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Johnson Pump SPX Flow CombiLine Series Instruction Manual

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CombiLine - CombiBlocHorti
Circulation pumps
CL-CBH/EN (1901) 7.6
Orginal instructions
Read and understand this manual prior to operating or servicing this product
INSTRUCTION MANUAL

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Summary of Contents for Johnson Pump SPX Flow CombiLine Series

  • Page 1 INSTRUCTION MANUAL CombiLine - CombiBlocHorti Circulation pumps Orginal instructions CL-CBH/EN (1901) 7.6 Read and understand this manual prior to operating or servicing this product...
  • Page 3 EC Declaration of conformity (Directive 2006/42/EC, appendix II-A) Manufacturer SPX Flow Technology Assen B.V. Dr. A.F. Philipsweg 51 9403 AD Assen The Netherlands hereby declares that all pumps member of productfamilies CombiBloc, CombiBlocHorti, CombiChem, CombiLine, CombiLineBloc and CombiNorm whether delivered without drive (last position of serial number = B), or delivered as an assembly with drive (last position of serial number = A), are in conformity with the provisions of Directive 2006/ 42/EC (as altered most recently) and where applicable the following directives and...
  • Page 4 Declaration of incorporation (Directive 2006/42/EC, appendix II-B) Manufacturer SPX Flow Technology Assen B.V. Dr. A.F. Philipsweg 51 9403 AD Assen The Netherlands hereby declares that the partly completed pump (Back-Pull-Out unit), member of productfamilies CombiBloc, CombiBlocHorti, CombiChem, CombiLine, CombiLineBloc and CombiNorm is in conformity with the following standards: •...
  • Page 5 SPXFLOW is a global multi-industry manufacturing leader. The company's highly- specialized, engineered products and innovative technologies are helping to meet rising global demand for electricity and processed foods and beverages, particularly in emerging markets. Johnson Pump Horticulture De Hondert Margen 23 2678 AC De Lier The Netherlands Tel.
  • Page 6 INT Horti/EN (1512) 1.2...

  • Page 7: Table Of Contents

    CombiLine-CombiBlocHorti Table of Contents Introduction Preface Safety Guarantee Inspection of delivered items Forwarding and storage instructions 1.5.1 Packaging 1.5.2 Opening the packaging Ordering parts General Description of the pump 2.1.1 CombiLine (CL) 2.1.2 CombiBlocHorti (CBH) 2.1.3 General Type code Serial number Applications Construction 2.5.1...
  • Page 8 Installing a CBH pump Connecting the electric motor Commissioning Inspection Commissioning Pump in operation Maintenance Bearings Mechanical seal Environmental influences Noise Motor Failures Faults Faults and possible causes Causes and possible solutions Disassembly and assembly General 7.1.1 Special tools 7.1.2 Back Pull Out-unit Precautions 7.2.1...
  • Page 9 CombiLine-CombiBlocHorti Dimensions CombiLine ND10 Dimensions CombiBlocHorti Parts Ordering parts Recommended spare parts CombiLine with thread connections CombiLine with flange connections CombiBlocHorti Electric motor Technical data 10.1 Technical data pumps 10.2 Technical data electric motor 10.3 Tightening torques 10.4 Tightening torques CombiLine 4/4 and 5/4 10.5 Recommended liquid locking agents 10.6...
  • Page 10 CL-CBH/EN (1901) 7.6...

  • Page 11: Introduction

    CombiLine-CombiBlocHorti 1 Introduction Preface This manual is intended for technicians and maintenance staff and for those who are in charge of ordering spare parts This manual contains important and useful information for the proper functioning and maintenance of this pump. It also contains important instructions to prevent potential accidents and damage, and to ensure safe and fault-free operation of this pump.

  • Page 12: Safety

    Safety This manual contains instructions for working safely with the pump. Operators and maintenance staff must be familiar with these instructions. Installation, operation and maintenance has to be done by qualified and well prepared personnel. Below is a list of the symbols used for those instructions and their meaning: Personal danger for the user.

  • Page 13: Forwarding And Storage Instructions

    CombiLine-CombiBlocHorti Forwarding and storage instructions 1.5.1 Packaging The pump is packed in a solid cardboard box. The bigger types are provided with a wooden bottom. The pump is bolted down on this bottom. The forwarding and storage instructions are stated on the box by means of symbols. Adhere to these instructions. Furthermore, the box contains the same information about the pump as the information written on the label on the cover of this manual.
  • Page 14 Introduction CL-CBH/EN (1901) 7.6...

  • Page 15: General

    CombiLine-CombiBlocHorti 2 General Description of the pump 2.1.1 CombiLine (CL) The CombiLine is a built-in in-line circulation pump range. These pumps are easy to install in straight pipelines, inlet and outlet flange connections have the same size and pattern and are positioned in-line. 2.1.2 CombiBlocHorti (CBH) The CombiBlocHorti is a close-coupled foot-mounted pump range.

  • Page 16: Serial Number

    Serial number Serial number of the pump or pump unit are shown on the name plate off the pump and on the label on the cover of this manual. Example: 19-001160 year of manufacture 001160 unique number Applications The CombiLine is a built-in circulation pump that can be used in the following areas: •...

  • Page 17: Electric Motor

    CombiLine-CombiBlocHorti 2.5.6 Electric motor The electric motor has an extended shaft, on which the impeller is mounted. The forces on the impeller are absorbed by the motor bearings. The bearings are dust-proof and greased for life, so they are maintenance-free. The protection class for all motors is IP 55.
  • Page 18 ‘End suction close coupled inline water pump’ (ESCCi) means a water pump of which the water inlet of the pump is on the same axis as the water outlet of the pump; ‘Vertical multistage water pump’ (MS-V) means a glanded multistage (i > 1) rotodynamic water pump in which the impellers are assembled on a vertical rotating shaft, which is designed for pressures up to 2500 kPa (25 bar), with a nominal speed of 2900 rpm and a maximum flow of 100 m...
  • Page 19 CombiLine-CombiBlocHorti • ‘House of Efficiency’ The decision scheme ‘House of Efficiency’ takes into account design and application purposes as well as the pump minimum efficiency dependence on flow. The minimum acceptable efficiency is therefore different for each pump type. The pass-or-fail scheme is based on two criteria A and B.

  • Page 20: Energy Efficient Pump Selection

    2.6.3 Energy Efficient Pump Selection In selecting the pump, care should be taken to ensure that the duty point required is as close as possible to the pump’s Best Efficiency Point (BEP). Different heads and flows can be achieved by changing the diameter of the impeller and thereby eliminating unnecessary energy loss.

  • Page 21: Scope Of Implementing Directive 2009/125/Ec

    Name plate, example: Figure 3: Name plate horticulture MEI ≥ Ø eff. CR Nr. 04029567 Johnson Pump Horticulture De Hondert Margen 23 NL-2678 AC De Lier Table 1: Name plate horticulture CL 80-200 Product type and size 19-001160 Year and serial number 0,40 Minimum Efficiency Index at max.
  • Page 22 Table 2: MEI value, CombiLine Speed MEI value according [rpm] prEN16480 Remarks Material Cast iron 65-200 1450 > 0,40 80-125 1450 > 0,40 80-160 1450 > 0,40 80-200 1450 > 0,40 100-150 1450 > 0,40 100-160 1450 > 0,40 100-200 1450 >...

  • Page 23: Re-Use

    CombiLine-CombiBlocHorti 4 Manufacturer: SPX Flow Technology Assen B.V. Registration number at Chamber of Commerce 04 029567 Johnson Pump Horticulture De Hondert Margen 23 2678 AC De Lier The Netherlands 5 Product type and size identifier are marked on the rating plate. An example and explanation is given in paragraph 2.6.5 "Product information"...

  • Page 24: Scrapping

    Scrapping If it has been decided to scrap a pump, the same flushing procedure as described in paragraph 2.7 "Re-use" should be followed. General CL-CBH/EN (1901) 7.6...

  • Page 25: Installation

    CombiLine-CombiBlocHorti 3 Installation Safety • Read this manual carefully before installing the pump and putting it into operation. Non-observance of these instructions may cause serious damage to the pump that is not covered by our guarantee terms. Follow the instructions step by step. •...

  • Page 26: Installing A Cl Pump

    • If necessary mount valves before and after the pump. Do not use quick-acting valves, as they may cause high pressure impulses in the pump and the piping (water hammer pressure). • Before installing the pump, all piping should be flushed, to eliminate all dirt, grease or possible other particles.

  • Page 27: Commissioning

    CombiLine-CombiBlocHorti 4 Commissioning Inspection Prior to commissioning the pump: • Check if the fuses have been installed. • Check if the impeller can rotate freely. Do this by rotating the shaft end with a screwdriver through the hole in the protective cover of the electric motor. •...
  • Page 28 Commissioning CL-CBH/EN (1901) 7.6...

  • Page 29: Maintenance

    CombiLine-CombiBlocHorti 5 Maintenance Flawed maintenance will result in shorter lifespan, possible break down and in any event loss of warranty. Bearings Both motor bearings have been greased for their lifetime and require no maintenance. Mechanical seal A mechanical seal generally requires no maintenance, however, it should never be allowed to run dry.

  • Page 30: Failures

    Failures 1 If the pump shows problems, the cause may be elsewhere in the system. First check whether this is the case. 2 If you are sure the problem is within the pump, try to determine the cause. See chapter 6 "Faults". Then take the necessary measures. 3 See chapter 7 "Disassembly and assembly"...

  • Page 31: Faults

    CombiLine-CombiBlocHorti 6 Faults Faults in a pump system can have various causes. The fault may not be in the pump, it may also be caused by the pipe system or the operating conditions. Firstly, always check that installation has been executed in accordance with the instructions in this manual and that the operating conditions still correspond with the specifications for which the pump was purchased.

  • Page 32: Causes And Possible Solutions

    Causes and possible solutions A Electrical connection is faulty: • Consult your electrician B Wrong sense of rotation: • Consult your electrician C Pump not filled with liquid: • Open valves • Fill pump with fluid • De-aerate the system D NPSH available too low: •...
  • Page 33 CombiLine-CombiBlocHorti L Suction valve is not entirely open: • Open the valve M Defective mechanical seal: • Dismantle the pump and replace the mechanical seal N O-ring faulty: • Dismantle the pump and replace the O-ring O Bent shaft: • Dismantle the pump. Replace shaft, mechanical seal and impeller P Damaged impeller: •...
  • Page 34 Faults CL-CBH/EN (1901) 7.6...

  • Page 35: Disassembly And Assembly

    CombiLine-CombiBlocHorti 7 Disassembly and assembly General 7.1.1 Special tools Special tools can make certain operations easier. The instructions will indicate when these tools should be used. 7.1.2 Back Pull Out-unit The pump is designed with a Back Pull Out-system. This means that in case of repairs, the pump casing does not have to be removed from the piping (unless the fault is in the pump casing itself).

  • Page 36: Disassembly

    Disassembly 7.3.1 Disconnecting the motor Make sure that the electricity supply to the pump has been disconnected and that the pump cannot be switched on by others! 1 Open the cover of the terminal box on the motor. 2 Loosen the supply wires. Mark the wires and the corresponding terminals for later reconnection.

  • Page 37: Assembly

    CombiLine-CombiBlocHorti 7.4.2 Assembly 1 Clean and degrease the fitting edge of the pump casing where the wear ring is to be mounted. 2 Degrease the outer edge of the wear ring and put a few drops of Loctite 641 on it. 3 Fit the wear ring in the pump casing.

  • Page 38: Impeller

    1 Loosen the fastening nuts (0810) of the lantern piece, see figure 5. If the pump is still in the piping, start from the bottom side and proceed along the two sides upward, see figure 6. 2 Pull the Pull-out unit straight out of the pump casing (0100). Figure 6: Sequence of loosening the lantern piece fastening nuts.

  • Page 39: Mechanical Seal

    CombiLine-CombiBlocHorti 7.5.3 Mechanical seal 1 Remove the impeller key (1860) from the shaft end. 2 If present, remove the shaft sleeve (1200) with the rotating part of the mechanical seal (1220B) from the shaft. 3 Pull the rotating part of the mechanical seal off the shaft or the shaft sleeve. 4 To remove the static part of the mechanical seal first remove the lantern piece, see paragraph 7.5.4 "Lantern piece".

  • Page 40: Disassembling The Electric Motor

    Disassembling the electric motor The item numbers used refer to figure 17 on page 59. 7.6.1 Electric motor stator 1 Put the electric motor vertically with the shaft end pointing downward. Let the motor flange rest on e.g. 2 wooden blocks with an opening in the working surface for the shaft end.

  • Page 41: Assembly

    CombiLine-CombiBlocHorti Assembly For correct tightening moments see paragraph 10.3 "Tightening torques". All parts should be clean and undamaged. Bearings and mechanical seal should be left in the packing as long as possible. Assembling the electric motor The item numbers used refer to figure 17 on page 59. 7.8.1 Electric motor bearings 1 Place the shaft (2420-8) end up on the work table, the key way side up.

  • Page 42: Assembling The Pump

    Assembling the pump The item numbers used refer to the parts lists and drawings of chapter 9 "Parts". 7.9.1 Mechanical seal A mechanical seal is a vulnerable precision part. Leave the mechanical seal inside its original packaging until you mount it. Make sure the work site is free from dust and that the parts and tools are clean.

  • Page 43: Pull-Out Unit

    CombiLine-CombiBlocHorti 7.9.3 Pull-out unit 1 If the studs (0800) were dismantled, screw them into the pump casing (0100). 0100 0800 Figure 9: Pump casing with studs. 2 Grease the outer rim of the impeller entry with Molycote 107. 3 Grease the sealing collar of the lantern piece with Molycote 111 and place the O-ring (0300) in the groove.
  • Page 44 Disassembly and assembly CL-CBH/EN (1901) 7.6...

  • Page 45: Dimensions And Weights

    CombiLine-CombiBlocHorti 8 Dimensions and weights Weight The weight of the pump is indicated on the label on the cover of this manual and on a similar label on the packaging. Dimensions CombiLine 4/4 and 5/4 31.5 Figure 10: Dimensions drawing CombiLine 4/4 and 5/4. Pump type G 1 1/2 Dimensions and weights...
  • Page 46 Dimensions CombiLine ND6 S x T Figure 11: Dimensions drawing CombiLine ND6. Table 4: Flange dimensions CombiLine ND6. EN1092-2 (DIN2531) PN6 and ISO7005 S x T 4 x 14 4 x 14 4 x 14 4 x 14 4 x 18 4 x 18 Dimensions and weights CL-CBH/EN (1901) 7.6...
  • Page 47 CombiLine-CombiBlocHorti ND6 acc. to EN1092-2 (DIN2531) PN6 and ISO7005 32-125 250 125 125 40C-125 250 125 125 75,5 40-160 320 160 160 115 115 72,5 118,5 40 40-200 360 180 180 76,5 141 141 93,5 50-125 280 140 140 76,5 50-160 340 170 170 87,5 18,5 120 115 107,5 127,5 50...
  • Page 48 Dimensions CombiLine ND10 S x T Figure 12: Dimensions drawing CombiLine ND10. Table 5: Flange dimensions CombiLine ND10. EN1092-2 (DIN2532) PN10 and ISO7005 S x T 4 x 18 8 x 18 8 x 18 8 x 18 8 x 18 8 x 22 Dimensions and weights CL-CBH/EN (1901) 7.6...
  • Page 49 CombiLine-CombiBlocHorti ND10 acc. to EN1092-2 (DIN2532) PN10 and ISO7005 65-125 340 170 170 115 22 120 100 127,5 101 65 M16 G3/8 G3/8 G1/8 65-160 340 170 170 106,5 22 135 115 124 88,5 128,5 65 M16 G3/8 G3/8 G1/8 65-200* 440 220 220 132,5 21 151 141 133,5 102,5 169,5 65 M16 G3/8 G3/8 G3/8 80-125...
  • Page 50 Motor 80 90S 90L 100L 100L 112M 132S 132M 160M 160L 160L 180L 4 poles 150-125 150-160 150-200 125A-250 1046 150-250 1006 984 1053 200-200 1065 1043 1013 1112 3 kW 18,5 kW Motor 112M 132S 132M 160M 160L 132S 160M 6 poles 100-200...

  • Page 51: Dimensions Combiblochorti

    CombiLine-CombiBlocHorti Dimensions CombiBlocHorti aj x al ∅ ai x ∅ Figure 13: Pump dimensions CombiBlocHorti. Dimensions and weights CL-CBH/EN (1901) 7.6...
  • Page 52 ISO 7005 PN16 ai x ak aj x al am 8 x 18 8 x 18 8 x 18 8 x 18 8 x 23 8 x 18 8 x 23 8 x 23 ISO 7005 ≅ EN 1092-2 ISO 7005 PN10 ai x ak aj x al 8 x 23 8 x 23 8 x 23 8 x 23...
  • Page 53 CombiLine-CombiBlocHorti Motor 100L 100L 112M 132S 132M 160M 160L 160L 180L 4 poles 80C-200 80-250 100-160 100C-200 100C-250 125-250 150-125 150-160 150-200 150-250 200-200 250-200 3 kW 18,5 kW Motor 112M 132S 132M 160M 160L 132S 160M 6 poles 80C-200 80-250 100-160 100C-200...
  • Page 54 Dimensions and weights CL-CBH/EN (1901) 7.6...

  • Page 55: Parts

    CombiLine-CombiBlocHorti 9 Parts Ordering parts When ordering parts always quote the following data: 1 Your address. 2 The quantity, item number and the description of the part. 3 The pump number. The pump number is stated on the label on the cover of this manual and on the name plate of the pump.

  • Page 56: Combiline With Thread Connections

    CombiLine with thread connections 2400 0950 0900 0110 2405 0300 1860 1825 1820 0120 0100 2420 0810 0800 1220 Figure 14: Sectional drawing of CL 4/4-5/4. See figure 14. Item Quantity Description Material 0100 pump casing cast iron 0110 lantern piece cast iron 0120* impeller...

  • Page 57: Combiline With Flange Connections

    CombiLine-CombiBlocHorti CombiLine with flange connections 2400 0950 0900 2405 0110 0320 0300 1320 1860 1820 0120 2420 1220 0800 0810 1200 0350 0100 0310 Figure 15: CombiLine. Parts CL-CBH/EN (1901) 7.6...
  • Page 58 See figure 15. Item Quantity Description Material 0100 pump casing cast iron 0110 lantern piece cast iron 0120* impeller cast iron 0300* O-ring EPDM plug steel 0310 plug steel 0320 plug steel 0350 0800 stud steel 0810 steel 0900 steel 0950 stud steel...

  • Page 59: Combiblochorti

    CombiLine-CombiBlocHorti CombiBlocHorti 2400 0950 2405 0900 0110 0320 0300 1320 1860 1820 1220 0130 0120 0310 0100 2420 0800 0810 1200 Figure 16: CombiBlocHorti. Parts CL-CBH/EN (1901) 7.6...
  • Page 60 See figure 16 Item Quantity Description Material 0100 pump casing cast iron 0110 lantern piece cast iron 0120* impeller cast iron 0130* wear ring cast iron 0300* O-ring EPDM plug steel 0310 plug steel 0320 0800 stud steel 0810 steel 0900 steel 0950...

  • Page 61: Electric Motor

    CombiLine-CombiBlocHorti Electric motor 2420-1 2420-2 2420-10 2420-3 2420-4 2420-5 2420-9(B) 2420-8 2420-12 2420-6 2420-7 2420-9(A) 2420-11 2420-10 Figure 17: Exploded view of electric motor. Parts CL-CBH/EN (1901) 7.6...
  • Page 62 See figure 17. Item Quantity Description 2420-1* fan cover 2420-2* 2420-3* tie rod 2420-4 bearing block 2420-5 wave spring 2420-6* stator 2420-7 inner circlip 2420-8 shaft with rotor 2420-9* ball bearing 2420-10* oil seal 2420-11 motor flange 2420-12 cable junction box Parts marked with * are available as spare parts.

  • Page 63: 10 Technical Data

    CombiLine-CombiBlocHorti 10 Technical data 10.1 Technical data pumps CombiLine CombiBlocHorti 50Hz 400 m 600 m Maximum capacity 60Hz 500 m 700 m 50Hz 1 - 28 m 1 - 26 m Maximum delivery head 60Hz 4 - 40 m 3 - 38 m Maximum temperature 140 °C 140 °C...

  • Page 64: Technical Data Electric Motor

    10.2 Technical data electric motor Type, Frequency, Insulation, Voltage: see name plate on the electric motor. General 50Hz 1450 min (4 pole) 50Hz 950 min (6 pole) Nominal speed 60Hz 1750 min (4 pole) 60Hz 1150 min (6 pole) Speed CL4/4 and CL5/4 1450 min / 2900 min 50Hz...

  • Page 65: Tightening Torques

    CombiLine-CombiBlocHorti 10.3 Tightening torques Item Description Thread 0800 stud 0810 0900 motor fastening nut 0950 stud 1820 cap nut pump with shaft sleeve pump without shaft sleeve 10.4 Tightening torques CombiLine 4/4 and 5/4 Item Description 0800 stud 12,5 0810 12,5 0900 motor fastening nut...

  • Page 66: Noise Data

    10.6 Noise data The noise production of a pump depends strongly upon the operating conditions. The values stated below are for each pump type, equipped with its largest possible motor power (electric motor: 4-pole, 50 Hz). Table 7: Noise data. dB(A) max.

  • Page 67: Hydraulic Performance

    CombiLine-CombiBlocHorti 10.7 Hydraulic performance 10.7.1 Performance overviews CombiLine 80A-250 100A-250 125A-250 150-250 40-200 80-200 100-200 65-200 125C-200 150-200 200-200 40-160 4/4 and 5/4 2900rpm 80-160 100-160 125-160 150-160 65-160 50-160 150-125 32-125 50-125 100-150 65-125 80-125 40C-125 4/4 and 5/4 80 100 150 200 [m/h]...
  • Page 68 80A-250 100A-250 125A-250 150-250 100-200 125C-200 150-200 200-200 40-200 80-200 65-200 125-160 150-160 40-160 80-160 100-160 150-125 65-160 50-160 32-125 50-125 100-150 65-125 80-125 40C-125 4/4 and 5/4 5 6 7 8 10 40 50 60 80 100 150 200 [m/h] Figure 20: Performance overview CL 1750 min...

  • Page 69: Performance Overviews Combiblochorti

    CombiLine-CombiBlocHorti 10.7.2 Performance overviews CombiBlocHorti 100C-250 80-250 125-250 150-250 100C-200 200-200 150-200 80C-200 250-200 100-160 150-160 150-125 40 50 60 80 100 150 200 300 400 [m/h] Figure 22: Performance overview CBH 1450 min 100C-250 80-250 125-250 150-250 100C-200 200-200 150-200 80C-200 250-200...
  • Page 70 100C-250 80-250 125-250 150-250 100C-200 200-200 150-200 80C-200 250-200 100-160 150-160 150-125 40 50 60 80 100 150 200 400 500 [m/h] Figure 24: Performance overview CBH 1750 min 100C-250 80-250 125-250 150-250 100C-200 200-200 150-200 80C-200 250-200 100-160 150-160 150-125 15 20 40 50 60...

  • Page 71: Permitted Forces And Torques On The Flanges For Combiblochorti

    CombiLine-CombiBlocHorti 10.8 Permitted forces and torques on the flanges for CombiBlocHorti Forces and moments acting on the pump flanges due to pipe loads can cause misalignment of the pump, deformation and overstressing of the pump casing, or overstressing of the fixing bolts between the pump and the baseplate. The values can be applied simultaneously in all directions with positive or negative signs, or separately on each flange (suction and discharge).
  • Page 72 Technical data CL-CBH/EN (1901) 7.6...
  • Page 73 CombiLine-CombiBlocHorti Index Accessories ......23 Electricity company ....24 Applications .
  • Page 74 Working switch ..... 24 Packaging ......11 grips .
  • Page 75 Horizontal self-priming centrifugal pump CombiLine - CombiBlocHorti Circulation pumps Johnson Pump Horticulture De Hondert Margen 23, 2678 AC De Lier, THE NETHERLANDS Phone: + 31 (0) 174 51 84 10 Fax: + 31 (0) 174 51 84 44 E-Mail: johnson-pump.horticulture@spxflow.com www.spxflow.com/johnson-pump...

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