81 78 77
55-100 APP 90 87 82 80 77 75
55-200 APP 84 82 79 77 76 73
55-250 APP 86 84 82 79 78 75
55-300 APP, EPP, WPP 88 86 84 81 80 77
61-500 APP, EPP 93 91 88 87 84
61-600 APP, WPP 92 91 87 86 83
62-400 APP 91 90 86 85 82
Table 10, Sound power level LwA / open impellers (dB)

3550 2950 1760 1480 1180 980 880 740 710 590
51-300 APP 96 94
53-200 APP, WPP 94 95
53-250 APP, WPP 95 96
53-300 APP 97 97
54-400 APP, WPP 98 95
54-500 APP 95 94
55-100 APP 98 95
55-300 APP, EPP, WPP 94 94
61-500 APP, EPP 96 101 96
61-600 APP, WPP 100 99 95
62-400 APP 99 99 94
Vortex impellers
Table 11, Sound pressure level LpA / vortex impellers (dB)
3550 2950 1760 1480 1180 980 880 740 710 590
21-50 NPP 76 72 <70 <70
21-80 NPP 76 <70 <70
22-50 NPP, WPP 77 <70 <70 <70 <70 <70
22-80 NPP 71 <70 <70 <70 <70
31-100 NPP 73 71 <70 <70 <70
32-80 NPP, WPP 76 73 <70 <70 <70
32-100 NPP, WPP 77 75 <70 <70 <70
32-125 WPP 79 77 72 <70 <70
33-80 NPP 79 77 72 <70 <70 <70 <70
33-100 NPP, WPP 80 79 72 70 <70 <70 <70
42-150 NPP 81 79 74 71 <70
42-200 NPP 82 80 75 72 <70
44-150 NPP, WPP 84 82 78 74 72 <70 <70
44-200 NPP, WPP 82 78 75 72 <70
53-100 WPP 79 72 74 <70
53-150 WPP 81 74 76 72
53-200 WPP 82 75 77 73

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions

3550 2950 1760 1480 1180 980 880 740 710 590
53-250 NPP, WPP 84 77 79 76
9.3 Maximum size of solid particles

The maximum sizes of solid spherical particles which can flow through the pump (casing/impeller) are presented in
Table 12 (A, Process Pump) and Table 13 (APP, EPP, NPP, WPP).
Table 12, Max. size of solid particles ( mm) (A, Process Pump)
Impeller type
Pump size Pump types Special Special
Open1 Open2 Low flow1 Vortex1
open1 open2
10-32 A 10 - - - 3 -
10-50 A 14 - - - - -
10-65 A 11 - - - - -
11-32 A 12 - - - 5 -
11-40 A 16 - - - - 19
11-50 A 21 - - - - 22
20-65 A 16 - - - - -
20-80 A 17 - 34 - - -
21-65 A 17 - - - - 24
21-80 A 19 - 36 - - 26
21-100 A 29 - 36 - - 37
22-32 A 12 - - - 4 -
22-40 A 15 - - - - 18
22-50 A 18 - - - - 22
22-65 A 23 - - - - 26
22-80 A 20 - 37 - - 29
23-40 A 16 - - - 5 18
23-50 A 21 - - - - 24
31-100 A 25 - 43 - - 30
31-125 A 29 - 50 - - 35
31-150 A 28 - 39 - - 42
32-65 A 21 - - - - 21
32-80 A 26 - 40 - - 30
32-100 A 24 - 42 - - 35
32-125 A 29 - 50 - - -
33-80 A 25 - 35 - - 30
33-100 A 30 - 44 - - -
33-125 A 30 - 54 - - -
41-200 A 34 - 38 - - 48
41-300 A 44 - 51 - - -
41-400 A 44 46 49 51 - -
42-150 A 27 - 54 - - -
42-200 A 32 - 44 - - -
43-250 A 43 - 48 - - -
43-350 A 53 - 61 - - -
43-500 A 52 54 58 60 - -
44-150 A 31 - 59 - - 48
44-200 A 33 - 60 - - 45
51-250 A 43 - 51 - - -
51-300 A 47 - 53 - - -

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions
Impeller type
Pump size Pump types Special Special
Open1 Open2 Low flow1 Vortex1
open1 open2
51-400 A 58 - 68 - - -
51-500 A 58 60 64 66 - -
53-100 A 24 - 31 - - -
53-150 A 33 - 42 - - -
53-200 A 46 - 50 - - -
53-250 A 47 - 55 - - -
53-300 A 50 - 60 - - -
53-400 A 55 - 62 - - -
55-100 A 28 - 37 - - -
55-200 A 39 - 50 - - -
55-250 A 54 - 59 - - -
55-300 A 56 - 65 - - -
60-500 A 68 - 79 - - -
60-600 A 67 70 74 77 - -
63-400 A 60 - 72 - - -
63-500 A 66 - 75 - - -
63-600 A 82 - 94 - - -
63-700 A 81 84 90 93 - -
71-250 A - - 68 - - -
71-300 A - - 75 - - -
71-400 A - - 81 - - -
71-500 A - 69 - - - -
71-600 A - - 107 - - -
72-300 A - - 75 - - -
72-400 A - - 85 - - -
72-500 A - - 93 - - -
72-600 A - 79 - - - -
Table 13, Max. size of solid particles ( mm) (APP, EPP, NPP, WPP)
Impeller type
Pump size Pump types Special Special Low
Closed1 Closed2 Open1 Open2 Vortex1
open1 open2 pulse1
11-32 APP 4 - 8 - - - - -
11-40 APP 8 - 12 - - - - -
11-50 APP 10,5 - 16 - - - - -
21-50 NPP 25 - - - - - 35 -
21-65 APP 16 - 22 - - - - -
21-80, 8S APP 23 - 30 - - - - -
21-80 NPP 45 - - - - - 50 -
22-32 APP - - 7 - - - - -
22-32 WPP - - 7 - - - - -
22-40 APP 5 - 10 - - - - -
22-50 APP 8 - 14 - - - - -
22-50 NPP 25 - - - - - 35 -
22-50 WPP 10 - 18 - - - 22 -
22-65 APP 12 - 18 - - - - -
22-80, 8S APP 18 - 24 - 24 - - -
22-80 NPP 45 - - - - - 50 -
23-40 APP - - 9 - - - - -
23-50 APP 6 - 12,5 - - - - -

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions
Impeller type
open1 open2 pulse1
23-50 WPP 9 - 20 - - - - -
31-65 EPP 9 - 9 - - - -
31-100, 10S APP 25 - 32 - - - - -
31-100 EPP 14 - 15 - - -
31-100 NPP 55 - - - - - 60 -
31-125,10P APP 32 - 36 - - - - -
31-150 APP 40 - 41 - - - - -
32-65 APP 9 - 16 - - - - -
32-80, 8S APP 13 - 22 - 33 - - -
32-80 NPP 45 - - - - - 50 -
32-80 WPP 16 - 27 - - - 30 -
32-100, 10S APP 18 - 24 - 24 - - -
32-100 EPP 18 - 18 - - - - -
32-100 NPP 55 - - - - - 60 -
32-100 WPP 18 - 32 - - - 35 -
32-125, 10P APP 26 - 32 - 32 - - -
32-125 WPP 26 - 42 - - - 40 -
33-80 NPP 45 - - - - - 50 -
33-100, 10S APP 13 - 18 - 29 - - 6
33-100 NPP 55 - - - - - 60 -
33-100 WPP 16 - 30 - - - 34 -
33-125, 10P APP 22 - 29 - 29 - - 11
41-150 EPP 36 - 35 - - - - -
41-200 APP 43 - 47 - 54 - - -
41-200 EPP 47 - 42 - - - - -
41-300 APP 46 - 56 - 70 - - -
42-150 APP 34 - 38 - 38 - - -
42-150 EPP 30 - 28 - - - - -
42-150 NPP 75 - - - - - 80 -
42-200 APP 35 - 48 - 49 - - -
42-200 EPP 39 - 39 - - - - -
42-200 NPP 85 - - - - - 85 -
42-250 EPP 54 - 54 - - - - -
43-100 EPP 16 - 16 - - - - -
43-150 EPP 24 - 27 - - - - -
43-250 APP 54 - 62 - 63 - - -
43-300 APP 53 - 54 - 71 - - -
44-150 APP 27 - 27 - 27 - - 10
44-150 NPP 75 - - - - - 75 -
44-150 WPP 30 - 44 - - - 50 -
44-200 APP 41 - 46 - 46 - - 19
44-200 NPP 85 - - - - - 80 -
44-200 WPP 41 - 54 - - - 60 -
51-250 APP 52 - 54 - 54 - - 23
51-300 APP 48 - 69 - 69 - - 30
52-350 APP 65 - 63 - 84 - - -
52-350 EPP 63 - 63 - 63 - - -
52-400 APP 73 - 95 - 95 - - -
53-100 APP 17 - 27 - - - - 10
53-100 EPP 17 - 24 - - - - -

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions
Impeller type
open1 open2 pulse1
53-100 WPP 18 - 37 - - - 40 -
53-150 APP 29 - 39 - - - - 15
53-150 WPP 33 - 52 - - - 58 -
53-200 APP 35 - 35 - 35 - - 13
53-200 EPP 32 32 32 32 32 - - -
53-200 WPP 38 - 55 - - - 61 -
53-250 APP 49 - 49 - 49 - - 20
53-250 EPP 47 - 48 - - - - -
53-250 NPP 113 - - - - - 113 -
53-250 WPP 52 - 70 - - - 77 -
53-300 APP 62 - 64 - 64 - - 27
53-300 EPP 65 65 55 - - - - -
54-300 EPP 66 - 66 - - - - -
54-400 APP 74 - 74 - 94 - - -
54-400 WPP 105 - 110 - - - - -
54-500 APP 113 - 113 - 113 - - -
54-500 EPP 80 - - - - - - -
55-100 APP 30 - 30 - - - - -
55-200 APP 34 - 46 - - - - -
55-250 APP 43 - 43 - 43 - - -
55-300 APP 67 - 68 - 68 - - -
55-300 EPP 61 - 67 - - - - -
55-300 WPP 61 - 79 - - - - -
61-500 APP - - 86 86 107 107 - -
61-500 EPP - - 107 107 107 107 - -
61-600 APP - - 132 132 132 132 - -
61-600 WPP 133 - 150 - - - - -
62-400 APP - - 132 132 132 132 - -
9.4 Tightening instruction for the flanges of AHLSTAR pumps

1 The purpose of the tightening torque is to provide an adequate pre-tightening for the flange connection via
screw forces. The friction forces influencing in the screw thread and head have a great importance here. This
is why it is always necessary to lubricate both the threaded surface of the screw and the washer of the screw
before installation. The values in this instruction are based on a value of 0.20, which corresponds to slightly
oiled joint surfaces. If the friction coefficient f of the selected lubricant differs greatly from this, the tightening
torque must be corrected using value:
Secondary flange forces, which may arise during tightening and which are the result of the misalignment of
the flanges, must be minimised. It is recommended to pre-weld the pipes so that the backing flanges are
attached to the flanges of the pump. In this case, there is no need to use the full torque. The permitted
misalignments on the sealing surfaces are presented in Table 14. The values are measured from the
extreme edge of the sealing surface.

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions
Table 14, Permitted misalignments on sealing surfaces

Nominal size of connection Permitted misalignment on sealing surfaces (a)
DN 150 0,2 mm
> DN 150 0,4 mm
2 The use of washers is recommended. When the screw is M24, one washer is used, and when the screw is
>M24, two washers are used.
3 Check the cleanliness of the sealing surfaces before installation. If necessary, clean the sealing surfaces
with a soft brush in the direction of the circumference, not in the direction of the radius.
4 The use of different material groups (carbon steel - stainless) in the flanges and screws may lead to a
harmful change in the internal forces of the connection as the temperature changes, and is therefore
prohibited.
5 The screws must be tightened using a torque wrench which is calibrated every two years in accordance with
ISO 6789.
6 The tightening must be performed in four stages. Follow the order given in Fig. 2 and first tighten 30% of the
final torque. After this, follow the same order and tighten 60% of the final torque. In the third stage, tighten
the screws to the final torque in the same order. Finally, secure the torque by tightening the screws
clockwise using the final value. The permissible torques depend on the flange standard used. The
permissible torques can be found in tables 15 to 20.
Fig. 2
The tightening torques must be checked within 24 hours from commissioning.
7 The following maximum torques have been calculated assuming that the friction coefficient is 0.2. The effect
of the friction coefficient must be taken into account by using the ratio given under item 1.
CAUTION
Exceeding the maximum torques can lead to permanent deformations in the flanges.

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions
8 The screws used in the calculations are full-threaded hexagon head screws in accordance with ISO 4017.
The inch-sized screws are ANSI B18.2.1 UNC.
9 The values have been calculated according to ASME BPVC VIII-8 so that the stresses in the flange do not
exceed 0.8 x yield strength of the flange at the design temperature of 180C. It should be noted that these
are the maximum torques in accordance with the strength of the flange, and the actual torque must be
selected on the basis of the seal used and the operating conditions.
Table 15, Maximum torques, flange drilling PN10

Carbon steel pumps Cast iron pumps
Screws Screw Torque (Nm)
DN Torque (Nm) Torque (Nm)
(qty) size
8.8 12.9 8.8 12.9 8.8 12.9
32 4 16 90 90 50 50 50 50
40 4 16 120 120 60 60 60 60
50 4 16 180 180 100 100 100 100
65 8 16 150 150 80 80 80 80
80 8 16 170 170 100 100 100 100
100 8 16 220 220 120 120 120 120
125 8 16 270 270 150 150 150 150
150 8 20 410 410 230 230 230 230
200 8 20 450 450 250 250 250 250
250 12 20 520 520 300 300 300 300
300 12 20 620 690 390 390 390 390
350 16 20 410 410 230 230 230 230
400 16 24 800 800 460 460 460 460
500 20 24 1080 1260 720 720 720 720
600 20 27 1530 1530 860 860 860 860
700 24 27 1590 2110 1190 1190 1190 1190

Carbon steel pumps Cast iron pumps
DN Torque (Nm) Torque (Nm)
(qty) size
8.8 12.9 8.8 12.9 8.8 12.9
32 4 16 90 90 50 50 25 25
40 4 16 120 120 60 60 35 35
50 4 16 180 180 100 100 55 55
65 8 16 150 150 80 80 45 45
80 8 16 170 170 100 100 55 55
100 8 16 220 220 120 120 65 65
125 8 16 270 270 150 150 85 85
150 8 20 410 410 230 230 125 125
200 12 20 300 300 170 170 95 95
250 12 24 580 580 330 330 - -
300 12 24 690 690 390 390 - -
350 16 24 430 430 240 240 - -
400 16 27 780 780 440 440 - -
500 20 30 1050 1050 600 600 - -
600 20 33 1090 1090 630 630 - -
700 24 33 2610 2610 1460 1460 - -

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions

Carbon steel pumps
DN Torque (Nm)
(qty) size
8.8 12.9 8.8 12.9
32 4 16 90 90 50 50
40 4 16 120 120 60 60
50 4 16 180 180 100 100
65 8 16 150 150 80 80
80 8 16 170 170 100 100
100 8 20 220 220 120 120
125 8 24 350 350 190 190
150 8 24 410 410 240 240
200 12 24 280 280 150 150
250 12 27 520 520 290 290
300 16 27 440 440 250 250
350 16 30 430 430 230 230
400 16 33 670 670 400 400
500 20 33 1030 1030 580 580
600 20 36 1220 1220 680 680
700 24 39 2000 2000 1170 1170
Table 18, Maximum torques, flange drilling ASME B16.5 Class 150 / ASME B16.1 Class 125
Carbon steel pumps, Cast iron pumps,
ASME B16.5 Class 150
Screws Screw ASME B16.5 Class 150 ASME B16.1 Class 125
DN Torque (Nm) Torque (Nm) Torque (Nm)
(qty) size (inch)
8.8 12.9 8.8 12.9 8.8 2.9
32 4 1/2 100 100 50 50 30,0 30,0
40 4 5/8 160 160 90 90 50,0 50,0
50 4 5/8 200 200 110 110 65,0 65,0
65 4 5/8 350 350 190 190 105,0 105,0
80 4 5/8 420 420 230 230 130,0 130,0
100 8 5/8 170 170 100 100 55,0 55,0
125 8 3/4 290 290 170 170 95,0 95,0
150 8 3/4 390 390 220 220 120,0 120,0
200 8 3/4 400 400 230 230 127,0 127,0
250 12 7/8 470 470 270 270 150,0 150,0
300 12 7/8 470 470 260 260 140,0 140,0
350 12 1 550 550 310 310 160,0 160,0
400 16 1 600 600 340 340 180,0 180,0
500 20 1 1/8 1200 1200 690 690 360,0 360,0
600 20 1 1/4 1310 1310 740 740 420,0 420,0
700 28 1 1/4 1580 1580 900 900 480,0 480,0
Table 19, Maximum torques, flange drilling ASME B16.5 Class 300
Carbon steel pumps
DN Torque (Nm)
(qty) size (inch)
8.8 12.9 8.8 12.9
32 4 5/8 100 100 50 50
40 4 3/4 140 140 70 70
50 8 5/8 80 80 50 50
65 8 3/4 160 160 90 90
80 8 3/4 180 180 100 100
100 8 3/4 180 180 100 100

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions
Carbon steel pumps

DN Torque (Nm)
(qty) size (inch)
8.8 12.9 8.8 12.9
125 8 3/4 210 210 120 120
150 12 3/4 160 160 90 90
200 12 7/8 200 200 120 120
250 16 1 300 300 160 160
300 16 1 1/8 380 380 210 210
350 20 1 1/8 260 260 140 140
400 20 1 1/4 440 440 240 240
500 24 1 1/4 660 660 390 390
600 24 1 1/2 790 790 430 430
700 28 1 5/8 1120 1120 650 650
Table 20, Maximum torques, flange drilling JIS B 2220 16K / JIS B 2239 10K
Carbon steel pumps, Cast iron pumps,
JIS B 2220 16K
Screws Screw JIS B 2220 16K JIS B 2239 10K
DN Torque (Nm) Torque (Nm) Torque (Nm)
(qty) size
8.8 12.9 8.8 12.9 8.8 2.9
32 4 16 90 90 50 50 30 30
40 4 16 130 130 70 70 45 45
50 8 16 100 100 60 60 30 30
65 8 16 170 170 90 90 50 50
80 8 20 220 220 130 130 90 90
100 8 20 250 250 140 140 95 95
125 8 22 280 280 160 160 120 120
150 12 22 210 210 120 120 90 90
200 12 22 270 270 160 160 115 115
250 12 24 400 400 230 230 175 175
300 16 24 390 390 230 230 190 190
350 16 30 460 460 260 260 265 265
400 16 30 690 690 410 410 355 355
500 20 30 450 450 260 260 485 485
600 24 30 - - - - 420 420
700 24 30 - - - - 735 735

SERIES 2.15
AHLSTAR
PROCESS PUMPS
Hoisting and transfers
1 Safety measures
2 Hoisting and transfers

Series 2.15 Page
INSTRUCTIONS
USER'S MANUAL AHLSTAR June 2012 G
1 Safety measures
The total gross and net weights of the delivery are always found in the packing list affixed to the product or packing.
WARNING
Hoisting and transfers instructions must be strictly followed to avoid dropping of crates or individual
assemblies.
Special attention is to be paid to the stability of

Pump
Pump and baseplate with or without motor
Spare parts
The center of gravity with these items should always be checked before hoistings and transfers.
Personal protective equipment such as helmet, safety shoes and gloves is to be used.
If suitable lifting equipment is not available, heavy assemblies must be transferred by using skids etc. on the ground
level.
Lifting accessories must bear the identification of the manufacturer, material and the maximum working load.
Lifting ropes used directly for lifting or supporting the pump or pump unit must not include any splicing other than at
their ends. Textile ropes and slings must not include any knots, connections or splicing other than at the ends of the
sling, except in the case of an endless sling.
The lifting accessories must always be able to adequately support the hoisted assembly.
The lifting ropes must be adequate, and they must be adjusted so that the product is not damaged during hoisting. A
lifting chain must not be in contact with the product during hoisting (if it is, painted and machined surfaces may be
damaged).
WARNING
Make sure that accepted and undamaged ropes and lifting accessories are available. The lifting
capacity of the lifting accessories and ropes must correspond to the weight of the goods lifted.
WARNING
Never stand under a hanging load.

Series 2.15 Page
INSTRUCTIONS
2 Hoisting and transfers
The figures are for reference only, and the actual product and lifting equipment may differ from those presented.
NOTE
If the ordered assembly contains:
- an API baseplate, follow the enclosed lifting instruction N31478, or
- a Heavy Duty baseplate, follow the enclosed lifting instruction N31481.
The crates or individual assemblies must never be dropped to the ground during transfer. Refer to Figures 1 - 12 for
examples of proper lifting techniques.
Fig. 1 .........The transportation crate is hoisted according to figure 1. The permissible lifting points are marked on the
crate.
Fig. 1

Series 2.15 Page
INSTRUCTIONS
Fig. 2 .........The pump-motor-baseplate assembly is hoisted from under the suction case of the pump and from under
the motor.
Fig. 3 .........With tangential pumps, also ensure the balance of hoisting by means of a lifting eye fastened to the
discharge flange.
Fig. 2 Fig. 3
Fig. 4 .........The pump-baseplate assembly is hoisted from under the suction flange of the pump and from the lifting
eyes fastened to the baseplate.
Fig. 5 .........With tangential pumps, also ensure the balance of hoisting by means of a lifting eye fastened to the
discharge flange.
Fig. 4 Fig. 5

Series 2.15 Page
INSTRUCTIONS
Fig. 6 .........The radial pump is hoisted from the lifting eyes fastened to the discharge flange of the pump.
Fig. 7 .........The tangential pump is hoisted from the lifting eyes fastened to the suction and discharge flanges of the
pump and to the end of the shaft. Pay attention to the centre of gravity.
Fig. 6 Fig. 7
Wet end
Fig. 8 .........The radial volute case is hoisted from the lifting eyes fastened to the discharge flange.
Fig. 9 .........The tangential volute case is hoisted from the lifting eyes fastened to the discharge flange. It is
recommended to place the lifting eyes symmetrically with respect to the division plane of the volute case
and as close to each other as possible. Pay attention to the centre of gravity.
Fig. 8 Fig. 9

Series 2.15 Page
INSTRUCTIONS
Spare parts and coupling
Fig. 10 .......Heavy (> 25 kg) individual components can be lifted for example on a pallet.
Fig. 10
Bearing parts
Fig. 11 .......The bearing is hoisted from the openings in the bearing housing and from the shaft.
Fig. 11

Series 2.15 Page
INSTRUCTIONS
Baseplate
Fig. 12 .......The baseplate is hoisted from the lifting eyes fastened to the mounting holes.
Fig. 12
2.1 Motor, gear and other accessories

When hoisting the motor, gear and other accessories, the instructions provided by the relevant manufacturer must
always be followed.
2.2 Accessories
If the assembly includes accessories such as a noise cover, the cover may have to be removed before hoisting the
assembly in order to prevent the cover from being damaged.

SERIES 2.15
SPP id: 110901 / en / N31570 / 1
AHLSTAR
PROCESS PUMPS
Commissioning
1 Purchase inspection
2 Storage

Series 2.15 Page
INSTRUCTIONS
USER'S MANUAL AHLSTAR September 2011 G
Commissioning
SPP id: 110901 / en / N31570 / 1 / Page 2 (3)
1 Purchase inspection
Check carefully that the delivery meets your order and is in accordance with the packing list and parts list of the
pump. Inform the supplier immediately about any defects or damage observed.
Do not remove the cover plates or plugs protecting the openings before the installation of pipes. Foreign particles
inside the pump may damage it at starting.
Examine the crate and wrapping before discarding them since parts and accessories are sometimes wrapped
individually or fastened into the crate.
If the pump unit is not installed immediately, it should be stored under conditions that will prevent deterioration due to
damage and/or corrosion. The long-term storage requirements should always be specified in the purchase order.
2 Storage
2.1 Short-term (less than 3 months)

When it is necessary to store a pump for a short term before the installation, it must be stored in a dry location where
it cannot be affected by dirt or corrosion. Protection plates on the pump openings should not be removed.
The pump bearings and drive elements must be properly protected against any foreign matter. To prevent rusting or
seizing, lubricate the pump unit before storing and turn the pump shaft by hand at least once every two weeks.
2.2 Long-term
NOTE
The grease/oil lubricants must be changed before the pump is taken into use.
WARNING
The rust preventives must be cleaned off carefully before the pump is taken into use. Solvents
containing rust preventives can cause irritation to the skin and/or the respiratory system. Prolonged
physical contact and breathing of vapor are to be avoided.
If the pump or pump unit is stored for more than 3 months, the following procedures must be observed:
Store the product in a dry place.
Drain any liquid from the pump.
Rotate the pump shaft by hand at least once every month to prevent bearing damage.
With cast iron pumps equipped with gland packing, remove the gland packings (461.21) from the stuffing box
and apply rust preventives in the stuffing box.
With oil lubrication, the bearing unit is emptied of oil before the delivery. Fill the bearing unit with oil or coat
the interior of the unit with a rust preventing film.
Apply rust preventing agents to the unprotected parts, such as the shaft end, pump flanges and coupling. If
necessary, protect the volute casing and shaft sealing with volatile corrosion inhibitors.

Series 2.15 Page
INSTRUCTIONS
Commissioning
SPP id: 110901 / en / N31570 / 1 / Page 3 (3)
Observe the storage instructions of any accessory equipment (e.g. electric motors) included in the delivery.
If the pump unit is covered with a plastic sheet, the bottom should remain open to allow for ventilation.

SERIES 2.15
AHLSTAR
PROCESS PUMPS
1 Safety procedures before installation

2 Wet end
3 Sealing unit
4 Coupling unit
5 Baseplate
6 Drive motor

Series 2.15 Page
INSTRUCTIONS ISO
1 Safety procedures before installation
NOTE
A pump should have adequate space for proper installation and maintenance actions.
All parts for the installation must be thoroughly cleaned before the installation. All traces of antirust agents should be
cleaned off from the pump flanges, shaft assembly and drive elements. Avoid any damage to installed parts when
handling them.
WARNING
Personal protective equipment such as helmet, safety shoes and gloves are to be used.
Fastener information
Table 1 shows the rated and maximum moments of torque for fasteners presented in these instructions. Note the
special values for the titanium screws. These shown values are only valid for fasteners where the moment values
are not separately given.
Table 1, Fastener information

Titanium screws (76)
Moments (Nm)
Screw size Moments (Nm)
Rating Max. value Rating Max. value
M5 3.5 4.0 2.1 2.7
M6 6.0 7.0 3.6 4.5
M8 14 18 8.9 11
M10 30 35 18 22
M12 50 60 30 38
M16 130 160 70 92
M20 250 300 140 180
M24 420 520 250 310
M30 800 1000 490 615
2 Wet end
2.1 Pipework
Supporting
The pipes must be mounted and supported so that the piping does not exert on the pump any forces and moments
which exceed the values given under item Safety instructions/Admissible forces and moments on pump flanges.
When planning the support locations remember the allowance for thermal expansion. Fig. 1.
Fit the pipe flanges accurately to the pump flanges. Flanges which have not been properly aligned must not be
forced to position.

Series 2.15 Page
INSTRUCTIONS ISO
Fig. 1
Suction pipe below the pump

The suction pipe must be made as short as possible. Avoid points where air pockets or turbulence may be formed.
If the liquid level is below the pump, the suction pipe must gradually rise towards the pump. A sufficient length of the
pipe end must be under the liquid level so that air cannot enter the pump. Fig. 2.
Fig. 2
Suction pipe above the pump

The suction pipe must descend gradually towards the pump. Fig. 3.
Fig. 3
Extension piece
The cones must be eccentric and in such a position that the upper level will be horizontal, alternative A in Fig. 4. If
extension pieces are used, they must be formed so that gathering of gases cannot occur. At higher consistencies
(c > 4 %), conical pipe parts must be avoided, alternative B in Fig. 4.

Series 2.15 Page
INSTRUCTIONS ISO
Fig. 4
Suction pipe design
WARNING
If there is a possibility of a dangerous return flow after the shutdown of the pump, a nonreturn device
shall be installed in the outlet piping.
CAUTION
Never use the pump as a support for the piping system.
If the suction pipe has branches, they must be located as far from the pump as possible, and they must be formed
advantageously with regard to the flow. The suction pipe must always be made as short as possible. Fig. 5.
A shut-off valve must be placed in the discharge pipe after the potential check valve. Before commissioning, clean
the entire suction piping and suction pit carefully from any objects that might have got into them during the work.
These may damage the pump
Fig. 5

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3 Sealing unit
3.1 Auxiliary piping
Piping for shaft seal

In order to ensure trouble-free operation of the shaft seal, it must be provided with sealing, flushing or cooling liquid
in certain applications in accordance with the sectional drawing and the parts list. The nominal sizes of the
connections are also given in the parts list and dimensional drawing of the pump.
The nominal pressure of the sealing liquid must be as high as the nominal pressure of the pump, and its maximum
temperature must be as high as the maximum permitted temperature of the pump.
The sealing water equipment is installed in the pump. In certain sealing systems, the sealing liquid equipment
contains a back-pressure valve; see sectional drawing.
Clean the sealing liquid piping carefully before installation and commissioning.
The reservoir of the seal pot sealing water equipment must be installed in a vertical position at least 500 mm above
the center line of the shaft seal. Install the pipes as short as possible so that the shaft seal is at the lowest point.
Piping for degassing in a gas separator (-GM, -GS)

The piping for degassing is connected to the degassing outlet (C50.21) of the pump. The degassing outlet is on the
right-hand side when seen from the drive. The precise size and direction of the connection are shown in the
dimensional drawing.
If a separate degassing pump (vacuum pump) is used, there is also a separate vacuum relief valve.
The size of the degassing pipe is determined by the amount of gas, the length of the pipe, the risk of clogging, etc.
The pipe size generally suitable is shown in Table 2.
Table 2, Suitable pipe sizes for degassing

Sealing unit size Outlet size C50.21 Suitable pipe size
10 Rp 1/2 DN25 or DN32
11 Rp 1 DN25 or DN32
20 Rp 1/2 DN40 or DN50
21, 22, 23 Rp 1 DN40 or DN50
31, 32, 33 Rp 1 DN40 or DN50
41, 42, 43, 44 Rp 1 1/4 DN40 or DN50
51, 52, 53, 54, 55 Rp 1 1/4 DN50 or DN65
60, 61, 62, 63 Rp 1 1/4 DN80 or DN100
Piping for degassing in an air separating pump (-R)

The piping for degassing is connected to the degassing outlet (C50.21) of the pump, Fig. 6. The degassing outlet
can be on the left or right side of the pump depending on the design alternative, Fig. 6. The precise size and
direction of the connection are shown in the dimensional drawing.

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Design A Degassing on the left Design B Degassing on the right
C52.21 Return circulation C50.21 Degassing
C50.21 Degassing C52.21 Return circulation
Fig. 6
In order to prevent the pumped liquid from flowing out while the pump is not running, the piping is often supplied with
a shut-off valve (ball valve) equipped with an open-closed actuator. The control of the valve must be arranged so
that the valve is open while the motor of the pump is running and otherwise closed.
If a separate degassing pump (vacuum pump) is used, there is also a separate vacuum relief valve.
The size of the degassing pipe is determined by the amount of gas, the length of the pipe, the risk of clogging, etc.
The pipe size generally suitable is shown in Table 3.
Table 3, Suitable pipe sizes for degassing and return circulation

Sealing unit size Outlet size C50.21 and C52.21 Suitable pipe size
11 DN25 DN25 or DN32
21, 22, 23 DN40 DN40 or DN50
31, 32, 33 DN40 DN40 or DN50
42, 43, 44 DN40 DN40 or DN50
51, 52, 53, 54, 55 DN50 DN50 or DN65
61, 62 DN80 DN80 or DN100
Return circulation piping in an air separating pump (-R)

The piping for the return circulation connects the return circulation outlet (C52.21) of the air separating design (-R)
with the suction pipe of the pump, Fig. 7.
The piping for the return circulation should be installed so as to minimize friction losses. Table 3 shows the suitable
pipe size. The return circulation pipe can be equipped with a shut-off valve and sight glass if necessary.
C52.21
C50.21
Fig. 7

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Piping for degassing in a liquid ring pump (-LM, -S)

Connect the degassing piping to the degassing connection (C50.21) of the pump. The degassing connection of the -
LM design liquid ring pump is on the right-hand side when seen from the drive. The degassing connection of the -S
design liquid ring pump can be either on the right or left side of the pump. The precise size and direction of the
connection are shown in the dimensional drawing.
WARNING
Some of the pumped liquid will run out of the degassing connection during pumping. Lead and handle
this liquid appropriately.
The mixture of gas and liquid discharging from the degassing connection is normally led back into the process by
taking the degassing pipe underneath the liquid level, see examples in Figures 8, 9 and 10.
The suitable pipe size for the degassing piping is determined on the basis of pipe length, clogging risk etc. Normally,
the suitable pipe size is one corresponding to the size of the degassing connection or the following larger size.
A vacuum relief valve and a pressure indicator, connected to the connection (C34.21) opposite the degassing
connection, are usually included in the degassing piping.
Starting with a straight suction pipe
Closed valve on startup
Volume 2
Either external water or return circulation
Volume 1
Degassing pipe
Vacuum relief valve
Pressure indicator
Fig. 8

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Starting with a straight suction pipe, liquid level beneath the pump
Volume 0 and Volume 2,

both as small as possible Closed valve on startup
Volume 2
Volume 0
External water
Minimum surface level
Degassing pipe
Vacuum relief valve

Pressure indicator
Fig. 9

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Gooseneck start
Volume 2 = 0,5 *)1,5**) x Volume 1 Back pressure valve ***)

Volume 0 = as small as possible
Volume 0 Closed valve on startup ***)
Volume 2
Either external water or return circulation
Minimum surface level
Volume 1
Degassing pipe
*) = slow start
Vacuum relief valve
**) = fast start Pressure indicator
***) = If the valves need to be placed in the reverse order,
they must be as close to each other as possible.
Fig. 10
4 Coupling unit
4.1 Installation and alignment of coupling
WARNING
Before beginning any installation or alignment procedures, make sure the drive motor cannot be
started by any means.
NOTE
Satisfactory performance of the coupling depends on correct installation and alignment.

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When applicable, the coupling has already been installed and prealigned at the pump factory. However, the
alignment may change due to faulty hoistings, poor baseplate support or piping support, thermal expansion or the
like. Therefore, check the shaft alignment of the coupling and re-align through the following stages:
1 After supporting of piping and before starting the pump, tighten the fixing screws of the pump and align the
coupling to the required accuracy. Fig. 12.
2 After running the pump with water, look for changes caused by the water run. Correct the changes by
altering the supporting of the piping. Tighten the fixing screws of the pump and align the coupling.
3 Carry out hot alignment if the temperature of the pumped liquid is higher than 100C (212 F). Carry out the
hot alignment during production run immediately after the pump is stopped while the pump and the motor are
still at the operating temperature. The need for hot alignment depends on the extent of temperature
differences and the coupling type chosen.
Check the alignment by measuring the angular and parallel misalignments in vertical (6 and 12 oclocks) and
horizontal (3 and 9 oclocks) directions. During the alignment, the coupling halves have to be locked together so that
they do not move with respect to each other. If needed, correct the alignment by adding or removing shims from
under the feet of the motor and by shifting the motor horizontally until the shafts are aligned within the given
tolerances. Fig. 12.
Optional alignment blocks can be used to shift the motor horizontally, see Fig. 11.
Fig. 11
4.2 Maximum tolerances for coupling alignment

The maximum tolerances for angular and parallel alignments are given in Fig. 12.
Z max Y max
D (mm) 1500 rpm 1500 rpm 1500 rpm 1500 rpm
mm mm mm mm
- 100 0.08 0.06 0.05 0.04 0.10 0.06
101 - 200 0.11 0.05 0.06 0.03 0.15 0.10
201 - 300 0.15 0.03 0.10 0.02 0.20 0.15
301 - 400 0.20 0.03 0.10 0.02 0.25 0.15
Fig. 12

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5 Baseplate
5.1 Installation at the site
NOTE
If the ordered assembly contains an API or Heavy Duty baseplate, follow the enclosed installation at
the site instruction N31664.
NOTE
When welding the foundation screws, connect the earth clamp to the baseplate, never to the pump!
The pump base must be sturdy enough to endure vibration, stress and potential forces caused by the piping.
If there are grounds to suspect that the base is not suitable for installation, the base must be strengthened by
making a concrete support stand or in some equivalent manner. Also note the bottom beams in the foundation or
cavities for the different types of foundation screws.
5.2 Grouted baseplate of steel
Installation using welded foundation screws

The bottom beams in the foundation are cast in advance according to the dimensional drawing of the pump. The
strength requirements for the bottom beams are given in Table 4. In order to facilitate the alignment of the beams, a
so-called concrete frame can be used. The recommended accuracy for the installation of the beams is 10 mm in all
directions. The actual installation becomes much easier, if the upper surfaces are horizontal.
Place foundation screws (918.61) in the fixing holes of the baseplate. The distance between the foundation and the
lower edge of the baseplate must be at least 50 mm. Each foundation screw is fixed to the baseplate by means of
hexagonal nuts (2 pcs/foundation screw). Fig. 13 - 14.
Lower the pre-installed pump-motor-baseplate-assembly onto the floor so that the foundation screws are above the
beams and the pump is in its position in the lateral and longitudinal direction. Now the foundation screws can be
welded to the beams.
Adjust the position of the baseplate before grouting by turning the hexagonal nuts of the foundation screws, until the
assembly lies horizontally and at the correct height.
Table 4, Welded foundation screw

The capacity of the bottom beam e.g. I-beam
Foundation (min.) HxBxL
screw Fv Fh
min. dimensions (mm)
tension N sheat N
M16 x 160 8600 7500 100 x 100 x 100
M20 x 160 17300 14400 100 x 100 x 150
M24 x 200 28100 23300 120 x 120 x 200
M30 x 200 39000 32200 140 x 140 x 250

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Fig. 13, Baseplate for pump and motor, T-base (STD,SLP)

Pump mounting sizes 11, 12, 13, 21, 22, 23, 24, 25, 26, 31, 32, 33, 34, 35,
41, 42, 43, 44, 45, 46, 47, 48, 49, 4A, 51, 52, 53, 54, 55, 56, 57, 58, 59, 5A, 5C, 5D,
5E, 5F, 5G, 5H, 61, 62

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Fig. 14, Baseplate for pump and motor, Rectangular (STD)

Pump mounting sizes 5J, 5K, 5L, 63, 64, 65, 66, 67, 68, 74, 75, 77, 78, 79, 7A, 7B, 7C,
7D
Installation using chemical foundation screws

The foundation screw holes are drilled according to the dimensional drawing of the pump. The recommended
accuracy for the location of the holes is +10 mm. Roughen the holes. Clean the holes well by brushing and blasting.
Install the ampules into the holes. Install the foundation screws (918.61) by hammering to the bottom of the holes
and turn them a couple of rounds. Let the glue of the ampules harden. The screws can be loaded according to the
following table.
Table 5, Chemical foundation screws

Ambient temperature C Time of hardening Time for load
> +20 10 min 2h
+10 20 min 4h
0 60 min 10 h
min -5 5h 28 h
Lift the preinstalled pump and baseplate and fix it into the foundation screws by two nuts (2 pcs). Adjust the position
of the baseplate before grouting by turning the hexagonal nuts of the foundation screws until assembly lies
horizontally and at the correct height.

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Installation using grouted foundation screws

The foundation screw cavities are made in advance (by casting of concrete, drilling) in the concrete frame according
to the dimensional drawing of the pump, Table 6 and Fig. 15 or 16. The recommended accuracy for the location of
the cavities is 10 mm.
Place the foundation screws (918.61) in the fixing holes of the baseplate, taking into account the distance between
the foundation and the lower edge of the baseplate which must be at least 50 mm and the minimum dimension U2
according to Table 6. Each foundation screw is fixed to the baseplate by means of hexagonal nuts (2 pcs/foundation
screw).
Lift the pre-installed pump and baseplate onto the mounting blocks so that the distance between the foundation and
the lower edge of the baseplate is at least 50 mm and so that the foundation screws fit into their cavities and the
pump is in its position in the lateral and longitudinal directions.
Grout the foundation screws. Use only non-shrinking solder concrete of high quality. Allow the concrete to set for
about 1 or 2 days.
Remove the mounting blocks and adjust the position of the baseplate by turning the hexagonal nuts until the
assembly lies horizontally and at the correct height.
Table 6, Grouted foundation screws

Foundation screw (mm)
Size
~e Umin U2min
M16 x 250 100 200 160
M20 x 320 125 250 200
M24 x 400 125 300 240
M30 x 450 160 400 300

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Fig. 15, Baseplate for pump and motor, T-base (STD, SLP)
41, 42, 43, 44, 45, 46, 47, 48, 49, 4A, 51, 52, 53, 54, 55, 56, 57, 58, 59, 5A, 5C, 5D,
5E, 5F, 5G, 5H, 61, 62

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7D
Foundation
The recommended dimensioning for the foundation is given in Fig. 17 and 18. The dimensions for the baseplate are
given in the dimensional drawing Baseplate for pump and motor.
The suitable concrete reinforcement is recommended because of the concrete shrinkage and the loads of the
foundation. The amount of the concrete reinforcement depends on the size and the loads of the foundation and must
be carefully calculated by the local civil engineer according to local standards and regulations.
Pour concrete into the mold. The recommended strength grade for the concrete is about 35 MPa (design strength K
35).
The upper surface of the foundation is leveled so that it is slanting in accordance with Fig. 17 or 18. In pump
mounting sizes 5J, 5K, 5L, 63, 64, 65, 66, 67, 68, 74, 75, 77, 78, 79, 7A, 7B, 7C and 7D, the casing remaining under
the motor can be covered with concrete up to the mounting level surface of the motor. Water the grouting during its
drying to prevent cracking.
Recheck the alignment of the coupling after the grouting according to section Installation and alignment of
coupling.

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L1 + min. 110, when B2 + min. 110, when

L1 2000 L1 2000
L1 > 2000 L1 > 2000
5 mm
Fig. 17, Baseplate for pump and motor, T-base (STD, SLP)
41, 42, 43, 44, 45, 46, 47, 48, 49, 4A, 51, 52, 53, 54, 55, 56, 57, 58, 59, 5A, 5C, 5D,
5E, 5F, 5G, 5H, 61, 62

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L1 2000 L1 2000
L1 > 2000 L1 > 2000
5 mm

7D
5.3 Steel baseplate installed with mechanical feet

Fasten each machine base (963.61) into the fixing holes in the baseplate and install the washers (554.66) under the
hexagonal nuts. There are 3, 4, 5 or 6 fixing holes. Use the studs in the machine bases to adjust the baseplate to the
correct height and horizontally, and tighten the hexagonal nuts.
Fig. 19

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5.4 Concrete baseplate installed with mechanical feet

Mount each machine base (898.61) with a stud bolt (3 pcs) on the bottom of the baseplate. Use the nut in the
mechanical feet to adjust the baseplate so that it is horizontal and at the correct height.
Fig. 20
6 Drive motor
6.1 Installation of the motor on the baseplate

If the motor has not been installed on the baseplate by the pump manufacturer, the installation should be carried out
as follows:
Heat the coupling half on the motor side to approx. 100C (212 F) and push it onto the motor shaft in such a way
that the space between the ends of the shaft is according to the dimensional drawing (usually the front face of the
coupling is even with the end of the shaft).
When installing the coupling, also see instructions supplied by the coupling manufacturer.
Fasten the coupling spacer to the coupling half of the motor without the flexible element.
Check that the pump is aligned as accurately as possible to the middle of the fixing holes of the motor. Lift the motor
onto the riser blocks on the baseplate.
Align the coupling in accordance with section 4.1 Installation and alignment of coupling and the coupling
manufacturers separate installation instructions supplied with this manual. Align the coupling by moving the motor
vertically by means of the riser blocks or shims placed under the feet of the motor and laterally by moving the motor
and its riser blocks sideways. Please note that there is an additional lateral adjustment allowance of a minimum of
3 mm (0.12 in) under the riser blocks or the feet of the motor.
When installing the motor, pay special attention to the clearance of the coupling spacer (see the coupling installation
instruction) so that the spacer can be removed without detaching the motor.

SERIES 2.15
AHLSTAR
PROCESS PUMPS
Operation
1 Safety procedures before start-up

2 Starting the pump
3 Controls during the first run
4 Shut-down procedure
5 Controls after the first run
6 Trouble-shooting -operation

Series 2.15 Page
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Operation
1 Safety procedures before start-up
Before starting the pump for the first time and after service repairs, the following precautionary measures are always
to be checked carefully to prevent any accidents and to guarantee a trouble-free operation of the pump.
WARNING
Make sure that the motor cannot be started by any means accidentally during the following
procedures.
WARNING
Make sure that the fixing screws of the pump and the motor are tightened according to the instructions.
WARNING
During operation - leakage of hazardous substances can occur - prepare proper means for a safe
waste removal.
NOTE
Pressure containing pump parts are not pressure vessels within the meaning of the regulations for
pressure vessels.
CAUTION
The pump will be damaged if run in the wrong direction.
1.1 Wet end
Leakage test
The pump parts and the piping shall be able to withstand a leakage test before the start-up. Leakage, particularly in
the suction piping, can seriously reduce the performance of the pump and make it impossible to prime the pump
before the start-up.
1.2 Sealing unit
Shaft seal and sealing water

Depending on the shaft seal fitting used, make sure that the shaft seal piping has been mounted correctly and that
the sealing liquid pressures, liquid volumes and service intervals correspond to the table below.

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Operation
Table 1, Sealing unit types (dynamical seal, mechanical seal, gland packing)
Sealing unit Shaft seal fluid
type N FR FC FE QF BF G
DS11 X X
DS12 X X
DS13 X X
DS14 X X
MS11 X X
MS12 X X
MS21 X X
MS31 X
MS32 X X
MS35 X
MS41 X X
MS33 X X
MS34 X X
MS42 X X
MS51 X X
MS52 X X
MS61 X
MS71 X X X
MS72 X X
MS81 X X
MS91 X
PG11 X X X X
Table 2, Sealing unit types (liquid ring pump, gas separator, air separating pump)
Sealing unit Shaft seal fluid
type N FR FE QF BF QFFR BFFR QFFE BFFE
LM11 X
LM11 X (*
LM21 X
LM21 X
LM21 X (*
LM21 X (*
SM11 X
SM11 X (*
SM21 X
SM21 X
SM21 X (*
SM21 X (*
RM11 X (*
GM11 X
GM11 X
GM12 X
GM12 X
GM21 X X
GM22 X X
GS11 X
GS12 X

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Operation
N = No sealing liquid
FR = Internal circulation
FC = Circulation closed loop
FE = External flushing liquid; PT + 0.05 MPa, 3 l/min
*) For high vacuum level external flushing must be doubled or tripled.
BF = Pressurized external flowing sealing liquid; PT + 0.05 MPa (minimum), 3 l/min
Except with the seal pot sealing water equipment, the needed sealant fluid flow is generated by the pumping effect
of the shaft seal. The sealant fluid can be water (Tamb>0C) or a suitable water glycol mixture (Tamb< 0C) or some
other liquid depending on the process application. Sealing fluid Tmax = 100C, Pmax = 1.6 MPa.
QF = Non-pressurized (max 0.05 MPa), 3 l/min
G = Grease once a week. Grease must be suitable for the elastomers of mechanical seal.
QFFR = Quench sealing fluid, Recirculation flushing fluid
BFFR = Barrier sealing fluid, Recirculation flushing fluid
QFFE = Quench sealing fluid, External flushing fluid; PT + 0.05 MPa, 3 l/min
BFFE = Barrier sealing fluid, External flushing fluid; PT + 0.05 MPa, 3 l/min
Impellers with balancing holes
pT= p0-0.005 MPa

Where pT = pressure behind the impeller (MPa)
p0 = inlet pressure (MPa)
Atmospheric pressure used as reference pressure = 0 MPa
Impellers without balancing holes
Where pT = pressure behind the impeller (MPa)

p0 = inlet pressure (MPa)
= density of the liquid being pumped (kg/m3)
H = pump head at the operating point in question (m)
n = rotating speed of the pump (r/min)
d2 = impeller back plate diameter (m)
db = impeller back vane diameter (m)
d5 = impeller hub diameter is 0.04 m in bearing unit no. 1,
in bearing unit no. 2 0.05 m, in bearing unit no. 3 0.06 m,
in bearing unit no. 4 0.07 m, in bearing unit no. 5 0.09 m,
in bearing unit no. 6 0.10 m and in bearing unit no. 7 0.12 m.
Atmospheric pressure used as reference pressure = 0 MPa
The flushing liquid and sealing liquid must fulfill the following quality requirements:
maximum particle size 50 m
maximum solid material content 2 mg/l.

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Operation
1.3 Bearing unit
Lubrication
WARNING
A pump unit operating without proper lubrication will damage the bearings and cause a pump seizure.
Use grease lubrication always when the pump is mounted in an inclined position.
Check the oil or grease used for the lubrication of both the pump and motor bearings before start-up. Condensation
or ingress of dirt and water may occur if the pump unit is stored for a long time before installation and start-up.
1.4 Drive motor
Direction of rotation
Fig. 1
Before commissioning, always check the motor for correct rotation.
It is imperative to detach the coupling spacer before checking the rotation direction of the motor.
The motor rotation must be counter-clockwise when viewed from the coupling end (D-end, Fig. 1) of the motor. (The
pump rotation is clockwise when viewed from the coupling end.)
The direction of rotation must correspond to the arrow sign (972.31) on the bearing housing (330.31).
1.5 Coupling unit
Free rotation
Rotate the coupling by hand with the coupling spacer detached.
Coupling alignment
Check that the coupling has been properly aligned according to the instructions in Section Installation and alignment
of coupling.

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Operation
WARNING
Before starting - all safety devices (e.g. coupling guards) must always be correctly installed. For
explosive areas, guards with non-sparking materials are to be used.
1.6 Baseplate
Vibration of the baseplate should be monitored by means of regular measurements, especially if the baseplate is
equipped with mechanical feet. If the vibration values exceed the highest permissible values, the cause of vibration
should be determined.
2 Starting the pump
WARNING
The product is meant only for the purpose for which it is sold - never operate beyond the intended use
described in these instructions.
WARNING
If your pump has no gas separator (-GM, -GS), liquid ring (-LM, -S) or air separating (-R) pump in the
sealing unit, make sure that the pump is sufficiently filled with the pumped liquid before starting.
CAUTION
Observe immediately after start-up the instrumentation showing the discharge pressure. If the pressure
is not quickly reached, stop the motor and check causes for the low pressure.
CAUTION
If it is necessary to adjust the amount of pumped liquid, do it by adjusting the discharge valve. Never
use the suction valve for flow adjustment.
2.1 Pumps equipped with gland packings, mechanical seals or dynamic sealing
units
Open the valves for sealing water if any, and adjust suitable pressure and flow according to Table 1.
Check that there is abundant leakage at the gland packing. If there is no continuous leakage, slacken the
stuffing box gland. If this does not help, remove the packings and re-pack the stuffing box less tight.

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Operation
Fill the pump so that at least the suction pipe and pump casing are filled with liquid. Let the air come out of
the upper part of the tangential volute casing by opening the screwed plug (903.13) in connection (C54.11).
Check that the suction valve is fully open and discharge valve closed.
Start the motor.
Open the discharge valve gradually until the desired amount of liquid is reached.
Check that the gland packing leakage is still abundant. If not, slacken the stuffing box gland immediately. If
this does not help and the gland packing becomes hot, stop the pump and find out the reason for the
disturbance. When the gland packing has been operating trouble-free for 10 minutes it may be tightened.
Tighten it by turning the hexagonal nuts approx. 1/6 turns at a time at 5 - 10 minutes intervals until the
leakage is at least 30 - 80 drops a minute. While tightening, make sure that the stuffing box gland remains
perpendicular to the shaft.
Follow the instructions given by the manufacturer of the sealing water equipment for filling, bleeding and
operation setup.
2.2 Pumps equipped with liquid ring pumps (-LM, -S)

Open the sealing liquid and/or flushing liquid valves and adjust the pressure and the flow rate to a suitable
level in accordance with Table 2.
Let the flushing liquid flow for about 1 to 2 minutes so that all necessary spaces are filled with the liquid.
Make sure that the suction valve is fully open and that the discharge valve is closed.
Start the motor.
Adjust the desired vacuum by means of the vacuum relief valve (Fig. 2):
Undo the locking nut (6) which locks the valve spindle (2).
Turn the valve bushing (3) to the desired direction while holding the valve spindle (2) in place. When you turn
the bushing (3) clockwise, the vacuum grows as the force of the spring (4) closing the valve spindle (2)
increases. When you turn the bushing (3) counterclockwise, the vacuum reduces as the force of the spring
(4) decreases.
When the desired vacuum is reached, lock the valve spindle (2) to the bushing (3) with the locking nut (6).
Fig. 2

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Operation
CAUTION
There is a risk of destroying the suction impeller of a liquid ring pump by cavitation, if the vacuum level
has been adjusted too high or the vacuum relief valve has been taken off and the connection has been
plugged.
When the pump starts to pump and the pressure on the discharge side rises, open the discharge valve until
the desired liquid volume is reached. If the pump and suction pipe are full of liquid, the pressure will rise
immediately after starting. If the pump is empty when being started, it takes some time for the pressure to
rise.
2.3 Pumps equipped with gas separators (-GM, -GS) or air separating pumps (-R)
Open the sealing liquid valves of the pump and of the potential degassing pump and adjust the flow rate to a
suitable level in accordance with Table 2.
Make sure that the suction valve is fully open and that the discharge valve is closed.
Start the motor of the degassing pump if there is one.
Adjust the desired vacuum by means of the vacuum relief valve (see pumps equipped with liquid ring
pumps).
Start the motor.
Open the degassing valve between the pump and the potential degassing pump.
Open the discharge valve carefully until the desired liquid volume is reached.
If the pump is used as a self-priming pump, do not open the discharge valve until the degassing pump has
sucked the pump full of liquid, the pump starts to pump and the pressure starts to rise on the discharge side.
Make sure that the pumped liquid does not flow out through the degassing connection. If it does, reduce the
vacuum created by the degassing pump by means of a potential vacuum relief valve. The sealing liquid may
flow out through the degassing connection.
3 Controls during the first run
WARNING
Personal injuries may occur if personal protective equipment is not used when servicing the product.
When pumping hazardous liquids, skin and eye protection are required.
CAUTION
Do not operate the pump below the minimum recommended flow or with the discharge valve closed.
Cavitation or recirculation can lead to a quick pump failure.
By controlling the pump operation and output regularly, the possible need for service and repair can be anticipated.
In this way, the pump efficiency is kept high, the process is trouble-free and the maintenance costs are low.

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Operation
Control the temperature of the gland packing and maintain the leakage at 30 - 80 drops/minute by adjusting the
stuffing box gland.
The flow and pressure of sealing water must be kept at the enclosed values given by the seal manufacturer.
When the seal pot sealing water equipment is operating, check that the sealing fluid is flowing in the correct direction
the return hose must be warm.
Check the temperature and vibration of bearings through regular measuring. If one or the other increases, it may be
a sign of incorrect lubrication or bearing damage. The measuring studs (SPM, M8 x 24) are in the bearing housing
for controlling the bearings.
Also, any noises from the pump and its vibration have to be controlled and the reasons for unusual noises or
vibration detected.
The condition of the coupling can be monitored with a stroboscope through the perforation in the coupling guard.
4 Shut-down procedure
Close the discharge valve to prevent the pumped liquid from flowing back.
Close the degassing valve between the pump equipped with a gas separator (-GM, -GS) or air separating
pumps (-R) and the potential degassing pump.
Stop the motor.
Stop the motor of a potential degassing pump.
Close the suction valve if there is reason to doubt that the pumped liquid will flow out of the suction piping.
Close the cooling and flushing liquid valves, if any.
If the pump has a sealing liquid valve, it cannot be closed until the pump has been drained or until at least
the pressure has been relieved from the pump.
During longer shut-downs, the pump must be checked every now and then. Turn the shaft manually a few times. If
the pumped liquid congeals or solidifies easily, if it is corrosive, or if the pump is exposed to freezing, drain the pump
and suction piping for the shut-down period. At the same time, flush the pump with clean water.
5 Controls after the first run
NOTE
The correct final alignment of the coupling is important for the pump operation.
When the pump unit has run for a sufficient length of time to bring the pump and motor up to the normal operating
temperature, check the coupling alignment according to Section Installation and alignment of coupling.
With hot liquid pumps, check the tightness of the casing cover fixing screws. Adjust torque in accordance with the
reference values.
With pumps equipped with gland packing, check proper leakage from the stuffing box.
With pumps equipped with mechanical seals, ensure that the flushing or cooling supplies are functioning adequately.
Make sure that the sealing water system is working properly.
Check that there is no overheating in the pump or motor bearings.

Series 2.15 Page
INSTRUCTIONS ISO
Operation
6 Trouble-shooting - operation
During the start-up period, problems are mostly caused by pump selection mistakes, poor process design,
operational mistakes or foreign objects in the process.
During the long-term operation of a pump unit, problems are mostly caused by random failures, process changes or
corrosion and wear.
Problems can normally be traced to either poor maintenance or exceeding the limitations for the intended use of the
pump.
The following problem tracing analysis includes the most common malfunctions and their possible causes. If the
pump does not function properly, it is important to trace the actual reasons, so that the repairs and required
modifications can be done without delay. Table 3 - Table 10.
Table 3, Symptom: Pump not delivering liquid

Probable cause: Remedy:
Wrong direction of rotation Change the direction of rotation acc. to the arrow sign on the
bearing unit
Pump not adequately primed or a vapor lock in the suction Reprime the pump and suction piping
pipe
Flushing liquid is not on (liquid ring pumps (-LM, -S)) Open the flushing liquid valve
Difference between inlet pressure and vapor pressure too Check the suction piping arrangements
small
Air leakage in suction opening, suction piping or shaft seal Check the suction piping. Readjust the shaft seal
Suction piping, suction valve or impeller clogged Check the suction piping and the pump for any obstructions
Rotational speed too low Check the speed requirements/limitations
Flow resistance of the piping higher than the head generated Check resistancies and reduce losses
by the pump
Unexpected air/gas content in the pumped liquid Consult manufacturer for further instructions
Suction tank level low Check the required inlet/suction head
Table 4, Symptom: Insufficient head

Unexpected viscosity of the pumped liquid Consult manufacturer for further instructions
Wrong direction of rotation Change the direction of rotation acc. to the arrow sign on the
bearing unit
by the pump
Pressure containing pump parts worn/damaged/clogged Check the pump and replace defective parts, if necessary
Suction tank level low Check the required inlet/suction head
Table 5, Symptom: Insufficient (or irregular) flow

Vapor lock in the suction pipe Reprime the pump and suction piping
Suction head too high Check that the suction valve is fully open and that the suction
line is unobstructed
small
Air leakage in suction opening, suction piping or shaft seal Check the suction piping and readjust the shaft seal

Series 2.15 Page
INSTRUCTIONS ISO
Operation

Suction piping, suction valve or impeller partially clogged Check the suction piping and the pump for any obstructions
by the pump
Table 6, Symptom: High power consumption

Rotational speed too high Check the speed requirements/limitations
Wrong direction of rotation Change the direction of rotation acc.to the arrow sign on the
bearing unit
Flow resistance of the piping much higher/lower than the head Check the piping arrangements
generated by the pump
Unexpected specific gravity of the pumped liquid Consult manufacturer for further instructions
Pump and motor incorrectly aligned Realign the pump and motor assembly, make sure there is no
strain on the pump.
Crooked or eccentric shaft Reassemble the pump and renew the shaft and bearings, if
necessary
Rotating objects or pump parts chafing inside the pump Reassemble the pump and check the clearances
Mechanical tightness of pump components Reassemble the pump and check the clearances
Table 7, Symptom: Excessive noise and/or vibration

small (cavitation)
Air leakage in suction opening, suction piping or shaft seal Check the suction piping/readjust the shaft seal
by the pump
Pump functioning below the recommended minimum flow Check the pumping system requirements
(cavitation)
Pump foundation not rigid enough Strengthen the foundation
Inadequate piping support exerting strain on the pump Check the piping support requirements
Pump and motor incorrectly aligned Realign the assembly, make sure there is no strain on the
pump.
Crooked or eccentric shaft Reassemble the pump and renew the shaft and bearings, if
necessary
Mechanical tightness of pump components Reassemble the pump and check the clearances
Bearings worn or loose Reassemble the pump and replace the bearings, if necessary
Inadequate or excessive lubrication Check the pump for proper lubrication
Impeller damaged or out of balance Reassemble the pump and replace the impeller, if necessary
Table 8, Symptom: Bearings wear rapidly

Pump and motor incorrectly aligned Realign the pump assembly, make sure there is no strain on
the pump. Replace the bearings, if necessary.
Crooked or eccentric shaft Reassemble the pump and straighten or replace the shaft

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INSTRUCTIONS ISO
Operation

Inadequate or excessive lubrication Check the pump for proper lubrication
Badly installed and/or dirty bearings Renew bearings, if necessary. Check the quality and amount
of lubricant
Table 9, Symptom: Pump overheats/seizes

Pump not adequately primed Reprime the pump and suction piping
Flushing liquid is not on (liquid ring pumps (-LM, -S)) Open the flushing liquid valve.
Difference between inlet pressure and vapor pressure too Check the suction piping arrangements. The pump may
small operate below the recommended minimum flow (cavitation)
Pump functioning below the recommended minimum flow Check the pumping system requirements
(cavitation)
Pump and motor incorrectly aligned Realign the assembly, make sure there is no strain on the
pump
Bearings worn Reassemble the pump and replace the bearings, if necessary
Crooked or eccentric shaft Reassemble the pump, straighten or renew the shaft
Discharge valve closed Open the discharge valve
Discharge valve clogged Check the pipe and flush it if necessary
Table 10, The liquid pumped flows out through the degassing connection (pumps equipped with gas
separators (-GM, -GS) and air separating pumps (-R))
Inlet height too high Check the suction height limits
Pump speed too small Check the speed requirements and restrictions
Degassing vacuum too high Adjust the degassing vacuum by means of the vacuum relief
valve

SERIE 2.15
AHLSTAR
PROCESS PUMPS
1 General
2 Wet end
3 Sealing unit
4 Bearing unit

Series 2.15 Page
INSTRUCTIONS ISO
1 General
NOTE
Refer to the sectional drawings when reading through these instructions.
NOTE
Preventive maintenance is also a relevant safety factor.
NOTE
If the pump performance does not fulfill the process requirements, the pump is to be disassembled and
inspected. All worn parts should be changed to new genuine spare parts.
Regular and systematic preventive and predictive maintenance can extend the product lifetime and requires fewer
repairs and spare parts. Monitoring of instrumentation and physical examinations are a vital part of todays quality
maintenance. We recommend that the maintenance system includes a historical record kept for each pump, its
condition and performance. This will help to prevent sudden failures and aid in case of possible fault tracing
analyses. In the process industries, one process downtime caused by a pump normally costs much more than the
price of the pump.
Preventive maintenance consists of the following actions:
Bearing lubrication
Temperature, noise, vibration monitoring and inspections
Monitoring the discharge pressure, capacity and power demand
Inspections regarding corrosion and wear
Shaft seal monitoring
Regular pump washdowns
Monitoring the pump and pipings for leakage
Quarterly checks of the tightness of critical fasteners, such as foundation screws and pump & motor
fasteners onto the baseplate
General measuring instruments for pump operation are presented in Table 1.
Table 1, Measuring instruments

Fixed instruments: Portable instruments:
Pressure gauges & indicators Vibration analysers
Flow meters Tachometers
Ammeters / wattmeters / voltmeters Thermometers
Speed indicators Noise level indicators
Temperature detectors Ultrasonic indicators (wall thickness)
Vibroswitches
Any fixed or portable instruments may in themselves create a possible failure and require regular monitoring to ensure their
correct functioning.

Series 2.15 Page
INSTRUCTIONS ISO
1.1 Temperatures
During operation, the following surface temperatures are to be observed regularly:
volute casing (102.11)
bearing housing (330.31)
shaft sealing, measured from the casing cover (161.21) or from the stuffing box housing (451.21)
casing (100.21) measured at both the suction impeller and mechanical seal (liquid ring pumps (-LM, -S))
motor (800.41)
The reasons for any deviations in temperatures are to be checked immediately to prevent further and more serious
damage.
1.2 Noise and vibration analysis

A regular follow-up of the pump noise and vibration gives a good view regarding the condition and wear of bearings
and also other wearing parts of the pump. This enables timely predictive maintenance routines and reduces the
potential for unexpected shut-downs. Admissible vibration severity values are presented in Section Safety
instructions/Balance and vibration.
1.3 Discharge pressure

A regular control of the pressure generated by the pump, the rated flow and the power need of the drive unit gives a
good view regarding the condition and wear of the hydraulic parts of the pump. The follow-up enables such
preventive maintenance actions as clearance adjustments or parts renewals to be scheduled accordingly.
1.4 Pump washdown

The pump is designed to prevent external liquids from entering the bearing unit. However, direct spraying of high-
pressure water to the labyrinth rings (423.31 and 423.32) must be avoided.
2 Wet end
2.1 Corrosion and wear

When the pumps are operating under corrosive and/or abrasive conditions, a regular follow-up of wall thicknesses in
the case and case cover is necessary. When the wall thickness has worn more than the permitted corrosion
allowance of 3.0 mm, the mechanical durability (pressure limits) stated in these instructions is no longer guaranteed.
Due to the casting tolerances (ISO 8062-3: 2007), the nominal wall thicknesses stated in the casting drawings
cannot be used for assessing excessive corrosion and wear. If corrosion and wear are expected, the wall
thicknesses of the volute case and case cover should be measured at specific points before the first start-up. These
values serve later as reference values for assessing excessive corrosion and wear.
2.2 Adjustment of clearance between sideplate and impeller

If the pump has an adjustable sideplate (135.11), the clearance between the impeller and sideplate is adjusted
without disassembling the pump as follows (Fig. 1):

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INSTRUCTIONS ISO
920.11 909.11
135.11
230.11
Fig. 1
Slacken the hexagonal nuts (920.11) of the adjusting screws (909.11).
If your pump is provided with a vortex impeller, use the adjusting screws to move the sideplate so that the
clearance between the sideplate and the impeller is 5 mm (A11-40: 4 mm) (pump type: A).
If the pump is provided with a vortex impeller, move the sideplate using the adjusting screws so that there is
a minimum of stagger between the volute casing and sideplate (pump type: NPP, WPP).
If your pump is provided with an impeller other than a vortex impeller, turn each adjusting screw alternately
counter-clockwise until the sideplate touches the impeller. Then turn the adjusting screws clockwise 1/3 turns
to obtain a 0.5 mm clearance between the sideplate and impeller.
After the adjustment, tighten the hexagonal nuts, whereby the adjusting screws will be locked. The adjusting
screw must not turn during tightening.
By turning the coupling by hand, check that the pump can rotate freely.
The sideplate can be adjusted altogether 3 - 4 mm towards the impeller. If further adjustment is needed,
change the impeller and sideplate in order to keep the right clearance.
3 Sealing unit
WARNING
Always stop the motor before any of the following maintenance actions to the pump. Make sure that
the motor cannot be started by any means accidentally during the repairs.
WARNING
Always drain the pump before disassembling the shaft seal. When pumping hazardous liquids, make
sure that there is no trapped liquid remaining in pump parts.
3.1 Gland packing

Gland-packed pumps must be checked regularly to ensure that there is a slight leakage from the gland. An
excessively tight gland causes wear to the shaft sleeve and increased power demand. Refer to the instructions in
Section Operation/Controls during the first run.

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INSTRUCTIONS ISO
WARNING
Never use gland packing material containing asbestos. It may cause a health hazard.
Maintenance of shaft seals

Remove the used gland packing from the stuffing box housing by using a flexible extraction tool (Fig. 2).
Clean the stuffing box housing and open any clogged sealing liquid holes.
Fig. 2
If there are scratches or wearing marks on the shaft wearing sleeve (part 524.21 in Table 2) or in the stuffing
box housing, replace the damaged parts.
We recommend the use of precompressed gland packings. However, if you need to cut the packings from a
sealing band, proceed as follows: turn four rounds of the sealing band around a wooden pattern having the
same thickness as the shaft wearing sleeve (part 524.21 in Table 2) and use a sharp knife to cut the packing
rings straight and axially without overdimensioning or underdimensioning, Fig. 3. The dimensions of the
stuffing box housing and the total length of the band to be cut without working allowances are given in Table
2.
Fig. 3
When packing new packing rings, be very precise, and keep the parts clean.
Lubricate the shaft sleeve and packing rings lightly with oil.
Push the first packing ring tightly against the neck bush. The ends of the rings must be exactly against each
other.
The second ring is placed against the first one so that the joints are at 180 angle to each other, Fig. 4.
Next put the lantern ring into the seal chamber.
Fit also the last two rings with the joints at 180 angle to each other.
After all the packing rings and the lantern ring have been fitted, tighten the nuts of the stuffing box gland by
hand.
The shaft seal is taken into use according to Section Operation/Controls during the first run.

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INSTRUCTIONS ISO
Table 2, Dimensioning of stuffing box
524.21
d D
Stuffing box Total length of the

Shaft size
d x D x a (mm) packing ring (mm)
1 40 x 60 x 10 640
2 50 x 70 x 10 770
3 60 x 85 x 12.5 930
4 70 x 95 x 12.5 1050
5 90 x 122 x 16 1350
6 100 x 132 x 16 1460
7 120 x 152 x 16 1710
Gland packing
1st ring
2nd ring
lantern ring stuffing box gland
3rd ring
4th ring
Fig. 4
3.2 Mechanical seal

Mechanical seals are normally installed and adjusted at the factory before the delivery. The general principle is that
the mechanical seal does not leak at all. The lifetime of a mechanical seal depends on the cleanliness and
lubricating properties of the pumped liquid and the sealing liquid. If the mechanical seal leaks, stop the pump and
replace the mechanical seal.
CAUTION
The dry running of mechanical seals will damage the sliding surfaces and cause leakage of pumped
liquid.

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INSTRUCTIONS ISO

Mechanical seals do not normally require any preventive maintenance actions during their operation. If any problems
occur, the whole seal package is normally renewed. For longer-term shutdown, it is recommended that the sealing
space be flushed, preferably using clean water, if possible.
3.3 Dynamic seal
Dynamic seal, ring type (DS11, DS12)

The expeller (604.21) design of the dynamic seal prevents the leakage of pumped liquid through the stuffing box
during operation. During shut-down, the leakage is prevented by the static seal design (435.21).
Dynamic seals do not normally require any preventive maintenance actions. During the first years of operation, the
static seal (435.21) can yet wear so much that some leakage can occur during stoppages. The static seal is again
functional when sliding the thrust ring (475.21) away from the volute casing so long that the leakage stops. The
thrust ring must always be secured with the nuts (920.21) during operation. This adjustment can be done several
times during the lifetime of the static seal. The wear allowance of the static seal is about half of its thickness. If the
seal has worn more or otherwise damaged, it must be replaced with a new one.
Dynamic seal, plate type (DS13, DS14)

The expeller (604.21) design of the dynamic seal prevents the leakage of pumped liquid through the stuffing box
during operation. During shut-down, the leakage is prevented by the static seal design (435.21).
Dynamic seals do not normally require any preventive maintenance actions. During the first years of operation, the
static seal (435.21) can yet wear so much that some leakage can occur during stoppages. The static seal is again
functional when sliding the thrust ring (475.21) towards the volute casing so long that the leakage stops. The thrust
ring must always be secured with the grub screws (904.21) during operation. This adjustment can be done several
times during the lifetime of the static seal. The wear allowance of the static seal is about half of its thickness. If the
seal has worn more or otherwise damaged, it must be replaced with a new one.
4 Bearing unit
4.1 Grease lubrication

All the grease-lubricated bearings have been lubricated before the shipment. The pump has one cylinder roller
bearing unit (deep groove ball bearing on shaft size 7) and two single row angular contact ball bearings (O-system,
Table 3).
Table 3, Pump bearings

Shaft size Impeller side Coupling side
1 NUP 307 ECJ 7308 BECBM
7 6324 7326 BCBM
SKF designation. If bearings by other manufacturers are used, the corresponding bearing types are required.

Series 2.15 Page
INSTRUCTIONS ISO
Amounts of lubricants and re-lubrication intervals are described in Table 4 and in Table 5 depending on the speed of
rotation.
Table 4, Initial and re-lubrication (50 Hz speeds of rotation)

1)
Re-lubrication interval (hours, bearing housing
Initial lubrication (g) Re-lubrication (g)
temperature < +55 C)
Shaft size
Impeller Coupling Impeller Coupling 740 980 1480 2950
495 rpm 590 rpm
side side side side rpm rpm rpm rpm
1 30 50 10 15 - - 16000 12000 8000 3500
2 55 85 15 25 - - 14000 10000 6500 3000
3 85 135 20 30 - - 12000 8000 5500 2500
4 145 210 25 40 - - 10000 7500 4500 -
5 220 390 40 60 - - 8500 6000 3500 -
6 250 450 50 70 - - 8500 6000 - -
7 350 600 70 140 12000 10000 8500 6000 - -
1)
Every 15 C rise in the surface temperature shortens the lubrication interval to a half.
Table 5, Initial and re-lubrication (60 Hz speeds of rotation)

1)
Re-lubrication interval (hours, bearing housing temperature <
Initial lubrication (g) Re-lubrication (g)
+55 C)
Shaft size
Impeller Coupling Impeller Coupling 445 510 590 710 890 1180 1780 3540
side side side side rpm rpm rpm rpm rpm rpm rpm rpm
1 30 50 10 15 - - - - 15000 10000 7000 3000
2 55 85 15 25 - - - - 13000 8500 5500 2500
3 85 135 20 30 - - - - 11000 7000 4500 2000
4 145 210 25 40 - - - - 9000 6500 3500 -
5 220 390 40 60 - - - - 7500 5000 2500 -
6 250 450 50 70 - - - - 7500 5000 - -
7 350 600 70 140 13000 12000 10000 8500 7500 4500 - -
1)
Every 15 C rise in the surface temperature shortens the lubrication interval to a half.
Grease grades
CAUTION
Never mix different grease grades (consistency, thickeners). The mixed grease becomes softer and
does not lubricate the bearings properly.
NOTE
All greasing equipment and fittings used must be clean to prevent any impurities from entering the
bearing housing.
NOTE
The surface temperature of the bearing unit can temporarily rise after regreasing due to an excess
amount of grease.

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INSTRUCTIONS ISO
For normal conditions when the bearing housing surface temperature is below +80 C, we recommend lithium or
lithium-calcium-based mineral greases for roller bearings, such as:
Shell Alvania EP2
Mobil, Mobilgrease XHP 222
The first re-lubrication should be done before the initial commissioning of the pump.
If the bearings run hotter and the surface temperatures are above +80 C, we recommend the use of the following
special greases:
Shell Limona LX1
Mobil, Mobilgrease XHP 461
These special greases can also be used with surface temperatures below +80 C.
Always consult the pump manufacturer about the use of any special greases (not mentioned in these instructions).
4.2 Oil lubrication
CAUTION
For delivery, the bearing housing of the pump has been emptied of oil. Remember to refill it before
starting.
Bearing unit 1-6 (Oil splash lubrication, Oil bath lubrication)
For lubrication, use only high-quality mineral oils, the viscosity of which is ISO VG 46.
E.g.
Shell Tellus Oil S46
Mobil DTE Oil Medium
Viscosity of oil at the operating temperature must not be below 12 cSt (65 SSU). The operating temperature is ca 15
C higher than the surface temperature of the bearing housing.
ISO solid contaminant code of oil: -/17/14 (ISO 4406)
Bearing unit 7 (Oil splash lubrication)
For lubrication, use only lubrication oils of a good quality the viscosity of which in normal conditions is ISO VG 100 -
ISO VG 150.
E.g.
Shell Tellus Oil S 100
Mobil DTE Oil Heavy
The viscosity of the oil at operating temperature must not be lower than 16 cSt (84 SSU).The operating temperature
is about 15 C higher than the surface temperature of the bearing housing.
First oil filling (Oil splash lubrication)

Remove the venting device (672.31) and add oil so that the level reaches the middle of the sight glass
(642.31).

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INSTRUCTIONS ISO
Loose the socket head screw (914.31) and remove the constant level oiler (638.31). Fill it with oil and put it
back.
First oil filling (Oil bath lubrication)
Without using the constant level oiler
642.31
Fig. 5
Unscrew the venting device (672.31) and add oil up to the middle of the sight glass (642.31), Fig. 5. When pump is
running oil level in the sight glass can be little variable. With lower speed oil level can go little bit lower and higher
speed go little up (air is mixing into oil. Screw the venting device (672.31) back in place. See the oil volumes in Table
8.
With using the constant level oiler
672.31
642.31 638.21
Fig. 6
Install the constant level oiler (638.31) in the bearing unit. Adjust the constant level oiler (638.31) to the correct
height (0 mm) and tighten the locking screw. Unscrew the venting device (672.31), add oil up to the middle of the
sight glass (642.31) and screw the venting device (672.31) back in place. Undo the glass cup of the constant level
oiler (638.31) and fill it with oil, and place the glass cup of the constant level oiler (638.31) back in place.
Oil change
After commissioning, oil should be changed for the first time after about 100 hours of operation and thereafter
according to
Table 6 and more often if the operating conditions cause contamination or change in other properties of the oil used.

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INSTRUCTIONS ISO
Table 6, Oil changes

Surface temperature of bearing housing Oil change interval
65 C 1 year
75C 6 months
Table 7, Oil volumes (Oil splash lubrication)

Oil volume (ml)
Shaft size Bearing Constant level
Glass cup
housing oiler
1 ~140 140 100
2 ~350 140 100
3 ~460 140 100
4 ~1030 140 100
5 ~1500 140 100
6 ~2500 140 100
7 ~3900 140 100
Table 8, Oil volumes (Oil bath lubrication)

Bearing unit Oil volume (l)
1 0.2
2 0.5
3 0.6
4 0.9
5 2.2
6 3.7

SERIES 2.15
SPP id: Version 14 > / 110901 / en / N31574 / 1
AHLSTAR
PROCESS PUMPS
1 General
2 Pump unit
3 Wet end
4 Sealing unit
5 Bearing unit

Series 2.15 Page
INSTRUCTIONS ISO
SPP id: Version 14 > / 110901 / en / N31574 / 1 / Page 2 (27)
1 General
NOTE
Refer to the sectional drawings when reading through these instructions.
1.1 Safety instructions and environmental aspects to be noted before corrective

maintenance
WARNING
When pumping hazardous liquids, secure that there is no trapped liquid remaining in pump parts.
Pumps which convey hazardous media must be carefully decontaminated before any repairs. Skin and
eye protection are required during decontamination. Precautions are needed for personal or
environmental safety.
Some of the disassembled parts and assemblies are heavy, unstable and due to design requirements
they contain sharp edges (e.g. impeller, sideplate, casing cover). Use proper hoistings and supports to
prevent personal injury.
WARNING
Hazardous substances must be kept away from the environment. These substances should be
collected and sent for proper handling. All recyclable components should be taken to a proper
recycling system.
1.2 Necessary equipment / tools
Normally available working tools

Hoisting accessories. Note the safety requirements!
Wrenches for hexagonal screws, sizes (mm): 13, 14, 16, 18, 19, 22, 24, 30
Allen wrenches for socket head screws, sizes (mm): 2,5, 4, 5, 6, 8, 10, 14
Torque wrenches for moments (Nm): 30, 50, 130, 250, 420, 800
- for hexagonal, sizes (mm): 18, 24, 30, 36
- for socket head, sizes (mm): 8, 10, 14, 17, 19, 22, 27
Hooked wrenches, sizes (SKF): HN8, HN10, HN12, HN14, HN18, HN22, HN26
Extractors
Bearing heater
Dial indicators
Cleaning agents & equipment
Lubricating agents & equipment

Series 2.15 Page
INSTRUCTIONS ISO
Special tools
Detachment tool for the casing wear ring/sideplate. Fig. 1.
Pipe punch series for roller bearings and lubrication rings. Fig. 7.
Securing tool for impeller head screw. Fig. 3.
2 Pump unit
2.1 Disassembly
NOTE
Ensure that all eventual spare parts are available before the disassembly.
Preliminaries
1 Close the discharge valve.
2 Stop the motor. Make sure that the motor cannot be started by any means during the repair.
3 Close the suction valve.
4 Drain the pump carefully. For this, use the threaded plug (903.11) potentially situated at the bottom of the
volute case (102.11).
5 Disconnect potential guards, pipes and sealing water equipment relating to degassing and shaft seal.
6 Remove the guard jackets (686.51 and 686.52) and coupling (840.51) spacer.
7 Drain oil from an oil-lubricated bearing housing by unscrewing the threaded plug (903.32).
Detachment of exchange unit

1 Unscrew the hexagon head screws (901.11) and the hexagon head screws (901.62) of the support foot from
the baseplate (890.61).
2 Suspend the exchange unit by a hoist at the maintenance opening of the adapter or underneath the adapter.
3 Pull out the exchange unit by using the hexagon head screws (901.11).
2.2 Reassembly
Preliminaries
Clean all gasket surfaces and fittings from rust and layers.
Inspect for unusual erosion, pitting and wear in parts.
Inspect keyways and bores for damage.
Inspect the pump and baseplate for cuts and cracks.
Installation of exchange unit

1 Fix the support foot of the bearing unit by means of the hexagon head screws (901.32).

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INSTRUCTIONS ISO
2 Heat the coupling flange to approx. +100C and push it on the shaft with the front surface at the shaft end
level.
3 Suspend the exchange unit with a hoist at the maintenance opening of the adapter or underneath the
adapter.
4 Fit the gasket (400.21) into the case cover (161.21).
5 Install the exchange unit in its place, lubricate the hexagon head screws (901.11) with Molycote Ti 1200
lubricant and tighten them in a cross bolt pattern little by little; first 30% of moment in Table 1, then 60% of
moment in Table 1 and then 100% of moment in Table 1. Finally tighten the screws screw by screw
clockwise with 100% of moment given in Table 1.
Table 1, Exchange unit fastening screws (901.11)

Moment (Nm)
Screw size
Rating Max. value
M12 50 60
M16 130 160
M20 250 300
M24 420 520
6 Check the impeller clearance according to the Section Preventive maintenance.

7 Place adjusting plates under the support foot. The plates must have the same thickness as the gap under
the support foot. Do not close the gap by tightening.
8 Fix the support foot (183.31) to the baseplate (890.61) with the hexagon head screws (901.62).
9 Lubricate the bearing unit with oil or grease according to lubricating instructions in Section Operation.
10 Install the coupling spacer according to the coupling manufacturers instructions.
11 Fix the coupling guard jackets (686.51and 686.52). The coupling guard must be adjusted so that the space
between the coupling guard and motor is approx. 5 mm.
12 Install the auxiliary pipings, guards, accessories and sealing unit equipment according to sectional drawings.
WARNING
Proper adjustment of the coupling guard jacket is a relevant safety factor.
3 Wet end
3.1 Disassembly
Detachment of casing wear ring (pump types: APP and EPP / closed impeller)
The casing wear ring (502.11) between the closed impeller and volute casing and also the casing wear ring (502.12)
between the impeller and casing cover in the pump type EPP can be removed with a suitable tool by using the three
notches situated under the casing wear ring, Fig. 1.
Detachment of sideplate
1 Unscrew the three nuts (920.11).
2 Turn the potential adjusting screws (909.11) counter-clockwise. As a result the sideplate protrudes out.

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INSTRUCTIONS ISO
3 The sideplate can now be removed with a proper tool from the volute casing. Fig. 1.
16
250
2
40
25
Fig. 1
Detachment of impeller
1 Fasten the exchange unit firmly to a vice.
2 Unscrew the cap screw socket head (914.11) of the impeller (230.11).
3 Prevent the shaft (210.31) from rotating at the coupling (840.51) end.
4 Detach the impeller by turning it counter-clockwise. Push e.g. pieces of wood between the impeller vanes to
ease the detachment. Never use metal bars or the like, because they might damage the impeller vanes. Fig.
2.
Fig. 2
3.2 Reassembly
Installation of impeller
WARNING
The socket head screw (914.11) must be secured to avoid loosening of the impeller.
1 Make sure that the o-rings behind the impeller are properly installed.
2 Prevent the shaft from rotating from the coupling end and insert the impeller (230.11) into its place. The
clearance between the impeller and case cover (161.21) is about 1.0 mm.
3 Lock the impeller with the socket head capscrew (914.11) onto which the o-ring (412.14) has been fitted.

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INSTRUCTIONS ISO
4 Tighten the socket head screw to the torque value given in Table 2. Note the special values for the titanium
screws.
Table 2, Impeller locking screw 914.11

Titanium screws (76)
Torque (Nm)
Shaft size Screw size Torque (Nm)
Rating Max. value Rating Max. value
1 M10 30 40 18 22
2 M12 50 60 30 38
3 M16 130 140 70 92
4 M20 250 260 140 180
5 M24 420 440 250 310
6 M30 800 820 490 615
7 M36 1450 1500 850 1070
Secure the socket head capscrew (914.11) by bending its flange into one hole on the impeller. Use a tool
with the head shape and dimensions shown in Fig. 3.
The same socket head screw can be used many times. There are two extra holes on the impeller for
securing later on.
L D
R
Shaft size L (mm) D (mm) R (mm) Smin (mm)
0
1, 2 6.5 4 2 6
- 0.5
0
3, 4 7.5 6 3 7
- 0.5
0
5, 6, 7 9.0 8 4 8
- 0.5
Fig. 3
Installation of sideplate
APP, NPP, WPP
1 Grease the o-rings (412.11 and 412.13) lightly and fit them into the grooves of the sideplate (135.11).
2 Screw the adjusting screws (909.11) all the way into the sideplate.
3 Install the sideplate into the volute case (102.11).
4 Fix the nuts (920.11) to the adjusting screws.

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INSTRUCTIONS ISO
A, Process pump
1 Grease the o-ring (412.11) lightly and fit it into the groove of the sideplate (135.11).
2 Grease the o-ring (412.12) lightly and fit it into the groove of the adjusting screws (909.11).
3 Screw the adjusting screws (909.11) all the way into the sideplate.
4 Install the sideplate into the volute case (102.11).
5 Spread Loctite 577 paste (400.13) on the sideplate (135.11) of the low flow impeller just before the
installation of the exchange unit. Push the sideplate (135.11) against the case cover (161.21) by the
adjusting screws (909.11) and tighten the nuts (920.11).
6 Fix the nuts (920.11) to the adjusting screws.
Fixed sideplate of pump type EPP (open impeller)
1 Screw the studs (902.11) tightly into place in the sideplate.

2 Push the back-up rings (516.11) and o-rings (412.12) onto the studs against the sideplate.
3 Install the sideplate into place in the volute case (102.11).
4 Mount and tighten the nuts (920.11).
Installation of casing wear ring (pump types: APP and EPP / closed impeller)
Tap the casing wear ring (502.11) into the volute case (102.11) (and the wear ring (502.12) into the case cover
(161.21) of an EPP pump) with a soft hammer. Check that the wear ring is tightly against the bottom of its groove at
each side.
4 Sealing unit
4.1 Disassembly
CAUTION
The threaded hole in the casing cover is only meant for lifting the casing cover.
Dynamic seal, ring type (types DS11 and DS12)

1 Loosen the hexagon head screws (901.21) and remove the guards (683.21 and 683.22).
2 Unscrew the hexagon head screws (901.21).
3 Detach the case cover (161.21) by levering from the slot between the case cover and adapter (344.31). In
heavier casing covers, there is a threaded hole (size M8) for lifting the cover by using an eye screw. Detach
the gasket (400.22) or o-ring (412.23).
4 Remove the expeller (604.21) from the shaft.
5 By using the hexagon head screws (901.21) as extractors, pull the stuffing box housing (451.21) out of the
guideway in the adapter. The stuffing box housing (451.21) with its incorporated parts will also come out.
6 Remove the shaft wearing sleeve (524.21) from the shaft.
7 Unscrew the nuts (920.21) and detach the thrust ring (475.21) from the stuffing box housing (451.21).
Detach the o-ring (412.24) from the thrust ring.
8 Remove the static seal (435.21) and o-rings (412.25) from the shaft wearing sleeve (524.21).

Series 2.15 Page
INSTRUCTIONS ISO
9 Unscrew the hexagon head screws (901.33) of the adapter and draw the adapter out by using the same
screws as extractors.
Dynamic seal, plate type (types DS13 and DS14)

2 Uncrew the hexagon head screws (901.21).
heavier case covers, there is a threaded hole (size M8) for lifting the cover by using an eye screw.
4 Detach the expeller (604.21) from the shaft.
5 By using the hexagon head screws (901.21) as extractors, draw the stuffing box housing (451.21) out of the
guiding in the adapter.
6 The cover plate for seal (471.21) and the static seal (435.21) can be detached by unscrewing the nuts
(920.21).
7 Unscrew the grub screws (904.21) and detach the thrust ring (475.21) from the shaft.
8 Unscrew the hexagonal screws (901.33) of the adapter and draw the adapter out by using the same screws
as extractors.
Mechanical seal, standard integrated single (types MS11 and MS12)

3 By using the said screws as extractors, draw the case cover (161.21) out of the adapter (344.31). In heavier
casing covers, there is a threaded hole (size M8) for lifting the cover by using an eye screw. The
components of the mechanical seal (433.21) come off the shaft.
4 Unscrew the hexagon head screws (901.22) of the case cover (161.21) and remove the seal ring (411.21).
5 The mechanical seal can now be removed from the case cover (161.21) and dismantled according to the
seal manufacturer's instructions.
Mechanical seal, standard integrated double (type MS21, pump types A, APP, NPP and WPP)
4 Unscrew the hexagon head screws (901.22) of the case cover (161.21) and remove the seal ring (411.21).
6 Remove the rotating part on the atmospheric side of the mechanical seal (433.21) from the shaft by opening
the hexagonal retainer screws.
as extractors.
Mechanical seal, standard integrated double (type MS21, pump type EPP)

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INSTRUCTIONS ISO
4 Unscrew the nuts (920.21) of the case cover (161.21).
Mechanical seal, cartridge single on the shaft without shaft sleeve (types MS31, MS32 and
MS35)
3 Unscrew the nuts (920.21).
casing covers, there is a threaded hole (size M8) for lifting the cover by using an eye screw. All parts
belonging to the mechanical seal (433.21) will remain on the shaft.
5 The mechanical seal can now be removed from the shaft and from the casing cover and dismantled
according to the seal manufacturer's instructions.
Mechanical seal, cartridge single on the shaft sleeve (types MS33 and MS34)
case covers, there is a threaded hole (size M8) for lifting the cover by using an eye screw. All parts
6 Remove the shaft wearing sleeve (524.21) from the shaft with an extractor.
Mechanical seal, cartridge double on the shaft without shaft sleeve (type MS41)

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INSTRUCTIONS ISO
as extractors.
Mechanical seal, cartridge double on the shaft sleeve (type MS42)

casing covers, there is a threaded hole (size M8) for lifting the cover by using an eye screw. All parts
Mechanical seal, element single (types MS51 and MS52)

Mechanical seal, element double (type MS61)

Mechanical seal, ready-fitted single (types MS71 and MS72)


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INSTRUCTIONS ISO
Mechanical seal, ready-fitted double (type MS81)

Mechanical seal, US, outside single (type MS91)

case covers, there is a threaded hole (size M8) for lifting the cover by using an eye screw.
4 The rotating part of the mechanical seal (433.21) will remain on the shaft.
5 The cover plate for seal (471.21) and the static part of the mechanical seal can be detached from the case
cover by unscrewing the screws (914.21).
6 The rotating part can now be removed from the shaft and dismantled according to the seal manufacturer's
instructions.
Gland packing (type PG11)

2 Unscrew the hexagon head screws (901.21) of the case cover (161.21).
belonging to the gland packing, except the shaft wearing sleeve (524.21), will stay in the casing cover.
4 Unscrew the nuts (920.21) and remove the two-piece stuffing box gland (452.21). The neck bush (456.21),
gland packing (461.21) and lantern ring (458.21) can now be drawn out of the casing cover.

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INSTRUCTIONS ISO
Liquid ring pump, standard integrated single (type LM11)

1 Detach the pipe (700.23) with the peripheral equipment from the case (100.21) if a vacuum relief valve
(695.21) is included in the delivery.
3 Remove the case cover (161.21) by levering from the slot between the case cover and adapter (344.31).
4 Remove the o-ring (412.23) from the case (100.21).
5 Remove the suction impeller (231.21) from the shaft. Notice the compressor rings (487.21) between the
suction impeller and mechanical seal (433.21).
6 Remove the o-rings (412.21 and 412.22).
7 Remove the rotating part on the product side of the mechanical seal from the shaft.
8 Pull the case (100.21) out of the guideway in the adapter (344.31) with the help of hexagon head screws
(901.21).The static parts of the mechanical seal (433.21) will follow.
9 Unscrew the hexagon head screw (901.22) of the case (100.21). Remove the seal ring (411.21).
10 The mechanical seal can now be removed from the case (100.21) and dismantled according to the seal
manufacturer's instructions.
Liquid ring pump, standard integrated double (type LM21)

5 Remove the suction impeller (231.21) from the shaft.
6 Remove the o-rings (412.21 and 412.22).
7 Remove the rotating part on the product side of the mechanical seal from the shaft.
(901.21). The static parts of the mechanical seal (433.21) will follow.
9 Unscrew the hexagon head screw (901.22) of the case (100.21). Remove the seal ring (411.21).
10 The mechanical seal can now be removed from the case (100.21) and dismantled according to the seal
manufacturer's instructions.
Liquid ring pump, element single (type SM11)


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INSTRUCTIONS ISO
5 Remove the suction impeller (231.21) from the shaft. Pull the shaft wearing sleeve (524.21) from the shaft.
The rotating part of the mechanical seal (433.21) will come off, too, and the static part will remain in the
cover plate for seal. Notice the compressor rings (487.21) between the suction impeller and shaft wearing
sleeve.
6 Pull the case (100.21) out of the guideway in the adapter with the help of hexagon head screws (901.21).
Detach the cover plate for seal (471.21) by unscrewing the socket head capscrews (914.21).
7 The rotating part of the mechanical seal can now be removed from the shaft wearing sleeve and the static
part from the cover plate for seal. Make sure not to damage the sliding surfaces.
Liquid ring pump, ready-fitted double (type SM21)

3 Detach the case cover (161.21) by levering from the slot between the case cover and adapter (344.31).
5 Remove the suction impeller (231.21) from the shaft. The rotating part on the product side of the mechanical
seal (433.21) will come off, too, and the static part will remain in the case. Notice the compressor rings
(487.21) between the suction impeller and mechanical seal.
(901.21).
7 The static part of the mechanical seal is detached from the case (100.21) by unscrewing the socket head
capscrews (914.21).
8 The rotating part on the atmospheric side of the mechanical seal can be removed from the shaft by opening
Air separating pump, element single (type RM11)

1 Open the two hexagon head screws (901.21) of the case cover (161.21).
2 By using the above mentioned screws as extractors, push the case cover (161.21) and cover (160.21) out of
the stuffing box housing (451.21).The gasket (400.23) may be replaced if needed.
3 The case cover and cover may be detached from each other, so that the condition of the o-ring (412.23) and
the gasket (400.23) may be checked and replaced if needed.
4 Pull the expeller (235.21) off the shaft by levering against the stuffing box housing. The rotating parts of the
mechanical seal (433.21) follow with the expeller.
5 Special care should be taken not to damage the sliding surfaces of the mechanical seal. The mechanical
seal can be removed from the expeller by detaching the locking screws of the seal.
6 Unscrew the nuts (920.22) of the stuffing box housing (451.21) and lever the stuffing box housing out of the
bearing housing (330.31) guide using the two slots at the interface of the bearing housing.
7 The stationary seat of the mechanical seal (433.21) can be removed from the stuffing box housing. Special
care should be taken not to damage the sliding surfaces of the seal.
Gas separator, standard integrated single (types GM11 and GM12)


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INSTRUCTIONS ISO
2 Detach the case cover (161.21) by levering from the slot between the casing cover and adapter (344.31). In
heavier case covers, there is a threaded hole (size M8) for lifting the cover by using an eye screw. Detach
4 By using the hexagonal screws (901.21) as extractors, pull the stuffing box housing (451.21) out of the
guideway in the adapter. The stuffing box housing (451.21) with its incorporated parts will also push all
components off the shaft.
5 Unscrew the hexagon head screw (901.22) of the stuffing box housing (451.21). Remove the seal ring
(411.21).
6 The static parts of the mechanical seal (433.21) can now be removed from the case cover (161.21).
Gas separator, standard integrated double (types GM21 and GM22)

guideway in the adapter. The stuffing box housing (451.21) with its incorporated parts will also push all
components off the shaft.
5 Unscrew the hexagon head screw (901.22) of the stuffing box housing (451.21). Remove the seal ring
(411.21).
6 The static parts of the mechanical seal (433.21) can now be removed from the stuffing box housing (451.21).
Gas separator, static seal (types GS11 and GS12)

guideway in the adapter. The stuffing box housing (451.21) with its incorporated parts will also come out.
6 Remove the shaft wearing sleeve (524.21) from the shaft.
7 Unscrew the nuts (920.21) and detach the thrust ring (475.21) from the stuffing box housing (451.21).
Detach the o-ring (412.24) from the thrust ring.
8 Remove the static seal (435.21) and o-rings (412.25) from the thrust ring (475.21).

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INSTRUCTIONS ISO
4.2 Reassembly
Dynamic seal, ring type (types DS11 and DS12)

1 Fix the adapter (344.31) to the bearing housing (330.31) with the hexagon head screws (901.33).
2 Grease the o-ring (412.25) slightly and place it into the groove of the static seal (435.21). Push the static seal
(435.21) to the thrust ring (475.21).
3 Grease the o-ring (412.24) slightly and place it into its proper groove in the thrust ring (475.21). Place the
thrust ring (475.21) on the stuffing box housing (451.21) and fix it with the studs (902.21) and nuts (920.21).
Do not tighten the nuts.
4 Push the shaft wearing sleeve (524.21) onto the shaft against the shoulder.
5 Push the stuffing box housing with its parts into its place in the adapter (344.31).
6 Grease the o-ring (412.22) slightly and place it into its proper groove in the expeller (604.21). Place the o-
ring (412.21) in the middle of the expeller and push the expeller onto the shaft.
7 Mount the gasket (400.22) or o-ring (412.23) into its place in the stuffing box housing (451.21).
8 Push the case cover (161.21) into its place in the adapter (344.31) and fasten the hexagon head screws
(901.21). Continue the assembly according to the following section Installation of impeller.
9 When the exchange unit is fully assembled, pull the thrust ring (475.21) and the static seal (435.21) against
the shaft wearing sleeve (524.21). The assembly groove (3 mm x 0.5 mm) in the thrust ring comes out 0.5
mm from the stuffing box housing end. Tighten the nuts (920.21) by hand so that the thrust ring is precisely
aligned with the shaft. Tighten the locking nuts. The distance between the face of the case cover and the
thrust ring is according to Fig. 4.
10 Loosen the hexagon head screws (901.21) and mount the guards (683.21 and 683.22). Tighten the screws.
Shaft size D (mm)

1 17
2 17
3 20
4 20
5 24
6 24
Fig. 4
Dynamic seal, plate type (types DS13 and DS14)


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INSTRUCTIONS ISO
2 Slide the thrust ring (475.21) with its o-ring (412.25) and grub screws (904.21) along the shaft to a
preliminary position up to the hindmost shoulder.
3 Install the o-ring (412.24), static seal (435.21) and cover plate for seal (471.21) into the stuffing box housing
(451.21) by using studs (902.21) and nuts (920.21). Observe that the static seal must be placed in the right
way and centrally in its guiding slot in the stuffing box housing.
4 Push the stuffing box housing with its parts into its place in the adapter.
5 Push the expeller (604.21) with the o-rings (412.21, 412.22) fitted in its hub onto the shaft.
6 Install the gasket (400.22) into the stuffing box housing or the o-ring (412.23) into the case cover (161.21).
7 Push the case cover into its place in the adapter and fasten the hexagon head screws (901.21). Continue the
assembly according to the following section "Installation of impeller".
8 When the exchange unit is fully assembled, place the thrust ring (475.21) at the right position on the shaft
and fasten the grub screws (904.21). The distance between the face of the cover plate for seal and the
shoulder of the thrust ring must be 10 mm. Fig. 5.
10 mm
471.21
475.21
Fig. 5
Mechanical seal, standard integrated single (types MS11 and MS12)

2 Push the static part of the mechanical seal (433.21) into the case cover (161.21) by means of the installation
sleeve.
3 Push the seal ring (411.21) onto the hexagon head screw (901.22).
4 Mount the static part of the mechanical seal (433.21) with the hexagon head screw (901.22).
5 Push the case cover (161.21) together with the incorporated parts onto the adapter (344.31). Fix the screws
(901.21, 901.22).
6 Push the rotating part of the mechanical seal onto the shaft against the shoulder. Continue the assembly
according to the following section Installation of impeller.
Mechanical seal, standard integrated double (type MS21, pump types A, APP, NPP and WPP)
2 Mount the rotating part on the atmospheric side of the mechanical seal (433.21) onto the shaft against the
shoulder.
sleeve.
4 Push the seal ring (411.21) onto the hexagon head screw (901.22).
5 Mount the static part of the mechanical seal (433.21) with hexagon head screw (901.22).

Series 2.15 Page
INSTRUCTIONS ISO
(901.21).
7 Push the rotating part of the mechanical seal (433.21) onto the shaft against the shoulder. Continue the
assembly according to the following section Installation of impeller.
Mechanical seal, standard integrated double (type MS21, pump type EPP)
shoulder.
3 Install the static part of the mechanical seal (433.21) into the case cover (161.21).
4 Mount the static part of the mechanical seal (433.21) with studs (902.21), washers (554.21) and nuts
(901.21).
(901.21).
6 Push the rotating part of the mechanical seal (433.21) onto the shaft against the shoulder. Continue the
assembly according to the following section Installation of impeller.
Mechanical seal, cartridge single on the shaft without shaft sleeve (types MS31, MS32 and
MS35)
2 Mount the mechanical seal (433.21) into the case cover (161.21). Follow the instructions provided by the
seal manufacturer.
3 Push the case cover (161.21) together with the incorporated parts onto the shaft. Follow the instructions
provided by the seal manufacturer. Fix the screws (901.21). Tighten the nuts (920.21).
4 Complete all the lockings, fixings and other seal-related jobs as described in the seal manufacturer's
instructions. Continue the assembly according to the following section Installation of impeller.
Mechanical seal, cartridge single on the shaft sleeve (types MS33 and MS34)
seal manufacturer.
3 Push the shaft wearing sleeve (524.21) onto the shaft.
Mechanical seal, cartridge double on the shaft without shaft sleeve (type MS41)
seal manufacturer.

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INSTRUCTIONS ISO
Mechanical seal, cartridge double on the shaft sleeve (type MS42)

1 Fix the adapter (344.31) to the bearing housing (330.31) with the hexagon head screw (901.33).
seal manufacturer.
3 Push the shaft wearing sleeve (524.21) onto the shaft.
Mechanical seal, element single (types MS51 and MS52)

2 Mount the mechanical seal (433.21) parts into the cover plate for seal (471.21) and onto the shaft wearing
sleeve (524.21) according to the seal manufacturer's instructions. Make sure that the cylinder pin (562.22) is
in the proper position.
3 Place the gasket (400.23) in the cover plate for seal (471.21). Fix the cover plate for seal on the case cover
(161.21) with the flange (723.21). Tighten the nuts (920.21).
4 Push the case cover (161.21) together with the incorporated parts onto the shaft. Fix the screws (901.21).
5 Push the shaft wearing sleeve (524.21) together with the incorporated parts onto the shaft against the
shoulder. Continue the assembly according to the following section Installation of impeller.
Mechanical seal, element double (type MS61)

2 Mount the mechanical seal (433.22) onto the shaft against the shoulder.
3 Mount the mechanical seal (433.21 and 433.22) parts into the cover plate for seal (471.21) and onto the
shaft wearing sleeve (524.21) according to the seal manufacturer's instructions. Make sure that the cylinder
pins (562.22 and 562.23) are in the proper position.
4 Place the gasket (400.23) in the cover plate for seal (471.21). Fix the cover plate for seal on the case cover
(161.21) with the nuts (920.21).
6 Push the shaft wearing sleeve (524.21) together with the incorporated parts onto the shaft against the
shoulder. Continue the assembly according to the following section Installation of impeller.
Mechanical seal, ready-fitted single (types MS71 and MS72)

2 Install the gasket (400.21) if included in the delivery

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INSTRUCTIONS ISO
3 Mount the static part of the mechanical seal (433.21) into the case cover (161.21), and the outer rotating part
onto the shaft according to the seal manufacturers instructions. Tighten the nuts (920.21).
Mechanical seal, ready-fitted double (type MS81)

2 Install the gasket (400.21) if included in the delivery.
3 Mount the static part of the mechanical seal (433.21) into the case cover (161.21), and the outer rotating part
onto the shaft according to the seal manufacturers instructions. Tighten the nuts (920.21).
Mechanical seal, US, outside single (type MS91)

2 Mount the static part of the mechanical seal (433.21) into the case cover (161.21) with the cover plate for
seal (471.21). Follow the instructions provided by the seal manufacturer. Tighten the socket head capscrews
(914.21).
4 Push the rotating part of the mechanical seal (433.21) almost to its proper place on the shaft wearing sleeve.
Follow the instructions provided by the seal manufacturer.
6 Mount the mechanical seal (433.21) into its final place according to the seal manufacturer's instructions.
Complete all the lockings, fixings etc. as described in the manufacturer's instructions. Continue the assembly
Gland packing (type PG11)

2 Place the case cover (161.21) on a horizontal surface with the sealing cavity upwards.
3 Place the neck bush (456.21) to the bottom of the sealing cavity.
4 Put the shaft wearing sleeve (524.21) in an upright position to the middle of the sealing cavity.
5 Insert the first two gland packings (461.21), the lantern ring (458.21), the other two gland packings and the
two-piece stuffing box gland (452.21). Tighten the nuts (920.21) by hand.
6 Push the casing cover with gland packing parts onto the shaft. Check that the shaft wearing sleeve is placed
towards the shaft shoulder.
7 Attach the case cover to the adapter with hexagon head screws (901.21). Continue the assembly according
to the following section Installation of impeller.

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INSTRUCTIONS ISO
Liquid ring pump, standard integrated single (type LM11)

2 Push the case (100.21) into its guideway into the adapter (344.31). Fix the hexagon head screws (901.21).
3 Put the series of compressor rings (487.21) onto the shaft.
4 Push the rotating part of the mechanical seal (433.21) onto the shaft against the shoulder.
5 Push the suction impeller (231.21) onto the shaft. Do not insert the o-ring (412.21) at this stage.
6 Measure the gap between the suction impeller (231.21) and case (100.21), and adjust it according to Table 3
by taking off or adding compressor rings (487.21). While measuring the gap, make sure that both the casing
and the suction impeller are tightly in their guideway pressed all the way to the bottom. Measure the gap
between the end of the suction impeller hub and the casing because the front face of the vanes is slightly
conical.
Table 3, Gap between the suction impeller and casing

Shaft size Gap (mm)
1 0.2 - 0.3
2 0.2 - 0.3
3 0.2 - 0.3
4 0.25 - 0.35
5 0.3 0.4
6 0.3 0.4
7 After adjusting the gap, remove the parts again so as to perform the actual assembly.
8 Push the static part of the mechanical seal (433.21) into the case (100.21) by means of the installation
sleeve. Follow the instructions provided by the seal manufacturer.
9 Place the seal ring (411.21) onto the hexagon head screw (901.22) and mount the static part of the
mechanical seal (433.21) using this screw.
11 Push the compressor rings (487.21) onto the shaft against the shoulder.
12 Push the rotating part of the mechanical seal (433.21) onto the shaft.
13 Grease the o-ring (412.22) slightly and place it into its proper groove in the suction impeller (231.21). Push
the suction impeller onto the shaft.
14 Push the cylinder pin (562.21) into its hole in the case (100.21).
15 Place the o-ring (412.23) into its groove in the case.
16 Install the case cover (161.21) into its guideway into the adapter (344.31). Tighten the hexagon head screws
Liquid ring pump, standard integrated double (type LM21)

3 Put the series of compressor rings (487.21) onto the shaft.
by taking off or adding compressor rings (487.21). While measuring the gap, make sure that both the casing
between the end of the suction impeller hub and the casing because the front face of the vanes is slightly
conical.

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INSTRUCTIONS ISO
shoulder.
10 Place the seal ring (411.21) onto the hexagon head screw (901.22) and mount the static part of the
mechanical seal (433.21) using this screw.
12 Push the compressor rings (487.21) onto the shaft against the shoulder.
13 Push the rotating part of the mechanical seal (433.21) onto the shaft.
14 Grease the o-ring (412.22) slightly and place it into its proper groove in the suction impeller (231.21). Push
the suction impeller onto the shaft.
16 Place the o-ring (412.23) into its groove in the case.
Liquid ring pump, element single (type SM11)

1 Fix the adapter (344.31) into the bearing housing (330.31) with hexagonal screws (901.33).
2 Push the case (100.21) into its guideway into the adapter (344.31).
3 First, push the shaft wearing sleeve (524.21) and then the series of compressor rings (487.21) onto the
shaft.
4 Push the suction impeller (231.21) onto the shaft. Do not install the o-rings (412.21), the parts of the
mechanical seal (433.21) nor the cover plate for seal (471.21) yet.
by taking off or adding compressor rings (487.21). While measuring the gap, make sure that both the case
and the suction impeller are tightly in their guideway pressed all the way to the bottom.
Measure the gap between the end of the suction impeller hub and the case. The gap is bigger at the vanes
of the suction impeller, since the front face of the vanes is slightly conical.
Once the gap between the suction impeller and case is correct, the gap between the suction impeller and the
case cover (161.21) will also become automatically correct.
6 After adjusting the gap, remove the suction impeller, shaft wearing sleeve and case again so as to perform
the actual assembly.
7 Fasten the cylinder pins (562.22 and 562.21) into the cover plate for seal (471.21) and case (100.21).
8 Install the static part of the mechanical seal (433.21) into the cover plate for seal (471.21). Make sure that
the position of the static part in relation to the cylinder pin is correct. Place the o-ring (412.24) into the groove
in the cover plate for seal. Install the cover plate for seal into the case (100.21) with socket head capscrews
(914.21).
9 Install the case (100.21) with its parts into its guideway into the adapter (344.31).
10 Install the rotating part of the mechanical seal (433.21) into place into the shaft wearing sleeve (524.21) and
push the shaft wearing sleeve onto the shaft.
11 Install the needed the compressor rings (487.21) onto the shaft.
12 Place the o-ring (412.21) into its groove and then push the suction impeller (231.21) onto the shaft.
13 Install the o-ring (412.23) into its groove in the case (100.21).
14 Install the case cover (161.21) into its guideway into the adapter (344.31). Make sure that the cylinder pin
(562.21) goes into its hole in the case cover. Fix the screws (901.21). Continue the assembly according to
the following section Installation of impeller.

Series 2.15 Page
INSTRUCTIONS ISO
Liquid ring pump, ready-fitted double (type SM21)

1 Fix the adapter (344.31) into the bearing housing (330.31) with hexagonal screws (901.33).
3 Push the inner rotating part of the mechanical seal (433.21) on the shaft against the shoulder. Remove the
o-ring from the periphery of the part.
4 Put the series of compressor rings (487.21) onto the shaft against the front face of the part of the mechanical
seal.
by taking off or adding compressor rings (487.21). While measuring the gap, make sure that both the case
between the end of the suction impeller hub and the case because the front face of the vanes is slightly
conical.
8 Push the outer rotating part of the mechanical seal onto the shaft against the shoulder.
9 Install the static part of the mechanical seal into the case (100.21). Fasten the socket head capscrews
(914.21).
11 Push the inner rotating part of the mechanical seal (433.21) onto the shaft. Put the o-ring (which was
removed in item 3) back into its groove to the periphery of the part.
12 Push the compressor rings (487.21) onto the shaft against the front face of the part of the mechanical seal.
13 Place the o-ring (412.21) into its groove inside the suction impeller and then push the suction impeller
(231.21) onto the shaft.
15 Place the o-ring (412.23) into its groove in the case (100.21).
Air separating pump, element single (type RM11)

1 Press the stationary seat of the mechanical seal (433.21) with its o-ring into the adapter (344.31) without
damaging the sliding surface of the seal.
2 Fix the stuffing box housing (451.21) to the bearing housing (330.31) with the nuts (920.22) of the studs
(902.22). Do not damage the sliding surface of the seal.
3 Fix the rotating part of the mechanical seal (433.21) on the expeller (235.21), making sure it fits tightly
against the shoulder and lock it with the locking screws of the seal. The sliding surfaces must not be
damaged.
4 Push the expeller with seal onto the shaft.
5 Fit the o-ring (412.23) on the cover (160.21).
6 Fit the gaskets (400.23) in their places between the cover (160.21) and the case cover (161.21) and between
the cover (160) and the stuffing box housing (451.21).
7 Fix the combination of cover and case cover to the adapter with hexagon head screws (901.21). Continue
the assembly according to the following section Installation of impeller.
Gas separator, standard integrated single (types GM11 and GM12)


Series 2.15 Page
INSTRUCTIONS ISO
3 Place the seal ring (411.21) onto the hexagon head screw (901.22). Mount the static part of the mechanical
seal (433.21) to the stuffing box housing (451.21) using the screw.
7 Install the gasket (400.22) or o-ring (412.23) into its place in the stuffing box housing (451.21).
Gas separator, standard integrated double (types GM21 and GM22)

2 Mount the rotating part on the atmospheric side of the mechanical seal (433.21) against the shaft sleeve.
4 Place the seal ring (411.21) onto the hexagon head screw (901.22). Mount the static part of the mechanical
seal (433.21) to the stuffing box housing (451.21) using the screw.
8 Install the gasket (400.22) or o-ring (412.23) into its place in the stuffing box housing (451.21).
Gas separator, static seal (types GS11 and GS12)

2 Grease the o-ring (412.25) slightly and place it into the groove of the static seal (435.21). Push the static seal
(435.21) to the thrust ring (475.21).
3 Grease the o-ring (412.24) slightly and place it into its proper groove in the thrust ring (475.21). Place the
thrust ring (475.21) on the stuffing box housing (451.21) and fix it with the studs (902.21) and nuts (920.21).
Do not tighten the nuts.
7 Mount the gasket (400.22) or o-ring (412.23) into its place in the stuffing box housing (451.21).
9 When the exchange unit is fully assembled, pull the thrust ring (475.21) and the static seal (435.21) against
the shaft wearing sleeve (524.21). The assembly groove (3 mm x 0.5 mm) at the thrust ring comes out 0.5
mm from stuffing box housing end. Tighten the nuts (920.21) by hand so that the thrust ring is precisely
aligned with the shaft. Tighten the locking nuts. The distance between the face of the casing cover and the
thrust ring is according to Fig. 6.

Series 2.15 Page
INSTRUCTIONS ISO
Shaft size D (mm)

1 17
2 17
3 20
4 20
5 24
6 24
Fig. 6
5 Bearing unit
5.1 Disassembly
NOTE
Always renew the bearings once they have been removed from the shaft.
Bearing unit (grease and oil splash)

1 Fasten the bearing unit firmly to a vice at the bearing housing (330.31).
2 Detach the coupling (840.51) using an extractor.
3 Unscrew the hexagon head screws (901.31) and washers (554.31) of the bearing cover (360.31). Remove
the guard end (685.51).
4 Draw the bearing cover out by using the hexagon head screws (901.31). As a result, the deflector (507.31)
will also come off.
5 Strike the pump side end of the shaft (210.31) with a soft hammer, where upon the shaft with its bearings will
come off the bearing housing. Simultaneously the other deflector (507.31) also comes off. Note that the lugs
in the oil ring (644.31) should fit into the grooves in the bearing housing (330.31).
6 Fasten the shaft with its bearings to a vice and detach the bearing nut (923.31) and lockwasher (931.31).
7 Detach the antifriction bearings (320.31 and, 320.32) and oil ring (644.31) from the shaft with an extractor or
by means of a hammer and a punch.

Series 2.15 Page
INSTRUCTIONS ISO
Bearing unit (oil bath)

1 Fasten the bearing unit firmly to a vice at the bearing housing (330.31).
2 Detach the coupling (840.51) using an extractor.
3 Unscrew the hexagon head screws (901.31) of the bearing cover (360.31). Remove the guard end (685.51).
4 Draw the bearing cover out by using the hexagon head screws (901.31). As a result, the deflector (507.31)
will also come off.
5 Strike the pump side end of the shaft (210.31) with a soft hammer, where upon the shaft with its bearings will
come off the bearing housing. Simultaneously the other deflector (507.32) also comes off.
6 Fasten the shaft with its bearings to a vice and detach the bearing nut (923.31) and lockwasher (931.31).
7 Detach the antifriction bearings (320.31 and, 320.32) from the shaft with an extractor or by means of a
hammer and a punch.
5.2 Reassembly
NOTE
It is absolutely necessary to place the bearings correctly according to the O-system (so called Back-
To-Back-Design).
Bearing unit (grease and oil splash)

1 Check the shaft (210.31) in a span. Their maximum radial difference is 0.05 mm.
2 Fasten the shaft to a vice with the impeller end of the shaft upwards. Use soft sheets between the vice clamp
jaws to avoid shaft damage. Use a punch to push the oil ring (644.31) onto the shaft. Heat the cylinder roller
bearing (320.31) (deep groove ball bearing on shaft size 7) to ca +100C and push it onto the shaft.
Remember to place the spacer ring of the bearing on the shaft shoulder side. Fig. 7.
L
D
d
Shaft size (mm) 1 2 3 4 5 6 7

d 37 47 57 67 87 105 125
D 50 60 71 80 100 115 135
Lmin 185 205 220 280 320 360 400
Fig. 7
3 Let the bearing cool down. Then tap it tightly by the inner ring against the shoulder using a pipe punch.
Rotate the pipe punch between the blows.
4 Turn the shaft so that the coupling side is upwards, fasten it to a vice.
5 Heat the two angular contact ball bearings (320.32) to approx. +100C and push them onto the shaft. Let the
bearings cool down.

Series 2.15 Page
INSTRUCTIONS ISO
6 Place the lockwasher (931.31) on the shaft.

7 Tighten the angular contact ball bearings by means of the bearing nut (923.31) tightly against the shaft
shoulder, use a suitable hooked wrench.
8 Bend the lockwasher tooth into the bearing nut slots.
9 Tighten the bearing housing (330.31) vertically to the vice with the coupling side upwards.
10 Grease the o-ring (412.32) of the labyrinth ring (423.31) lightly and stretch it into its groove. Tap the labyrinth
ring (423.31) into the bearing housing (330.31) with a soft hammer. Make sure that the water holes in the
labyrinth ring will end up underneath.
11 Grease the o-ring (412.32) of the labyrinth ring (423.32) lightly and stretch it into its groove. Tap the labyrinth
ring (423.32) into the bearing cover (360.31) with a soft hammer. Make sure that the water holes in the
labyrinth ring will end up underneath.
12 Heat the bearing housing first slightly (max. +80C) to ease the installation of the shaft unit.
13 Lower the shaft carefully into the bearing housing. Note that the lugs in the oil ring (644.31) should fit into the
grooves in the bearing housing (330.31).
14 Grease the o-ring (412.31) of the bearing cover lightly and stretch it into its groove.
15 Set the bearing cover into its place. Place the guard end (685.61) on the bearing cover, mount the washers
(554.31) and fix it with the hexagon head screws (901.31) into the bearing housing.
16 Place the deflectors (507.31) with care onto the shaft by using e.g. a special pipe punch shown in Fig. 8.
Grease the rubber lip before installation.
Shaft size Coupling side Impeller side

(mm) d D Lmin d D Lmin
1 24 35 160 30 35 160
2 32 45 180 40 45 180
3 42 55 195 50 55 195
4 48 65 250 60 65 250
5 75 85 290 80 85 290
6 90 100 320 90 100 320
7 110 120 180 110 120 360
Fig. 8

Series 2.15 Page
INSTRUCTIONS ISO
Bearing unit (oil bath)

1 Check the shaft (210.31) with its shaft wearing sleeve (524.21) in a span. Their maximum radial difference is
0.05 mm.
2 Fasten the shaft to a vice with the impeller end of the shaft upwards. Use soft sheets between the vice clamp
jaws to avoid shaft damage. Heat the cylinder roller bearing (320.31) to ca +100C and push it onto the shaft.
Remember to place the spacer ring of the bearing on the shaft shoulder side. Fig. 7.
3 Let the bearing cool down. Then tap it tightly by the inner ring against the shoulder using a pipe punch.
Rotate the pipe punch between the blows.
4 Turn the shaft so that the coupling side is upwards, fasten it to a vice.
5 Heat the two angular contact ball bearings (320.32) to approx. +100C and push them onto the shaft. Let the
bearings cool down.
6 Place the lockwasher (931.31) on the shaft.
7 Tighten the angular contact ball bearings by means of the bearing nut (923.31) tightly against the shaft
shoulder, use a suitable hooked wrench.
8 Bend the lockwasher tooth into the bearing nut slots.
9 Tighten the bearing housing (330.31) vertically to the vice with the coupling side upwards.
10 Tap the labyrinth ring (423.31) into the bearing housing (330.31) with a soft hammer. Make sure that the
water holes in the labyrinth ring will end up underneath.
11 Tap the labyrinth ring (423.32) into the bearing cover (360.31) with a soft hammer. Make sure that the water
holes in the labyrinth ring will end up underneath.
12 Heat the bearing housing first slightly (max. +80C) to ease the installation of the shaft unit.
13 Lower the shaft carefully into the bearing housing. Make sure not to damage the labyrinth ring in the bearing
housing.
14 Grease the o-ring (412.31) of the bearing cover lightly and stretch it into its groove.
15 Set the bearing cover cautiously into its place. Make sure that the water holes in the labyrinth ring will end up
underneath. Place the coupling guard end (685.51) on the bearing cover. Secure these to the bearing
housing with the hexagon head screws (901.31).
16 Tighten the hexagon head screws (901.31) of the bearing cover.
17 Place the deflectors (507.31 and 507.32) with care onto the shaft by using e.g. a special pipe punch shown
in Fig. 8. Grease the rubber lip before installation.

SERIES 2.15
SPP id: 110901 / en / N31575 / 1
AHLSTAR
PROCESS PUMPS
1 Recommended spare parts

Series 2.15 Page
INSTRUCTIONS ISO
SPP id: 110901 / en / N31575 / 1 / Page 2 (3)
1 Recommended spare parts
To avoid long and expensive outages, we recommend that the following spare parts be kept in store preferably as
spare part units, spare part kits and maintenance kits rather than as individual parts. The number of spare parts is
evaluated for two years use in normal operating conditions, Table 1 - Table 4.
1.1 Wet end

Table 1, Spare parts recommendation (APP, EPP, NPP, WPP)
Number of identical parts and units in various pumps
6 8
WEEN.1 Wet end 1 2 3 4 5 >10
7 9
Number of recommended spare parts
Spare part kit 1 1 1 1 2 2 3 30 %
Service kit 2 4 6 8 8 9 12 150 %
102.11 Volute case 1 10 %
135.11 Sideplate 1 1 1 1 2 2 3 30 %
230.11 Impeller 1 1 1 1 2 2 3 30 %
502.11 Casing wear ring 1 2 2 2 3 3 4 50 %
412 O-rings 2 4 6 8 8 9 10 100 %
Refer to the parts lists of the pumps when estimating the number of needed spare parts.
Table 2, Spare parts recommendation (A, Process pump)

6 8
WEEN.1 Wet end 1 2 3 4 5 >10
7 9
Spare part kit 1 1 1 1 2 2 3 30 %
Service kit 2 4 6 8 8 9 12 150 %
102.11 Volute case 1 10 %
135.11 Sideplate 1 1 1 1 2 2 3 30 %
230.11 Impeller 1 1 1 1 2 2 3 30 %
412 O-rings 2 4 6 8 8 9 10 100 %
1.2 Sealing unit

Table 3, Spare parts recommendation
6 8
SEUN.2 Sealing unit 1 2 3 4 5 >10
7 9
Spare part kit 1 2 3 4 5 6 7 90 %
Service kit 2 4 6 8 8 9 12 150 %
100.21 Case 1 10 %
161.21 Case cover 1 10 %
231.21 Suction impeller 1 1 1 1 2 2 3 30 %
400 Gaskets 2 4 6 8 8 9 12 150 %
412 O-rings 2 4 6 8 8 9 10 100 %
433.21 Mechanical seal 1 2 3 4 5 6 7 90 %
435.21 Static seal 1 2 3 4 5 6 7 90 %

Series 2.15 Page
INSTRUCTIONS ISO
SPP id: 110901 / en / N31575 / 1 / Page 3 (3)

6 8
SEUN.2 Sealing unit 1 2 3 4 5 >10
7 9
451.21 Stuffing box housing 1 10 %
452.21 Stuffing box gland 1 10 %
456.21 Neck bush 1 10 %
458.21 Lantern ring 1 10 %
461.21 Gland packing 24 32 400 %
475.21 Thrust ring 1 2 3 4 5 6 7 90 %
487.21 Compressor ring 1 10 %
524.21 Shaft wearing sleeve 1 2 2 2 3 3 4 50 %
542.21 Throttle bushing 1 10 %
604.21 Expeller 1 1 1 1 2 2 3 30 %
1.3 Bearing unit

Table 4, Spare parts recommendation
6 8
BEUN.3 Bearing unit 1 2 3 4 5 >10
7 9
Spare part kit 1 1 1 2 2 3 4 50 %
Service kit 2 4 6 8 8 9 10 100 %
183.31 Support foot 1 10 %
210.31 Shaft 1 1 1 2 2 2 3 30 %
320.31 Antifriction bearing 1 1 1 2 2 3 4 50 %
320.32 Antifriction bearing 2 4 6 8 50 %
330.31 Bearing housing 1 10 %
344.31 Adapter 1 10 %
412 O-rings 2 4 6 8 8 9 10 100 %
423 Labyrinth ring 1 10 %
507.31 Deflector 4 8 8 10 100 %
923.31 Bearing nut 1 1 1 2 2 2 3 30 %
931.31 Lockwasher 1 1 1 2 2 2 3 30 %
940.31 Key 1 1 1 2 2 2 3 30 %

SPP id: 111220 / Replaces 110101 / en / C10151 / 4
1 (26)
20000461en.doc
John Crane Safematic Oy

P.O. Box 10
FI-40951 MUURAME, FINLAND
Tel. +358 10 8525 611 Fax: +358 10 8525 600
E-mail: safematic@johncrane.fi
Internet: www.johncrane.com
INSTALLATION AND OPERATION INSTRUCTIONS, EN
No. 20000461
Date 23.6.2008
Revision no. 1
Revision date 26.9.2011
UP
AHLSTAR PUMP
SEALS JCS1, JCS1F, JCS1G, JCS1A, JCS2P, JCS2AP AND JCS2EP
Should you have any questions about the products, please get in touch with the nearest supplier or a
representative of John Crane Safematic Oy.
A part of Smiths Group plc VAT reg. No. FI10985536

Residence: Muurame
Business Identity Code: 1098553-6
INSTALLATION AND OPERATION 2 (26)
INSTRUCTION
20000461en.doc
CONTENTS
1 GENERAL DESCRIPTIONS........................................................................................................................ 4
1.1 JCS1 seal .................................................................................................................................................... 4
1.2 JCS1F seal .................................................................................................................................................. 4
1.3 JCS1G seal.................................................................................................................................................. 4
1.4 JCS1A seal.................................................................................................................................................. 4
1.5 JCS2P seal .................................................................................................................................................. 5
1.6 JCS2AP seal ............................................................................................................................................... 5
1.7 JCS2EP seal................................................................................................................................................ 5
2 SAFETY ....................................................................................................................................................... 5
3 STORAGE.................................................................................................................................................... 5
4 MATERIALS AND DESIGN......................................................................................................................... 6

1. Table Tightening torque values. ................................................................................................................6
5 INFORMATION ON OPERATING CONDITIONS ....................................................................................... 6
5.1 JCS1, JCS1F, JCS1G and JCS1A seal ..................................................................................................... 6
2. Table Permissible seal operating conditions. ............................................................................................7
5.2 JCS2P, JCS2AP and JCS2EP seal............................................................................................................ 7
3. Table Permissible seal operating conditions. ............................................................................................7
4. Table SmartFlow IG operation with JCS2P and JCS2AP seals. ...............................................................7
5. Table Recommended sealant fluid quality values .....................................................................................8
6 INSTALLATION ........................................................................................................................................... 8
6.1 Preparations ............................................................................................................................................... 8
6.2 Installation of JCS1 and JCS1F seals ...................................................................................................... 9
6.3 Installation of JCS1G seal ....................................................................................................................... 11
6.4 Installation of JCS1A seal ....................................................................................................................... 13
6.5 Installation of JCS2P seal........................................................................................................................ 15
6.6 Installation of JCS2AP seal ..................................................................................................................... 17
6.7 Installation of JCS2EP seal ..................................................................................................................... 20
7 DETACHING .............................................................................................................................................. 21
7.1 Detaching JCS1, JCS1G and JCS1F seals ............................................................................................ 22
7.2 Detaching JCS1A seal ............................................................................................................................. 22
7.3 Detaching JCS2P seal.............................................................................................................................. 22
7.4 Detaching JCS2AP seal ........................................................................................................................... 22
7.5 Detaching JCS2EP seal ........................................................................................................................... 22
8 ADJUSTMENT AND CONTROL ............................................................................................................... 23
8.1 Flush water control and monitoring for the JCS1F and JCS1A seals stuffing box ......................... 23
6. Table Use with Safeunit Ultima................................................................................................................23
8.2 Seal fluid control and monitoring for the JCS2P and JCS2AP seals.................................................. 23
7. Table Use with SmartFlow IG. .................................................................................................................23
8. Table Use with Safeunit Ultima................................................................................................................23
9. Table Use with Safesiphon 10. ................................................................................................................23
8.3 Seal water control and monitoring for the JCS2EP seal ...................................................................... 23
10. Table Use with Safeunit Ultima..............................................................................................................23
8.4 Using the JCS2P and JCS2AP seals in a closed seal fluid system .................................................... 24
11. Table Use with Safesiphon 10. ..............................................................................................................24
9 SERVICE AND MAINTENANCE ............................................................................................................... 25

Residence: Muurame
INSTRUCTION
20000461en.doc
10 DISPOSAL ................................................................................................................................................. 26
12. Table Seal disposal. ..............................................................................................................................26
13. Table Packaging disposal......................................................................................................................26
11 APPENDICES ............................................................................................................................................ 26

Residence: Muurame
INSTRUCTION
20000461en.doc
1 GENERAL DESCRIPTIONS
1.1 JCS1 seal
The Safeseal JCS1 is a single-acting seal integrated in the target device. It has been developed
for use with environmentally clean lubricant liquids with low consistency (08%), such as water,
UP
different oils, solvents and pulp. The JCS1 is specifically designed for Sulzer AHLSTAR
pumps. The seal faces receive their lubrication and cooling from the pumped product. The
balanced design of the seal allows trouble-free operation, even with sudden pressure
fluctuations. This design ensures reliable and long-lasting operation under the most demanding
conditions. The seal is designed to guarantee long-lasting and trouble-free use, reduce seal
fluid consumption and prevent environmental emissions.
1.2 JCS1F seal
The Safeseal JCS1F is a single-acting seal integrated in the target device. It is used in hot
water targets where the JCS1 seal cannot be used. The JCS1F seal always uses recirculation
of process fluid in the seal space or external flushing in order to prevent dry running or to cool
UP
the seal. The JCS1F is specifically designed for Sulzer AHLSTAR pumps. Pressurized,
continuous water flushing through throttle bushing design to the process produces clean
lubrication on seal faces. This also prevents any dry running during pump start-up. The seal is
designed for demanding conditions in which clean fluid lubricates the seal faces. Typical uses
include high-temperature condensed steam pumps. The seal is designed to guarantee long-
lasting and trouble-free use, reduce seal fluid consumption and prevent environmental
emissions.
1.3 JCS1G seal
The Safeseal JCS1G is a single-acting seal integrated in the target device. It has been
developed for use with environmentally clean lubricant fluids with low consistency (08%), such
as water, different oils, solvents and pulp, in applications with the risk of dry running. The
UP
JCS1G is specifically designed for Sulzer AHLSTAR pumps. The seal faces receive most of
the lubrication and cooling from the pumped product. Lubrication is further ensured by grease in
the space between the seal and the shaft. The balanced design of the seal allows trouble-free
operation, even with sudden pressure fluctuations. This design ensures reliable and long-lasting
operation under the most demanding conditions. The seal is designed to guarantee long-lasting
and trouble-free use, reduce seal fluid consumption and prevent environmental emissions.
1.4 JCS1A seal
The Safeseal JCS1A is a single-acting seal integrated in the target device. It has been
developed for use with environmentally clean lubricant liquids with low consistency (08%),
such as water, different oils, solvents and pulp. The JCS1A is specifically designed for Sulzer
UP
AHLSTAR liquid ring pumps and gas separators. The seal faces receive their lubrication and
cooling from the pumped product or from an external flushing system. The balanced design of
the seal allows trouble-free operation, even with sudden pressure fluctuations. This design
ensures reliable and long-lasting operation under the most demanding conditions. The seal is
designed to guarantee long-lasting and trouble-free use, reduce seal fluid consumption and
prevent environmental emissions.

Residence: Muurame
INSTRUCTION
20000461en.doc
1.5 JCS2P seal
The Safeseal JCS2P is a double-acting seal integrated in the devicet. It is designed to be used
in pumps for environmentally hazardous and abrasive liquids when operating limits for single-
UP
acting seals are exceeded. The JCS2P is specifically designed for Sulzer AHLSTAR pumps.
When designing the JCS2P, use of the seal in a closed seal fluid system was a priority. The
seal structure offers adequate seal fluid circulation in the system, and thus a separate
circulating pump is not needed. The seal faces receive their lubrication and cooling from the
sealant fluid. The double-balanced design of the seal allows the use of both pressurized and
non-pressurized sealant fluid. This design ensures reliable and long-lasting operation under the
most demanding conditions. The seal is designed to guarantee long-lasting and trouble-free
use, reduce seal fluid consumption and prevent environmental emissions.
1.6 JCS2AP seal
The Safeseal JCS2AP is a double-acting seal integrated in the device. It is designed to be used
UP
acting seals are exceeded. The JCS2AP is specifically designed for Sulzer AHLSTAR liquid
ring pumps and gas separators. When designing the JCS2AP, use of the seal in a closed seal
fluid system was a priority. The seal structure offers adequate seal fluid circulation in the
system, and thus a separate circulating pump is not needed. The seal faces receive their
lubrication and cooling from the sealant fluid. The double-balanced design of the seal allows the
use of both pressurized and non-pressurized sealant fluid. This design ensures reliable and
long-lasting operation under the most demanding conditions. The seal is designed to guarantee
long-lasting and trouble-free use, reduce seal fluid consumption and prevent environmental
emissions.
1.7 JCS2EP seal
The Safeseal JCS2EP is a double-acting seal integrated in the device. It is designed to be used
acting seals are exceeded. The seal faces receive their lubrication and cooling from the sealant
fluid. The cooling design integrated with the seal improves the cooling of the seal. The double-
balanced design of the seal allows the use of both pressurized and non-pressurized sealant
fluid. This design ensures reliable and long-lasting operation under the most demanding
conditions. The seal is designed to guarantee long-lasting and trouble-free use, reduce seal
fluid consumption and prevent environmental emissions.
2 SAFETY
John Crane Safematic products are designed and manufactured to operate safely if used
properly. Installation and operating instructions follow the general requirements set for product
use. General and mill-specific safety regulations must also be followed. The user must also take
into account the possible dangers that can arise from eventual fault situations.
3 STORAGE
John Crane Safematic products must be stored in their original protective packaging in a dry
place. When stored properly, the products and their parts will remain undamaged and in
working order. The product packaging should be opened as close to the device device as
possible for ease of installation and less risk of damage to the products.
Caution After a long storage period (more than 6 months), the seal should be
checked carefully and, if possible, pressure-tested with pressurized air or
water before being put into service.

Residence: Muurame
INSTRUCTION
20000461en.doc
4 MATERIALS AND DESIGN
The materials and design of the product are shown in the attached bill of materials of the
assembly drawing. The seal type and identifying information are marked on the product.
Warning A burnt fluorinated rubber seal (FKM, such as Viton, FFKM, such as
Chemraz or FPM) must be handled in the same way as highly corrosive
substances.
1. Table Tightening torque values.
Thread size Torque Unit

M4 1.5 Nm
M5 3 Nm
M6 4 Nm
M8 11 Nm
M10 16 Nm
M12 40 Nm
5 INFORMATION ON OPERATING CONDITIONS
Warning Information about any abnormal seal operating conditions is marked on the
assembly drawing.
5.1 JCS1, JCS1F, JCS1G and JCS1A seal
Caution The seal may not be run without the liquid to be pumped.
Caution The JCS1F may not be run without recirculation of process liquid or external
flushing.
Caution The JCS1G must be filled with grease before start-up. Ensure that air has
been drained from inside the fluid when filling. Category NLG 1-2 greases
may be used for lubrication. The manual lubrication interval is approximately
one month. The seal may also be connected to an automatic lubrication
system.

Residence: Muurame
INSTRUCTION
20000461en.doc
2. Table Permissible seal operating conditions.
Explanation Quantity Value Unit

Product temperature Tmax 90 (195) C (F)
(JCS1, JCS1G and JCS1A)
Product temperature (JCS1F) Tmax 120 (250) C (F)
Stuffing box pressure pmax 16 (225) bar (psi)
Velocity v 20 (65) m/sec (ft/sec)
5.2 JCS2P, JCS2AP and JCS2EP seal
Fluids, condensates, lye, masses, silts and various chemicals. Pumps in applications
susceptible to wear and environmentally hazardous products, such as pumps used in pulp mill
cooking departments, evaporating plants and causticizing plants, and paper mill additive pumps.
Caution Do not use the seal without sealant fluid. Use only water as sealant fluid. If
its necessary to use other fluid, make sure its compliant with the elastomers
of the seal. If needed, contact the seal manufacturer.
Note When pumping abrasive and poorly lubricating fluids, the sealant fluid
pressure should exceed the pressure of the product pumped by
approximately 10%.
3. Table Permissible seal operating conditions.
Explanation Quantity Value Unit

Product temperature Tmax 180 (350) C (F)
Stuffing box pressure pmax 25 (360) bar (psi)
Sealant fluid pressure pmax 15 (215) bar (psi)
Velocity v 20 (65) m/sec (ft/sec)
4. Table SmartFlow IG operation with JCS2P and JCS2AP seals.
Explanation, value and unit

SmartFlow IG automatically controls and regulates sealant fluid flow in accordance with the
cooling needs of the seal.
o o
SmartFlow IG does not close if the liquid coming from the outlet side exceeds 45 C (113 F).
For detailed instructions on SmartFlow IG operation, please see manual 20000402.
Caution Ensure that air has been carefully removed from SmartFlow IG before start-
up. The system pressure is the same as the supply pressure of the sealant
fluid system.
Note For seal fluid flow and pressure control with the JCS2EP seal, we
recommend the Safeunit Ultima sealant fluid control and monitoring unit.

Residence: Muurame
INSTRUCTION
20000461en.doc
5. Table Recommended sealant fluid quality values
Explanation Value Unit

Solids content; may not contain clay or similar fine-grained max10 mg/l
materials
Solids particle size max 50 m
Silicate content max 10 mg/l
Permanganate number max 30 -
Iron content max 1 mg/l
Total hardness < 10 dH
Note Exceeding these values will shorten the life span of the seal.
6 INSTALLATION
6.1 Preparations
Check that no product damage has occurred during transportation. During installation, follow
the assembly and installation instructions for the target device and exercise care and
cleanliness.
Avoid touching the seal faces. If you have to touch the seal faces, clean them with a cleaning
solvent and a soft cloth before pressing the faces against each other.
Remove sharp burrs from all shoulders that have elastomers slid over them during installation.
Lubricate component mating surfaces and elastomers prior to installation.
Note The components can be manually pressed in place. Do not install them by
hitting them!
Caution Use silicone oil or a soap solution for lubrication. Mineral-based oil or grease
cannot be used with EPDM rubber.

Residence: Muurame
INSTRUCTION
20000461en.doc
6.2 Installation of JCS1 and JCS1F seals
Figure 1. 46101_JCS1_1.pdf
The seal is installed to the stuffing box cover from the impeller end.
Lubricate the elastomers on the seal body using soap solution, for example.
Insert the seal in the stuffing box so that the M10 hole on the seal body is aligned with the
hole (unthreaded 12 mm hole) used to attach the seal.
Attach the seal body onto the stuffing box cover with an M10 hexagonal screw (1 pc).
Note Install the screw seal under the screw head.

Residence: Muurame
INSTRUCTION
20000461en.doc
Attach the stuffing box cover with the seal to the bearing unit.
Install the thrust ring and thrust ring elastomers. If the slot seal of the thrust ring is not in
place inside the thrust ring, insert it in place so that the spring inside it will not touch the
product to be pumped; i.e., place the spring on the bearing side.
Check that the impeller hub at the seal end is well rounded or beveled.
Lubricate the slot seal with a soap solution, for example.
Tighten the thrust ring against the shaft shoulder on the impeller.

Residence: Muurame
INSTRUCTION
20000461en.doc
6.3 Installation of JCS1G seal
Figure 5. 46105_JCS1G_1.pdf

Residence: Muurame
INSTRUCTION
20000461en.doc
Pack grease into the seal so that there is grease at least up to the seal rings seal face.

Residence: Muurame
INSTRUCTION
20000461en.doc
Install the thrust ring and thrust ring elastomers. If the slot seal packing of the thrust ring is
not in place inside the thrust ring, insert it in place so that the spring inside it will not touch
the product to be pumped; i.e., place the spring on the bearing side.
Ensure that the seal has been fully packed with grease by pumping more grease into the
seal until grease starts to leak out in between the seal body and the shaft.
6.4 Installation of JCS1A seal
Figure 10. 46110_JCS1A_1.pdf

The seal is installed to the stuffing box from the impeller end.

Residence: Muurame
INSTRUCTION
20000461en.doc
Lock the seal body to the stuffing box with one (1) M10 hexagonal screw.

Attach the stuffing box with the seal to the bearing unit.

Install the shaft thrust ring.
Continue the installation process in accordance with the instructions from the pump
manufacturer.

Residence: Muurame
INSTRUCTION
20000461en.doc
6.5 Installation of JCS2P seal
Figure 14. 46114_JCS2P_1.pdf

Slide the locking ring and the thrust ring on the shaft against the shaft shoulder in such a
way that the locking ring pin enters the thrust ring hole as shown.
Tighten the two (2) locking ring retainer screws evenly.


Residence: Muurame
INSTRUCTION
20000461en.doc



Residence: Muurame
INSTRUCTION
20000461en.doc

product to be pumped; i.e., place the spring on the bearing side.
6.6 Installation of JCS2AP seal
Figure 19. 46119_JCS2AP_1.pdf


Residence: Muurame
INSTRUCTION
20000461en.doc

The seal is installed to the stuffing box from the impeller end.

Lock the seal body to the stuffing box with one (1) M10 hexagonal screw.

Residence: Muurame
INSTRUCTION
20000461en.doc

Attach the stuffing box with the seal to the bearing unit.

Install the shaft thrust ring.
Continue the installation process in accordance with the instructions from the pump
manufacturer.

Residence: Muurame
INSTRUCTION
20000461en.doc
6.7 Installation of JCS2EP seal
Figure 24. 46124_JCS2EP_1.pdf

Figure 25. 46125_JCS2EP_2.pdf and 46126_JCS2EP_2.1.pdf

The seal is installed to the stuffing box cover from the bearing end.
Push the seal inside the pump cover so that the plane surface machined on the seal body
points upward when the cover is fastened to the pump.
Fasten the seal to the cover with the stud bolts located on the cover.

Residence: Muurame
INSTRUCTION
20000461en.doc
Figure 26. 46127_JCS2EP_3.pdf

Make sure that the seal is correctly mounted to the cover. The machined plane surface on
the seal body must point upwards after the cover has been installed.
Figure 27. 46128_JCS2EP_4.pdf and 46129_JCS2EP_4.1.pdf

product to be pumped; in other words, place the spring on the bearing side.
Lubricate the packing with a soap solution, for example.
7 DETACHING
Note To detach and re-install the seal, follow the instructions given in the
installation and operation manual.

Residence: Muurame
INSTRUCTION
20000461en.doc
7.1 Detaching JCS1, JCS1G and JCS1F seals

Dismantle the pump in accordance with the instructions from the pump manufacturer.
Pull the thrust ring package off the shaft.
Detach the stuffing box cover from the bearing unit.
Remove the M10 fastening screw (1 screw).
Pull the seal out.
7.2 Detaching JCS1A seal

Detach the stuffing box from the bearing unit.
Pull the seal out.
7.3 Detaching JCS2P seal

Disconnect the seal water device and hoses.
Pull the seal out.
Unscrew the two (2) locking ring set screws.
Pull the thrust ring on the atmosphere side and the locking ring off the shaft.
7.4 Detaching JCS2AP seal

Detach the stuffing box from the bearing unit.
Pull the seal out.
7.5 Detaching JCS2EP seal

Detach the seal from the stuffing box cover.
Pull the seal out.
Residence: Muurame
INSTRUCTION
20000461en.doc
8 ADJUSTMENT AND CONTROL
8.1 Flush water control and monitoring for the JCS1F and JCS1A seals stuffing box
For flush water flow control, we recommend the John Crane Safematic Safeunit Ultima flow
meter. For additional information, please contact the closest supplier or a John Crane
Safematic representative.
6. Table Use with Safeunit Ultima.

For detailed instructions on Safeunit Ultima use, see instruction 20000402.
8.2 Seal fluid control and monitoring for the JCS2P and JCS2AP seals
For seal fluid flow control, we recommend the John Crane Safematic SmartFlow IG. The JCS2P
and JCS2AP seals may also be used with a John Crane Safematic Safeunit Ultima flow meter
and a John Crane Safematic Safesiphon 10 sealant fluid system. For additional information,
please contact the closest supplier or a John Crane Safematic representative.
7. Table Use with SmartFlow IG.

For detailed instructions on SmartFlow IG use, see instruction 20000402.

9. Table Use with Safesiphon 10.

For detailed instructions on Safesiphon 10 use, see instruction 20000465.
8.3 Seal water control and monitoring for the JCS2EP seal
For seal fluid flow control, we recommend the John Crane Safematic Safeunit Ultima flow
meter.


Residence: Muurame
INSTRUCTION
20000461en.doc
8.4 Using the JCS2P and JCS2AP seals in a closed seal fluid system
The JCS2P and JCS2AP seals have been designed for use in a closed sealant fluid system,
such as the John Crane Safematic Safesiphon 10 system. The design of these seals ensures
adequate fluid flow in a closed system by means of pumping, and thus a separate circulating
pump is not needed. The fluid flow direction in the system is defined based on the pump
rotation direction: when the pump rotates clockwise, the fluid goes out of the right-side
connection, and when the situation is studied from the bearing side, the fluid goes out of the left-
side connection.
Figure 28. 46130.pdf

Safesiphon 10 flow direction.
Note Please note the instructions from the manufacturer of the closed fluid system
regarding connections and take into account the above-mentioned fluid flow
direction when installing the system.
11. Table Use with Safesiphon 10.

For detailed instructions on Safesiphon 10 use, see instruction 20000465.

Residence: Muurame
INSTRUCTION
20000461en.doc
9 SERVICE AND MAINTENANCE
To maintain John Crane Safematic Safeseal in the best operating condition, we recommend
that the seals always be checked in connection with equipment maintenance. Before
disassembling the device, check the seal for tightness and possible leaks. Seal maintenance
intervals depend on the process used, and no exact time can be determined (one to ten years).
When device maintenance is performed, a seal that has been in use for a long period should be
replaced, as it will have to be detached from the device (even though no seal leakages were
apparent). If you want to re-install the seal that was removed, you should check the condition of
the seal faces and elastomers, clean the device stuffing box and the seal thoroughly and
lubricate the O-ring faces with silicone grease.
When service or maintenance is required, please contact the seal manufacturer or its
representative. John Crane Safematic Oy belongs to John Crane Group, whose worldwide
service outlets are also at your service.
Note Before contacting them, find out the type and identification information from
the seal or from the Installation and Operation Instructions stored in the
vicinity of the device.
We use a customer-specific information file, which makes it possible to provide a fast, precise
and sensible service and rebuilding of old seals. On the basis of the monitoring reports, it is
possible to perform necessary service and maintenance work as well as material and
construction updates on the seal.

Residence: Muurame
INSTRUCTION
20000461en.doc
10 DISPOSAL
John Crane Safematic products have been designed in such a way that their components can
be reused and rebuilt at an authorized John Crane service outlet. John Crane Safematic Oy
belongs to John Crane Group, whose worldwide service outlets are also at your service. If
something is unclear, please contact the manufacturer or its representative.
12. Table Seal disposal.
Seal components can be recycled and disposed of as follows:

Seal The materials of John Crane Safematic seals are shown in the attached
components bill of materials of the assembly drawing and they can be recycled
according to local instructions and regulations.
Metal Local instructions and regulations.
components
Elastomers A burnt fluorinated rubber seal (FKM e.g. Viton, FFKM e.g. Isolast or
FPM) should be handled in the same way as strong corrosive
substances.
Seal faces The carbon used in the seals is antimony (element Sb) impregnated and
it should be sent to hazardous waste treatment according to local
instructions and regulations.
13. Table Packaging disposal.
Seal packaging can be recycled and disposed of as follows:

Wood, cardboard, paper or plastic packaging is used to pack John Crane
Safematic products John Crane Safematic Oy has attended to its
recycling obligations related to its packaging in accordance with the
European Union directive 94/67/EC and, nationally, in accordance with
the Decision 962/97 of the Finnish Council of State, by joining the joint
organ of packaging producer organizations known as the Environmental
Register of Packaging (PYR Ltd).
Wood, Can be recycled according to local instructions and regulations.
cardboard and
paper
Padding plastic Padding plastic made of recycled polyethylene plastic (PE) can be
recycled or incinerated according to local instructions and regulations.
11 APPENDICES
Assembly drawing and bill of material

Residence: Muurame
18
17
2 21
O-ring
A
9 3 10 4 11 12 1
Fastening screw
Sealing washer
This constructional drawing applies for following seal models:

Bearing unit A1 A2 A3 A4 A5 A6 A7
Shaft size [mm] 30 40 50 60 80 90 110
Seal model 309140 309141 309142 309143 309144 309145 309577
NIMITYS LAATU MITAT . MALLI MR / OSA

PIIR NO
OSA AINES ( MASSA KG ) KPL
NO
OSAN ERITTELY
SUUNN.
KaL PIIRT.
KaL SAFESEAL
KORVAA KORVATTU
JCS1 PVM.
12.6.2008
SUHDE PIIR. NO REV.
MUURAME - FINLAND
AHLSTAR UP A MS11 309210X A
18
17
2 21
O-ring
A
9 3 10 4 11 12 1
Fastening screw
Sealing washer

Shaft size [mm] 30 40 50 60 80 90 110
Seal model 309146 309147 309148 309149 309150 309151 309578

PIIR NO
NO
OSAN ERITTELY
SUUNN.
KaL PIIRT.
KaL SAFESEAL
KORVAA KORVATTU
JCS1F PVM.
21.9.2009
SUHDE PIIR. NO REV.
MUURAME - FINLAND
AHLSTAR UP A MS12 309211X A
17
2 18 21
O-ring
9 3 10 4 11 12 1 14
Fastening screw
Sealing washer

Shaft size [mm] 30 40 50 60 80 90 110
Seal model 309152 309153 309154 309155 309156 309157 309579
DESCRIPTION MATERIAL DIMENSIONS, TYPES QTY/ITEM

DETAIL DRAW
ITEM MATERIAL DESCRIPTION ( WEIGHT KG ) PCS
SPECIFICATION OF ITEM
DESIGNED
KaL DRAWN
KaL SAFESEAL PREVIOUS DRG NEW DRG
JCS1G DATE
12.6.2008
SCALE DRAWING NUMBER REV.
MUURAME - FINLAND AHLSTAR UP A MS11 309212X A

A
16
3.1 4.1
15 18
2
O-ring
8 3 9 4 10 11 1
Fastening screw
A Sealing washer
Bearing unit A1 A2 A3 A4 A5 A6
Shaft size [mm] 30 40 50 60 80 90
Seal model 307780 307758 307730 307701 308002 308206
PIIR NO
NO
OSAN ERITTELY
SUUNN.
KaL PIIRT.
KaL TARK.
SAFESEAL KORVAA KORVATTU
JCS1A PVM.
09.09.2005
SUHDE PIIR. NO REV.
MUURAME - FINLAND AHLSTAR UP A LM11, GM11, GM12 307904 X

A
3.1 4.1 7.1 8.1
17 20
2 18 5 13 15 21 16 22
O-ring
A 9 3 10 4 11 12 1 14 19 6 7 8
Fastening screw
Sealing washer

Shaft size [mm] 30 40 50 60 80 90 110
Seal model 309062 309063 309064 309065 309066 309070 309580
PIIR NO
NO
OSAN ERITTELY
SUUNN.
Kal PIIRT.
KaL TARK.
SAFESEAL KORVAA KORVATTU
JCS2P PVM.
07.03.2008
SUHDE PIIR. NO REV.
MUURAME - FINLAND AHLSTAR UP A MS21 309069 X

29
24
27
14 23
29 26
18 22
17
A
Seal water OUT
O-ring
2
4 11 1 5 13 15 21 16 20
25 19 6 7 8
9 3 10 12
SECTION A-A
Bearing unit E3 E4 E5 E6
Shaft size [mm] 50 60 80 90
Seal model 309111 309112 309113 309114
PIIR NO
NO
Seal water IN OSAN ERITTELY
SUUNN.
KaL PIIRT.
KaL SAFESEAL
KORVAA KORVATTU
JCS2EP PVM.
13.6.2008
SUHDE PIIR. NO REV.
A MUURAME - FINLAND
SULZER AHLSTAR UP E MS21 309216X
17
15 16 18 5 14
O-ring
2 8 3 9 4 10 11 1 12 13 6 7 19
Fastening screw
Sealing washer

Bearing unit A1 A2 A3 A4 A5 A6
Shaft size [mm] 30 40 50 60 80 90
Seal model 309101 309102 309103 309104 309105 309106
DESCRIPTION MATERIAL DIMENSIONS, TYPES QTY/ITEM
DETAIL DRAW
ITEM MATERIAL DESCRIPTION ( WEIGHT KG ) PCS
SPECIFICATION OF ITEM
DESIGNED
KaL DRAWN
KaL SAFESEAL PREVIOUS DRG NEW DRG
JCS2AP DATE
8.5.2008
SCALE DRAWING NUMBER REV.
MUURAME - FINLAND AHLSTAR UP A LM21, GM21, GM22 309187X

BILL OF MATERIALS (EN)
Code 2005X1XXXX Date 11.06.2008

Revision Designed SSa
Description JCS1-XX-XXXX
309210
Equipment AHLSTAR UP A1 MS11
Part Code Pcs Draw no. Description Material Dimensions

01 1 BODY
02 1 INTERMEDIATE RING
03 1 THRUST RING
03.1 1 FACE
04 1 SEALING RING
04.1 1 FACE
09 1 SLOT SEAL
10 1 O-RING
11 1 SLOT SEAL
12 1 SLOT SEAL
17 3 DRIVE PIN
18 3 DRIVE SCREW
21 1 SPRING
23 20000461 1 INSTALLATION INSTRUCTION
23.1 309210X 1 ASSEMBLY DRAWING

Description JCS1F-XX-XXXX
309211X
Equipment AHLSTAR UP

01 1 BODY
03 1 THRUST RING
03.1 1 FACE
04 1 SEALING RING
04.1 1 FACE
09 1 SLOT SEAL
10 1 O-RING
11 1 SLOT SEAL
12 1 SLOT SEAL
17 1 DRIVE PIN
18 3 DRIVE SCREW
21 1 SPRING

Description JCS1G-XX-XXXX-
309212

01 1 BODY
03 1 THRUST RING
03.1 1 FACE
04 1 SEALING RING
04.1 1 FACE
09 1 SLOT SEAL
10 1 O-RING
11 1 SLOT SEAL
12 1 SLOT SEAL
14 1 O-RING
17 3 DRIVE PIN
18 3 DRIVE SCREW
21 1 SPRING

Description JCS1A-XX-XXXX-
307904

01 1 BODY
03 1 THRUST RING
03.1 1 FACE
04 1 SEALING RING
04.1 1 FACE
08 1 SLOT SEAL
09 1 O-RING
10 1 SLOT SEAL
11 1 SLOT SEAL
15 3 DRIVE PIN
16 3 DRIVE SCREW
18 1 SPRING

Revision A Designed MaT
Description JCS2P-XX-XXXX-
309069

01 1 BODY
03 1 THRUST RING
03.1 1 FACE
04 1 SEALING RING
04.1 1 FACE
05 1 PRESSURE RING
06 1 SEALING RING
06.1 1 FACE
07 1 THRUST RING
07.1 1 FACE
08 1 LOCKING RING
09 1 SLOT SEAL
10 1 O-RING
11 1 SLOT SEAL
12 1 SLOT SEAL
13 1 O-RING
14 1 O-RING
15 1 O-RING
16 1 O-RING
17 3 DRIVE PIN
18 3 DRIVE SCREW
19 3 DRIVE PIN
20 1 DRIVE PIN
21 1 SPRING
22 2 SET SCREW
23.1 309069x 1 ASSEMBLY DRAWING

Revision Designed JuV
Description JCS2EP-XX-XXXX-
309216

01 1 BODY
03 1 THRUST RING
03.1 1 FACE
04 1 SEALING RING
04.1 1 FACE
05 1 PRESSURE RING
06 1 SEALING RING
06.1 1 FACE
07 1 THRUST RING
07.1 1 FACE
08 1 LOCKING RING
09 1 SLOT SEAL
10 1 O-RING
11 1 SLOT SEAL
12 1 SLOT SEAL
13 1 O-RING
14 1 O-RING
15 1 O-RING
16 1 O-RING
17 3 DRIVE PIN
18 3 DRIVE SCREW
19 3 DRIVE PIN
20 1 DRIVE PIN
21 1 SPRING
22 2 SET SCREW
26 1 FLOW GUIDE
27 1 FLOW GUIDE
29 2 CLINCH NAIL

Description JCS2AP-XX-XXXX
309187

01 1 BODY
03 1 THRUST RING
03.1 1 FACE
04 1 SEALING RING
04.1 1 FACE
05 1 SEALING RING
05.1 1 FACE
06 1 THRUST RING
06.1 1 FACE
07 1 LOCKING RING
08 1 SLOT SEAL
09 1 O-RING
10 1 SLOT SEAL
11 1 SLOT SEAL
12 1 O-RING
13 1 O-RING
14 1 O-RING
15 3 DRIVE PIN
16 3 DRIVE SCREW
17 1 DRIVE PIN
18 1 SPRING
19 2 SET SCREW
1 (11)
20000465en.doc

P.O. Box 10
FI-40951 MUURAME, FINLAND
Tel. +358 10 8525 611 Fax: +358 10 8525 600
E-mail: safematic@johncrane.fi
Internet: www.johncrane.com
INSTALLATION AND OPERATION INSTRUCTION, EN
No. 20000465
Date 27.6.2008
Revision no. 6
Revision date 8.12.2009
Safesiphon 10 sealant fluid system
Models: 309071, 309072, 309073, 309500 and 309675

Sulzer AHLSTARUP
Should you have any questions about the products, please get in touch with the nearest supplier or a
representative of John Crane Safematic Oy.
A part of Smiths Group plc VAT Reg. No. FI10985536

Domicile: Muurame
INSTRUCTION
20000465en.doc
CONTENTS
1 GENERAL DESCRIPTION.......................................................................................................................... 3
2 SAFETY....................................................................................................................................................... 4
3 STORAGE ................................................................................................................................................... 4
4 MATERIALS, BILL OF MATERIAL AND DIMENSIONAL DRAWING ...................................................... 4

4.1 Materials............................................................................................................................................... 4
1. Table Materials. ............................................................................................................................................ 4
4.2 Bill of material ..................................................................................................................................... 5
2. Table Operational components, Figure 3...................................................................................................... 5
4.3 Dimensional drawings ........................................................................................................................ 6
5 INFORMATION ON OPERATING CONDITIONS....................................................................................... 8
3. Table Safesiphon 10 systems allowed operating conditions. ....................................................................... 8
4. Table Recommended seal water quality. ...................................................................................................... 8
6 PREPARATIONS AND INSTALLATION.................................................................................................... 9
6.1 Preparations ........................................................................................................................................ 9
6.2 Reservoir installation ......................................................................................................................... 9
6.3 Pipe and hose installation.................................................................................................................. 9
6.4 Support and base installation.......................................................................................................... 10
6.5 Reservoir filling ................................................................................................................................. 10
6.6 Start-up .............................................................................................................................................. 10
7 SERVICE AND MAINTENANCE .............................................................................................................. 10
8 DISPOSAL................................................................................................................................................. 11
5. Table Disposal of Safesiphon 10 devices. .................................................................................................. 11
6. Table Packaging disposal. .......................................................................................................................... 11

Domicile: Muurame
INSTRUCTION
20000465en.doc
1 GENERAL DESCRIPTION
The John Crane Safematic Safesiphon 10 sealant fluid system is designed for use with double-
acting mechanical seals in several different sectors of industry and in several areas of
application. The Safesiphon 10 system keeps the mechanical seal cooled and lubricated; this
correct operating environment for the seal will significantly extend its life span and reduce
maintenance and replacement costs.
The Safesiphon 10 sealing support system effectively protects mechanical seals. It clearly
reduces seal fluid consumption or may even completely eliminate the use of seal fluid.
Furthermore, it reduces the amount of wastewater generated. A disturbance in the plants seal
fluid system does not affect the Safesiphon 10 system.
The Safesiphon 10 system prevents seals from running dry and becoming damaged. The
system prevents transfer of impurities from one seal to another, and it reduces or even
prevents dilution of the process fluid.
Equipment nameplate
1
2
Figure 1. 46506.cdr
1. Equipment type
2. Manufacturing year
3. Ex -marking II 2GD T5 (Group II, Cat 2, Gas (G), Dust (D), maximum surface temperature
(T5) 100C / 212 oF)

Domicile: Muurame
INSTRUCTION
20000465en.doc
2 SAFETY
John Crane Safematic products are designed and manufactured to operate safely if used
properly. Installation and operating instructions follow the general requirements set for product
use. General and mill-specific safety regulations must also be followed. The user must also
take into account the possible dangers that can arise from eventual fault situations.
Warning label:
Figure 2. 46507.jpg
Caution Do not rub the plastic parts of the equipment with a dry cloth. This may
cause electrostatic charging hazard in explosive atmospheres.
3 STORAGE
John Crane Safematic products must be stored in their original protective packaging and in a
dry place. When stored properly, the products and their parts will remain undamaged and in
working order. The product packaging should be opened as close to the target device as
possible for ease of installation and less risk of damage to the products.
4 MATERIALS, BILL OF MATERIAL AND DIMENSIONAL DRAWING
The Safesiphon 10 is delivered assembled and tested. The system includes as standard
components a pressure gauge, a temperature gauge, a bleed nipple and an integrated support
foot. The system has been designed in accordance with the requirements of the PED device
directive.
4.1 Materials
Safesiphon 10 system materials have been selected so that the systems corrosion resistance
is sufficient in normal factory environments. The products external corrosion resistance
complies with EN 1.4301 (AISI 304); the product has been internally designed to be used with
water and glycol.
1. Table Materials.
Component Material
Tank AISI 304
Stand AISI 304
Valves AISI 316
Connectors AISI 316
Hoses PVC/Nitrile, 16 bar / 230 psi
Plastic and rubber components ABS, NBR
Display Glass
Protective tube PMMA

Domicile: Muurame
INSTRUCTION
20000465en.doc
4.2 Bill of material
Figure 3. 46501.cdr and 46502.cdr
2. Table Operational components, Figure 3.

Drawing number 309071 and 309072 309073 and
309500 309675
Pressurized
In sealant fluid In compressed
RESERVOIR FITTINGS with a manual
line air line
pump
(1) Tank X X X
(2) Level indicator X X X
(3) Pressure gauge, 016 bar X X X
(4) Temperature gauge X X X
(5) Check valve X
(6) Fill valve X
(7) Drain valve X X X
(8) Bleed screw X X X
(9) Fasteners X X X
(10) ISO 7/1 Rp 3/8" X X X
(11) Water supply hose (1.5 m) X
(12) To seal-hose X X X
(13) From seal-hose X X X
(14) Drain hose (1.5 m) X X X
(15) Manual pump X
(16) Stand and fasteners 309071 X X
(17) Pressure regulator X
(18) Safety valve X X
A full selection of Safesiphon 10 system spare parts is available.

Domicile: Muurame
INSTRUCTION
20000465en.doc
4.3 Dimensional drawings
The dimensions of the Safesiphon 10 system are shown in the drawings below.
Figure 4. 46504.jpg

Domicile: Muurame
INSTRUCTION
20000465en.doc
Figure 5. 46505.jpg
Figure 6. 46506.jpg
Fastening of the stand

Domicile: Muurame
INSTRUCTION
20000465en.doc
5 INFORMATION ON OPERATING CONDITIONS
The following operating condition information is available for the Safesiphon 10 system.
3. Table Safesiphon 10 systems allowed operating conditions.

Description Value Unit
Max. pressure max.16 (230) bar (psi)
o
Max. temperature max. 100 (210) C (oF)
Nominal volume 10 (2.6) l (gal)
4. Table Recommended seal water quality.
Description Value Unit
Solids content; may not contain clay or similar max.10 mg/l
fine-grained materials
Solids particle size max. 50 m
Silicate content max. 10 mg/l
Permanganate number max. 30 -
Iron content max. 1 mg/l
Total hardness < 10 dH
Note Exceeding these values will shorten the life span of the seal.
Note If the device is placed in a space where the temperature decreases below
0oC (32oF), a mixture of water and glycol must be used as the liquid.
Note The sealant fluid may be water or a water glycol mixture, taking into
account the materials used in the system. In case some fluid other than
water or glycol is to be used as the sealant fluid, please contact the sales
department of John Crane Safematic.
Note Please note the seal manufacturers instructions on process-specific

sealant fluid flow and seal operating temperatures.

Domicile: Muurame
INSTRUCTION
20000465en.doc
6 PREPARATIONS AND INSTALLATION
6.1 Preparations
Check that no product damage has occurred during transportation. During installation, follow
the assembly and installation instructions for the target device, and exercise care and
cleanliness.
Note Ensure that there is sufficient space available for installing the system. The
equipment must be stopped and the seal water flow shut down during
installation.
6.2 Reservoir installation
The reservoir must be installed in vertical orientation so that the base is approx. 500 mm above
the center line of the stuffing box.
Note The system must be installed in a place where it will be easy to read and
service.
Note When the system is used with back to back seals, it is important to set the
reservoir pressure at least 1 bar higher than process pressure.
Compressed air may be used in pressurizing.
6.3 Pipe and hose installation
Install the pipes and hoses so that they are as short as possible. There may be only one point
that is clearly the lowest, to which the fluid will flow from the reservoir as directly as possible.
Fluid flow from the lowest point through the seal back to the reservoir must be arranged in a
straightforward manner so that the pipe and hose ascend towards the tank at each section.
Horizontal pipe and hose sections must be as short as possible. There may be no bends in the
pipes and hoses of the system in the vertical direction, except at the lowest point.
Caution Pipes used in the system must be at least 12 mm in diameter, and hoses
must be at least 1/2".
Caution The corrosion resistance of the tubes and hoses must be similar to that of
the other materials in the system.

Domicile: Muurame
INSTRUCTION
20000465en.doc
6.4 Support and base installation
The reservoir must be mounted on its designated support (309075) or on other structures so
that its position in relation to the seal complies with the instructions.
6.5 Reservoir filling

1. Open the bleed screw (pos. 8).
2. Detach from the reservoir the return hose coming from the seal (pos. 13) by holding the
end of the hose at the same height as the connection.
3. Fill the reservoir until fluid that does not contain any air bubbles starts to leak from the
return hose.
4. Reattach the hose to the reservoir.
5. Fill the reservoir to the desired surface level.
6. Tighten the bleeding screw.
6.6 Start-up
Having started the device, check that the sealing fluid flows in the correct direction by testing
the hose temperature. The return hose must be hotter. If necessary, reverse the hoses.
7 SERVICE AND MAINTENANCE
When service or maintenance is required, please contact the manufacturer or its

representative. John Crane Safematic Oy is a part of the John Crane Group, whose worldwide
service outlets are also at your service.

Domicile: Muurame
INSTRUCTION
20000465en.doc
8 DISPOSAL
John Crane Safematic products are designed in such a way that their components can be
reused and rebuilt at an authorized John Crane service outlet. In unclear cases, please contact
the manufacturer or its representative. John Crane Safematic Oy is a part of the John Crane
Group, whose worldwide outlets are also at your service.
5. Table Disposal of Safesiphon 10 devices.

Product components can be recycled and disposed of as follows:
Product The materials of John Crane Safematic products are shown in the
components attached bill of materials of the assembly drawing, and they can be
recycled in accordance with local guidelines and regulations.
Metal components Can be recycled in accordance with local guidelines and regulations
applying to the recycling and handling of acid-proof steel (SS2343,
AISI316, EN 1.4436).
Elastomers Elastomers can be recycled or treated as waste in accordance with
local guidelines and regulations applying to the recycling and treatment
of EPDM rubber.
Electronic Can be recycled in accordance with local guidelines and regulations
components applying to the recycling and handling of electronic components.
Plastic Can be recycled in accordance with local guidelines and regulations
applying to the recycling and treatment of PTFE (white plastic) and
POM (black plastic).
6. Table Packaging disposal.
Product packaging can be recycled and disposed of as follows:
Wood, cardboard, paper or plastic packaging is used to pack John
Crane Safematic products. John Crane Safematic Oy has attended to
its recycling obligations related to packaging in accordance with
European Union Directive 94/67/EC and, nationally, in accordance with
decision 962/97 of the Council of State, by joining the joint organ of
packaging producer organizations known as the Environmental
Register of Packaging PYR.
Wood, cardboard Can be recycled in accordance with local guidelines and regulations.
and paper
Padding plastic Padding plastic manufactured from recycled polyethylene (PE) can be
recycled or incinerated in accordance with local guidelines and
regulations.

Domicile: Muurame
11
23
12 20 4 20 3
13
24
1
2
29
5
21
6
8 10 9 8
9
25 26
22
27
8 21
9 19 29
DRAIN VALVE 14 18
10 15
9 16
8 17 28
20 4 20 3
18
19 OSA
PIIR NO
AINES ( MASSA KG ) KPL
NO
OSAN ERITTELY
7,21 kg
SUUNN.
JuV PIIRT.
JuV 2214309071
KORVAA KORVATTU
SAFESIPHON 10 PVM.
26.6.2009
10 l - 16 bar SUHDE PIIR. NO REV.
MUURAME - FINLAND
SULZER AHLSTAR UP 309071x A
Code 2214309071 Date 26.06.2009

Revision A Designed JuV
Description SAFESIPHON 10
309071
Equipment SULZER AHLSTAR UP

01 22774007 1 309061 TANK AISI304
02 22600120 1 PRESSURE GAUGE ABS MUOVI
03 22600016 2 408073 FASTENING SCREW AISI316
04 22600017 2 408072 CLAMP AISI316
05 22774008 1 408074 GLASS TUBE GLASS
06 22774009 1 408075 CASING TUBE PMMA
07 22600265 1 THERMOMETER AISI316
08 22640708 4 405129 HOSE COUPLING AISI316
09 22640755 4 HOSE CLAMP AISI316
10 22640150 2 HOSE TEXTILE REINFORCED
11 12407846 1 408210 VENTING SCREW AISI316
12 12401170 1 460718 UNION FITTING AISI316
13 12650100 1 ADAPTER AISI316
14 22641810 1 EQUEAL TEE AISI316
15 12644750 1 DOUBLE NIPPLE AISI316
16 13602620 1 BALL VALVE AISI316
20 22680550 4 O-RING NBR
21 12680600 2 O-RING NBR
22 22600018 1 309075 STAND AISI304
23 21662170 4 ALLEN SCREW AISI316
24 22660450 4 HEX NUT AISI316
25 22641550 1 402256 ADAPTER AISI316
26 22600850 1 402039 CHECK VALVE AISI316
28 12660540 4 SLOT-AND-WEDGE BOLT Zn
29 22680700 2 O-RING NBR
30 20000465 1 20000465 INSTALLATION INSTRUCTION
11
12 20 4 20 3 23
27
13
24
15
26
25 15
1 29
2 21
8 10 9 8
9
22
15
16 21
29
8 17
9
DRAIN VALVE 14
10
15
9 28
16 20 4 20 3
8
17
PIIR NO
18 NO
OSAN ERITTELY
7,21 kg
19
SUUNN.
JuV PIIRT.
JuV 2214309072
KORVAA KORVATTU
SAFESIPHON 10 PVM.
26.6.2009
MUURAME - FINLAND
Code 2214309072 Date 26.06.2009

309072

01 22774007 1 309061 TANK AISI304
04 22600017 2 408072 CLAMP AISI316
05 22774008 1 408074 GLASS TUBE GLASS
06 22774009 1 408075 CASING TUBE PMMA
13 12650100 1 ADAPTER AISI316
20 22680550 4 O-RING NBR
21 12680600 2 O-RING NBR
22 22600018 1 309075 STAND AISI304
24 22660450 4 HEX NUT AISI316
25 22641850 1 COUPLING AISI316
26 22600021 1 RELIEF VALVE AISI316
27 22600022 1 PRESSURE REGULATOR AISI316
29 22680700 2 O-RING NBR
11
23
20 4 20 3
25 13 12
24
14
15
30
1
26
2 21
27
5
28
6
8 10 9 8
9
7 22
17
21
8 30
9
DRAIN VALVE 14
10
15
9 20 4 20 3
16 29
8
17
PIIR NO
18 NO
OSAN ERITTELY
7,21 kg
19
SUUNN.
JuV PIIRT.
JuV 2214309073
KORVAA KORVATTU
SAFESIPHON 10 PVM.
26.6.2009
MUURAME - FINLAND
Code 2214309073 Date 26.06.2009

309073

01 22774007 1 309061 TANK AISI304
04 22600017 2 408072 CLAMP AISI316
05 22774008 1 408074 GLASS TUBE GLASS
06 22774009 1 408075 CASING TUBE PMMA
13 12650100 1 ADAPTER AISI316
17 12650100 1 ADAPTER AISI316
20 22680550 4 O-RING NBR
21 12680600 2 O-RING NBR
22 22600018 1 309075 STAND AISI304
24 22660450 4 HEX NUT AISI316
26 22790185 1 PUMP AISI316
28 22660446 4 HEX NUT AISI316
30 22680700 2 O-RING NBR
11
13 12 20 4 20 3
5
28
6 21
8 10 9 8
9
25 26
27
8
21
9 14 18 19
DRAIN VALVE
10 28
15
9 16
8 17
20 4 20 3
18
19 OSA
PIIR NO
AINES ( MASSA KG ) KPL
NO
OSAN ERITTELY
7,21 kg
SUUNN.
MaT PIIRT.
MaT 2214309500
KORVAA KORVATTU
SAFESIPHON 10 PVM.
26.6.2009
MUURAME - FINLAND
Code 2214309500 Date 26.06.2009

Revision A Designed MaT
309500

01 22774007 1 309061 TANK AISI304
04 22600017 2 408072 CLAMP AISI316
05 22774008 1 408074 GLASS TUBE GLASS
06 22774009 1 408075 CASING TUBE PMMA
13 12650100 1 ADAPTER AISI316
20 22680550 4 O-RING NBR
21 12680600 2 O-RING NBR
25 22641550 1 402256 ADAPTER AISI316
26 22600850 1 402039 CHECK VALVE AISI316
28 22680700 2 O-RING NBR
23
20 4 20 3
25 13 11
24
14 12
15
30
1
26
2 21
27
5
28
6
8 10 9 8
9
7 22
17
21
30
9
Steel reinforced
hose DRAIN VALVE 14
10
15
9 20 4 20 3
16 29
8
17
PIIR NO
18 NO
OSAN ERITTELY
7,21 kg
19
SUUNN.
JuV PIIRT.
JuV 2214309675
KORVAA KORVATTU
SAFESIPHON 10 PVM.
29.6.2009
MUURAME - FINLAND
SULZER AHLSTAR UP 309675x
Code 2214309675 Date 25.06.2009

Revision Designed JuV
309675

01 22774007 1 309061 TANK AISI304
04 22600017 2 408072 CLAMP AISI316
05 22774008 1 408074 GLASS TUBE GLASS
06 22774009 1 408075 CASING TUBE PMMA
10 22640200 2 HOSE STEEL REINFORCED
13 12650100 1 ADAPTER AISI316
17 12650100 1 ADAPTER AISI316
20 22680550 4 O-RING NBR
21 12680600 2 O-RING NBR
22 22600018 1 309075 STAND AISI304
24 22660450 4 HEX NUT AISI316
26 22790185 1 PUMP AISI316
28 22660446 4 HEX NUT AISI316
30 22680700 2 O-RING NBR
Installation Instructions ~ Rexnord Viva Elastomer Couplings

(Page 1 of 6) Type V, VS and VSX Sizes 110-460
This is the Original Document in English Language
The designation ATEX (Atmosphere Explosibles) has established itself for the new guidelines. ATEX controls all
regulations for the condition of explosion-proof equipment.
Model No. _____________________ Category ______________________ Reference _____________________

Mfg Year_______________________ Max Temperature _______________
1. General Information
1.1. Viva Couplings are designed to provide a mechanical connection between the rotating shafts of mechanical equipment, using
a torsionally soft exible element to accommodate inherent misalignment while transmitting the power and torque between the
shafts.
1.2. These instructions are intended to help you install and maintain your Viva coupling. Please read these instructions prior to installing the
coupling, and prior to maintenance of the coupling and connected equipment. Keep these instructions near the coupling installation
and available for review by maintenance personnel.
1.3. Rexnord Industries, LLC owns the copyright of this material. These Installation and Maintenance instructions may not be reproduced in
whole or in part for competitive purposes.
1.4. Symbol descriptions:
Danger of injury to persons.
Damages on the machine possible.
Pointing to important items.
2. Safety and Advice Hints
DANGER!
2.1. Safety should be a primary concern in all aspects of coupling installation, operation, and maintenance.
2.2. Proper lockout-tag out procedures must be followed to safeguard against unintentional starting of the equipment.
2.3. Because of the possible danger to person(s) and/or property, from accidents which may result from improper use or installation of these
products, it is extremely important to follow the proper selection, installation, maintenance and operational procedures.
2.4. All personnel involved in the installation, service, operation, maintenance, and repair of this coupling and the connected
equipment must read, understand and comply with these Installation and Maintenance instructions.
2.5. All rotating power transmission products are potentially dangerous and can cause serious injury. They must be properly guarded in
compliance with OSHA, ANSI, ATEX, European machine safety standards and other local standards. It is the responsibility of the user to
provide proper guarding.
PRECAUTION! For this coupling to meet the ATEX requirements, you must precisely follow these
installation and maintenance instructions, and the supplement form 0005-08-49-01. This supplement
outlines the ATEX requirements. If the operator does not follow these instructions, the coupling will
immediately be considered non-conforming to ATEX.
2.6. For ATEX requirements the guard must have a minimum of 12.7 mm (1/2 inch) radial clearance to the coupling outside diameter
(coupling sizes shown in Table 1 are equivalent to the coupling outside diameter in millimeters) and allow for proper ventilation.
2.7. Make sure to disengage the electrical power and any other sources of potential energy before performing work on the coupling.
2.8. Do not make contact with the coupling when it is rotating and/or in operation.
2.9. All work on the coupling must be performed when the coupling is at rest under no load.
Rexnord Industries, LLC, 5555 S. Moorland Rd., New Berlin, WI 53151-7953 508-510
Telephone: 262-796-4060 Fax: 262-796-4064 November 2010
e-mail: info@rexnord.com web: www.rexnord.com Supercedes 02/10

3. Rexnord Viva Coupling Design and Part Numbers

Type V Type VS and VSX
7 3 6
1 2
1
5
5
Figure 1
Table 1 Viva Part Numbers

Elastomer Element Hubs
Element High
Coupling Rough Taper Bushed British Standard
Type V Type VS Type VSX QD Hubs* Capscrews Speed Rings
Size Bore Steel Hubs Inch* Whitworth Threads
1 1 1 7 5
5 66
22 33 (BSW)
110 7392646 7392702 7392702X 7392746 7392768 7392770 7392766 7393097 7393046
125 7392650 7392706 7392706X 7392774 7392797 7392799 7392795 7393097 7393049
130 7392654 7392710 7392710X 7392803 7392827 7392829 7392825 7393097 7393052
150= 7392656 7392712 7392712X 7392833 7392856 7392858 7392854 7393101 7393055
170= 7392658 7392714 7392714X 7392833 7392856 7392858 7392854 7393101 7393055
190 7392662 7392718 7392718X 7392862 7392884 7392886 7392882 7393101 7393058
215 7392666 7392722 7392722X 7392890 7392912 7392914 7392910 7393105 7393061
245 7392670 7392726 7392726X 7392918 7392933 7392935 7392931 7393105 7393064
290 7392674 7392730 7392730X 7392939 7392954 7392956 7392952 7393109 7393067
365 7392678 7392734 7392734X 7392960 7392966 7392969 7392964 7393120 7393070
425 7392682 7392738 7392738X 7392972 7392978 7392981 7392976 7393120 7393073
460 7392686 7392742 7392742X 7392984 7392990 7392993 7392988 7393120 7393076
Note: Hubs are interchangeable with standard or spacer ex elements.

* Bushings are not included.
= V150/V170 utilize same hubs, high speed rings and capscrews
4. Hub mounting
DANGER!
Be sure to disengage the electrical power and any other sources of potential
energy before you perform work on the hub and coupling assembly.
4.1. Examine the coupling assembly to insure there is no visible damage.

4.2. Clean the hub bores and shafts using lint free cloth. Remove any nicks or burrs.
4.3. When assembled, the key(s) should have a close side-to-side t in the keyway in both the hub and shaft, with a slight clearance over the
top of the key.
CAUTION: When heating hubs is required, use of an oven is preferred. An open ame is not
recommended. If ame heating is considered mandatory, it is important to provide uniform heating to
avoid distortion and excessive temperature. A thermal stick (crayon marker) applied to the hub surface
will help determine the hub temperature.
DANGER!
Touching hot hubs causes burns. Wear safety gloves to avoid contact with hot surfaces.
508-510 Rexnord Industries, LLC, 5555 S. Moorland Rd., New Berlin, WI 53151-7953
November 2010 Telephone: 262-796-4060 Fax: 262-796-4064
Supercedes 02/10 e-mail: info@rexnord.com web: www.rexnord.com

4.4. Rexnord Viva hubs can be installed: D E F
~ ush with the shaft end (D)

~ extended beyond the end of the shaft (E)
~ recessed behind the shaft end (F) Figure 2
ATTENTION! Shaft engagement length should be >0,8 times shaft diameter, bushed hubs must engage 100%.
5. Straight Bore with Clearance/Slip Fit

5.1. Install the key(s) in the shaft.
5.2. Check to be sure that the set screw(s) in the hub does not protrude into the keyway and/or the bore. If needed, loosen the set screw to
provide clearance during assembly.
5.3. Slide the hub up the shaft to the desired axial position.
ATTENTION! Use half element to set proper hub spacing.

5.4. Assemble and tighten the set screw(s), using a calibrated torque wrench, to the values shown in Table 2.
Table 2 - Set Screw Tightening Torque
Set Screw Tightening torque Internal Hex Size Set Screw Tightening torque Internal Hex Size
Thread Size Thread Size
inch lb-in lb-ft Nm inch mm lb-in lb-ft Nm mm
1/4 66 6 7 1/8 M6 55 5 6 M3
5/16 132 11 15 5/32 M8 110 9 12 M4
3/8 240 20 27 3/16 M10 220 18 25 M5
1/2 600 50 68 1/4 M12 440 37 50 M6
ATTENTION! Never use two set screws with one on top of the other in the same tapped hole.
6. Straight Bore with Interference Fit

6.1. Accurately measure the bore and shaft diameters to assure proper t.
6.2. Install the key(s) in the shaft.
6.3. Heat the hub in an oven until the bore is sufciently larger than the shaft.
6.4. 350F (177C) is usually sufcient for carbon steel hubs. Do not exceed 500F (260C).
6.5. Higher temperatures may be required for higher interference t levels where alloy steel hubs may be encountered. A general rule to
consider is that for every 160F increase in temperature, steel will expand 0.001 inch for every inch of shaft diameter (or .029 mm/100C).
When calculating temperatures, also consider additional expansion to provide clearance and allow for a loss of heat and subsequent
shrinkage during the handling process.
6.6. With the hub expanded, install it quickly on the shaft to the desired axial position. A pre-set axial stop device can be helpful.
7. Tapered bushed hubs
7.1. When using tapered bushings, follow bushing manufacturers instructions.
8. Rexnord Viva Type V coupling hub / element mounting options (see table 3)
C C C
Arrangement Arrangement Arrangement

A (IN) (IN) B (OUT) (IN) C (OUT) (OUT)
Figure 3
Table 3 Type V Mounting Options

Coupling Sizes
Hub
110 125 130 150 170 190 215 245 290 365 425 460
Arrangement
Dimension C (mm)
A 9 9 7 9 9 7 11 7 8 20 19 19
B 32 32 31 35 35 34 38 40 54 76 76 76
C 55 55 55 60 60 60 64 73 94 131 133 132

9. Rexnord Viva Type VS coupling hub / element mounting Options (See table 4)
Shaft
Gap
Table 4 - Spacer coupling (VS) Hub mounting options for industry shaft gaps
Rexnord Viva ISO (mm) Ansi (inch)
coupling size 100 140 180 250 300 3,5 5 7 9,5 12
C2-B1 C1-C1 B1-B1 C2-C1
Both hubs mounted VS 110
101 139 3,47 4,98
outward B1-B1 C1-C2* B1-B2 C2-C2*
Shaft VS 125
Gap 101 139 3,42 4,93
C2-C2 C1-C1 B1-B1 C2*-C2*
VS 130
100 140 3,50 5,12
B1-B1 C1-C1 D1-D1 B1*-D1* D1*-D1* D1-D2*
VS 150
102 140 179 3,52 5,04 6,87
One hub mounted outward B1-B1 C1-C1 D1-D1 B1*-D1* D1*-D1* D1-D2*
VS 170
One hub mounted inward 102 140 179 3,52 5,04 6,87
Shaft B1-B1 C1-C1 D1-D1 C1*-C1* D1*-D1* D1-D1
Gap VS 190
102 141 179 3,50 4,94 7,04
B1-B1 C1-C1 D1-D1 C1*-C1* D1*-D1* D1-D1
VS 215
103 142 181 3,50 5,06 7,14
B1-B2 D1-C1* D2-D1 B1*-D1* B2-C1 D1-C1
VS 245
106 142 185 3,50 4,95 6,89
Both hubs mounted
inward B2*-B2* B2*-B1 C1-B2* C1-C1 B1*-B2* C2*-B1* B2-B1 C1-C2
VS 290
100 143 179 257 3,54 4,92 6,94 9,70
DCBA ABCD
C1*-C1* B1-B1 C1-C1 D1-D1 B1-B1* B1-B1 C1-C1 D1-D1
VS 365
137 180 250 300 4,86 7,09 9,85 11,81
21 12
C2*-C2* B1-B1 C1-C1 D1-D1 B1-B2* B1-B1 C1-C1 D1-1D
X X VS 425
137 180 250 299 4,86 7,08 9,84 11,77
C2*-C2* B1-B1 C1-C1 D1-D1 B1-B2* B1-B1 C1-C1 D1-D1
VS 460
X X 137 180 250 299 4,86 7,08 9,84 11,77
* hub mounted inward

Figure 4
10. Rexnord Viva element mounting

10.1. Mount rst half element to the hubs using only original Rexnord Viva fasteners provided (do not substitute with non-approved
capscrews).
10.2. Rotate the shaft 180 degrees and secure second half element.
10.3. If shaft cannot be rotated, mount half elements at 90 degrees.
Figure 5
ATTENTION! Elements are weight balanced and must be used in pairs as packaged.

DANGER!
Incorrectly tightened capscrews could cause coupling component(s) to dislodge during operation and result in
personal injury. TIGHTEN CAPSCREWS BY USING TORQUE WRENCH.
10.4. Ensure that all capscrews are tightened to the torques specied in Table 5.

Figure 6
Table 5 Capscrew Torque

Wrench Wrench
Viva Bolt Torque Viva Bolt Torque
Part No. Size Part No. Size
Size Size Size Size
mm Nm ft lb in lb mm Nm ft lb in lb
110 7393097 M8 13 27 20 240 215 7393105 M10 13 53 39 468
125 7393097 M8 13 27 20 240 245 7393105 M10 13 53 39 468
130 7393097 M8 13 27 20 240 290 7393109 M12 15 92 68 816
150 7393101 M10 13 53 39 468 365 7393120 M14 19 158 117 1404
170 7393101 M10 13 53 39 468 425 7393120 M14 19 158 117 1404
190 7393101 M10 13 53 39 468 460 7393120 M14 19 158 117 1404
ATTENTION! When installing the element, rst seat all the capscrews with a light torque, then tighten all
capscrews to proper torque using a torque wrench.
ATTENTION! Do not lubricate capscrew threads
ATTENTION! Capscrews must have a thread-locking adhesive applied.
ATTENTION! Capscrews must be replaced with original Rexnord Viva fastener kit after three installations or when
replacing elastomer element.
DANGER!
Incorrectly tightened capscrews could cause coupling component(s) to dislodge during operation and result in
personal injury.
11. Shaft Alignment

11.1. Move the equipment into place.
ATTENTION! Soft Foot The equipment must rest at on its base. If one or more feet of the machine are shorter, longer, or
angled in some way to prevent uniform contact (a condition commonly known as soft foot) it must now be corrected.
11.2. Move the connected equipment to achieve acceptable alignment.
11.3. Table 6 shows recommended installation limits for Parallel and Angular alignment limits.
11.4. These dimensions are suggested for initial installation. Additional capacity is available to compensate for thermal and structural
equipment movement.

b
B
Figure 7 b (max)__________ mm
a (min)___________ mm
360 KW (actual) x 100
a
KW% =
A
KW (max limit table 6)
K
r
r
Kr (actual) x 100
Kr% =
100% 360 Kr (max limit)
90%
80%
Kw% + Kr % 100%
70% Table 6 - Drive Alignment Limits (max)
angular displacements K %
B
(b-a) mm Kr mm (b-a) inch Kr inch
Angular displacements Kw% w
60%
110 4,2 1,6 0.165 0.063
50%
125 4,9 1,6 0.193 0.063
D 40%
A 130 5,5 1,6 0.217 0.063
30% 150= 6,1 1,6 0.240 0.063
20% 170= 6,6 1,6 0.260 0.063
10%
190 6,1 2,4 0.240 0.095
215 7,3 2,4 0.287 0.095
10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 245 8,9 2,4 0.350 0.095
Parallel displacements K %
radial displacements Kr % r
290 11,2 2,4 0.441 0.095
365 8,2 3,2 0.323 0.126
425 9,9 3,2 0.390 0.126
r
460 9,4 3,2 0.370 0.126
ATTENTION! Improper alignment of the equipment or hubs may result in hub contact with equipment or guard and sparking.
12. Preventative Maintenance
DANGER!
Do not make contact with the coupling when it is rotating and/or in operation
12.1. Periodic visual inspection is necessary to evaluate the condition of the ex element. Inspection can be done during the operation
using a strobe light.
12.2. When inspecting the element look for:

~5PcXVdTRaPRZbPcT[T\T]cb_[Xcb Inspect Here
~DaTcWP]T3XbR^[^aPcX^]
~BdaUPRTRaPRZX]VX]Q^Sh^U DaTcWP]TT[T\T]c
ATTENTION! Replace Element if necessary.

Figure 8
13. Element Replacement
DANGER!
Stop the motor and lock it out to prevent start-up during installation of coupling.
13.1. Always replace both half elements.
13.2. Install both half elements from the same box.
13.3. Follow installation instructions (see Section 5, Rexnord Viva Element Installation).
DANGER!
Tighten element capscrews to proper torque by using a torque wrench (see Table 3).
SPP id: 080303 / en / C10080 / 1
Low Voltage Motors for Hazardous Areas

Manual
Installation, operation,
maintenance and safety
manual .......................................... EN 3
Montage-, Betriebs-,
Wartungs- und
Sicherheitsanleitung.................. DE 21
Manuel dinstallation,
dexploitation, de maintenance
et de scurit.............................. FR 41
Manual de instalacin,
funcionamiento, mantenimiento
y seguridad ...................................ES 61
Manuale dinstallazione,
funzionamento e
manutenzione .............................. IT 83
More languages see web site

www.abb.com/motors&drives
> Motors > Document library
SPP id: 080303 / en / C10080 / 1
2 ABB/Low Voltage Motors/ Ex manual 01-2007

SPP id: 080303 / en / C10080 / 1
Low Voltage Motors for Hazardous Areas

Installation, operation, maintenance and safety manual
EN
Table of Contents Page
Low Voltage Motors for Hazardous Areas ...........................................................................3

1. Introduction ......................................................................................................................5
1.1 Declaration of Conformity ..........................................................................................5
1.2 Validity .......................................................................................................................5
1.3 Conformity ..................................................................................................................5
1.4 Preliminary Checks ....................................................................................................6
2. Handling .............................................................................................................................6
2.1 Reception check ........................................................................................................6
2.2 Transportation and storage .......................................................................................6
2.3 Lifting .........................................................................................................................6
2.4 Motor weight ..............................................................................................................7
3. Installation and commissioning ......................................................................................7
3.1 General ......................................................................................................................7
3.2 Insulation resistance check ........................................................................................8
3.3 Foundation .................................................................................................................8
3.4 Balancing and fitting coupling halves and pulleys ......................................................8
3.5 Mounting and alignment of the motor ........................................................................8
3.6 Slide rails and belt drives ...........................................................................................8
3.7 Motors with drain plugs for condensation ..................................................................9
3.8 Cabling and electrical connections ............................................................................9
3.8.1 Flameproof motors .........................................................................................9
3.8.2 Dust Ignition Proof motors DIP, Ex tD .........................................................10
3.8.3 Connections for different starting methods ..................................................10
3.8.4 Connections of auxiliaries ............................................................................10
3.9 Terminals and direction of rotation ...........................................................................10
3.10 Protection against overload and stalling ..................................................................10
4. Operation .........................................................................................................................11
4.1 Use ...........................................................................................................................11
4.2 Cooling .....................................................................................................................11
4.3 Safety considerations ...............................................................................................11
5. Hazardous area motors in variable speed operation ..................................................12
5.1 Introduction ..............................................................................................................12
5.2 Main requirements according to EN and IEC standards ..........................................12
5.3 Winding insulation ....................................................................................................12
5.3.1 Phase to phase voltages .............................................................................12
5.3.2 Phase to ground voltages ............................................................................12
5.3.3 Selection of winding insulation for ACS800-converters .............................13
5.3.4 Selection of winding insulation with all other converters .............................13
5.4 Thermal protection of windings ................................................................................13
5.5 Bearing currents .......................................................................................................13
5.5.1 Elimination of bearing currents with ABB ACS800 converters ....................13
5.5.2 Elimination of bearing currents with all other converters .............................13
5.6 Cabling, grounding and EMC ...................................................................................13
5.7 Operating speed ......................................................................................................14
5.8 Dimensioning the motor for variable speed application ...........................................14
5.8.1 General ........................................................................................................14
5.8.2 Dimensioning with ABB ACS800 converters with DTC control ....................14
5.8.3 Dimensioning with other voltage source PWM-type converters ..................14
5.8.4 Short time overloads ....................................................................................14
5.9 Rating plates ............................................................................................................14
5.10 Commissioning the variable speed application ........................................................14
ABB/Low Voltage Motors/ Ex manual 01-2007 3 EN

SPP id: 080303 / en / C10080 / 1
6. Maintenance ....................................................................................................................15
6.1 General inspection ...................................................................................................15
6.2 Lubrication ...............................................................................................................16
6.2.1 Motors with permanently greased bearings .................................................16
6.2.2 Motors with regreasable bearings ................................................................16
EN
6.2.3 Lubrication intervals and amounts ...............................................................17

6.2.4 Lubricants ....................................................................................................17
7. After Sales support .........................................................................................................18
7.1 Spare parts ..............................................................................................................18
7.2 Dismantling, re-assembly and rewinding .................................................................18
7.3 Bearings ...................................................................................................................18
8. Environmental requirements .........................................................................................18
8.1 Noise levels ..............................................................................................................18
9. Troubleshooting ..............................................................................................................19
EN 4 ABB/Low Voltage Motors/ Ex manual 01-2007

SPP id: 080303 / en / C10080 / 1
1. Introduction 1.3 Conformity

As well as conforming to the standards relating to
NOTE!
mechanical and electrical characteristics, motors
These instructions must be followed to ensure safe
EN
designed for explosive atmospheres must also conform
and proper installation, operation and maintenance of
to one or more of the following European or IEC-
the motor. They should be brought to the attention of
standards for the protection type in question:
anyone who installs, operates or maintains the motor
or associated equipment. Ignoring these instructions EN 60079-0 (2004); General requirements
may invalidate all applicable warranties. IEC 60079-0 (2004) concerning electrical apparatus
for explosive gas atmospheres
WARNING EN 60079-1 (2004); Std. concerning flameproof
Motors for hazardous areas are specially designed IEC 60079-1 (2003) enclosures d protection
to comply with official regulations concerning the EN 60079-7 (2003), Std. concerning increased safety
risk of explosion. The reliability of these motors IEC 60079-7 (2001) e protection
may be impaired if they are used improperly, badly EN 60079-15 (2003), Std. concerning type nA
connected, or altered in any way no matter how IEC 60079-15 (2001), protection
minor. EN60079-15 (2005),
IEC 60079-15 (2005)
Standards relating to the connection and use of
prEN 61241-0 (2005); General requirements
electrical apparatus in hazardous areas must be
IEC 61241-0 (2004) concerning electrical apparatus
taken into consideration, especially the national
for use in the presence of
standards for installation in the country where the
combustible dust
motors are being used. Only trained personnel
familiar with these standards should handle this EN 61241-1 (2004); Std. concerning Dust Ignition
type of apparatus. IEC 61241-1 (2004) Protection and Tightness against
dust (tD-protection)
Note: the standards, according to which motors are
1.1 Declaration of Conformity certified, are listed in the appropriate certificate.
All ABB motors with a CE-mark on the rating plate ABB LV motors (valid only for Group II) can be installed
comply with the ATEX Directive 94/9/EC. in areas corresponding to the following markings:
Zone Category or Marking
1.2 Validity 1 Category 2 or Ex d, Ex de, Ex e
These instructions are valid for the following ABB 2 Category 3 or Ex nA
electrical motor types, when used in explosive atmos- 21 Category 2 or DIP, IP 65 or Ex tD A21
pheres.
22 Category 3 or DIP, IP 55 (non-conductive dust),
Non-sparking Ex nA or Ex tD A22
series M2A*/M3A*, sizes 90 to 280
According to the EN 500XX series, certified motors
series M2GP, sizes 71 to 250
have EEx markings instead of Ex.
series M2B*/M3G*, sizes 71 to 450
Increased safety Ex e Atmosphere;
series M2A*/M3A*, sizes 90 to 280 G explosive atmosphere caused by gases
series M2B*/M3H*, sizes 80 to 400 D explosive atmosphere caused by combustible dust
Flameproof enclosure Ex d, Ex de
series M2J*/M3J*, M2K*/M3K*, sizes 80 to 400
Dust Ignition Protection (DIP, Ex tD)
series M2V*, M2A*/M3A*, sizes 71 to 280
series M2B*/M3B*/M3G*, sizes 71 to 450
series M2GP, sizes 71 to 250
(Additional information may be required by ABB when
deciding on the suitability of certain motor types used in
special applications or with special design modifica-
tions.)
These instructions are valid for motors installed and
stored in ambient temperatures above 20C and
below +60C. Check that the motor range in question is
suitable for this whole ambient temperature range. In
ambient temperatures exceeding these limits, please
contact ABB.

SPP id: 080303 / en / C10080 / 1
1.4 Preliminary Checks 2. Handling

Users should check all documentation quoted in the
standard technical information in conjunction with data 2.1 Reception check
concerning standards on explosion-proofing, such as:
EN
Immediately upon receipt check the motor for external

a) Gas group damage (e.g. shaft-ends and flanges and painted
Industry Gas group Gas type (examples) surfaces) and if found, inform the forwarding agent
Explosive IIA Propane without delay.
atmospheres IIB Ethylene
other than mines IIC Hydrogen/Acetylene Check all rating plate data, especially voltage, winding
connection (star or delta), category, type of protection
b) Marking temperature and temperature class. The type of bearing is specified
Temperature class T1 T2 T3 T4 T5 T6 T125C T150C on the rating plate of all motors except the smallest
Max. temperature C 450 300 200 135 100 85 125 150 frame sizes.
Max. temperature 400 250 155 90 55 40 80 105
rise of surface K In case of a variable speed drive application check the
at 40C maximum loadability allowed according to frequency
stamped on the motors second rating plate.
Max. temperature rise of surface is considered to be the
surface inside the motor (rotor) for temperature classes
T1, T2 and T3 and the outer surface of the motor (frame 2.2 Transportation and storage
and/or end shields) for other temperature classes. The motor should always be stored indoors (above
It should be noted that the motors are certified and 20C), in dry, vibration free and dust free conditions.
classified according to their group. This is determined During transportation, shocks, falls and humidity should
by reference to the ambient gas or dust atmosphere be avoided. In other conditions, please contact ABB.
and by the marking temperature, calculated as a func- Unprotected machined surfaces (shaft-ends and flang-
tion of the ambient temperature of 40C. es) should be treated against corrosion.
If the motor is to be installed in ambient temperatures It is recommended that shafts are rotated periodically
higher than 40C or at altitudes higher than 1000 me- by hand to prevent grease migration.
ters, please consult ABB for eventual new rating data
and test reports at the required ambient temperature. Anti-condensation heaters, if fitted, are recommended
to avoid water condensing in the motor.
The ambient temperature must not be less than -20C.
If lower temperatures are expected, please consult ABB. The motor must not be subject to any external vibra-
tions exceeding 0.5 mm/s at standstill so as to avoid
causing damage to the bearings.
Motors fitted with cylindrical-roller and/or angular
contact bearings must be fitted with locking devices
during transport.
2.3 Lifting
All ABB motors above 25 kg are equipped with lifting
lugs or eyebolts.
Only the main lifting lugs or eyebolts of the motor
should be used for lifting the motor. They must not be
used to lift the motor when it is attached to other equip-
ment.
Lifting lugs for auxiliaries (e.g. brakes, separate cooling
fans) or terminal boxes must not be used for lifting the
motor.
Motors with the same frame may have a different center
of gravity because of different output, mounting ar-
rangements and auxiliary equipment.
Damaged lifting lugs must not be used. Check that
eyebolts or integrated lifting lugs are undamaged before
lifting.
Lifting eyebolts must be tightened before lifting. If
needed, the position of the eyebolt can be adjusted
using suitable washers as spacers.

SPP id: 080303 / en / C10080 / 1
Ensure that proper lifting equipment is used and that

the sizes of the hooks are suitable for the lifting lugs.
3. Installation and
Care must be taken not to damage auxiliary equipment commissioning
and cables connected to the motor.
EN
WARNING
Disconnect and lock out before working on the
2.4 Motor weight motor or the driven equipment. Ensure no explo-
sive atmosphere is present while the work is in
The total motor weight can vary within the same frame
progress.
size (center height) depending on different output,
mounting arrangement and auxiliaries.
The following table shows estimated maximum weights 3.1 General
for motors in their basic versions as a function of frame All rating plate values relating to certification must be
material. carefully checked to ensure that the motor protection,
The actual weight of all ABBs motors, except the atmosphere and zone are compatible.
smallest frame sizes (56 and 63) is shown on the rating Standards EN 1127-1 (Explosion prevention and
plate. protection), EN 60079-14 (Electrical installations in
Frame Aluminum Cast iron Flameproof hazardous areas (gas)) and EN 50281-1-2/ EN 61241-
Size Weight kg Weight kg Weight kg 14 (Electrical installations in hazardous areas (combus-
71 8 13 - tible dust; selection and installation)) must be respect-
80 12 20 38 ed. Special attention should be paid to dust ignition
90 17 30 53 temperature and dust layer thickness in relation to the
100 25 40 69 motors temperature marking.
112 36 50 72
132 63 90 108
Remove transport locking if employed. Turn shaft by
160 110 175 180 hand to check free rotation if possible.
180 160 250 220 Motors equipped with roller bearings:
200 220 310 350 Running the motor with no radial force applied to the
225 295 400 450 shaft may damage the roller bearing.
250 370 550 550
280 405 800 800 Motors equipped with angular contact bearing:
315 - 1300 1300 Running the motor with no axial force applied in the
355 - 2500 2500 right direction in relation to the shaft may damage the
400 - 3500 3500 angular contact bearing.
450 - 4600 -
WARNING
If the motor is equipped with a brake and/or separate For Ex d and Ex de motors with angular contact
fan, contact ABB for the weight. bearings the axial force must not by any means
change direction, because the flameproof gaps
around the shaft change dimensions and may
even cause contact!
The type of bearing is specified on the rating plate.
Motors equipped with regreasing nipples:
When starting the motor for the first time, or after long
storage, apply the specified quantity of grease.
For details, see section 6.2.2 Motors with regreasable
bearing.
When fitted in a vertical position with the shaft pointing
downwards, the motor must have a protective cover to
prevent foreign objects and fluid from falling into the
ventilation openings. This task can also be achieved by
a separate cover not fixed to the motor. In this case the
motor must have a warning label.

SPP id: 080303 / en / C10080 / 1
3.2 Insulation resistance check Coupling halves or pulleys must be balanced after
machining the keyways. Balancing must be done in
Measure insulation resistance before commissioning accordance with the balancing method specified for the
and when winding dampness is suspected. motor.
EN
WARNING Coupling halves and pulleys must be fitted on the shaft

Disconnect and lock out before working on by using suitable equipment and tools which do not
the motor or the driven equipment. Ensure no damage the bearings and seals.
explosive atmosphere is present while executing Never fit a coupling half or pulley by hammering or by
insulation resistance check procedures. removing it using a lever pressed against the body of
Insulation resistance, corrected to 25C, must exceed the motor.
the reference value, i.e. 100 M (measured with 500 or
1000 V DC). The insulation resistance value is halved 3.5 Mounting and alignment of
for each 20C rise in ambient temperature.
the motor
WARNING
Ensure that there is enough space for free airflow
The motor frame must be grounded and the
around the motor. Minimum requirements for free space
windings should be discharged against the frame
behind the motor fan cover can be found from the
immediately after each measurement to avoid risk
product catalog or from the dimension drawings avail-
of electrical shock.
able from the Web: see www.abb.com/motors&drives.
If the reference resistance value is not attained, the Correct alignment is essential to avoid bearing failures,
winding is too damp and must be oven dried. The oven vibration and shaft and coupling damage.
temperature should be 90C for 12-16 hours followed
by 105C for 6-8 hours. Mount the motor on the foundation using the appropri-
ate bolts or studs and place shim plates between the
Drain hole plugs, if fitted, must be removed and closing foundation and the feet.
valves, if fitted, must be opened during heating. After
heating, make sure the plugs are refitted. Even if the Align the motor using appropriate methods.
drain plugs are fitted, it is recommended to disassemble If applicable, drill locating holes and fix the locating pins
the end shields and terminal box covers for the drying into position.
process.
Mounting accuracy of coupling half: check that clear-
Windings drenched in seawater normally need to be ance b is less than 0.05 mm and that the difference a1
rewound. to a2 is also less than 0.05 mm. See Figure 3.
Re-check the alignment after final tightening of the bolts
3.3 Foundation or studs.
The end user has full responsibility for preparation of Do not exceed permissible loading values for bearings
the foundation. as stated in the product catalogs.
Metal foundations should be painted to avoid corrosion.
Foundations must be even, and sufficiently rigid to 3.6 Slide rails and belt drives
withstand possible short circuit forces. They must be Fasten the motor to the slide rails as shown in Figure 2.
designed and dimensioned to avoid the transfer of
vibration to the motor and vibration caused by reso- Place the slide rails horizontally on the same level.
nance. Check that the motor shaft is parallel with the drive
shaft.
Belts must be tensioned according to the instructions of
3.4 Balancing and fitting the supplier of the driven equipment. However, do not
coupling halves and pulleys exceed the maximum belt forces (i.e. radial bearing
loading) stated in the relevant product catalogs.
As standard, balancing of the motor has been carried
out using half key, and the shaft is marked with RED WARNING
tape, with the text Balanced with half key. Excessive belt tension will damage bearings and
When balancing with full key, the shaft is marked with can cause shaft breakage. For Ex d and Ex de-
YELLOW tape, with the text Balanced with full key. motors excessive belt tension may even cause
danger by eventual mutual contact of the flame-
In case of balancing without key, the shaft is marked path parts.
with BLUE tape, with the text Balanced without key.

SPP id: 080303 / en / C10080 / 1
3.7 Motors with drain plugs for Earthing must be carried out according to local regula-
tions before the machine is connected to the supply
condensation voltage.
Check that drain holes and plugs face downwards. The earth terminal on the frame has to be connected to
EN
PE (protective earth) with a cable as shown in Table 5
Non-sparking & Increased safety motors
of EN 60079-0:
Motors with sealable plastic drain plugs are delivered
with these in the closed position in aluminium motors
Minimum cross-sectional area of protective conductors
and in the open position in cast iron motors. In clean
Cross-sectional area of phase Minimum cross-sectional area
environments, open the drain plugs before operating conductors of the installation, of the corresponding protective
the motor. In very dusty environments, all drain holes S, mm2 conductor, SP, mm2
should be closed. S 16 S
16 < S 35 16
Flameproof motors S > 35 0.5 S
Drain plugs, if requested, are located at the lower part
of the end shields in order to allow condensation to In addition, earthing or bonding connection facilities on
escape from the motor. Turn the knurled head of the the outside of electrical apparatus must provide effec-
plug to check free operation. tive connection of a conductor with a cross-sectional
Dust Ignition Protection Motors area of at least 4 mm2.
The drain holes must be closed on all dust ignition The cable connection between the network and motor
protection motors. terminals must fulfill the requirements stated in the
national standards for installation or in the standard EN
3.8 Cabling and electrical 60204-1 according to the rated current indicated on the
rating plate.
connections Ensure that the motor protection corresponds to the
The terminal box on standard single speed motors environment and weather conditions; for example,
normally contains six winding terminals and at least one make sure that water cannot enter the motor or the
earth terminal. terminal boxes.
In addition to the main winding and earthing terminals, The seals of terminal boxes (other than Ex d) must be
the terminal box can also contain connections for placed correctly in the slots provided, to ensure the
thermistors, heating elements or other auxiliary devices. correct IP class. A leak could lead to penetration of dust
or water, creating a risk of flashover to live elements.
Suitable cable lugs must be used for the connection of
all main cables. Cables for auxiliaries can be connected
into their terminal blocks as such. 3.8.1 Flameproof motors
Motors are intended for fixed installation only. If not There are two different types of protection for the
otherwise specified, cable entry threads are metric. The terminal box:
protection class and the IP-class of the cable gland Ex d for M2JA/M3JP-motors
must be at least the same as those of the terminal Ex de for M2KA/M3KP-motors
boxes.
Ex d-motors; M2JA/M3JP
Ensure only certified cable glands for increased safety Certain cable glands are approved for a maximum
and flameproof motors are used. For non-sparking amount of free space in the terminal box. The amount
motors, cable glands must comply with EN 60079-0. of free space for the motor range is listed below.
NOTE! Motor type Terminal box Motor type Terminal box

Cables should be mechanically protected and M2JA 80-400 free volume M3JP free volume
80 - 132 1.45 - 1.7 dm3 80 -132 1.0 dm3
clamped close to the terminal box to fulfill the appro-
160 - 180 3 dm3 160 - 180 5.2 dm3
priate requirements of EN 60079-0 and local installa-
200 - 250 8.5 dm3 200 - 250 10.5 dm3
tion standards (e.g. NFC 15100).
280 - 315 15 dm3 280 - 315 24 dm3
Unused cable entries must be closed with blanking 355 - 400 79 dm3 355 - 400 79 dm3
elements according to the protection and IP class of the
terminal box. When closing the terminal box cover ensure that no
dust has settled on the surface gaps. Clean and grease
The degree of protection and diameter are specified in the surface with non-hardening contacting grease.
the documents relating to the cable gland.
WARNING
WARNING Do not open the motor or the terminal box while
Use appropriate cable glands and seals in the the motor is still warm and energized when an
cable entries according to the protection type and explosive atmosphere is present.
the type and diameter of the cable.

SPP id: 080303 / en / C10080 / 1
Ex de-motors; M2KA/M3KP Other starting methods and severe starting condi-

The letter e or box Ex e is shown on the terminal box tions:
cover. In case other starting methods are used, such as a soft
starter, or if starting conditions are particularly difficult,
Ensure that assembly of the terminal connection is
please consult ABB first.
EN
carried out precisely in the order described in the

connection instructions, which are found inside the
terminal box. 3.8.4 Connections of auxiliaries
The creepage distance and clearance must conform to If a motor is equipped with thermistors or other RTDs
EN 60079-7. (Pt100, thermal relays, etc.) and auxiliary devices, it is
recommended they be used and connected by appro-
priate means. For certain protection types, it is manda-
3.8.2 Dust Ignition Proof motors DIP, tory to use thermal protection. More detailed information
Ex tD can be found in the documents delivered with the
Motors have as standard the terminal box fitted on the motor. Connection diagrams for auxiliary elements and
top with cable entry possible from both sides. A full connection parts can be found inside the terminal box.
description is contained in the product catalogs. Maximum measuring voltage for the thermistors is 2.5
Pay special attention to the sealing of the terminal box V. Maximum measuring current for Pt100 is 5 mA.
and cables to prevent the access of combustible dust Using a higher measuring voltage or current may cause
into the terminal box. It is important to check that the errors in readings.
external seals are in good condition and well placed
because they can be damaged or moved during hand- 3.9 Terminals and direction of
ling.
When closing the terminal box cover, ensure that no
rotation
dust has settled on the surface gaps and check that the The shaft rotates clockwise when viewing the shaft face
seal is in good condition if not, it has to be replaced at the motor drive end, and the line phase sequence -
with one with the same material properties. L1, L2, L3 - is connected to the terminals as shown in
Figure 1.
WARNING
To alter the direction of rotation, interchange any two
Do not open the motor or the terminal box while
connections on the supply cables.
the motor is still warm and energized when an
explosive atmosphere is present. If the motor has a unidirectional fan, ensure that it
rotates in the same direction as the arrow marked on
3.8.3 Connections for different the motor.
starting methods
The terminal box on standard single speed motors
3.10 Protection against overload
normally contains six winding terminals and at least one and stalling
earth terminal. This enables the use of DOL- or Y/D
All hazardous area motors must be protected against
starting. See Figure 1.
overloads, see IEC/EN 60079-14 and IEC 61241-14.
For two-speed and special motors, the supply connec-
For increased safety motors (Ex e) the maximum
tion must follow the instructions inside the terminal box
tripping time for protective devices must not be longer
or in the motor manual.
than the time tE shown on the motor rating plate.
The voltage and connection are stamped on the rating
plate.
Direct-on-line starting (DOL):
Y or D winding connections may be used.
For example, 690 VY, 400 VD indicates Y-connection
for 690 V and D-connection for 400 V.
Star/Delta starting (Y/D):
The supply voltage must be equal to the rated voltage
of the motor when using a D-connection.
Remove all connection links from the terminal block.
For increased safety motors, both direct-on-line and
star-delta starting of motors are allowed. In case of star-
delta starting, only Ex-approved equipment is allowed.

SPP id: 080303 / en / C10080 / 1
4. Operation 4.3 Safety considerations

The motor is intended for installation and use by quali-
4.1 Use fied personnel, familiar with health and safety require-
EN
ments and national legislation.
The motors are designed for the following conditions
unless otherwise stated on the rating plate. Safety equipment necessary for the prevention of
accidents at the installation and operating site must be
Normal ambient temperature limits are -20C to provided in accordance with local regulations.
+40C.
Maximum altitude 1000 m above sea level. WARNING
Tolerance for supply voltage is 5% and for frequen- Emergency stop controls must be equipped with
cy 2% according to EN / IEC 60034-1 (2004), restart lockouts. After emergency stop a new start
paragraph 7.3, Zone A. command can take effect only after the restart
The motor can only be used in applications it is intend- lockout has been intentionally reset.
ed for. The rated nominal values and operational
conditions are shown on the motor rating plates. In Points to observe
addition, all requirements of this manual and other 1. Do not step on the motor.
related instructions and standards must be followed. 2. The temperature of the outer casing of the motor may
be hot to the touch during normal operation and
If these limits are exceeded, motor data and construc- especially after shut-down.
tion data must be checked. Please contact ABB for 3. Some special motor applications require special
further information. instructions (e.g. using frequency converter supplies).
Particular attention must be paid to corrosive atmos- 4. Be aware of rotating parts of the motor.
pheres when using flameproof motors; ensure that the 5. Do not open terminal boxes while energized.
paint protection is suitable for the ambient conditions as
corrosion can damage the explosion-proof enclosure.
WARNING
Ignoring any instructions or maintenance of the
apparatus may jeopardize safety and thus prevent
the use of the machine in hazardous areas.
4.2 Cooling
Check that the motor has sufficient airflow. Ensure that
no nearby objects or direct sunshine radiate additional
heat to the motor.
For flange mounted motors (e.g. B5, B35, V1), make
sure that the construction allows sufficient air flow on
the outer surface of the flange.

SPP id: 080303 / en / C10080 / 1
5. Hazardous area motors ABB non-sparking cast iron motors have been type
tested with ABB ACS800 converters utilizing DTC
in variable speed control, and these combinations can be selected using
the dimensioning instructions provided in Chapter 5.8.2.
operation
EN
In the case of voltage source PWM converters with a

minimum switching frequency of 3 kHz or higher,
5.1 Introduction preliminary dimensioning instructions provided in
Chapter 5.8.3 in this manual can be used. The final
This part of the manual provides additional instructions
values must be verified by combined tests.
for motors used in hazardous areas in frequency
converter supply. Dust ignition proof motors DIP, Ex tD
According to the standards, the motor must be dimen-
Additional information may be required by ABB to
sioned so that the maximum outer surface temperature
decide on the suitability for some machine types used in
of the motor is limited according to the temperature
special applications or with special design modifica-
class (e.g. T125C). For more information on a tem-
tions.
perature class lower than 125C, please contact ABB.
ABB DIP/Ex tD motors (125C) have been type tested
5.2 Main requirements with ACS800 converters utilizing DTC control, and
according to EN and IEC these combinations can be selected using the dimen-
sioning instructions provided in Chapter 5.8.2.
standards In the case of any other voltage source converter with
Flameproof motors Ex d, Ex de pulse width modulation type of control (PWM), com-
According to the standards, the motor must be dimen- bined tests are usually needed to confirm the correct
sioned so that the maximum outer surface temperature thermal performance of the motor. These tests can be
of the motor is limited according to the temperature avoided if DIP-motors are equipped with thermal sen-
class (T4, T5, etc.). In most cases this requires either sors intended for control of the surface temperatures.
type tests or control of the outer surface temperature of Such motors have the following additional markings on
the motor. the rating plate: - PTC with the tripping temperature
and DIN 44081/82.
Most ABB flameproof motors for temperature class T4
have been type tested with ABB ACS800 converters In the case of voltage source PWM converters with a
utilizing Direct Torque Control (DTC), and these combi- minimum switching frequency of 3 kHz or higher,
nations can be selected using the dimensioning instruc- instructions provided in Chapter 5.8.3 can be used for
tions provided in Chapter 5.8.2. preliminary dimensioning.
In case of other voltage source converters (not DTC-

controlled as ACS800) with pulse width modulation type 5.3 Winding insulation
of control (PWM), combined tests are usually needed to
confirm the correct thermal performance of the motor. 5.3.1 Phase to phase voltages
These tests can be avoided if flameproof motors are
The maximum allowed phase to phase voltage peaks in
equipped with thermal sensors intended for control of
the motor terminal as a function of the rise time of the
surface temperatures. Such motors have the following
pulse can be seen in Figure 4.
additional markings on the rating plate: - PTC with the
tripping temperature and DIN 44081/82. The highest curve ABB Special Insulation applies to
motors with a special winding insulation for frequency
In the case of voltage source PWM converters with a
converter supply, variant code 405.
minimum switching frequency of 3 kHz or higher,
instructions provided in Chapter 5.8.3 must be used for The ABB Standard Insulation applies to all other
preliminary dimensioning. motors covered by this manual.
For more information on T5 and T6 temperature class
flameproof motors used with variable speed drives, 5.3.2 Phase to ground voltages
please contact ABB. The allowed phase to ground voltage peaks at motor
Increased safety motors Ex e terminals are:
ABB does not recommend the use of random wound Standard Insulation 1300 V peak
low voltage increased safety motors with variable speed
drives. This manual does not cover these motors in Special Insulation 1800 V peak
variable speed drives.
Non-sparking motors Ex nA
According to the standards, the combination of motor
and converter must be tested as a unit or dimensioned
by calculation.

SPP id: 080303 / en / C10080 / 1
5.3.3 Selection of winding NOTE!

insulation for ACS800- According to the local installation rules, it may be
possible to also connect the thermistors to equipment
converters other than a thermistor relay; for example, to the
EN
In the case of ABB ACS800 single drives with a diode control inputs of a frequency converter.
supply unit, the selection of winding insulation and
filters can be made according to table below:
5.5 Bearing currents
Nominal supply
Bearing voltages and currents must be avoided in all
voltage UN of
variable speed applications to ensure the reliability and
the converter Winding insulation and filters required
safety of the application. For this purpose insulated
UN 500 V ABB Standard insulation
bearings or bearing constructions, common mode filters
UN 600 V ABB Standard insulation + dU/dt filters
and suitable cabling and grounding methods must be
OR
used.
ABB Special insulation
(variant code 405)
UN 690 V ABB Special insulation 5.5.1 Elimination of bearing currents
(variant code 405) with ABB ACS800 converters
AND
In the case of the ABB ACS800 frequency converter
dU/dt-filters at converter output
with a diode supply unit (uncontrolled DC voltage), the
following methods must be used to avoid harmful
For more information on resistor braking and converters
bearing currents in the motors:
with controlled supply units, please contact ABB.
Frame size
5.3.4 Selection of winding 250 and smaller No actions needed
insulation with all other 280 315 Insulated non-drive end bearing
converters 355 450 Insulated non-drive end bearing
AND
The voltage stresses must be limited below accepted
Common mode filter at the converter
limits. Please contact the system designer to ensure the
safety of the application. The influence of possible filters ABB uses insulated bearings which have aluminum
must be taken into account while dimensioning the oxide coated inner and/or outer bores or ceramic rolling
motor. elements. Aluminum oxide coatings are also treated
with a sealant to prevent dirt and humidity penetrating
5.4 Thermal protection of into the porous coating. For the exact type of bearing
insulation, see the motors rating plate. Changing the
windings bearing type or insulation method without ABBs per-
All cast iron ABB Ex motors are equipped with PTC mission is prohibited.
thermistors to prevent the winding temperatures from
exceeding the thermal limits of used insulation materials 5.5.2 Elimination of bearing currents
(usually Insulation Class B or F). with all other converters
NOTE! The user is responsible for protecting the motor and
If not otherwise indicated on the rating plate, these driven equipment from harmful bearing currents. In-
thermistors do not prevent motor surface tempera- structions described in Chapter 5.5.1 can be followed,
tures exceeding the limit values of their temperature but their effectiveness cannot be guaranteed in all
classes (T4, T5, etc.). cases.
ATEX-countries:
The thermistors must be connected to a thermistor 5.6 Cabling, grounding and EMC
circuit relay functioning independently and that is To provide proper grounding and to ensure compliance
dedicated to reliably trip off the supply to the motor with any applicable EMC requirements, motors above
according to the requirements of the Essential Health 30 kW must be cabled using shielded symmetrical
and Safety Requirements in Annex II, item 1.5.1 of the cables and EMC glands, i.e. cable glands providing
ATEX Directive 94/9/EC. 360 bonding. Also for smaller motors symmetrical and
Non-ATEX countries: shielded cables are highly recommended. Make the
It is recommended that the thermistors are connected to 360 grounding arrangement at all the cable entries as
a thermistor circuit relay functioning independently and described in the instructions for the glands. Twist the
that is dedicated to reliably trip off the supply to the cable shields into bundles and connect to the nearest
motor. ground terminal/busbar inside the terminal box, con-
verter cabinet, etc.

SPP id: 080303 / en / C10080 / 1
NOTE! 5.8.3 Dimensioning with other

Proper cable glands providing 360 bonding must be voltage source PWM-type
used at all termination points, e.g. at motor, convert- converters
er, possible safety switch, etc.
EN
Preliminary dimensioning can be done by using follow-

For motors of frame size IEC 280 and upward, addi- ing guideline loadability curves, see Figures 7 and 8.
tional potential equalization between the motor frame These guideline curves assume a minimum switching
and the driven equipment is needed, unless both are frequency of 3 kHz. To ensure safety, the combination
mounted on a common steel base. In this case, the high must either be tested or thermal sensors intended for
frequency conductivity of the connection provided by control of the surface temperatures must be used.
the steel base should be checked by, for example,
measuring the potential difference between the compo- NOTE!
nents. The actual thermal loadability of a motor may be
More information about grounding and cabling of lower than shown by guideline curves.
variable speed drives can be found in the manual
Grounding and cabling of the drive system (Code: 5.8.4 Short time overloads
3AFY 61201998).
ABB flameproof motors usually provide a possibility for
short time overloading. For exact values, please see the
5.7 Operating speed motors rating plate.
For speeds higher than the nominal speed stated on Overloadability is specified by three factors:
the motors rating plate, ensure that either the highest
I OL Maximum short time current
permissible rotational speed of the motor or the critical
T OL The length of allowed overload period
speed of the whole application is not exceeded.
T COOL Cooling time required after each overload
period. During the cooling period motor current
5.8 Dimensioning the motor for and torque must stay below the limit of allowed
continuous loadability.
variable speed application
5.9 Rating plates
5.8.1 General The following parameters must be shown on the rating
In the case of ABB ACS800 converters with DTC plates of hazardous area motors intended for variable
control, the dimensioning can be done by using the speed operation:
loadability curves shown in paragraph 5.8.2 or by using
speed range
ABBs DriveSize dimensioning program. The tool is
power range
downloadable from the ABB website (www.abb.com/
voltage and current range
motors&drives). The loadability curves are based on
type of torque (constant or quadratic)
nominal supply voltage.
converter type and required minimum switching
frequency
5.8.2 Dimensioning with ABB
ACS800 converters with DTC 5.10 Commissioning the
control variable speed application
The loadability curves (or load capacity curves) present- The commissioning of the variable speed application
ed in Figures 5 and 6 show the maximum allowed must be done according to the instructions for the
continuous output torque of the motors as a function of frequency converter and local laws and regulations.
supply frequency. The output torque is given as a The requirements and limitations set by the application
percentage of the nominal torque of the motor. must also be taken into account.
NOTE! All parameters needed for setting the converter must be
The maximum speed of the motor must not be taken from the motor rating plates. The most often
exceeded even if the loadability curves are given up needed parameters are:
to 100 Hz. Motor nominal voltage
For dimensioning motors and protection types other Motor nominal current
than those mentioned in Figures 5 and 6, please con- Motor nominal frequency
tact ABB. Motor nominal speed
Motor nominal power
Note: In case of missing or inaccurate information, do
not operate the motor before ensuring correct settings!

SPP id: 080303 / en / C10080 / 1
ABB recommends using all the suitable protective

features provided by the converter to improve the safety
6. Maintenance
of the application. Converters usually provide features WARNING
such as (names and availability of features depend on Voltage may be connected at standstill inside the
EN
manufacturer and model of the converter): terminal box for heating elements or direct winding
Minimum speed heating.
Maximum speed
Acceleration and deceleration times WARNING
Maximum current Standards relating to repair and maintenance of
Maximum Torque electrical apparatus in hazardous areas must be
Stall protection taken into consideration. Only competent person-
nel acquainted with these standards should handle
WARNING this type of apparatus.
These features are only additional and do not Depending on the nature of the work in question,
replace the safety functions required by the stand- disconnect and lock out before working on motor
ards. or driven equipment. Ensure no explosive gas or
dust is present while work is in progress.
6.1 General inspection

1. Inspect the motor at regular intervals. The frequency
of checks depends on, for example, the humidity level
of the ambient air and on the local weather condi-
tions. This can initially be determined experimentally
and must then be strictly adhered to.
2. Keep the motor clean and ensure free ventilation
airflow. If the motor is used in a dusty environment,
the ventilation system must be regularly checked and
cleaned. For DIP/Ex tD motors, respect the environ-
ment specifications stated in standard EN 50281-1-2./
EN 61241-14
3. Check the condition of shaft seals (e.g. V-ring or
radial seal) and replace if necessary.
For DIP/Ex tD motors, the shaft seals should be
changed after 8000 hours of use or a maximum of
two years depending of environmental conditions as
mentioned above (1). Note: If the DIP/Ex tD motor is
equipped with dust tight bearings of the 2RS type, it
is enough to change seals every second year.
4. Check the condition of connections and mounting and
assembly bolts.
5. Check the bearing condition by listening for any
unusual noise, vibration measurement, bearing
temperature, inspection of spent grease or SPM
bearing monitoring. Pay special attention to bearings
when their calculated rated life time is coming to an
end.
When signs of wear are noticed, dismantle the motor,
check the parts and replace if necessary. When bea-
rings are changed, replacement bearings must be of the
same type as those originally fitted. The shaft seals
have to be replaced with seals of the same quality and
characteristics as the originals when changing bearings.
For flameproof motors, periodically turn the knurled
head of the drain plug, if equipped, in order to prevent
jamming. This operation must be done when the motor
is at standstill. The frequency of checks depends on the
humidity level of the ambient air, and on the local
weather conditions. This can initially be determined
experimentally and must then be strictly adhered to.

SPP id: 080303 / en / C10080 / 1
In the case of the IP 55 motor and when the motor has These values are valid for permitted load values given
been delivered with a plug closed, it is advisable to in the product catalog. Depending on application and
periodically open the drain plugs in order to ensure that load conditions, see the applicable product catalog or
the way out for condensation is not blocked and allows contact ABB.
condensation to escape from the motor. This operation
EN
Operation hours for vertical motors are half of the above

must be done when the motor is at a standstill and has
values.
been made safe to work on.
6.2.2 Motors with regreasable

6.2 Lubrication bearings
WARNING Lubrication information plate and general lubrica-
Beware of all rotating parts. tion advice
If the machine is equipped with a lubrication information
WARNING plate, follow the given values.
Grease can cause skin irritation and eye inflamma- On the lubrication information plate, greasing intervals
tion. Follow all safety precautions specified by the regarding mounting, ambient temperature and rotational
manufacturer of the grease. speed are defined.
Bearing types are specified in the respective product During the first start or after a bearing lubrication a
catalogs and on the rating plate of all motors except temporary temperature rise may appear, approximately
smaller frame sizes. 10 to 20 hours.
Reliability is a vital issue for bearing lubrication inter- Some motors may be equipped with a collector for old
vals. ABB uses the L1-principle (i.e. that 99% of the grease. Follow the special instructions given for the
motors are certain to make the life time) for lubrication. equipment.
After regreasing an Ex tD-motor, clean the motor end
6.2.1 Motors with permanently shields so they are free of any dust layer.
greased bearings
A. Manual lubrication
Bearings are usually permanently greased bearings of
1Z, 2Z, 2RS or equivalent types. Regreasing while the motor is running
Remove grease outlet plug or open closing valve if
As a guide, adequate lubrication for sizes up to 250 can fitted.
be achieved for the following duration, according to L1. Be sure that the lubrication channel is open
For duties with higher ambient temperatures please Inject the specified amount of grease into the bearing.
contact ABB. The formula to change the L1 values Let the motor run for 1-2 hours to ensure that all
roughly to L10 values: L10 = 2.7 x L1. excess grease is forced out of the bearing. Close the
Duty hours for permanently greased bearings at ambi- grease outlet plug or closing valve if fitted.
ent temperatures of 25 and 40C are: Regreasing while the motor is at a standstill
Duty hours Duty hours Regrease motors while running. If it is not possible to
Frame size Poles at 25C at 40C regrease the bearings while the motors are running,
71 2 32 000 20000 lubrication can be carried out while the machine is at a
71 4-8 41 000 25000 standstill.
80-90 2 24 000 15000
80-90 4-8 36 000 22000
In this case use only half the quantity of grease and
100-112 2 21 000 12000
then run the motor for a few minutes at full speed.
100-112 4-8 33 000 20000 When the motor has stopped, apply the rest of the
132 2 16 000 10000 specified amount of grease to the bearing.
132 4-8 29 000 18000 After 1-2 running hours close the grease outlet plug or
160 2 37 000 23000 closing valve if fitted.
160 4-8 76 000 48000
B. Automatic lubrication
180 2 31 000 19000
The grease outlet plug must be removed permanently
180 4-8 71 000 44000
with automatic lubrication or open closing valve if fitted.
200 2 25 000 15000
200 4-8 61 000 38000 ABB recommends only the use of electromechanical
225 2 22 000 14000 systems.
225 4-8 56 000 35000
250 2 17 000 11000
The amount of grease per lubrication interval stated in
250 4-8 48 000 30000 the table should be doubled if an automatic regreasing
system is used.
When 2-pole motors are automatically regreased, the
note concerning lubricant recommendations for 2-pole
motors in the Lubricants chapter should be followed.

SPP id: 080303 / en / C10080 / 1
6.2.3 Lubrication intervals and 6.2.4 Lubricants

amounts WARNING
Lubrication intervals for vertical machines are half of the Do not mix different types of grease.
EN
values shown in the table below. Incompatible lubricants may cause bearing
The lubrication intervals are based on a bearing operat- damage.
ing temperature of 80C (ambient temperature +25). When regreasing, use only special ball bearing grease
Note! An increase in the ambient temperature raises the with the following properties:
temperature of the bearings correspondingly. The
values should be halved for a 15C increase in bearing good quality grease with lithium complex soap and
temperature and may be doubled for a 15C decrease with mineral- or PAO-oil
in bearing temperature. base oil viscosity 100-160 cST at 40C
consistency NLGI grade 1.5 - 3 *)
Higher speed operation, e.g. in frequency converter temperature range -30C - +140C, continuously.
applications, or lower speed with heavy load will require
shorter lubrication intervals. *) For vertical mounted motors or in hot conditions a
stiffer end of scale is recommended.
WARNING The above mentioned grease specification is valid if the
The maximum operating temperature of the grease ambient temperature is above -30C or below +55C,
and bearings, +110C, must not be exceeded. and the bearing temperature is below 110C; otherwise
The designed maximum speed of the motor must consult ABB regarding suitable grease.
not be exceeded. Grease with the correct properties is available from all
the major lubricant manufacturers.
Frame Amount 3600 3000 1800 1500 1000 500-900
size of grease r/min r/min r/min r/min r/min r/min Admixtures are recommended, but a written guarantee
g/bearing must be obtained from the lubricant manufacturer,
Ball bearings especially concerning EP admixtures, that admixtures
Lubrication intervals in duty hours do not damage bearings or the properties of lubricants
112 10 10000 13000 18000 21000 25000 28000 at the operating temperature range.
132 15 9000 11000 17000 19000 23000 26500
160 25 7000 9500 14000 17000 21000 24000 WARNING
180 30 6000 9000 13500 16000 20000 23000 Lubricants containing EP admixtures are not
200 40 4000 6000 11000 13000 17000 21000 recommended in high bearing temperatures in
225 50 3000 5000 10000 12500 16500 20000
frame sizes 280 to 450.
250 60 2500 4000 9000 11500 15000 18000
280 35 2000 3500 The following high performance greases can be used:
280 70 8000 10500 14000 17000
315 35 2000 3500
Esso Unirex N2, N3 or S2 (lithium complex base)
315 90 6500 8500 12500 16000 Mobil Mobilith SHC 100 (lithium complex base)
355 35 1200 2000 Shell Albida EMS 2 (lithium complex base)
355 120 4200 6000 10000 13000 Klber Klberplex BEM 41-132 (special lithium base)
400 40 1000 1600 FAG Arcanol TEMP110 (lithium complex base)
400 130 2800 4600 8400 12000
450 40 1000 1600 NOTE!
450 140 2400 4000 8000 8800 Always use high speed grease for high speed 2-pole
Roller bearings machines where the speed factor is higher than
Lubrication intervals in duty hours 480,000 (calculated as Dm x n where Dm = average
160 25 3500 4500 7000 8500 10500 12000 bearing diameter, mm; n = rotational speed, r/min).
180 30 3000 4000 7000 8000 10000 11500
200 40 2000 3000 5500 6500 8500 10500 The following greases can be used for high speed cast
225 50 1500 2500 5000 6000 8000 10000 iron motors but not mixed with lithium complex greases:
250 60 1300 2200 4500 5700 7500 9000
Klber Klber quiet BQH 72-102 (polyurea base)
280 35 1000 1800
Lubcon Turmogrease PU703 (polyurea base)
280 70 4000 5300 7000 8500
315 35 1000 1800 If other lubricants are used, check with the manufac-
315 90 3000 4300 6000 8000 turer that the qualities correspond to those of the above
355 35 600 1000 mentioned lubricants, or, if the compatibility of the
355 120 2000 3000 5000 6500 lubricant is uncertain, contact ABB.
400 120 500 800
400 130 1400 2300 4200 6000
450 120 500 800
450 140 1200 2000 4000 4400

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7. After Sales support 8. Environmental

requirements
7.1 Spare parts
8.1 Noise levels
EN
Spare parts must be original parts or approved by ABB

unless otherwise stated. Most of ABBs motors have a sound pressure level not
Requirements in standard IEC 60079-19 must be exceeding 82 dB(A) ( 3 dB) at 50 Hz.
followed. Values for specific machines can be found in the
When ordering spare parts, the motor serial number, full relevant product catalogs. At 60 Hz sinusoidal supply
type designation and product code, as stated on the the values are approximately 4 dB(A) higher compared
rating plate, must be specified. to 50 Hz values in the product catalogs.
For sound pressure levels at frequency converter
supply, please contact ABB.
7.2 Dismantling, re-assembly
and rewinding
Follow the instructions given in standard IEC 60079-19
regarding dismantling, re-assembly and rewinding. Any
operation must be undertaken by the manufacturer, i.e.
ABB, or by an ABB authorized repair partner.
No manufacturing alterations are permitted on the parts
that make up the explosion-proof enclosure and the
parts that ensure dust-tight protection. Also ensure that
the ventilation is never obstructed.
Rewinding must always be carried out by an ABB
authorized repair partner.
When re-assembling the end shield or terminal box to
the frame of flameproof motors, check that the spigots
are free of paint and dirt with only a thin layer of special
non-hardening grease. In the case of DIP/Ex tD motors,
when re-assembling the end shields on the frame
special sealing grease or sealing compound must be
reapplied to the spigots. This should be the same type
as originally applied to the motor for this kind of protec-
tion.
7.3 Bearings
Special care should be taken with the bearings.
These must be removed using pullers and fitted by
heating or using special tools for the purpose.
Bearing replacement is described in detail in a separate
instruction leaflet available from the ABB Sales Office.
Special recommendations apply when changing the
bearings of DIP/Ex tD-motors (as the seals should be
changed at the same time).
Any directions placed on the motor, such as labels,
must be followed. The bearing types indicated on the
rating plate must not be changed.
NOTE!
Any repair by the end user, unless expressly ap-
proved by the manufacturer, releases the manufac-
turer from his responsibility to conformity.

SPP id: 080303 / en / C10080 / 1
9. Troubleshooting
These instructions do not cover all details or variations in equipment nor provide for every possible condition to be
met in connection with installation, operation or maintenance. Should additional information be required, please
EN
contact the nearest ABB Sales Office.
Motor troubleshooting chart

Your motor service and any troubleshooting must be handled by qualified persons who have the proper tools and
equipment.
TROUBLE CAUSE WHAT TO DO

Motor fails to start Blown fuses Replace fuses with proper type and rating.
Overload trips Check and reset overload in starter.
Improper power supply Check to see that power supplied agrees with motor
rating plate and load factor.
Improper line connections Check connections against diagram supplied with
motor.
Open circuit in winding or control Indicated by humming sound when switch is closed.
switch Check for loose wiring connections.
Also ensure that all control contacts are closing.
Mechanical failure Check to see if motor and drive turn freely. Check
bearings and lubrication.
Short circuited stator Indicated by blown fuses. Motor must be rewound.
Poor stator coil connection Remove end shields and locate fault.
Rotor defective Look for broken bars or end rings.
Motor may be overloaded Reduce load.
Motor stalls One phase may be open Check lines for open phase.
Wrong application Change type or size. Consult equipment supplier.
Overload Reduce load.
Low voltage Ensure the rating plate voltage is maintained. Check
connection.
Open circuit Fuses blown, check overload relay, stator and push
buttons.
Motor runs and then Power failure Check for loose connections to line, to fuses and to
dies down control.
Motor does not Not applied properly Consult equipment supplier for proper type.
accelerate up to
Voltage too low at motor Use higher voltage or transformer terminals or reduce
nominal speed
terminals because of line drop load. Check connections. Check conductors for
proper size.
Starting load too high Check the motors starts against no load.
Broken rotor bars or loose rotor Look for cracks near the rings. A new rotor may be
required, as repairs are usually temporary.
Open primary circuit Locate fault with testing device and repair.
Motor takes too long Excessive load Reduce load.
to accelerate and/or
Low voltage during start Check for high resistance. Make sure that an
draws high current
adequate cable size is used.
Defective squirrel cage rotor Replace with new rotor.
Applied voltage too low Correct power supply.

SPP id: 080303 / en / C10080 / 1
TROUBLE CAUSE WHAT TO DO

Wrong rotation Wrong sequence of phases Reverse connections at motor or at switchboard.
direction
EN
Motor overheats Overload Reduce load.

while running
Frame or ventilation openings Open vent holes and check for a continuous stream
may be full of dirt and prevent of air from the motor.
proper ventilation of motor
Motor may have one phase open Check to make sure that all leads and cables are well
connected.
Grounded coil Motor must be rewound.
Unbalanced terminal voltage Check for faulty leads, connections and transformers.
Motor vibrates Motor misaligned Realign.
Weak support Strengthen base.
Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective bearings Replace bearings.
Bearings not in line Repair motor.
Balancing weights shifted Rebalance rotor.
Contradiction between balancing Rebalance coupling or rotor.
of rotor and coupling (half key
full key)
Polyphase motor running single Check for open circuit.
phase
Excessive end play Adjust bearing or add shim.
Scraping noise Fan rubbing end shield or fan Correct fan mounting.
cover
Loose on bedplate Tighten holding bolts.
Noisy operation Air gap not uniform Check and correct end shield fits or bearing fits.
Rotor unbalance Rebalance rotor.
Hot bearings Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension.
Pulleys too far away from shaft Move pulley closer to motor bearing.
shoulder
Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of the drive.
Insufficient grease Maintain proper quality and amount of grease in
bearing.
Deterioration of grease or Remove old grease, wash bearings thoroughly in
lubricant contaminated kerosene and replace with new grease.
Excess lubricant Reduce quantity of grease, bearing should not be
more than half full.
Overloaded bearing Check alignment, side and end thrust.
Broken ball or rough races Replace bearing, clean housing thoroughly first.

SPP id: 080303 / en / C10080 / 1
Figure 1. Connection diagram

Abbildung 1. Anschlussschaltbild
Figure 1. Schma de connexion
Figura 1. Diagrama de conexiones
Figura 1. Schema di collegamento
Figure 2. Belt drive

Abbildung 2. Riementrieb
Figure 2. Entranement courroie
Figura 2. Accionamiento por correas
Figura 2. Accoppiamento a cinghia
ABB/Low Voltage Motors/ Ex manual 01-2007 103

SPP id: 080303 / en / C10080 / 1
Figure 3. Mounting of half-coupling or pulley

Abbildung 3. Montage von Kupplungshlften und Riemenscheiben
Figure 3. Montage dun demi-accouplement ou dune poulie
Figura 3. Montaje de acoplamientos o polea
Figura 3. Montaggio di semigiunti o pulegge
Figure 4. Allowed phase to phase voltage peaks at motor terminals as a function of rise time.
Rise time defined according to IEC60034-17.
..... ABB Special insulation; ----- ABB Standard insulation; ___ IEC TS 60034-17
Abbildung 4. Zulssige Phase-zu-Phase-Spannungsspitzen an Motorklemmen als Funktion der Anstiegszeit.
Definition der Anstiegszeit nach IEC60034-17.
..... ABB Spezialisolierung; ----- ABB Standardisolierung; ___ IEC TS 60034-17
Figure 4. Pics de tension phase-phase au niveau des bornes du moteur en tant que fonction de temps
de hausse. Temps de hausse dfini en conformit de la norme IEC60034-17.
..... ABB Isolation spciale ; ----- Isolation standard ABB ; ___ IEC TS 60034-17
Figura 4. Picos de tensin permitidos entre fases en los bornes del motor en funcin del tiempo de aumento.
Tiempo de aumento definido segn la norma IEC60034-17.
..... Aislamiento especial de ABB; ----- Aislamiento estndar de ABB; ___ IEC TS 60034-17
Figura 4. Picchi di tensione da fase a fase ammessi ai morsetti del motore in funzione del tempo di salita.
Tempo di salita definito in conformit a IEC60034-17.
..... Isolamento speciale ABB; ----- Isolamento standard ABB; ___ IEC TS 60034-17

SPP id: 080303 / en / C10080 / 1
Loadability curves with ACS800 converters with DTC control
Belastbarkeitskurven fr ACS800-Frequenzumrichter mit DTC-Steuerung
Courbes de capacit de charge avec convertisseurs ACS800 et commande DTC
Curvas de capacidad de carga con convertidores ACS800 dotados de control DTC
Curve di caricabilit con convertitori ACS800 e controllo DTC
Figure 5. Flameproof motors Ex d, Ex de, cast iron (type M3GP) dust ignition proof motors,
(DIP/Ex tD); nominal frequency of the motor 50/60 Hz
Abbildung 5. Motoren mit druckfester Kapselung Ex d, Ex de, Grauguss (Typ M3GP), Staubexplosionsschutz-
motoren, (DIP, Ex tD); Nennfrequenz des Motors 50/60 HzFigura 5.
Figure 5. Moteurs enveloppe antidflagrante Ex d, Ex de, moteurs en fonte (type M3GP) pour atmosph-
res de poussires combustibles, (DIP/Ex tD) ; frquence nominale du moteur de 50/60 Hz
Figura 5. Motores antideflagrantes Ex d, Ex de, hierro fundido (tipo M3GP) motores a prueba de ignicin
de polvo, (DIP/Ex tD); frecuencia nominal del motor 50/60 Hz
Figura 5. Motori a prova desplosione Ex d, Ex de, motori in ghisa (tipo M3GP) con protezione da polveri
combustibili, (DIP/Ex tD); frequenza nominale del motore 50/60 Hz
50 Hz 60 Hz

SPP id: 080303 / en / C10080 / 1
Figure 6. Non-sparking motors Ex nA, cast iron (type M3GP) and aluminium dust ignition proof motors
(DIP/Ex tD T125C), nominal frequency of the motor 50/60 Hz
Abbildung 6. Nicht funkende Motoren Ex nA, Aluminium und Grauguss (Typ M3GP), Staubexplosionsschutz-
motoren (DIP/Ex tD T125C); Nennfrequenz des Motors 50/60 Hz
Figure 6. Moteurs non producteurs dtincelles Ex na, moteurs en fonte (type M3GP) et en aluminium pour
atmosphres de poussires combustibles (DIP/Ex tD T125C), frquence nominale du moteur
de 50/60 Hz
Figura 6. Motores antichispas Ex nA, aluminio y hierro fundido (tipo M3GP) motores a prueba de ignicin
de polvo (DIP/Ex tD T125 C), frecuencia nominal del motor 50/60 Hz
Figura 6. Motori non-sparking Ex nA, motori in ghisa (tipo M3GP) e alluminio con protezione da polveri
combustibili (DIP/Ex tD T125C), frequenza nominale del motore 50/60 Hz
50 Hz 60 Hz

SPP id: 080303 / en / C10080 / 1
Guideline loadability curves with other voltage source PWM-type converters
Belastbarkeitskurven als Richtlinie fr spannungsgespeiste PMW-Frequenzumrichter
Courbes de capacit de charge de rfrence avec dautres convertisseurs PTW de source de tension
Curvas indicativas de capacidad de carga con otros convertidores de fuente de tensin de tipo PWM
Curve di caricabilit per altre origini di tensione con convertitori tipo PWM
Figure 7. Flameproof motors Ex d, Ex de, cast iron dust ignition proof motors (DIP/Ex tD T125C);
nominal frequency of the motor 50/60 Hz
Abbildung 7. Motoren mit druckfester Kapselung Ex d, Ex de, Grauguss-Staubexplosionsschutzmotoren
(DIP/Ex tD T125C); Nennfrequenz des Motors 50/60 Hz
Figure 7. Moteurs enveloppe antidflagrante Ex d, Ex de, moteurs en fonte pour atmosphres de
poussires combustibles (DIP/Ex tD T125C) ; frquence nominale du moteur de 50/60 Hz
Figura 7. Motores antideflagrantes Ex d, Ex de, motores de hierro fundido a prueba de ignicin
de polvo (DIP/Ex tD T125 C); frecuencia nominal del motor 50/60 Hz
Figura 7. Motori a prova desplosione Ex d, Ex de, motori in ghisa con protezione da polveri
combustibili (DIP/Ex tD T125C); frequenza nominale del motore 50/60 Hz
50 Hz 60 Hz

SPP id: 080303 / en / C10080 / 1
Figure 8. Non-sparking motors Ex nA, cast iron dust ignition proof motors (DIP/Ex tD);
nominal frequency of the motor 50/60 Hz
Abbildung 8. Nicht funkende Motoren Ex nA, Grauguss-Staubexplosionsschutzmotoren (DIP, Ex tD),
Nennfrequenz des Motors 50/60 Hz
Figure 8. Moteurs non producteurs dtincelles Ex nA, moteurs en fonte pour atmosphres de poussires
combustibles (DIP/Ex tD) ; frquence nominale du moteur de 50/60 Hz
Figura 8. Motores antichispas Ex nA, motores de hierro fundido a prueba de ignicin de polvo (DIP/Ex tD),
frecuencia nominal del motor 50/60 Hz
Figura 8. Motori non-sparking Ex nA, motori in ghisa con protezione da polveri combustibili
(DIP/Ex tD), frequenza nominale del motore 50/60 Hz
50 Hz 60 Hz

SPP id: 080303 / en / C10080 / 1

SPP id: 080303 / en / C10080 / 1
Low Voltage Motors

Manufacturing sites (*) and some of the larger sales companies.
Australia France Korea Switzerland

ABB Australia Pty Ltd ABB Entrelec ABB Korea Ltd. ABB Schweiz AG
601 Blackburn Road ZA La Boisse BP 90145 7-9fl, Oksan Bldg., 157-33 Normelec/CMC Components
Notting Hill VIC 3168 300 Rue des Prs-Seigneurs Sungsung-dong, Kangnam-ku Motors&Drives
Tel: +61 (0) 8544 0000 FR-01124 Montluel Cedex Seoul Badenerstrasse 790
Fax: +61 (0) 8544 0001 Tel: +33 4 37 40 40 00 Tel: +82 2 528 2329 Postfach
Fax: +33 4 37 40 40 72 Fax: +82 2 528 2338 CH-8048 Zrich
Austria Tel: +41 (0) 58 586 0000
ABB AG Germany Malaysia Fax: +41 (0) 58 586 0603
Clemens Holzmeisterstrasse 4 ABB Automation Products GmbH ABB Malaysia Sdn. Bhd.
AT-1810 Wien Motors & Drives Lot 608, Jalan SS 13/1K Taiwan
Tel: +43 (0) 1 601 090 Wallstaedter Strasse 59 47500 Subang Jaya, Selangor ABB Ltd.
Fax: +43 (0) 1 601 09 8305 DE-68526 Ladenburg Tel: +60 3 5628 4888 6F, No. 126, Nanking East Road,
Tel: +49 (0) 6203 717 717 Fax: +60 3 5631 2926 Section 4i
Belgium Fax: + 49 (0) 6203 717 600 Taipei, 105 Taiwan, R.O.C.
Asea Brown Boveri S.A.-N.V. Mexico Tel: +886 (0) 2 2577 6090
Hoge Wei 27 Hong Kong ABB Mxico, S.A. de C.V. Fax: +886 (0) 2 2577 9467
BE-1930 Zaventem ABB (Hong Kong) Ltd. Apartado Postal 111
Tel: +32 (0) 2 718 6311 Tai Po Industrial Estate, CP 54000 Tlalnepantla Thailand
Fax: +32 (0) 2 718 6657 3 Dai Hei Street, Edo. de Mxico, Mxico ABB Limited (Thailand)
Tai Po, New Territories, Tel: +52 5 328 1400 161/1 SG Tower,
Canada Hong Kong Fax: +52 5 390 3720 Soi Mahadlekluang 3,
ABB Inc., BA Electrical Machines Tel: +852 2929 3838 Rajdamri, Bangkok 10330
10300 Henri-Bourassa Blvd, West, Fax: +852 2929 3505 The Netherlands Tel: +66 2 665 1000
Saint-Laurent, Quebec ABB B.V. Fax: +66 2 665 1042
Canada H4S 1N6 India* Dept. LV motors (APP2R)
Tel: +1 514 832-6583 ABB Ltd. P.O.Box 301 The United Kingdom
Fax: +1 514 332-0609 32, Industrial Area, N.I.T NL-3000 AH Rotterdam ABB Ltd
Faridabad 121 001 Tel: +31 (0) 10 4078 879 Drives, Motors and Machines
China* Tel: +91 (0) 129 502 3001 Fax: +31 (0) 10 4078 345 Daresbury Park
ABB Shanghai Motors Co., Ltd. Fax: +91 (0) 129 502 3006 Daresbury, Warrington
88 Tianning Road Norway Cheshire, WA4 4BT
Minhang(Economical and Techno- Indonesia ABB AS Tel: +44 (0) 1925 741 111
logical Development Zone) PT. ABB Sakti Industri P.O.Box 154 Vollebekk Fax: +44 (0) 1925 741 212
200245 Shanghai JL. Gajah Tunggal Km.1 NO-0520 Oslo
Tel: +86 21 5472 3133 Jatiuwung, Tangerang 15136 Tel: +47 22 872 000 USA
Fax: +86 21 5472 5025 Banten, Indonesia Fax: +47 22 872 541 ABB Inc.
Tel: + 62 21 590 9955 Low Voltage Motors
Chile Fax: + 62 21 590 0115 - 6 Singapore 16250 W. Glendale Drive
Asea Brown Boveri S.A. ABB Industry Pte Ltd New Berlin, WI 53151
P.O.Box 581-3 Ireland 2 Ayer Rajah Crescent Tel: +1 262 785 3200
Santiago Asea Brown Boveri Ltd Singapore 139935 Fax: +1 262 780 8888
Tel: +56 (0) 2 5447 100 Components Division Tel: +65 6776 5711
Fax: +56 (0) 2 5447 405 Belgard Road Fax: +65 6778 0222 Venezuela
Tallaght, Dublin 24 Asea Brown Boveri S.A.
Low Voltage Motors/Manual Ex-motors ML 01-2007 3GZF500730-47 Rev A

Denmark Tel: +353 (0) 1 405 7300 Spain* P.O.Box 6649
ABB A/S Fax: +353 (0) 1 405 7327 Asea Brown Boveri, S.A. Carmelitas,
Automation Products Automation Products - Fbrica Caracas 1010A
Emil Neckelmanns Vej 14 Italy* Motores Tel: +58 (0) 2 238 2422
DK-5220 Odense S ABB SACE SpA P.O.Box 81 Fax: +58 (0) 2 239 6383
Tel: +45 65 47 70 70 LV Motors ES-08200 Sabadell
Fax: +45 65 47 77 13 Via dell' Industria 18 Tel: +34 93 728 8500
IT-20010 Vittuone, Milano Fax: +34 93 728 8741
Finland* Tel: +39 02 90341
ABB Oy Fax: +39 02 9034 7289 Sweden*
Motors ABB Automation Technologies AB
P.O.Box 633 Japan LV Motors
FI-65101 Vaasa ABB K.K. SE-721 70 Vsters
Tel: +358 (0) 10 22 11 26-1 Cerulean Tower Tel: +46 (0) 21 329 000
Fax: +358 (0) 10 22 47372 Sakuragaoka-cho, Shibuya-ku Fax: +46 (0) 21 329 140
Tokyo 150-8512
Tel: +81 (0) 3 578 46251
Fax: +81 (0) 3 578 46260
http://www.abb.com/motors&drives
http://online.abb.com/bol
Series 2.15 Page
DECLARATION
March 2012 H
Declaration of quality
We certify that AHLSTAR pump has been manufactured, tested and inspected according to the following
international standards (if no other specified requirements exist):
EN ISO 5199:2002 Technical specifications for centrifugal pumps -- Class II
EN 2858:2010 (ISO 2858:1975) End-suction centrifugal pumps (rating 16 bar) -- Designation, nominal duty
point and dimensions (standard's range up to size 44-200)
EN ISO 9001:2001 Quality management systems -- Requirements
1 Inspection before assembly
Components to be assembled have been examined.

Installation dimensions have been examined.
Information on the nameplate has been examined.
2 Materials
Materials have been manufactured according to the standard specified in order specification and part list.
3 Balancing of rotating components
All rotating components are balanced according to ISO 1940 G6.3 standard, and the low pulse impeller according to
ISO 1940 G2.5.
4 Hydrostatic test
All pressure containing parts (eg. casing, casing cover etc.) including their fasteners have been hydrostatically tested
with clean water at ambient temperature (15 C minimum for carbon steel). The hydrostatic test has been
considered satisfactory when the test pressure is maintained for at least 10 min. without visible leakage. The
hydrostatic pressure is 1.5 times the design pressure.
5 Performance test
Performance test has been done according to the EN ISO 9906 grade 2.
During performance tests the pump vibration, bearing temperature and visually the shaft seal have been checked.
6 Final inspection
A final inspection has been done so, that the scope of supply is correct and complete according to the purchase
order, including component identification, painting and preservation and technical documentation.

Series 2.15 Page
DECLARATION
March 2012 H
Declaration of quality
7 Preparation for dispatch
All internal parts made of material which are not resistant to corrosive attack by the environment have been drained
and treated with a water displacing rust-preventative prior to shipment.
Exterior surfaces, except for machined surfaces, have been given at least one coat of the manufacturers standard
paint which shall be selected taking into account environmental considerations. The under-side of baseplates have
been prepared for grouting.
Exterior machined surfaces of cast iron and carbon steel parts have been coated with a suitable rust preventative.
Bearings and bearing housings have been protected by preservative oil which is compatible with the lubricant. A
label warning (oil lubricated bearing housings must be filled with oil to the proper level prior to starting) have securely
attached to the pump.
Information on preservation agents and their removal have been securely attached to the pump.
All openings to the pressure chamber have weather-resistant closures substantial enough to withstand accidental
damage.
Each unit have been prepared and small piping and auxiliaries secured, to prevent damage during shipment and
storage.
The pump and all components supplied loose with it have been clearly and durably marked with the prescribed
identification number.
Kotka 1.3.2012
Ilkka Sinisalo
Head Operations BA SPP

Series 2.15 Page
CERTIFICATE ISO
March 2012 H
Material Certificate
Based on the continuous tests we certify that the analysis values as well as the mechanical-technological data of
material are within the standard EN 10204-2.2 and the following limits. The material options are mentioned in the
product specification and in the part list.
Material alternatives
Part no. Description Code Material
WEEN.1 WET END
53 A48 CL 35 B
46 A216 WCB
41 A890 3A
4E A747 CB7Cu-2
102.11 Volute case
4L A890 1B
4T A890 5A
4U 654 SMO
EJ SULZER 2304
5B A532 IIIA
46 A216 WCB
41 A890 3A
135.11 Sideplate 4E A747 CB7Cu-2
4L A890 1B
4T A890 5A
4U 654 SMO
41 A890 3A
4E A747 CB7Cu-2
175.11 Flow straightener 4L A890 1B
4T A890 5A
4U 654 SMO
5B A532 IIIA
41 A890 3A
4E A747 CB7Cu-2
230.11 Impeller
4L A890 1B
4T A890 5A
4U 654 SMO
41 A890 3A
4E A747 CB7Cu-2
502.11
Casing wear ring 4L A890 1B
502.12
4T A890 5A
4U 654 SMO
SEUN.2 SEALING UNIT
41 A890 3A
46 A216 WCB
4E A747 CB7Cu-2
100.21 Case
4L A890 1B
4T A890 5A
4U 654 SMO
53 A48 CL 35 B
41 A890 3A
46 A216 WCB
161.21 Case cover
4E A747 CB7Cu-2
451.21 Stuffing box housing
4L A890 1B
4T A890 5A
4U 654 SMO
41 A890 3A
231.21 Suction impeller 4E A747 CB7Cu-2
235.21 Expeller 4L A890 1B
604.21 Expeller 4T A890 5A
4U 654 SMO
41 A890 3A
475.21 Thrust ring
4U 654 SMO

Series 2.15 Page
CERTIFICATE ISO
March 2012 H
Part no. Description Code Material

BEUN.3 BEARING UNIT
183.31 Support foot 52 A48 CL 30 B
52 A48 CL 30 B
330.31 Bearing housing
53 A48 CL 35 B
344.31 Adapter 5H A395 60-40-18
360.31 Bearing cover 52 A48 CL 30 B
Material specifications
Tensile Yield
strength strength Elongation Hardness
SPP id MCN Marking Typical chemical analysis %
MPa MPa % HB
(ksi) (ksi)
Carbon max 0.02
Manganese max 1.0
Silicon max 0.8
Phosphorus max 0.03
Sulphur max 0.01
3L 254 SMO
Chromium 19.5-20.5
Nickel 17.5-18.5
Molybdenum 6.0-6.5
Copper 0.5-1.0
Nitrogen 0.18-0.22
Carbon max 0.06
Manganese max 1.00
Silicon max 1.00
Phosphorus max 0.04
655 450
41 J0265 A890 3A Sulphur max 0.04 25 (230)
(95) (65)
Chromium 24.0-27.0
Nickel 4.0-6.0
Molybdenum 1.75-2.5
Nitrogen 0.15-0.25
Carbon max 0.30
Manganese max 1.00
Silicon max 0.60
Phosphorus max 0.04
Sulphur max 0.045
485-655 250
46 J0297 A216 WCB Copper max. 0.30 22 (160)
(70 95) (36)
Nickel max. 0.50
Chromium max. 0.50
Molybdenum max 0.20
Vanadium max. 0.03
(Cu+Ni+Cr+Mo+V) max 1.00
Carbon max 0.07
Manganese max 0.70
Silicon max 1.00
Phosphorus max 0.035
1205 1035
4E J0264 A747 CB7Cu-2 Copper 2.50-3.20 5 (400)
(174) (150)
Chromium 14.0-15.5
Nickel 4.5-5.5
Molybdenum max 0.50
Niobium 0.15-0.35 %
Carbon max 0.04
Manganese max 1.0
Silicon max 1.00
Phosphorus max 0.04
690 485
4L J0266 A890 1B Sulphus max 0.04 16 (250)
(100) (70)
Chromium 24.5-26.5
Nickel 4.75-6.0
Molybdenum 1.75-2.25
Copper 2.75-3.25

Series 2.15 Page
CERTIFICATE ISO
March 2012 H
Tensile Yield
strength strength Elongation Hardness
SPP id MCN Marking Typical chemical analysis %
MPa MPa % HB
(ksi) (ksi)
Carbon max 0.03
Manganese max 1.5
Silicon max 1.00
Phosphorus max 0.04
680 515
4T (* J0267 A890 5A Sulphus max 0.04 18 (250)
(99) (75)
Chromium 24.0-26.0
Nickel 6.0-8.0
Molybdenum 4.0-5.0
Nitrogen 0.10-0.30
Carbon max 0.025
Chromium 23.0-25.0
Nickel 21.0-23.0 600 350
4U J0271 654 SMO 40 (220)
Molybdenum 7.1-7.5 (87) (51)
Copper 0.3-0.7
Nitrogen 0.45-0.55
Carbon 3.2-3.7
200
52 F0066 A48 CL 30 B Silicon1.7-2.4 (170-220)
(29)
Manganese 0.4-0.9
Carbon 3.2-3.7
250
53 F0067 A48 CL 35 B Silicon1.7-2.4 (170220)
(36)
Manganese 0.4-0.9
Carbon 2.0-3.3
Manganese max 2.0
Silicon max 1.5
Phosphorus max 0.10
5B F0068 A532 IIIA Copper max 1.2 (min. 600)
Sulphus max 0.06
Chromium 23.0-30.0
Nickel max 2.5
Molybdenum max 3.0
Carbon min 3.0
415 275
5H F0047 A395 60-40-18 Silicon max 2.5 18 143-187
(60) (40)
Phosphorus max 0.08
Carbon max 0.06
Chromium 22.0-24.0
Nickel 3.5-5.5 550 360
EJ SULZER 2304 25 (200)
Molybdenum 0.1-0.6 (80) (52)
Copper 0.1-0.6
Nitrogen 0.05-0.20
*) At Sulzer Karhula foundry, the PRE target value of the material ASTM A890 5A (4T) is 41. The minimum accepted value of 4T
is 40.
Kotka 1.3.2012
Ilkka Sinisalo

Series Page
Hydrostatic pressure test certificate CERTIFICATION

April 2010 H04
SPP id: 100920 / Replaces 100430 / en / N05670_100117418 / 7
Customer Customer Order No. Customer Item/Tag

Puerto Impala Barrancabermeja e-mail P-08 A
Project name Sulzer Order No. / Position Witnessed
0000219505 / 10 Yes / No
Manufacturer Test date The temperature of water used in the

Sulzer Pumps Finland Oy test is ambient temperature. For ferrous
25.10.2013
materials min. water temperature is 7oC
Product type Serial Number Pump material
(45oF)
A33-100 100117418 41
Measured test values
Test pressure MPa (bar) Max allowed operating pressure at 20oC Test duration Test standard
(68oF) MPa (bar)
2,40 (24,00) 1,00 (10,00) 10 min ISO 5199
The pump hydrostatic pressure test has been made acc. to the above conditions without any visible leakage during the test. The test is
acceptable.
Mntt 25.10.2013
Ilkka Sinisalo
Series Page
Vibration test report REPORT

September 2008 H10

Project name Witnessed
Yes / No
Manufacturer Test date

Sulzer Pumps Finland Oy 07.11.2013
Product type Serial Number Test standard
A33-100 100117418 ISO 5199
Pump speed Flow Head Dimension
1759 rpm 55,44 l/sec 53,94 m h = 280,00 mm
Point 1 (Total RMS) Point 2 (Total RMS) Max. allowed (Total RMS)
Horizontal 1,10 mm/s Horizontal 0,60 mm/s 4.5 mm
Vertical 0,70 mm/s Vertical 1,10 mm/s
Measuring equipment type / equipment number
ST5484E / H1_416561_(V1) (mm/s),V1_416564_(V2) (mm/s),H2_416559_(V3) (mm/s),V2_416562_(V4) (mm/s)
The pump vibration test has been made during the standard performance test acc. to the above results. The test results are below the
max allowed values and the test is accepted.
Mntt 07.11.2013
Ilkka Sinisalo
Series Page
Bearing temperature test report REPORT

September 2008 H11

Yes / No
Manufacturer Test date
Sulzer Pumps Finland Oy 07.11.2013
Product type Serial Number Impeller Water temperature
A33-100 100117418 916274 / 340,0 mm 24,58 C
Pump speed Flow Head
1759 rpm 55,44 l/sec 53,94 m
Time (min) Point 1 Horizontal C (F) Point 1 Vertical C (F) Point 2 Horizontal C (F) Point 2 Vertical C (F) Max allowed C (F)
00 min 20,50 (68,90) 20,50 (68,90) 20,70 (69,26) 20,80 (69,44) 65 (149)
03 min 21,00 (69,80) 21,00 (69,80) 21,10 (69,98) 21,30 (70,34) 65 (149)
06 min 21,70 (71,06) 21,60 (70,88) 21,40 (70,52) 21,90 (71,42) 65 (149)
09 min 22,10 (71,78) 22,00 (71,60) 21,80 (71,24) 22,40 (72,32) 65 (149)
12 min 22,70 (72,86) 22,50 (72,50) 22,20 (71,96) 22,90 (73,22) 65 (149)
15 min 23,10 (73,58) 22,90 (73,22) 22,60 (72,68) 23,30 (73,94) 65 (149)
18 min 23,60 (74,48) 23,30 (73,94) 22,90 (73,22) 23,80 (74,84) 65 (149)
21 min 24,00 (75,20) 23,70 (74,66) 23,20 (73,76) 24,10 (75,38) 65 (149)
24 min 24,40 (75,92) 24,00 (75,20) 23,60 (74,48) 24,50 (76,10) 65 (149)
27 min 24,70 (76,46) 24,40 (75,92) 23,70 (74,66) 24,90 (76,82) 65 (149)
30 min 25,00 (77,00) 24,80 (76,64) 24,00 (75,20) 25,20 (77,36) 65 (149)
Measuring equipment type
PT100 / H1_5264_(T1) ('C),V1_5271_(T2) ('C),H2_5272_(T3) ('C),V2_5273_(T4) ('C)
The pump roller bearing temperature test has been made during the standard performance test acc. to the above results. The test
results are below the max allowed values and the test is accepted.
Mntt 07.11.2013
Ilkka Sinisalo
Series Page
CERTIFICATION
Performance Certificate September 2008 H05a
SPP id: 100430 / Replaces 080915 / en / N04386_100117418 / 3 / Page 1 (2)

Yes / No
Manufacturer Test date Test standard
Sulzer Pumps Finland Oy 07.11.2013 ISO 9906 G2
Product type Serial number Impeller Water temperature
A33-100 100117418 916274 / 340,0 mm 25 C
Guaranteed values for acceptance test:
Specified speed Flow Head Efficiency
1760 rpm 55,50 l/sec 54,00 m 71,00 %
Test results based on the specified speed of rotation
Test speed Flow Head Efficiency
1759 rpm 55,44 l/sec 53,94 m 69,36 %
80 100
e (%)
H(m) 90
70
80
60
70
50 60
40 50
30 40
30
20
20
10 10
0 0
60,0 0 20 40 60 80 100
P(kW) Q(l/sec)
50,0
40,0
30,0
20,0
10,0
0,0
0,0 20,0 40,0 60,0 80,0 100,0
Q(l/sec)
The above items have been tested in accordance with the requirements of the test procedure/standard and are acceptable to specification.
Mntt 07.11.2013
Ilkka Sinisalo
Series Page
CERTIFICATION
Performance Certificate September 2008 H05b
SPP id: 100430 / Replaces 080915 / en / N04386_100117418 / 3 / Page 2 (2)

Manufacturer Test date Test standard
Sulzer Pumps Finland Oy 07.11.2013 ISO 9906 G2
Product type Serial number Impeller Water temperature
A33-100 100117418 916274 / 340,0 mm 25 C
Guaranteed values for acceptance test:
Specified speed Flow Head Efficiency
1760 rpm 55,50 l/sec 54,00 m 71,00 %
Test results based on the specified speed of rotation
Test speed Flow Head Efficiency
1759 rpm 55,44 l/sec 53,94 m 69,36 %
1,100 81
e (%)
H/Hg
79
77
1,050
75
73
1,000 71
69
67
0,950
65
63
0,900 61
0,900 0,950 1,000 1,050 1,100
Q/Qg
H/Hg e-%
Head/Flow relative to guarantee value Tolerance cross ISO 9906 Grade1/Grade2/Annex A/Sulzer
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Series Page
CERTIFICATION ISO
March 2012 H14m
Certificate of surface treatment
We certify that AHLSTAR pump has been finished according to the option mentioned in the product specification.
1 Product outside surface treatment

Atmospheric-corrosivity category C4, ISO 12944-2, temperatures <150 C, zinc-rich primer
1.1 Wet end outside surface treatment

Relates to part numbers 102.11 (volute case) and 175.11 (flow straightener)
1.1.1 Painting, standard method

Painting of wet end is made according to EN-ISO 12944-5 standard
Preparation of steel substrates grade Sa 2 according to standard ISO 8501-1
Painting of cast iron and carbon steel components:

Atmospheric corrosivity category C4 according to standard 12944-2 "Classification of environment"
Paint system A4.14/M EPZn[R] EP200/3
1 x priming coat (EPZn[R]) 40 m
1 x intermediate coat (EP) 80 m
1 x top coat (EP) 80 m
Nominal dry film thickness 200 m
Machined surfaces paint system EP80/1
Painting of stainless steel components:

Paint system EP80/1
1.1.2 Sandblast
Outside surfaces of volute casing made of stainless steel is sandblasted.
1.2 Sealing unit outside surface treatment

Relates to part numbers 100.21 (case), 161.21 (case cover) and 451.21 (stuffing box housing)
1.2.1 Painting, Standard method

Painting of sealing unit is made according to EN-ISO 12944-5 standard
Painting of cast iron and carbon steel components:

Series Page
CERTIFICATION ISO
March 2012 H14n
Atmospheric corrosivity category C4 according to standard 12944-2 "Classification of environments"
Painting of stainless steel components:

Paint system EP80/1
1.2.2 Sandblast
Outside surfaces of sealing unit component made of stainless steel is sandblasted.
1.3 Bearing unit outside surface treatment

Relates to part numbers 183.31 (support foot), 330.31 (bearing housing), 344.31 (adapter) and
360.31 (bearing cover)

Painting of bearing unit is made according to EN-ISO 12944-5 standard
Painting of cast iron components:

Atmospheric corrosivity category C4 according to standard 12944-2 "Classification of environments"
Bearing housing unmachined innersurfaces paint system EP80/1
1.4 Coupling guard surface treatment

Relates to part numbers 685.51 (guard end), 686.51 (guard jacket) and 686.52 (guard jacket)

Paint system powder paint EP100/1

Series Page
CERTIFICATION ISO
March 2012 H14o
Paint system Liquid paint EP120/2
1.4.2 Non-treated
Stainless steel/Brass guards are without painting.
1.5 Baseplate surface treatment

Relates to part number 890.61 (baseplate)
1.5.1 Hot galvanizing

Steel baseplates are hot dip galvanized according to standard EN-ISO 1461.

Painting of baseplate is made according to EN-ISO 12944-5 standard
Preparation of steel substrates grade P2 according to standard EN-ISO 8501-3
Painting of steel components:

Atmospheric corrosivity category C4 according to standard EN-ISO 12944-2 "Classification of
environments"
1.5.3 Non-treated
Stainless steel baseplates are without painting.
Kotka 1.3.2012
Ilkka Sinisalo

Sulzer Pumps Finland Oy Product Specification: General

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Sulzer Pumps Finland Oy Description A33-100

Serial Number 100117418

Sulzer Pumps Finland Oy Contact Person Tatu Pykalainen

Sulzer Pumps Finland Oy Contact Person Tatu Pykalainen

Motor environment: Explosion proof Motor nominal voltage: 480 VD

Sulzer Pumps Finland Oy Contact Person Tatu Pykalainen

D01.31 1 PART LIST, BEARING UNIT N31024EN

D02.01 1 DIMENSIONAL DRAWING, PUMP P12396EN

D02.02 1 DIMENSIONAL DRAWING, DRIVE MOTOR P12465EN

D02.03 1 DIMENSIONAL DRAWING, ASSEMBLY P30543EN

D02.11 1 DIMENSIONAL DRAWING, WET END CONNECTIONS P12447EN

D02.12 1 Dimensional drawing P02184EN

D02.21 1 DIM.DRAW.,SEAL.UNIT CONNECT. P12459EN

D02.31 1 DIM. DRAW., BEARING UNIT CONNECT. P30572EN

D02.61 1 DIMENSIONAL DRAWING, FOUNDATION SCREW P12525EN

D03.11 1 CHARACTERISTIC CURVE K18493EN

D04.01 1 SECTIONAL DRAWING, PUMP N15579EN

D04.03 1 SECTIONAL DRAWING, ASSEMBLY N30766EN

D04.11 1 SECTIONAL DRAWING, WET END N15583EN

D04.21 1 SECTIONAL DRAWING, SEALING UNIT N16117EN

D04.25 1 SECTIONAL DRAWING, GUARDS N30338EN

D04.31 1 SECTIONAL DRAWING, BEARING UNIT N31011EN

D04.32 1 SECTIONAL DRAWING, LUBRICATION EQUIPMENT N31320EN

D04.41 1 SECTIONAL DRAWING, SEALING WATER EQ. N31549EN

D04.51 1 SECTIONAL DRAWING, COUPLING UNIT N31039EN

D04.61 1 SECTIONAL DRAWING, BASEPLATE N30768EN

D04.62 1 SECTIONAL DRAWING, FOUNDATION SCREW N15634EN

D05.00 1 INSTRUCTION, CONTENTS N31566EN

D05.01 1 INSTRUCTION, INTENDED USE N31567EN

D05.02 1 INSTRUCTION, SAFETY INSTRUCTIONS N31568EN

D05.03 1 INSTRUCTION, HOISTING AND TRANSPORT. N31569EN

D05.04 1 INSTRUCTION, COMMISSIONING N31570EN

D05.05 1 INSTRUCTION, INSTALLATION N31571EN

D05.06 1 INSTRUCTION, OPERATION N31572EN

D05.07 1 INSTRUCTION, PREVENTIVE MAINTENANCE N31573EN

D05.08 1 INSTRUCTION, CORRECTIVE MAINTENANCE N31574EN

D05.09 1 INSTRUCTION, SPARE PARTS RECOMM. N31575EN

D05.21 1 INSTRUCTION, SHAFT SEAL C10151EN

D05.43 1 INSTRUCTION, SEALING WATER EQUIPMENT C10150EN

D05.51 1 INSTRUCTION, COUPLING, REX VIVA C10014EN

D05.81 1 ATEX INSTRUCTION, DRIVE MOTOR C10080EN

D06.02 1 QUALITY OF CONFORMITY N15715EN

D07.01 1 MATERIAL CERTIFICATE N15716EN

D07.012 1 Hydrostatic pressure test certificate N05670EN_100117418

D07.014 1 Vibration test report N30186EN_100117418

D07.015 1 Inspection record, Bearing temperature N30238EN_100117418

Sulzer Pumps Finland Oy Contact Person Tatu Pykalainen

D07.02 1 Performance Certificate N04386EN_100117418

D07.022 1 CERTIFICATE EN10204-2.1 N30527EN

D07.09 1 CERTIFICATE, SURFACE TREATMENT N31223EN

C20.21 CON-C20 1 SEALING LIQUID INLET ISO 7/1-Rp 3/8

C20.41 CON-C20 1 SEALING LIQUID INLET 3/8"

C21.21 CON-C21 1 SEALING LIQUID OUTLE ISO 7/1-Rp 3/8

C27.11 CON-C27 1 DISCHARGE PIPE CONN. ISO 7/1-Rp 3/8

C40.11 CON-C40 1 DRAINING OF PUMP ISO 7/1-Rp 3/8

C42.31 CON-C42 1 OIL FILLING ISO 7/1-Rp 1/2

C43.31 CON-C43 1 DRAINING OF LUBRICAT ISO 7/1-Rp 1/2

102.11 9165890141-C 1 VOLUTE CASE A33-100 (41) A890 3A

Material and NDT tests: Material test EN 10204-2.2

Flange drilling: ASME B16.5-2009 CLASS 150

Wet end connections: Yes Wet end drain. C40, bottom

We.inside surface treatment: Standard surface treatment

We.outside surface treatment: Standard,1xEP Top coat (prim.