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SIHISuperNova Programme

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

Intended application Chapter 2


Application, description

Planning the installation Chapter 3


Requirements, piping system, accessories

Unpacking, storage, transport Chapter 4


Supply, interim storage, corrosion protection

Installing the pump Chapter 5


Assembly at site, tools, checks

Start-up and shut-down Chapter 6


Important requirements

Maintenance, dismantling, assembly Chapter 7


Intervals, cleaning

Troubleshooting Chapter 8
If something does not work

Technical data Chapter 9


Dimensions, permissible values

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!

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
Safety issues Page 1 of 3 Chapter 1

1. Safety • the identification plate


This operating manual gives basic instructions, and that these are kept legible.
which must be observed during installation,
operation and maintenance of the pump. It is 1.2 Qualification and training of
therefore imperative that this manual is read by personnel
the responsible personnel / operator(s) prior to The personnel responsible for operation,
assembly and commissioning. It must always be maintenance, inspection and assembly must be
kept available at the site of pump installation. adequately qualified. The scope of responsibility
It is not only the general safety instructions and supervision of the personnel must be exactly
contained in this chapter “Safety” which must be defined by plant management. If the staff do not
observed, but also the specific information have the necessary knowledge, they must be
provided in the other chapters. trained and instructed. This task may be
performed by the machine manufacturer or
1.1 Identification of safety supplier on behalf of the plant management.
symbols in the operating Moreover, plant management must ensure that
instructions the contents of the operation instructions are fully
Safety symbols are given in these operating understood by plant operators and other relevant
instructions. Non compliance with these would personnel such as maintenance staff.
affect safety and are identified by the following
symbol 1.3 Hazards in case of non
compliance with safety
instructions
Non compliance with the safety instructions may
result in risk to personnel as well as to the
Danger symbol as per DIN 4844-W9 environment and the pump/pump set and result in
(ISO 3864 - B.3.1) the loss of any right to claim damages.
For example, non-compliance may result from, or
Or in case of danger of electric current with: lead to, the following:
• failure of important functions of the pump/pump
set/plant
• failure of specified procedures of maintenance
and repair
Danger symbol as per DIN 4844 W-8 • exposure of people to electrical, mechanical
(ISO 3864 - B.3.6) and chemical hazards
The word • danger to the environment owing to hazardous
ATTENTION substances being released.

identifies those safety regulations where non-


compliance may pose a danger to the pump and
its function. It is imperative that the appropriate
safety information is attached to the pump/pump
set, for example:
• an arrow indicating the direction of rotation
• symbols indicating fluid connections
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.
Safety issues Page 2 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.

1.5 Safety instructions relating to


operation
• If high or low temperature pump/pump set In this section information is given for operation in
components involve hazards, steps must be areas where an explosion hazard exists.
taken to avoid accidental contact.
• Guards for moving parts (e.g. couplings) must
1.7.1 Complete pump sets
not be removed from the pump/pump set while If the pump is combined with other mechanical or
in operation. electrical components in one set, the category of
• Any leakage of hazardous (e.g. explosive, the complete unit will correspond, based upon the
toxic, hot) fluids (e.g. from the shaft seal) must Directive 94/9/EC, only to that category with which
be drained safely so as to prevent any risk to all of its components comply.
persons or the environment. Statutory
regulations are to be complied with. Note:
• Hazards from electricity are to be avoided by These comments are of particular importance
the user (see for example the VDE- when pumps, which conform to a given category
specifications and the bye-laws of the local of Directive 94/9/EC, are powered by a driver
power supply utilities). which is not in the same category.
Although the pump may bear the Ex sign, the set
1.6 Safety instructions relevant for should not be used in areas with an explosion
maintenance, inspection and hazard when the motor is not classified for this
assembly work application.
It is the plant manegement’s responsibility to This means that plant management personnel
ensure that all maintenance, inspection and should always check that all elements of the set
assembly work is performed by authorized comply with the Directive 94/9/EC.
personnel who have adequately familiarised
themselves with the subject matter by studying
1.7.2 Execution of coupling guards
this manual in detail. Coupling guards that are to be used in areas with
Any work on the machine must only be performed an explosion hazard, have to fulfil one of the
when it is at a standstill. It is imperative that the following criteria:
procedure for shutting down the machine • consist of non-sparking material, e.g. brass.
described in this manual is followed. • if they consist of sparking material, e.g. steel
Pumps and pump sets, which convey hazardous sheet, they must be designed in such a way
media, must be decontaminated. that the rotating parts will not come in contact
On completion of the work all safety and with any part of the guard if errors, that could
protective guards must be re-installed and made be foreseen, are committed by the user, e.g if
a person steps on the guard.
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.
Safety issues Page 3 of 3 Chapter 1

1.7.3 Monitoring technical 1.10 Warranty / guarantee


parameters Sterling Fluid Systems guarantee satisfactory
When using pumps in areas with an explosion operation if:
risk, the operator must check the following • the pump is installed and operated in
parameters regularly: compliance with these instructions and in
• leakage of shaft seals operating conditions approved by Sterling Fluid
• bearing temperature Systems
• that the pump is always filled with liquid during • modifications are only undertaken with Sterling
operation Fluid Systems’ written agreement.
• that the pump does not operate against a
closed valve for any length of time.
The operator must ensure that pumps, which
show evidence of abnormal operation, are
switched off and not started again until the cause
of the abnormal operation has been eliminated.

1.7.4 Avoiding external damage


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

1.8 Unauthorized alterations and


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

1.9 Unauthorized mode of operation


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

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.
Intended application Page 1 of 3 Chapter 2

2. Application 2.3 Construction and mode of


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

• The pump may only be used for the


application(s) stated. Otherwise hazards for
people and environment may arise.

ATTENTION

• Do not exceed fluid density stated.


Otherwise, there is a the danger of motor
overload.
• The pump must not be operated beyond its
characteristic curve – otherwise there is a
danger of cavitation and motor damage.

2.2 Accessories
The accessories included in the scope of supply
are indicated in the delivery note or in the order
confirmation. The corresponding operating and
installation instructions are also indicated in the
Annex relating to accessories.
If it is intended to mount other accessories on the
pump or on the pump set, please inform the
manufacturer in advance in order that appropriate
technical advice can be given.

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
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

For local contact details: In the search to improve continuously its products,  (Sterling Fluid Systems BV) 2001
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products at any time without prior notice
Intended application Page 3 of 3 Chapter 2

Example of a pump designation: 2.5 Shaft sealing


Depending on the application, different shaft
1-3 4 5-7 8-10 11 12 13-15 16-17 18 sealing executions are offered (see 2.4)
ZLND 125 250 A C 041 OB 2 • a stuffing box with lantern ring (executions
041, 052, and optionally 051) or mechanical
Casing gasket
seals according to DIN 24960 are utilised in
Construction the following cases:
Shaft sealing • if the pump draws from a suction line,
Bearings:B,C,S,T or 2 • if the pump is fed by a feed line with a
Hydraulic: A/B/D pressure of less than 0.5 bar or
• if the pumped liquid is at or near its boiling
Impeller size
point.
Nominal discharge Provision of the sealing liquid is as follows:
• 041: Internal self sealing ISO 5199 plan 01
• 052: External self sealing ISO 5199 plan 08
Pump series
• 051: External self sealing ISO 5199 plan 09
• Mechanical seal: ISO 5199 plan 02. API plan
11
• Mechanical seal execution plus external
flushing: ISO 5199 plan 08, API plan 32
Mechanical seal execution plus quench: ISO
5199 plan 09. API plan 62.

ATTENTION

Section 2.4 does not contain the codes for all


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

For local contact details: In the search to improve continuously its products,  (Sterling Fluid Systems BV) 2001
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products at any time without prior notice
Planning the installation Page 1 of 2 Chapter 3

3.0 Planning the installation

3.1 Piping system Ensure that air pockets cannot be created.


Unequal nominal widths of the suction branch and
suction line must be compensated by eccentric
ATTENTION
transition pieces.

• Note the arrows on the pump branches


indicating the direction of flow. Flow straightener

• Choose nominal widths of the pipelines


according to the nominal widths of the pump
branches or larger ones with the
corresponding reductions.
• Flange sealing must not protrude on the
inside.
• Ensure that the pipework is clean before
installing of the pump. Connection of eccentric pipe transitions
• Support the pipework in order to avoid
distortions at the pump components (risk of It is recommended that a filter is installed in front
damage to pump components) of the pump with a filter surface of at least 3 times
• Avoid abrupt changes of cross section and the pipe cross section (approx. 100 meshes/cm²).
direction.
• Where different diameter pipework is to be The suction opening of the suction line should be
used, connection should be by eccentric well below the liquid level, and a strainer should
transition pieces. This will avoid the formation be used.
of air pockets in the pipework. The strainer must be far enough from the bottom
• For difficult pumping on the suction side, to to avoid excessive inlet losses, which could impair
stabilise the flow, a pipe length 15 times the pumping performance. It is advisable to check that
diameter of the suction branch should be there is no leakage.
installed before the suction branch. 7
• The flow rate in the suction line or inflow line, 6

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


4
4

3.1.1 Suction line / inflow line


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

positive suction head operation suction lift operation

For local contact details: In the search to improve continuously its products,  (Sterling Fluid Systems BV) 2001
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products at any time without prior notice.
Planning the installation Page 2 of 2 Chapter 3

A shut-off valve should be installed in the feed


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

3.1.2 Discharge line


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

3.1.3 Inlet and outlet connections


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

3.1.4 Pressure control


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

3.2 Electrical connections


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

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.
Unpacking, storage, transport Page 1 of 2 Chapter 4

4. Unpacking, storage, handling 4.4 Handling


The pump or pump set must be lifted and handled
4.1 Safety measures as shown in the following sketches.

• Never stay below the suspended load.


• Keep a safe distance while the load is being
transported.
• Use only approved lifting appliances, which
are in good condition.
• Adjust the length of the lifting appliances in
such a way that the pump and/ or the pump
set, is suspended horizontally. Pump without motor

• Do not use the eyebolts on the pump


components for lifting the assembled pump or
the complete set.
• Do not remove documents, which are
attached to the pump.
• Do not remove the protection covers from the
pump suction/discharge. Otherwise, there
may be a risk of contamination.

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

For local contact details: In the search to improve continuously its products,  (Sterling Fluid Systems BV) 2001
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products at any time without prior notice
Unpacking, storage, transport Page 2 of 2 Chapter 4

4.5.2 Renewing corrosion protection


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

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products at any time without prior notice
Installing the pump Page 1 of 3 Chapter 5

5. Installing the pump

5.1 Requirements 5.4.3 Base, foundation


The pump and the pump set, must have been The pump must be installed on a flat floor or
unpacked and handled as described in Chapter 4. foundation free from vibration. In case of doubt
use vibration dampening feet.
5.2 Use of trained staff The pump set must be correctly mounted on the
Only appropriately trained staff must undertake foundations. To avoid distortion of the pump set
the work described in this chapter. and/or the foundation, parallel shims must be
used between the base plate and foundation.
5.3 Safety measures Prior to installing, checks should be made with
regard to:
- possible damage to the pump or the
pump set that may occur in transit
- ease of running ( check that the shaft is
free to rotate by hand )
• Connect the pipework carefully to prevent the - the foundation dimensions.
pumped liquid escaping during operation and The following preparatory work must be carried
endangering operating personnel. out before to placing the pump:
• Ensure that the suction or inflow line, and the - roughen and clean foundation surface
discharge line are closed by valves. - remove shuttering/cores from the anchor
• Ensure that all electrical connections are holes
“dead”. Otherwise, there is a risk of electric - blow the anchor holes clean
shock. - check the position and dimensions of
• Pay attention to relevant internal plant the anchor holes against the arrangement
regulations. drawing.
• Avoid accidental contacts with hot
components. 5.4.4 Installation of the set
ATTENTION
• Remove the protective coating by following The complete set mounted on the base plate must
the instructions of Chapter 4. Otherwise there be placed on the foundation with its foundation
is a danger of contamination . (rag) bolts hanging below the baseplate.

5.4.5 Space required


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

5.4.2 Permissible ambient conditions


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

For local contact details: In the search to improve continuously its products,  (Sterling Fluid Systems BV) 2001
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products at any time without prior notice
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.

5.6 Alignment of the set

Place shims under the base plate on both sides of


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

For local contact details: In the search to improve continuously its products,  (Sterling Fluid Systems BV) 2001
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products at any time without prior notice
Installing the pump Page 3 of 3 Chapter 5

5.9 Mounting the pump and


installation into pipework
The following instructions must be carried out:

1. remove the protective covers from the pump


flanges and the auxiliary pipework
connections.
2. correctly insert the flange seals.
3. connect the suction or feed line.
4. connect the discharge line

The pump must be aligned with the pipework. The


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

5.10 Final work


The following final steps must be undertaken:
1. check the tightness of the connecting flanges.
2. check for easy running of the pump (for that
purpose turn the motor fan or the coupling).
3. check the coupling alignment.
4. install the coupling guard.

5.11 Hydrostatic pressure test


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

• The max. permissible pressure for a


pressure test is 1.3 times the nominal
pump pressure.
• The nominal pump pressure is indicated
in the technical data sheet.

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products at any time without prior notice
Starp-up and shut-down Page 1 of 3 Chapter 6

6. Start-up and shut-down


operations

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.

• Electrical connections must be made 6.4 Electrical connection


according to the European Regulations and The motor must be connected at set out in the
Directives for the Standards in Industry and in circuit diagram in the terminal box.
compliance with the instructions of the local
power supply utilities of the country 6.5 Checks before switching-on
concerned. Before switching on the pump unit, the following
• Only appropriately authorized personnel may points should be checked:
carry out this work. 1. is all pipework connected and are the unions
tight?
ATTENTION 2. is the pump including the pipework filled
properly?
• Fill the pump correctly; otherwise the shaft 3. is the shut-off valve in the discharge line
seal could be destroyed. closed?
• Fill the supply lines correctly. 4. is the shut-off valve in the suction line
• Check the direction of rotation only when the completely opened?
pump is filled. 5. is the motor ready for operation?
• Fill the pump slowly if hot media are being 6. is the direction of rotation of the motor
pumped in order to avoid distortions or heat correct?
shock. (check by running the motor for a short time)
• When handling explosive, toxic, hot, 7. is the coupling aligned exactly?
crystalline or corrosive media, ensure that 8. has the shaft seal been installed?
there is no risk to people or the environment. 9. are the supply lines, if any, to the shaft seal
• Control the output at constant speed at the open?
discharge side only. The valve at the suction 10. in the case of oil lubrication - has the bearing
side must always be completely open during housing been correctly filled with oil?
operation to avoid the risk of cavitation. 11. is the gland finger slightly tight?.

For local contact details: In the search to improve continuously its products,  (Sterling Fluid Systems) 2001
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products at any time without prior notice.
Starp-up and shut-down Page 2 of 3 Chapter 6

6.7 Switching frequency

Size Permissible number of


starts equally spaced
per hour
32-125, 32-160, 32-200, 32-250,
40-125, 40-160, 40-200, 40-250,
50-125, 50-160, 50-200, 65-125,
65-160, 65-200, 65-250, 80-160, 15
80-200, 80-250,100-160,
Fasten gland nuts 100-200, 100-250, 100-315,
125-200, 150-200, 150-250
40-315, 50-250, 50-315, 65-315,
80-315, 80-400, 100-400,
125-250, 125-315, 125-400,
6.6 Start-up operation 150-315, 150-400, 150-500, 8
200-250, 200-315, 200-400,
For starting proceed as follows: 200-500, 250-300, 250-315,
1. open fully the valve on the suction side 250-400, 250-500, 300-400, 300-500

2. close the valve on the discharge side


3. switch on the motor
4. check the pressure gauges at the pressure 6.8 Special instructions
measuring points During operation the following points must be
If the pumping pressure does not increase observed:
consistently with increasing speed, switch off the - control the speed and the delivery head
motor again and vent the pump one more. - ensure that the pump runs without vibration
5. After reaching operating speed, regulate the - control the liquid level in the suction line and/or
operating point of the pump by adjusting the inflow tank
valve in the discharge line (see technical data - control the bearing temperature (max.
for permissible range of operation). temperature 100 °C)
6. For “running in” the packing, the gland should - control the pressure in the supply lines according
be tightened only slightly (even in the case of to the following limits:
considerable leakage initially). After approx. External flushing:
30 minutes tighten the gland to such an extent • Impeller size 125
that it leaks only slightly. Check it several Buffer pressure = pW + 0,5 bar
times, until leakage from the packing is about • Rest of impeller sizes:
20 to 40 drops a minute. In extreme operating Buffer pressure = pW + H + 2,5 bar

3
conditions and high temperatures this rate Flow = 0,1 – 0,2 m /h
may be higher. pW = suction pressure, in bar
H = differential pressure of pump, in bar
Pumping against a closed valve in the discharge
line is permitted only if a minimum output via a Quench
bypass line is guaranteed. Maximum pressure = 4 bar
Heating
Maximum pressure = 4 bar, with
water steam to 140 C

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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

For executions with stuffing box: If the leakage


increases considerably and cannot be adjusted by
retightening the gland, the packing is worn and
must be replaced by a new one.
For executions with mechanical seal: If the initial
leakage does not disappear within 5 minutes of
operation, stop the pump, dismantle the seal and
check for damage of the seal faces and auxiliary
sealing.

6.9 Shutting-down
Before shutting down close the valve on the
discharge side.
After shutting down, all valves may be closed. The
valves of the auxiliary pipework connections,
(quench, heating, external flush, code 052, code
051), have to be closed in the last place.
If there is a risk of very low ambient temperatures,
remove the pump and then drain it using the
threaded plug 90.30.

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products at any time without prior notice.
Maintenance, dismantling, assembly Page 1 of 10 Chapter 7

7. Maintenance, dismantling, grease nipple


assembly

7.1 Requirements
The pump or the pump set must have been shut
down in the manner described in Chapter 6.

7.2 Use of trained staff


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

lubrication low activity middle and high


intervals activity
for grease n ≤ 1500 1/min 1500 < n ≤ 3000 1/min
lubrication every 5000 hours every 2500 hours
• For explosive, toxic, hot, crystalline as well as at the latest after 12 months
different pumping media ensure that people
and the environment are not endangered. After about 10000 hours of activity or the latest
• Flush the pump with clean liquid before after two years, the bearings have to be
dismantling. disassembled, washed and refilled with grease.
• The working place for disassembly or Under extremely unfavourable circumstances (wet
assembly must be clean. or dusty environment or high temperatures of the
• Before reinstallation, the pump must be free of environment) the lubrication intervals have to be
any dangerous material. chosen considerably shorter.
For renewing or adding lubrication grease, only
lithium soap bearing grease have to be utilised
7.4 Maintenance and inspection (e.g. Mobilux 2, Shell Aero Grease 16, Esso
The pump requires only limited maintenance. Unirex N3).

7.4.1 Bearing with grease lubrication


The pumps with bearing brackets 25, 35 and 45
use an antifriction bearing, lubricated for service
life, on the drive side and on the pump side.
The pumps with bearing brackets 55 and 65 must
be greased through grease nipples 63.60.

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Maintenance, dismantling, assembly Page 2 of 10 Chapter 7

7.4.2 Bearing with oil lubrication Oil change intervals


The pump is supplied empty (no oil). Before the If the bearings are new, change the oil after about
initial start up, pour oil into the oil inlet hole until 200 hours and subsequently annually. These
the oil level reaches the mark on the dipstick. intervals only apply if the bearing temperature
does not exceed 50 ºC. If the bearing temperature
during operation is above 50 ºC but below 80 ºC
and/or if there is danger of contamination, the oil
Oil filling
should be renewed about every six months.
Oil properties:
Operating Ambient temp.
temp. of < 0ºC
bearing up
to 80ºC
n≤1500 n>1500
rpm rpm

Type of lubrication CL68 CL46 CL22


DIN 51517

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 )

oil and put into its correct position. 25 0.22


The bearing housing will be supplied with oil from 35 0.38
the constant level oiler with the correct amount as 45 0.57
long as there is oil in the reservoir. 55 1.50
See sketch of oiling system below 65 2.00
1. Oil reservoir
2. Screw-in elbow ATTENTION
3. Fill in oil here
4. Never fill with oil here, always use the oil inlet The lubricating oil must be extremely pure,
hole. resistant to ageing, must have good viscosity-
temperature behaviour, good water separating
properties and corrosion protection.

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Maintenance, dismantling, assembly Page 3 of 10 Chapter 7

7.4.3 Stuffing box 7.4.4 Mechanical seal


If leakage makes it necessary, the packing rings The mechanical seal should have little or no
should be retightened. After extended periods and visible leakage. Where there is considerable
frequent retightening, the packing rings gradually leakage, check the mechanical seal. To do this, it
lose their shape and elasticity. We therefore is necessary to dismantle the rotating part(s).
recommend replacing the packing material at 43.30 16.10

regular intervals. As a typical indication, after an


operating time of approx. 2500 hours or when the
gland has been retightened by approximately half
the width of a packing ring.
Repacking
When repacking, the stuffing box rings used up,
as well as, the lantern ring are to be removed
50.40 21.10

carefully from the shaft seal chamber. The shaft


and shaft protection sleeve must not be
damaged. 7.4.5 Drive motor
Otherwise perfect sealing cannot be guaranteed The drive motor must be maintained according to
and the shaft sleeve would then need replacing. the instructions of the manufacturer.
If the pump is installed, cut soft packing rings
diagonally, bend them in a spiral shape, position
them on the pump shaft and bend them carefully 7.5 Dismantling
into a ring form.
Push the packing rings as well as the lantern ring 7.5.1 Preparation for the dismantling
by means of the gland into the shaft seal
chamber. The cut joints should be staggered by Proceed as follows:
180°. Tighten the nuts at the gland steadily until • disconnect power to the motor
resistance is felt when rotating the pump shaft by • drain the plant, at least within the pump area,
hand. Remove the gland again and fasten the i.e. between the valves on the suction- and
nuts slightly. If the pump is removed in order to discharge side
carry out repacking, it is useful to push the • if necessary, disconnect any measuring
packing rings in the delivered condition, that probes or control devices and remove them
means closed over the shaft sleeve. • drain liquid from the pump by means of the
drain plug
Lantern ring
• dismantle shaft seal supply lines, if any.
If oil lubricated bearings are used, drain the oil
from the bearing housing.
• the pump casing must not be detached from
the pipe union
• remove motor mounting bolts and move the
Packing rings motor so that there is sufficient space to
remove the back pull out unit. When using a
spacer coupling repositioning of the motor is
not necessary.

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Maintenance, dismantling, assembly Page 4 of 10 Chapter 7

• dismantle guard coupling, pump feet and


coupling. Design with stuffing box
1. Remove the Allen head screws 91.40 and
7.5.2 Replacement parts detach the casing cover 16.10.
The item numbers necessary for ordering spare 1. Detach hexagonal nuts 92.01 and studs
parts are provided in the component parts list in 90.21.
the Annex. 2. Loosen hexagonal screws 90.23 and detach
packing housing 45.10 and gland 45.20 with
7.5.3 Dismantling the pump the pressure ring 45.70.
• For executions with bearing housings 25,35 3. Detach packing ring 46.10 and lantern ring
and 45. 45.80.
10.20 40.00 90.10
4. Detach the shaft sleeve 52.40.

16.10 40.05 45.10 90.23 45.70 52.40 91.40

46.10 45.80 92.01 45.20 90.21 55.40 92.01

90.30

Design with a mechanical seal


1. Mark the position of the parts in relation to
each other by a coloured pencil or a scribing 1. Detach the distance ring 50.40.
tool. 2. Remove the rotating part of the mechanical
2. Remove the hexagonal screws 90.10. seal 43.30.
3. Remove the back pull out unit from the volute 3. Remove the Allen head screws 91.40 and
casing 10.20. detach the casing cover 16.10.

90.13 68.10 92.20 23.00 94.01 50.40 43.30 16.10 91.40

68.10 90.13

4. Remove flat gasket 40.00.


5. Remove hexagonal screws 90.13 and remove
protective screen 68.10.
6. Loosen impeller nut 92.20.
7. Remove impeller 23.00 and key 94.01.

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Maintenance, dismantling, assembly Page 5 of 10 Chapter 7

Design with quench (AX3, AXS, AXK) Bearing design B, C or 2 :


Detach the cover 16.50, O-ring 41.23 and lip 1. Release hexagonal screws 90.11, remove
seals 42.11. V-seal 42.20 in case of grease lubrication,
dismantle bearing cover 36.00 and flat gasket
16.10 41.23 42.11 16 .50 40.02. Remove the lip seal 42.10 if pump is oil
lubricated.
2. Release the thrower 50.70
3. Undo hexagonal screws 90.12, remove
washer 93.01 and dismantle the pump foot
18.30.
4. For oil lubricated pumps, remove the oil dip
stick 91.60 and remove the constant level
oiler (CLO) 63.80 if any.

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

Detach the cover 16.50, O-rings 41.22 and


41.23.

16.10 41.22 41.23 16. 50

18.30 93.01 90.12

5. Pull out complete shaft 21.00 with both ball


bearings 32.10 and support washers for ball
bearing 50.50 if any.
6. Remove ball bearings 32.10 and support
washers for ball bearing 50.50.

32.10 50.50 21.00 50.50 32.10

4. Remove the static part of the mechanical seal


43.30 and pin 56.10.

43.30 16.10 56 .10

• For executions with bearing housings 55 and


65:
90.80
10.20 90.20 40.00 92.00 92.06

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.

40.01 52.30 50.40 43.30 16.10 90.22 40.06 47.10

4. Loosen impeller nut 92.20 and helicoil 93.00.


5. Remove impeller 23.00, key 94.01 and flat
gasket 40.03. Unscrew hexagonal nuts 92.02
and detach the casing cover 16.10.

Design with a stuffing box: 56.00 50.21 56.10 90.24

1. Remove hexagonal nuts 92.01 and studs Bearing design S or T :


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

90.14 36.01 63.60 42.10 40.02 50.70 33.00 93.21 40.02 42.10 36.00 63.60 94.00 90.11

18.30 93.01 90.12


56.00 50.21 90.21 55.40 92.01

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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:

Thread M8 M10 M12 M16 M20 M24 M30 M36

Torque 12 25 40 90 175 300 500 700

Nm Nm Nm Nm Nm Nm Nm Nm

7.6 Post dismantling activities 7.7.2 Pump assembly


Proceed as follows:
7.6.1 Hints for cleaning. Bearing design B, C or 2 :
• Clean all parts. • For executions with bearing housings 25,35
• Clean the clearances and sealing surfaces and 45:
with an appropriate liquid. 1. Prior to installing bearings, the support
washer for ball bearing 50.50 must be
7.6.2 Points to be checked replaced, (only bearing housing 25). Install
The following pump components, if installed, must ball bearings (use new ball bearings, if
be checked: necessary). Before installation, the ball
• Mechanical seal : If the running faces are bearings must be heated to 80ºC in an oil
damaged or worn, replace the mechanical bath.
seal. (Only bearing design C or 2).
• Shaft and shaft sleeve : Check the shaft 2. For a pump with oil lubrication, using a tool,
within the stuffing box. If the shaft has worn press lip seal 42.10 in the bearing housing
badly and is grooved, a new shaft or shaft 33.00. When lip seals are used, the lip should
sleeve should be used. point towards the drive end.
• Clearances : The difference in diameter 32.10 50.50 21.00 50.50 32.10

between impeller clearance area and casing


or cover clearance area should be 0.3 mm to
0.5 mm. In the case of excessive wear in the
clearance area, wear rings must be installed.
• Radial seal ring : If the radial seal ring is
damaged, it must be replaced.
3. Insert the shaft assembly into the bearing
housing from the drive end towards non-drive
end.

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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

18.30 93.01 90.12

6. Fasten pump foot 18.30 and insert the thrower


50.70.
Design with quench (AX3, AXS, AXK)
• For executions with stuffing box: Insert the lip seals 42.11 and the O-ring 41.23 in
the cover 16.50.
7. Position the shaft sleeve 52.40 on the shaft.
8. Insert the packing housing 45.10 with the 16.10 41.23 42.11 16 .50

gasket 40.05 in the casing cover 16.10.


9. Install one of the packing rings 46.10 in the
packing housing, the lantern ring 45.80 and
then, the remaining packing rings.
10. Fasten hexagonal screws 90.23 , fix the studs
90.21 and hexagonal nuts 92.01.

16.10 40.05 45.10 90.23 45.70 52.40

Attach the cover 16.50 and casing cover 16.10.

16.10 1 6 . 50

46.10 45.80 92.01 45.20 90.21 55.40 92.01

11. Finally, install the pressure ring 45.70 and the


gland 45.20. Fix the washer 55.40 and the
following hexagonal nuts 92.01.
12. Adjust the stuffing box as described in
Chapter 7.4.3.
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Maintenance, dismantling, assembly Page 9 of 10 Chapter 7

Design with heating (AY3, AYS, AYK) 10.20 40.00 90.10

Insert the O-rings 41.22 and 41.23 in the cover


16.50.

16.10 41.22 41.23 16. 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

protective screens 68.10 with the hexagonal


screws 90.13.

90.13 68.10 92.20 23.00 94.01 50.40 43.30 16.10 33.00 91.40

4. Install the bearing cover of the pump side with


68.10 90.13 the flat gasket 40.02 and the grease nipple
11. Insert the gasket 40.00 between the pull out 63.60 if any.
unit and volute casing. Tighten hexagonal
screws 90.10.
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Maintenance, dismantling, assembly Page 10 of 10 Chapter 7

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

18.30 93.01 90.12

• For executions with stuffing box:

9. Mount the shaft sleeve 52.40 on to the shaft 56.00 50.21 56.10 90.24
unit.
12. Join the casing cover 16.10, the bearing
10. In the casing cover, insert one of the packing
housing 33.00 and fasten hexagonal nuts
rings 46.10, the lantern ring 45.80, the
92.02.
remaining packing rings and finally the gland
45.20. 92.20
93.00 40.03 23.00 94.01 16.10 90.22 92.02

11. Fix the studs 90.21, the washers 55.40 and


the nuts 92.01. Adjust the stuffing box as
described in Chapter 7.4.3.
12. Mount the wear rings 50.21 with grub screws
56.00.

16.10 90.22 46.10 45.80 45.20 40.01 52.40

Finally:
13. Insert the flat gasket 40.01, keys 94.01,
impeller 23.00 and flat gasket 40.03.
14. Tighten the impeller nut 92.20 with the helicoil
93.00.
15. Insert the wear ring 50.20 with grub screws
56.00 and then, insert studs 90.20.
56.00 50.21 90.21 55.40 92.01 16. Insert flat gasket 40.00 between the unit and
the volute casing 10.20. Tighten hexagonal
nuts 92.00.

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Troubleshooting Page 1 of 1 Chapter 8

8. Help in case of trouble

8.1 Use of trained staff


Trouble shooting must be undertaken only by appropriately trained personnel.

8.2 Symptoms, causes and remedies

Symptom Cause Remedy


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

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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

Shaft sealing operating limits: LWA (dB)

Shaft sealing execution Temperature range


041, 052 -40°C to + 110°C
BJ3, BJS, BJJ -20°C to + 120°C
AF3, AX3, AY3, A93 -30°C to +150°C
AFS,AXS,AYS,A9S,AFK,AXK,AYK,A9K -20°C to + 180°C
C23, C2S, C2J -40ºC to + 150ºC

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

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.
Technical data Page 2 of 3 Chapter 9

Permissible branch forces and moments:

Values according to ISO/DIN 5199 – Class II


(1997) – Annex B, Family Nº 2 for mounting on
sheet metal baseplates and frames without
grouting for pumping temperatures up to 110 ºC
and up to 120 ºC for grouted baseplates / frames.

• Material execution 0B / 0C / 0E:

DN Fy Fz Fx ∑F My Mz Mx ∑M
flanges (N) (N) (N) (N) (Nm) (Nm) (Nm) (Nm)
32 400 500 440 780 360 420 520 760
40 400 500 440 780 360 420 520 760
50 540 660 600 1040 400 460 560 820
Top branch z-Axis

65 820 1000 900 1580 460 520 640 940


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

80 900 820 1000 1580 460 520 640 940


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

• Material execution 4B:


Multiply by ƒ = 1,536; which is the relationship of
E – modules between 1.4408 and GG-25.

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.
Techical Data Page 3 of 3 Chapter 9

Maximum permissible speeds at 50 Hz:

Max. speed Max. speed Max. speed Max speed


Size rpm Size rpm Size rpm Size rpm
32125 32160 32250 403154)503154)
32200 40125 40250 653154) 803154) 150500 200315
40160 40200 3600 50250 3000 80400 100315 1800 200400 200500 1500
50125 50160 65250 100400 125250 250300 250315
50200 65125 80250 125315 125400 250400 250500
65160 652001) 1002502) 150200 1502503) 300400 300500
801601) 80200 1252002) 150315 150400
100160 100200 200250

For material specification 4B:the max. speed changes to : 1) 3000 rpm 2)


1800 rpm 3)
1500 rpm
4)
In material specification 0E and 4B max. speed 3000 rpm

Operating range:

(Continuous operation)

Sizes

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.

See the specific performance curve for more details.

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 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

ueo uio uAL ue um2 u k1 u eo u io


u k2
um1 : Pressure gauge. Only available on request uk1 : Quench Inlet
um2 : Pressure gauge. Only available on request uk2 : Heating Inlet
ue : Drainage uk3 : 051 Inlet (Stuffing box)
ueo : Oil drainage uk4 : 052 External sealing (Stuffing box)
uio : Constant level oiler (CLO) uk5 : External Flushing
ufo : Oil filling uk6 : Quench Outlet
uAL : Drainage for leakage. Threaded hole only available on request uk7 : Heating Outlet
us : Sensor uk8 : 051 Outlet (Stuffing box)
Size um1 um2 ue ueo uio ufo uAL us uk1 uk2 uk3 uk4 uk5 uk6 uk7 uk8
321251)
32160
32200
32250
401251)
40160
40200 G1/4
40250
40315
501251)
50160
50200 G1/8
50250
50315
651251)
65160
65200
65250
65315
80160 G1/4
80200
80250
80315 G1/4 ∅15.65 ∅13 M8
80400 G1 / 4
100160
100200 G3/8
100250 G1/8
100315
100400 G1 / 4
125200
G1/8
125250
125315
G1 / 4
125400
150200
G1/8
150250
150315
150400 G1 / 4
200250

Drawings are indicative only.

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 2 of 14 Chapter 10

Connections for bearing brackets 55 and 65

um1 um3 ufo um1

ufo
uk4
uk8
uk9
View X

uk3

uio umo ueo uAL ue um2 ueo uio umo


uAL

um1 : Self sealing connection um3 : Pressure gauge connection


um2 : Pressure/vacuum gauge. Only available on request uk3 : 051 Inlet (Stuffing box)
ue : Drainage uk4 : 052 External sealing (Stuffing box)
ueo : Oil drainage uk8 : 051 Outlet (Stuffing box)
uio : Constant level oiler umo : Oil level control
ufo : Oil filling uk9 : 041 inlet (Stuffing box)
uAL : Drainage for leakage

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

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 3 of 14 Chapter 10

10.2 Table of Dimensions

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.

Flange connections to DIN 2501 PN 16 DIN 2501 PN 10


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

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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 5 of 14 Chapter 10

10.3 Parts list

When ordering spare parts give the following


information: position number, the complete pump
designation and the serial number, which can be
found on the nameplate fixed to the pump.

Pos. Nr. Description Pos. Nr. Description

10.20 Volute casing 64.20 Oil level sight glass


10.200 Casing plug 67.20 Plug
10.201 Hexagonal screw 68.10 Protection screen
10.202* O-ring 70.30 Pipe
16.10 Casing cover 73.10 Compression nut
16.50 Cover 73.11 Screw connection
18.30 Pump foot 90.10 Hexagonal screw
21.00* Shaft 90.11 Hexagonal screw
23.00* Impeller 90.12 Hexagonal screw
32.10* Ball bearing 90.13 Hexagonal screw
32.11* Ball bearing 90.14 Hexagonal screw
33.00 Bearing housing 90.20 Stud
36.00 Bearing cover 90.21 Stud
36.01 Bearing cover 90.22 Stud
40.00* Flat gasket 90.23 Hexagonal screw
40.01* Flat gasket 90.24 Hexagonal screw
40.02* Flat gasket 90.25 Stud
40.03* Flat gasket 90.30 Threaded plug
40.05* Flat gasket 90.31 Threaded plug
40.06* Flat gasket 90.32 Threaded plug
41.10* Flat gasket 90.33 Threaded plug
41.11* Flat gasket 90.34 Threaded plug
41.22* O-ring 90.41 Grub screw
41.23* O-ring 90.80 Hexagonal screw
42.10* Lip seal 91.40 Allen head screw
42.11* Lip seal 91.60 Dip stick
42.20* V – seal 92.00 Hexagonal nut
43.30* Mechanical seal 92.01 Hexagonal nut
45.10 Packing housing 92.02 Hexagonal nut
45.20 Gland 92.06 Hexagonal nut
45.70* Pressure ring 92.20* Impeller nut
45.80* Lantern ring 93.00* Helicoil
46.10* Packing ring 93.01 Washer
47.10* Mechanical seal cover 93.21* Circlip
50.20* Wear ring 94.00* Key
50.21* Wear ring 94.01* Key
50.40* Distance ring 94.02* Key
50.50* Support washer for ball bearing 99.99 Plastic plug
50.70* Thrower
52.30* Shaft sleeve * Recommended spare parts
52.40* Shaft sleeve
55.40 Washer
56.00 Grub screw
56.10 Pin
63.60 Grease nipple
63.80 Constant level oiler

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

ZLND 32125 to 200250 AB


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

Mechanical seal code


BJ3/BJS/BJJ

92.20 94.01 90.30 90.10 91.40 50.70 18.30 93.01 90.12 90.11 94.00

Mechanical Seal Mechanical Seal


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

Mechanical Seal Mechanical Seal


code AX3/AXS/AXK code AY3/AYS/AYK
10.20 23.00 50.40 43.30 40.00 16.10 99.99 41.23 56.10 42.11 16.50 10.20 23.00 50.40 43.30 40.00 16.10 99.99 41.23 41.22 56.10 16.50

Mechanical Seal
code A93/A9S/A9K
10.20 23.00 50.40 43.30 40.00 16.10 99.99 56.10

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 7 of 14 Chapter 10

ZLND 32125 to 200250 AC/A2


MECHANICAL SEALS 0B 2

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

Mechanical seal code


BJ3/BJS/BJJ

92.20 94.01 90.30 90.10 91.40 50.70 33.00 63.81 90.31 18.30 93.01 90.12 90.11 94.00

Mechanical Seal Mechanical Seal


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

Mechanical Seal Mechanical Seal


code AX3/AXS/AXK code AY3/AYS/AYK
10.20 23.00 50.40 43.30 40.00 16.10 99.99 41.23 56.10 42.11 16.50 10.20 23.00 50.40 43.30 40.00 16.10 99.99 41.23 41.22 56.10 16.50

Mechanical Seal
code A93/A9S/A9K
10.20 23.00 50.40 43.30 40.00 16.10 99.99 56.10

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 8 of 14 Chapter 10

ZLND 32125 to 200250 AB


STUFFING BOX 0B 2

68.10
10.20 23.00 52.40 40.00 16.10 40.05 90.23 45.70 45.20 90.13 32.10 50.50 33.00 36.00 42.20 21.00

Stuffing box code


041

92.20 94.01 90.30 45.10 46.10 45.80 92.01 90.10 91.40 55.40 90.21 50.70 18.30 93.01 90.12 90.11 94.00

Stuffing box
code 052

10.20 52.40 45.80 40.00 99.99 92.01 45.70 55.40


23.00 45.10 16.10 40.05 46.10 45.20 90.21

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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

ZLND 32125 to 200250 AC/A2


STUFFING BOX 0B 2

90.23 45.20 68.10 32.10 63.80


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

Stuffing box code


041

92.20 94.01 45.10 46.10 45.80 92.01 91.40 90.21 33.00 63.81 90.31 18.30 93.01 90.12 90.11 94.00
90.30 90.10 55.40 50.70

Stuffing box
code 052

10.20 52.40 45.80 40.00 99.99 92.01 45.70 55.40


23.00 45.10 16.10 40.05 46.10 45.20 90.21

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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

ZLND 200315 to 300500 and 150500 AS


MECHANICAL SEALS 0B 2

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

Mechanical seal code


BJ3/BJS/BJJ

40.01 90.30 90.24 90.14 18.30 90.12 90.11


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

Shaft seal Shaft seal


Code AF3/AFS/AFK Code C23/C2S/C2J

50.40 23.00 40.00 73.11 47.10 56.10 50.40 23.00 40.00 73.11 47.10 52.30
10.20 43.30 16.10 40.06 41.11 90.24 52.30 10.20 43.30 16.10 40.06 41.11 90.24

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

ZLND 200315 to 300500 and 150500 AT/A2


MECHANICAL SEALS 0B 2

40.03 23.00 73.11 90.80 73.10 90.22 50.70 67.20 93.21 90.11 94.00
10.20 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

Mechanical seal code


BJ3/BJS/BJJ

40.01 90.30 43.30 90.24 36.01 64.20 18.30 90.12 36.00


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

Shaft seal Shaft seal


Code AF3/AFS/AFK Code C23/C2S/C2J

50.40 23.00 40.00 73.11 47.10 56.10 50.40 23.00 40.00 73.11 47.10 52.30
10.20 43.30 16.10 40.06 41.11 90.24 52.30 10.20 43.30 16.10 40.06 41.11 90.24

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

ZLND 200315 to 300500 and 150500 AS


STUFFING BOX 0B 2

40.03 23.00 73.11 90.80 73.10 90.22 50.70 33.00 32.10 36.00 94.00
10.20 45.80 16.10 41.11 90.34 40.00 92.06 41.10 70.30 92.02 45.20 36.01 93.21 63.60 21.00

Stuffing box code 041

40.01 46.10 90.14 18.30 90.12 90.11


92.20 94.01 50.20 90.30 50.21 52.40 90.20 55.40 90.21 32.11 93.01 40.02 42.10
93.00 56.00 56.00 92.00 92.01

Shaft seal
Code 052

45.80 23.00 40.00 55.40 90.21


10.20 46.10 16.10 90.33 45.20 92.01 52.40

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

ZLND 200315 to 300500 and 150500 AT/A2


STUFFING BOX 0B 2

40.03 23.00 73.11 90.80 73.10 90.22 50.70 67.20 93.21 90.11 94.00
10.20 45.80 16.10 41.11 90.34 40.00 92.06 41.10 70.30 92.02 45.20 90.14 32.11 33.00 32.10 21.00

Stuffing box code 041

40.01 90.30 46.10 36.01 64.20 18.30 90.12 36.00


92.20 94.01 50.20 50.21 52.40 90.20 55.40 90.21 90.31 63.80 93.01 40.02 42.10
93.00 56.00 56.00 92.00 92.01

Shaft seal
Code 052

45.80 23.00 40.00 55.40 90.21


10.20 46.10 16.10 90.33 45.20 92.01 52.40

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

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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
SIHI SuperNova Program

Supplementary operating instructions in accordance to EC directive


94/9/EC (ATEX) for the intended use in potentially explosive
atmospheres of the following pumps types, manufactured by
Sterling Fluid Systems (Spain), S.A.:
ZLN, ZLK and ZLI (Industrial Pumps)
ULN (Self Priming Pumps)
ZTN, ZTK and ZTI (Thermal Oil Pumps)
ZHN, ZDN, ZEN and ZLI (Hot Water Pumps)

These supplementary operating instructions give only general instructions for the
use of pumps in conditions that need explosion protection. The operating
instructions of the specific pump must be taken into consideration as well.

Contents Page
1 General objective 2
2 Safety issues 2
2.1 Identification of safety symbols in 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.

2.1 Identification of safety symbols in the supplementary operating instructions


In these supplementary operating instructions the safety instructions related to explosion protection are marked with:

The sign

is used to highlight safety instructions where non-compliance may pose a damage to the pump and its functions.

2.2 Compliance with regulations


It is imperative to comply with the safety instructions contained in these supplementary operating instructions, the
operating instructions of the pump type concerned, the relevant national and international explosion protection
regulations, health and safety regulations and the operator’s own internal work, operation and safety regulations.

Ex symbol relates to additional requirements, which must be complied with when the pump is operated in
hazardous areas.

In addition the following must be observed:

If 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,

Non-compliance may also result in hazards to persons by explosion.

2.3 Qualification and training of personnel


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

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.

If necessary, additional explosion protection regulations must be considered.

3 Instructions concerning design of pump and accessories

3.1 General
The pumps and the accessories for installations in hazardous areas must comply with the relevant category of
mechanical and electrical equipment.

Some details are pointed out below:

3.2 Pump pressure containment components

For handling inflammable fluids, the pump pressure containment components must be made of ductile
material.

3.3 Coupling, coupling guard


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

In hazardous areas coupling guards must be of non-sparking material, whereby the coupling material must be
considered.

3.4 Belt drives


Belts must include some electrically conductive material.

4 Instructions concerning installation and start-up of pump sets


In addition to the normal installation instructions, the specific criteria for explosion proof are listed below:

4.1 Coupling

The coupling must be installed, started-up and operated in accordance with the operating instructions of the
coupling manufacturer. Misalignment of the coupling may result in inadmissible temperatures at the coupling and
pump and motor bearings. It has to be ensured, that the half couplings are correctly aligned at all times.

4.2 Connection to power supply

Only a properly trained electrician must effect connection to the power supply. The available main voltage
must be checked against the data on the motor rating plate and an appropriate start-up method must be selected.
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.

4.4 Belt drive

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).

5.2 Explosion protection

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.

5.3 Pump filled and vented


Especially dry running of a pump results in friction and non-allowed temperature rise. Therefore precautions have to
be taken to prevent dry running.

It is necessary that the system of suction and discharge lines and thus the wetted pump 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.

Example of marking on the pump part:


CE Ex II 2 G c T1 - T5

The safety instructions published in section 5.8 must be complied with.

5.5 Fluid handled

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)

c Specific heat of liquid [J / kg K]


2
g Acceleration due to gravity [m /s]
H Pump head [m]
Tf Temperature of fluid handled [º C]
To Temperature of casing surface [º C]
η Pump efficiency [-]
∆ϑ Temperature difference [º C]

5.8 Temperature limits

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):

Temperature classes Permissible Max. permissible fluid


as per EN 13463-1: surface temperature for compliance
temperature with temperature class

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.

Sterling Fluid Systems


In the search to improve continuously its products, Sterling Fluid Systems
reserves the right to modify its products at any time without prior notice

For local contact details: www. sterlingfluidsystems.com

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

Herewith we declare that the pump type:

In the version supplied by us complies with the following relevant regulations:

EU Machine Directive 98/37/EC, Appendix I No. 1


EU Directive 94/9/EC, Group II, category 2, atmosphere G (Ex II 2 G c T1-T5)

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.

Harmonised standards used, in particular:

EN 809 EN 733 EN 1127 - 1


EN 292 part 1 EN 13463 - 1
EN 292 part 2 prEN 13463 - 5
In the actual version.

National technical standards and specifications used, in particular:

UNE-EN 809 UNE-EN 1127-1


UNE-EN 292-1 UNE-EN 13463 - 1
UNE-EN 292-2

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.

Sterling Fluid Systems, (Spain), S.A.

Business Unit Manager

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
Telephone: +33 (0)1 34 82 39 00 Sterling Fluid Systems (Belgium)
Fax: +33 (0)1 34 82 39 61 Groot-Bijgaarden
E-Mail: sterlingsihi@easynet.fr Telephone: +32 (0)2 481 7711
Fax: +32 (0)2 481 7737
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Schaffhausen
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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Dägeling/Holstein
Telelphone: +49 (0) 4821 9000-0 Sterling Fluid Systems (UK)
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E-Mail: sat@sterlingsat.de Telephone: +44 (0)161 9286371
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