13-BA8062 EN Ex-Immersible pump€¦ · This manual is protected by copyright and is exclusively...

Instructions

Ex-Immersible pump

13-BA8062 EN

Translation of the original instructions

Before starting work, read these instructions!

Hidrostal AGGigering 278213 NeunkirchSwitzerland T +41 (0) 52 687 06 87F +41 (0) 52 681 20 [email protected] Revision status 140702 This manual is protected by copyright and is exclusively for internal purpo-ses.Transfer of this manual to third parties, reproductions in any mannerand form – in full or in part – as well as exploitation and/or communicationof content without written permission from the manufacturer, except for in-ternal purposes, is prohibited.

Table of contents1 General information .................................................. 71.1 Information about these instructions ...................................... 7

1.2 Explanation of symbols ............................................................. 8

1.3 Disclaimer ................................................................................... 9

1.4 Terms of warranty ...................................................................... 10

1.5 Customer service and product monitoring ............................. 10

1.6 Spare parts ................................................................................. 10

2 Safety requirements ................................................. 132.1 Introduction ................................................................................ 13

2.2 Responsibility of the operator .................................................. 13

2.3 Personnel requirements ............................................................ 14

2.4 Intended use ............................................................................... 152.4.1 Application restrictions ................................................................. 15

2.5 Personal protective equipment ................................................ 15

2.6 Special dangers ......................................................................... 152.6.1 Mechanical hazards ..................................................................... 16

2.6.2 Biohazards ................................................................................... 16

2.6.3 Electrical hazards ......................................................................... 17

2.6.4 Hazards in the work area ............................................................. 17

2.6.5 Hazards from potentially explosive atmospheres ........................ 18

2.7 Safety mechanisms and devices, protection against restart,emergency shutdown, what to do in the event of danger oraccidents ....................................................................................

19

3 Specifications ............................................................ 213.1 Intended purpose ....................................................................... 21

3.2 General information ................................................................... 21

3.3 Operating conditions ................................................................. 21

3.4 Operating materials ................................................................... 223.4.1 Overview of hydraulic cooling oil ................................................. 22

3.5 Type plate ................................................................................... 233.5.1 Ex marking ................................................................................... 26

4 Design and functions ............................................... 294.1 Overview ..................................................................................... 29

Table of contents

Hidrostal AG 3

4.2 Electric motors ........................................................................... 30

4.3 Operational safety components ............................................... 33

4.4 Hydraulics ................................................................................... 35

4.5 Connections ............................................................................... 35

4.6 Controls ...................................................................................... 35

5 Transport and storage .............................................. 375.1 Transport .................................................................................... 375.1.1 Symbols and information on packaging ....................................... 37

5.1.2 Packages with anchor points ....................................................... 38

5.1.3 Pallet transport by forklift ............................................................. 38

5.1.4 Pallet transport by crane .............................................................. 39

5.1.5 Crane transport of unpacked pump ............................................. 39

5.2 Storage ........................................................................................ 39

6 Installation and initial commissioning .................... 41

7 Operation ................................................................... 43

8 Maintenance .............................................................. 458.1 Maintenance schedule ............................................................... 46

8.2 Service connections and inspection openings ....................... 47

8.3 Tightening torque for greased screw thread ........................... 48

8.4 Maintenance work ...................................................................... 488.4.1 Preparation tasks for maintenance .............................................. 48

8.4.2 Visual inspection .......................................................................... 48

8.4.2.1 Pump and motor .......................................................................... 48

8.4.2.2 Electric motor, motor cover, cable inlet and cable ....................... 49

8.4.3 Check/readjust impeller clearance ............................................... 49

8.4.3.1 Check impeller clearance "B" ....................................................... 49

8.4.3.2 Checking impeller clearance "S" .................................................. 50

8.4.3.3 Checking clearance "C" ............................................................... 51

8.4.3.4 Readjusting impeller clearance "C" .............................................. 52

8.4.3.4.1 Adjustable pump with three adjusting screws .............................. 52

8.4.3.4.2 Non-adjustable pumps ................................................................. 54

8.4.4 Checking the oil ........................................................................... 56

8.4.4.1 Cooling method "F" ...................................................................... 56

8.4.4.2 Purpose of checking the oil (cooling methods "E" and "K") ......... 56

8.4.4.3 Draining in a vertical position (cooling type "E") .......................... 58

8.4.4.4 Draining in a vertical position (cooling type "K") .......................... 59

Table of contents

4 Hidrostal AG

8.4.4.5 Draining in a horizontal position (cooling type "E") ...................... 60

8.4.4.6 Draining in a horizontal position (cooling type "K") ...................... 61

8.4.4.7 Analysing the drained liquid ......................................................... 61

8.4.4.8 Refilling the oil chamber (cooling method "E") ............................. 62

8.4.4.9 Refilling the oil chamber (cooling method "K") ............................. 63

8.4.5 Replacing the pump ..................................................................... 63

8.4.5.1 Checking the suitability of the replacement pump ....................... 63

8.4.5.2 Replacing the pump ..................................................................... 64

8.4.5.3 Checking the rotational direction .................................................. 65

8.5 Measures after completion of work .......................................... 66

9 Faults ......................................................................... 679.1 Safety .......................................................................................... 67

9.2 Malfunction table ....................................................................... 68

9.3 Measures after completion of work .......................................... 71

10 Disassembly .............................................................. 7310.1 Safety .......................................................................................... 73

10.2 Disassembly ............................................................................... 73

10.3 Disposal ...................................................................................... 74

11 Appendix .................................................................... 75

Table of contents

Hidrostal AG 5

Table of contents

6 Hidrostal AG

General information

Information about these instructionsThe target group of these operating instructions is the pump operator oncethe system, in which the pump is fitted, has been handed over by the systembuilder to the operator in ready-for-use condition.The selection of the suitable pump, the safe and correct integration into thesystem, the description of the operation, the installation and commissioningare the system manufacturer's responsibility and are NOT covered in theseoperating instructions.These operating instructions contribute to the safe and efficient handling ofthe machine. The fundamental prerequisite for safe working is theadherence to all safety information, warnings and operating instructionsgiven in the manual.Before starting any task, personnel must carefully read and understand thismanual.These instructions are part of the machine and must be stored in an easilyaccessible location for personnel to consult before starting work.If the machine is sold or transferred, the operating instructions must also bepassed on to the new owner.Besides these operating instructions, the instructions and information as wellas the signs on the machine also apply. Any advice on technicalmodifications must be attached to these instructions. Furthermore, the localaccident prevention regulations and general safety regulations for theapplication range of the machine apply.Illustrations in these instructions are provided for general understanding andmay differ from the actual design of the machine.If these operating instructions are lost, please order replacementimmediately (delivery against a nominal charge). Contact data see Imprint[–> 2].

1

1.1Target group

How to use these operatinginstructions

Obligation to read themanualStorage location

Resale

Other applicabledocuments, regulationsand directives

Illustrations in theseinstructionsLoss of the operatinginstructions

General information1Information about these instructions

Hidrostal AG 7

Explanation of symbolsSafety information and warnings are highlighted using symbols in theseoperating instructions. Signal words are found at the start of the safetyinformation and warnings and are used to express the severity of the hazard.Safety information must be observed and you must proceed with due care toprevent accidents, injuries or damage to property.

DANGER... indicates an imminent dangerous situation that will result indeath or serious injuries if not prevented.

WARNING... indicates a potentially dangerous situation that could resultin death or serious injuries.

CAUTION... indicates a potentially dangerous situation that could resultin minor injuries.

NOTICE... indicates a potentially dangerous situation that could resultin damage to property.

NOTE... indicates helpful advise and recommendations as well asinformation for efficient and trouble-free operation.

WARNING... indicates a potentially dangerous situation that could resultin death or serious injuries.

The warning symbol indicates potentially explosiveatmospheres in which ATEX- and IECEx guidelines apply.Non-compliance with these contents and instructions canresult in loss of explosion protection.

1.2

1General information

Explanation of symbols

8 Hidrostal AG

DisclaimerThe applicable standards, directives and regulations, the state of technology,and our years of experience have all been considered in the writing of theinformation and safety instructions in this operating instructions.The delivery contents or the machine design may vary from the descriptionsand illustrations in these instructions due to optionally ordered items, theproduction of customised parts or the latest technical modifications.Beyond the contractually negotiated obligations, the General Terms &Conditions and delivery terms of the supplier also apply. These are subjectto the applicable laws at the time of signing of the contract.The publication date of these operating instructions applies. Hidrostal AGreserves the right to make technical changes to the machine as part ofdevelopment to improve its safety and functionality.The manufacturer excludes liability for damage and accidents related to thefollowing points:

▪ Non-intended use of the machine▪ Non-compliance with the information and warnings given in these

operating instructions▪ Work on, or with the machine, by unqualified or unauthorized personnel▪ Installation of non-genuine spare parts▪ Unauthorised modifications without written approval from the

manufacturer▪ Use of unauthorised operating materials

1.3Information in theseinstructions

Delivery

Technical changes

Disclaimer

General information1Disclaimer

Hidrostal AG 9

Terms of warrantyThe terms and conditions can be found in the purchase agreement and thesupplier's General Terms & Conditions.The supplier will make final decisions on claims following the return or returnshipment of all defective components, or following an on-site inspection ifnecessary. The replacement of defective parts does not extend the warrantyperiod of the machine. Modifications or significant repairs by the operator orthird parties undertaken without the written consent of the supplier void thewarranty.

Customer service and productmonitoringPlease contact our customer service department if there are technicalqueries or any problems or questions that cannot be resolved with theseoperating instructions. Contact data see Imprint [–> 2].In our efforts to constantly improve our products, we are interested inhearing, via the Customer Service department, about your experiences inworking with the machine.Please inform us of any problems, faults or errors that you may haveencountered while operating the machine.Always notify the manufacturer of any accidents or hazardous incidents.

Spare partsSpare parts should be obtained from an authorised dealer or directly frommanufacturer. Contact data see Imprint [–> 2].

NOTEUse of spare parts that belong to another type of pump.Use of non-genuine spare parts.Loss of permission to use in potentially explosiveatmospheres!• The authorisation for pump use in potentially explosive

atmospheres is only granted if the pump satisfies thetechnical design requirements documented by themanufacturer.

• The authorisation for pump use in potentially explosiveatmospheres will be withdrawn if spare parts from otherpump models or non-OEM spare parts are used.

When using non-approved spare parts, all claims concerning warranty,service, damage and/or liability against manufacturer or his agents, dealersand representatives will be forfeited.

1.4Location

Fundamentals

1.5

Customer service

Product monitoring

1.6


Terms of warranty

10 Hidrostal AG

NOTEWhen making spare parts enquiries or placing spare partsorders, complete information must be provided such as Typedesignation in the contract.The spare parts list can be found in Appendix [➙ 75].

General information1Spare parts

Hidrostal AG 11


Spare parts

12 Hidrostal AG

Safety requirements

IntroductionThis section provides an overview of all key safety aspects for optimumsafety of personnel, as well as safe and reliable operation.Non-compliance with the operating instructions as well as the safetyinformation and warnings listed in this manual can result in considerablerisks.These operating instructions can only include the risks identified based on arisk assessment. Risks that occur due to working conditions, the location ofthe machine and the interfaces with external components must bedetermined and the on site safety instructions amended accordingly.

Responsibility of the operatorSince the machine is intended for use in a commercial environment, thesystem operator is strictly subject to the statutory requirements governingsafety at the workplace. In addition to the safety warnings in these operatinginstructions, the safety, accident prevention and environmental protectionregulations governing the location where the machine is to be used are alsoapplicable.The operators must inform themselves about the applicable occupationalsafety regulations. A risk assessment must also be carried out to identifyadditional risks resulting from the specific working conditions at the locationof operation.According to the results of the risk assessment of the workplace, theoperator must initiate, implement and document the operating instructions. The operator is responsible for ensuring that these operating instructions arekept up to date with the current legal requirements for the entire service lifeof the machine.The operator must manage the responsibilities for work on or with themachine, including naming a party to be responsible for the safe operation ofthe machine and coordinating all tasks.The operator must ensure that all personnel who carry out work on or withthe machine have read and understood these and other supplementaryoperating instructions.The operator must provide operating personnel with the necessary personalprotective equipment.Where applicable, before commissioning, the operator must make sure thatthe machine into which this product is to be installed, or of which itrepresents a component, corresponds to the fundamental safetyrequirements and stipulations of all relevant directives.To keep the machine in a technically flawless condition at all times, theoperator will ensure that the maintenance intervals prescribed in theseoperating instructions are followed. The operator will furthermore ensure thatall necessary safety mechanisms and devices are properly installed on themachine. The safety mechanisms and devices must be inspected regularlyto check that they are all present and functioning properly.

2

2.1

2.2Fundamentals

Risk assessment

Operating instructions

Responsibilities

Information flow

Personal protectiveequipmentSafety requirements

Technically flawlesscondition

Safety requirements2Introduction

Hidrostal AG 13

Personnel requirementsAuthorised personnel are those who carry out their task reliably and whoseresponses are not impaired by e.g. drugs, alcohol or medication.In the choice of personnel, the age requirements applicable to theinstallation location of the machine must be observed.

WARNINGIncorrect handling due to inadequate qualification andknowledge.Unauthorised persons who do not meet the requirementsdescribed here are unaware of the hazards in the work area.Risk of severe injury!• All tasks may only be carried out by suitably qualified

personnel.• Keep unauthorised personnel away from the danger areas.

In the operating instructions, the qualifications for the various tasks arespecified as follows:Trained personnel possess the technical education, knowledge andexperience as well as knowledge of applicable standards and regulationsthat allow them to execute work assigned to them and to independentlyrecognise and avoid potential dangers.Trained personnel are also trained by Hidrostal or a Hidrostal sales partnerin how to operate the pump. The completion of training programs must bedocumented.Only trained Hidrostal personnel or trained personnel of a Hidrostal salespartner are allowed to carry out service work. Nobody else is allowed toperform this work. To have the required work performed, please contact ourService department, see Imprint [–> 2].Trained electricians possess the technical education, knowledge andexperience as well as knowledge of applicable standards and regulationsthat allow them to execute work on electrical equipment and toindependently recognise and avoid potential dangers.Qualified electricians are trained for the specific site where they work andknow the relevant directives, standards and specifications.Forklift drivers must be at least 18 years old and their physical, mental stateand personal characteristics must be such that they are capable of driving aforklift either in seated or standing position.Furthermore, forklift drivers must have received training in how to operate aforklift in seated or standing position.Forklift drivers must have demonstrated to the operator their ability tooperate a forklift in a seated or standing position and have been instructed inwriting by the operator to do so.Hoisting equipment operators have been trained and authorised to performthis work.Instructed persons have been informed by trained personnel about theassigned tasks and possible hazards in case of incorrect behaviour. Thecompletion of training programs should be documented.

2.3General

Trained personnel

Manufacturers (servicecentre)

Trained electricians

Forklift drivers

Hoisting equipmentoperatorsInstructed persons(operators)

2Safety requirements

Personnel requirements

14 Hidrostal AG

Intended useThe pump is exclusively intended for pumping liquids and viscous, non-combustible media.If extremely abrasive or aggressive media are circulated, the pump must beconstructed of resistant material.Immersible pumps can operate continuously in a completely dry environmentor when they are fully submerged.The pump is authorised for use in potentially explosive atmospheres incompliance with Ex marking, see chapter Type plate [➙ 23].The pump must be kept in a clean and sound condition and its constructionmay not be altered from its delivered state.Intended use also includes compliance with all information contained inthese operating instructions.Any use beyond the one intended, or other use of the machine, is regardedas misuse and can result in dangerous situations.

Application restrictions

WARNINGNon-compliance with requirements governing effectiveexplosion protection.Risk of explosion!• Comply with the Ex marking restrictions indicated in chapter

Type plate [➙ 23].• The Ex approval applies to the external environment of the

pump. Explosive atmospheres within the circulated mediumare NOT permissible.

• Make sure that the system requirements in chapter Safetymechanisms and devices, protection against restart,emergency shutdown, what to do in the event of dangeror accidents [➙ 19] are satisfied.

• Make sure that the pump is serviced correctly, see chapterMaintenance [➙ 45].

Personal protective equipmentSome tasks require personal protective equipment to be worn. In addition to the personal protective equipment specified in these operatinginstructions, also observe the warnings located in the work area.

Special dangersThe following section indicates residual risks determined by a riskassessment.

▪ The safety instructions listed here and the warnings in the other chaptersof these instructions must be observed in order to reduce health hazardsand avoid dangerous situations.

2.4

2.4.1Potentially explosiveatmosphere

2.5

2.6

Safety requirements2Intended use

Hidrostal AG 15

Mechanical hazards

WARNINGSuspended loads.From corrosion and/or mechanical loading of weakenedanchor points.Risk of fatal injury!• Never stand below suspended loads.• Only use suitable hoisting equipment.• Only move loads under supervision.• Bring the load to the ground before leaving the work area.• If there is a suspicion of weakened anchor points, secure

the load with suitable sling gear.

WARNINGTipping loads.Risk of severe injury!• Always sufficiently secure components against tipping.• Only use suitable hoisting equipment.• Only move loads under supervision.

CAUTIONSharp edges on the edge and inside the pump chamber.Risk of injury!• Proceed carefully when working in the vicinity of sharp

edges.• Wear protective gloves!

Biohazards

WARNINGContact with infectious substances.Risk of severe illness!• Obtain binding information about the hazards relating to the

medium from the system operator.• Wear personal protective equipment.• Thoroughly clean the pump.• Carefully dispose of liquid drained from the oil chamber.• Thoroughly clean tools after use.

2.6.1

2.6.2


Special dangers

16 Hidrostal AG

Electrical hazards

DANGERContact with live parts.Damaged cable insulationRisk of fatal injury!• In case of damaged insulation, disconnect the power supply

immediately and have it repaired.• Before connecting the machine to the power supply,

compare the specifications Type plate [➙ 23] with thoseof the grid and only connect if they are identical.

• Any work on the electrical system must be performed byauthorised electricians.

Hazards in the work area

CAUTIONInsufficient lighting in the work area.Risk of injury!• Provide adequate lighting at the workplace.• Immediately replace defective lighting components.

WARNINGDirt and items left lying around represent tripping hazards.Risk of severe injury!• Always keep the work area clean.• Remove objects that are no longer required.• Use black/yellow tape to mark areas where there is a risk of

tripping.

WARNINGWork at the pump location, noise from neighbouring pumps,tank overflowing.Risk of injury!Risk of permanent health damage!• Always wear hearing protection in the vicinity of running

pumps.• Prior to entering a tank, ensure at the control console that

the tank will not be flooded as long as work is in progress.

2.6.3

2.6.4

Safety requirements2Special dangers

Hidrostal AG 17

Hazards from potentially explosiveatmospheresThe pump is suitable for use in a potentially explosive atmosphere in whichthe exterior environment of the pump conforms to the identification on therating plate. See Type plate [➙ 23]. A potentially explosive atmosphere inthe pump chamber is NOT permitted.Explosion protection can only be guaranteed if the pump is installed andmaintained as intended.

WARNINGPotentially explosive atmosphere in the pump chamber.Overheating from the pump running dry.Risk of explosion!• Level control, flow metering or flow monitoring should be

used on the machine to detect if the pump is running dryand, if so, to switch off the pump.

WARNINGOverheating from bearing damage.Risk of explosion!• Regular maintenance (bearing lubrication) ensures that

bearing defects are detected early, and that the pump isshut down.To prevent cavitation, ensure that the pump is onlyoperated inside its tolerance curve.

WARNINGSparks or hot surfaces following shaft breaks caused by thepump blocking.Risk of explosion!• Apply suitable system measures (e.g. a grill) to prevent

objects from blocking the pump.

WARNINGSparks or hot surfaces caused by the impeller grinding on thehousing parts.Risk of explosion!• Have the impeller clearance checked and adjusted by

qualified personnel (see Personnel requirements [➙ 14])only.

2.6.5


Special dangers

18 Hidrostal AG

WARNINGUnnoticed breakdown of safety mechanisms and devices.Risk of explosion!• The operation of safety mechanisms and devices must be

controlled either by a system control that is designed todetect faults or by regular servicing intervals to check thecorrect functioning in accordance with the systemmanufacturer's regulations.

Safety mechanisms and devices,protection against restart, emergencyshutdown, what to do in the event ofdanger or accidentsThe system manufacturer is responsible for ensuring the safety of thesystem in which the pump is installed. This aspect is not covered in theseoperating instructions.The following minimum requirements must be satisfied to ensure explosionprotection:

▪ Level control, flow metering or flow monitoring to shut down the pump if itis running dry.

▪ Regular maintenance (bearing lubrication) ensures that a bearing defectis detected early, and that the pump is shut down.

▪ Monitoring of the operating conditions to prevent the pump operatingoutside the tolerance curve (risk of cavitation!)

▪ Grills or other comparable measures are used to prevent objects fromblocking the pump intake.

▪ Monitoring the correct functioning of safety mechanisms and deviceswith a system control or by checking the pump at frequent intervals.

Furthermore, the system must be fitted with at least a lockable mains switchto ensure that all the conductors connected to the pump are voltage free andto prevent an unintentional restart.See chapter Operational safety components [➙ 33] for information onoperational safety components that are either included as standard in thepump or that are optionally available from the system manufacturer.

2.7

Safety requirements2Safety mechanisms and devices, protection against restart, emergency shutdown,

what to do in the event of danger or accidents

Hidrostal AG 19

2Safety requirementsSafety mechanisms and devices, protection against restart, emergency shutdown,what to do in the event of danger or accidents

20 Hidrostal AG

Specifications

Intended purposeWARNINGNon-compliance with requirements governing effectiveexplosion protection.Risk of explosion!• Comply with the Ex marking restrictions indicated in chapter

Type plate [➙ 23].• The Ex approval applies to the external environment of the

pump. Explosive atmospheres within the circulated mediumare NOT permissible.

• Make sure that the system requirements in chapter Safetymechanisms and devices, protection against restart,emergency shutdown, what to do in the event of dangeror accidents [➙ 19] are satisfied.

• Make sure that the pump is serviced correctly, see chapterMaintenance [➙ 45].

The pump is exclusively intended for pumping liquids and viscous, non-combustible media.If extremely abrasive or aggressive media are circulated, the pump must beconstructed of resistant material.

General information

NOTEFor contract-related technical data (dimensions, weights,performance, connected loads, etc.) refer to enclosed deliverydrawings and data sheets, see chapter Appendix [➙ 75].

Operating conditions NOTICE

Frozen medium inside the pump.Danger of failure of the pump housing!• Make sure that the medium inside the pump and the

connected hose lines does not freeze.• It is particularly important to make sure that the volume

behind the impeller is drained on pumps that are subject tofrost (e. g. by blowing out with compressed air).

3

3.1Potentially explosiveatmosphere

Permissible media

3.2

3.3Temperature

Specifications3Intended purpose

Hidrostal AG 21

Designation Value

Temperature of medium max. 40 °C

Ambient temperature max. 40 °C

The pump is designed for continuous operation (S1 pursuant to EN60034-1:10/2010).

NOTICEUse in incorrect installation position.Impairs the function of the monitoring equipment!• Use the pump only when it is installed in the position that is

specified on the delivery documents.

The pump can be used either in a vertical or in a horizontal installationposition. The installation position is specified on the delivery documents.Operating a pump that is built for vertical installation horizontally is notpermitted.A pump that is designed for horizontal installation can usually be convertedfor vertical installation (manufacturer/service engineer). The conversion mustbe documented on the delivery documents.

Operating materials

Overview of hydraulic cooling oil Name Manufacturer Density at

15 °C [kg/m³]Viscosity at40 °C [mm²/s]

Flash pointCOC [°C]

used by manufacturer: Rinatol 856 Ess+MüllerCH-8200Schaffhausen

850 14.2 190

alternative oilsrecommended bymanufacturer:

Tellus T 15 Shell Oil 871 15 170

Bartran HV 15 BP 874 15 160

Equivis ZS 15 Total 853 15 174

WARNINGUsing unapproved oil can lead to insufficient cooling andinadequate lubrication of seals.Risk of explosion!• Use only the oils that are listed in the table above.

Duration

Installation position

3.4

3.4.1

3Specifications

Operating materials

22 Hidrostal AG

Type plateThe type plate is located on the motor housing.

1

23 4 5

6 7 89 10 1112 13 14 15

16 17 18 192023

28

222124

2625 2729

Item Designation Example

1 Manufacturer Hidrostal AG8213 NeukirchSwitzerland

2 Type H05K-MH3R +HEVC4-XIEK1 +XC1B5I-10

3 Classification of the cooling methods 51W0*

4 IP rating IP68

5 Operating mode, rating class S1

6 Nominal output 45 kW

7 Speed 1463 min⁻¹8 Frequency 50 Hz

9 Phase sequence D*

10 Nominal voltage 380 - 420 V

11 Nominal motor current 89.0 A

12 Type of protection iB*

13 Temperature class Ex T4

14 Version EN60034 standard -1:2010

15 Power factor 0.88

16 Starting current/nominal current ratio 7.0

17 Response time of thermal motorprotection

28 s

3.5

Ex-protection type plate,mains operation

Specifications3Type plate

Hidrostal AG 23


18 Temperature class of windinginsulation

F

19 Reserve field NA**

20 PTC thermistor type *

21 Tripping unit *

22 ID number of notified body 0344

23 Ex marking 94/9/EC PTB 99*

24 EC-type-examination certificate 1076*

25 Year of manufacture 2011

26 Serial number 200999

27 Weight 801 kg

28 Flow rate l/s*

29 Delivery height M*

* Fields can remain empty.** not applicable

1

23 4 5

6 78 9 10 11

12 13 14 1516 17 18

19 20

2725

2928

2126

2224

23

3130303033

303534

32

36 3837


1 Manufacturer Hidrostal AG8213 NeukirchSwitzerland

2 Type D100-M03R + DNXQ2-MIEQ1 + XC1A2I-13

3 Classification of the coolingmethods

41W0*

4 IP rating 68*

5 Operating mode, rating class S1*

Ex-protection type plate,inverter operation(frequency inverter)

3Specifications

Type plate

24 Hidrostal AG


6 Inverter type *

7 Motor data at frequency 50 Hz

8 Nominal output 15 kW

9 Nominal speed 2873 min⁻¹10 Phase sequence D*

11 Nominal voltage 380 - 420 V

12 Type of protection ib*

13 Temperature class EX T4

14 Version EN60034 standard -1:2010

15 Nominal current 30.0 A

16 Tripping unit *

17 Temperature class F

18 Reserve field NA**

19 PTC thermistor type S150*

20 Response time of thermal motorprotection

17 s

21 ID number of notified body 0344

22 Ex marking 94/9/EC PTB 00*

23 EC-type-examination certificate 1011*

24 Year of manufacture 2012

25 Serial number 216000

26 Weight 249.00 kg

27 Flow rate l/s* (customer data)

28 Delivery height m* (customer data)

29 Speed 1 min⁻¹ * (customer data)

30 Torque 1 Nm* (customer data)

31 ON time %* (customer data)

32 ON time min* (customer data)

33 Torque 2 Nm* (customer data)

34 Speed 2 min⁻¹ * (customer data)

35 Starting torque Nm* (customer data)

36 Max. shaft power kW* (customer data)

37 Speed at max. shaft power min⁻¹ * (customer data)

38 Frequency at max. shaft power 25 - 55 Hz* (customerdata)

* Fields can remain empty.** not applicable


Hidrostal AG 25

Ex marking

WARNINGUse of pump in potentially explosive atmospheres.Risk of explosion!• Make sure that the pump is only used in potentially

explosive atmospheres as listed on the type plate.• The Ex Approval is applicable for the exterior environment

of the pump. Explosive atmospheres inside the pumpchamber, i.e. in the circulated medium, are NOTpermissible.

Hidrostal pumps intended for use in potentially explosive atmospheres aredelivered with the following markings in compliance with Directives 94/9/ECand EN 60079-0:

▪ II 2G EEx d IIB T3

▪ II 2G EEx d IIB T4

▪ II 2G EEx d [ib] IIB T3

▪ II 2G EEx d [ib] IIB T4

▪ II 2G Ex d IIB T3

▪ II 2G Ex d IIB T4

▪ II 2G Ex d [ib] IIB T3

▪ II 2G Ex d [ib] IIB T4The elements of the marking are explained below:

Equipment intended for use in potentially explosive atmospheres inaccordance with Directive 94/9/EC

II Equipment group II: Applies to equipment intended for use in areasliable to be endangered by explosive atmospheres but not for useunderground in mines and those parts of surface installations ofsuch mines, liable to be endangered by firedamp and/orcombustible dust.

2 Category 2: Equipment in this category is intended for use in areasin which explosive atmospheres occasionally occur.

G Material group G: explosive gases, vapours, mist

EExEx

Electrical equipment (old marking)In combination with the following ignition protection category:electrical equipment (new marking)

d[ib]

Ignition protection category, pressure resistant encapsulated (driveunit)Ignition protection category, intrinsically safe for Ex zones 1 and 2(moisture probe)

3.5.1

3Specifications

Type plate

26 Hidrostal AG

IIB Suitable for gases of explosion group IIB, also includes gases ofexplosion group IIA.

T3T4

Temperature category T3: max. surface temperature = 200 °CTemperature category T4: max. surface temperature = 135 °C


Hidrostal AG 27

3Specifications

Type plate

28 Hidrostal AG

Design and functions

OverviewCooling methods "E" and "F"1 Cable cover

2 Electric motor with cooling jacket

3 Oil chamber

4 Hydraulic part

5 Suction flange

6 Pressure flange

Cooling method "K"1 Cable cover

2 Electric motor

3 Oil chamber

4 Hydraulic part

5 Suction flange

6 Pressure flange

The impeller of the hydraulic part (3) sucks in the conveyed medium via thesuction flange (4) and conveys it to the pressure flange (5).

4

4.1

2

1

3

4

5

6

1

2

3

4

5

6

Design and functions4Overview

Hidrostal AG 29

Electric motorsImmersible pumps can operate continuously in a completely dry environmentor when they are fully submerged.Depending on motor size and application, various cooling methods "E", "K","F" can be applied (second digit of motor code):On this type, the pump is equipped with an oil cooling jacket (1) with forcedcirculation.

1 Cooling jacket of stator housing

2 Oil filler opening

3 Oil drain opening

4 Flushing connection

The waste heat of the motor is displaced to the cooling oil, which circulatesin the cooling jacket. The oil discharges the waste heat through the sealingpart of the motor (serves as heat exchanger). The oil is displaced by animpeller on the motor shaft.

4.2

Self-cooling (coolingmethod "E")

2

1

3 4

4Design and functions

Electric motors

30 Hidrostal AG

On this type, the waste heat of the motor is transferred directly to thesurrounding liquid (pump submerged) or the air (pump not submerged) viathe stator housing (1).

1 Stator housing

2 Opening to drain, fill in, and test the oil

3 Flushing port to remove obstructions from behind the impeller

Convection cooling(cooling method "K")

1

2 3

Design and functions4Electric motors

Hidrostal AG 31

On this type, the cooling oil circulates using an external cooling system.

1 Cooling jacket of stator housing

2 Cooling oil outlet

3 Cooling oil inlet

4 Oil drain opening


This type is suitable for applications where self-cooling is not sufficient,particularly when the temperature of the circulated liquid is too high for aneffective cooling.

Forced cooling (coolingmethod "F")

2

1

3

54


Electric motors

32 Hidrostal AG

Operational safety components NOTICE

Incorrect design of system control.Bypassing of safety components.Danger of damage!• ALL of the safety components below will only function

correctly if the system control analyses them correctly.

The following components can be installed:

1 Bearing temperature sensor in the upper bearing (optional)

2 Coil head with integrated temperature limiter (bimetal switch or PTCsensor)

3 Bearing temperature sensor in the lower bearing (optional)

4 Float switch (optional)

5 Moisture sensor (optional)

4.3

Design and functions4Operational safety components

Hidrostal AG 33

NOTICEImproper electrical connection.Danger of damage!• Never connect a PTC sensor to more than 2.5 V.

Temperature monitoring sensors can protect the motor against excessivetemperatures in case of blocked rotors (PTC sensors only), excessive start-ups, incorrect rotation, increased ambient temperature and impaired cooling.Two bimetal switches and one PTC sensor are integrated in the coil head (2)of the motor. Depending on the specific application, the sensors areconnected via cables to the control unit.The control unit must always evaluate a bimetal switch for 130 °C and thePTC sensor for 150 °C. The pump must be switched off when the bimetalswitch 130 °C responds. After the pump has cooled down, it can be switchedback on automatically. If the PTC sensor 150 °C responds, the pump mustbe switched off and may NOT be switched back on after the motor hascooled down. The pump must be checked in an authorised workshop.Bimetal switches can be directly connected to the motor's control circuit(max. of 250 VAC, 2.5 A).PTC sensors must be connected to an electronic analysis unit (max. 2.5 V).The bearing temperatures of the lower and upper bearings of the electricmotor are monitored by temperature probes. Potential bearing damage canbe detected early. These sensors can be analysed to provide additionalpump protection and trigger a precautionary shutdown.A possible leak on the motor seal is monitored by means of a float switch inthe dry chamber. If liquid leaks into the dry chamber, the contact in the floatswitch is opened. This can prevent the grease from dissolving, causingdamage to the bearing and the winding head. These switches can be connected to provide additional pump protection andtrigger a precautionary switch-off.The moisture sensor monitors the seal at the medium side for leakage. Thesensor and the electronic evaluation system measure the electricalresistance of the sealing medium. The resistance decreases as the watercontent in the sealing medium increases. The electronic evaluation systemcan trigger an alarm when a value of 60 kOhm is reached.These sensors can be evaluated to provide additional pump protection, andto initiate a precautionary shutdown.

Temperature monitoringwith bimetal switch andPTC sensor:

Bearing temperaturesensor (1.3) (optional):

Float switch (4) (optional)

Moisture sensor (5)(optional):


Operational safety components

34 Hidrostal AG

Hydraulics

1

23

4

5

1 Suction cone

2 Screw centrifugal impeller (impeller)

3 Pressure flange

4 Spiral casing

5 Suction flange

ConnectionsThe pump is connected to the energy supply by means of one or moreelectrical cables. See Appendix [➙ 75] for the wiring diagram.The design and documentation of the system's internal connections are theresponsibility of the system manufacturer and are not covered in theseoperating instructions.

Controls

NOTEThe device has no separate controls. A system control is usedfor operation.The control unit is not part of these operating instructions.

4.4

4.5

4.6

Design and functions4Hydraulics

Hidrostal AG 35


Controls

36 Hidrostal AG

Transport and storageThe system manufacturer is responsible for transporting the pump as part ofthe facility construction or modernisation. The system manufacturer providesthe operator with a turnkey system.This chapter focuses on the transport and storage of replacement pumps.

Transport

WARNINGUnsafe behaviour.Incorrect handling due to inadequate qualification andknowledge.Risk of severe injury!• Observe the information and personnel requirements in

chapter Safety requirements [➙ 13].

Symbols and information on packagingDepending on its size and shape, the transport container is suitable fortransport by forklift or by crane.Weight specifications can either be found on the outside of the packaging oron the pump's type plate, depending on the type of packaging used.

▪ Observe the symbols and information on the packaging. The arrows indicate the top side of the package. They must always pointupwards, otherwise the contents can be damaged.

Only affix fastening materials (fastening chains, hoisting straps) at the pointsdesignated with this symbol.

Indicates the centre of gravity of a package.The centre of gravity must be taken into account during lifting and transport.

5

5.1

5.1.1

Transport and storage5Transport

Hidrostal AG 37

Protect the packaging against water and keep dry.

Indicates packages that cannot be stacked.

Packages with anchor pointsPackages which have anchor points can be transported directly by craneunder the following conditions:

▪ The crane and lifting gear must be designed for the weight of thetransported item.

▪ The operator must be authorised to operate the crane.Protective equipment:

▪ Hard hat1. Fasten belts or multiple-point suspension gear appropriately.2. Make sure that the transported item is hanging straight, check if the

package has an off-centre centre of gravity.3. Start the transport.

Pallet transport by forkliftPackages that are fastened on pallets can be transported by forklift underthe following conditions:

▪ The forklift must be designed for the weight of the transported item.▪ The transported item must be securely fastened to the pallet.

Personnel:▪ Forklift drivers

1. Drive the forklift with the forks in between the pallet deck-boards.2. Drive the forks in far enough that they protrude on the opposite side.3. Ensure that the pallet cannot tip as a result of an off-centre centre of

gravity.4. Lift the pallet with the transported item and start the transport.

5.1.2

5.1.3

5Transport and storage

Transport

38 Hidrostal AG

Pallet transport by cranePackages that are fastened on pallets can be transported by crane under thefollowing conditions:

▪ The crane and lifting gear must be designed for the weight of thetransported item.

▪ The operator must be authorised to operate the crane.1. Fasten belts or multiple-point suspension gear onto the pallet

appropriately and protect the pallet from slipping.2. Check that the transported items are not damaged by the fastening

equipment. If necessary, use other fastening equipment.3. Ensure that the pallet cannot tip as a result of an off-centre centre of

gravity.4. Start the transport.

Crane transport of unpacked pump

WARNINGSuspended loads.From corrosion and/or mechanical loading of weakenedanchor points.Risk of fatal injury!• Never stand below suspended loads.• Only use suitable hoisting equipment.• Only move loads under supervision.• Bring the load to the ground before leaving the work area.• If there is a suspicion of weakened anchor points, secure

the load with suitable sling gear.

Storage

NOTEThe delivery documents provided with the pump includeimportant information on the permissible installation position ofthe pump.• Store the delivery documents or copies of them together

with the pump.

5.1.4

5.1.5

5.2

Transport and storage5Transport

Hidrostal AG 39

NOTEThe transport packaging also protects the pump duringstorage.The transport packaging of a replacement pump can be usedto return a defective pump.

Store the pump under the following conditions:▪ Do not store outside.▪ Keep dry and dust-free.▪ Do not expose to aggressive media.▪ Do not expose to any mechanical agitations and vibrations.▪ Turn the shaft of the impeller via the front screw every two weeks to

prevent any storage damage. If it cannot be turned in the packaging,remove the pump from the packaging and re-pack it once it has beenturned.

▪ Storage temperature: –10 … +40 °C.▪ Relative humidity: max. 60 %.▪ If storage exceeds 3 months, check general condition of all parts and of

packaging at regular intervals.▪ Prevent the cable ends from coming into contact with water, as capillary

action will cause the water to flow into the cables.

NOTICEFrozen liquid inside an already used pump.Danger of failure of the pump housing!➢ Before putting a used pump into storage:• Make sure that the oil is free from water, see chapter

Checking the oil [➙ 56].• Ensure there is no water in any of the hollow parts of the

pump.

NOTEIt is possible that the packages contain storage instructionsthat go beyond the requirements mentioned here. Pleasefollow them.

Pump storage

5Transport and storage

Storage

40 Hidrostal AG

Installation and initialcommissioningThe system manufacturer is responsible for the installation and initial startupof the pump as part of system construction or modernization. The systemmanufacturer hands over an operational system to the company operatingthe system. Installation and initial startup are thus not included in theseoperating instructions.Chapter Replacing the pump [➙ 63] explains how to replace a defectivepump with a replacement pump.

6

Installation and initial commissioning6

Hidrostal AG 41

6Installation and initial commissioning

42 Hidrostal AG

OperationThe pump is switched on and off and monitored by the control for the systeminto which the pump is integrated.The pump has no separate controls.The system control is not covered in these operating instructions.

WARNINGPotentially explosive atmosphere in the pump chamber.Risk of explosion!• Ensure that draining the sump does NOT cause any

potentially explosive atmosphere to build up in the pumpchamber.

The pump can operate continuously in a completely dry environment orwhen it is fully submerged.To cool the pump, it need not be continuously immersed.To start the pump, the "ON" level must be at least as high as the impeller tip.

7

Dry run times

Cooling times

Operation7

Hidrostal AG 43

7Operation

44 Hidrostal AG

Maintenance

WARNINGUnsafe behaviour.Incorrect handling due to inadequate qualification andknowledge.Risk of severe injury!• Observe the information and personnel requirements in

chapter Safety requirements [➙ 13].

WARNINGContact with infectious substances.Risk of severe illness!• Obtain binding information about the hazards relating to the

medium from the system operator.• Wear personal protective equipment.• Thoroughly clean the pump.• Carefully dispose of liquid drained from the oil chamber.• Thoroughly clean tools after use.

WARNINGPotentially explosive atmosphere.Risk of fatal injury!• Obtain written approval before beginning any work.• Make sure that the work area is sufficiently ventilated so

that no explosive atmospheres can build up during work.• If the risk of an explosive atmosphere in the work area

cannot be excluded: Only use tools that are authorised foruse in potentially explosive atmospheres.

NOTEUse of spare parts that belong to another type of pump.Use of non-genuine spare parts.Loss of permission to use in potentially explosiveatmospheres!• The authorisation for pump use in potentially explosive

atmospheres is only granted if the pump satisfies thetechnical design requirements documented by themanufacturer.

• The authorisation for pump use in potentially explosiveatmospheres will be withdrawn if spare parts from otherpump models or non-OEM spare parts are used.

8

Maintenance8

Hidrostal AG 45

WARNINGWork at the pump location, noise from neighbouring pumps,tank overflowing.Risk of injury!Risk of permanent health damage!• Always wear hearing protection in the vicinity of running

pumps.• Prior to entering a tank, ensure at the control console that

the tank will not be flooded as long as work is in progress.

Maintenance scheduleInterval Maintenance work Personnel

Initially after approx.1000 oh (operatinghours)

Check pump for damage, see chapter Visual inspection[➙ 48]

Instructed persons(operators)

Check oil level, see chapter Checking the oil [➙ 56] Trained personnel

Annually Check pump for damage, see chapter Visual inspection[➙ 48]


Check the electric motor, motor cover, cable inlet and cablefor any damage and resistance-free connection, seechapter Visual inspection [➙ 48]


Check oil level, see chapter Checking the oil [➙ 56] Trained personnel

Check impeller clearance, readjust if necessary, seechapter Check/readjust impeller clearance [➙ 49]

Trained personnel

after circulation of solidsubstances, e.g. gravel

Check impeller clearance, readjust if necessary, seechapter Check/readjust impeller clearance [➙ 49]

Trained personnel

8.1

8Maintenance

Maintenance schedule

46 Hidrostal AG

Service connections and inspectionopenings

1

23

3

4

1 Connection at pressure flange

2 Connection as drain opening for horizontally installed pumps withvertical outlet

3 Locations of the additional connections for horizontally installedpumps with horizontal outlet (option)

4 Inspection opening in the enclosure to check the hydraulic system(hydraulic size E05Q/E125, and more)

WARNINGOpen inspection openings on spiral housing.Risk of severe injury!• Inspection openings are only to be opened at complete

standstill and with power supply switched off and protectedagainst restart.

The inspection openings can only be opened with tools. After completion ofwork and before restart, the inspection openings must be closed and allfasteners properly mounted again.

8.2

Maintenance8Service connections and inspection openings

Hidrostal AG 47

Tightening torque for greased screwthreadScrew threadsize

Tightening torque forstainless steel screwthread A1/A2/A4 [Nm]

M6 7

M8 17.5

M10 35.5

M12 61.5

M16 147

M20 285

M24 310

Maintenance workPersonal protective equipment:

▪ Protective clothing▪ Protective gloves▪ Safety shoes▪ Safety goggles▪ Hearing protection

Preparation tasks for maintenance1. Turn off pump or system and protect against restart.

➢ If the pump is submerged in the sump:2. Remove the pump from the sump with suitable lifting gear.3. Hose down pump with water.

4. Position the pump in a vertical position on a surface and attach lifting

gear on the drive unit to prevent it from tipping.

Visual inspection

Pump and motorPersonnel:

▪ Instructed persons (operators)1. Check the pump for mechanical damage.

8.3

8.4

8.4.1

8.4.2

8.4.2.1

8Maintenance

Tightening torque for greased screw thread

48 Hidrostal AG

Electric motor, motor cover, cable inlet andcablePersonnel:

▪ Trained electricians1. Check electric motor, motor cover, cable inlet and cable for visual

damage.

Check/readjust impeller clearancePersonnel:

▪ Trained personnelPersonal protective equipment:

▪ Protective clothing▪ Safety shoes

Required tool:▪ Feeler gauge

Check impeller clearance "B"

B1

23

4

5

Impeller clearance "B" is the gap between impeller (1) and seal (2) or rearcone (2).The impeller clearance "B" must be kept as small as possible to hinder fibresor solids from entering the seal space. Due to abrasive media, the clearancecan increase over time.1. Make sure that the pump is positioned in a vertical position on a surface

and attach lifting gear on the drive unit to prevent it from tipping.2. Remove hexagon nuts (3) and washers (4).3. Lift the drive unit off the hydraulic unit.4. Using a feeler gauge, measure the impeller clearance "B" between

impeller (1) and seal (2) or rear cone (2) at several points on thecircumference.

5. Compare the smallest measured value with the value listed in thefollowing table:

8.4.2.2

8.4.3

8.4.3.1

Maintenance8Maintenance work

Hidrostal AG 49

Hydraulic size Permissible impeller clearance "B"

B, C, D, E 0.2 … 0.5 mm

F, H 0.3 … 0.8 mm

I, L, M 0.5 … 1.5 mm

NOTEContact the service centre if the clearance is too large or toosmall, see Imprint [–> 2].

6. Ensure that all adjustable spacers (5) are positioned on the hydraulicunit.

7. Lower the drive unit onto the hydraulic unit.8. Position the washers (4).9. Screw the hexagon nuts (3) onto the studs, and tighten them in

diagonally opposite sequence.

Checking impeller clearance "S"

1

2

S

Impeller clearance "S" is the gap between impeller tip (1) and wear ring (2).▪ Using a feeler gauge, check the clearance between impeller tip (1) and

wear ring (2). The clearance must be approximately 1 ... 2 mm.

NOTEContact the Service Centre if the clearance is too small or ifthe impeller tip is in contact with the wear ring. See Imprint [–> 2].

8.4.3.2

8Maintenance

Maintenance work

50 Hidrostal AG

Checking clearance "C"

1

2

C

Impeller clearance "C" is the gap between the impeller (1) and inlet cone (2).1. Measure the gap between impeller (1) and inlet cone (2) with a feeler

gauge after 0, ¼, ½ and ¾ impeller rotations.2. Compare the measured value with the max. permissible value listed in

the following table. The gap may be as small as required but the impeller(1) may not grind on the inlet cone (2) at any point.

3. If the measured value exceeds the max. permissible value or theimpeller (1) grinds on the inlet cone (2), adjust the impeller clearance,see Readjusting impeller clearance "C" [➙ 52].

Hydraulic size Max. impeller clearance "C"

B 0.2 mm

C,D 0.3 mm

E 0.4 mm

F 0.6 mm

H 0.8 mm

I 1.0 mm

L,M 1.5 mm

8.4.3.3


Hidrostal AG 51

Readjusting impeller clearance "C"

Adjustable pump with three adjusting screws

The impeller clearance is set via three adjusting screws (arrows) on thecasing.1. Make sure that impeller clearance "S" is within the permissible range,

see Checking impeller clearance "S" [➙ 50].2. Make sure that the pump is positioned in a vertical position on a surface

and attach lifting gear on the drive unit to prevent it from tipping.3. Loosen the lock nuts (1) and then unscrew by a couple of turns.

➢ With pump models L500 and M700:4. Loosen the locking screws next to the adjusting screws (2).

5. Slowly and evenly tighten all three adjusting screws (2) clockwise untilthe inlet cone locks the impeller. Ensure that the same amount ofrotations are performed on each adjusting bolt (2) allowing the inlet coneto remain concentric to the impeller.⇨ The gap between impeller and inlet cone is removed.

6. The number of rotations of the adjusting screws (2) required to set theimpeller clearance can be determined from the table, see chapterChecking clearance "C" [➙ 51], and the thread pitch of the adjustingscrews (2).

7. Turn all three adjusting screws (2) back with the same number ofanticlockwise rotations.

8. Hold the adjusting screws (2) using an open-end wrench and tighten thecounter nuts (1) until the resistance increases.⇨ The contact surface of the inlet cone is positioned on the adjusting

screws (2).

8.4.3.4

8.4.3.4.1

1

2

1

2

8Maintenance

Maintenance work

52 Hidrostal AG

9. Check the gap between the impeller and the inlet cone with a feelergauge after 0, ¼, ½ and ¾ impeller rotations, see the table in chapterChecking clearance "C" [➙ 51].

➢ If the clearance is uneven:10. Have the pump checked by a service centre and have it repaired, if

necessary.

➢ If the clearance is even but is outside the tolerance range:11. Loosen counter nuts (1).12. Tighten all three adjusting screws (2) with the same number of clockwise

rotations (in case of excessive clearance), or counter clockwise (in caseof insufficient clearance).

13. Check the gap between the impeller and inlet cone with a feeler gaugeafter 0, ¼, ½ and ¾ impeller rotations, see the table in chapter Checkingclearance "C" [➙ 51].

➢ If the clearance is even and within the tolerance range:14. Hold the adjusting screws (2) using an open-end wrench and tighten the

counter nuts (1), see Tightening torque for greased screw thread[➙ 48].

C


Hidrostal AG 53

Non-adjustable pumps

1 2

44

D

On non-adjustable pumps, the impeller clearance is adjusted via adjustmentspacers (4). Clearance D can be adjusted depending on the thickness of theadjustment spacers.1. Make sure that the former impeller clearance "S" has been measured

and the value noted down as Sold.

2. Make sure that the pump is positioned in a vertical position on a surfaceand attach lifting gear on the drive unit to prevent it from tipping.

3. Remove all the hexagon nuts (1) and spring rings (2).4. Lift the drive unit of the pump (3) up from the hydraulics.

3

5. Remove all adjustment spacers (4).6. Measure the thickness of the old adjustment spacers and note them

down as Dold.

7. Lower the drive unit of pump (3) back onto the hydraulics.

3

D

8.4.3.4.2

4

8Maintenance

Maintenance work

54 Hidrostal AG

8. Measure the gap D between drive unit and pump casing at severalpoints on the circumference and use them to calculate the mean value.

9. Add about 0.5–1.0 mm to the calculated value. The result is the requiredthickness of the adjustment spacer Dnew to obtain clearance "C", seetable in the chapter Checking clearance "C" [➙ 51].

➢ By reducing the thickness of the adjusting spacer, the impeller clearance"S" is reduced accordingly.

10. The new impeller clearance Snew is calculated as follows:Snew = Sold – (Dold – Dnew)

➢ If the calculated new impeller clearance Snew is smaller than 0.5 mm:

11. Assemble the pump and send to a service centre for repair.➢ If the expected new impeller clearance Snew is equal to or greater than

0.5 mm:12. Continue with adjusting the impeller clearance "C".13. Lift the drive unit of the pump (3) up from the hydraulics.

3

4

14. Use an adjustment spacer (4) on every stud with the thickness Dnew.

3

15. Lower the drive unit of pump (3) back onto the hydraulics.

2

16. Put all spring rings (2) back again.


Hidrostal AG 55

1

17. Attach all hexagon nuts (1) and tighten according to Tightening torquefor greased screw thread [➙ 48].

18. Check that the impeller turns smoothly.

Checking the oil

Cooling method "F"1 Cooling jacket of stator housing

2 Cooling oil outlet

3 Cooling oil inlet

4 Oil drain opening


On pumps with cooling method "F", the oil circuit has an external coolingsystem.The oil is filled, checked, re-filled or changed in the external cooling system.Information about this can be found in the documentation of the externalcooling system or in the system documentation.Once the pump is separated from the cooling circuit (2, 3), the residual oilcan be drained at the oil filler opening (4).

Purpose of checking the oil (coolingmethods "E" and "K")The oil chamber acts as a barrier between the pump chamber on the oneside and the drive on the other. It prevents the medium leaking into the driveunit.The oil also dissipates heat from the drive unit to the medium and thus coolsthe pump.The oil chamber is sealed using a mechanical seal on the pump chamberside and the drive side.A mechanical seal is NOT a perfect "dynamic seal", however, the leakageacross an intact mechanical seal is relatively low.

8.4.4

8.4.4.1

2

1

3

54

8.4.4.2

8Maintenance

Maintenance work

56 Hidrostal AG

Operational wear, especially from abrasive media circulating in the pump,will increase the leakage of the mechanical seal to the pump chamber andallows more of the medium to enter the oil chamber.Provided that the pump is fitted with a moisture sensor, and the sensorsignals are properly evaluated by the control unit, an alarm is triggered if anexcessive amount of liquid leaks into the oil chamber. The pump can then beshut down and repaired before costly damage is caused to the drive unit.If

▪ the pump is NOT fitted with a moisture probe or▪ the moisture probe is NOT analysed by the system control▪ a non-conductive medium is circulated or▪ you are unsure whether the moisture probe is working correctly or if its

measurements are correct,the oil must be checked regularly.In this way, any damage of the mechanical seal on the pump chamber sidecan be detected in time, and the pump can be shut down and repairedbefore costly damage is caused to the drive unit.If the mechanical seal functions properly, the oil is not subject to operationalwear, and can be used for an almost unlimited time.Personnel:

▪ Trained personnelProtective equipment:

▪ Safety goggles▪ Protective clothing▪ Safety shoes

Required tools:▪ Clean collection tank▪ Transparent beaker▪ Funnel with a fine-particle sieve and/or filter paper

Prerequisites:▪ Make sure that Preparation tasks for maintenance [➙ 48] has been

carried out first.

WARNINGLiquid possibly leaking under pressure.Risk of severe injury!• Wear safety goggles when opening the screw plug.


Hidrostal AG 57

Draining in a vertical position (cooling type"E")1. Stand pump on its suction flange.2. Make sure that the pump is secured with lifting gear to prevent it tipping.3. Tilt the pump so that the position of the screw plug (1) on the cooling

jacket is slightly raised.4. Loosen the screw plug until a brief hissing sound is heard or liquid runs

out.

➢ If a brief hissing sound is heard:5. Hold a cleaning cloth under the screw plug and tip the pump back into

the vertical position. If no more liquid leaks out, it can be expected thatlittle or no medium has leaked into the oil chamber.Replace and tighten the screw plug (1).

➢ If liquid is discharged:6. A significant amount of liquid has leaked into the oil chamber. Tilt the

pump further to release any pressurised gas.Once the pressure has been relieved: replace the screw plug (1).

7. Turn or tilt the pump so that the screw plug (2) on the oil chamber isfacing downwards.

8. Position a clean collection tank underneath the pump.9. Remove the screw plug (2).10. Allow the oil to drain into the collection tank.

8.4.4.3

1

2

8Maintenance

Maintenance work

58 Hidrostal AG

Draining in a vertical position (cooling type"K")1. Stand pump on its suction flange.2. Make sure that the pump is secured with lifting gear to prevent it tipping.3. Tip the pump to slightly raise the position of the screw plug (1).4. Loosen the screw plug until a brief hissing sound is heard or liquid runs

out.

➢ If a brief hissing sound is heard:5. Hold a cleaning cloth under the screw plug and tip the pump back into

the vertical position. If no more liquid leaks out, it can be expected thatlittle or no medium has leaked into the oil chamber.Replace and tighten the screw plug (1).

➢ If liquid is discharged:6. A significant amount of liquid has leaked into the oil chamber. Tilt the

pump further to release any pressurised gas.Once the pressure has been relieved: replace the screw plug (1).

7. Turn or tilt the pump so that the screw plug (1) is facing downwards.8. Position a clean collection tank underneath the pump.9. Remove the screw plug (1).10. Allow the oil to drain into the collection tank.

8.4.4.4

1


Hidrostal AG 59

Draining in a horizontal position (coolingtype "E")

1

1. Stand the pump so that the screw plug (1) on the cooling jacket is facingupwards.

2. Remove the screw plug (1).⇨ A brief hissing sound indicates that the oil circuit was pressurised.

3. Hold a cleaning cloth under the opening and turn the pump to the sideuntil the liquid level reaches the opening.

➢ If the pump can be turned by at least 22.5° without any liquid leakingfrom the opening:

4. It can be expected that little or no medium has leaked into the oil circuit.

➢ If liquid is discharged before it reaches the 22.5° position:5. It is to be expected that a significant amount of liquid has leaked into the

oil circuit.

6. Replace the screw plug (1).7. Turn the pump so that the screw plug (1) is facing downwards.8. Position a clean collection tank underneath the pump.9. Remove the screw plug (1).10. Allow the oil to drain into the collection tank.

8.4.4.5

1

22,5°

8Maintenance

Maintenance work

60 Hidrostal AG

Draining in a horizontal position (coolingtype "K")1. Stand the pump on a surface so that the screw plug (1) on the oil

chamber is facing upwards.2. Remove the screw plug (1).

3. Hold a cleaning cloth under the opening and turn the pump to the sideuntil the liquid level reaches the opening.

➢ If the pump can be turned by at least 45° without any liquid leaking fromthe opening:

4. It can be expected that little or no medium has leaked into the oilchamber.

➢ If liquid is discharged before it reaches the 45° position:5. It is to be expected that a significant amount of liquid has leaked into the

oil chamber.

6. Replace the screw plug (1).7. Turn the pump so that the screw plug (1) is facing downwards.8. Position a clean collection tank underneath the pump.9. Remove the screw plug (1).10. Allow the oil to drain into the collection tank.

Analysing the drained liquid1. Pour the liquid from the collection tank into a clean, transparent

container, e.g. a beaker, and allow it to stand for several minutes.

➢ If the liquid is bright, clear and thin, it could be the case that water hasleaked onto the base of the tank:

2. Continue to use the oil, see chapter Refilling the oil chamber.3. Dispose of any water on the tank base as special waste.

➢ If you are unsure about the oil condition:4. Dispose of the liquid as special waste.5. Refill the oil chamber with clean oil, see chapter Refilling the oil

chamber.

➢ If the liquid is dark in colour and/or cloudy and/or remains viscous, a highlevel of medium has contaminated the oil:

6. Dispose of the liquid as special waste.

8.4.4.6

1

45°

8.4.4.7


Hidrostal AG 61

7. Send the pump to the service centre to repair the mechanical seal on thepump chamber side.

Refilling the oil chamber (cooling method"E")➢ If the screw plug (2) on the oil chamber was loosened:1. Anneal the copper O-ring on the locking screw (2) or replace with a new

soft-annealed copper O-ring.2. Replace the screw plug (2) on the oil chamber and tighten by hand.

➢ To fill the pump in a vertical position:3. Stand the pump up.

➢ To re-use the oil you have just drained:4. Pour the oil that has been separated from the water through a fine-

particle sieve or filter paper into the chamber, top up with new oil, ifnecessary, until the oil level is just below the filling opening (between (2)and (3)).

➢ To fill the pump in a horizontal position:5. Turn the pump on its side so that the filling opening is turned approx.

22.5° from its highest position.➢ To re-use the oil you have just drained:6. Pour the oil that has been separated from the water through a fine-

particle sieve or filter paper into the chamber, top up with new oil, ifnecessary, until the oil level is just below the filling opening.

7. Anneal the copper O-ring on the screw plug (1) or replace with a newsoft-annealed copper O-ring.

8. Replace the screw plug (1) and tighten by hand.9. Re-start the pump.

8.4.4.8

1

2

2

3

1

22,5°

8Maintenance

Maintenance work

62 Hidrostal AG

Refilling the oil chamber (coolingmethod "K")1. Anneal the copper O-ring on the screw plug (1) or replace with a new

soft-annealed copper O-ring.

➢ To fill the pump in a vertical position:2. Stand the pump up.➢ To re-use the oil you have just drained:3. Pour the oil that has been separated from the water through a fine-

particle sieve or filter paper into the chamber, top up with new oil, ifnecessary, until the oil level is just below the filling opening (between (2)and (3)).

➢ When using new oil:4. Pour in new oil until the oil level is just below the filling opening (between

(2) and (3)).

➢ To fill the pump in a horizontal position:5. Turn the pump on its side so that the filling opening is turned approx. 45°

from its highest position.➢ To re-use the oil you have just drained:6. Pour the oil that has been separated from the water through a fine-

particle sieve or filter paper into the chamber, top up with new oil, ifnecessary, until the oil level is just below the filling opening.

➢ When using new oil:7. Pour in new oil until the oil level is just below the filling opening.

8. Replace the screw plug (1) and tighten by hand.9. Re-start the pump.

Replacing the pumpPersonnel:

▪ Trained electriciansProtective equipment:

▪ Protective clothing▪ Hard hat▪ Safety shoes

Prerequisites:▪ Make sure that Preparation tasks for maintenance [➙ 48] has been

carried out first.

Checking the suitability of the replacementpump

▪ Make sure that the replacement pump is not damaged.

8.4.4.9

2

3

1

45°

8.4.5

8.4.5.1


Hidrostal AG 63

WARNINGReplacement pump without sufficient explosion protection.Risk of explosion!• Make sure that only replacement pumps marked with the

same or higher explosion protection are used, see chapterType plate [➙ 23].

▪ Make sure that the information on the type plates of the defective pumpand the replacement pump are identical. If you are unsure, contact thesupplier.

▪ Make sure that the cable harness of the defective pump and thereplacement pump is identical (compare the wiring diagram of thedefective pump with that of the replacement pump).

WARNINGThe position of the Operational safety components [➙ 33]determines where the pump should be installed.Hazard from malfunctioning operational safetycomponents!Risk of explosion!• Only use replacement pumps that are intended for

installation in the required position.

▪ Ensure that the orientation (vertical/horizontal) of the installation positionof the replacement pump is the same as the orientation of the defectivepump (check the specification on the delivery documents. If in doubt,please contact the supplier or a service centre).

Replacing the pump1. Document the connections of the defective pump in the switch cabinet

using photos or written notes and compare the wiring diagram of thedefective pump with that of the replacement pump.

2. Make sure that the system or the affected system part is switched offand cannot be switched back on unintentionally.

3. Make sure that all the lines to be disconnected, including the operationalsafety component lines, have zero voltage.

4. Electrically isolate the connections of the defective pumps in the controlcabinet.

WARNINGMissing or insufficient earthing.Danger of electric shock!• Make sure that the pump is connected to the protective

earth (PE).

8.4.5.2

8Maintenance

Maintenance work

64 Hidrostal AG

5. Connect the replacement pump in accordance with the drawings or thewiring diagram in the control cabinet.

Checking the rotational direction

WARNINGTurning impeller.Risk of severe injury!• Never touch the suction or pressure flange.

NOTICEImpeller loosens with wrong impeller rotation!Danger of damage!• Make sure that the rotational direction has been checked

before commissioning the replacement pump.

NOTEWrong rotational direction.Drastically reduced flow rate!• In case of incorrect rotational direction, simply swap two of

the cable conductors of the pump or speed which is in thewrong rotational direction at the corresponding startingswitch in the control panel.

• Never swap over the primary conductors to the controlpanel. This would change the rotational field for allconsumer components.

NOTEDo not suspend and switch on the pump! When switched on,the pump will turn counter to the motor's direction of rotationand immediately turn around its own axis!

8.4.5.3


Hidrostal AG 65

1. Make sure that the pump is positioned in a vertical position on a surfaceand attach lifting gear on the drive unit to prevent it from tipping.

2. Run the pump for approx. one second and observe the direction of thestarting jolt.

➢ When viewed from above, if the pump jolts in an anti-clockwise direction(see adjacent figure):

3. The direction of rotation is correct with Pt. 5.

➢ When viewed from above, if the pump jolts in a clockwise direction:4. The direction of rotation is incorrect.

With direct start-up: switch 2 of the 3 cable conductors for the testedrotation speed on the control panel.With a star/triangle start-up configuration: exchange U1 with W1 and U2with W2 in the control panel.

5. On pump units with several speeds, repeat the test for each speed.6. Re-start the pump.

Measures after completion of workThe following steps are to be executed following completion of maintenancework and prior to switch-on of the system:1. Check all screw connections that were previously loosened for tightness.2. Check if all protective devices and covers that were previously removed

are properly installed again.3. Ensure that all tools, materials and other equipment used have been

removed from work area.4. Clean work area and device and remove any escaped substances, such

as liquids, processing material or the like.5. Ensure that all safety devices of the system function properly.6. Ensure that no persons are in the danger zone.

8.5

8Maintenance

Measures after completion of work

66 Hidrostal AG

FaultsThe following chapter describes possible causes of malfunctions, and thenecessary remedial actions. If malfunctions occur more frequently, shortenthe maintenance intervals as required by the actual load. If you cannoteliminate malfunctions with the information given below, contact themanufacturer or service partner. See Imprint [➙ 2].

SafetyDANGERContact with live parts.Risk of fatal injury!• Before starting work, switch off the electrical supply and

secure against switching on.

WARNINGUnauthorized switching on of the energy supply.Risk of severe injury!• Make sure that the energy supply cannot be switched on if

there are persons in the danger zone.




The following fundamentals apply:1. Push the emergency STOP immediately for faults that represent an

immediate danger to persons or property.2. Turn off system and protect against restart or an automatic switch-on.3. Immediately inform the supervisors at the working site about the fault.4. Determine the cause of the fault.5. Depending on the type of malfunction, either have the malfunction

rectified by authorised qualified personnel or rectify it yourself.

NOTEThe malfunction table below provides you with informationregarding who is authorised to troubleshoot the malfunction.

9

9.1Electrical installation

Secure against switchingon

Potentially explosiveatmosphere

In the event of faults

Faults9Safety

Hidrostal AG 67

Malfunction tableFaultdescription

Cause Remedial action Personnel

No delivery Pump not vented Vent pump Instructed persons(operators)

Speed too low Check all three phases for failure,check mains frequency, check phaseconnections


Speed too low infrequency inverter (FI)operation

Check the speed selected at the FI Instructed persons(operators)

Air penetrates at suctionside

Check suction line and/or fluid level Instructed persons(operators)

Pressure line obstructed/gate valve closed

Check pressure line/gate valve Instructed persons(operators)

Air or gas in conveyedmedium

Check the conveyed medium for air orgas


Air or gas at the rear sideof the impeller



Delivery height too high(exceeds calculation)

Check delivery height, check gatevalve


Impeller or suction lineobstructed

Check pump and suction line forobstructions


Insufficient flowrate

Air penetrates at suctionside

Check suction line and/or fluid level Trained personnel




Wrong rotationaldirectionIncreased vibrations

Check the rotational direction, correct ifnecessary. See chapter Checking therotational direction [➙ 65]



Check the delivery height Instructed persons(operators)



Thick matterconcentration higherthan assumed

Check thick matter concentration Instructed persons(operators)




Excessive impellerclearance

Check the impeller clearance Instructed persons(operators)

Impeller damaged Check the impeller for damage, replaceit if necessary

Service centre

Voltage too low Check the voltage. With star-deltastarting: Check the switchover function


9.2

9Faults

Malfunction table

68 Hidrostal AG

Faultdescription


Insufficientdelivery pressure



Speed too low infrequency inverter (FI)operation

Check the speed selected at the FI Instructed persons(operators)






Wrong rotationaldirection

Check the rotational direction, correct ifnecessary. See chapter Checking therotational direction [➙ 65]


Excessive impellerclearance

Check the impeller clearance, readjustit if necessary. See chapter Check/readjust impeller clearance [➙ 49]

Trained personnel


Service centre

Voltage too low Check voltage Trained electricians

Impeller too small Check the impeller,replace if necessary

Trained personnelService centre

Air or gas at the rear sideof the impeller



Air entering suction line Check level monitoring Instructed persons(operators)




Decreasing flowrate, or pressureloss after startup

Air penetrates on suctionside

Check level monitoring Instructed persons(operators)

Vibrations Speed too high Check all three phases for failure,check mains frequency, check phaseconnections


Speed too high infrequency inverter (FI)operation

Check the speed selected at the FI;reduce it if necessary


Air entering suction line Check level monitoring Instructed persons(operators)







Check delivery height, check gatevalve





Faults9Malfunction table

Hidrostal AG 69

Faultdescription



Service centre

Motor damaged Check the motor, repair it if necessary Qualified electricianService centre

Loose anchoring Check the anchoring; correct ifnecessary

Trained personnel

Bearings worn out Check the bearings for damage,replace if necessary


Impeller out-of-balance Check the impeller,replace if necessary


Impeller brushes againstsuction cover


Trained personnel

Motoroverloaded





Speed too high Check all three phases for failure,check mains frequency, check phaseconnections





Specific gravity ofdelivery medium higherthan assumed

Check the specific weight of theconveyed medium

Trained personnel



Loss of coolant Check coolant / oil level, top up ifnecessary. See chapter Checking theoil [➙ 56]

Trained personnel

Wrong impeller installed Check the impeller type Service centre




Thick sludge and smallimpeller clearance

Increase the impeller clearance Instructed persons(operators)

Pump is notrunning

Main switch is OFF Set main switch to "ON" position Instructed persons(operators)

Thermal overcurrent tripresponded or is notproperly connected

Check overcurrent trip Trained electricians


9Faults

Malfunction table

70 Hidrostal AG

Faultdescription



ON level not reached;defective sensor orswitch

Check fluid level; check function oflevel switch, replace it if necessary

Trained personnel

Pump is verynoisy




Air penetrates on suctionside

Check suction line and/or fluid level Instructed persons(operators)




Suction head too high Check suction head Instructed persons(operators)

Insufficient suctionpressure with hot liquids

Check suction pressure, increase ifnecessary

Trained personnel

Suction pipe insufficientlysubmerged

Check immersion depth of suction pipe Instructed persons(operators)


Loose anchoring Check the anchoring; correct ifnecessary

Trained personnel



Trained personnel

Pump runs to the right ofthe pump characteristiccurve

Check operating data and operatingconditions

Trained personnel

Measures after completion of workThe following steps are to be executed following completion of maintenancework and prior to switch-on of the system:1. Check all screw connections that were previously loosened for tightness.2. Check if all protective devices and covers that were previously removed

are properly installed again.3. Ensure that all tools, materials and other equipment used have been

removed from work area.4. Clean work area and device and remove any escaped substances, such

as liquids, processing material or the like.5. Ensure that all safety devices of the system function properly.6. Ensure that no persons are in the danger zone.

9.3

Faults9Measures after completion of work

Hidrostal AG 71

9Faults

Measures after completion of work

72 Hidrostal AG

DisassemblyOnce the system has reached the end of its service life, disassemble it anddispose of it in an environmentally compatible way.

SafetyDANGERContact with live parts.Risk of fatal injury!• Before starting disassembly, switch off and permanently

disconnect from the electrical supply.




WARNINGStored residual energy, sharp edged components, points andcorners on and in the system or on the required tools.Risk of severe injury!• Before starting work, make sure that there is sufficient

space.• Be careful with open, sharp-edged components.• Make sure that the work area is orderly and clean! Loose

components and tools stacked or lying around are potentialsources of accident.

• Correctly dismantle components. Caution: somecomponents are heavy. Where necessary, use hoistingdevices.

• Secure components so that they cannot fall or tip.• If in doubt, consult the manufacturer.

DisassemblyPrior to the start of disassembly:

▪ Turn off system and protect against restart.

10

10.1Electrical installation

Potentially explosiveatmosphere

Improper disassembly

10.2

Disassembly10Safety

Hidrostal AG 73

▪ Physically disconnect the system from all power supplies and allowstored residual energy to discharge.

▪ Remove operating and supplementary materials and any remainingprocessing materials and dispose of appropriately.

Then, clean assemblies and parts correctly and dismantle modules based onthe local workplace safety and environmental regulations.

DisposalIf no return or disposal agreements have been made, then dismantledcomponents must be recycled as follows:

▪ Scrap the metal parts.▪ Plastic elements must be recycled.▪ Other components must be sorted and disposed of according to the type

of material.

NOTEIncorrect disposal of materials.Risk of environmental pollution!• Electrical scrap, electronic components, lubricants and

other auxiliary materials must only be disposed of byapproved, specialist companies.

• If in doubt, contact the local authorities or specialist wastedisposal companies to inquire about environmentaldisposal.

10.3

10Disassembly

Disposal

74 Hidrostal AG

Appendix▪ Technical drawings▪ CE Declaration of Conformity▪ Spare parts list▪ Wiring diagram

11

Appendix11

Hidrostal AG 75

11Appendix

76 Hidrostal AG

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