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Range: ZLND
Volute casing pump complying with EN 733 / DIN 24255*
PUMP DESCRIPTION: ______________________________
SERIAL NUMBER: ____________________
Operating instructions
Safety issues Chapter 1
Safety instructions and compliance
Troubleshooting Chapter 8
If something does not work
Annex Chapter 10
Technical data, dimensions table, sectional drawings
*
With certain exceptions – see Technical Catalogue
Attention: Both the pump and/or the pump set must be installed and commissioned by qualified technical
personnel only and these installation, commissioning and operating instructions must be strictly observed.
Failure to do so could result in:
• danger to you and your colleagues,
• the pump or the pump unit may be damaged,
Note that the manufacturer is not liable for damages resulting from failure to observe these instructions.
Please be aware of your responsibility to your colleagues when working on the pump or the pump set!
Safety instructions marked with included in this Operating Instructions and in the
Supplementary Operating Instructions, which must be attached to this Operating Instruction, have to
be considered in particular when operating this pump in potentially explosive atmospheres!
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Safety issues Page 1 of 3 Chapter 1
1.4 Compliance with regulations operative again. Prior to re-starting the machine,
relating to safety at work the instructions listed under “first commissioning”
When operating the pump the safety instructions are to be observed.
contained in this manual, the relevant national
accident prevention regulations and any other 1.7 Safety instructions for the use in
service and safety instructions issued by plant areas with explosion hazard
management must be observed.
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Intended application Page 1 of 3 Chapter 2
ATTENTION
2.2 Accessories
The accessories included in the scope of supply
are indicated in the delivery note or in the order
confirmation. The corresponding operating and
installation instructions are also indicated in the
Annex relating to accessories.
If it is intended to mount other accessories on the
pump or on the pump set, please inform the
manufacturer in advance in order that appropriate
technical advice can be given.
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Intended application Page 2 of 3 Chapter 2
2.4 Description
Type
size Hydraulic + Bearing Shaft seal Material design Casing gasket
A• First hydraulic 041: Self-sealed, uncooled packing rings 0B: Cast iron GG25
B• Second hydraulic 2: confined flat
D• Double volute 052: Uncooled packing rings, external seal liquid 0C: Cast iron GG25, gasket of EWP
Bronze G-CuSn10 impeller 210 material
BJ3,C23,AF3,AX3,AY3,A93:SiC/Carbon, EPDM
0E: Cast iron GG25,
• B Two ball bearings
BJS,C2S,AFS, AXS,AYS,A9S: SiC/ SiC, Viton Stainless steel 1.4408 imp. 4: confined flat
greased for life (2Z)
gasket of PTFE
• C Two ball bearings oil BJJ,C2J,AFK,AXK,AYK,A9K: SiC/Carbon, Viton 4B: Stainless steel 1.4408
ZLND lubricated
• 2 Oil lubrication
32125 configurations with CLO
to • S One double row
300500 angular contact bearing plus
one ball bearing, grease
lubricated
• T One double row ball
bearing plus ball bearing, oil
lubricated
Alternatively
A or B 32160, 32200 Alternatively Alternatively
A 32125 to 200315, 250315 041,052,BJ3,C23,AF3,AX3,AY3,A93,BJS,C2S,
D 200400 to 300500 AFS,AXS,AYS,A9S,BJJ,C2J,AFK,AXK,AYK,A9K 0B, 0C, 0E, 4B 2, 4
Alternatively B, C, 2, S or T
Codes AX3, AXS, AXK: are equivalent to AF3, AFS, AFK respectively plus quench
Codes AY3, AYS, AYK: are equivalent to AF3, AFS, AFK respectively plus heating
Codes A93, A9S, A9K: are equivalent to AF3, AFS, AFK respectively plus external flushing
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Intended application Page 3 of 3 Chapter 2
ATTENTION
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Planning the installation Page 1 of 2 Chapter 3
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Planning the installation Page 2 of 2 Chapter 3
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Unpacking, storage, transport Page 1 of 2 Chapter 4
4.2 Unpacking
Before unpacking, a visual check of the packing is
recommended. If transport damage is visible, the
Pump set
extent should be noted on the receipt or on the
delivery note. Potential claims must be lodged
immediately with the carriers or the insurance
4.5 Protection against corrosion
In general, a protective coating is only applied to
company.
the following executions: OB, OC and OE.
4.3 Interim storage
If the pump or the pump unit is not installed
4.5.1 Removal of protective coating
To remove the protective coating, the pump
immediately after delivery, it must be stored free
should be filled and drained several times using
from vibration in a dry room.
appropriate agents, e.g. solvent naphtha, diesel
oil or alkaline detergent. Flush with water, if
necessary.
The pump must be installed and started up
immediately afterwards.
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Unpacking, storage, transport Page 2 of 2 Chapter 4
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Installing the pump Page 1 of 3 Chapter 5
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Installing the pump Page 2 of 3 Chapter 5
5.4.6 Position
In principle the ZLND pumps are installed half of the N-EUPEX B ( FLENDER ) coupling
horizontally. must be 2 - 3 mm (see fig.).
If other manufacturer’s couplings are used, follow
the manufacturer’s instructions. After installation
on the foundation and connecting the pipework,
the coupling alignment must be checked and re-
aligned, if necessary. Moreover, after reaching the
operating temperature the alignment of the
coupling must be checked again.
The coupling requires a guard that meets DIN
31001 in order to avoid accidental contact during
operation.
5.5 Motor In any event, the operating instructions of the
Before assembly check the direction of rotation of coupling manufacturer must be followed, since the
the motor (indicated by an arrow on the pump coupling is a component incorporated by Sterling
casing). If this is not possible the direction of Fluid Systems.
rotation of the complete unit can only be checked ruler
only if the pump is filled.
In any event, the operating instructions of the
motor manufacturer must be followed, since the
motor is generally incorporated by STERLING
FLUID SYSTEMS into the pump set.
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Installing the pump Page 3 of 3 Chapter 5
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Starp-up and shut-down Page 1 of 3 Chapter 6
6.1 Requirements
The pump or the pump set, must be installed acc. • If there is no bypass line, do not run the
to the instructions of Chapter 5. pump with the control valve closed for any
length of time.
6.2 Use of trained staff • Safety measures should be taken by the
Only appropriately trained staff must carry out the end user to ensure (for example by
work described in this chapter. means of a relief valve) that the
permissible pump casing pressure is not
6.3 Safety measures exceeded during operation
• Repeat the alignment of the coupling at
operating temperature. Re-align the pump
or the motor, if necessary.
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Starp-up and shut-down Page 2 of 3 Chapter 6
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Starp-up and shut-down Page 3 of 3 Chapter 6
- shaft seal
Executions with stuffing box:
For correct operation of the shaft seal a slight
leakage (20 - 40 drops per minute) is essential. If
the leakage is reduced too much by retightening
the packing, it will be destroyed. When handling explosive, toxic, hot, crystalline or
If the pump is equipped with code 052 or code corrosive media, ensure that people and the
051, the supply lines to the stuffing box have to be environment are not endangered. Even if the
open before the pump is started. pump has been drained using the threaded plug
Executions with mechanical seal: 90.30, residues can remain in the pump. For
During running-in slight leakage may occur. If the transport, the pump must be free from any
pump is equipped with an external flush, quench dangerous material. In case of extended periods
or heating, the flush, quench or heating supply out of service, protect the pump against corrosion.
has to be switched on before the pump is started.
The mechanical seal must be allowed to cool
before the next re-start.
ATTENTION
6.9 Shutting-down
Before shutting down close the valve on the
discharge side.
After shutting down, all valves may be closed. The
valves of the auxiliary pipework connections,
(quench, heating, external flush, code 052, code
051), have to be closed in the last place.
If there is a risk of very low ambient temperatures,
remove the pump and then drain it using the
threaded plug 90.30.
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Maintenance, dismantling, assembly Page 1 of 10 Chapter 7
7.1 Requirements
The pump or the pump set must have been shut
down in the manner described in Chapter 6.
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Maintenance, dismantling, assembly Page 2 of 10 Chapter 7
t Kinematic viscocity
2
61.2 to 41.8 to 19.8 to
at 50ºC in mm /s 74.8 50.8 24.2
Oil drainage Constant level oiler
Neutralisation figure Maximum 0.15 mg KOH/g
Ash ( as Ash Oxide ) Maximum 0.02% weight
As an additional accessory, it is possible to Water content Maximum 0.1% weight
connect a constant level oiler. In this case, the Suitable motor oil SAE 20 and 20W SAE 10W
bearing support must be filled with oil through the
oil inlet hole, until the oil is visible in the screw-in
elbow, the oil reservoir having been removed. Oil quantities:
Subsequently the oil reservoir should be filled with Bearing Bracket Oil ( litre )
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Maintenance, dismantling, assembly Page 3 of 10 Chapter 7
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Maintenance, dismantling, assembly Page 4 of 10 Chapter 7
90.30
68.10 90.13
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Maintenance, dismantling, assembly Page 5 of 10 Chapter 7
Design with heating (AY3, AYS, AYK) 50.70 42.20 42.10 33.00 91.60 40.02 42.10 36.00 90.11 42.20 94.00
90.30 50.20
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Maintenance, dismantling, assembly Page 6 of 10 Chapter 7
1. Mark the position of all parts with a colour pen Design with a mechanical seal:
or scribing tool in order to be able to 1. Loosen hexagonal screws 90.24 and withdraw
reassemble the pump correctly. the mechanical seal cover 47.10 with the flat
2. Unscrew hexagonal nuts 92.00. gasket 40.06, static part of the mechanical
3. Withdraw pull out assembly from the volute seal 43.30 with pin 56.10.
casing 10.20. Withdraw the flat gasket 40.00. 2. Remove the shaft sleeve 52.30 with the
The wear ring 50.20, if it is necessary can be distance ring 50.40, the rotating part of the
removed. mechanical seal 43.30 and the flat gasket
40.01.
92.20
93.00 40.03 23.00 94.01 16.10 90.22 92.02
3. Loosen grub screw 56.00.
4. Detach the pin 56.00 and then, the wear ring
50.21.
90.14 36.01 63.60 42.10 40.02 50.70 33.00 93.21 40.02 42.10 36.00 63.60 94.00 90.11
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Maintenance, dismantling, assembly Page 7 of 10 Chapter 7
5. Pull out complete shaft with both ball bearings 7.7 Assembly
32.10 and 32.11 and circlip 93.21. 7.7.1 Tightening torque
When tightening the bolts the following torques
32.11 21.00 93.21 32.10
must be used:
Nm Nm Nm Nm Nm Nm Nm Nm
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Maintenance, dismantling, assembly Page 8 of 10 Chapter 7
4. Attach the bearing cover 36.00, with its radial • For executions with mechanical seal:
seal inserted, if it is oil lubricated, and the flat
gasket 40.02;( the lip of the radial seal ring 7. Insert the static part of the mechanical seal
should point towards the non drive end). Then 43.30, with the pin 56.10 if any, in the casing
fasten hexagonal screws 90.11. In case of cover 16.10.
grease lubrication, mount the V- seals 42.20
43.30 16.10 56.10
in the shaft and lean one against the bearing
housing 33.00. Insert the key 94.00.
5. Insert the oil dip stick 91.60 and the CLO
63.80 if any.
50.70 42.20 42.10 33.00 91.60 40.02 42.10 36.00 90.11 42.20 94.00
16.10 1 6 . 50
90.30
Bearing design S or T :
Attach the cover 16.50 and casing cover 16.10.
• For executions with bearing housings 55 and
65:
16.10 16.50
Carry out the following steps:
1. Fit the shaft unit.
2. If the shaft is to be fitted with new bearings,
they should be heated in an oil bath to a
temperature of 80º C before assembling. First,
install the ball bearing 32.11, then the circlip
93.21 and finally ball bearing 32.10. Make
sure that the bearing is pressed home against
the shoulders of the shaft.
3. If the lip seals have been removed, they must
be exchanged. The lip seals should be fitted
into the bearing cover with a bush, pressing
8. Attach the bearing housing 33.00 and the on the external ring of the oil seals. The lips
casing cover 16.10. should point towards the bearing after
9. Insert the rotating part of the mechanical seal installation. Pay attention to the bearing
43.30 and the distance ring 50.40. covers to avoid fitting them incorrectly.
10. Insert the key 94.01, impeller 23.00 and
tighten the impeller nut 92.20. Attach the 32.11 21.00 93.21 32.10
90.13 68.10 92.20 23.00 94.01 50.40 43.30 16.10 33.00 91.40
5. When fitting the rotating unit in the bearing • For executions with mechanical seal:
housing 33.00, the circlip 93.21 must be 9. Install the mechanical seal cover 47.10 with
inserted in the groove in the bearing housing. the mechanical seal stationary part 43.30 and
6. Insert the bearing cover 36.01 with the flat its pin 56.10 if any, then place the flat gasket
gasket 40.02 and the grease nipple 63.60 if 40.06 and hexagonal screws 90.24.
any. 10. Insert the shaft sleeve 52.30 with the rotating
7. Mount the plug 67.20, the oil level sight glass part of the mechanical seal 43.30 and the
64.20 and the constant level oiler ( CLO ) distance ring 50.40.
63.80, where oil lubrication is used. 11. In the casing cover 16.10, insert the wear ring
8. Fasten pump foot 18.30 and insert the thrower 50.21 with grub screws 56.00 and the studs
50.70. 90.22.
90.14 36.01 63.60 42.10 40.02 50.70 33.00 93.21 40.02 42.10 36.00 63.60 94.00 90.11
40.01 52.30 50.40 43.30 16.10 90.22 40.06 47.10
9. Mount the shaft sleeve 52.40 on to the shaft 56.00 50.21 56.10 90.24
unit.
12. Join the casing cover 16.10, the bearing
10. In the casing cover, insert one of the packing
housing 33.00 and fasten hexagonal nuts
rings 46.10, the lantern ring 45.80, the
92.02.
remaining packing rings and finally the gland
45.20. 92.20
93.00 40.03 23.00 94.01 16.10 90.22 92.02
Finally:
13. Insert the flat gasket 40.01, keys 94.01,
impeller 23.00 and flat gasket 40.03.
14. Tighten the impeller nut 92.20 with the helicoil
93.00.
15. Insert the wear ring 50.20 with grub screws
56.00 and then, insert studs 90.20.
56.00 50.21 90.21 55.40 92.01 16. Insert flat gasket 40.00 between the unit and
the volute casing 10.20. Tighten hexagonal
nuts 92.00.
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Troubleshooting Page 1 of 1 Chapter 8
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Technical data Page 1 of 3 Chapter 9
9. Technical Data
For technical information about the pump or pump Direction of rotation:
set, which is not described in this chapter, see the Clockwise seen from the drive end of the pump.
specific data sheet. Note that data relating to a Materials of construction, and of shaft seals:
specific order may conflict with information See Chapter 2.4.
provided here. In any such case, the order Vibrations:
specific information will override data provided in ZLND range pumps comply with VDI 2056 and
the general technical documentation. ISO 5199 Class K for pumps with a driving power
Pressure component operating limits: of up to 15 kW and Class M with a driving power
of more than 15 kW
Material Temperature Pressure Sizes Noise levels:
-40ºC to 120ºC 16 bar All The noise levels of the pump comply with the
4B
120ºC to 170ºC 14 bar All Directive 001/30 - 1992 of the EUROPUMP
16 bar 32125 to 80315
-20ºC to 120ºC
10 bar 80400 to 300500 Commission.
0B/0C/0E
14 bar 150500
14 bar 32125 to 80315
The following table provides approximate values:
120ºC to 170ºC
9 bar 80400 to 300500
8 bar 150500
P (kW)
ATTENTION
pump without motor
Note that additional noise can be generated by:
• All indicated operating limits are not valid
• the driver.
for all liquids which can be pumped. See
• a possible misalignment of the coupling.
technical data or delivery note.
• pipework (note: the larger the pipe diameter,
the lower the pipe noise).
Flange locations:
Axial suction flange, discharge flange radially
upwards.
Flanges:
Material design 4B: Complies with DIN 2543
PN16.
Material design 0B, 0C, 0E : DIN 2533 PN16 /
1)
2532 PN10
Flanges drilled according to ANSI 150 can be
supplied.
1)
150-200,150-250 and 200-250
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Technical data Page 2 of 3 Chapter 9
DN Fy Fz Fx ∑F My Mz Mx ∑M
flanges (N) (N) (N) (N) (Nm) (Nm) (Nm) (Nm)
32 400 500 440 780 360 420 520 760
40 400 500 440 780 360 420 520 760
50 540 660 600 1040 400 460 560 820
Top branch z-Axis
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Techical Data Page 3 of 3 Chapter 9
Operating range:
(Continuous operation)
Sizes
32125 to 80400
100315 to100400
0,3 Qopt < Q < 1,1 Qopt
125315 to 125400
150250 to 150500
100160 to 100250
125200 to 125250
0,5 Qopt < Q < 1,1 Qopt
150200
200500 to 300500
0,7 Qopt < Q < 1,2 Qopt 200250 to 200400
This operating range is applicable if waterlike liquids are pumped. If liquids having distinctly different physical
properties are handled, it may be necessary to narrow the permissible operating range.
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Annex Page 1 of 14 Chapter 10
10. Annex
10.1 Connections
Connections for bearing brackets 25, 35 and 45.
u m1 ufo u m1 u k6
1)
Only for Impellers ∅125
u k7
ufo um1
u k4
u s ufo us u k5 u k3
u k8
u k4
u k5 u k6
u k8 u k7
u k3
u k1
u k2
u eo u io
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products at any time without prior notice
Annex Page 2 of 14 Chapter 10
ufo
uk4
uk8
uk9
View X
uk3
Size um1 um2 ue ueo uio ufo uAL um3 uk3 uk4 uk8 umo uk9
150500
200315
200400
200500
250300
250315 G1/4 G1/2 G1/2 G1/4 G1/4 ∅20 G1/2 G1/2 G1/4 G1/4 G1/4 G3/4 G1/4
250400
250500
300400
300500
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Annex Page 3 of 14 Chapter 10
a f x
d l
2
D
øk
DN
2
d
2
h
2
d
1
k6 t
u
h
1
DN
1
øk c
D
m s s
2 2 1
w b 110
m
1 n
2
n
1
All dimensions in mm
Size BB Pump dimensions Foot dimensions End shaft
DN2 DN1 a f h1 h2 b c m1 m2 n1 n2 s1* s2* w x d1 l t u
32125 25 32 50 80 360 112 140 50 15 100 70 190 140 M12 M12 260 100 24 50 27 8
32160 25 32 50 80 360 132 160 50 15 100 70 240 190 M12 M12 260 100 24 50 27 8
32200 25 32 50 80 360 160 180 50 15 100 70 240 190 M12 M12 260 100 24 50 27 8
322501) 25 32 50 100 360 180 225 65 15 125 95 320 250 M12 M12 260 100 24 50 27 8
40125 25 40 65 80 360 112 140 50 15 100 70 210 160 M12 M12 260 100 24 50 27 8
40160 25 40 65 80 360 132 160 50 15 100 70 240 190 M12 M12 260 100 24 50 27 8
40200 25 40 65 100 360 160 180 50 15 100 70 265 212 M12 M12 260 100 24 50 27 8
40250 25 40 65 100 360 180 225 65 15 125 95 320 250 M12 M12 260 100 24 50 27 8
403151) 35 40 65 125 470 225 250 65 18 125 95 345 280 M12 M12 340 100 32 80 35 10
50125 25 50 65 100 360 132 160 50 15 100 70 240 190 M12 M12 260 100 24 50 27 8
50160 25 50 65 100 360 160 180 50 15 100 70 265 212 M12 M12 260 100 24 50 27 8
50200 25 50 65 100 360 160 200 50 15 100 70 265 212 M12 M12 260 100 24 50 27 8
50250 25 50 65 100 360 180 225 65 15 125 95 320 250 M12 M12 260 100 24 50 27 8
503151) 35 50 65 125 470 225 280 65 17 125 95 345 280 M12 M12 340 100 32 80 35 10
65125 25 65 80 100 360 160 180 65 15 125 95 280 212 M12 M12 260 100 24 50 27 8
65160 25 65 80 100 360 160 200 65 15 125 95 280 212 M12 M12 260 100 24 50 27 8
65200 25 65 80 100 360 180 225 65 15 125 95 320 250 M12 M12 260 140 24 50 27 8
65250 35 65 80 100 470 200 250 80 15 160 120 360 280 M16 M12 340 140 32 80 35 10
65315 35 65 80 125 470 225 280 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
80160 25 80 100 125 360 180 225 65 15 125 95 320 250 M12 M12 260 140 24 50 27 8
80200 35 80 100 125 470 180 250 65 15 125 95 345 280 M12 M12 340 140 32 80 35 10
80250 35 80 100 125 470 200 280 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
80315 35 80 100 125 470 250 315 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
804001) 45 80 125 125 530 280 355 80 18 160 120 435 355 M16 M12 370 140 42 110 45 12
1001601) 35 100 125 125 470 200 280 80 18 160 120 360 280 M16 M12 340 140 32 80 35 10
100200 35 100 125 125 470 200 280 80 18 160 120 360 280 M16 M12 340 140 32 80 35 10
100250 35 100 125 140 470 225 280 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
100315 35 100 125 140 470 250 315 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
100400 45 100 125 140 530 280 355 100 18 200 150 500 400 M20 M12 370 140 42 110 45 12
1252001) 35 125 150 140 470 250 315 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
125250 35 125 150 140 470 250 355 80 18 160 120 400 315 M16 M12 340 140 32 80 35 10
125315 45 125 150 140 530 280 355 100 18 200 150 500 400 M20 M12 370 140 42 110 45 12
125400 45 125 150 140 530 315 400 100 18 200 150 500 400 M20 M12 370 140 42 110 45 12
1502001) 35 150 200 160 470 280 400 100 20 200 150 550 450 M20 M12 340 140 32 80 35 10
1502501) 35 150 200 160 470 280 400 100 20 200 150 500 400 M20 M12 340 140 32 80 35 10
150315 45 150 200 160 530 280 400 100 18 200 150 550 450 M20 M12 370 140 42 110 45 12
150400 45 150 200 160 530 315 450 100 18 200 150 550 450 M20 M12 370 140 42 110 45 12
2002501) 45 200 200 160 590 280 400 100 22 200 150 500 400 M20 M12 430 180 42 110 45 12
1)
Transnorm pump sizes, not included in DIN 24255 / EN 733. Flanges drilled according to ANSI 150 on request.
*Holes for bolts of the dimensions indicated.
For local contact details: In the search to improve continuously its products, © (Sterling Fluid Systems BV) 2001
www.sterlingfluidsystems.com Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice
Annex Page 4 of 14 Chapter 10
Table of Dimensions
a f x
l
d2
DN2 øk D
h2
d2
d 1k6 t
u
h1
DN1
øk
D
c
m s s
2 b 2 1
w 140
m n
1 2
n
1
All dimensions in mm
Size BB Pump dimensions Foot dimensions End shaft
DN2 DN1 a f h1 h2 b c m1 m2 n1 n2 s1* s2* w x d1 l t u
1505001) 55 150 200 180 670 400 500 100 22 200 150 640 540 M20 M16 489 180 50 115 53.5 14
2003151) 55 200 250 200 670 355 450 100 22 200 150 550 450 M20 M16 489 180 50 115 53.5 14
2004001) 55 200 250 180 670 355 500 100 22 200 150 550 450 M20 M16 489 180 50 115 53.5 14
2005001) 55 200 250 200 670 425 560 100 22 200 150 660 560 M20 M16 489 180 50 115 53.5 14
2503001) 55 250 300 305 655 425 550 120 28 240 190 700 600 M20 M16 474 180 50 115 53.5 14
2503151) 55 250 300 250 670 375 560 120 28 240 190 620 520 M20 M16 489 180 50 115 53.5 14
2504001) 65 250 300 250 720 400 600 120 29 240 190 700 600 M20 M16 508 180 602) 145 64 18
2505001) 65 250 300 250 720 450 670 120 32 240 190 750 650 M20 M16 503 180 602) 145 64 18
3004001) 65 300 350 300 720 425 670 120 30 250 190 760 660 M24 M16 508 180 602) 145 64 18
3005001) 65 300 350 300 720 480 670 140 32 250 190 840 720 M24 M16 508 180 602) 145 64 18
1)
Transnorm pump sizes, not included in DIN 24255 / EN 733. Flanges drilled according to ANSI 150 on request.
2)
For these sizes the clearance corresponds to M6.
*Holes for bolts of the dimensions indicated.
For local contact details: In the search to improve continuously its products, © (Sterling Fluid Systems BV) 2001
www.sterlingfluidsystems.com Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice
Annex Page 5 of 14 Chapter 10
For local contact details: In the search to improve continuously its products, © (Sterling Fluid Systems BV) 2001
www.sterlingfluidsystems.com Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice
Annex Page 6 of 14 Chapter 10
92.20 94.01 90.30 90.10 91.40 50.70 18.30 93.01 90.12 90.11 94.00
Mechanical Seal
code A93/A9S/A9K
10.20 23.00 50.40 43.30 40.00 16.10 99.99 56.10
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www.sterlingfluidsystems.com Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice
Annex Page 7 of 14 Chapter 10
68.10
10.20 23.00 50.40 43.30 40.00 16.10 90.13 42.10 32.10 50.50 63.80 91.60 40.02 36.00 21.00
92.20 94.01 90.30 90.10 91.40 50.70 33.00 63.81 90.31 18.30 93.01 90.12 90.11 94.00
Mechanical Seal
code A93/A9S/A9K
10.20 23.00 50.40 43.30 40.00 16.10 99.99 56.10
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www.sterlingfluidsystems.com Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice
Annex Page 8 of 14 Chapter 10
68.10
10.20 23.00 52.40 40.00 16.10 40.05 90.23 45.70 45.20 90.13 32.10 50.50 33.00 36.00 42.20 21.00
92.20 94.01 90.30 45.10 46.10 45.80 92.01 90.10 91.40 55.40 90.21 50.70 18.30 93.01 90.12 90.11 94.00
Stuffing box
code 052
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www.sterlingfluidsystems.com Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice
Annex Page 9 of 14 Chapter 10
92.20 94.01 45.10 46.10 45.80 92.01 91.40 90.21 33.00 63.81 90.31 18.30 93.01 90.12 90.11 94.00
90.30 90.10 55.40 50.70
Stuffing box
code 052
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www.sterlingfluidsystems.com Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice
Annex Page 10 of 14 Chapter 10
40.03 23.00 43.30 90.80 73.10 90.22 73.11 50.70 33.00 32.10 36.00 94.00
10.20 50.40 16.10 90.34 40.00 92.06 41.10 70.30 92.02 41.11 47.10 36.01 93.21 63.60 21.00
50.40 23.00 40.00 73.11 47.10 56.10 50.40 23.00 40.00 73.11 47.10 52.30
10.20 43.30 16.10 40.06 41.11 90.24 52.30 10.20 43.30 16.10 40.06 41.11 90.24
For local contact details: In the search to improve continuously its products, © (Sterling Fluid Systems BV) 2001
www.sterlingfluidsystems.com Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice
Annex Page 11 of 14 Chapter 10
40.03 23.00 73.11 90.80 73.10 90.22 50.70 67.20 93.21 90.11 94.00
10.20 50.40 16.10 41.11 90.34 40.00 92.06 41.10 70.30 92.02 47.10 90.14 32.11 33.00 32.10 21.00
50.40 23.00 40.00 73.11 47.10 56.10 50.40 23.00 40.00 73.11 47.10 52.30
10.20 43.30 16.10 40.06 41.11 90.24 52.30 10.20 43.30 16.10 40.06 41.11 90.24
For local contact details: In the search to improve continuously its products, © (Sterling Fluid Systems BV) 2001
www.sterlingfluidsystems.com Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice
Annex Page 12 of 14 Chapter 10
40.03 23.00 73.11 90.80 73.10 90.22 50.70 33.00 32.10 36.00 94.00
10.20 45.80 16.10 41.11 90.34 40.00 92.06 41.10 70.30 92.02 45.20 36.01 93.21 63.60 21.00
Shaft seal
Code 052
For local contact details: In the search to improve continuously its products, © (Sterling Fluid Systems BV) 2001
www.sterlingfluidsystems.com Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice
Annex Page 13 of 14 Chapter 10
40.03 23.00 73.11 90.80 73.10 90.22 50.70 67.20 93.21 90.11 94.00
10.20 45.80 16.10 41.11 90.34 40.00 92.06 41.10 70.30 92.02 45.20 90.14 32.11 33.00 32.10 21.00
Shaft seal
Code 052
For local contact details: In the search to improve continuously its products, © (Sterling Fluid Systems BV) 2001
www.sterlingfluidsystems.com Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice
Annex Page 14 of 14 Chapter 10
COPYRIGHT WARNING
Please read this notice
The material you are viewing in this document is protected
by Copyright and may only be used in accordance with
Copyright, Designs and Patent legislation.
You are not permitted to copy - either in full or in
part - nor substantially extract, reproduce or re-use any
of the contents of this document in any material form or in
any medium without permission from the Copyright
holders or their assignees. Any unlawful use of the
material in this document may result in claims for civil
remedies, including an injunction to restrain further use
and a claim for damages; or may result in criminal penalties.
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www.sterlingfluidsystems.com Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice
SIHI SuperNova Program
These supplementary operating instructions give only general instructions for the
use of pumps in conditions that need explosion protection. The operating
instructions of the specific pump must be taken into consideration as well.
Contents Page
1 General objective 2
2 Safety issues 2
2.1 Identification of safety symbols in the supplementary operating instructions 2
2.2 Compliance with regulations 2
2.3 Qualification and training of personnel 2
2.4 Safety instructions for maintenance, inspection and installation work 3
3 Instructions referring to design of pump and accessories 3
3.1 General 3
3.2 Pump pressure containment components 3
3.2 Coupling, coupling guard 3
3.4 Belt drive 3
4 Instructions referring to installation and start-up of pump sets 3
4.1 Coupling 3
4.2 Connection to power supply 3
4.3 Earthing 3
4.4 Belt drive 3
5 Instructions concerning operation and servicing 3
5.1 Unauthorised modes of operation 3
5.2 Explosion protection 3
5.3 Pump filled and vented 4
5.4 Marking 4
5.5 Fluid pumped 4
5.6 Checking of direction of rotation (see also pump-specific operating manual) 4
5.7 Pump operating mode 5
5.8 Temperature limits 5
5.9 Maintenance 6
1 General Objective
Pumping systems can be operated in hazardous areas. It is the obligation of the operator to define the zone and to
select the pump with the correct category for this zone.
The pump installation and operation must take the Operating Instructions into accounts that are described in these
supplementary operating instructions. They contain important information for safe and reliable pump operation in
hazardous areas. This information plus all information given for all components of the system (e.g. the operating
instructions for the pump) are of vital importance to avoid risks.
These supplementary operating instructions do not take into account national nor local regulations; the operator must
ensure that such regulations are strictly observed by all, including the personnel in charge of the installation.
For any further information or instructions exceeding the scope of this manual or in case of damage please contact
Sterling Fluid Systems nearest customers service.
2 Safety issues
These supplementary operating instructions contain fundamental information concerning all actions with pumping
systems, when operated in hazardous areas like: installation, inspection, operation, monitoring and maintenance.
Therefore these – and all other instructions with related to safety must be known and available with easy access to all
personnel, which is involved in the above stated actions.
Not only must the general safety instructions established in this chapter on ”Safety issues” be complied with, but also
the safety instructions outlined under specific headings as well as the safety instructions contained in the specific
operating manual of the specific pump.
The sign
is used to highlight safety instructions where non-compliance may pose a damage to the pump and its functions.
Ex symbol relates to additional requirements, which must be complied with when the pump is operated in
hazardous areas.
If the pumps / units are located in hazardous areas, it is imperative to make sure that the correct category of
pump and equipment is selected and that unauthorised modes of operation are prevented. Non-compliance may
result in first: increased risk of explosion and second: the specified temperature limits might be exceeded.
Non-compliance with these safety instructions may also result in the loss of any rights to claim damages.
In addition to the hazards indicated in the operating manual of the relevant pump type,
Page 2
2.4 Safety instructions for installation work, inspection operation and maintenance
The operator is responsible to assure that all installation work, inspection, operation and maintenance must be
carried out by authorised and qualified specialist personnel, which is thoroughly familiarised with the pump operating
instructions and these supplementary operating instructions.
3.1 General
The pumps and the accessories for installations in hazardous areas must comply with the relevant category of
mechanical and electrical equipment.
For handling inflammable fluids, the pump pressure containment components must be made of ductile
material.
In hazardous areas coupling guards must be of non-sparking material, whereby the coupling material must be
considered.
4.1 Coupling
The coupling must be installed, started-up and operated in accordance with the operating instructions of the
coupling manufacturer. Misalignment of the coupling may result in inadmissible temperatures at the coupling and
pump and motor bearings. It has to be ensured, that the half couplings are correctly aligned at all times.
Only a properly trained electrician must effect connection to the power supply. The available main voltage
must be checked against the data on the motor rating plate and an appropriate start-up method must be selected.
It is strongly recommend to use a motor protection device (motor protection switch).
In hazardous areas, compliance with national and local regulations form an additional requirement for
electrical connections.
4.3 Earthing
To eliminate risks due to electrostatic charging, the pump set must be earthed directly or through an earthing
line.
Belt-driven pump sets must always be earthed. The condition of the belts must be checked regularly.
Page 3
5 Instructions concerning operation and maintenance
5.1 Unauthorised modes of operation
The warranty relating to the operating reliability and safety of the unit supplied is only valid if the equipment is used in
accordance with its designated use as described in the following sections of this supplementary operating manual
and the pump-specific operating manual. The limits stated in the data sheet must not be exceeded under any
circumstances.
Any operation of the pump outside the permissible operating range and any unauthorised modes of operation
may result in the specified temperature limits being exceeded (see section 5.8).
If the pumps / units are installed in hazardous areas where compliance with EC directive 94/9/EC is required,
the measures and instructions given in the following sections 5.3 to 5.9 must be carried out with no excuse, to ensure
explosion protection.
It is necessary that the system of suction and discharge lines and thus the wetted pump internals including
seal chamber and auxiliary systems are completely filled with the fluid to be handled at all times during pump
operation, so that an explosive atmosphere is prevented.
If the operator cannot warrant this condition, appropriate monitoring devices must be used.
Improper installation (e.g. vertical installation) may impair the self-venting properties of the seal chamber, so that gas
bubbles may be collected in the pump and cause the mechanical seal to run dry.
High negative pressure on the suction side (e.g. due to clogged suction-side strainers or low system pressure)
may result in air intake at the shaft seal forming gas bubbles in the pump. This may also cause the mechanical seal
to run dry. Suitable monitoring facilities shall be installed, if necessary.
For design-inherent reasons, however, it is not always possible to exclude the existence of a certain residual
volume not filled with liquid after the pump has been filled prior to start of operation. However, once the motor is
started up the pumping effect will immediately fill this volume with pumped fluid.
It is imperative to make sure that the seal chambers and auxiliary seal systems are properly vented from air and filled
with liquid.
5.4 Marking
The Ex marking on the pump only refers to the pump part, i.e. the coupling and motor must be considered
separately. The coupling must have an EC Declaration of Manufacturer and the EC marking. The driver must be
treated separately.
Abrasive particles in the fluid handled may erode the casing walls to such an extent that fluid may escape.
When handling inflammable media, it has to be ensured that the fluid does not contain any abrasive particles, or that
the pump is regularly checked with respect to erosion.
5.6 Checking the direction of rotation (see also pump-specific operating manual)
If the explosion hazard also exists during the installation phase, the direction of rotation must never be
checked by starting up the unfilled pump unit, even for a short period, to prevent temperature increases resulting from
contact between rotating and stationary components. If it is not possible to fill the pump, the direction of rotation must
be checked with the pump / motor coupling removed.
Page 4
5.7 Pump operating mode
Make sure that the pump is always started up with the suction-side shut-off valve fully open and the discharge-side
shut-off valve slightly open. However, the pump can also be started up against a closed swing check valve. Only after
the pump has reached full rotational speed shall the discharge-side shut-off valve be adjusted to comply with the duty
point.
Pump operation with closed shut-off valves in the suction and / or discharge pipes is not permitted. In this
case, there is a risk of the pump casing reaching a high surface temperatures after a very short time, due to a rapid
temperature rise in the pumped fluid inside the pump.
Additionally, the resulting rapid pressure build-up inside the pump may cause excessive stresses on the pump
materials and even cause it to burst.
The minimum flows indicated in the relevant pump operating manuals refer to water and water-like liquids. Longer
operating periods with these liquids and at the flow rates indicated will not cause an additional increase in the
temperatures on the pump surface. However, if the physical properties of the fluids handled are different from water,
it is essential to check if an additional heat build-up may occur and if the minimum flow rate must therefore be
increased.
The calculation formula below can be used to check if an additional heat build-up may lead to a dangerous
temperature increase at the pump surface.
To = Tf + ∆ϑ
∆ϑ = ((g * H) / (c * η))*(1 - η)
In normal pump operation, the highest temperatures are to be expected on the surface of the pump casing, at
the shaft seal, at the bearing areas and at the pump shaft end in close coupled executions.
Unless the pump is equipped with an additional heating facility, the surface temperature at the pump casing will
correspond to the temperature of the fluid handled, assuming that the pump surface is freely exposed to the
atmosphere.
In any case, responsibility for compliance with the specified fluid temperature (operating temperature) lies with the
plant operator. The maximum permissible fluid temperature depends on the temperature class to be complied with.
The following limits for the maximum permissible fluid temperature must be observed for the individual temperature
classes as per EN13463-1 given below (temperature increase in the shaft seal area, if any, has been taken into
consideration):
T5 100 º C 80 º C
T4 135 º C 115 º C
T3 200 º C 180 º C
T2 300 º C 280 º C
T1 450 º C Temperature limit of pump
Safety note:
The permissible operating temperature of the pump in question is indicated in the technical data. If the pump is to be
operated at a higher temperature, the technical data are missing or if the pump is part of a pool of pumps, the
maximum permissible operating temperature must be requested from the pump manufacturer.
Page 5
Because of the very close contact between pumps and motors in close coupled design (ZLK and ZLI,
Industrial Pumps; ZTK and ZTI, Thermal Oil Pumps; and ZLI, Hot Water Pumps), there is a thermal influence
between pump and motor.
Especially for motors with protection type EExe (increased safety) the possibility exists that the declaration of
conformity looses its validity, as for the EC type examination an ambient temperature of 40°C is taken as a basis.
This admissible ambient temperature could be exceeded in the area of the motor flange when pumping hot liquids.
In the event of fluid temperature above 80ºC, the temperature category of the unit / set is determined by the pump not
by the motor.
The motor is usually rated for continuous operation at the data indicated in the technical data. Frequent motor
start-ups may result in increased surface temperatures at the motor. Contact the motor manufacturer, if necessary.
Based on ambient temperatures of max. 40 º C and assuming that the pump unit is properly serviced and operated
and that the surfaces in the bearing area are freely exposed to the atmosphere, compliance with temperature class
T4 is warranted for surfaces in the area of the rolling element bearings.
If temperature classes T5 (100ºC) and T6 (85ºC) have to be complied with, special measures may have to taken with
regard to bearing temperature. In such cases, and if ambient temperatures are higher, contact the manufacturer.
Operator’s errors or malfunctions may result in substantially higher temperatures. Please refer to section 5.1 in this
context.
Mechanical seals may exceed the specified temperature limits if run dry. Dry running may not only result from
an inadequately filled seal chamber, but also from excessive gas content in the fluid pumped.
Pump operation outside the specified operating range may also result in dry running.
Shaft seals shall be regularly checked for leakage.
The above stated and also stated in other paragraphs related to the mechanical seal, is also applicable for
any shaft sealing execution (i.e. packing rings, lip seal rings, etc.)
In any case the operator has the responsibility to check the real compatibility between the normal leakage of the fluid
and the atmosphere in the case of shaft sealing made by packing rings.
It has to be verified, that V-rings are properly fitted to the shaft. Only proper contact should be exist between
the sealing lip and the shaft.
5.9 Maintenance
Only a pump set, which is properly operated and maintained in perfect technical condition, will give safe and
reliable operation.
This also applies to the reliable function of the rolling element bearings whose actual lifetime largely depends on the
operating mode and operating conditions.
Regular checks of the lubricant and the running noises will prevent the risk of excessive temperatures as a result of
bearings running hot or defective bearing seals.
The correct function of the shaft seal must be checked regularly.
Any auxiliary systems installed must be monitored, if necessary, to make sure they function correctly.
Static sealing elements shall be regularly checked for leakage.
The coupling guard and any other guards of fast rotating components must be regularly checked for deformation and
sufficient distance from rotating elements.
Regularly verify the correct position and the status of plastic components exposed to the atmosphere.
It is strongly recommended to draw up a maintenance schedule, which includes the above-mentioned points.
In case of repair only original Sterling Fluid Systems spare parts must be used, which comply with the
corresponding EC Directives.
Page 6
Sterling Fluid Systems (Spain), S.A.
Vereda de los Zapateros, s/n
28223 Pozuelo de Alarcon (Madrid) España
Phone: 0034 91 7091310, Fax: 0034 91 7159700
Declaration of Conformity
In the sense of the EU Directive 98/37/EC, Appendix II B
And that is destined for installation in a machine / assembly with other machines to form a
single machine and that it may not be commissioned until it has been determined that the
machine in which this pump is to be installed or with which this pump is to be assembled
complies with the clauses of the EU Machine Directive in the version of 98/37/EC and
94/9/EC.
Unauthorised alterations of the pump unit and any use not in accordance with valid
regulations and / or intended use result in a loss of validity of this declaration.
J. A. Cobo
June 10, 2003
Europe: Sterling Fluid Systems (Italy)
www.sterlingfluidsystems.com/europe Monza, Milan
Telephone.:+39 (0) 39 28 241
Fax: +39 (0) 39 2824 220
Sterling Fluid Systems (Austria) E-Mail: sterlingitaly@sidro.it
Wien
Telephone: +43 (0)1 680 00 50 Sterling Fluid Systems (Romania)
Fax: +43 (0)1 680 0521 Bucuresti
E-Mail: sales_austria@sterlingsihi.de Telephone: +40 (0) 21 610 7188
Fax: +40 (0) 21 210 8287
Sterling Fluid Systems (France) E-Mail: sales_romania@sterlingsihi.de
Trappes
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Fax: +33 (0)1 34 82 39 61 Groot-Bijgaarden
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Fax: +32 (0)2 481 7737
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Athens
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Fax: +30 (0) 210 956 81 21 Itzehoe
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Fax: +31 (0)251 226 309 Veszprém
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Telephone: +41 (0)52 6440606 Sterling Fluid Systems (Polska)
Fax: +41 (0)52 6440616 Warszawa
E-Mail: info@sterlingfluid.ch Telephone: +48 (0) 22 849 7097
Fax: +48 (0) 22 849 6726
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Olomouc
Telephone: +420 587 433 651 Sterling Fluid Systems (Spain)
Fax: +420 587 433 653 Madrid
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Fax: +34 91 715 9700
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Dägeling/Holstein
Telelphone: +49 (0) 4821 9000-0 Sterling Fluid Systems (UK)
Fax: +49 (0) 4821 9000-501 Altrincham/Cheshire
E-Mail: sat@sterlingsat.de Telephone: +44 (0)161 9286371
Fax: +44 (0)161 9252129
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