Circulating pump Typ Z, FZ, SZ, NZ, ZL, FZL, SZL, NZL, ZB

Nr.

272

15

- D

Circulating pump

Typ Z, FZ, SZ, NZ, ZL, FZL, SZL, NZL,

ZB, FZB, SZB, NZB

Operator´s manualGB

EG-KonformitätserklärungEC-Declaration of Conformity

Hersteller / manufacturerSchmalenberger GmbH+Co KGStrömungstechnologieIm Schelmen 9-11D-72072 Tübingen / Germany

Produkt / productKreiselpumpen / Circulating pumps

Typ / modelZ, FZ, NZ, SZ, ZL, ZB, FZL, FZB, SZL, SZB, NZL, NZB

Hiermit erklären wir, dass die spezifische Bauart in Übereinstimmung mit den folgenden Richtlinien hergestellt worden ist:We hereby declare that the specific type has been produced in accordance with the following standards:

EG - Richtlinien / EEC Directives• 2006/42/EG• 2006/95/EG• 2004/108/EG

Zur sachgerechten Umsetzung der in der EG-Richtlinie genannten Sicherheits- und Gesundheitsanforderungen wurde(n) fol-gende Norm(en) herangezogen:For the relevant implementation of the safety and health requirements mentioned in the Directives, the following standard(s) must be required:

Harmonisierte Normen / Harmonised StandardsEN ISO 12100-1, EN ISO 12100-2, EN 61000-6-2, EN 61000-6-3, EN 809, EN ISO 14121-1

Tübingen, den 21. Dezember 2009

-------------------------------------------------------------------------------------------------Leiter Qualitätssicherung / Manager of quality assurance

Tel. +49(0)7071 7008-18

2 Pumpe Typ ZVersion: 27215 - D

Schmalenberger GmbH + Co. KGD-72072 Tübingen / Germany

EG-EinbauerklärungEC Declaration of Incorporation

Hersteller / manufacturerSchmalenberger GmbH & Co. KGStrömungstechnologieIm Schelmen 9-11D- 72072 Tübingen / Germany

Produkt / productKreiselpumpe falls geliefert ohne Antrieb / Centrifugal pump if delivered without drive

Typ / modelZB, ZL, FZB, FZL, NZB, NZL, SZB, SZL

ist eine unvollständige Maschine nach Richtlinie 2006/42EG Artikel 2g und ausschließlich zum Zusammenbau mit einer an-deren Maschine vorgesehen,is an incomplete machine in accordance with Regulation 2006/42EC Article 2g and is provided exclusively for assembly with another machine,

den folgenden grundlegenden Anforderungen der Richtlinie 2006/42/EG entspricht:which meets the following basic requirements of Regulation 2006/42/EC:

Anhang I, Artikel 1.1.1, 1.1.2, 1.1.3, 1.1.5.Appendix I, Article 1.1.1, 1.1.2, 1.1.3, 1.1.5.

Harmonisierte Normen die verwendet wurden: Harmonised standards that were used:DIN EN 12100-1, DIN EN 12100-2, EN 809, EN ISO 14121-1

Die unvollständige Maschine entspricht weiterhin Bestimmungen der Richtlinien:The incomplete machine further more meets the requirements of Regulations:• 94/9/EG - gilt nur für Produkte mit ATEX-Kennzeichnung 3G oder 3D auf dem Pumpenleistungsschild.• 94/9/EC - applies only to products with ATEX mark 3G or 3D on the pump rating plateNormen die verwendet wurden / Standards that were used: EN 13463-1, EN 13463-5

Die zur Maschine gehörenden speziellen technischen Unterlagen nach Anhang VII Teil B wurden erstellt.The special technical documentation that belongs to the machine has been created in accordance with Appendix VII Part B.

Die unvollständige Maschine darf erst dann in Betrieb genommen werden, wenn festgestellt wurde, dass die Maschine, die in die unvollständige Maschine eingebaut werden soll, den Bestimmungen der Richtlinie Maschinen (2006/42/EG) entspricht.The incomplete machine must not be placed in operation until it has been determined that the machine to be installed in the incomplete machine is in compliance with the requirements of the Machinery Directive (2006/42/EC).

Tübingen, den 21. Dezember 2009

-------------------------------------------------------------------------------------------------Leiter Qualitätssicherung / Manager of quality assurance

Tel. +49(0)7071 7008-18

3Pumpe Typ ZVersion: 27215 - D

Schmalenberger GmbH + Co. KGD-72072 Tübingen / Germany


Schmalenberger GmbH + Co. KG D-72072 Tübingen / Germany

Contents

1 General Details............................................................................. 6

1.1 User Information................................................................................................ 6

1.2 Usage Instructions............................................................................................. 6

1.3 Relevant Documentation ................................................................................... 6

2 Safety Instructions....................................................................... 6

2.1 General.............................................................................................................. 6

2.2 Signs and Symbols............................................................................................ 7

2.3 User Responsibilities......................................................................................... 7

2.4 Safety Instructions for Installation ..................................................................... 7

2.5 Safety Instructions for Connection .................................................................... 7

2.6 Safety information for setting up........................................................................ 7

2.7 Safety Instructions for Operation....................................................................... 8

2.7.1 Temperature...................................................................................................... 8

2.8 Safety Instructions for Maintenance and Repairs.............................................. 8

2.9 Potential Sources of Risk with the Centrifugal Pump........................................ 8

2.9.1 Danger of getting caught or crushed! ................................................................ 8

2.9.2 Danger of burns!................................................................................................ 8

3 Transport, Storage, Installation.................................................. 9

3.1 Transport and Storage ...................................................................................... 9

3.1.1 Transport ........................................................................................................... 9

3.1.2 Storage.............................................................................................................. 9

3.1.3 Conservation ..................................................................................................... 9

3.2 Unpacking, Cleaning and Assembly.................................................................. 9

3.2.1 Unpacking ......................................................................................................... 9

3.2.2 Cleaning .......................................................................................................... 10

3.2.3 Assembly......................................................................................................... 10

3.3 Installing and Connecting ................................................................................ 10

3.3.1 Check before you start installing ..................................................................... 10

3.3.2 Installing the unit ............................................................................................. 11

3.3.3 Connecting the Pipework. ............................................................................... 11

3.3.4 Electrical Connections..................................................................................... 12

4 Operating the Pump................................................................... 13

4.1 Initial Start-up .................................................................................................. 13

4.1.1 Starting the pump............................................................................................ 13



4.2 Operating........................................................................................................ 13

4.2.1 Operation Monitoring ...................................................................................... 13

4.2.2 Miscellaneous................................................................................................. 14

4.3 Indications of Faulty Operation....................................................................... 14

4.3.1 General........................................................................................................... 14

4.3.2 Faults.............................................................................................................. 14

4.4 Shutdown........................................................................................................ 14

4.5 Fault Elimination ............................................................................................. 15

5 Maintenance / Repair ................................................................. 17

5.1 Maintenance / Service .................................................................................... 17

5.1.1 Checks............................................................................................................ 17

5.1.2 Lubrication and change of lubricant................................................................ 17

5.2 Repair ............................................................................................................. 17

5.2.1 Dismantling Preparations ............................................................................... 18

5.2.2 Dismantling / Removal of the Pump ............................................................... 18

5.2.3 Dismantling / Dismantling the Pump............................................................... 18

5.2.4 Dismantling the pump Type Z, FZ 4013, FZ 5016, SZ 4013, SZ 5016........... 19

5.2.5 Dismantling the pump Type NZ, FZ 6520....................................................... 19

5.2.6 Shaft sealing ring / throttling bush .................................................................. 20

5.2.7 Pump re-assembly.......................................................................................... 20

5.2.8 Bearing support .............................................................................................. 20

6 Appendix ..................................................................................... 21

6.1 Shutdown / Storage / Conservation................................................................ 21

6.1.1 Storage of New Pumps................................................................................... 21

6.1.2 Longer Periods of Shutdown >3 months ........................................................ 21

6.1.3 Restarting after Periods of Storage ................................................................ 21

6.2 Disposal.......................................................................................................... 22

6.3 Documentation for pump operation ................................................................ 22

6.4 Data sheet ...................................................................................................... 22

7 Important Instructions ............................................................... 23

7.1 Factory repair ................................................................................................. 23

7.2 Ordering Spare Parts...................................................................................... 23

8 Spare parts list and Drawing..................................................... 24

Schmalenberger GmbH & Co. KGD-72072 Tübingen - Germany


1 General Details

1.1 User Information

This operator’s manual makes it easier toget to know the centrifugal pump and tomake full use of its facilities.The operator’s manual contains importantinstructions how to use the centrifugalpump safely, properly and economically. The label specifies the machine series, theframe size, the most important operatingdata and the serial number. We requestthat you always quote it in case of queries,when placing subsequent orders andespecially when ordering spare parts.

1.2 Usage Instructions

The centrifugal pump must only be used inaccordance with the original pumpspecifications and operating instructions.Any other usage or operation where thesefigures are exceeded is not permitted. Themanufacturer is not liable for damageresulting from such improper use.

1.3 Relevant Documentation

Technical documentation for the centrifugalpump consists of:• Centrifugal pump operator’s manual• Drive operator’s manual• Manual for accessories listed in the

specifications manual• Acceptance report from the TÜV

(Technical Certification Authority) etc.• Pilot run report• Performance run report• Installation drawing (dimensions sheet)• Test certificate for explosion model• Conformity statement / manufacturer’s

declaration• Specifications with all data

Not all the above documentation has beenproduced and supplied in every case. Forthis please check the details in thespecifications.

2 Safety Instructions

2.1 General

- Prior to starting up, make sure that the

operators have read and understood the

operator’s manual. Not the operator but

the owner is responsible for safety!

- Use the pump only if it is in perfect technicalcondition, in accordance with theregulations, observing safety requirementsand danger conditions and strictly adheringto all the instructions in the operator’smanual!

- Promptly remedy any faults that couldinfluence safety.

- Under all operating conditions pleaseobserve:

Warning!

Mortal danger!

In the case of hot, caustic orpoisonous delivery media!If the pipe strength is exceededleaks can occur in thecentrifugal pump or in theflange connections, forexample, that could result invast amounts of medium beingexpelled.Remove fluid that has leakedout in such a way that there isno danger to people or theenvironment. Legalrequirements must be adheredto.


Pumpe Typ ZVersion: 27215 - D

7

2.2 Signs and Symbols

In this operating manual the followingsymbols are used to draw your attention tosources of danger. The symbols areintended to attract your attention to theseinstructions!Symbol Meaning:

- Notices attached directly to the pump, e.g.arrows indicating direction of rotation and themarking for fluid connections, must alwaysbe observed and maintained in a clearlylegible condition.

2.3 User Responsibilities

- The centrifugal pump has been built usingstate-of-the-art technology and incompliance with recognised safetyregulations. Despite that there could bedanger to life and limb of the user or to thirdparties or damage to property in the way thatyou employ the blower.

- So the owner / user must ensure that-the operator’s manual is alwaysavailable for users to read.

-the safety instructions in this operator'smanual are carefully observed.

2.4 Safety Instructions for

Installation

- Keep the centrifugal pump firmly attached toappropriate lifting gear until it is finallyinstalled.

- The centrifugal pump is designed to be builtinto a total machine or plant. The centrifugalpump is delivered without any protectionagainst accidental contact. If necessary, thesystem supplier must fit appropriateprotective covers in integrating thecentrifugal pump into the plant (e.g. if hotliquids with a temperature over 60° C aredelivered).


Connection

- Electrical equipment must be installed andmaintained exclusively by qualifiedelectricians in accordance with regulationsVDE 0105 and IEC 364.

- Danger from electric shocks must becompletely excluded (for details see thecountry specific regulations and / or those ofthe local power supply company).

- The details on the type plate mustcorrespond to the electrical supply beingconnected to.

2.6 Safety information for setting

up

- Before switching on or starting up thecentrifugal pump, make sure that no-one willbe endangered by the start-up of the pump!

Attention! Danger of injury!

This sign warns you of thedanger of mechanical effects.

Warning! Mortal danger!

This sign warns you of thedanger from electric shocks.

iInformation:

This sign warns you of handlingthat could damage or destroythe pump. It also instructs youin the economic use of thepump.




Operation

2.7.1 Temperature


Maintenance and Repairs

- Regardless of what nature they may be,repairs must only be carried out by qualifiedpersons and the centrifugal pump must beemptied first.

- The attached pipeworkmust be depressurized.

- Allow the pump to cool off.

- Prior to carrying out repairs to the pump itmust be isolated from the electrical supplyand protected from unintentional switchingon.

- If fluids are delivered that may result in anykind of effect that is hazardous to health, themoist surfaces of the pump must besubjected to appropriate measures (rinsing,cleaning, washing) to make handling them

completely harmless before any kind of workis undertaken on the pump.

2.9 Potential Sources of Risk

with the Centrifugal Pump

It is impossible to eliminate all potential

risks!

2.9.1 Danger of getting caught or

crushed!

When installing or removing the centrifugalpump you may get caught or crushedbetween the cover plate and theinstallation housing.

2.9.2 Danger of burns!

The centrifugal pump motor gets hot duringoperation and must be protected fromdirect contact.

!Important:

The centrifugal pump must beimmediately stopped ifabnormal electrical voltages,temperatures, noises,vibrations, leakages or otherfaults should arise.

Warning!

Danger of burns!

The centrifugal pump housinggets hot during operation. If thetemperature rises to over+50°C, the centrifugal pumpmust be protected from directcontact by the operator.


Secure the centrifugal pumpduring installation or removalwith appropriate lifting gear.


Ensure that the operator doesnot touch the centrifugal pump!Fix a protective cover to theunit.Allow the centrifugal pump tocool down before you carry outmaintenance or repair work.



9

3 Transport, Storage,

Installation

3.1 Transport and Storage

3.1.1 Transport

Pumps that are designed to be built intocontainers must be transported lying down!The eyebolts on the motor are designed tocarry only the weight of the motor. To liftthe combined motor and pump aggregatesuitable attachments must be made so thatboth units are catered for! If necessary thecentre of mass is indicated on the pumpunit and on the packing material, andplaces for applying lifting hooks aremarked.

Hoisting example for pumps designed tobe built into containers

3.1.2 Storage

- Interim storageEven for short periods of interim storage,store on a wooden base in a dry, wellventilated and vibration free environmentat constant temperature.

- Unsuitable storageIf unsuitable storage conditions prevail(e.g. high humidity) or if the pump is to bestored for longer than 6 weeks, then thepump housing should be filled with oil (seechapter 3.1.3.).

- Long periods of storageAfter a storage period of more than 2 yearsthe motor roller bearings and bearingsupports need to be re-greased orreplaced entirely.

3.1.3 Conservation

The centrifugal pumps that we deliver aretreated with a conservation materialcorresponding to the storage time quotedus by the purchaser. This conservationmust be removed before start-up. Seechapter 3.2.2 “Cleaning”.If the pump is to be taken out of service fora longer period of time or if the originallyenvisaged storage time is going to beconsiderably exceeded, then conservationmust be undertaken as protection againstcorrosion. How to do this is described in detail inchapter 6.1 “Shutdown and Storage”.

3.2 Unpacking, Cleaning and

Assembly

3.2.1 Unpacking

For transportation purposes the pump isfastened to a palette by bands. Fortransportation over long distances it ispacked in crates or boxes .


Use only suitable andtechnically perfect lifting andload-bearing equipment withsufficient carrying power! Never stand or workunderneath swinging loads!



After removing the retaining bands extractthe pump out of its packing with the help ofsuitable lifting equipment. Observe theinstructions in section 3.1.1.

3.2.2 Cleaning

A number of measures are taken forprotection against transportation damageand corrosion. Check your pump for whichmeasures have been taken.1. Covering lid on the nozzles2. Shaft protection for deliveries without the

motor3. Protective paint on exposed parts.

These protective measures must beremoved before the pump is set up orinstalled. Under no circumstances mustimpurities be left inside the pump.

3.2.3 Assembly

In general the pump is delivered fullyassembled and can be installed directly.

In special cases the pump is deliveredwithout the drive motor. Prior to installingthe pump in the plant, install the drivemotor into the pump.

Other external accessories, such as a blasttank or similar equipment, that have notbeen assembled with the pump at thefactory, should be mounted on the pumpafter it has been installed in the system oron the pump base.

3.3 Installing and Connecting

3.3.1 Check before you start

installing

• Have the machine, the system and thecontainer nozzles been properly preparedin accordance with the figures on thedimensions sheet or installation plan?

!Important:

Depending on the deliverymedium to be used, the interiorof the pump should be cleanedof residual traces of oil. Use acleaning agent that will not beharmful to the throttling sectionand pump materials. Make surethat the pump is carefully driedafter cleaning.The cleaning agents that can beused include spirit, Ritzol 155 ora strongly alkaline soapsolution, for example. If a steamjet cleaner is to be used, then letthe solvent work itself in for atime first. Then also please takecare not to damage the electricmotor and bearings.

!Important:Before installation check that thepump runs freely and easily.

Explosion proof /

Safety Instructions

Electrical appliances that areoperated in areas where thereis a danger of explosion, mustcomply with the explosion proofrequirements. This is stated onthe factory plate of the motor.For installations in areas wherethere is a danger of explosion,the local explosion regulationsand those on the test certificatesupplied with the delivery, andwhich was issued by theresponsible inspectionauthority, must be observed.The test certificate suppliedmust be kept at the installationlocation (e.g. the master’soffice).



11

• Has the concrete base got adequatestrength (minimum of B 15) in accordancewith DIN 1045?

• Is the concrete base hydrated? • Is the surface level and even?

3.3.2 Installing the unit

These centrifugal pumps must only beinstalled in a vertical position.

Except for special models, the pumps arealways placed on the cover plate (baseplate) and fastened down by screws.When installed on a foundation thecentrifugal pump must be set up with theaid of a spirit level.

3.3.3 Connecting the Pipework.

In the case of pipework the nominal boreshould be at least the same as the pumpconnections.Connection pieces to larger nominal boresshould be carried out with approx. 8°expansion angle to avoid significant loss ofpressure.The suction pipe to the pump must beinstalled to rise continuously, on thepressure side it must fall continuously.Depending on the type of system and pumpbeing used, it is recommended thatbackflow prevention and shut-off devicesare installed.Expansion of the pipes due to temperaturemust be remedied by suitable measures. Ingeneral, we recommend the installation ofcompensators immediately between thepump and the pipes. Valves that close very suddenly (abruptly)must be avoided in the pipework. Theresulting pressure surges can greatlyexceed the maximum permitted housingpressure of the pump! To prevent toostrong pressure surges dampers or blasttanks should be installed.

Warning!

Stability, Danger of injury!Pumps with a motor at the top arevery top heavy. These pumps mustbe safeguarded against tipping upduring installation or removal e.g.with the help of ropes.

Warning!

Under no circumstances mustthe pump be used as anchorpoint for the pipework. Noforces or moments (e.g. due totwisting or heat expansion)from the pipework must act onthe pump. The pipes must besupported as close as possibleto the centrifugal pump andconnected to it free of alltension. This should be done byusing suitable compensators.



Often welding beads, scales and otherimpurities do not get dislodged for someperiod of time. They should be kept clear ofthe pump by inserting a sieve in the suctionpipe. The free cross-section of the sievemust be 3 times the cross-section of thepipe so that there is not too large aresistance built up due to foreign bodiesthat flow in. Hat-shaped sieves containinga mesh wire net having a mesh size of 2.0mm and 0.5 mm wire diameter made ofcorrosion resistant material have proveduseful in practice.

3.3.4 Electrical Connections

The electrical connections to the pumpmust be carried out by a specialisedcompany in the electrical engineeringbranch approved by the local energyprovider, taking into account the technicalconnection requirements. The connections must be carried out by aqualified electrician. For this refer to theTAB of the EVS, the VBG 4(§3) and DINVDE 1000-10/1995-5, for example.The relevant DIN VDE (Association ofGerman Engineers) regulations 0100 andin the case of explosion protection 0165must be observed.Compare the available power supplyvoltage with the details on the motor’sfactory plate and select the appropriateswitching.We recommend the use of a motorprotection facility. Explosion protectedmotors in protection class IP 54, increasedsafety (Ex)–e and temperature class T3,

must always be connected in accordancewith DIN VDE 0170/0171 via a motorprotection switch.Connect the motor in accordance with thecircuit diagram in the terminal box oraccording to the figures 3.3-1 or 3.3-2.

Delta connection ∆ (low voltage)

Fig. 3.3-1 Connection for 3-phase motors, connection ∆

Star connection Y (high voltage)

Fig. 3.3-2 Connection for 3-phase motors, connection Y

Time relay setting

For three-phase motors with star-deltaconnection it must be ensured that theswitching points between star and deltafollow each other very rapidly. Longswitching times can result in damage to thepump. Setting of the time relay for star-delta connection: < 3 sec.

Direction of rotation check

The direction of rotation of the motor mustagree with the direction of the rotationarrow on the motor housing of the pump(seen from the motor, in a clockwisedirection). Check by rapidly switching onand off.If the direction of rotation is wrong, changeany two phases L1, L2 or L3 of the powersupply in the motor terminal box over.

iInformation:At the end of installation, beforestarting up the system thecontainers, pipes and connectionsmust be thoroughly cleaned, rinsedand blown through.

W2 U2 V2

U1 V1 W1

L1 L2 L3

W2 U2

U1 V1 W1

L1 L2 L3

V2



13

Additional motor equipment

If particular control devices are to be usede.g. in connection with the installation ofthe pump in a process engineering facility,the instructions of the manufacturer of thecontrol devices must be strictly observed.

4 Operating the Pump

4.1 Initial Start-up

4.1.1 Starting the pump

Make sure that the shut-off device on thepressure end is half open before startingthe pump up! Once the maximum rotationspeed has been reached, slowly open it upand adjust to full operational level.

4.2 Operating

4.2.1 Operation Monitoring

In most cases the pump is controlled fromthe central point of the overall facility. Aprerequisite for a perfectly functioningpump is adherence to the data provided forits installation and use. See the chapter onspecifications.

1. Temperature of the delivery fluid: -Never operate the pump at temperaturesin excess of those stated in the originalspecification.

2. Switching frequency: - To avoid a largetemperature increase in the motor andexcessive strain on the pump, the motorand bearings, do not switch the motor onand off more than once per minute.

3. Minimum amount: - If the sort of facilityincludes the possibility of a run againstclosed shut-off device on the pressure-end, a minimum delivery rate at t -30 to+70° C 15% of Qopt. over +70 to +110° C25% of Qopt. must be supplied during thistime.

4. Density of the delivery fluid: - Thepower input of the pump changes inproportion to the density of the deliveryfluid. In order to prevent the motor beingoverloaded, the density must correspondto the specifications.

Warning!

Prior to initially starting up thepump please make sure thatthe following prerequisiteshave been met:1. The pump has been

connected properlyelectrically and with allrequisite safety features.

2. The pump is filled withdelivery medium or there is aminimum level of fluid in thetank / pool (pump is covered).

3. Please observe: Runningdry creates increased wearand must be avoided at allcosts!

4. The rotating parts of thepump have been covered bya protective shield. (Inaccordance with UVV(Accident PreventionRegulations) the centrifugalpump may only be operated ifa safety shield has beenfitted).

5. The pump shaft turns easily.6. The direction of rotation has

been checked.7. The minimum distance

between the suction inlet andtank wall is 150 mm.

iInformation:

Pay particular attention to thefollowing points for the manualoperation of the pump:



4.2.2 Miscellaneous

Installed reserve pumps must be run brieflyonce a week to ensure that they are alwaysready for operation. They should be run forapprox. 5 minutes.

4.3 Indications of Faulty

Operation

4.3.1 General

When operated via a central control facilityfaulty operation can be largely ruled out. In the case of manual operation, but alsowithin a control complex, please observethe following instructions.Avoid damage to the pump and make surethat:• The pump always runs quietly and

vibration free.• The pump does not run dry.• A longer period of operation with closed

shut-off device is avoided to preventheating up the delivery medium. For therequired minimum delivery see section4.2.1.

• The maximum permitted roomtemperature of +40° is not exceeded.

• The maximum ball bearing temperaturedoes not exceed room temperature by + 50° C and neverexceeds + 90° C (measured on theoutside of the motor housing).

• During pump operation the shut-off devicein the supply line is not closed.

4.3.2 Faults

In case of faults in the operation of thepump, that were not caused by the controlfacility or other foreign devices, proceed asfollows:1. Locate the site of the fault or defect.2. Determine the cause.3. Remedy the fault.

In chapter 4.5 “Fault Elimination” there isa table listing the most frequent faults, theircause and the recommended way toeliminate them.

4.4 Shutdown

1. Close the shut-off device in the pressurepipe. If backflow prevention is fitted to thepressure pipe the shut-off device canremain open, provided that there is backpressure.

2. Switch motor off. Allow it to come to rest.Depending on the sort of facility, the pumpshould be allowed sufficient idle run time– with the heat source, if any, switched offto allow the delivery fluid temperature toreduce – to prevent an accumulation ofheat within the pump

.

Warning!

If there is a danger that thepump may freeze and / or foroccasions where it is to be at astandstill for longer periods oftime, the pump must beemptied or protected againstfreezing up (by auxiliaryheating).



15

4.5 Fault Elimination

Table 1: The causes and elimination of faults

Pu

mp

sta

nd

s s

till

too

lit

tle

de

liv

ery

ra

te f

rom

pu

mp

mo

tor

ov

erl

oa

d

too

lo

w p

um

p p

res

su

re

too

hig

h p

um

p p

res

su

re

hig

h m

oto

r /

be

ari

ng

te

mp

era

ture

pu

mp

le

ak

s

pu

mp

ru

ns

no

isil

y,

run

nin

g n

ois

es

pu

mp

te

mp

era

ture

to

o h

igh

Cause of the fault Elimination of the fault

x x Back pressure too high, pump isdelivering against too high a pressure,system resistance too great, pipe toosmall

Set new operating point, system dirty,increase rotation speed, install a newimpeller, clean pipes, increase pipesize, install larger pump

x x x Pump / pipework not completelyvented, air suction through too small acovering, gas build-up, air bubble inthe pipework, high percentage of air inthe medium, supply or impellerblocked.

Increase fluid level, correct levelcontrol, install pump lower down, ventthe system, clean pipework, changepipework, de-gas the medium,decrease resistance in the supplypipe, fully open valves in the suctionpipe, clean sieves and suctionconnections, install a relief valvedirectly in front of the non-return valve.

x x Wrong phase sequence, wrongelectrical connections, rotation speedto low, gap between wearing plate andopen impeller too large, air entering viathe throttling section

Change over two of the phases in theterminal box, increase rotation speed(*) (if necessary, get new motor),decrease the gap between wearingplate and open impeller, renewthrottling section, install pump lowerdown or increase fluid level

x x Worn internal parts (e.g. impeller) Remove foreign body from pumphousing, replace worn parts, renewthrottling section

x x Pump back pressure is lower thanstated in the specifications, electricalconnections wrong

Set operating point precisely, increaseback pressure e.g.: by throttling thepump on the pressure side, perhapsturn off impeller (*), larger motor (*),compare electrical connections withthose on the motor rating plate;observe circuit diagram in chapter3.3.4

x x Higher density or greater viscosity ofthe delivery medium than in thespecifications

New pump correlation (*)

x Cavitation Throttle pump on pressure side, largerpump (*)

x System resistances too low,manometer defective

Increase back pressure, e.g. bythrottling the pump on the pressureside, larger pump (*), larger impeller (*)



(*) Please contact the manufacturer

x Foreign body in the pump, throttlingsection worn, motor bearingsdefective, safety switch was triggereddue to motor overload, safety switchtoo small, winding defective

Remove foreign body from the pumphousing, clean or change pumphousing, renew throttling section,renew motor bearings, check electricalconnections / compare to motorratings plate, throttle pump, smallerimpeller (*), larger motor (*)

x x Impeller imbalanced, bearingdefective, too little / too much or wronglubricant

Clean impeller, balance the impeller(*), renew bearings, add / decrease orcompletely change the lubricant

x x Coupling distance not maintained,pump wrongly adjusted, pumpdistorted or resonance vibrations in thepipework, several pumps on oneconsole, increased axial thrust

Set correct distance, adjust pumpcorrectly, check pipework connections/ pump mountings, single pumpsetting, connect pipework viacompensators, install vibration damperunder the pump, stiffen the tank, cleanrelief bores in the impeller

x Rotation speed to high, pump too large(wrong design)

Decrease rotation speed, smallerpump (*), turn off impeller (*)

x Pump delivery too small, pipeworkblocked, closed valve on pressure side

Re-set pump, install a bypass for lowvolume requirements, clean pressurepipe, switch pump on only whenrequired, pump must not run too longagainst closed valve;no reduction in temperature: use asmaller pump (*)

x Gaskets defective, pump badlyadjusted, throttling section defective

Renew gaskets, adjust pumpprecisely, check pipework connections,renew throttling section.

Table 1: The causes and elimination of faults

Pu

mp

sta

nd

s s

till

too

lit

tle

de

liv

ery

ra

te f

rom

pu

mp

mo

tor

ov

erl

oa

d

too

lo

w p

um

p p

res

su

re

too

hig

h p

um

p p

res

su

re

hig

h m

oto

r /

be

ari

ng

te

mp

era

ture

pu

mp

le

ak

s

pu

mp

ru

ns

no

isil

y,

run

nin

g n

ois

es

pu

mp

te

mp

era

ture

to

o h

igh

Cause of the fault Elimination of the fault



17

5 Maintenance / RepairGeneral Instructions

The operator must ensure that allmaintenance, service and repair work onthe pump is carried out exclusively byauthorised and specially trained persons. Itmust be established beyond doubt that theperson has studied the operator’s manualin detail. We recommend the creation of andadherence to a maintenance schedule.That will enable you to avoid expensiverepairs and have a reliable and trouble-freepump operation.Only original spare parts must be used forrepairs. If work has to be carried out on themotor

the instructions in the manual from therelevant motor manufacturer must beobserved..

5.1 Maintenance / Service

Use the following information to create amaintenance schedule. These arerecommendations of minimumrequirements that must be adjusted to localconditions of use of the pump and mayneed amending accordingly.

5.1.1 Checks

Continuous checks:

• Pump delivery data (pressure, amount)• Power take-up

Daily checks:

• Pump running is quiet and vibration free• Bearing temperature (see section 4.3.1)

Monthly checks:

• Wear on the coupling (elastic component)• Screws are tight

5.1.2 Lubrication and change of

lubricant

Pumps in their standard models only havebearings in the drive motor. In the modelswith IEC motor and intermediate stub thebearings in the intermediate stub are filledwith a grease that cannot be replenished.This grease lasts for the working life of theunit and cannot be replenished. Defectivebearings must be replaced.

5.2 Repair

General

Always carry out repair work on theremoved pump in an appropriateworkshop. Be sure to observe the general instructionsat the beginning of the chapter! The following instructions will enable you todismantle the pump and to re-assemble itproperly with the requisite spare parts inplace.

Mortal danger!

In order to prevent electricshocks, work on the terminalbox and the machine controllermust never be carried out beforethe electrical connections havebeen isolated or disconnected.


Mortal Danger!

The pump must be safeguardedagainst unintentional switching on(be disconnected) if checking ormaintenance work is to beundertaken.

iInformation:Also take note of the explodeddiagram in chapter 8 “Spare partslist / Drawing”.



The work can be undertaken with the usualworkshop tools. Special tools are notrequired, with the exception of for theinstallation of a new throttling bush. After dismantling, thoroughly clean all theindividual parts of the pump. Check theindividual parts for wear and damage. Partsthat are not perfect must be reworked orreplaced.

5.2.1 Dismantling Preparations

When used in a facility, inform the shiftleader or manager.

5.2.2 Dismantling / Removal of the

Pump

The pump must be allowed to reach roomtemperature.• Disconnect the power supply.• Close valves (on the suction and pressure

sides).• Remove existing additional connections.• Release pressure and suction nozzles.• Disconnect motor.• Release pump base plate• Completely lift out the pump (out of the

tank, etc.)• Empty the pumpWhen emptying the pump please observethe following instructions!

5.2.3 Dismantling / Dismantling the

Pump

Before you begin

Begin the work only once you havechecked that:• The required spare parts are available

and that they will fit this pump or yourparticular model thereof. Make sure that inyour spare parts order the pump serialnumber was quoted.

• You have all the required tools andaccessories for the work.

!Important:Prior to starting to dismantle it thepump must be safeguardedagainst accidental switching on (itmust be disconnected). Warningon the switching cabinet!

!Important:For the following work, please besure to observe local regulationsand conditions.

Warning!1. If the pump was used to deliver

liquids that are hazardous tohealth, then great care must betaken in emptying the pumpthat neither persons nor theenvironment are placed at riskthrough the process.

2. If necessary, wear protectiveclothing and protective mask!

3. The rinsing liquid used and anyresidual fluid out of the pumpmust be caught and disposedof properly and without placingpersons or the environment inany danger.

4. Pumps that deliver liquids thatare hazardous to health mustbe decontaminated. In drainingthe delivery medium off caremust be taken that neitherpersons nor the environmentare placed in any danger.

5. Legal requirements must beadhered to!

iInformation:Use only original spare parts for therepairs!During re-assembly all the gasketsmust be renewed.



19

Observing these instructions is aprerequisite for trouble-free operation ofthe pump and for the acceptance ofpotential claims under guarantee.

5.2.4 Dismantling the pump Type Z,

FZ 4013, FZ 5016, SZ 4013, SZ

5016

Step 1:

Unscrew the spiral housing mountingscrews pos. 901.1 and remove the spiralhousing pos. 102. Remove the from theconnecting piece pos. 145 and pull off thepressure pipe pos. 710. Now remove thetwo round gaskets pos. 412.

Step 2:

Unscrew and remove the impeller nut pos.922 and the distance washer pos. 554.01.Now you can pull off the impeller pos. 233and remove the key pos. 940.

Step 3:

Dismantle the connecting piece pos. 145with the hexagon socket screws pos. 914.Now you can pull off the connecting piecepos. 145 together with the cover plate pos.167. Then take the protective shaft sleeve pos.524 from the motor shaft pos. 818.Make sure that for the dense shaft bushing(DWF) that the connecting piece pos. 145is pulled off together with the shaft sealingring pos. 420. Now remove the counter ring pos. 475.

Step 4:

The throttling bush pos. 542 is glued intothe connecting piece pos. 145. Dismantlethe throttling bush only if it is to be replaced. The replacement is described in chapter5.2.6.

5.2.5 Dismantling the pump Type

NZ, FZ 6520

Step 1:

Unscrew the hexagon screws pos. 901.04out of the pressure pipe and remove them.Now remove the hexagon nut pos. 920.05from the spiral housing. Lift the spiralhousing pos. 102 off. Now you can remove the two clampgaskets pos. 400.01 and 400.02.

Step 2:

Unscrew and remove the impeller nut pos.922 and the distance washer pos. 554.01.Now you can pull off the impeller pos. 233and remove the key pos. 940.

Step 3:

Dismantle the pressure cover pos. 163 byunscrewing the hexagon nut pos. 920.06and remove the protective shaft sleevepos. 524.Make sure that for the dense shaft bushingthat you take off the shaft sealing ring pos.420.Remove the intermediate piece pos. 132.By unscrewing the hexagon screws pos.901.01 on the motor flange and thetransition piece pos. 721, you can removethe intermediate piece together with thecover plate pos. 167 and the pressure pipepos. 710.

iInformation:For the SZ model you first have tounscrew the hexagon socketscrews pos. 914 from the wearingplate in order to be able to removethe wearing plate pos. 164.When re-assembling install newgaskets and a new wearing plate.



Step 4:

The throttling bush pos. 542 is glued orpressed into the throttling bush holder pos.542. The throttling bush holder is glued intothe pressure cover pos. 163. Dismantle thethrottling bush only if it is to be replaced. The replacement is described in chapter5.2.6.

5.2.6 Shaft sealing ring / throttling

bush

With the delivery of a new throttling bushyou will receive fitting instructions (AA-

18003) how to install it correctly in yourcentrifugal pump. To fit the throttle bush you need a specialcentring tool that may be ordered from themanufacturer.

5.2.7 Pump re-assembly

Re-assembly is basically in the reverseorder to dismantling.

Observe the following preparatory steps:• Thoroughly clean all individual parts of dirt

and residual glue (throttling bush seating).• Inspect all parts for wear and be sure to

replace any that are worn or damaged.• Clamp gaskets and O-rings must always

be replaced by new ones. Grease O-ringsprior to installation.

• If a new throttling bush made of siliconcarbide (SiC/SiC) was glued in place, thenthe glue must be allowed to harden forapprox. 24 hours before assembly canproceed. See assembly instructions (AA-

18003). Make sure that this period of timeis observed!

• During assembly tighten screwconnections crosswise. Use a torquewrench for this.

The following table lists the recommendedtightening torque for DIN 13 regularthread:

The figures are for new screws, notgreased. Use of screw strain limit of 90%.

5.2.8 Bearing support

If your pump is equipped with an IEC norm-motor (described as option “B”) as thedrive, then between the cover plate and themotor there is a bearing support forsupporting the pump shaft and coupling.

There are two types of connectingintegrated in the pumps.Version 1: Bearing bracket with 1 ballbearingVersion 2: Bearing pedestal with 2 ballbearings and coupling

iInformation:

When re-assembling installnew gaskets.

iInformation:The throttling bushes built used inthe centrifugal pumps are not

wear-free.

Warning!When dismantling the pumpinspect the throttling bush andprotective shaft sleeve for damage.Be sure to replace a damagedthrottling bush and / or protectiveshaft sleeve.

!Important:Never use a throttling bush youhave made yourself! We canaccept no liability.

Screw category: 5.6 6.9 8.8

Screw ∅ M8 10.8 21.6 25.5 NM

Screw ∅ M10 21.6 42.0 50.0 NM

Screw ∅ M12 38.2 73.5 87.2 NM

Screw ∅ M16 93.2 178 211 NM



21

The bearings are sealed and filled with agrease that cannot be replenished. Thecoupling is designed to have a long servicelife under normal usage.To change the coupling or a bearing,proceed as follows:Version 1:

• Remove 1 protective plate from thebearing retainer. Loosen the set screw onthe shaft if one is present.

• Dismantle the pump as described insections 5.2.1 to 5.2.5 to replace the ballbearing.

• Loosen the bearing retainer pos. 330. Usethe extraction thread and screws pos. 901for this. Pull the shaft pos. 215 and ballbearing pos. 326 off the motor pos. 801.

• Remove the retaining ring pos. 932.02and pull the shaft and ball bearing out ofthe bearing retainer.

• Remove the retaining ring pos. 932.01from the shaft and pull off the ball bearing.

Version 2:

• Loosen the drive of the bearing supportpos. 331. Remove the motor pos. 801together with the upper half coupling. Nowyou can replace the inner coupling partpos. 840.

• To replace the ball bearings pos. 321 andpos. 321.01 the pump has to be removedand dismantled as described in sections5.2.4 and 5.2.5.

• Next dismantle the bearing stub togetherwith the shaft pos. 211 from the coverplate pos. 167.

• Remove the retaining rings pos. 932 fromthe shaft pos. 211 and from the bearingsupport. Dismantle the ball bearings pos.321 and 321.01.

• Be sure to clean all parts in advance andcheck them for damage or wear. Replacedefective parts! Assemble the parts inreverse order.

6 Appendix

6.1 Shutdown / Storage /

Conservation

Every pump leaves the factory carefullyassembled. If initial operation is predictedto be a long time after delivery werecommend the following measures forstorage of the centrifugal pump.

6.1.1 Storage of New Pumps

When requested, new pumps receive aconservation protection corresponding tothe storage time stated by the purchaser. Ifthis period of time is considerablyexceeded the condition of the pump mustbe checked and, if required, re-conserved.

6.1.2 Longer Periods of Shutdown

>3 months

1. Pump remains installedTo ensure that the pump is always ready foroperation and to prevent the formation ofdeposits inside the pump and in itsimmediate vicinity, the pump aggregateshould be run for a short time (approx. 15minutes) monthly or quarterly during longerperiods of inactivity. Prerequisite for this isthat sufficient fluid is supplied to the pump.2. Pump is removed and storedTo remove the pump proceed as outlined inchapter 5. Prior to storing the pump it must bethoroughly cleaned and conserved.Conservation must be done both internallyand externally.

6.1.3 Restarting after Periods of

Storage

De-conservation

Before the stored pump is re-installed theconservation agent (covering or filling)must be removed. Proceed as described inchapter 3.2.2



Restarting

Re-install the pump according to theprocedure described in chapter 3.3.Immediately after completing the abovework, all safety and protective measuresmust be properly installed and checked thatthey function.Before the pump is re-started the checksand maintenance measures stated inchapter 5.1 must be carried out. For thenew re-start the points listed in section 4.1“Initial Start-up” must also be observed.

6.2 Disposal

If you want to take the pump completely outof service and never re-use it then pleaseobserve the local regulations for thedisposal of industrial waste.

6.3 Documentation for pump

operation

The following documents are enclosed:• Operator’s manual• Dimensional sketchIn case of complaints regarding the pumpmotor, please contact us or the motormanufacturer.

6.4 Data sheet

Please see the enclosed data sheet for theactual dimensions of the pump delivered toyou.

Warning!

After long periods of storageunder conservation conditionscheck the shape stability andelasticity of the Elastomers (O-rings and mechanical seals).Brittle rings must be replaced.Elastomers made of EPDMshould be replaced in anyevent.

Important:Mortal danger /

Poison

Pumps that have deliveredpoisonous, caustic or otherchemical substances which arehazardous to the health ofpeople and animals must bethoroughly cleaned and / ordecontaminated prior to beingdisposed of.

The cleaning agents and restsof the delivery medium mustalso be handled in accordancewith legal requirements.

If corresponding laws apply inthe area where the pump isoperated, then the pump mustbe dismantled. Thecomponents must then beseparated into the differentmaterials and disposed ofseparately.

!Important:If changes are made to the pumpdelivered to you, your guarantee isinvalidated!



23

7 Important Instructions

7.1 Factory repair

Please observe the following instructions ifthe pump is sent back to the factory forrepair:1. If you send the pump back to the

manufacturer for repair or an upgradethen please be sure to enclose precisedetails of the media that were delivered bythe pump.

3. Only pumps that are completely emptyand clean will be accepted for repair.

7.2 Ordering Spare Parts

When ordering spare parts please do notfail to give us the following importantinformation:• Pump serial number and type description• Delivery medium• Part number from the spare parts list• Part description• Material data from the specifications or

the order confirmation

With this information you make it mucheasier for us to deliver the correct sparepart for your pump!

8 Spare parts list and

drawing

!Important:2. If the delivered media were

poisonous, caustic, etc. thenplease be sure to enclose acopy of the safety sheet for themedia!

iInformation:

Centrifugal pumps with blockmotor are described as drivevariant “A”.

Centrigugal pumps with norm-motor and coupling aredescribed as drive variant “B”.

Sch

male

nbe

rge

r Gm

bH

& C

o. K

GD

-720

13 T

üb

ing

en - G

erm

an

yP

um

p T

yp

ZV

ers

ion: 2

72

15 - D

24

473475420

524

914

145

554.03920

400 901.03167

920 730

554.02

901.02

720

901.01

710 412

102

922 554.01

233

542

711

721

802920554940 818

05.00 / BZZ-03-02

801901

940

920.01550.01

901.01

550.01920840

932321550211

331932.01550321.01

932.01550932

AB

940

914.01

164

233

Typ Z, FZ 4013, FZ 5016,

SZ 4013, SZ 5016

Typ ZL, FZL 4013,

FZL 5016, SZL 4013,

SZL 5016


Pump Typ ZVersion: 27215 - D

25

Hyd

rau

lic

Co

nn

ec

tio

nN

orm

mo

tor


26 Pump Typ ZVersion: 27215 - D

8.1 Typ Z, FZ 4013, FZ 5016, SZ 4013, SZ 5016, ZL, FZL 4013, FZL 5016, SZL

4013, SZL 5016, ZB, FZB 4013, FZB 5016 SZB 4013, SZB 5016

Pos.: Quantity Denomination: Notice:

102 1 Spiral housing

145 1 Connecting piece

164 1 Wearing plate

167 1 Cover plate

211 1 Pump shaft

215 1 Pump hollow shaft

233 1 Impeller

321 1 Radial ball bearing

321.01 1 Radial ball bearing

326 1 Roller bearing

330 1 Bearing retainer

331 1 Bearing support

400 1 Clamp gasket

412 2 Round gasket (O ring)

420 1 Shaft sealing ring

473 1 Sealant carrier

475 1 Counter-ring

524 1 Protective shaft sleeve

542 1 Throttling bush

550 3 Supporting ring

550.01 1 Washer

554 4 Distance washer

554.01 1 Distance washer



710 1 Pressure pipe

711 1 Suction pipe extension

720 1 Angle (pipe bend 90°)

721 1 Transition piece

730 1 Pipe connection



27

801 1 IEC Norm motor, for Type Z-L / Z-B

802 1 Block motor, for type Z

818 1 Motor shaft

840 1 Coupling

901 4 Hexagon screw

901.01 4 Hexagon screw




902 4 Plug screw

914 4 Cylinder head screw with hexagon socket

914.01 Cylinder head screw with hexagon socket

920 4 Hexagon nut for 901

920.01 4 Hexagon nut for 901.01

920.02 4 Hexagon nut for 902



922 1 Impeller nut

932 2 Retaining ring

932.01 2 Retaining ring

940 1 Fitting key

940.02 1 Fitting key


Schm

ale

nb

erg

er G

mb

H &

Co

. KG

D-7

20

13 T

üb

inge

n - G

erm

any

28

Pu

mp

Typ

ZV

ers

ion: 2

72

15 - D

721

901.03

132554.02920.02

901.02167

920.03

168

920.02

400.01

922 554.01

233

542.02

903

721

802920.01940 819

801901

940

920.01

550.01

901.01

550.01920840

932321550211

331932.01550321.01

932.01550932

AB

940

920.06

920.01 920.05

554.03

901.01

902.02

920.06

524

542.01

163

102

903

920.04

400.02

700

901.04

420

Typ NZ, FZ 6520

Typ NZL, FZL 6520



29

8.2 Typ / Type / Type / Tipo / Modello: NZ, FZ 6520, NZL, FZL 6520


102 1 Spiral housing

132 1 Intermediate piece

145 1 Connecting piece

163 1 Pressure cover

164 1 Wearing plate

167 1 Cover plate

168 1 Cover plate

211 1 Pump shaft

233 1 Impeller

321 1 Radial ball bearing

321.01 1 Radial ball bearing

331 1 Bearing support

400 1 Clamp gasket

411 1 Sealing ring

412 2 Round gasket (O ring)

420 1 Shaft sealing ring

473 1 Sealant carrier

475 1 Counter-ring

512 1 Wearing ring

524 1 Protective shaft sleeve

542 1 Throttling bush

550 3 Supporting ring

554 4 Distance washer

700 1 Pipework

710 1 Pressure pipe

721 1 Transition piece

730 1 Pipe connection

738 1 Angle (pipe bend 90°)

801 1 IEC Norm motor, for Type NZL / FZL

802 1 Block motor

819 1 Motor shaft


30 Pump Typ ZVersion: 27215 - D

840 1 Coupling

901 4 Hexagon screw

902 2 Stud bolt

903 1 Plug screw

904 1 Threaded rod

913 1 Ventilation screw

914 4 Cylinder head screw withhexagon socket

922 1 Impeller nut

932 2 Retaining ring

940 2 Fitting key




Schmalenberger GmbH + Co. KG Telefon: +49 (0)7071 70 08 - 0

Strömungstechnologie Telefax: +49 (0)7071 70 08 - 59

Im Schelmen 9 - 11 Internet: www.schmalenberger.de

D-72072 Tübingen / Germany E-Mail: [email protected]

© 2010 Schmalenberger GmbH + Co. KG ; All Rights reserved

This document is subject to change without notice

Pump Typ Z

Version: 27215 - D

Documents

Circulating pump Typ Z, FZ, SZ, NZ, ZL, FZL, SZL, NZL, ZB