Table of Contents
Troubleshooting
Related Manuals for OSNA NMH Series
Summary of Contents for OSNA NMH Series
- Page 1 Original Operating Manual NMH/NMV High-Pressure Centrifugal Pump OSNA-Pumpen GmbH Brückenstrasse 3 49090 Osnabrück, Germany Phone: +49 541 1211 - 0 Fax: +49 541 1211 - 220 Internet: http://www.osna.de E-mail: info@osna.de Ver.17-02...
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Page 3: Table Of Contents
Contents GENERAL ............................6 About this operating manual ....................6 Target groups .......................... 6 Other valid documents ......................6 Warning notices and symbols ....................7 Copyright/changes ........................7 SAFETY ............................8 Correct and proper use ......................8 General safety instructions ...................... 9 2.2.1 Product safety ........................ - Page 4 ASSEMBLY AND INSTALLATION ....................21 Preparing for installation ......................21 5.1.1 Preparing the installation location..................21 5.1.2 Preparing the base surface and foundations ..............21 5.1.3 Removing the preservative ....................22 Installation ..........................23 5.2.1 Installing the pump ......................23 5.2.2 Securing the pump unit ......................
- Page 5 Operating the stand-by pump ....................41 Shaft seal ..........................42 6.5.1 Mechanical seal ......................... 42 6.5.2 Gland packing ........................42 MAINTENANCE AND REPAIR ..................... 43 General information ....................... 43 Operational monitoring ......................44 Maintenance .......................... 45 7.3.1 Anti-friction bearings and grease lubrication ..............46 7.3.2 Servicing the electric motors .....................
- Page 6 List of Tables Table 1: Target groups and their tasks ....................6 Table 2: Other valid documents and their purposes ................6 Table 3: Warning notices and consequences of non-observance ............7 Table 4: Symbols and their meanings ..................... 7 Table 5: Sound pressure level .......................
- Page 7 List of Images Figure 1: Model code ..........................13 Figure 2: Standard version type plate ....................13 Figure 3: ATEX version type plate ......................13 Figure 4: Scope of delivery for NMH with free shaft ................14 Figure 5: Scope of delivery for NMV without motor ................14 Figure 6: Scope of delivery for NMH as complete unit ................
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Page 8: General
1 General This operating manual: 1 General is part of the pump · 1.1 About this operating manual is valid for all type series mentioned · This operating manual contains important in- describes safe and proper use in all · structions that must be observed during instal- phases of operation lation, operation and maintenance. -
Page 9: Warning Notices And Symbols
OSNA-Pumpen GmbH. dangerous injury Any violation is punishable and subject to situation CAUTION compensation. Potentially Material dam- OSNA GmbH reserves the right to change the NOTICE dangerous contents of this documentation without notice. situation Additional Death, minor to information severe physical... -
Page 10: Safety
2 Safety Avoiding obvious misuse (examples) 2 Safety Observe the operating limits of the · pump for temperature, pressure, flow Observe the additional instructions for rate and speed. pumps in areas at risk of explosion. The manufacturer shall not bear any liability for damages caused as a result of non- observance of this documentation. -
Page 11: General Safety Instructions
Any use that goes beyond the purposes described above shall be considered im- dent prevention, as well as the rele- proper use. OSNA shall bear no liability for vant standards and specifications of the respective country. any resulting damages. The owner bears full risk for improper use. -
Page 12: Duties Of Personnel
2 Safety specifications of the VDE and the local for moving components: contact energy supplier). protection for the pump, installed by the customer for potential electrostatic charges: provide appropriate earthing Switch off the motor during all assem- · bly and maintenance works, and se- cure against reactivation. -
Page 13: Dangers Of Non-Observance Of The Safety Instructions
2 Safety Switch off the motor during all assem- 2.5 Unauthorized modes of opera- · bly and maintenance works, and se- tion cure against reactivation. The operational safety of the machine is only Reinstall the safety mechanisms after · guaranteed when it is used for the intended working on the pump according to purpose according to the operating manual (→... -
Page 14: Noise Emissions
2 Safety 2.6.3 Noise emissions Conditions for measurement: Distance to pumping unit: 1 m · Operation: Free of cavitation · Motor: IEC standard motor · Tolerance: ± 3 dB(A) · Noise emissions in dB(A) Drive power in kW 1450 min 2900 min 0.75 11.0... -
Page 15: Layout And Function
3 Layout and function 3.1.2 Type plate 3 Layout and function Standard configuration: 3.1 Labeling 3.1.1 Pump type labeling This operating manual applies NMH/NMV type series. Model code: Figure 2: Standard version type plate ATEX configuration: Figure 1: Model code Figure 3: ATEX version type plate Key: Type series... -
Page 16: Scope Of Delivery Of An Nmh/Nmv High-Pressure Centrifugal Pump
3 Layout and function 3.2 Scope delivery NMH/NMV high-pressure centrifugal pump The customer can order the pump: - with a free shaft (NMH) or without motor (NMV) - as a complete unit, i.e. fully assembled on base plate with drive motor, coupling and coupling guard Figure 7: Scope of delivery for NMV as complete unit Key:... -
Page 17: Technical Data
3 Layout and function Both vertical and horizontal pumps can be Flange: fitted with either an uncooled mechanical seal or an uncooled gland packing. NMH/NMV Suction side Pressure side series 3.4 Technical data Main parameters: NMH/NMV at speed = 1450 min Table 8: Pump series' flange sizes (gray cast iron) Delivery... -
Page 18: Functional And Operating Elements
3 Layout and function 3.7 Functional and operating ele- ments Shaft wearing sleeve: Shaft wearing sleeve Uncooled gland Up to 110 °C Up to 100 °C packing Uncooled mechan- Up to 140 °C Up to 140 °C ical seal Figure 9: Mechanical seal Table 10: Maximum authorized operating temperature at the shaft seal The technical dry running properties of gland... -
Page 19: Figure 10: Pressure-Side External Flushing Connection (Optional)
3 Layout and function Figure 10: Pressure-side external flushing connection (optional) Figure 11: Suction-side external flushing connection (optional) NMH/NMV High Pressure Centrifugal Pump... -
Page 20: Transport And Intermediate Storage
4 Transport and intermediate storage 4 Transport and intermediate storage DANGER 4.1 Transport Risk of death or crushed limbs from falling Weight information (→ Other valid docu- transported goods! ments) ► Choose lifting equipment that is suitable for the total weight to be transported. 4.1.1 Unpacking and checking the de- livery condition ►... -
Page 21: Intermediate Storage
4 Transport and intermediate storage 4.2 Intermediate storage Ensure during intermediate storage that the pump is not exposed to any weather conditions for a long period of time. If the pump is de- commissioned for a longer period of time (ap- proximately 2 to 3 months), ensure that it is fully drained. -
Page 22: Disposal
4 Transport and intermediate storage 4.4 Disposal NOTICE Plastic parts may be contaminated by toxic or radioactive pumping media. If this is the case, cleaning is not sufficient. Damage to bearings due to high water pressure or splashing water! ► Do not use water jets or steam jet cleaners WARNING to clean the bearing areas and motor. -
Page 23: Assembly And Installation
5 Assembly and installation 5.1.1 Preparing the installation loca- tion 5 Assembly and installation ► Ensure that the installation location meets the following conditions: 5.1 Preparing for installation pump is freely accessible from all – sides sufficient space for installing/removing –... -
Page 24: Removing The Preservative
5 Assembly and installation 5.1.3 Removing the preservative NOTICE Only necessary for preserved pump. Damage to seals due to incorrect cleaning agent! ► Ensure that the cleaning agent does not WARNING corrode the seals. Risk of poisoning from preservatives and cleaning agents in the food and drinking 1. -
Page 25: Installation
5 Assembly and installation 5.2 Installation 5.2.1 Installing the pump Prior to installation, remove the packaging (if present) and check the pump for any transport damage. Ensure that the installation area is dry and free of frost. Figure 15: Mounting material for complete units If the pump and motor are delivered separate- ly, place the pump onto the foundation without the motor, align using a precision spirit level... -
Page 26: Figure 17: Aligning The Base Plate
5 Assembly and installation 4. Align the pump unit to the required height and system dimensions as fol- lows using steel shims: Use one steel shim (2) to the left NOTICE and right of each foundation screw (1). If the distance between the an- choring holes is greater than 700 mm, add additional steel shims (3) Material damage due to strain on the base... -
Page 27: Securing The Pump Unit
5 Assembly and installation 5.2.3 Assembling the motor Remove any metal shavings and dirt · residues from all touch guard ele- ments. Only necessary if the pump unit is complet- ed at the installation location. The motor must meet the require- ·... -
Page 28: Fine Alignment Of The Coupling
5 Assembly and installation 5.3 Fine alignment of the coupling The unit is correctly aligned when a ruler placed across both halves of the coupling is the same distance from the respective shaft at all points around the circumference. Do not Figure 18: Positional alignment of the shafts forget to turn the measurement point by hand. -
Page 29: Vertical Configuration
5 Assembly and installation 5. Tighten the grub screws on both cou- 5.3.2 Vertical configuration pling halves. Vertical pumps are always delivered with a 6. Place suitable bearing plates beneath complete coupling (assembled on the the motor/pump until the ends of the pump). -
Page 30: Aligning The Motor
5 Assembly and installation 2. Check the alignment of the motor to the pump. DANGER 3. If the height displacement persists, re- peat the alignment process. Risk of death due to rotating parts! 4. Afterwards, tighten the motor screws. ► Use personal protective equipment when performing work on the pump. -
Page 31: Planning Pipelines
5 Assembly and installation 3. Perform the following steps on all ad- justment screws (3): Hold the adjustment screw (3) at the hexagon head (2) and loosen the lock nut (4). CAUTION Adjust the adjustment screw (3) by the required angle. Hold the adjustment screw (3) at the hexagon head (2) and tighten Before commissioning new systems, the... - Page 32 5 Assembly and installation vents contamination from penetrating the shaft seal, and therefore also prevents excessive Key: wear. Eccentric taper piece Shut-off valve Sealing and flushing fluid pressure Suction pipe Elbow The pressure of sealing and flushing fluid should always be 1 bar above the pump oper- Foot valve with inlet strainer ating pressure.
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Page 33: Avoiding Contaminations In The Pipelines
5 Assembly and installation 5.5.2 Avoiding contaminations in the 1. Calculate the forces in the pipeline and observe all operating conditions: pipelines cold/warm empty/filled pressurized/unpressurized 1. Clean all pipeline components and fit- tings prior to assembly. change in the flange position 2. -
Page 34: Optimizing Changes In Cross-Section And Direction
5 Assembly and installation > 5x DNs Preventing backflow Install a non-return valve between the dis- charge nozzle and the shut-off valve to prevent > 5x DNd medium backflow after the pump is switched off. Ensure compliance with the recommended pipeline lengths when installing the pump. -
Page 35: Installing The Suction Pipe
5 Assembly and installation 1. Install auxiliary pipelines to the auxilia- 2. Prevent air pockets by routing the ry connections, sealed and without pipeline constantly declining to the tension (à Installation plan). pump. 2. Prevent air pockets by routing the 3. -
Page 36: Electrical Connection
5 Assembly and installation 5.7 Electrical connection DANGER CAUTION Risk of death due to rotating parts! ► Use personal protective equipment when performing work on the pump. Electrical connection must be carried out ► Prevent the keys from being slung away by a specialist electrician, in line with the when checking the direction of rotation. -
Page 37: Earthing The Pump
5 Assembly and installation 2. Ensure that no danger arises due to Ensure that motors, couplings and · electrical energy. monitoring devices provided by the customer meet the specified category and temperature class in the respec- 3. Install an EMERGENCY STOP switch. tive ATEX zone (à... -
Page 38: Commissioning/ Decommissioning
6 Commissioning/decommissioning 6.1.2 Filling the pump 6 Commissioning/ decommissioning ü Auxiliary operating system ready 6.1 Commissioning ü Preservative removed (à 5.1.3 Removing the preservative, 6.1.1 Determining the pump configura- pg 22) tion 1. Fill the pump and suction pipe with pumping medium. -
Page 39: Checking Direction Of Rotation
6 Commissioning/decommissioning The cast direction of rotation arrow on the pump indicates the specified direction of rota- tion. Before checking the direction of rotation, se- WARNING cure the pump against activation. 1. Decouple the motor from the pump. Risk of poisoning or injury due to hazard- ous pumping media! 2. -
Page 40: Starting The Pump
6 Commissioning/decommissioning DANGER DANGER Never operate the pump without the cou- Risk of injury due to running pump! pling guard. ► Do not touch the running pump. ► Do not perform any work on the running pump. 6.1.4 Starting the pump Pump correctly installed and connect- Motor correctly installed and connect- DANGER... -
Page 41: Decommissioning
6 Commissioning/decommissioning 8. Set a slight leakage on the gland pack- ing, if present (à 6.5.2 Gland packing, pg 42). NOTICE 6.2 Decommissioning Open the suction-side fitting, and do not use it to control the flow rate. Do not close the pressure-side fitting! DANGER Do not open the pressure-side fitting above the... -
Page 42: Table 13: Measures Depending On The Behavior Of The Pumping Medium
6 Commissioning/decommissioning Pump to be Measure Shut down for ► Take measures according to the longer period pumping medium WARNING ► Close suction and pressure-side Drained fittings. ► Deactivate the motor and se- Disassembled cure against unauthorized reactiva- tion. ► Observe the storage measures Risk of poisoning or injury due to hazard- Put into stor- (→... -
Page 43: Switching Off The Pump
6 Commissioning/decommissioning Take the following measures before recom- missioning following operating interruptions of > 1 year: 6.2.1 Switching off the pump Shut down Measure 1. Pressure-side fitting closed (recom- time mended) > 1 year ► Check visually for leaks Replace elastomer seals 2. -
Page 44: Shaft Seal
6 Commissioning/decommissioning 6.5 Shaft seal WARNING 6.5.1 Mechanical seal Excessive tightening places too much ten- sion on the packing rings. This leads to wear and ultimately loss of tightness in the NOTICE stuffing box. Material damage due to dry running! Replace the gland packing if the leaks in the stuffing box persist. -
Page 45: Maintenance And Repair
7 Maintenance and repair 7 Maintenance and repair WARNING 7.1 General information Risk of poisoning or injury due to hazard- We can provide trained customer service ous pumping media! technicians for assembly and repair work. Please present proof of the conveyed goods upon request. -
Page 46: Operational Monitoring
7 Maintenance and repair years. If operating under unfavorable condi- tions, such as high room temperature, high 7.2 Operational monitoring humidity, dusty air, aggressive industrial at- mospheres, etc., check the bearings at an earlier time, and clean and relubricate if nec- Ensure that the pump runs smoothly and quiet- essary. -
Page 47: Maintenance
7 Maintenance and repair DANGER The use of pumps in ATEX zones is subject to additional requirements! Risk of injury due to hot pump compo- nents! à 9.1.4 Operation, pg 59 ► Use personal protective equipment when performing work on the pump. 7.3 Maintenance Service life of the anti-friction bearings in DANGER... -
Page 48: Anti-Friction Bearings And Grease Lubrication
7 Maintenance and repair 7.3.1 Anti-friction bearings and grease lubrication Relubricate after no more than 7500 operat- ing hours or 1 year under normal operating The use of pumps in ATEX zones is subject conditions. to additional requirements! 1. Clean the anti-friction bearings thor- à... -
Page 49: Servicing The Mechanical Seals
7 Maintenance and repair Ø In the event of heavy leakage, replace the mechanical seal with auxiliary seals and check that the auxiliary op- erating systems function properly. DANGER 7.3.4 Servicing the gland packing Only perform the inspection when the sys- tem is switched off and secured. -
Page 50: Sending The Pump To The Manufacturer
7 Maintenance and repair longer possible to adjust the gland, insert an additional packing ring or replace the packing rings. Figure 26: Suction-side stuffing box (standard) Dimensions [mm] Pump type Figure 25: Pressure-side stuffing box (standard) NMH/NMV 32 NMH/NMV 40 NMH/NMV 50 Replacing the packing rings: NMH/NMV 65... -
Page 51: Disassembling The Pump
7 Maintenance and repair ü Auxiliary operating system shut down, 7.5 Disassembling the pump depressurized and drained ü Manometer removed together with supply lines and holders DANGER 1. Only send pumps or individual compo- nents to the manufacturer together with a verifiable and completely filled out clearance certificate. - Page 52 7 Maintenance and repair ü When using couplings with spacer: spacer removed ü Auxiliary operating system shut down, DANGER depressurized and drained ü Manometer removed together with supply lines and holders Risk of injury due to running pump! ► Do not touch the running pump. ►...
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Page 53: Ordering Spare Parts
7 Maintenance and repair 7.6 Ordering spare parts Please have the following information to hand when ordering spare parts (à type plate, cross-section diagram): Customer number (if available) · Short designation of the pump series · Order number/pump number · Year of production ·... -
Page 54: Faults And Troubleshooting
8 Faults and troubleshooting 8 Faults and troubleshooting Number Fault Pump does not deliver Please consult the manufacturer should you experience any faults that are not described in Flow rate too low the following table, or cannot be traced back to Flow rate too high the described causes. - Page 55 8 Faults and troubleshooting Fault number Cause Remedy Geodetic delivery head and/or ► Remove deposits in pump and/or pipeline resistance too high pressure pipe. ► Install larger impeller and consult manufacturer. Pressure-side fitting not opened ► Open pressure-side fitting. far enough Pressure line blocked ►...
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Page 56: Table 19: Troubleshooting Table
8 Faults and troubleshooting Fault number Cause Remedy Lubricant: too much, too little or ► Reduce, increase or replace lubri- not suitable cant. Tie bolts not tightened correctly ► Tighten tie bolts. Mechanical seal worn ► Replace mechanical seal. Defective casing seal ►... -
Page 57: Appendix
9 Appendix Observe the enclosed data sheet. 9 Appendix · Ensure the following at all times: · 9.1 Additional ATEX instructions Pump earthed (earthing screw lo- cated on the bearing housing of the pump) à 5.7.2 Earthing the pump, pg 35 Additional requirements for safe operation No contact between the coupling in areas at risk of explosion... -
Page 58: Explosion Protection Marking
Appendix 9.1.2 Explosion protection marking ATEX marking DANGER The pumps in the NMH/NMV series meet the following ATEX Ex protection class: Only use the pump up to the temperature class indicated on the type plate. II G 2 c T3 1 2 3 4 5 6 The surface temperature of the pump must always be lower than the lowest ignition tem-... -
Page 59: Installation And Connection
9 Appendix Ex atmosphere Equipment groups/areas of use/zone/cate- gory The Ex atmosphere describes the type of ex- plosive atmosphere in a zone. Pumps are divided into equipment groups and categories according to the area in which they are used. The zone is based on the likelihood Ex atmosphere Meaning of an explosive atmosphere, and differentiates... -
Page 60: Table 24: Possible Devices For Monitoring Self-Warming Due To Dry Running
9 Appendix Performing measures for category 2 The motor must meet the require- · ments of the area at risk of explosion (group, category). Ensure that there are monitoring devices to prevent self-warming caused by dry running. If using a frequency inverter, please ·... -
Page 61: Operation
9 Appendix 9.1.4 Operation 9.1.5 Maintenance and repair Observing the maximum authorized operat- Maintenance intervals shorten under diffi- ing temperature cult operating conditions. Observe the maximum authorized operating Performing measures temperature (à data sheet). Replace the anti-friction bearing in the ·... -
Page 62: Spare Parts List For Constant Operation Over Two Years As Per Din 24296
9 Appendix 9.2 Spare parts list for constant operation over two years as per DIN 24296 Number of identical pumps Part no. Part designation (including reserve pumps) 6 and 7 8 and 9 > 9 Set/quantity of spare parts Pump shaft with small parts Impeller (set) Radial grooved ball bearing (set) -
Page 63: Cross-Sections
9 Appendix 9.3 Cross-sections Figure 27: Cross-section of NMH with mechanical seal NMH/NMV High Pressure Centrifugal Pump... -
Page 64: Figure 28: Cross-Section Of Nmh With Gland Packing
9 Appendix Figure 28: Cross-section of NMH with gland packing NMH/NMV High Pressure Centrifugal Pump... -
Page 65: Table 28: Nmh Parts List
9 Appendix Part no. Designation Part no. Designation Casing Multiple ring Suction casing Casing wear ring Delivery casing Correction ring Stage casing 504/1 Spacer ring 171/1 Diffuser 504/2 Spacer ring 171/2 Diffuser Retaining ring Thrower Shaft wearing sleeve Pump shaft Spacer sleeve 230/1 Impeller... -
Page 66: Figure 29: Cross-Section Of Nmv With Mechanical Seal
9 Appendix Figure 29: Cross-section of NMV with mechanical seal NMH/NMV High Pressure Centrifugal Pump... -
Page 67: Figure 30: Cross-Section Of Nmv With Gland Packing
9 Appendix Figure 30: Cross-section of NMV with gland packing NMH/NMV High Pressure Centrifugal Pump... -
Page 68: Table 29: Nmv Parts List
9 Appendix Part no. Designation Part no. Designation Casing Multiple ring Suction casing Casing wear ring Delivery casing Correction ring Stage casing 504/1 Spacer ring 171/1 Diffuser 504/2 Spacer ring 171/2 Diffuser Retaining ring Pump stool Thrower Shaft wearing sleeve 524/1 Shaft wearing sleeve Pump shaft... -
Page 69: Declaration Of Conformity As Per Ec Directive 2006/42/Ec, Annex Iia
DIN EN ISO 13857 : 2008 · DIN EN 60034 : 2007 · DIN EN 60204-1 : 2009 · Authorized representative for the composition of technical documentation for OSNA-Pumpen GmbH: Mr. Rik Arensmann Brückenstrasse 3 49090 Osnabrück, Germany Osnabrück, 31.10.2016 _______________________________ Rik Arensmann... -
Page 70: Declaration Of Conformity As Per Ec Directive 2014/34/Ec, Annex Vi
DIN EN ISO 13463-1 : 2009 · DIN EN ISO 13463-5 : 2011 · DIN EN ISO 15198 : 2007 · Authorized representative for the composition of technical documentation for OSNA-Pumpen GmbH: Mr. Rik Arensmann Brückenstrasse 3 49090 Osnabrück, Germany Osnabrück, 24.02.2017 _______________________________ Rik Arensmann... -
Page 71: Clearance Certificate
9 Appendix 9.6 Clearance Certificate Please copy and send with the pump. Clearance Certificate Legal provisions oblige all businesses to protect their employees, other persons and the environment from damaging effects when handling hazardous substances. Products and their components may therefore only be repaired or inspected when the following declaration has been fully and correctly filled out and singed by an authorized and qualified specialist. - Page 72 +49 541 1211 – 0 - Planning - Maintenance Fax: +49 541 1211 – 220 - Project management - Repair Internet: http://www.osna.de - Assembly E-mail: info@osna.de OSNA customer service Tel.: +49 541 1211 – 254 Emergency service Tel.: +49 171 4151 – 674...
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