V-101946-0075a-0178 - 3241-Pu-301 - 100204001

Sulzer Pumps
Solution Pumps MDR

3241-PU-301
Mina Justa Project
Ausenco’s Code V-101946-0075A-0178
JU-001-06-0075A-0000-08-MDR-0001
Project Number: 10194601-0075A
Sulzer Pumps
Rev. 1
2020.11.02
SULZER CONFIDENTIAL
Table of Contents
Solution Pumps MRD ............................................................................................................................... 1
PRODUCT SPECIFICATION ...................................................................................................... 4
PART LIST .................................................................................................................................. 7
EC Declaration of Conformity 12
Quality Plan ............................................................................................................................... 13
Painting Procedure ................................................................................................................... 31
Declaration of quality ............................................................................................................... 35
1 Inspection before assembly .................................................................................... 35
2 Materials.................................................................................................................... 35
3 Balancing of rotating components ........................................................................... 35
4 Hydrostatic test ........................................................................................................ 35
5 Performance test ...................................................................................................... 35
6 Final inspection ........................................................................................................ 35
7 Preparation for dispatch ........................................................................................... 36
DIMENSIONAL DATA ............................................................................................................... 37
Bare shaft pump .......................................................................................................... 37
IEC motor ..................................................................................................................... 38
Pump on baseplate (STD) .......................................................................................... 39
Wet end connections ................................................................................................... 40
Flange drillings ............................................................................................................ 41
Sealing unit connections .............................................................................................. 45
Bearing unit connections .............................................................................................. 46
Grouted foundation screw ........................................................................................... 47
Speed Curve ............................................................................................................................. 48
Open1 .......................................................................................................................... 48
CROSS SECTION DRAWINGS .............................................................................................. 49
Pump ............................................................................................................................ 49
Assembly..................................................................................................................... 50
Wet end ........................................................................................................................ 51
Sealing unit ................................................................................................................. 52
Guards ......................................................................................................................... 53
Bearing unit .................................................................................................................. 54
Coupling unit ............................................................................................................... 55
Baseplate ..................................................................................................................... 56
Foundation screw / grouted, 918G ............................................................................. 57
USER'S MANUAL (IOM) ........................................................................................................... 60
Intended use ................................................................................................................ 60
Safety instructions…………………………………………………………………………..67
SULZER CONFIDENTIAL
Hoisting and transfers .................................................................................................. 94
Commissioning .......................................................................................................... 101
Installation at the site ................................................................................................ 104
Operation .................................................................................................................. 125
Preventive maintenance ........................................................................................... 138
Corrective maintenance ............................................................................................ 150
Spare parts recommendation................................................................................... 187
Seal IOM ................................................................................................................................ 190
1 General descriptions ............................................................................................. 193
2 Safety ..................................................................................................................... 194
3 Storage................................................................................................................... 194
4 Materials and Design ............................................................................................. 195
5 Information on operating conditions ...................................................................... 195
6 Installation .............................................................................................................. 197
7 Detaching ............................................................................................................... 210
8 Adjustment and control .......................................................................................... 213
9 Service and maintenance ..................................................................................... 215
10 Disposal ................................................................................................................ 216
11 APPENDICES ...................................................................................................... 216
Couplings IOM ........................................................................................................................ 231
Low voltage motors ................................................................................................................. 237
1. Introduction ............................................................................................................ 240
2. Safety considerations ............................................................................................ 240
3. Handling ................................................................................................................. 241
4. Installation and commissioning ............................................................................. 242
5. Operation ............................................................................................................... 245
6. Low voltage motors in variable speed operation .................................................. 246
7. Maintenance ........................................................................................................... 249
8. After Sales Support ................................................................................................ 253
9. Environmental El requirements ............................................................................. 253
10.Troubleshooting .................................................................................................... 254
11.Figures .................................................................................................................. 256
Certificates .............................................................................................................................. 262
Balancing test certificate, 1-plane .............................................................................. 262
Hydrostatic pressure test certificate .......................................................................... 263
Painting certificate ...................................................................................................... 264
PERFORMANCE TEST REPORT ............................................................................. 266
Declaration of compliance with the order EN 10204 2.1 .......................................... 267
Certificate of surface treatment .................................................................................. 268
SULZER CONFIDENTIAL
Sulzer Pumps Finland Oy Description A43-350
Serial Number 100204001
PRODUCT SPECIFICATION Reference no. 495727/000010
Time of delivery/EXW 10.09.2019
Date printed 11.12.2019 Page 1
Customer
MARCOBRE S.A.C. Sulzer Bombas Chile Limitida
RUC: 20508972734 Luis Carrera No 1289
CAL.ESQUILACHE NRO. 371 INT. 901B Oficina 304
SAN ISIDRO VITACURA, REGION METROPOLITANA
15073 LIMA CHILE
PERU
Cust. Order 0030020022 Equipment 3241-PU-301
Cust. PO line Id
Country code PE
GENERAL
Product design: SI, mm-dimensioned structure Material of construction: 4U / J0271 / AVESTA 654 SMO
Version: Version 14 Performance tests: ISO 9906 / HI 14.6 Gr 2B
Pump type: A, Process Pump Guaranteed efficiency: Yes
Pump construction type: Long coupled Material and NDT tests: Material test EN 10204-2.1
Product category: Pump product Structural tests: Bal. ISO 1940, G 6.3, 1-plane
Structural tests: Hydrost. Pressure Test, 10 min Product scope: Pump
Product scope: Drive unit Product scope: Package
Product scope: Documents Inspection of assembly: Paint film thickn.check Pump
Inspection of assembly: Paint film thickn.check Assem. Pump scope: Wet end
Pump scope: Sealing unit Pump scope: Bearing unit
Inside surface treatment: Standard surface treatment Drive unit scope: Drive motor
Outside surface treatment: Special surface treatment Package scope: Coupling unit
Package scope: Baseplate Classification: C, Engineered
Quality requirement: 2006/42/EC Quality requirement: EN ISO 5199:2002, 9001:2008
____________________________________________________________________________________________________
PROCESS DATA
Process: Copper Lx-Sx-Ew Leaching Temperature (°C): 50,0 °C
Application: INTERMEDIATE LEACH SOLUTION NPSH available (m): 10,7 m
Units: SI Capacity Q (m3/h): 1.159,00 m3/h
Pumped liquid: AQUEOUS LEACH SOLUTION Head H (m): 14,4 m
Density (kg/m3): 1.100,0 kg/m3 Notes for Process data: VISCOSITY: 1.79 CP
____________________________________________________________________________________________________
PUMP
Pump size: 43-350 Seal. unit elastomer material: (93) FKM, Fluorocarbon
Impeller type: Open 1 Sealing unit gasket material: (84) PTFE/ Glass
Impeller number: 920543 Shaft seal material: C/SiC
Impeller holes: Balance holes Shaft seal fluid: N, Without fluid
Impeller diameter: 410,0 mm Mechanical seal type: FD25, John Crane, JCS1
Impeller max.diameter: 410,0 mm Sealing unit connections: No Temperature measuring C48
Impeller min. diameter: 342,5 mm Sealing unit equipment: 683, Stainless steel guards
Sideplate cutting grooves: Not included in the delivery Su.inside surface treatment: Standard surface treatment
Volute case material: (4U) AVESTA 654 SMO Su.outside surface treatment: Special
Impeller material: (4U) AVESTA 654 SMO Sealing unit color shade: Standard, NCS 1700
Sulzer Bombas Chile Limitida Contact Person Ian Pena

Luis Carrera No 1289 LBU Order 0030020022
Oficina 304 LBU Position 000010
Vitacura, Region Metropolitana Reference no. 495727/000010
Equipment 3241-PU-301
Telephone
Customer
15073 LIMA CHILE
PERU
Cust. PO line Id
Country code PE
Sideplate material: (4U) AVESTA 654 SMO Specialities of Sealing unit: Su.outside surface treat., SO
Flange drilling: ASME B16.5-2009 CLASS 150 Adapter size: 43
Max allowable working pressure: 16,0 bar Support foot size: H 440
Hydrostatic test pressure: 24,0 bar Shaft size: Shaft 4, D48
Wet end connections: Yes Wet end drain. C40, bottom Wet end connections: Yes Wet end bleed C54
Wet end connections: No Disharge pipe C27 Wet end connections: No Pressure measuring C36
Wet end connections: No Temperature measuring C48 Bearing lubrication type: Grease
Wet end o-ring material: (93) FKM, Fluorocarbon Bearing housing material: Cast Iron
We.inside surface treatment: Standard surface treatment Shaft material: 3N / S0402 / EN1.4410 / SS2328
We.outside surface treatment: Special Bearing unit connections: No Temperature measuring C48
Wet end color shade: Standard, NCS 1700 Bu.outside surface treatment: Special
Specialities of Wet end: We.outs. surface treatm., WOS Bearing unit color shade: Standard, NCS 1700
Sealing unit size: Sealing unit 43 Specialities of Bearing unit: Bu.outs. surface treatm., BOS
Shaft size: Shaft 4, D60 Pump type designation: A43-350
Sealing unit type: MS11, Integrated Single, Open Dimensional drawing of Pump: P12923
Case cover material: (4U) AVESTA 654 SMO Specialities of Pump: Wet end, WEEN.1
Specialities of Pump: Sealing unit, SEUN.2 Specialities of Pump: Bearing unit, BEUN.3
Case cover cutting grooves: Not included in the delivery Special parts of Pump: INERTA51 MIOX-TEKNOPLAST HS150
Special parts of Pump: SEALS IN VITON
____________________________________________________________________________________________________
DRIVE MOTOR
Motor Supplier: Pump supplier Motor frame material: Cast Iron
Motor standard: IEC, Standard frame size Motor type: M3BP, Process performance
Motor mounting: Foot Motor nominal voltage: 460 VD
Motor manufacturer: ABB Motors Motor IEC code: 315S80
Motor protection: IP56 Motor variable speed: Yes
Motor efficiency class: IE2, High efficiency Motor Catalog code: 3GBP314220-ADG
Motor synchronous speed: 900 rpm Motor options: 126, TAG PLATE
Motor options: 157 TERMINAL BOX DEGREE OF PRO Motor options: 567 SEPARATE TERMINAL BOX MAT.
Motor options: 568 SEPARATE TERMINAL BOX HEAT Motor options: 999 SPECIAL PAINTING SYSTEM
Motor options: 002, Restamping volt. freq. Motor options: 114, Special paint colour, sta
Motor options: 148, Routine test report Motor options: 178, Stainless steel/acid proo
Motor options: 403, Degree of protection IP56 Motor options: 451, Heating element 200-240 V
Motor options: 701, Insulated bearing at N-en Motor options: 704, EMC cable gland

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Customer
15073 LIMA CHILE
PERU
Cust. PO line Id
Country code PE
Motor frequency: 60 Hz Specialities of Drive motor: INERTA51 MIOX-TEKNOPLAST HS150

Motor power (kW): 75,00 kW
____________________________________________________________________________________________________
WET END PERFORMANCE
Operational Point: Standard range Efficiency: 87,9 %
Variable rotational speed: Yes Capacity Q water (m3/h): 1.159,00 m3/h
Pump rotational speed: 874 rpm Head H water (m): 14,4 m
Characteristic curve: K52771 A SI O 600-1000 rpm NPSH required water (m): 4,2 m
Capacity Q (m3/h): 1.159,00 m3/h Rated power P water (kW): 51,6 kW
Head H (m): 14,4 m Efficiency water: 87,9 %
NPSH required (m): 4,2 m Motor synchronous speed: 900 rpm
Rated power P (kW): 56,9 kW Motor power: 75,00 kW
____________________________________________________________________________________________________
ASSEMBLY
Drive type: Direct drive Motor IEC mounting size: IEC 315S80-95
Pump shaft dimension: 48 x 110 mm Baseplate type: Type STD
Motor synchronous speed: 900 rpm Baseplate material: Stainless steel
Motor power kW: 75,00 kW Baseplate equipment: 918, Foundation screw, Grouted
Motor shaft dimension: 80 x 170 mm Baseplate surface treatment: Standard,1xEP Top coat (prim.)
Coupling type: Elastic type Rex Viva VS Baseplate color shade: Standard, NCS 1700
Coupling guard material: Stainless steel Specialities of Baseplate: BASEPLATE PAINTED
Co.guard surface treatment: Standard,1xEP Top coat Dim. drawing of Assembly: 970918
Co.guard color shade: Standard, NCS 0582-Y09R Specialities of Assembly: Coupling unit, COUN.5
Specialities of Assembly: Baseplate, BAPL.6 Specialities of Coupling unit: COUPLING SERVICE FACTOR: 1.5
Special parts of Assembly: 840.51, Coupling Pump mounting size: 49, H570 L570 B850/ 190
____________________________________________________________________________________________________
DOCUMENTS
Certificates: Hydraulic performance Certificates: Hydrostatic test
Certificates: Material test (EN 2.1 / EN3.1) Certificates: Impeller balancing
Certificates: Paint film thickness Certificates: Outside surface treatment
Specialities of Documents: Outside surface treatm.certif.</ End user language for book: ES, Spanish

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PART LIST Reference no. 495727/000010
Customer Instructions
D01.01 1 QUALITY OF CONFORMITY N15715EN
D02.01 1 DIMENSIONAL DRAWING, PUMP P12923EN
D02.02 1 DIMENSIONAL DRAWING, DRIVE MOTOR P12465EN
D02.03 1 DIMENSIONAL DRAWING, ASSEMBLY P30486EN
D02.11 1 DIMENSIONAL DRAWING, WET END CONNECTIONS P13098EN
D02.12 1 Dimensional drawing P02184EN
D02.21 1 DIM.DRAW.,SEAL.UNIT CONNECT. P12459EN
D02.31 1 DIM. DRAW., BEARING UNIT CONNECT. P30572EN
D02.61 1 DIMENSIONAL DRAWING, FOUNDATION SCREW P12525EN
D03.11 1 CHARACTERISTIC CURVE K52771EN
D04.01 1 SECTIONAL DRAWING, PUMP N15579EN

D04.03 1 SECTIONAL DRAWING, ASSEMBLY N30766EN
D04.11 1 SECTIONAL DRAWING, WET END N15583EN
D04.21 1 SECTIONAL DRAWING, SEALING UNIT N15596EN
D04.25 1 SECTIONAL DRAWING, GUARDS N30338EN
D04.31 1 SECTIONAL DRAWING, BEARING UNIT N31010EN
D04.51 1 SECTIONAL DRAWING, COUPLING UNIT N31039EN
D04.61 1 SECTIONAL DRAWING, BASEPLATE N30768EN
D04.62 1 SECTIONAL DRAWING, FOUNDATION SCREW N15634EN
D05.00 1 INSTRUCTION, CONTENTS N32197ES
D05.01 1 INSTRUCTION, INTENDED USE N31567ES
D05.02 1 INSTRUCTION, SAFETY INSTRUCTIONS N31568ES
D05.03 1 INSTRUCTION, HOISTING AND TRANSPORT. N31569ES
D05.04 1 INSTRUCTION, COMMISSIONING N31570ES
D05.05 1 INSTRUCTION, INSTALLATION N31571ES
D05.06 1 INSTRUCTION, OPERATION N31572ES
D05.07 1 INSTRUCTION, PREVENTIVE MAINTENANCE N31573ES
D05.08 1 INSTRUCTION, CORRECTIVE MAINTENANCE N32198ES
D05.09 1 INSTRUCTION, SPARE PARTS RECOMM. N31575ES
D06.21 1 INSTRUCTION, SHAFT SEAL C10151ES
D06.51 1 INSTRUCTION, COUPLING C10014ES
D06.81 1 INSTRUCTION, DRIVE MOTOR C10017ES
D07.011 1 Cert. ISO1940 G1.0/G2.5/G6.3 Static N05669EN_100204001
D07.012 1 CERTIFICATE HYDROSTATIC TEST N05670EN_100204001
D07.018 1 PAINTING CERTIFICATE N30397EN_100204001
D07.019 1 PAINTING CERTIFICATE N30398EN_100204001
D07.02 1 Performance Certificate N04386EN_100204001
D07.022 1 CERTIFICATE EN10204-2.1 N30527EN
D07.09 1 CERTIFICATE, SURFACE TREATMENT N33613EN

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Connections
C40.11 CON-C40 1 DRAINING OF PUMP ISO 7/1-Rp 3/8
C41.31 CON-C41 2 GREASE FILLING ISO 7/1-Rp 1/8
C43.31 CON-C43 1 DRAINING OF LUBRICAT ISO 7/1-Rp 1/2
C54.11 CON-C54 1 BLEED CONNECTION ISO 7/1-Rp 3/8
Parts
102.11 920663014U-C 1 VOLUTE CASE A43-350 (4U) 654 SMO
Material and NDT tests: Material test EN 10204-2.1
Flange drilling: ASME B16.5-2009 CLASS 150
Wet end connections: Yes Wet end drain. C40, bottom
We.inside surface treatment: Standard surface treatment

We.outside surface treatment: Special
102V 920662014U-1 1 VOLUTE CASE CASTING A43-350 (4U) 654 SMO
135.11 920674014U-C 1 SIDEPLATE O A43-350 (4U) 654 SMO
135V 920673014U-1 1 SIDEPLATE CASTING O A43-350 (4U) 654 SMO
161.21 920374014U-C 1 CASE COVER M A43 (4U) 654 SMO
Sealing unit connections: No Temperature measuring C48
Su.inside surface treatment: Standard surface treatment
Su.outside surface treatment: Special
183 9250870152 1 SUPPORT FOOT H 440 (52) A48 CL 30 B
183.31 9250870152/1 1 SUPPORT FOOT H 440 SPECIAL PAINTING (52) A48 CL 30 B
183V 9219830152 1 SUPPORT FOOT CASTING H 440 (52) A48 CL 30 B
210.31 94124901BB-1 1 SHAFT A4 (BB) EN 1.4410
230.11 920543014U-C 1 IMPELLER OB 410 B107 Z6 A43-350 (4U) 654 SMO
Structural tests: Bal. ISO 1940, G 6.3, 1-plane
Impeller diameter: 410,0 mm
Impeller max.diameter: 410,0 mm
Impeller min. diameter: 342,5 mm
230V 920542014U-1 1 IMPELLER CASTING OB 410 B107 Z6 A43-350 (4U) 654 SMO
320.31 G433000313 1 ANTIFRICTION BEARING NUP 313 ECJ
320.32 G325007314 2 ANTIFRICTION BEARING 7314 BECBM
330 9319360153 1 BEARING HOUSING A4 (53) A48 CL 35 B
330.31 9319360153/2 1 BEARING HOUSING A4 SPECIAL PAINTING (53) A48 CL 35 B
339.31 A4-33913-C 1 BEARING UNIT A 13/ 4

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Shaft size: Shaft 4, D48
Bearing housing material: Cast Iron
Shaft material: 3N / S0402 / EN1.4410 / SS2328
Bearing unit connections: No Temperature measuring C48
Bu.outside surface treatment: Special
344 931363015H 1 ADAPTER A43 (5H) A395 60-40-18
344.31 931363015H/1 1 ADAPTER A43 SPECIAL PAINTING (5H) A395 60-40-18
360 9175260152-1 1 BEARING COVER 4 (52) A48 CL 30 B
360.31 9175260152/1 1 BEARING COVER A4 SPECIAL PAINTING (52) A48 CL 30 B
400.21 E805430884 1 GASKET 430(-3/-4)/415(-1/-2)X0,5 (84) PTFE/Glass
411.21 ESC2191701 1 SEAL RING UA 16-10-1,5 / FKM75+SUS304 FKM 75 + SUS304
412.11 E11H399393 1 O-RING 399,3X5,7 SMS1586 (93) FKM
412.12 E11801039F 3 O-RING 10,3X2,4 SMS 1586 (9F) FFKM
412.14 E113020193 1 O-RING 20,1X1,6 SMS1586 (93) FKM

412.21 E11B044293 1 O-RING 44,2X3 SMS 1586 (93) FKM
412.31 E11H139391 1 O-RING 139,3X5,7 SMS1586 (91) NBR
412.32 E11B084591 2 O-RING 84,5X3 SMS1586 (91) NBR
423.31 9268280131 2 LABYRINTH RING A4 (31) SS2303
433.21 FD251600/1 1 MECHANICAL SEAL JCS1-60-GXVO-4U-309143 C-SiC/VITON/4U
507.31 EL1206506M 2 DEFLECTOR 9RB 65 (6M) AISI304/NBR
554.11 B310017037 16 WASHER ISO 7089-16-200 HV-A4 (37) A4 ISO3506
554.23 B380006437 1 WASHER 6,4 DIN 9021 (37) A4 ISO3506
556.61 9187111334/1 4 RISER BLOCK IEC315 210 X 150 X 40 (34) SS2343
559.61 9194750032 4 SHIM IEC315-355 (32) SS2333
571.21 9267240132 1 CLAMP A1-A6 (32) SS2333
636.31 GH140201B8 2 LUBRICATION NIPPLE A R1/8K DIN71412 (B8) EN10088-3-1.4305
644.31 9185690112 1 OIL RING A4 (12) Fe P01 EN10130
683.21 93322701BG 1 GUARD A43 (BG) EN 1.4301
683.22 93322701BG 1 GUARD A43 (BG) EN 1.4301
683.23 92717401BG 1 GUARD A4 T (BG) EN 1.4301
685.51 2840340134/2 1 GUARD END D410/D120,S4 SPECIAL PAINT (34) SS2343
686.51 93129601BA/1 1 GUARD JACKET D410 L400 SPECIAL PAINTING (BA) EN 1.4404
686.52 3844780134/1 1 GUARD JACKET D410 L210 SPECIAL PAINTING (34) SS2343
800.81 MOT1001876 1 MOTOR M3BP

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840.51 KA39048080 1 COUPLING VS290-R-FBH D48H7/D80H7 DIN6885
REX VIVA VS 290-R FBH d1/d2=48H7/D80H7+ISO R773 (SFS2636)
860.51 KA29S00000 1 COUPLING PART HIGH SPEED RING SET VS290 (2H) C45 EN10083-2
861.51 KA29H04800 1 COUPLING HUB FBH 290 D48H7+ KEY WAY JS9 (2H) C45 EN10083-2
861.52 KA29H08000 1 COUPLING HUB FBH 290 D80H7+ KEY WAY JS9 (2H) C45 EN10083-2
869.51 KA29F00000 1 FLEXIBLE PART REX VIVA VS290
890.61 93064001BA/1 1 BASEPLATE STD20 PM49 IEC315S80-95 (BA) EN 1.4404
897.61 919437014C 4 ALIGNMENT BLOCK IEC315 - 355 (4C) A743 CF-8
901.11 A121164539 16 HEXAGON HEAD SCREW M16X45 ISO4017 (39) A4-80 ISO3506
903.11 CC1404004U 1 THREADED PLUG ISO 7/1-R 3/8 SCC101 (4U) 654 SMO
903.31 CC14050034 1 THREADED PLUG ISO 7/1-R 1/2 SCC101 (3K) AISI 316L
909.11 916864054U 3 ADJUSTING SCREW M10X45 (4U) 654 SMO
914.11 384275044U 1 CAP SCREW, SOCKET HD M20X50 (4U) 654 SMO
914.51 A611103539 3 CAP SCREW, SOCKET HD M10X35 ISO4762 (39) A4-80 ISO3506
920.11 B111100039 3 NUT M10 ISO4032 (39) A4-80 ISO3506
920.51 B222704030 3 NUT M10 - PTROM-1040 (30) SS
923.31 GA11001410 1 BEARING NUT KM14 (10) S EN10025
931.31 GC10001410 1 LOCK WASHER MB14 (10) S EN10025
932.51 B710001030 3 RETAINING RING Ø10 - DIN471 (30) SS
940.31 B810907015 1 KEY B-14X9X70 ISO/R 773 (15) CK45K DIN1652
970.31 WK3095227A 2 SIGN SULZER LOGO L95 W22 (6D) Al (aluminium)
971.01 93265001BG 1 NAME PLATE CENTRIF PUMP KOTKA (S0708) EN 1.4301
975.51 SS00050802 1 WARNING SIGN
Guard adjustment, in english
976.11 9425430700 1 MANDATORY ACTION SIG MAWP (ES)
976.51 SS0006M021 1 MANDATORY ACTION SIG
Coupling alignment

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BAPL.6 A-BAPL13-C 1 BASEPLATE A 13
Inspection of assembly: Paint film thickn.check Pump
Pump mounting size: 49, H570 L570 B850/ 190
Motor IEC mounting size: IEC 315S80-95
Baseplate type: Type STD
Baseplate material: Stainless steel
Baseplate equipment: 918, Foundation screw, Grouted
Baseplate surface treatment: Standard,1xEP Top coat (prim.)
Baseplate color shade: Standard, NCS 1700
Specialities of Baseplate: BASEPLATE PAINTED
COUN.5 A-COUN13-C 1 COUPLING UNIT A 13
Units: SI
Quality requirement: 2006/42/EC
Inspection of assembly: Paint film thickn.check Pump

Pump shaft dimension: 48 x 110 mm
Motor synchronous speed: 900 rpm
Motor power kW: 75,00 kW
Motor shaft dimension: 80 x 170 mm
Coupling type: Elastic type Rex Viva VS
Coupling guard material: Stainless steel
Co.guard surface treatment: Standard,1xEP Top coat
Co.guard color shade: Standard, NCS 0582-Y09R
Specialities of Coupling unit: COUPLING SERVICE FACTOR: 1.5
Separate Delivered Parts
918.61 AP11244039 3 FOUNDATION SCREW M24X400 SAP100 (39) A4-80 ISO3506
Reference standard: DIN 529 FORM C
Thread lenghth (b) = 160mm
920.61 B111240039 6 NUT M24 ISO4032 (39) A4-80 ISO3506
975.31 SS00050202 2 WARNING SIGN
Corrosive / Irritating liquid

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EC Declaration of Conformity
as defined by EC machinery directive 2006/42/EC, Annex IIA
Manufacturer: Sulzer Pumps Finland Oy

Pajatie 75, 48600 KOTKA, Finland
Contact person: Head Global Product Development Industry

Jukka-Pekka Peri
Sulzer Pumps Finland Oy
P.O.Box 66, FI-48601 Kotka, Finland
herewith declares that
Centrifugal pump, type: A43-350
Serial number: 100204001
is in conformance with directive 2006/42/EC (machinery directive) and where applicable following other EC directives 2014/30/EU
(electromagnetic compatibility). Harmonized standard EN 809:1998+A1:2009/AC:2010
has been applied to the design and manufacture of the product.
KOTKA 11.12.2019
Enno Danke
Head of Operations Industry BU
This declaration only concerns the machine as it was brought to the market. This declaration does not cover parts added to the machine by
the end user afterwards and/or operations carried out on the machine by the end user.
COPYRIGHT © SULZER PUMPS FINLAND OY

SAP doc No. Technical Quality Sulzer Pumps Tender/Project No.
Customer Issued by (Name/LE)
Sulzer P.O. No.
 Standard Quality Plan Released by (Name/LE)
TAG No.  Special Quality Plan Rev. Date Page 1 of 18
Project /Site: Market / Business Segment(s) Pump Type(s) Pressure Retaining Material
Cast iron / Chromium iron / Carbon
AHLSTAR steel / Martensitic stainless/ Austenitic /
Duplex
Inspectorate
Standard Rev.
Product Type of No. of
Third Party
Task /
Customer
Control/Test Operation (DIN-number) Form / Specification / Acceptance Criteria Document Document/ Remarks
Supplier
Item No.
Mat. Status / Record Record
Sulzer
1 Volute Case (102) C
1.1 Material Certification
1.1.1 - Chemical analysis AC Material Specification, N31057 D 1
1.1.2 - Mechanical properties AC Material Specification, N31057 D 1
1.1.3 - Heat treatment AC Material Specification, N31057 O O 7
1.2 NDT
Inspection procedure: TP-0012
1.2.1 - Casting Visual Examination AC Acceptance: N04620 O O 7 See note 1.
Casting markings: N04543
Inspection procedure and acceptance:
1.2.2 - Machined Visual Examination FM O O 7 See note 1.
TP-0015 and Machining drawing
Magnetic Particle
1.2.3 - Magnetic particle Examination AC O O 7 examination is only for
Acceptance: EN 1369 level 3
carbon steel, as castings
Cast/Chromium iron
1.3 Welding
excluded
- Procedure Qualification and PQR according to international standard,
1.3.1 AC O 7
Specification EN ISO 15614-1 (preferred) or ASME IX
1.3.2 - Casting repair AC WPS/PQR, N31058 O 7
1.4 Function
Inspectorate (see Note A) Product Form Material Status Type of Document/Record
O Observed B Bar AC As Cast 1 EN 10204 – 2.1 5 CE-Declaration/Marking
H Hold Point C Casting AF As Forged 2 EN 10204 – 2.2 6 With Report
W Witness F Forging FM Finish Machined 3 EN 10204 – 3.1 7 Without Report
D Document Review W Wrought PM Proof Machined 4 EN 10204 – 3.2 ST Product Marking
H HIP-Component RM Raw Material
P Plate
Subject to legislation, verification documentation detailed above may be held at Sulzer or supplier premises. When required, Manufacturing Record Dossiers shall be compiled in accordance with project
requirements and held by Sulzer.
Revision: 5 Date: July 06, 2017 Amendment: Standards update, clarification of acceptance limits, clarifications to inspectorates, EN 10204-2.1 to default
SULZER
This Quality Plan has been issued and released by the Concept Responsible LE and is published underCONFIDENTIAL
the authority of the Technical Quality Working Group Doc No: N31089
Sulzer P.O. No.
Duplex
Inspectorate
Standard Rev.
Third Party
Task /
Customer
Supplier
Item No.
Sulzer
1.4.1 - Casting main dimensions check AC Drawing O O 7
1.4.2 - Machined main dimensions check FM Drawing O O 7
Can be performed by
1.4.3 - Hydrostatic Pressure Test FM TP-0020 O O ST supplier or Sulzer based on
agreement.
2 Impeller (230) C
2.2 NDT
Cast/Chromium iron
2.3 Welding
excluded
2.3.1 AC O 7
P Plate
SULZER
Sulzer P.O. No.
Duplex
Inspectorate
Standard Rev.
Third Party
Task /
Customer
Supplier
Item No.
Sulzer
2.4 Function
Low pulse impellers
according :ISO21940-11
ISO 21940-11 G6.3 Single plane
2.4.3 - Balancing FM O O 7 G2.5 Single plane. Can be
N31867, N32468
performed by supplier or
Sulzer based on agreement.
3 Shaft (210) B
3.1.1 - Chemical analysis AC Material Specification, N31057 O O 1
3.1.2 - Mechanical properties AC Material Specification, N31057 O O 1
3.1.3 - Heat treatment AC Material Specification, N31057 O 7
3.2 NDT
3.2.1 - Visual Examination FM TP-0015, Drawing O O 7 See note 1.
3.3 Function

P Plate
SULZER
Sulzer P.O. No.
Duplex
Inspectorate
Standard Rev.
Third Party
Task /
Customer
Supplier
Item No.
Sulzer
3.3.1 - Dimension Check FM Drawing O O 7
4 Casing Wear Ring (502) C
4.2 NDT
4.3 Function
5 Case Cover (161) C

P Plate
SULZER
Sulzer P.O. No.
Duplex
Inspectorate
Standard Rev.
Third Party
Task /
Customer
Supplier
Item No.
Sulzer
5.2 NDT
Magnetic Particle
Cast/Chromium iron
5.3 Welding
excluded
5.3.1 AC O 7
5.4 Function
P Plate
SULZER
Sulzer P.O. No.
Duplex
Inspectorate
Standard Rev.
Third Party
Task /
Customer
Supplier
Item No.
Sulzer
Can be performed by
agreement.
6 Side Plate (135) C
6.2 NDT
Magnetic Particle
Cast/Chromium iron
6.3 Welding
excluded
6.3.1 AC O 7
P Plate
SULZER
Sulzer P.O. No.
Duplex
Inspectorate
Standard Rev.
Third Party
Task /
Customer
Supplier
Item No.
Sulzer
6.4 Function
7 Stuffing box housing (451) C
7.2 NDT
Magnetic Particle

P Plate
SULZER
Sulzer P.O. No.
Duplex
Inspectorate
Standard Rev.
Third Party
Task /
Customer
Supplier
Item No.
Sulzer
Cast/Chromium iron
7.3 Welding
excluded
7.3.1 AC O 7
7.4 Function
Can be performed by
agreement.
8 Expeller (604) C
8.2 NDT

P Plate
SULZER
Sulzer P.O. No.
Duplex
Inspectorate
Standard Rev.
Third Party
Task /
Customer
Supplier
Item No.
Sulzer
Magnetic Particle
8.3 Welding Cast iron excluded
8.3.1 AC O 7
8.4 Function
ISO 21940-11 G6.3 Single plane
8.4.3 - Balancing FM O O 7
N30544
9 Case (100) C
P Plate
SULZER
Sulzer P.O. No.
Duplex
Inspectorate
Standard Rev.
Third Party
Task /
Customer
Supplier
Item No.
Sulzer
9.2 NDT
Magnetic Particle
9.3.1 AC O 7
9.4 Function

P Plate
SULZER
Sulzer P.O. No.
Duplex
Inspectorate
Standard Rev.
Third Party
Task /
Customer
Supplier
Item No.
Sulzer
Can be performed by
agreement.
10 Suction Impeller (231) C
10.2 NDT
Magnetic Particle
10.3.1 AC O 7

P Plate
SULZER
Sulzer P.O. No.
Duplex
Inspectorate
Standard Rev.
Third Party
Task /
Customer
Supplier
Item No.
Sulzer
10.4 Function
11 Bearing Housing (330) C
11.2 NDT
11.3 Function

P Plate
SULZER
Sulzer P.O. No.
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Standard Rev.
Third Party
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Item No.
Sulzer
12 Adapter (344) C
12.2 NDT
12.3 Function
13 Pressure Retaining Fasteners (901) B
13.1.1 - Chemical analysis FM Material Specification, N31057 O O ST
13.1.2 - Mechanical properties FM Material Specification, N31057 O O ST

P Plate
SULZER
Sulzer P.O. No.
Duplex
Inspectorate
Standard Rev.
Third Party
Task /
Customer
Supplier
Item No.
Sulzer
14 Flow straightener (175) C/P
14.1.1 - Chemical analysis AC/RM Material Specification, N31057 D 1
14.1.2 - Mechanical properties AC/RM Material Specification, N31057 D 1
14.1.3 - Heat treatment AC Material Specification, N31057 O O 7 Only for casted component
14.2 NDT
14.3 Welding
14.3.1 AC/RM O 7
14.3.2 - Casting repair AC WPS/PQR, N31058 O 7 Only for casted component
14.4 Function

P Plate
SULZER
Sulzer P.O. No.
Duplex
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Third Party
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Item No.
Sulzer
15 Auxiliary Pipework (700) W
15.1.1 - Chemical analysis FM Material Specification, N31057 O O ST
15.1.2 - Mechanical properties FM Material Specification, N31057 O O ST
15.2 NDT
15.2.1 - Visual Examination AC Material Specification, N31057 O O 7
15.3 Piping Welding
- Procedure Qualification and
15.3.1 FM EN 15614-1 / ASME IX, drawing O 7
Specification
15.4 Function
- Performance test, Visual
15.4.1 FM No leaks during test run. O O 7
Examination
15.4.2 - Dimension check FM Drawing O O 7
16 Baseplate (890) P
16.1.1 - Chemical analysis FM Material Specification, N31057 O 7
16.1.2 - Mechanical properties FM Material Specification, N31057 O 7

P Plate
SULZER
Sulzer P.O. No.
Duplex
Inspectorate
Standard Rev.
Third Party
Task /
Customer
Supplier
Item No.
Sulzer
16.3 Welding
PQR according to international standard,
- Procedure Qualification and
16.3.1 PM EN ISO 15614-1 (preferred) or ASME IX, O 7
Specification
drawing
100 % Welds. Visual EN-ISO 17637,
16.3.2 - Visual Examination PM O 7
drawing
16.3 NDT
 Drawing
 Steel surfaces preparation before
FM /
16.3.1 - Visual Examination coating: EN ISO 8501-3 Grade P2 O O 7
Coated
 Hot dip galvanizing EN ISO 1461
 Painting: EN ISO 12944-7
16.4 Function
16.4.1 - Dimension check FM Drawing O 7
17 Pump Complete Assembly
17.1 Function
ISO9906 Grade 2B + Annex A
 Acceptance: against water values With water.
BSP
17.1.1 - Performance Test  ISO 9906 Grade 2B O 7 With manufacturing plant test
Assembly
 ISO 9906 Grade 1B for A hydraulics motor.
in bearing unit sizes 5, 6 and 7
P Plate
SULZER
Sulzer P.O. No.
Duplex
Inspectorate
Standard Rev.
Third Party
Task /
Customer
Supplier
Item No.
Sulzer
 N31047, Corrosivity Category C4, ISO
EN ISO 12944-5/A4.14/M
17.1.2 - Painting Assembly 12944-2 O O 7
Color – NCS 1700 light grey.
 EN ISO 12944-7
17.1.3 - Protection & Preservation check Package N30962 O 7
17.1.4 - Final inspection & Release Package N31210, N04543 O 7
Notes in the Quality Plan

O : No notice is given. Client can witness if present at time of test
H : Notice is given and test held until client attendance or receipt of written waiver. Notice period 10 working days or according contract
A
W: Notice is given and test carried out whether client attends or not provided the notice period agreed. Notice period 10 working days or according contract
D : Review of documents in Manufacturing Record Book (MRB) or similar Type of Documentation
1 From TP-0012 and TP-0015 chapter 3, personnel qualification is considered according to Sulzer internal process.
2
3

P Plate
SULZER
Sulzer P.O. No.
Duplex
Project and/or customer specific notes
This block could be added in case of issuing an Order Related Quality Plan, which needs approvals !!
Approvals Sulzer Pumps Customer 3rd Party
Name
Signature
Stamp
Date
Position

P Plate
SULZER
Technical Quality
Painting Procedure
Sulzer Pumps
Atmospheric-corrosivity category C5M, ISO 12944-2, temperatures <150°C, 2-pack epoxy primer Page
(ME) 1 of 4
1.0 Scope
The following details the surface preparation and the paint system to be applied for equipment exposed
to environment with corrosivity category C5M (very high, marine) as defined in ISO 12944-2. This paint
system can be applied in equipment, where temperature on painted surfaces remains below 150°C. It
must be noticed that in high temperatures some discoloration may happen, if that is not allowed, it is
recommended to apply high temperature paint system already in temperatures above 120°C.
2.0 Health, safety and environmental

The paints and coatings must not include substances which have use restrictions or obligations for
Sulzer based on health and safety or environmental impacts. The referenced documents to be followed:
- REACH -regulation (EU), list of substances requiring authorization and list of substances with very high
concern (SVHC)
- OSHA (US Occupational Safety & Health Administration) regulations
- EPA (US Environmental Protection Agency) regulations
The forbidden substances according to the regulations mentioned above, e.g.:
* Lead compounds, like
*Lead chromate (CAS no 7758-97-6)
*Lead chromate molybdate sulphate red (C.I. Pigment Red 104) (CAS no 12656-85-8)
*Lead sulfochromate yellow (C.I. Pigment Yellow 34) (CAS no 1344-37-2)
* Cadmium and cadmium compounds
* Cobalt and cobalt compounds, like
* Cobalt(II) sulphate (CAS: 10124-43-3)
* Cobalt(II) dinitrate (CAS: 10141-05-6)
* Cobalt(II) carbonate (CAS: 513-79-1)
* Cobalt(II) diacetate (CAS: 71-48-7)
* Chrome (VI+) compounds, like
* Zinc Chromate
Amount of Cadmium (Cd), CromeVI+ (Cr), Lead (Pb) and Mercury (Hg) shall not be over 10 ppm (10
mg/kg) each.
In the painting process, the safety instructions given by the paint manufacturer has to be
followed. Environmental regulations given by local authorities and paint manufacturer has to be followed.
Revision: 2 Date: 2011-11-17 Amendment: Initial issue

This document has been prepared and published by the Quality group of SPP Doc. No: TQ N31049
Uncontrolled valid at time of printing

Technical Quality
Painting Procedure
Sulzer Pumps
(ME) 2 of 4
3.0 Reference documents

ISO 12944-1 Paints and varnishes. Corrosion protection of steel structures by protective paint systems
Part 1: General introduction
Part 2: Classification of environments
Part 5: Protective paint systems
ISO 8501-1 Preparation of steel substrates before application of paints and related products, visual
assessment of surface cleanliness. Part 1: Rust grades and preparation grades of uncoated steel
substrates after overall removal of previous coatings
ISO 8501-3 Preparation of steel substrates before application of paints and related products. Visual
assessment of surface cleanliness. Part 3: Preparation grades of welds, edges and other areas with
surface imperfections
ISO 11126-1 Preparation of steel substrates before application of paints and related products –
Specifications for non-metallic blast-cleaning abrasives – Part 1: General introduction and classification
4.0 General
Examples of typical environments in corrosivity category C5M (very high, marine):

• Coastal and offshore areas with high salinity.
• Buildings or areas with almost permanent condensation and with high pollution
Paint system has been chosen to fulfil durability requirement of more than 15 years (durability "High") as
defined in ISO 12944-1. Durability is by no means "guarantee time", but a technical consideration that
can help the user set up a maintenance programme.
5.0 Cast iron and carbon steel components

5.1 Surface preparation
ISO 8501-1 grade Sa 2 ½ ("very thorough blast-cleaning"). When viewed without magnification, the
surface shall be free from visible oil, grease and dirt, and from mill scale, rust, paint coatings and foreign
matter. Any remaining traces of contamination shall show only as slight stains in the form of spots or
stripes. Additionally, welded steel substrates according to ISO 8501-3, preparation grade P2 (thorough
preparation).
5.2 Paint system
Paint system ISO 12944-5/ A5M.02/H-EP (2-pack epoxy paint, 320/4), dry film thickness 320 µm. Typical
coat thicknesses: primer coat 80 µm, intermediate coat 60 µm and top coat 2 x 90 µm.
5.3 Colour shade
Primer and intermediate coat colours are Sulzer standard. Top coat can be specified by customer, but if
not specified in purchase order, standard colour shade to be applied is NCS 1700 (Munsell N 8.0) semi-
gloss.


Technical Quality
Painting Procedure
Sulzer Pumps
(ME) 3 of 4
6.0 Stainless steel and titanium components

Components made of stainless steel and titanium do not require painting for corrosion prevention, but to
achieve consistent outlook they are typically painted with at least one coat.
6.1.1 Stainless steel
ISO 8501-1 grade Sa 2 ½.
6.1.2 Titanium
ISO 8501-1 grade Sa 2 ½,
• Blast-cleaning using a non-metallic abrasive material, ISO 11126-1
6.2 Paint system
Reference standard ISO 12944-5
Top coat, EP (2-pack epoxy paint), 1 x 80 µm, dry film thickness 80 µm
6.3 Colour shade
Top coat can be specified by customer, but if not specified in purchase order, standard colour shade to
be applied is NCS 1700 (Munsell N 8.0) semi-gloss.
7.0 Guards
Zinc-phosphated (Zn-Ph) (not aluminium), Yellow Chromating and Anodizing (only for aluminium),
Oxsilan or equivalent
7.2 Paint system
7.2.1 Powder paint
Top coat, EP (epoxy paint), 2 x 100 µm, dry film thickness 200 µm.
7.2.2 Liquid paint
Paint system ISO 12944-5/ A7.12/M-EP (2-pack epoxy paint, 240/3), dry film thickness 240 µm. Typical
coat thicknesses: primer coat 80 µm, intermediate coat 80 µm and top coat 80 µm.
7.3 Colour shade
Colour shade is standard safety yellow NCS 0582-Y09R (Munsell 2.5 Y 8/16) semi-gloss.
8.0 Surfaces, which are not painted

Some surfaces/ components in equipment are not painted as they either are of stainless material or are
protected by other means. These components include, but are not limited to:
• Stainless steel components, which are not practically accessible (like small casing covers)
• Stainless steel components immersed in liquid (like in vertical pumps and agitators)
• Stainless steel guards and base plates
• Brass guards
• Hot-dip galvanized components (for example base plates)
• Auxiliary components like lubricating equipment, grease nipples, sight glasses, constant level
oilers, breathers, measuring studs, shaft seal components, stainless steel pipings
• Plastic components
• Internal surfaces and components
• Shaft ends, drivers
• Flange gasket surfaces and mounting surfaces (for example under-side of pump feet)

Technical Quality
Painting Procedure
Sulzer Pumps
(ME) 4 of 4
9.0 Certificate and report

If required by the purchaser a painting certificate may be made available. The painting certificate
declares that the painting has been carried out in accordance with this Procedure.
If required by the purchaser a paint test report may be made available. Paint test report includes the
following information:
• Identification of the equipment (type, serial number)
• Nominal dry film thickness
• Results from film thickness measurement
• Date when the test was carried out
• Signature of the inspector or test controller


Series 2.15 Page
DECLARATION
February 2019 H
Declaration of quality
SPP id: 190219 / Replaces 180108 / en / N15715 / 10 / Page 1 (2)
/
We certify that AHLSTAR pump has been manufactured, tested and inspected according to the following
international standards (if no other specified requirements exist):
 EN ISO 5199:2002 Technical specifications for centrifugal pumps -- Class II
 EN 2858:2010 (ISO 2858:1975) End-suction centrifugal pumps (rating 16 bar) -- Designation, nominal duty
point and dimensions (standard's range up to size 44-200)
 EN ISO 9001:2008 Quality management systems -- Requirements
1 Inspection before assembly

Components to be assembled have been examined.
Installation dimensions have been examined.
Information on the nameplate has been examined.
2 Materials
Materials have been manufactured according to the standard specified in order specification and part list.
3 Balancing of rotating components

All rotating components are balanced according to ISO 1940 G6.3 standard, and the low pulse impeller according to
ISO 1940 G2.5.
4 Hydrostatic test
All pressure containing parts (eg. casing, casing cover etc.) including their fasteners have been hydrostatically tested
with clean water at ambient temperature (15 °C minimum for carbon steel). The hydrostatic test has been
considered satisfactory when the test pressure is maintained for at least 10 min. without visible leakage. The
hydrostatic pressure is 1.5 times the design pressure.
5 Performance test
Performance test has been done according to the EN ISO 9906 grade 2.
During performance tests the pump vibration, bearing temperature and visually the shaft seal have been checked.
6 Final inspection
A final inspection has been done so, that the scope of supply is correct and complete according to the purchase
order, including component identification, painting and preservation and technical documentation.
ORIGINAL INSTRUCTION
SULZER CONFIDENTIAL COPYRIGHT © SULZER PUMPS FINLAND OY
Series 2.15 Page
DECLARATION
February 2019 H
Declaration of quality
/
7 Preparation for dispatch
All internal parts made of material which are not resistant to corrosive attack by the environment have been drained
and treated with a water displacing rust-preventative prior to shipment.
Exterior surfaces, except for machined surfaces, have been given at least one coat of the manufacturer’s standard
paint which shall be selected taking into account environmental considerations. The under-side of baseplates have
been prepared for grouting.
Exterior machined surfaces of cast iron and carbon steel parts have been coated with a suitable rust preventative.
Bearings and bearing housings have been protected by preservative oil which is compatible with the lubricant. A
label warning (oil lubricated bearing housings must be filled with oil to the proper level prior to starting) have securely
attached to the pump.
Information on preservation agents and their removal have been securely attached to the pump.
All openings to the pressure chamber have weather-resistant closures substantial enough to withstand accidental
damage.
Each unit have been prepared and small piping and auxiliaries secured, to prevent damage during shipment and
storage.
The pump and all components supplied loose with it have been clearly and durably marked with the prescribed
identification number.
Kotka 19.2.2019
Enno Danke
SULZER CONFIDENTIAL COPYRIGHT © SULZER PUMPS FINLAND OY
Dimensional data - General Arrangement ISO units Document No. P12923en
A, Process pump, Size 41-400, 43-350, 43-500 Document version: 4
Release Date: 2016-06-01
Replaces: 2011-09-01
Subject: Bare shaft pump Page 1 of 1
C A D 180
DN2
J2
110
H2
FLANGE DRILLINGS
DN1
Drilling of flanges according to P02184
2xØ20
H1
J1
S1
K1
18
All dimensions are in nominal millimeters.
B 140 M2 60
180 M1 20 The right to any alteration in dimensions
N2 E without an advance notice is reserved.
N1
14
51.
Ø48 k7
1) Mass inertia moment J= kgm2
Size DN1 DN2 A C B D E H1 H2 S1 K1 M1 M2 N1 N2 J1 J2 kg J (1

41-400 300 400 200 380 110 700 530 570 400 28 25 250 190 940 850 32 37 610 0.70
43-350 350 350 260 410 90 719 549 570 400 28 25 250 190 940 850 36 36 635 0.95
43-500 350 500 320 465 90 709 539 685 470 28 25 250 190 940 850 36 43 945 1.10
ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS FINLAND OY

P12923en 4 2016-06-01 Product Version 13 >, 2.15 D (ISO)
Series 2.15 Page
DIMENSIONS ISO
DIMENSIONAL DATA – AHLSTAR September 2011 D
General Arrangement – Motor – ISO Units
SPP id: Version 13 > / 110901 / Replaces 090801 / en / P12465 / 4
Product scope: Drive motor (DRMO)

Motor standard: IEC motor
Dimensions in mm
DIMENSIONS OF FRAME DIMENSIONS OF SHAFT
IEC D F
A B C H K E GA
code Nominal Tolerance Nominal Tolerance
71 M 112 90 45 71 M6 14 j6 30 5 h9 16
80 M 125 100 50 80 M8 16 j6 40 5 h9 18
90 S 140 100 56 90 M8 18 j6 40 6 h9 20.5
90 L 140 125 56 90 M8 19 j6 40 6 h9 21.5
100 S 160 112 63 100 M10 22 j6 50 6 h9 24.5
100 L 160 140 63 100 M10 24 j6 50 8 h9 27
112 S 190 114 70 112 M10 28 j6 60 8 h9 31
112 M 190 140 70 112 M10 32 k6 80 10 h9 35
112 L 190 159 70 112 M10 38 k6 80 10 h9 41
132 S 216 140 89 132 M10 42 k6 110 12 h9 45
132 M 216 178 89 132 M10 48 k6 110 14 h9 51.5
132 L 216 203 89 132 M10 55 m6 110 16 h9 59
160 S 254 178 108 160 M12 60 m6 140 18 h9 64
160 M 254 210 108 160 M12 65 m6 140 18 h9 69
160 L 254 254 108 160 M12 70 m6 140 20 h9 74.5
180 S 279 203 121 180 M12 75 m6 140 20 h9 79.5
180 M 279 241 121 180 M12 80 m6 170 22 h9 85
180 L 279 279 121 180 M12 85 m6 170 22 h9 90
200 S 318 228 133 200 M16 90 m6 170 25 h9 95
200 M 318 267 133 200 M16 95 m6 170 25 h9 100
200 L 318 305 133 200 M16 100 m6 210 28 h9 106
225 S 356 286 149 225 M16 110 m6 210 28 h9 116
225 M 356 311 149 225 M16
225 L 356 356 149 225 M16 DIMENSIONS OF TYPE:
250 S 406 311 168 250 M20 IEC code A AB AC ADL ADR B
250 M 406 349 168 250 M20
250 L 406 406 168 250 M20 C H HA HC HD L K
280 S 457 368 190 280 M20
280 M 457 419 190 280 M20
280 L 457 457 190 280 M20 D F
E GA
315 S 508 406 216 315 M24 Nominal Tolerance Nominal Tolerance
315 M 508 457 216 315 M24
315 L 508 508 216 315 M24
355 S 610 500 254 355 M24
355 M 610 560 254 355 M24
355 L 610 630 254 355 M24
400 S 686 560 280 400 M30
400 M 686 630 280 400 M30
400 L 686 710 280 400 M30
450 L (1 800 1000 250 450 M36 1) Dimensions according to motor manufacturer ABB.

Dimensional data - General Arrangement ISO units Document No. P30486en
Size A43-350, pump mounting size 49 Document version: 3
Release Date: 2016-11-01
Replaces: 2011-09-01
Subject: Pump on baseplate (STD) Page 1 of 1
~L min. L4 470 680

260 719 180 410
350
110
14
400
36
350
51.5
FLANGE DRILLINGS
570
36 Ø48 k7
Drilling of flanges according to P02184
H
K2
K3
135
L3
L2 B3 All dimensions are in nominal millimeters.
~L1 B2
The right to any alteration in dimensions
without an advance notice is reserved.
ØS
1) Primary motor
B3
2) Max IEC-motor size, which can be

installed on baseplate.
Motor fixing holes are not drilled.
3) Weight without coupling and motor
Mass inertia moment 0.95 kgm2 (without coupling and motor)
Weight
IEC-motor (1 IEC-Motor (2 H L(1 L1 L2 L3 L4 S B2 B3 K2 K3
kg (3
225SM60…75 250S60…75 775 2040 1955 90 1830 80 30 1260 1190 14 180 805
250SM60…75 280S60…75 775 2040 1955 90 1830 90 30 1260 1190 14 180 815
280SM60…75 315S80…95 775 2250 1955 90 1830 100 30 1260 1190 14 180 865
315SLM80…95 355S100…125 845 2470 2300 125 2140 115 30 1340 1270 16 250 915
355S100…125 400M100…125 845 2640 2500 125 2340 130 36 1340 1270 16 250 945

P30486en 3 2016-11-01 Product Version 13 >, 2.15 D (ISO)
Series 2.15 Page
DIMENSIONS ISO
Wet end connections – ISO Units
Pump scope: Wet end (WEEN.1)

Pump type: A, Process Pump
Pump size: 41-400, 43-350, 43-500
Dimensions in mm
CONNECTIONS
C27.11 (ISO 7/1 - Rp 3/8) C36.11 (ISO 7/1 - Rp 3/8) C36.12 (ISO 7/1 - Rp 3/8)
Pump size
X Y Z X Y Z X Y Z
41-400 225 300 -380 -141 0 177 -225 300 -380
43-350 190 299 -431 -238 0 272 -190 299 -431
43-500 275 363 -500 -298 0 272 -275 363 -500
CONNECTIONS
C40.11 C40.12 C54.11
C48.11 (M8)
Pump size (ISO 7/1 - Rp 3/8) (ISO 7/1 - Rp 3/8) (ISO 7/1 - Rp 3/8)
X Y Z X Y Z X Y Z X Y Z
41-400 0 -526 0 -130 -498 0 154 145 -145 0 325 70
43-350 0 -525 -40 -148 -485 -40 176.5 160.9 -160.9 0 340 60
43-500 0 -665 -45 -185 -620 -45 166.6 160.9 -160.9 0 383 90

Series Page
DIMENSIONAL DATA DIMENSIONS ISO
Flange drillings ISO, EN, JIS and ASME September 2015 D00a
SPP id: 150921 / Replaces 130802 / en / P02184 / 10 / Page 1 (4)
ød
DN
Dimensional data
Flange drillings
ISO
ISO 7005-1:2011
ISO 7005-2:1988 n x ød1
ISO 7005-1:2011 choose either EN 1092-1:2007+A1:2013 or ASME B 16.5:2009

ISO 7005-1:1992 EN 1092-1:2007+A1:2013 PN10, PN16, PN25 and PN40 drilling dimensions are the same as in the
corresponding pressure class in the ISO standard. ASME B16.5:2009 class 300 and class 600
drilling dimensions correspond to PN50 and PN110 dimensions in the ISO standard.
Please take a note that ISO 7005-1:1992 has been replaced by ISO 7005-1:2011.
ISO 7005-2 ISO 7005-2 ISO 7005-2 ISO 7005-2 ISO 7005-2
PN10 PN16 PN25 PN40 PN50
DN d d1 n d d1 n d d1 n d d1 n d d1 n
25 85 14 4 85 14 4 85 14 4 85 14 4 89 18 4
32 100 19 4 100 19 4 100 19 4 100 19 4 98.5 18 4
40 110 19 4 110 19 4 110 19 4 110 19 4 114.5 22 4
50 125 19 4 125 19 4 125 19 4 125 19 4 127 18 8
65 145 19 4 145 19 4 145 19 8 145 19 8 149.5 22 8
80 160 19 8 160 19 8 160 19 8 160 19 8 168 22 8
100 180 19 8 180 19 8 190 23 8 190 23 8 200 22 8
125 210 19 8 210 19 8 220 28 8 220 28 8 235 22 8
150 240 23 8 240 23 8 250 28 8 250 28 8 270 22 12
200 295 23 8 295 23 12 310 28 12 320 31 12 330 26 12
250 350 23 12 355 28 12 370 31 12 385 34 12 387.5 29.5 16
300 400 23 12 410 28 12 430 31 16 450 34 16 451 32.5 16
350 460 23 16 470 28 16 490 34 16 510 37 16 514.5 32.5 20
400 515 28 16 525 31 16 550 37 16 585 40 16 571.5 35.5 20
450 565 28 20 585 31 20 600 37 20 610 40 20 628.5 35.5 24
500 620 28 20 650 34 20 660 37 20 670 43 20 686 35.5 24
600 725 31 20 770 37 20 770 40 20 795 49 20 813 42 24
700 840 31 24 840 37 24 875 43 24
800 950 34 24 950 40 24 990 49 24
900 1050 34 28 1050 40 28 1090 49 28
1200 1380 40 32 1390 49 32 1420 56 32

Series Page
Flange drillings ISO, EN, JIS and ASME September 2015 D00b
ød
DN
EN
EN 1092-1:2007+A1:2013
n x ød1
EN 1092-2:1997
EN 1092-1 EN 1092-1 EN 1092-1 EN 1092-1 EN 1092-1 EN 1092-1

PN10 PN16 PN25 PN40 PN63 PN100
DN d d1 n d d1 n d d1 n d d1 n d d1 n d d1 n
25 85 14 4 85 14 4 85 14 4 85 14 4 100 18 4 100 18 4
32 100 18 4 100 18 4 100 18 4 100 18 4 110 22 4 110 22 4
40 110 18 4 110 18 4 110 18 4 110 18 4 125 22 4 125 22 4
50 125 18 4 125 18 4 125 18 4 125 18 4 135 22 4 145 26 4
65 145 18 8 145 18 8 145 18 8 145 18 8 160 22 8 170 26 8
80 160 18 8 160 18 8 160 18 8 160 18 8 170 22 8 180 26 8
100 180 18 8 180 18 8 190 22 8 190 22 8 200 26 8 210 30 8
125 210 18 8 210 18 8 220 26 8 220 26 8 240 30 8 250 33 8
150 240 22 8 240 22 8 250 26 8 250 26 8 280 33 8 290 33 12
200 295 22 8 295 22 12 310 26 12 320 30 12 345 36 12 360 36 12
250 350 22 12 355 26 12 370 30 12 385 33 12 400 36 12 430 39 12
300 400 22 12 410 26 12 430 30 16 450 33 16 460 36 16 500 42 16
350 460 22 16 470 26 16 490 33 16 510 36 16 525 39 16 560 48 16
400 515 26 16 525 30 16 550 36 16 585 39 16 585 42 16 620 48 16
450 565 26 20 585 30 20 600 36 20 610 39 20
500 620 26 20 650 33 20 660 36 20 670 42 20 705 48 20 760 56 20
600 725 30 20 770 36 20 770 39 20 795 48 20 820 56 20
700 840 30 24 840 36 24 875 42 24 900 48 24 935 56 24
800 950 33 24 950 39 24 990 48 24 1030 56 24 1050 62 24
900 1050 33 28 1050 39 28 1090 48 28 1140 56 28 1170 62 28
1200 1380 39 32 1390 48 32 1420 56 32 1460 62 32 1530 78 32
EN 1092-2 EN 1092-2 EN 1092-2 EN 1092-2 EN 1092-2

PN10 PN16 PN25 PN40 PN63
DN d d1 n d d1 n d d1 n d d1 n d d1 n
25 85 14 4 85 14 4 85 14 4 85 14 4
32 100 19 4 100 19 4 100 19 4 100 19 4
40 110 19 4 110 19 4 110 19 4 110 19 4 125 23 4
50 125 19 4 125 19 4 125 19 4 125 19 4 135 23 4
65 145 19 4 145 19 4 145 19 8 145 19 8 160 23 8
80 160 19 8 160 19 8 160 19 8 160 19 8 170 23 8
100 180 19 8 180 19 8 190 23 8 190 23 8 200 28 8
125 210 19 8 210 19 8 220 28 8 220 28 8 240 31 8
150 240 23 8 240 23 8 250 28 8 250 28 8 280 34 8
200 295 23 8 295 23 12 310 28 12 320 31 12 345 37 12
250 350 23 12 355 28 12 370 31 12 385 34 12 400 37 12
300 400 23 12 410 28 12 430 31 16 450 34 16 460 37 16
350 460 23 16 470 28 16 490 34 16 510 37 16 525 41 16
400 515 28 16 525 31 16 550 37 16 585 41 16 585 44 16
450 565 28 20 585 31 20 600 37 20 610 41 20
500 620 28 20 650 34 20 660 37 20 670 44 20
600 725 31 20 770 37 20 770 41 20 795 50 20
700 840 31 24 840 37 24 875 44 24
800 950 34 24 950 41 24 990 50 24
900 1050 34 28 1050 41 28 1090 50 28
1200 1380 41 32 1390 50 32 1420 57 32

Series Page
Flange drillings ISO, EN, JIS and ASME September 2015 D00c
ød
DN
JIS
JIS B 2220:2012
JIS B 2239:2004 n x ød1
JIS B 2220 JIS B 2220 JIS B 2220 JIS B 2220 JIS B 2220 JIS B 2220
10K 16K 20K 30K 40K 63K
DN d d1 n d d1 n d d1 n d d1 n d d1 n d d1 n
25 90 19 4 90 19 4 90 19 4 95 19 4 95 19 4 100 23 4
32 100 19 4 100 19 4 100 19 4 105 19 4 105 19 4 110 23 4
40 105 19 4 105 19 4 105 19 4 120 23 4 120 23 4 130 25 4
50 120 19 4 120 19 8 120 19 8 130 19 8 130 19 8 145 23 8
65 140 19 4 140 19 8 140 19 8 160 23 8 160 23 8 175 25 8
80 150 19 8 160 23 8 160 23 8 170 23 8 170 23 8 185 25 8
100 175 19 8 185 23 8 185 23 8 195 25 8 205 25 8 220 27 8
125 210 23 8 225 25 8 225 25 8 230 25 8 250 27 8 265 33 8
150 240 23 8 260 25 12 260 25 12 275 27 12 295 33 12 305 33 12
200 290 23 12 305 25 12 305 25 12 320 27 12 345 33 12 360 33 12
250 355 25 12 380 27 12 380 27 12 390 33 12 410 33 12 430 39 12
300 400 25 16 430 27 16 430 27 16 450 33 16 470 39 16 485 39 16
350 445 25 16 480 33 16 480 33 16 495 33 16 515 39 16 530 46 16
400 510 27 16 540 33 16 540 33 16 560 39 16 570 39 16 590 46 16
450 565 27 20 605 33 20 605 33 20
500 620 27 20 660 33 20 660 33 20
600 730 33 24 770 39 24 770 39 24
700 840 33 24
800 950 33 28
900 1050 33 28
1200 1380 39 32
JIS B 2239 JIS B 2239 JIS B 2239

10K 16K 20K
DN d d1 n d d1 n d d1 n
25 90 19 4 90 19 4 90 19 4
32 100 19 4 100 19 4 100 19 4
40 105 19 4 105 19 4 105 19 4
50 120 19 4 120 19 8 120 19 8
65 140 19 4 140 19 8 140 19 8
80 150 19 8 160 23 8 160 23 8
100 175 19 8 185 23 8 185 23 8
125 210 23 8 225 25 8 225 25 8
150 240 23 8 260 25 12 260 25 18
200 290 23 12 305 25 12 305 25 12
250 355 25 12 380 27 12 380 27 12
300 400 25 16 430 27 16 430 27 16
350 445 25 16 480 33 16 480 33 16
400 510 27 16 540 33 16 540 33 16
450 565 27 20 605 33 20 605 33 20
500 620 27 20 660 33 20 660 33 20
600 730 33 24 770 39 24 770 39 24
700 840 33 24
800 950 33 28
900 1050 33 28
1200 1380 39 32

Series Page
Flange drillings ISO, EN, JIS and ASME September 2015 D00d
ød
DN
ASME
ASME B 16.1:2010
ASME B 16.5:2009
ASME B 16.47:1996 n x ød1
ASME B 16.1 ASME B 16.1

Class 125 Class 250
DN d d1 n d d1 n
25 79 16 4 89 19 4
32 89 16 4 98 19 4
40 98 16 4 114 22 4
50 121 19 4 127 19 8
65 140 19 4 149 22 8
80 152 19 4 168 22 8
100 191 19 8 200 22 8
125 216 22 8 235 22 8
150 241 22 8 270 22 12
200 299 22 8 330 25 12
250 362 25 12 387 29 16
300 432 25 12 451 32 16
350 476 29 12 514 32 20
400 540 29 16 572 35 20
450 578 32 16 629 35 24
500 635 32 20 686 35 24
600 749 35 20 813 41 24
700
800
900 1086 42 32 1168 57 32
1200 1422 42 44 1543 57 40
ASME B 16.5 ASME B 16.5 ASME B 16.5 ASME B 16.5

Class 150 Class 300 Class 400 Class 600
DN d d1 n d d1 n d d1 n d d1 n
25 79 16 4 89 19 4 89 19 4 89 19 4
32 89 16 4 98 19 4 98 19 4 98 19 4
40 98 16 4 114 22 4 114 22 4 114 22 4
50 121 19 4 127 19 8 127 19 8 127 19 8
65 140 19 4 149 22 8 149 22 8 149 22 8
80 152 19 4 168 22 8 168 22 8 168 22 8
100 191 19 8 200 22 8 200 25 8 216 25 8
125 216 22 8 235 22 8 235 25 8 267 29 8
150 241 22 8 270 22 12 270 25 12 292 29 12
200 299 22 8 330 25 12 330 29 12 349 32 12
250 362 25 12 387 29 16 387 32 16 432 35 16
300 432 25 12 451 32 16 451 35 16 489 35 20
350 476 29 12 514 32 20 514 35 20 527 38 20
400 540 29 16 572 35 20 572 38 20 603 41 20
450 578 32 16 629 35 24 629 38 24 654 44 20
500 635 32 20 686 35 24 686 41 24 724 44 24
600 749 35 20 813 41 24 813 48 24 838 51 24
ASME B 16.47 ASME B 16.47 ASME B 16.47 ASME B 16.47
Class 150 Class 300 Class 400 Class 600
700 864 35 28 940 44 28 940 51 28 965 54 28
800 978 41 28 1054 51 28 1054 54 28 1080 60 28
900 1086 41 32 1168 54 32 1168 54 32 1194 67 28
1200 1422 41 44 1372 51 32 1403 60 28 1461 73 32
a

Series 2.15 Page
DIMENSIONS ISO
DIMENSIONAL DATA –AHLSTAR September 2011 D
Sealing unit connections – ISO Units
Pump scope: Sealing unit (SEUN.2)

APP, Process Pump
NPP, Non-clogging Pump
WPP, Wear resistant Pump
Sealing unit type: Standard integrated mechanical seal, MS11, MS12, MS21
Dimensions in mm
CONNECTIONS
C20.21 C21.21 C22.21 C41.21
C48.21 (M8)
Sealing unit size (ISO 7/1 - Rp 3/8) (ISO 7/1 - Rp 3/8) (ISO 7/1 - Rp 3/8) (ISO 7/1 - Rp 1/8)
X Y Z X Y Z X Y Z X Y Z X Y Z
10 -321 0 -55 -321 0 55 -315 60 0 -321 0 -55 -357 39 67
11 -290 0 -55 -290 0 55 -315 60 0 -290 0 -55 -357 39 67
20 -393 0 -57 -393 0 57 -421 60 0 -393 0 -57 -464 40 69
21 -398 0 -57 -398 0 57 -421 62 0 -398 0 -57 -464 40 69
22 -399 0 -57 -399 0 57 -423 62 0 -399 0 -57 -468 50 87
23 -399 0 -57 -399 0 57 -423 62 0 -399 0 -57 -468 50 87
31 -417 0 -67 -417 0 67 -441 72 0 -417 0 -67 -485 55 95
32 -420 0 -67 -420 0 67 -433 72 0 -420 0 -67 -487 15 114
33 -418 0 -68 -418 0 68 -433 72 0 -418 0 -68 -481 75 130
41 -551 0 -70 -551 0 70 -574 75 0 -551 0 -70 -594 46 -80
42 -547 0 -70 -547 0 70 -559 77 0 -547 0 -70 -604 68 -117
43 -547 0 -70 -547 0 70 -570 75 0 -547 0 -70 -600 46 -80
44 -547 0 -70 -547 0 70 -562 77 0 -547 0 -70 -610 75 -130
51 -659 0 -86 -659 0 86 -686 91 0 -659 0 -86 -722 75 -130
52 -659 0 -86 -659 0 86 -660 91 0 -659 0 -86 -689 75 -130
53 -659 0 -86 -659 0 86 -691 91 0 -659 0 -86 -722 75 -130
54 -659 0 -86 -659 0 86 -691 91 0 -659 0 -86 -700 125 -217
55 -659 0 -86 -659 0 86 -691 91 0 -659 0 -86 -722 75 -130
60 -788 0 -92 -788 0 92 -819 100 0 -788 0 -92 -845 75 -130
61 -777 0 -94 -777 0 94 -803 105 0 -777 0 -94 -837 75 -130
62 -783 0 -92 -783 0 92 -809 99 0 -783 0 -92 -837 75 -130
63 -781 0 -92 -781 0 92 -811 100 0 -781 0 -92 -837 75 -130
71 -867 0 -106 -867 0 106 -892 117 0 -867 0 -106 -920 105 -182
72 -867 0 -106 -867 0 106 -892 117 0 -867 0 -106 -920 105 -182

Series 2.15 Page
DIMENSIONS ISO
Bearing unit connections – ISO Units
Pump scope: Bearing unit (BEUN.3)

APP, Process Pump
EPP, Hot liquid Pump
Bearing lubrication type: Grease, GR
Oil splash, OS
Dimensions in mm
CONNECTIONS
C41.31 C41.31
C42.31
Bearing unit (wet end side) (motor drive side)
(ISO 7/1 – Rp 1/2)
size (ISO 7/1 – Rp 1/8) (ISO 7/1 – Rp 1/8)
X Y Z X Y Z X Y Z
1 -200.75 80.9 12.5 -85.75 69.9 12.5 -152.75 70 0
2 -294.75 89.1 10 -117.75 83.9 10 -228.75 90.1 0
3 -308 116.4 10 -149 104 10 -235 116.5 0
4 -391.5 127.3 10 -157.5 116.1 10 -297.5 127.8 0
5 -490.75 157.6 10 -191.75 143.6 10 -361.75 158.1 0
6 -606.5 183.5 10 -224.5 178.5 10 -435.5 184 0
7 -715 249 15 -274 200 15 -480 204 0
CONNECTIONS
C48.31 C48.32
C43.31
Bearing unit (M10x1-10) (M10x1x-10)
size Size
X Y Z X Y Z X Y Z
(ISO 7/1 -)
1 -152.75 -72 ±52 R 1/4 -199.75 61.3 51.4 -111.75 69.9 12.5
2 -244.25 -89.5 0 R 1/2 -296.75 67.4 56.6 -147.75 85.9 14.5
3 -235 -115.5 0 R 1/2 -308 108.1 39.4 -187.5 110.1 0
4 -298.5 -126 0 R 1/2 -391.5 117.5 42.8 -197 120.2 0
5 -391.75 156.5 0 R 1/2 -490.75 143.8 52.3 -238.75 147.6 0
6 -435.66 -184 0 R 1/2 -606.5 169.1 61.6 -281.5 181.1 0
7 -480 -220 0 R 1/2 -715 232 85 -338 203 0

Series 2.15 Page
DIMENSIONS ISO
Grouted foundation screw – ISO Units
Assembly scope: Baseplate (BAPL.6)
Baseplate type: Baseplate for pump and motor
Baseplate equipment: Foundation screw / grouted, 918G
Dimensions in mm
DIMENSIONS
D ØS L ØE~ Umin U2min
M16 20 250 100 200 160
M20 25 320 125 250 200
M24 30 400 125 300 240
M30 36 450 160 400 300

AHLSTAR A43-350 (350-350-315)
Speed Curve K52771
SPP id: Version 13 > / 110901 / Replaces 081015 / en / K52771 / 3
Impeller type: Open1 / 920543 B107 Z6

Variable rotational speed: 600 … 1000 rpm
IMPELLER DIA
(mm)
410

Series 2.15 Page
CROSS SECTION
CROSS SECTION DRAWINGS – AHLSTAR September 2011 C
Pump
SPP id: Version 13 > / 110901 / Replaces 050101 / en / N15579 / 2
Product scope: Pump (PUMP.0)


Series 2.15 Page
CROSS SECTION
CROSS SECTION DRAWINGS – AHLSTAR November 2013 C
Assembly
Product scope: Assembly (ASSE.0)

APP, Process Pump
WPP, Wear Resistant Pump
Drive type: Direct drive, DD
Baseplate type: Baseplate for pump and motor, STD
Pump mounting size: 11, 12, 13, 21, 22, 23, 24, 25, 26, 31, 32, 33, 34, 35, 41, 42, 43, 44, 45, 46, 47, 48, 49, 4A,
51, 52, 53, 54, 55, 56, 57, 58, 59, 5A, 5C, 5D, 5E, 5F, 5G, 5H, 61, 62
Original CAD drawing number is 941013

Series 2.15 Page
CROSS SECTION
CROSS SECTION DRAWINGS – AHLSTAR February 2017 C
Wet end
Pump scope: Wet end (WEEN.1)

Impeller type: Open, O
Special open, SO

Series 2.15 Page
CROSS SECTION
Sealing unit

APP, Process Pump
Sealing unit type: Standard integrated single mechanical seal, MS11
Shaft seal fluid: Without fluid, N

Series 2.15 Page
CROSS SECTION
Guards

APP/APT, Process Pump
NPP/NPT, Non-clogging Pump
WPP/WPT, Wear resistant Pump
Sealing unit equipment: Guards, 683

Series 2.15 Page
CROSS SECTION
CROSS SECTION DRAWINGS – AHLSTAR June 2012 C
Bearing unit
Pump scope: Bearing unit (BEUN.3)

APP, Process Pump
EPP, Hot Liquid Pump
Bearing unit type: Grease lubrication, GR
*Antifriction bearing type:

A1-A6, upper view
A7, lower view
**Parts only on shaft size 7
***Not included on shaft size 1

Series 2.15 Page
CROSS SECTION
CROSS SECTION DRAWINGS – AHLSTAR June 2012 C
Coupling unit
Assembly scope: Coupling unit (COUN.5)
Coupling type: Elastic type, CT1, CT7

Series 2.15 Page
CROSS SECTION
Baseplate
Product scope: Baseplate (BAPL.6)

APP, Process Pump
Drive type: Direct drive, DD
Baseplate type: Baseplate for pump and motor, STD
Pump mounting size: 11, 12, 13, 21, 22, 23, 24, 25, 26, 31, 32, 33, 34, 35, 41, 42, 43, 44, 45, 46, 47, 48, 49, 4A,
51, 52, 53, 54, 55, 56, 57, 58, 59, 5A, 5C, 5D, 5E, 5F, 5G, 5H, 61, 62

Series 2.15 Page
CROSS SECTION
Grouted foundation screw
Assembly scope: Baseplate (BAPL.6)

Baseplate type: Baseplate for pump and motor
Baseplate equipment: Foundation screw / grouted, 918G

SERIES 2.15
SPP id: 190211 / Replaces 170201 / en / N32197 / 7
AHLSTAR
PROCESS PUMPS
Installation, operation and maintenance instruction
Intended use
Safety instructions
Hoisting and transportation
Commissioning
Installation at the site
Operation
Preventive maintenance
Corrective maintenance
Spare parts recommendation

Series 2.15 Page
INSTRUCTIONS ISO
USER'S MANUAL – AHLSTAR February 2019 G
Documents & Dates
Installation, operation and maintenance instruction
G ISO Cover
N32197 Feb - 17
G ISO Table of contents
G ISO N31567 Intended use Nov - 14
G ISO N31568 Safety instructions Feb - 17
G N31569 Hoisting and transportation Feb - 17
G N31570 Commissioning Sep - 11
G ISO N31571 Installation at the site Feb - 17
G ISO N31572 Operation Feb - 17
G ISO N31573 Preventive maintenance Feb - 17
G ISO N32198 Corrective maintenance Feb - 19
G ISO N31575 Spare parts recommendation Sep - 11

SERIES 2.15
AHLSTAR
PROCESS PUMPS
Intended use
1 General
2 Document identification
3 Type designation
4 Parts number designation
5 Nameplate designation
6 Capacity and head
7 Decommissioning

Series 2.15 Page
INSTRUCTIONS ISO
USER'S MANUAL – AHLSTAR November 2014 G
Intended use
1 General
WARNING
The pump and its accessories may only be used for the purpose for which they have been supplied.
The intended use is given in the order specification and in the following instructions concerning the main pumping
parameters and mechanical durability. If the intended use changes, the user must make sure that the pump can be
used in the new application and, if necessary, obtain the manufacturer’s permission for the change.
CAUTION
The maximum allowable working pressure of the pump is indicated in the product specification (under
item pump). Please note this also when using a frequency converter.
Table 1, Intended use in the process

Application data: Sources:
Pumped liquid and its properties (chemicals, solids, Product specification (under “Process data”)
consistency, temperature etc.)
Main pumping parameters (capacity, head, speed etc.) Product specification (under “Process data”) and nameplate of
the pump
Other necessary process data Product specification (under “Process data”)
Table 2, Delivery and design

Delivery and design data: Sources:
Product scopes (modules) Product specification
Product size Product specification and nameplate of the pump
Other design alternatives (impeller type and size, materials, Product specification
lubrication, flange drillings, shaft sealing type etc.)
Maximum allowable working pressure Product specification
Dimensions (pump, accessories, flanges etc.) Dimensional drawings
Weights and mass moments of inertia (bare pump, pump + Dimensional drawings
baseplate etc.)
Connections (lubrication, shaft seal, drainage etc.) Location shown in the parts list and in the sectional drawings
and dimensional drawings. Moreover, connections having
importance in view of safety have been marked on the
product.
Part details (maximum impeller diameter, bearing types, Parts list (under heading “Parts”)
fastener sizes etc.)
This instruction set covers the process pump with the supplementary accessories included in the delivery. All
supplied instructions are found in the parts list under the heading ”Customer instructions”.
Before commissioning, the operating staffs have to be instructed in the guidelines for correct and safe operation of
the product as stated in these instructions. This product must be serviced by qualified personnel who are familiar
with the design and operation of this product and the system with the essential safety aspects involved. The scope of
responsibilities and supervision of the personnel must be exactly defined by the plant operator.

Series 2.15 Page
INSTRUCTIONS ISO
Intended use
Our guarantee will be valid only if the installation, operation, maintenance and repairs of this pump are carried out in
accordance with these instructions. The plant operator is to make sure that the contents of these instructions are
fully understood by the operating personnel.
To assure a steady start-up, supervision or service from an authorized manufacturer representative is
recommended. During operation, periodic inspections should be made to assure safe operation under the prevailing
conditions.
Any modification may be made to the product only after consultation with the manufacturer. Using spare parts and
accessories authorized by the manufacturer is a relevant safety aspect. Only genuine spare parts which are in
accordance with the original delivery (in the parts list) are to be used. Use of other parts may exempt Sulzer from
any liability.
If any assistance regarding the product or its instructions is required, please contact our local representative for a
quick supply of the information you need.
The enclosed instructions regarding a possible long-term storage (more than 3 months) must be observed.
All customer instructions regarding this product and its main components are also available in an electronic format
for viewing and printing (depending on the end user’s software & hardware). If electronic format is needed, please
contact our local representative for further information.
If the delivery includes customer instructions or other information in an electronic format which can be
edited, we are only responsible for the contents of paper versions of these instructions and other
information supplied by us.
Keep these instructions at the place of operation for further reference!
2 Document identification
Sulzer product number
Series 2.15 Page

INSTRUCTIONS
Identification of Sulzer document
September 2011 G
SPP id: Version 11 > / 110901 / Replaces 050101 / en / N15652 / 1 / Page 1 (2)
Page number when the document has more than one

page (total number of pages)
Document version number
Document identification number
Language of the document
The date when this document was done previously (when needed)
The date when this document was done or updated
Product version number
Sulzer Pumps Finland Oy identification

Series 2.15 Page
INSTRUCTIONS ISO
Intended use
3 Type designation
A 4 3 - 250 - LM
A P P
LM = LM design liquid ring pump / mechanical seal

GM = GM design gas separator / mechanical seal
GS = GS design gas separator / static seal
S = S design liquid ring pump / mechanical seal
R = R design air separating pump / mechanical seal
Nominal diameter of discharge (mm) = 250 mm
Except the markings:
8S nominal diameter of discharge = 80 mm
10S nominal diameter of discharge = 100 mm
10P nominal diameter of discharge = 100 mm
Sealing unit size = 43
Shaft size = 4
Hydraulic construction
A = Standard process pump (mm-dimensioned structure)
APP = Standard process pump (mm-dimensioned structure)
EPP = Hot liquid pump (mm-dimensioned structure)
NPP = Non-clogging pump (mm-dimensioned structure)
WPP = Wear resistant pump (mm-dimensioned structure)
4 Parts number designation
4.1 Part numbers of modules

The delivery may include the entire pump product (PUPR.0) and/or pump spare parts. The installation-ready pump
unit is divided into the following modules: pump (PUMP.0), assembly (ASSE.0), drive unit (DRUN.0), measuring
instrumentation (MEIN.0), external degassing system (DESY.0) and documents (DOCU.0).
The pump (PUMP.0) is divided into the following modules: wet end (WEEN.1), sealing unit (SEUN.2) and bearing
unit (BEUN.3). The assembly is divided into the following modules: sealing water equipment (SWEQ.4), coupling unit
(COUN.5) and baseplate (BAPL.6). The drive unit (DRUN.0) is divided into two parts: motor (DRMO) and frequency
converter (FRCO). Documents are divided into two categories: documents supplied with the delivery and documents
supplied separately.
4.2 Part numbers of parts, connections and documents

Parts, which have part numbers consisting of a three/four-digit number plus two digits after a dot. The first digit after
the dot shows the number of the delivery unit or module in question, while the second digit distinguishes parts of the
same type from each other.
In the part number, the first digit after the dot is determined by the module. For instance, o-ring 412.11. If the module
has many parts with the same name, the second digit after the dot distinguishes the parts from each other. For
instance, 412.12 is the second o-ring in the wet end (WEEN.1).
Connections, which have part numbers consisting of the initial letter C, a two-digit number plus two digits after a dot.
The first digit after the dot shows the number of the delivery unit or module in question, while the second digit
distinguishes connections of the same type from each other.
Documents, which have part numbers consisting of the initial letter D, a two-digit number plus two digits after a dot.
The first digit after the dot shows the number of the delivery unit or module in question, while the second digit
distinguishes documents of the same type from each other.

Series 2.15 Page
INSTRUCTIONS ISO
Intended use
5 Nameplate designation
The following nameplates have been attached to the volute casing (102.11) of each pump:
 Nameplate (971.01), showing the pump’s identification data and flow properties. Fig. 1.
 Caution sticker (975.01) of maximum allowable working pressure of the pump. Fig. 2.
 Patent nameplate, showing the patents protecting the product. Fig. 3.
 ATEX nameplate (982.01), if the product is designed for use in potentially explosive environments. Fig. 4 and
Fig. 5.
1 3
2 4
7 6 5
Marking:
1 Pump type 5 Speed of rotation (rpm)
2 Serial No. = Job No. 6 Space for customer Pos. No.
3 Head (m) 7 Year of manufacture
4 Capacity flow (l/s)
Fig. 1
ATTENTION!
Always check the maximum
allowable working pressure
(MAWP) of this product from
the product specification.
4-942543-06
Fig. 2
MADE UNDER ONE OR MORE OF

THE FOLLOWING US PATENTS:
NOS. 4,863,353
4,594,052
OTHER PATENTS PENDING
Fig. 3
0123 II 2 G c T3
c = The protection class used is constructional safety
T3 = Temperature class, indicates the maximum surface temperature
(200ºC)
Ex = Explosion protection marking
II = Equipment group
2 = Equipment category
G = The equipment is used in explosive atmospheres caused by gases, vapours or mists
CE marking and the mark of the notified body.
0123 = TÜV Product service, München
Fig. 4

Series 2.15 Page
INSTRUCTIONS ISO
Intended use
II 3 G c T3
c = The protection class used is constructional safety
T3 = Temperature class, indicates the maximum surface temperature (200ºC)
Ex = Explosion protection marking
II = Equipment group
3 = Equipment category
G = The equipment is used in explosive atmospheres caused by gases, vapours or mists
Fig. 5
6 Capacity and head
The pump is always dimensioned according to the pumping values (flow, head) stated in the nameplate (971.01) of
the pump. Flow and head values that can be reached with the specific impeller diameter and operating speed are
given in the characteristic curve of the pump. The operating point on the curve can be changed by adjusting the
pumping system resistance e.g. by throttling the flow with the valve in the discharge piping. If the impeller diameter
or the rotational speed of the pump is changed, then the operating point will move totally to another head-flow curve.
The pump must not be used at other operating points without the following verifications:
 When the pump was selected in the original operating point, all factors affecting the mechanical durability
(e.g pressure and temperature limits) and pump design (pump, impeller type, shaft sealing and lubrication
etc.) were carefully considered. All these factors are to be checked also in the new operating point.
 The pump could temporarily operate even with the discharge valve closed. For continuous operation, a
minimum flow is still required. The required suction head (NPSH required) curve presented in the
characteristic curve always starts from the point of the minimum continuous flow allowed.
 The suction properties of the system (NPSH available) and drive motor power are always to be checked in a
new operating point.
 The efficiency of a pump is a relevant factor when estimating the lifetime costs of the pump. Therefore its
influence on the power need must be checked.
 The characteristic curve enclosed is always based on tests with clean water. Other types of pumped liquid
can change the head, flow or power need values radically. These factors were recognized when the pump
was originally selected and they must be considered also in the new operating point.
7 Decommissioning
Sulzer Pumps’ products are designed so that their service would be as easy as possible by replacing worn or
damaged parts with new, original Sulzer spare parts. Parts can also be re-used after reconditioning them at Sulzer
Customer Support Service Centers. Sulzer Customer Support Service Centers must be used in the assessment of
re-use and reconditioning. If you need additional instructions or guidance, please contact our representative.
The materials used in Sulzer Pumps’ products are disclosed in the parts list supplied with the product.
At the end of the life cycle of a product or its parts, the appropriate materials and parts must be recycled or disposed
of using methods which are acceptable in terms of environmental protection and which conform to local legislation
and regulations. If a product or its part contains environmentally harmful substances, they must be removed and
disposed of by following valid regulations.

Series 2.15 Page
INSTRUCTIONS ISO
Intended use
Packaging materials must be recycled or disposed of using methods which are acceptable in terms of environmental
protection and which conform to local legislation and regulations.
Make sure that hazardous substances are disposed of safely and that the personnel use appropriate personal
protective equipment. Safety considerations must always meet the requirements of valid regulations.

SERIES 2.15
AHLSTAR
PROCESS PUMPS
5 mm
MAX
0.2 in
Safety instructions
1 General
2 Safety of machinery
3 Definitions
4 Essential safety aspects
5 Ignition hazard assessment
6 Safety signs affixed to the product
7 Operating situations affecting product safety
8 Balance and vibration
9 Wet end
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1 General
This product is designed and tested for safe and reliable operation in the application for which it is specified and
sold. Remember, a pump is a piece of equipment with pressure containing parts and rotating elements which can
cause a hazard. Therefore, all the safety measures in the instructions are to be followed strictly. Personal injuries
may result if the instructions are not observed and followed.
It is not only the general safety instructions contained under this main heading ”Safety instructions” which are to be
observed, but also the specific safety information presented in other instructions relating to this delivery, relevant
national safety regulations or any other safety information issued by the plant operator.
The exact and detailed process and application data is relevant for the safe and reliable operation of the product.
Special environmental conditions at the place of installation should always be checked between the end user and
manufacturer. Such conditions are e.g.
 Abnormal temperature
 High humidity
 Corrosive atmospheres
 Pressure fluctuations
 Falling below the minimum permissible flow, dry running
 Explosive and/or fire risk zones
 Dust, sandstorms
 Earthquakes
Special safety measures are also needed when the type of liquid to be pumped is e.g. the following:
 Flammable
 Corrosive, abrasive
 Poisonous
 Crystallizing
 Solid containing
 Gas containing
Non-compliance with the safety and specific operating instructions may produce a risk to the personnel as well as to
the environment, e.g.
 Failure of important functions of the pump and/or plant
 Failure of specific procedures of maintenance and repair
 Exposure of people to electrical, mechanical and chemical hazards
 Endangering the environment owing to hazardous substances being released
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2 Safety of machinery
2.1 General
Our delivery does not include the design of the operating environment of the machine, nor the power circuits, control
circuits and controls for the machine required in the operation of the machine. However, the European Machinery
Directive 2006/42/EC on the safety of machinery and/or corresponding national legislation in the country where the
machine is used as well as directive 2014/34/EU for a device intended to be used in potentially explosive
atmospheres are mandatory in respect of the essential health and safety requirements related to the operation of the
entire process.
We require that the Customer has taken into account the essential requirements laid down in this instruction when
designing, purchasing and starting up the process control systems, other controls and equipment related to the
machine. Some of these requirements also concern the personnel in charge of the operation of the machine.
As far as the above is applicable, the Customer must also ensure that the valid legislation on electrical safety (such
as low-voltage directive) or electromagnetic compatibility of equipment (EMC directive) is followed.
During the operation of the machine, valid occupational safety legislation of the country where the machine is used
must also be followed.
2.2 Essential health and safety requirements
2.2.1 General remarks
2.2.1.1 Definitions
When necessary, the potential danger zones related to the machine and its operating environment, persons exposed
within the danger zone and all operator groups of the machine must be specified jointly between the Customer and
the Manufacturer, for example for the purpose of introductory training arranged for the operators of the machine.
2.2.1.2 Principles of safety integration
As a machine manufacturer, we have, in accordance with the contents of the delivery, followed the Machinery
Directive and/or the national legislation of the country where the machine is used in order to ensure safety
integration.
The installation, operating and safety instructions supplied with the machine must be followed on receipt of the
machine, in installing it at the point of operation and in its operation. Prior to final start-up, it must be ensured that the
machine, its controls and other equipment related to a safe use of the machine fulfill the requirements laid down in
the Machinery Directive and/or in national safety legislation.
2.2.1.3 Materials and products
The products related to the use of the machine (liquids transferred in the process) must not endanger the exposed
persons' safety or health. The process where the machine is used must be designed so that the use of liquids
causes no hazard.
2.2.1.4 Lighting
Maintenance areas necessary for the regular inspections of the machine must be provided with appropriate lighting.
2.2.1.5 Design of machinery to facilitate its handling
The environment of the machine must be designed so that, in order to facilitate the handling of the machine or its
various components, standard lifting gear can be attached above the machine if necessary. The environment must
be designed so that the various components can be handled safely in other respects as well. The handling and lifting
instructions supplied with the machine must be absolutely followed.
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2.2.2 Controls
2.2.2.1 Control and stopping devices
The controls of the machine must be safe and constructed in a way that will prevent a dangerous situation arising.
When designing the controls, the specified requirements laid down in the Machinery Directive and/or in the national
legislation of the country where the machine is used must be absolutely followed in terms of controls, starting
devices, stopping devices (including emergency stop devices) and selection of control and operating modes for the
machine and combinations of machinery.
The controls of the machinery must be designed so that fluctuations in energy supply or failures in the control circuit
do not lead to dangerous situations. The interactive software used in the controls between the operator and the
machine must be user-friendly.
2.2.3 Protection against mechanical hazards
2.2.3.1 Stability
Our delivery includes the appropriate accessories for securing the machine to the foundations. The installation
instructions supplied with the machine must be absolutely followed in order to ensure sufficient stability of the
machine/combination of machinery.
2.2.3.2 Risk of break-up during operation
The piping and hoses connected to the machine must be able to withstand the anticipated internal and external
stresses, and they must be firmly secured and protected against all loading and stress.
The instructions concerning the purpose of the machine, limitations of use, allowable flange forces and support of
piping, supplied with the machine, must be absolutely followed. During operation, there is always a risk of rupture in
the piping connected to the machine (risk of high-pressure/hot/harmful liquid spray) if the supplied instructions are
violated.
2.2.3.3 Risk due to falling or ejected objects
Necessary precautions must be taken to prevent risks from falling or ejected objects (e.g. tools used during
installation).
2.2.3.4 Risks due to sharp edges or angles
Due to the purpose and design of the machine, its parts have sharp edges and/or angles. During installation and
maintenance, the instructions supplied with the machine must be followed, and the appropriate personal protective
equipment must be used.
2.2.3.5 Risks related to variations in the rotational speed
The instructions supplied with the machine show the intended rotational speed of the machine and its maximum
rotational speed limits. The selection and adjustment of rotational speed must be performed so that these
instructions are adhered to.
2.2.3.6 Prevention of risks related to moving parts
The fixed guards used for preventing risks related to moving parts in the machine must be absolutely kept in place
while the machine is running. If a guard is not included in the delivery, it must be ensured prior to start-up that the
rotating parts are provided with guards in accordance with the valid legislation. If rotating parts of the machine seize
accidentally during operation, the machine must be stopped immediately and the cause of the fault must be
ascertained in accordance with the instructions supplied with the machine.
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2.2.4 Protection against other hazards
2.2.4.1 Electricity supply
The electrical drives of the machine must be designed, constructed and equipped so that all hazards of an electrical
nature can be prevented. The specific rules and valid legislation in force related to electrical equipment must be
absolutely followed. The electrical equipment related to a machine conforming to the Machinery Directive must fulfil
the detailed requirements laid down in standard EN 60204-1:2006.
2.2.4.2 Static electricity
The build-up of potentially dangerous electrostatic charges in the machine and its auxiliary equipment must be
prevented or restricted.
2.2.4.3 Errors of fitting
Errors made when fitting parts of the machine can be a source of risk. For this reason, the instructions supplied with
the machine must be absolutely followed during the installation and repairs of the machine.
Faulty liquid and electrical connections can also be a source of risk. With liquid connections, the instructions
supplied with the machine must be followed. Faulty electrical connections must be made impossible by the design,
or information on the risk must be given on cables and connectors.
2.2.4.4 Extreme temperatures
If necessary, the machine must be provided with warnings concerning high surface temperatures. In these cases,
additional steps should be taken to eliminate any risk of injury caused by contact with or proximity to machinery
parts. Maintenance requires the heating of some parts prior to installation. Carefulness is imperative during
installation, and appropriate personal protective equipment must be used during installation.
2.2.4.5 Fire and explosion
Exact and detailed information on the process and the purpose for which the machine is used are essential in terms
of safe operation of the machine. The specific circumstances prevailing at the point of use must always be checked
between the Customer and Manufacturer when the machine is being selected.
With equipment intended for use in potentially explosive atmospheres (ATEX), see section 5 (Ignition hazard
assessment.
2.2.4.6 Noise and vibration
The instructions supplied with the machine provide information on the emission of airborne noise and on the
balancing of rotating parts of the machine. The data given must be taken into account and necessary steps must be
taken in order to eliminate any risks caused by noise or vibration in accordance with the circumstances prevailing at
the point of use.
2.2.4.7 Radiation
The instructions supplied with the machine provide information on the emission of radiation potentially involved in the
measuring equipment of the machine. The operators of the machine must absolutely follow the safety instructions
concerning the use of this equipment.
2.2.4.8 Emissions
The instructions supplied with the machine provide information on the control of leakages in the immediate proximity
of the machine. If necessary, the following steps must be taken to eliminate harmful emissions involved in the
process:
 account of the emissions and their potential consequences (e.g. possibility of fire, appropriate extinguishing
equipment)
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 preventing exposure of operators
 controlled containment and evacuation of emissions
 cleaning of emissions and machinery
 appropriate personal protective equipment and warnings
2.2.4.9 Slipping, stumbling and falling
When installing, servicing and repairing the machine, the instructions supplied with the machine, safety instructions
applicable at the point of use and sufficient care and attention must be followed in order to prevent any slipping,
stumbling or falling.
2.2.5 Maintenance
2.2.5.1 Machinery maintenance
The maintenance and repair instructions supplied with the machine must be absolutely followed. The instructions
specify separately which measures require stopping and potential draining of the machine. Appropriate personal
protective equipment as required by the work performed must always be used, e.g.:
 hearing protectors
 eye protectors
 breathing protectors
 safety gloves, safety footwear, protective clothing
When servicing and repairing the machine, principles of ergonomics (avoiding excessive use of muscular power,
utilization of lifting gear, lifting positions, lighting of the area, cleanliness etc.) must also be taken into account.
2.2.5.2 Access to operating position and servicing points
Where the location design for the machine is not included in the delivery, steps must be taken to situate the machine
at the point of operation in a manner that enables safe maintenance and repairs of the machine. Provision of
sufficient maintenance space around the machine must be taken into account in the design of the operating
environment.
2.2.5.3 Isolation of energy sources
The controls of the machine must be designed so that they include clearly identified devices that can be used to
isolate the machine from all energy sources. These devices must be capable of being locked if reconnection of
energy could endanger exposed persons. After the energy is cut off, it must be possible to dissipate any energy
remaining or stored in the process (e.g. discharging pressure) without risk to exposed persons.
2.2.5.4 Operator intervention
The controls of the machine must be designed so that the need for operator intervention is limited.
2.2.5.5 Cleaning of (internal) parts of machine
The potential cleaning of the machine must take place in accordance with the instructions supplied with the machine
and the safety instructions applicable at the point of use so that cleaning can be carried out as safely as possible.
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2.2.6 Indicators
2.2.6.1 Information and warning devices
When designing the controls of the machine, the specified requirements laid down in the Machinery Directive and/or
national legislation of the country where the machine is used must be absolutely followed in terms of information and
warning devices used on the machine.
2.2.6.2 Warning of residual risks
The safety warnings related to the machine must be kept clean under all circumstances, and the warnings must be
renewed when necessary. All operators of the machine must be warned of the residual risks involved in electricity or
the controls in accordance with specified requirements laid down in the Machinery Directive and/or national
legislation of the country where the machine is used.
2.2.6.3 Marking and instructions
The marking and instructions for the machine must be drawn up in accordance with the Machinery Directive and/or
national legislation of the country where the machine is used. Steps must be taken to ensure that the marking and
instructions for other equipment related to a safe use of this machine conform to valid legislation.
In particular, it must be ensured that the point of use is provided with instructions for emergencies, such as:
 how to give alarm
 location of rescue and fire extinguishing equipment
 availability of first aid and necessary first aid equipment
3 Definitions
The following words are used in the instructions to indicate issues which require special attention.
WARNING
There is a risk of personal injury if the instruction is not adhered to.
CAUTION
There is a risk of damaging or destroying the product or equipment if the instruction is not adhered to.
NOTE
Is used in the text for highlighting necessary information or requirements which are essential to
observe.
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4 Essential safety aspects
All of the following relevant safety aspects are to be instructed to the operators and maintenance personnel before
putting the product into service.
General
 The product is meant only for the purpose for which it is sold - never operate beyond the intended use
described in these instructions.
 Personal injuries may occur if personal protective equipment is not used when servicing the product.
 Pump units which convey hazardous media must be decontaminated before beginning any maintenance
work.
 If there is a possibility that the pump or the pipeline contains explosive gases or vapours, it must be
ventilated carefully before working on the pump.
 If there is a possibility that there are explosive gases or vapours in the atmosphere surrounding the pump,
the pump’s environment must be ventilated carefully before working on the pump.
 All safety equipment (e.g. coupling and shaft sealing guards) must be properly in place before starting.
 External heat must not be used when dismantling the pump, as any liquid, gas, vapour or their combination
that remains in the pump may explode.
 All safety devices (e.g. coupling and shaft sealing guards) must be correctly installed before starting. For
explosive areas, guards with a non-sparking material are to be used.
 Tools used in an explosive air mixture must comply with the requirements of the relevant standard. Refer to
e.g EN 1127-1:2011 Annex A.
 In a potentially explosive environment, the pump must be lifted and transferred so that no sparking can
occur.
Wet end
 If there is a possibility of a dangerous return flow after the shutdown of the pump, a nonreturn device shall be
installed in the outlet piping.
 The pump must be sufficiently filled with the pumped liquid before starting (with the exception of liquid ring
pumps (-LM, -S), air separating pumps (-R) and pumps equipped with a gas separator (-GM, -GS)).
 The pump must run above the minimum recommended flow and never dry (with the exception of liquid ring
pumps (-LM, -S), air separating pumps (-R) and pumps equipped with a gas separator (-GM, -GS)).
 The suction valve must be open during operation.
 If leakage of harmful or dangerous substances can occur - prepare proper means for a safe waste removal.
 The parts in contact with the pumped liquid can be dangerously hot.
Sealing unit
 The product must always be equipped with a shaft sealing system compatible with the pumped liquid.
 The shaft seal must be sufficiently lubricated regardless of the pump operating point on the pump curve.
 The parts in contact with the pumped liquid can be dangerously hot.
Bearing unit
 For delivery, the bearing housing of the pump has been emptied of oil. Remember to refill it before starting.
 There is no protection against contact in the shaft seal area.
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Drive motor
 Always stop the drive unit before beginning any repair work on the pump. Make sure that the motor cannot
be started by any means accidentally during the repairs.
 The correct rotating direction of the drive unit must be checked before starting and the pump must rotate
freely (with coupling spacer removed).
Coupling unit
 The coupling must be properly aligned before starting.
Baseplate
 The pump baseplate must be properly installed before starting.
 Make sure that the baseplate of the pump is properly grounded.
5.1 General
1 Description of use
Group II category 2 Ex II 2 G c T1, T2, T3 and T4: The equipment is a centrifugal pump designed for use in
environments in which the release of flammable materials will give rise to a zone 1 potentially explosive
atmosphere (zone in which explosive atmospheres caused by mixtures of air and gases, vapours or mists
are likely to occur occasionally during normal operation). The pump is designed for pumping various liquids
in the process industry.
Group II category 3 Ex II 3 G c T1, T2, T3 and T4: The equipment is a centrifugal pump designed for use in
environments in which the release of flammable materials will give rise to a zone 2 potentially explosive
atmosphere (a place in which an explosive atmosphere consisting of a mixture with air of flammable
substances in the form of gas, vapor or mist is not likely to occur in normal operation but, if it does occur, will
persist for a short period only). The pump is designed for pumping various liquids in the process industry.
When pumping hot (>100 °C) liquids, the pump casing heats up to the temperature of the pumped liquid, i.e.
the maximum surface temperature does not depend on the pump itself but on the operating conditions.
2 Construction
The pump is horizontally mounted and has a single-stage end-suction design. The pump shaft is mounted on
antifriction bearings so that the bearing at the impeller end carries radial loads, while the bearings at the
clutch end carry mainly axial loads. The pump is made from cast iron (for non-corroding liquids) or acid-
resistant steel (for corroding liquids). The pump easily passes the required mechanical tests described in EN
ISO 80079-36:2016. There are no light metal or plastic parts that need consideration, or other relevant
restrictions as described in EN ISO 80079-36:2016.
The pump is designed in such a way that any predictable malfunction will not cause the pump to break in a
manner that would cause it to leak. In normal use, the liquid to be pumped is inside the pump. In the case of
a self-priming pump that will be used in potentially explosive atmospheres, the suction piping is to be set up
in such a manner that the pump is full of liquid when being started up. The pump uses either a single or
double mechanical seal selected according to the operating conditions, or if the situation demands it, a
dynamic seal. In the case of mechanical seals, the sliding surfaces are lubricated either by the pumped
liquid, external sealing liquid or grease
The pump installation is designed to withstand the expected forces and vibrations from the pump.
Instructions on how piping is to be supported are provided in the installation, operation and maintenance
documentation. The pump has been designed and manufactured in accordance with structural safety
principle "c", EN ISO 80079-37:2016.
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The assessment of the ignition risk in accordance with EN ISO 80079-36:2016 shows that based on the
structure of the pump and the tests carried out (temperature and impact resistance tests), the pump has no
ignition sources in normal use, during in-service maintenance or during repairs.
In the appended table N33727, an ATEX ignition hazard assessment has been conducted, taking into
account all possible sources of ignition found based on usage experience and their assessments, as well as
the explosion protection methods used.
WARNING
The pump must not be used without the written permission of Sulzer in any environment other than
that for which it has been sold, or within operating limits exceeding those indicated on the pump plate.
6 Safety signs affixed to the product
The following warnings and informative signs concerning the essential safety aspects are permanently fixed on the
product. Safety signs must always be observed and kept clean and legible in any operating condition. The user must
always check that the symbols or items presented in those are understood by all user groups before putting the
product into service.
Wet end
Item no. 975.11. Hot surface, do not touch (to be fixed when the temperature of the pumped liquid is > 60°C)
Sealing unit
ATTENTION!
This product is equipped with a
mechanical seal.
Do not run or rotate the seal dry!
Please read carefully through the
instructions for the product and
the mechanical seal before
commissioning.
4-941349-06
Item no. 976.21. Do not run or rotate the seal dry
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Bearing unit
Item no. 975.31. Splashing of corrosive or irritative substances (this sign is delivered unattached and it is to be
attached to both sides of the adapter if necessary)
Coupling unit
Item no. 976.51. Coupling alignment values
5 mm
MAX
0.2 in
Item no. 975.51. Coupling guard jacket to be adjusted during assembly
7 Operating situations affecting product safety
The following inadequate operating situations always have consequences which have an immediate effect on the
product safety and therefore they are not allowed in any operating conditions with this product.
Table 1, Typical inadmissible operating situations

Cause: Consequence:
Discharge valve not opened. Inadmissible pressure increase
Inlet pressure or piping system resistance incorrectly estimated when the pump
was originally selected.
The pump is operated at too high a rotational speed.
Discharge valve not opened. High temperatures (Wet end)
Discharge valve throttled too much.
Properties of the pumped liquid incorrectly estimated when the pump was
originally selected.
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Cause: Consequence:
Gland packing tightened too much. High temperatures (Sealing unit)
Adequate sealing water service neglected.
- Sealing water pump not started
- Sealing water valve not opened
- Sealing water equipment incorrectly adjusted
- Quality of the sealing water does not match our requirements.
Inlet pressure incorrectly estimated when the pump was originally selected.
Pump is not properly filled with the pumped liquid.
- Suction valve not opened
- Suction tank not properly filled
- Suction piping resistance or air tightness improperly checked
Pump lubrication carried out inadequately. High temperatures (Bearing unit)
- Oil/grease filling neglected
- Oil/grease quality incorrectly selected
- Relubrication carried out inadequately
Pump washdown carried out inadequately (sprayed water enters the bearing
unit).
Properties of the pumped liquid incorrectly estimated when the pump was
originally selected.
8 Balance and vibration
The pump is normally balanced according to ISO 21940-11 Grade G 6.3, but in specific cases according to ISO
21940-11 Grade G 2.5. Vibration does not exceed the vibration severity limits given in Table 2 when measured at
the manufacturer’s test facilities. These values are measured radially at the bearing housing at rated speed and flow
when operating without cavitation.
A pump equipped with a specially designed impeller may exceed the limits given in Table 2.
Table 2, Max. r.m.s values of vibration velocity

Shaft centerline height H1
Pump installation
≤ 225 mm > 225 mm
Pump on a grouted baseplate or on a concrete baseplate 3 mm/s 4.5 mm/s
Pump on a baseplate without grouting 4.5 mm/s 7.1 mm/s
9 Wet end
9.1 Admissible forces and moments on pump flanges

Forces and moments acting on the pump flanges due to pipe loads can cause misalignment of the pump and driver
shafts, deformation and overstressing of the pump casing, or overstressing of the fixing bolts between the pump and
baseplate.
This is a simple method for checking that loads transmitted to a pump by its piping remain within acceptable limits.
This is done by comparing the loads (forces and moments) calculated by the piping designer, with the maximum
values allowed on the flanges, as a function of their size and the installation conditions.
The basic values given in Table 3 are applicable to each of the pump flanges, respecting the sign convention of the
three axes through the flange. The values can be applied simultaneously in all directions with positive or negative
signs, or separately on each flange (suction and discharge).
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WARNING
The basic values mentioned in Table 3 should be multiplied by: 0.15 white iron, 0.29 titanium, 0.35
cast iron, 0.45 carbon steel and 0.7 stainless steel. The values mentioned in the table apply to pumps
equipped with a grouted baseplate or a concrete baseplate. A baseplate installed with machine feet
should be multiplied by 0.25.
x
z
Fig. 1
Table 3, Basic values of forces and moments

Top branch z-axis
Diameter DN Force (N) Moment (Nm)
Fy Fz Fx F* My Mz Mx M *
32 850 1050 900 1650 750 850 1100 1600
40 1000 1250 1100 1950 900 1050 1300 1900
50 1350 1650 1500 2600 1000 1150 1400 2050
65 1700 2100 1850 3300 1100 1200 1500 2200
80 2050 2500 2250 3950 1150 1300 1600 2350
100 2700 3350 3000 5250 1250 1450 1750 2600
125 3200 3950 3550 6200 1500 1900 2100 3050
150 4050 5000 4500 7850 1750 2050 2500 3650
200 5400 6700 6000 10450 2300 2650 3250 4800
250 6750 8350 7450 13050 3150 3650 4450 6550
300 8050 10000 8950 15650 4300 4950 6050 8900
350 9400 11650 10450 18250 5500 6350 7750 11400
400 10750 13300 11950 20850 6900 7950 9700 14300
500 13450 16600 14950 26050 10250 11800 14450 21300
600 16150 19900 17950 31250 14400 16600 20200 29900
700 18800 23880 21540 37500 17280 19920 24240 35880
End branch x-axis

32 900 850 1050 1650 750 850 1100 1600
40 1100 1000 1250 1950 900 1050 1300 1900
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End branch x-axis
50 1500 1350 1650 2600 1000 1150 1400 2050
65 1850 1700 2100 3300 1100 1200 1500 2200
80 2250 2050 2500 3950 1150 1300 1600 2350
100 3000 2700 3350 5250 1250 1450 1750 2600
125 3550 3200 3950 6200 1500 1900 2100 3050
150 4500 4050 5000 7850 1750 2050 2500 3650
200 6000 5400 6700 10450 2300 2650 3250 4800
250 7450 6750 8350 13050 3150 3650 4450 6550
300 8950 8050 10000 15650 4300 4950 6050 8900
350 10450 9400 11650 18250 5500 6350 7750 11400
400 11950 10750 13300 20850 6900 7950 9700 14300
500 14950 13450 16600 26050 10250 11800 14450 21300
600 17950 16150 19900 31250 14400 16600 20200 29900
700 21540 18800 23880 37500 17280 19920 24240 35880
*F and M are the vector sums of the forces and moments.
When all of the applied loads do not attain the maximum values allowed, one of these loads may exceed the normal
limit, provided that the following supplementary conditions are satisfied:
- any component of a force or of a moment shall be limited to 1.4 times the maximum allowed value;
- the actual forces and moments acting on each flange are governed by the following formula:
2 2
  F actual    M actual 
    2
F  M 
 max .allow .   max .allow . 
Under the maximum allowance forces and moments, the lateral displacement of the shaft end, relative to the fixed
point in space should not exceed the values indicated in Table 4.
Table 4, Lateral displacement

Shaft-end diameter (mm) Displacement (mm) *
< 30 0.15
31 to 40 0.20
> 40 0.25
* The displacement values given are for reference in checking the stiffness of the pump and its supports and are not the same
as the alignment requirements.
9.2 Sound level charts

Noise emission values are stated according to ISO 4871 and the essential requirements in the Machinery Directive
2006/42/EC.
The noise values are given in accordance with standard EN12639.
Sound power levels have been determined according to EN ISO 9614 Part II using sound intensity measurements.
It is not possible to measure all different pump applications. Therefore, some values have been determined by
calculations based on measurements with similar pumps and Europump’s Guide 001/30/E, Forecasting the Airborne
Noise Emission of Centrifugal Pumps.
LpA = A-weighted sound pressure level, dB re 20 Pa, at the relevant working station.
LwA = A-weighted sound power level, dB re 1 pW, if A-weighted sound pressure level exceeds 85 dB.
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[Directive 2006/42/EC: the A-weighted sound power level emitted by the machine if the A-weighted emission sound
pressure level at workstations exceeds level 80 dB (A)]
Open, special open, low flow and vortex impellers

Table 5, Sound pressure level LpA / open impellers (dB)
Pump Pump rot. speed (rpm)
Pump size
types 3550 2950 1760 1480 1180 980 880 740 710 590 510 495 445
10-32 A <70 <70 <70 <70
10-50 A <70 <70 <70 <70
10-65 A <70 <70 <70 <70
11-32 A <70 <70 <70 <70 <70
11-40 A <70 <70 <70 <70 <70
11-50 A 72 <70 <70 <70 <70
20-65 A <70 <70 <70 <70
20-80 A <70 <70 <70 <70
21-65 A 75 <70 <70 <70
21-80 A 77 73 <70 <70 <70
21-100 A 75 <70 <70 <70
22-32 A <70 <70 <70 <70 <70
22-40 A 74 <70 <70 <70 <70 <70 <70
22-50 A 76 73 <70 <70 <70 <70 <70
22-65 A 79 75 <70 <70 <70 <70 <70
22-80 A 81 77 <70 <70 <70 <70 <70
23-40 A 75 <70 <70 <70 <70 <70
23-50 A 77 <70 <70 <70 <70 <70
31-100 A 83 79 <70 <70 <70 <70 <70
31-125 A 81 73 <70 <70 <70 <70
31-150 A 75 <70 <70 <70 <70
32-65 A 72 <70 <70 <70 <70
32-80 A 72 <70 <70 <70 <70
32-100 A 74 <70 <70 <70 <70
32-125 A 76 72 <70 <70 <70
33-80 A 74 72 <70 <70 <70 <70
33-100 A 76 74 <70 <70 <70 <70
33-125 A 79 76 72 <70 <70 <70
41-200 A 81 78 74 71 <70
41-300 A 80 77 73 72 <70
41-400 A 80 77 73 72 <70
42-150 A 79 75 71 <70 <70
42-200 A 81 78 74 71 <70
43-250 A 88 85 81 78 76 73 72 <70
43-350 A 86 82 79 77 74 73 <70
43-500 A 86 82 79 77 74 73 <70
44-150 A 81 78 74 71 <70 <70
44-200 A 84 81 77 71 72 <70
51-250 A 90 87 83 80 78 75 74 71
51-300 A 88 84 81 79 76 75 72
51-400 A 89 85 82 80 77 73 73
51-500 A 89 85 82 80 77 76 73
53-100 A 86 83 79 76 74 71 70 <70
53-150 A 90 87 83 80 78 75 74 77
53-200 A 89 85 82 80 77 76 73
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Pump size
types 3550 2950 1760 1480 1180 980 880 740 710 590 510 495 445
53-250 A 91 87 83 82 79 78 75
53-300 A 88 85 83 80 79 76
53-400 A 88 85 83 80 79 76
55-100 A 88 84 81 79 76 75 72
55-200 A 92 88 85 83 80 79 76
55-250 A 90 87 85 82 81 78
55-300 A 91 88 86 83 82 79
60-500 A 92 89 86 84 81 80 77
60-600 A 92 89 86 84 81 80 77
63-400 A 90 88 85 84 81
63-500 A 91 89 85 85 82
63-600 A 92 90 86 86 82
63-700 A 92 90 86 86 82
71-250 A 90 86 83 80 80 79 77 77
71-300 A 86 84 81 80 79 77 77
71-400 A 88 86 84 83 82 79 79
71-500 A 90 89 85 85 84 81 81
71-600 A 91 89 86 86 85 84 81
72-300 A 88 84 84 82 81 79 79
72-400 A 89 85 85 85 81 81 79
72-500 A 87 86 85 84 83 81
72-600 A 89 88 86 85 85 84
Table 6, Sound power level LwA / open impellers (dB)

Pump size
types 3550 2950 1760 1480 1180 980 880 740 710 590 510 495 445
43-250 A 96 93
43-350 A 94
43-500 A 94
51-250 A 98 95
51-300 A 96
51-400 A 97 93
51-500 A 97 93
53-100 A 94
53-150 A 98 95
53-200 A 97 93
53-250 A 99 95
53-300 A 96 93
53-400 A 96 93
55-100 A 96
55-200 A 100 95 93
55-250 A 98 95 93
55-300 A 99 96 94
60-500 A 100 97 94
60-600 A 100 97 94
63-400 A 98 96 93
63-500 A 99 98 95 95
63-600 A 100 98 94 94
63-700 A 100 98 94 94
71-250 A 104 102
71-300 A 102
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Pump size
types 3550 2950 1760 1480 1180 980 880 740 710 590 510 495 445
71-400 A 104 102
71-500 A 105 104
71-600 A 105 104 101 101
72-300 A 103
72-400 A 104 102 101 99
72-500 A 103 102 100
72-600 A 104 104 101 99 99
Closed impellers
Table 7, Sound pressure level LpA / closed impellers (dB)
Pump rot. speed (rpm)
Pump size Pump types
3550 2950 1760 1480 1180 980 880 740 710 590
11-32 APP <70 <70 <70 <70 <70
11-40 APP <70 <70 <70 <70 <70
11-50 APP 72 <70 <70 <70 <70
21-50 NPP 71 <70 <70 <70 <70 <70
21-65 APP 75 <72 <70 <70 <70
21-80, 8S APP 77 74 <70 <70 <70
21-80 NPP 75 <70 <70 <70 <70
22-40 APP 75 71 <70 <70 <70 <70 <70
22-50 APP, WPP 76 73 <70 <70 <70 <70 <70
22-50 NPP 76 <70 <70 <70 <70 <70
22-65 APP 79 75 <70 <70 <70 <70 <70
22-80, 8S APP 81 78 <70 <70 <70 <70 <70
22-80 NPP <70 <70 <70 <70 <70
23-50 APP, WPP 77 <70 <70 <70 <70 <70
31-65 EPP 81 78 <70 <70 <70
31-100, 10S APP 83 80 71 <70 <70 <70 <70
31-100 EPP 84 81 <72 <70 <70 <70 <70
31-100 NPP <71 <70 <70 <70 <70
31-125, 10P APP 82 72 <70 <70 <70 <70
31-150 APP 75 72 <70 <70 <70
32-65 APP 79 71 <70 <70 <70 <70
32-80, 8S APP, WPP 81 <70 <70 <70 <70 <70
32-80 NPP 74 71 <70 <70 <70
32-100, 10S APP, WPP 82 74 71 <70 <70 <70
32-100 NPP 76 73 <70 <70 <70
32-125, 10P APP 85 73 73 <70 <70 <70
32-200 EPP 77 74 <70 <70
33-80 NPP 79 76 <72 <70 <70 <70 <70
33-100, 10S APP, WPP 74 74 <70 <70 <70 <70
33-100 NPP 80 77 73 70 <70 <70 <70
33-125, 10P APP, WPP 79 76 <72 <70 <70 <70
41-150 EPP 77 74 <70 <70 <70
41-200 APP 80 77 72 <70 <70
41-200 EPP 79 76 72 <70 <70
41-300 APP 82 79 75 72 <70
42-150 APP 79 76 71 <70 <70
42-150 EPP 80 78 73 71 <70
42-150 NPP 79 76 72 <70 <70
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3550 2950 1760 1480 1180 980 880 740 710 590
42-200 APP 81 78 74 71 <70
42-200 EPP 83 80 76 72 <70
42-200 NPP 80 77 73 70 <70
42-250 EPP 85 82 78 75 71
43-100 EPP 81 78 74 71 72
43-150 EPP 84 81 77 74 72
43-250 APP 85 82 78 75 73 <70
43-300 APP 83 79 76 74 <70
44-150 APP, WPP 81 78 74 71 74 <70
44-150 NPP 83 80 76 73 71 <70 <70
44-200 APP, NPP, WPP 84 81 77 74 <70 <70
51-250 APP 88 85 81 78 76 73 72
51-300 APP 87 83 80 78 74 73
52-350 APP 84 81 79 76 75
52-350 EPP - 81 - 76
52-400 APP 88 85 82 80 78
53-100 APP, EPP, WPP 85 82 78 75 73 70 <70
53-150 APP, WPP 87 84 80 77 75 72 71
53-200 APP, EPP, WPP 89 86 82 79 77 74 73
53-250 APP, WPP 88 84 81 79 76 75
53-250 EPP 88 85 81 78 75 73 72
53-250 NPP 81 83 77 78
53-300 APP 89 85 82 80 77 76
53-300 EPP 90 87 83 80 78 75 74
54-300 EPP 84 84 79 79
54-400 APP, WPP 87 87 82 82 78 78
54-500 APP 91 88 86 83 83 79
54-500 EPP 86 85 82 80 78 76
55-100 APP 90 87 83 80 78 75
55-200 APP 89 85 82 80 77 76 73
55-250 APP 91 87 84 82 79 78 75
55-300 APP, EPP, WPP 89 86 84 81 80 77
61-600 EPP 92 91 87 86 83
Table 8, Sound power level LwA / closed impellers (dB)

3550 2950 1760 1480 1180 980 880 740 710 590
51-300 APP 95 83
53-200 APP, EPP, WPP 94 82
53-250 APP, WPP 89 96 84
53-300 APP 97 85
54-400 APP, WPP 90 95
54-500 APP 91 96
55-100 APP 90 95 83
55-200 APP 97 85
55-250 APP 99 87
55-300 APP, EPP, WPP 89 94
61-600 WPP 100 100 95 95
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Open, special open and low pulse impellers

Table 9, Sound pressure level LpA / open impellers (dB)
3550 2950 1760 1480 1180 980 880 740 710 590
11-32 APP <70 <70 <70 <70 <70
11-40 APP <70 <70 <70 <70 <70
11-50 APP 72 <70 <70 <70 <70
21-65 APP 75 <70 <70 <70 <70
21-80, 8S APP 77 73 <70 <70 <70
22-32 APP, WPP <70 <70 <70 <70 <70
22-40 APP 74 <70 <70 <70 <70 <70 <70
22-50 APP, WPP 76 73 <70 <70 <70 <70 <70
22-65 APP 79 75 <70 <70 <70 <70 <70
22-80, 8S APP 81 77 <70 <70 <70 <70 <70
23-40 APP 75 <70 <70 <70 <70 <70
23-50 APP, WPP 77 <70 <70 <70 <70 <70
31-65 EPP 72 <70 <70 <70 <70
31-100, 10S APP 83 79 <70 <70 <70 <70 <70
31-100 EPP 72 <70 <70 <70 <70
31-125, 10P APP 81 73 <70 <70 <70 <70
31-150 APP 75 <70 <70 <70 <70
32-65 APP 72 <70 <70 <70 <70
32-80, 8S APP, WPP 72 <70 <70 <70 <70
32-100, 10S APP, WPP 74 <70 <70 <70 <70
32-100 EPP 77 74 <70 <70
32-125, 10P APP, WPP 76 72 <70 <70 <70
33-100, 10S APP, WPP 76 74 <70 <70 <70 <70
33-125, 10P APP 79 76 72 <70 <70 <70
41-150 EPP 77 74 <70 <70 <70
41-200 APP 79 76 72 <70 <70
41-200 EPP 80 77 72 70 <70
41-300 APP 82 79 74 <70 <70
42-150 APP 79 75 71 <70 <70
42-150 EPP 79 76 72 70 <70
42-200 APP 81 78 74 71 <70
42-200 EPP 83 80 75 73 71
42-250 EPP 84 81 75 74 71
43-100 EPP 81 78 74 71
43-150 EPP 84 81 77 74 72
43-250 APP 85 82 78 75 73 70
43-300 APP 83 79 76 74 71
44-150 APP, WPP 81 78 74 71 <70 <70
44-200 APP, WPP 84 81 77 74 72 <70
51-250 APP 88 84 80 77 76 72 <70
51-300 APP 86 82 79 77 74 73
52-350 APP 84 81 79 76 75
52-400 APP 87 84 82 79 78
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3550 2950 1760 1480 1180 980 880 740 710 590
53-100 APP, EPP, WPP 85 82 78 75 73 70 <70
53-150 APP, WPP 87 84 80 77 75 72 <70
53-200 APP, WPP 89 86 82 79 77 74 73
53-200 EPP 85 81 78 77 73 72
53-250 APP, WPP 88 84 80 79 75 75
53-250 EPP 83 78 76 73 71 <70
53-300 APP 89 85 82 80 77 76
53-300 EPP 85 81 78 76 73 72
54-400 APP, WPP 90 87 85 82 82 78
54-500 APP 87 86 82 82 78
54-500 EPP 86 83 81 78 77
55-100 APP 90 87 82 80 77 75
55-200 APP 84 82 79 77 76 73
55-250 APP 86 84 82 79 78 75
55-300 APP, EPP, WPP 88 86 84 81 80 77
61-500 APP, EPP 93 91 88 87 84
61-600 APP, WPP 92 91 87 86 83
62-400 APP 91 90 86 85 82
Table 10, Sound power level LwA / open impellers (dB)

3550 2950 1760 1480 1180 980 880 740 710 590
51-300 APP 96 94
53-200 APP, WPP 94 95
53-250 APP, WPP 95 96
53-300 APP 97 97
54-400 APP, WPP 98 95
54-500 APP 95 94
55-100 APP 98 95
55-300 APP, EPP, WPP 94 94
61-500 APP, EPP 96 101 96
61-600 APP, WPP 100 99 95
62-400 APP 99 99 94
Vortex impellers
Table 11, Sound pressure level LpA / vortex impellers (dB)
3550 2950 1760 1480 1180 980 880 740 710 590
21-50 NPP 76 72 <70 <70
21-80 NPP 76 <70 <70
22-50 NPP, WPP 77 <70 <70 <70 <70 <70
22-80 NPP 71 <70 <70 <70 <70
31-100 NPP 73 71 <70 <70 <70
32-80 NPP, WPP 76 73 <70 <70 <70
32-100 NPP, WPP 77 75 <70 <70 <70
32-125 WPP 79 77 72 <70 <70
33-80 NPP 79 77 72 <70 <70 <70 <70
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3550 2950 1760 1480 1180 980 880 740 710 590
33-100 NPP, WPP 80 79 72 70 <70 <70 <70
42-150 NPP 81 79 74 71 <70
42-200 NPP 82 80 75 72 <70
44-150 NPP, WPP 84 82 78 74 72 <70 <70
44-200 NPP, WPP 82 78 75 72 <70
53-100 WPP 79 72 74 <70
53-150 WPP 81 74 76 72
53-200 WPP 82 75 77 73
53-250 NPP, WPP 84 77 79 76
9.3 Maximum size of solid particles

The maximum sizes of solid spherical particles which can flow through the pump (casing/impeller) are presented in
Table 12 (A, Process Pump) and
Table 13 (APP, EPP, NPP, WPP).
Table 12, Max. size of solid particles (Ø mm) (A, Process Pump)
Impeller type
Pump size Pump types Special Special
Open1 Open2 Low flow1 Vortex1
open1 open2
10-32 A 10 - - - 3 -
10-50 A 14 - - - - -
10-65 A 11 - - - - -
11-32 A 12 - - - 5 -
11-40 A 16 - - - - 19
11-50 A 21 - - - - 22
20-65 A 16 - - - - -
20-80 A 17 - 34 - - -
21-65 A 17 - - - - 24
21-80 A 19 - 36 - - 26
21-100 A 29 - 36 - - 37
22-32 A 12 - - - 4 -
22-40 A 15 - - - - 18
22-50 A 18 - - - - 22
22-65 A 23 - - - - 26
22-80 A 20 - 37 - - 29
23-40 A 16 - - - 5 18
23-50 A 21 - - - - 24
31-100 A 25 - 43 - - 30
31-125 A 29 - 50 - - 35
31-150 A 28 - 39 - - 42
32-65 A 21 - - - - 21
32-80 A 26 - 40 - - 30
32-100 A 24 - 42 - - 35
32-125 A 29 - 50 - - 40
33-80 A 25 - 35 - - 30
33-100 A 30 - 44 - - 38
33-125 A 30 - 54 - - 40
41-200 A 34 - 38 - - 48
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Impeller type
Pump size Pump types Special Special
Open1 Open2 Low flow1 Vortex1
open1 open2
41-300 A 44 - 51 - - -
41-400 A 44 46 49 51 - -
42-150 A 27 - 54 - - -
42-200 A 32 - 44 - - -
43-250 A 43 - 48 - - -
43-350 A 53 - 61 - - -
43-500 A 52 54 58 60 - -
44-150 A 31 - 59 - - 48
44-200 A 33 - 60 - - 45
51-250 A 43 - 51 - - -
51-300 A 47 - 53 - - -
51-400 A 58 - 68 - - -
51-500 A 58 60 64 66 - -
53-100 A 24 - 31 - - -
53-150 A 33 - 42 - - -
53-200 A 46 - 50 - - 68
53-250 A 47 - 55 - - 78
53-300 A 50 - 60 - - -
53-400 A 55 - 62 - - -
55-100 A 28 - 37 - - -
55-200 A 39 - 50 - - -
55-250 A 54 - 59 - - -
55-300 A 56 - 65 - - -
60-500 A 68 - 79 - - -
60-600 A 67 70 74 77 - -
63-400 A 60 - 72 - - -
63-500 A 66 - 75 - - -
63-600 A 82 - 94 - - -
63-700 A 81 84 90 93 - -
71-250 A - - 68 - - -
71-300 A - - 75 - - -
71-400 A - - 81 - - -
71-500 A - 69 - - - -
71-600 A - - 107 - - -
72-300 A - - 75 - - -
72-400 A - - 85 - - -
72-500 A - - 93 - - -
72-600 A - 79 - - - -
Table 13, Max. size of solid particles (Ø mm) (APP, EPP, NPP, WPP)
Impeller type
Pump size Pump types Special Special Low
Closed1 Closed2 Open1 Open2 Vortex1
open1 open2 pulse1
11-32 APP 4 - 8 - - - - -
11-40 APP 8 - 12 - - - - -
11-50 APP 10,5 - 16 - - - - -
21-50 NPP 25 - - - - - 35 -
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Impeller type
open1 open2 pulse1
21-65 APP 16 - 22 - - - - -
21-80, 8S APP 23 - 30 - - - - -
21-80 NPP 45 - - - - - 50 -
22-32 APP - - 7 - - - - -
22-32 WPP - - 7 - - - - -
22-40 APP 5 - 10 - - - - -
22-50 APP 8 - 14 - - - - -
22-50 NPP 25 - - - - - 35 -
22-50 WPP 10 - 18 - - - 22 -
22-65 APP 12 - 18 - - - - -
22-80, 8S APP 18 - 24 - 24 - - -
22-80 NPP 45 - - - - - 50 -
23-40 APP - - 9 - - - - -
23-50 APP 6 - 12,5 - - - - -
23-50 WPP 9 - 20 - - - - -
31-65 EPP 9 - 9 - - - -
31-100, 10S APP 25 - 32 - - - - -
31-100 EPP 14 - 15 - - -
31-100 NPP 55 - - - - - 60 -
31-125,10P APP 32 - 36 - - - - -
31-150 APP 40 - 41 - - - - -
32-65 APP 9 - 16 - - - - -
32-80, 8S APP 13 - 22 - 33 - - -
32-80 NPP 45 - - - - - 50 -
32-80 WPP 16 - 27 - - - 30 -
32-100, 10S APP 18 - 24 - 24 - - -
32-100 EPP 18 - 18 - - - - -
32-100 NPP 55 - - - - - 60 -
32-100 WPP 18 - 32 - - - 35 -
32-125, 10P APP 26 - 32 - 32 - - -
32-125 WPP 26 - 42 - - - 40 -
33-80 NPP 45 - - - - - 50 -
33-100, 10S APP 13 - 18 - 29 - - 6
33-100 NPP 55 - - - - - 60 -
33-100 WPP 16 - 30 - - - 34 -
33-125, 10P APP 22 - 29 - 29 - - 11
41-150 EPP 36 - 35 - - - - -
41-200 APP 43 - 47 - 54 - - -
41-200 EPP 47 - 42 - - - - -
41-300 APP 46 - 56 - 70 - - -
42-150 APP 34 - 38 - 38 - - -
42-150 EPP 30 - 28 - - - - -
42-150 NPP 75 - - - - - 80 -
42-200 APP 35 - 48 - 49 - - -
42-200 EPP 39 - 39 - - - - -
42-200 NPP 85 - - - - - 85 -
42-250 EPP 54 - 54 - - - - -
43-100 EPP 16 - 16 - - - - -
43-150 EPP 24 - 27 - - - - -
43-250 APP 54 - 62 - 63 - - -
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Impeller type
open1 open2 pulse1
43-300 APP 53 - 54 - 71 - - -
44-150 APP 27 - 27 - 27 - - 10
44-150 NPP 75 - - - - - 75 -
44-150 WPP 30 - 44 - - - 50 -
44-200 APP 41 - 46 - 46 - - 19
44-200 NPP 85 - - - - - 80 -
44-200 WPP 41 - 54 - - - 60 -
51-250 APP 52 - 54 - 54 - - 23
51-300 APP 48 - 69 - 69 - - 30
52-350 APP 65 - 63 - 84 - - -
52-350 EPP 63 - 63 - 63 - - -
52-400 APP 73 - 95 - 95 - - -
53-100 APP 17 - 27 - - - - 10
53-100 EPP 17 - 24 - - - - -
53-100 WPP 18 - 37 - - - 40 -
53-150 APP 29 - 39 - - - - 15
53-150 WPP 33 - 52 - - - 58 -
53-200 APP 35 - 35 - 35 - - 13
53-200 EPP 32 32 32 32 32 - - -
53-200 WPP 38 - 55 - - - 61 -
53-250 APP 49 - 49 - 49 - - 20
53-250 EPP 47 - 48 - - - - -
53-250 NPP 113 - - - - - 113 -
53-250 WPP 52 - 70 - - - 77 -
53-300 APP 62 - 64 - 64 - - 27
53-300 EPP 65 65 55 - - - - -
54-300 EPP 66 - 66 - - - - -
54-400 APP 74 - 74 - 94 - - -
54-400 WPP 105 - 110 - - - - -
54-500 APP 113 - 113 - 113 - - -
54-500 EPP 80 - - - - - - -
55-100 APP 30 - 30 - - - - -
55-200 APP 34 - 46 - - - - -
55-250 APP 43 - 43 - 43 - - -
55-300 APP 67 - 68 - 68 - - -
55-300 EPP 61 - 67 - - - - -
55-300 WPP 61 - 79 - - - - -
61-500 APP - - 86 86 107 107 - -
61-500 EPP - - 107 107 107 107 - -
61-600 APP - - 132 132 132 132 - -
61-600 WPP 133 - 150 - - - - -
62-400 APP - - 132 132 132 132 - -
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9.4 Tightening instruction for the flanges of AHLSTAR pumps
1 The purpose of the tightening torque is to provide an adequate pre-tightening for the flange connection via
screw forces. The friction forces influencing in the screw thread and head have a great importance here. This
is why it is always necessary to lubricate both the threaded surface of the screw and the washer of the screw
before installation. The values in this instruction are based on a value of 0.20, which corresponds to slightly
oiled joint surfaces. If the friction coefficient µf of the selected lubricant differs greatly from this, the tightening
torque must be corrected using value:
Secondary flange forces, which may arise during tightening and which are the result of the misalignment of
the flanges, must be minimised. It is recommended to pre-weld the pipes so that the backing flanges are
attached to the flanges of the pump. In this case, there is no need to use the full torque. The permitted
misalignments on the sealing surfaces are presented in Table 14. The values are measured from the
extreme edge of the sealing surface.
Table 14, Permitted misalignments on sealing surfaces

Nominal size of connection Permitted misalignment on sealing surfaces (a)
≤ DN 150 0,2 mm
> DN 150 0,4 mm
2 The use of washers is recommended. When the screw is ≤M24, one washer is used, and when the screw is
>M24, two washers are used.
3 Check the cleanliness of the sealing surfaces before installation. If necessary, clean the sealing surfaces
with a soft brush in the direction of the circumference, not in the direction of the radius.
4 The use of different material groups (carbon steel - stainless) in the flanges and screws may lead to a
harmful change in the internal forces of the connection as the temperature changes, and is therefore
prohibited.
5 The screws must be tightened using a torque wrench which is calibrated every two years in accordance with
ISO 6789.
6 The tightening must be performed in four stages. Follow the order given in Fig. 2 and first tighten 30% of the
final torque. After this, follow the same order and tighten 60% of the final torque. In the third stage, tighten
the screws to the final torque in the same order. Finally, secure the torque by tightening the screws clockwise
using the final value. The permissible torques depend on the flange standard used. The permissible torques
can be found in tables 15 to 16.
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Fig. 2
The tightening torques must be checked within 24 hours from commissioning.
7 The following maximum torques have been calculated assuming that the friction coefficient is 0.2. The effect
of the friction coefficient must be taken into account by using the ratio given under item 1.
CAUTION
Exceeding the maximum torques can lead to permanent deformations in the flanges.
8 The screws used in the calculations are full-threaded hexagon head screws in accordance with ISO 4017.
The inch-sized screws are ANSI B18.2.1 UNC.
9 The values have been calculated according to ASME BPVC VIII-8 so that the stresses in the flange do not
exceed 0.8 x yield strength of the flange at the design temperature of 180°C. It should be noted that these
are the maximum torques in accordance with the strength of the flange, and the actual torque must be
selected on the basis of the seal used and the operating conditions.
WARNING
The maximum torque values given in Table 15 must be multiplied by the following factors: 0.4 for a
titanium case, 0.55 for a carbon steel case, 1.0 for a duplex steel case and stainless steel case.
Table 15, Flange drillings of steel cases, maximum torques

Torque (Nm)
DN EN 1092-1 PN10 EN 1092-1 PN16 EN 1092-1 PN25
8.8 12.9 8.8 12.9 8.8 12.9
32 90 90 90 90 90 90
40 120 120 120 120 120 120
50 180 180 180 180 180 180
65 150 150 150 150 150 150
80 170 170 170 170 170 170
100 220 220 220 220 220 220
125 270 270 270 270 350 350
150 410 410 410 410 410 410
200 450 450 300 300 280 280
250 520 520 580 580 520 520
300 620 690 690 690 440 440
350 410 410 430 430 430 430
400 800 800 780 780 670 670
500 1080 1260 1050 1050 1030 1030
600 1530 1530 1090 1090 1220 1220
SULZER CONFIDENTIAL
Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions
/
Torque (Nm)
DN EN 1092-1 PN10 EN 1092-1 PN16 EN 1092-1 PN25
8.8 12.9 8.8 12.9 8.8 12.9
700 1590 2110 2610 2610 2000 2000
Torque (Nm)
DN ASME B16.5 Class 150 ASME B16.5 Class 300 JIS B 2220 16K
8.8 12.9 8.8 12.9 8.8 12.9
32 100 100 100 100 90 90
40 160 160 140 140 130 130
50 200 200 80 80 100 100
65 350 350 160 160 170 170
80 420 420 180 180 220 220
100 170 170 180 180 250 250
125 290 290 210 210 280 280
150 390 390 160 160 210 210
200 400 400 200 200 270 270
250 470 470 300 300 400 400
300 470 470 380 380 390 390
350 550 550 260 260 460 460
400 600 600 440 440 690 690
500 1200 1200 660 660 450 450
600 1310 1310 790 790 - -
700 1580 1580 1120 1120 - -
Table 16, Flange drillings of cast iron cases, maximum torques

Torque (Nm)
DN EN 1092-2 PN10 EN 1092-2 PN16 ASME B 16.1 Class 125 JIS B 2239 10K
8.8 12.9 8.8 12.9 8.8 12.9 8.8 12.9
32 50 50 25 25 30,0 30,0 30 30
40 60 60 35 35 50,0 50,0 45 45
50 100 100 55 55 65,0 65,0 30 30
65 80 80 45 45 105,0 105,0 50 50
80 100 100 55 55 130,0 130,0 90 90
100 120 120 65 65 55,0 55,0 95 95
125 150 150 85 85 95,0 95,0 120 120
150 230 230 125 125 120,0 120,0 90 90
200 250 250 95 95 127,0 127,0 115 115
250 300 300 - - 150,0 150,0 175 175
300 390 390 - - 140,0 140,0 190 190
350 230 230 - - 160,0 160,0 265 265
400 460 460 - - 180,0 180,0 355 355
500 720 720 - - 360,0 360,0 485 485
600 860 860 - - 420,0 420,0 420 420
700 1190 1190 - - 480,0 480,0 735 735
SULZER CONFIDENTIAL
SERIES 2.15
AHLSTAR
PROCESS PUMPS
Hoisting and transfers
1 Safety measures
2 Hoisting and transfers

Series 2.15 Page
INSTRUCTIONS
1 Safety measures
The total gross and net weights of the delivery are always found in the packing list affixed to the product or packing.
WARNING
Hoisting and transfers instructions must be strictly followed to avoid dropping of crates or individual
assemblies.
Special attention is to be paid to the stability of

 Pump
 Pump and baseplate with or without motor
 Spare parts
The center of gravity with these items should always be checked before hoistings and transfers.
Personal protective equipment such as helmet, safety shoes and gloves is to be used.
If suitable lifting equipment is not available, heavy assemblies must be transferred by using skids etc. on the ground
level.
Lifting accessories must bear the identification of the manufacturer, material and the maximum working load.
Lifting ropes used directly for lifting or supporting the pump or pump unit must not include any splicing other than at
their ends. Textile ropes and slings must not include any knots, connections or splicing other than at the ends of the
sling, except in the case of an endless sling.
The lifting accessories must always be able to adequately support the hoisted assembly.
The lifting ropes must be adequate, and they must be adjusted so that the product is not damaged during hoisting. A
lifting chain must not be in contact with the product during hoisting (if it is, painted and machined surfaces may be
damaged).
WARNING
Make sure that accepted and undamaged ropes and lifting accessories are available. The lifting
capacity of the lifting accessories and ropes must correspond to the weight of the goods lifted.
WARNING
Never stand under a hanging load.
WARNING
In a potentially explosive environment, the pump must be lifted and transferred so that no sparking can
occur.

Series 2.15 Page
INSTRUCTIONS
2 Hoisting and transfers
The figures are for reference only, and the actual product and lifting equipment may differ from those presented.
NOTE
If the ordered assembly contains:
- an API baseplate, follow the enclosed lifting instruction N31478, or
- a Heavy Duty baseplate, follow the enclosed lifting instruction N31481.
The crates or individual assemblies must never be dropped to the ground during transfer. Refer to Figures 1 - 12 for
examples of proper lifting techniques.
Fig. 1 .........The transportation crate is hoisted according to figure 1. The permissible lifting points are marked on the
crate.
Fig. 1

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INSTRUCTIONS
Fig. 2 .........The pump-motor-baseplate assembly is hoisted from under the suction case of the pump and from under
the motor.
Fig. 3 .........With tangential pumps, also ensure the balance of hoisting by means of a lifting eye fastened to the
discharge flange.
Fig. 2 Fig. 3
Fig. 4 .........The pump-baseplate assembly is hoisted from under the suction flange of the pump and from the lifting
eyes fastened to the baseplate.
Fig. 5 .........With tangential pumps, also ensure the balance of hoisting by means of a lifting eye fastened to the
discharge flange.
Fig. 4 Fig. 5

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INSTRUCTIONS
Fig. 6 .........The radial pump is hoisted from the lifting eyes fastened to the discharge flange of the pump.
Fig. 7 .........The tangential pump is hoisted from the lifting eyes fastened to the suction and discharge flanges of the
pump and to the end of the shaft. Pay attention to the centre of gravity.
Fig. 6 Fig. 7
Wet end
Fig. 8 .........The radial volute case is hoisted from the lifting eyes fastened to the discharge flange.
Fig. 9 .........The tangential volute case is hoisted from the lifting eyes fastened to the discharge flange. It is
recommended to place the lifting eyes symmetrically with respect to the division plane of the volute case
and as close to each other as possible. Pay attention to the centre of gravity.
Fig. 8 Fig. 9

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INSTRUCTIONS
Spare parts and coupling
Fig. 10 .......Heavy (> 25 kg) individual components can be lifted for example on a pallet.
Fig. 10
Bearing parts
Fig. 11 .......The bearing is hoisted from the openings in the bearing housing and from the shaft.
Fig. 11

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INSTRUCTIONS
Baseplate
Fig. 12 .......The baseplate is hoisted from the lifting eyes fastened to the mounting holes.
Fig. 12
2.1 Motor, gear and other accessories

When hoisting the motor, gear and other accessories, the instructions provided by the relevant manufacturer must
always be followed.
2.2 Accessories
If the assembly includes accessories such as a noise cover, the cover may have to be removed before hoisting the
assembly in order to prevent the cover from being damaged.

SERIES 2.15
SPP id: 110901 / en / N31570 / 1
AHLSTAR
PROCESS PUMPS
Commissioning
1 Purchase inspection
2 Storage

Series 2.15 Page
INSTRUCTIONS
USER'S MANUAL – AHLSTAR September 2011 G
Commissioning
SPP id: 110901 / en / N31570 / 1 / Page 2 (3)
1 Purchase inspection
Check carefully that the delivery meets your order and is in accordance with the packing list and parts list of the
pump. Inform the supplier immediately about any defects or damage observed.
Do not remove the cover plates or plugs protecting the openings before the installation of pipes. Foreign particles
inside the pump may damage it at starting.
Examine the crate and wrapping before discarding them since parts and accessories are sometimes wrapped
individually or fastened into the crate.
If the pump unit is not installed immediately, it should be stored under conditions that will prevent deterioration due to
damage and/or corrosion. The long-term storage requirements should always be specified in the purchase order.
2 Storage
2.1 Short-term (less than 3 months)

When it is necessary to store a pump for a short term before the installation, it must be stored in a dry location where
it cannot be affected by dirt or corrosion. Protection plates on the pump openings should not be removed.
The pump bearings and drive elements must be properly protected against any foreign matter. To prevent rusting or
seizing, lubricate the pump unit before storing and turn the pump shaft by hand at least once every two weeks.
2.2 Long-term
NOTE
The grease/oil lubricants must be changed before the pump is taken into use.
WARNING
The rust preventives must be cleaned off carefully before the pump is taken into use. Solvents
containing rust preventives can cause irritation to the skin and/or the respiratory system. Prolonged
physical contact and breathing of vapor are to be avoided.
If the pump or pump unit is stored for more than 3 months, the following procedures must be observed:
• Store the product in a dry place.
• Drain any liquid from the pump.
• Rotate the pump shaft by hand at least once every month to prevent bearing damage.
• With cast iron pumps equipped with gland packing, remove the gland packings (461.21) from the stuffing box
and apply rust preventives in the stuffing box.
• With oil lubrication, the bearing unit is emptied of oil before the delivery. Fill the bearing unit with oil or coat
the interior of the unit with a rust preventing film.
• Apply rust preventing agents to the unprotected parts, such as the shaft end, pump flanges and coupling. If
necessary, protect the volute casing and shaft sealing with volatile corrosion inhibitors.

Series 2.15 Page
INSTRUCTIONS
Commissioning
SPP id: 110901 / en / N31570 / 1 / Page 3 (3)
• Observe the storage instructions of any accessory equipment (e.g. electric motors) included in the delivery.
• If the pump unit is covered with a plastic sheet, the bottom should remain open to allow for ventilation.

SERIES 2.15
AHLSTAR
PROCESS PUMPS
1 Safety procedures before installation

2 Wet end
3 Sealing unit
4 Coupling unit
5 Baseplate
6 Drive motor

Series 2.15 Page
INSTRUCTIONS ISO
1 Safety procedures before installation
NOTE
A pump should have adequate space for proper installation and maintenance actions.
All parts for the installation must be thoroughly cleaned before the installation. All traces of antirust agents should be
cleaned off from the pump flanges, shaft assembly and drive elements. Avoid any damage to installed parts when
handling them.
WARNING
Personal protective equipment such as helmet, safety shoes and gloves are to be used.
Equipment used in explosive locations must conform to the requirements of "Ex" protection. Verify this in
documentation (and machine plates) relating to the equipment and auxiliary devices. Fig. 1.
Fig. 1
Fastener information
Table 1 shows the rated and maximum moments of torque for fasteners presented in these instructions. Note the
special values for the titanium screws. These shown values are only valid for fasteners where the moment values
are not separately given.
Table 1, Fastener information

Titanium screws (76)
Moments (Nm)
Screw size Moments (Nm)
Rating Max. value Rating Max. value
M5 3.5 4.0 2.1 2.7
M6 6.0 7.0 3.6 4.5
M8 14 18 8.9 11
M10 30 35 18 22
M12 50 60 30 38
M16 130 160 70 92
M20 250 300 140 180
M24 420 520 250 310
M30 800 1000 490 615

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2 Wet end
2.1 Pipework
Supporting
The pipes must be mounted and supported so that the piping does not exert on the pump any forces and moments
which exceed the values given under item “Safety instructions/Admissible forces and moments on pump flanges”.
When planning the support locations remember the allowance for thermal expansion. Fig. 2.
Fit the pipe flanges accurately to the pump flanges. Flanges which have not been properly aligned must not be
forced to position.
Fig. 2
Suction pipe below the pump

The suction pipe must be made as short as possible. Avoid points where air pockets or turbulence may be formed.
If the liquid level is below the pump, the suction pipe must gradually rise towards the pump. A sufficient length of the
pipe end must be under the liquid level so that air cannot enter the pump. Fig. 3.
Fig. 3
Suction pipe above the pump

The suction pipe must descend gradually towards the pump. Fig. 4.
Fig. 4

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INSTRUCTIONS ISO
Extension piece
The cones must be eccentric and in such a position that the upper level will be horizontal, alternative A in Fig. 5. If
extension pieces are used, they must be formed so that gathering of gases cannot occur. At higher consistencies
(c > 4 %), conical pipe parts must be avoided, alternative B in Fig. 5.
Fig. 5
Suction pipe design
WARNING
If there is a possibility of a dangerous return flow after the shutdown of the pump, a nonreturn device
shall be installed in the outlet piping.
CAUTION
Never use the pump as a support for the piping system.
If the suction pipe has branches, they must be located as far from the pump as possible, and they must be formed
advantageously with regard to the flow. The suction pipe must always be made as short as possible. Fig. 6.
A shut-off valve must be placed in the discharge pipe after the potential check valve. Before commissioning, clean
the entire suction piping and suction pit carefully from any objects that might have got into them during the work.
These may damage the pump
Fig. 6

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INSTRUCTIONS ISO
3 Sealing unit
3.1 Auxiliary piping
Piping for shaft seal

In order to ensure trouble-free operation of the shaft seal, it must be provided with sealing, flushing or cooling liquid
in certain applications in accordance with the sectional drawing and the parts list. The nominal sizes of the
connections are also given in the parts list and dimensional drawing of the pump.
The nominal pressure of the sealing liquid must be as high as the nominal pressure of the pump, and its maximum
temperature must be as high as the maximum permitted temperature of the pump.
The sealing water equipment is installed in the pump. In certain sealing systems, the sealing liquid equipment
contains a back-pressure valve; see sectional drawing.
Clean the sealing liquid piping carefully before installation and commissioning.
The reservoir of the seal pot sealing water equipment must be installed in a vertical position at least 500 mm above
the center line of the shaft seal. Install the pipes as short as possible so that the shaft seal is at the lowest point.
Piping for degassing in a gas separator (-GM, -GS)

The piping for degassing is connected to the degassing outlet (C50.21) of the pump. The degassing outlet is on the
right-hand side when seen from the drive. The precise size and direction of the connection are shown in the
dimensional drawing.
If a separate degassing pump (vacuum pump) is used, there is also a separate vacuum relief valve.
The size of the degassing pipe is determined by the amount of gas, the length of the pipe, the risk of clogging, etc.
The pipe size generally suitable is shown in Table 2.
Table 2, Suitable pipe sizes for degassing

Sealing unit size Outlet size C50.21 Suitable pipe size
10 Rp 1/2 DN25 or DN32
11 Rp 1 DN25 or DN32
20 Rp 1/2 DN40 or DN50
21, 22, 23 Rp 1 DN40 or DN50
31, 32, 33 Rp 1 DN40 or DN50
41, 42, 43, 44 Rp 1 1/4 DN40 or DN50
51, 52, 53, 54, 55 Rp 1 1/4 DN50 or DN65
60, 61, 62, 63 Rp 1 1/4 DN80 or DN100
Piping for degassing in an air separating pump (-R)

The piping for degassing is connected to the degassing outlet (C50.21) of the pump, Fig. 7. The degassing outlet
can be on the left or right side of the pump depending on the design alternative, Fig. 7. The precise size and
direction of the connection are shown in the dimensional drawing.

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Design A Degassing on the left Design B Degassing on the right
C52.21 Return circulation C50.21 Degassing
C50.21 Degassing C52.21 Return circulation
Fig. 7
In order to prevent the pumped liquid from flowing out while the pump is not running, the piping is often supplied with
a shut-off valve (ball valve) equipped with an open-closed actuator. The control of the valve must be arranged so
that the valve is open while the motor of the pump is running and otherwise closed.
If a separate degassing pump (vacuum pump) is used, there is also a separate vacuum relief valve.
The size of the degassing pipe is determined by the amount of gas, the length of the pipe, the risk of clogging, etc.
The pipe size generally suitable is shown in Table 3.
Table 3, Suitable pipe sizes for degassing and return circulation

Sealing unit size Outlet size C50.21 and C52.21 Suitable pipe size
11 DN25 DN25 or DN32
21, 22, 23 DN40 DN40 or DN50
31, 32, 33 DN40 DN40 or DN50
42, 43, 44 DN40 DN40 or DN50
51, 52, 53, 54, 55 DN50 DN50 or DN65
61, 62 DN80 DN80 or DN100
Return circulation piping in an air separating pump (-R)

The piping for the return circulation connects the return circulation outlet (C52.21) of the air separating design (-R)
with the suction pipe of the pump, Fig. 8.
The piping for the return circulation should be installed so as to minimize friction losses. Table 3 shows the suitable
pipe size. The return circulation pipe can be equipped with a shut-off valve and sight glass if necessary.
C52.21
C50.21
Fig. 8

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Piping for degassing in a liquid ring pump (-LM, -S)

Connect the degassing piping to the degassing connection (C50.21) of the pump. The degassing connection of the -
LM design liquid ring pump is on the right-hand side when seen from the drive. The degassing connection of the -S
design liquid ring pump can be either on the right or left side of the pump. The precise size and direction of the
connection are shown in the dimensional drawing.
WARNING
Some of the pumped liquid will run out of the degassing connection during pumping. Lead and handle
this liquid appropriately.
The mixture of gas and liquid discharging from the degassing connection is led back into the process, see examples
in Figures 9, 10 and 11.
The suitable pipe size for the degassing piping is determined on the basis of pipe length, clogging risk etc. Normally,
the suitable pipe size is one corresponding to the size of the degassing connection or the following larger size.
A vacuum relief valve and a pressure indicator, connected to the connection (C34.21) opposite the degassing
connection, are usually included in the degassing piping.

Series 2.15 Page
INSTRUCTIONS ISO
Starting with a straight suction pipe, GP1/GP2
It is recommended to use a
suction grid in front of the pump:
Closed valve on
2DN1 startup
ØDN1
1...2t
Either external
water or return
circulation
Degassing pipe
Smin
Pressure indicator
Vacuum relief valve
The degassing pipe must be taken over the edge of the tank,
and the end of the pipe must remain above the surface of the
liquid level in the tank. An ascending section in the
degassing pipe decreases the capacity of the liquid ring
pump. If necessary, the degassing pipe can be taken into the
tank through the side of the tank, as far as possible from the
Minimum surface level above the suction pipe: suction pipe of the pump.
5 x Hdyn
Smin = max
4 x DN1
Us2
Hdyn = m
2×g
Q
Us = m
DN1 2 , g = 9,81 2
1000 × π x
2000 s
Q, flow rate in l/s
DN1, suction diameter in mm
Fig. 9

Series 2.15 Page
INSTRUCTIONS ISO
Starting with a straight suction pipe, liquid level beneath the pump, GP3
Volume 0 and Volume 2,

both as small as possible
Closed valve on
startup
Volume 2
2DN1
ØDN1
1...2t External water

t
Vacuum relief valve
Volume 0
Degassing pipe
Pressure indicator
Smin
Smin Minimum surface level

- degassing pipe below the minimum surface level
Minimum surface level above the suction pipe = Smin
Minimum surface level above the suction pipe:

5 x Hdyn
Smin = max
4 x DN1
Us2
Hdyn = m
2×g
Q
Us = 2 m
DN1 , g = 9,81
1000 × π x
2000 s2
Q, flow rate in l/s
Fig. 10

Series 2.15 Page
INSTRUCTIONS ISO
Gooseneck start, GP4
Volume 2 = 0,5 *)…1,5**) x Volume 1

Volume 0 = as small as possible
Back pressure valve ***)

2DN1
ØDN1
Closed valve on startup ***)

1...2t
t Volume 2
Volume 0
Either external water or
Degassing pipe return circulation
Vacuum relief valve
Pressure indicator
Volume 1
Smin
Minimum surface level

Smin - degassing pipe below the minimum surface level
Minimum surface level above the suction pipe = Smin
*) = slow start
**) = fast start
Minimum surface level above the suction pipe:
5 x Hdyn ***) = If the valves need to be placed in the
Smin = max reverse order, they must be as close to
4 x DN1
2 each other as possible.
Us
Hdyn = m
2×g
Q
Us = m
DN1 2 , g = 9,81 2
1000 × π x
2000 s
Q, flow rate in l/s
Fig. 11

Series 2.15 Page
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4 Coupling unit
4.1 Installation and alignment of coupling
WARNING
Before beginning any installation or alignment procedures, make sure the drive motor cannot be
started by any means.
NOTE
Satisfactory performance of the coupling depends on correct installation and alignment.
When applicable, the coupling has already been installed and prealigned at the pump factory. However, the
alignment may change due to faulty hoistings, poor baseplate support or piping support, thermal expansion or the
like. Therefore, check the shaft alignment of the coupling and re-align through the following stages:
1 After supporting of piping and before starting the pump, tighten the fixing screws of the pump and align the
coupling to the required accuracy. Fig. 13.
2 After running the pump with water, look for changes caused by the water run. Correct the changes by
altering the supporting of the piping. Tighten the fixing screws of the pump and align the coupling.
3 Carry out hot alignment if the temperature of the pumped liquid is higher than 100°C (212 °F). Carry out the
hot alignment during production run immediately after the pump is stopped while the pump and the motor are
still at the operating temperature. The need for hot alignment depends on the extent of temperature
differences and the coupling type chosen.
Check the alignment by measuring the angular and parallel misalignments in vertical (6 and 12 o’clocks) and
horizontal (3 and 9 o’clocks) directions. During the alignment, the coupling halves have to be locked together so that
they do not move with respect to each other. If needed, correct the alignment by adding or removing shims from
under the feet of the motor and by shifting the motor horizontally until the shafts are aligned within the given
tolerances. Fig. 13.
Optional alignment blocks can be used to shift the motor horizontally, see Fig. 12.
Fig. 12

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4.2 Maximum tolerances for coupling alignment

The maximum tolerances for angular and parallel alignments are given in Fig. 13.
Z max Y max
D (mm) 1500 rpm 1500 rpm 1500 rpm 1500 rpm
mm  mm  mm mm
- 100 0.08 0.06 0.05 0.04 0.10 0.06
101 - 200 0.11 0.05 0.06 0.03 0.15 0.10
201 - 300 0.15 0.03 0.10 0.02 0.20 0.15
301 - 400 0.20 0.03 0.10 0.02 0.25 0.15
Fig. 13
5 Baseplate
5.1 Installation at the site
NOTE
If the ordered assembly contains an API or Heavy Duty baseplate, follow the enclosed installation at
the site instruction N31664.
NOTE
When welding the foundation screws, connect the earth clamp to the baseplate, never to the pump!
The pump base must be sturdy enough to endure vibration, stress and potential forces caused by the piping.
If there are grounds to suspect that the base is not suitable for installation, the base must be strengthened by
making a concrete support stand or in some equivalent manner. Also note the bottom beams in the foundation or
cavities for the different types of foundation screws.

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5.2 Grouted baseplate of steel
Installation using welded foundation screws

The bottom beams in the foundation are cast in advance according to the dimensional drawing of the pump. The
strength requirements for the bottom beams are given in Table 4. In order to facilitate the alignment of the beams, a
so-called concrete frame can be used. The recommended accuracy for the installation of the beams is ±10 mm in all
directions. The actual installation becomes much easier, if the upper surfaces are horizontal.
Place foundation screws (918.61) in the fixing holes of the baseplate. The distance between the foundation and the
lower edge of the baseplate must be at least 50 mm. Each foundation screw is fixed to the baseplate by means of
hexagonal nuts (2 pcs/foundation screw). Fig. 14 - 15.
Lower the pre-installed pump-motor-baseplate-assembly onto the floor so that the foundation screws are above the
beams and the pump is in its position in the lateral and longitudinal direction. Now the foundation screws can be
welded to the beams.
Adjust the position of the baseplate before grouting by turning the hexagonal nuts of the foundation screws, until the
assembly lies horizontally and at the correct height.
Table 4, Welded foundation screw

The capacity of the bottom beam e.g. I-beam
Foundation (min.) HxBxL
screw Fv Fh
min. dimensions (mm)
tension N sheat N
M16 x 160 8600 7500 100 x 100 x 100
M20 x 160 17300 14400 100 x 100 x 150
M24 x 200 28100 23300 120 x 120 x 200
M30 x 200 39000 32200 140 x 140 x 250

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Fig. 14, Baseplate for pump and motor, T-base (STD,SLP)

Pump mounting sizes 11, 12, 13, 21, 22, 23, 24, 25, 26, 31, 32, 33, 34, 35,
41, 42, 43, 44, 45, 46, 47, 48, 49, 4A, 51, 52, 53, 54, 55, 56, 57, 58, 59, 5A, 5C, 5D,
5E, 5F, 5G, 5H, 61, 62

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Fig. 15, Baseplate for pump and motor, Rectangular (STD)

Pump mounting sizes 5J, 5K, 5L, 63, 64, 65, 66, 67, 68, 74, 75, 77, 78, 79, 7A, 7B, 7C,
7D
Installation using chemical foundation screws

The foundation screw holes are drilled according to the dimensional drawing of the pump. The recommended
accuracy for the location of the holes is ±10 mm. Roughen the holes. Clean the holes well by brushing and blasting.
Install the ampules into the holes. Install the foundation screws (918.61) by hammering to the bottom of the holes
and turn them a couple of rounds. Let the glue of the ampules harden. The screws can be loaded according to the
following table.
Table 5, Chemical foundation screws

Ambient temperature C Time of hardening Time for load
> +20 10 min 2h
+10 20 min 4h
0 60 min 10 h
min -5 5h 28 h
Lift the preinstalled pump and baseplate and fix it into the foundation screws by two nuts (2 pcs). Adjust the position
of the baseplate before grouting by turning the hexagonal nuts of the foundation screws until assembly lies
horizontally and at the correct height.

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Installation using grouted foundation screws

The foundation screw cavities are made in advance (by casting of concrete, drilling) in the concrete frame according
to the dimensional drawing of the pump, Table 6 and Fig. 16 or 17. The recommended accuracy for the location of
the cavities is ±10 mm.
Place the foundation screws (918.61) in the fixing holes of the baseplate, taking into account the distance between
the foundation and the lower edge of the baseplate which must be at least 50 mm and the minimum dimension U2
according to Table 6. Each foundation screw is fixed to the baseplate by means of hexagonal nuts (2 pcs/foundation
screw).
Lift the pre-installed pump and baseplate onto the mounting blocks so that the distance between the foundation and
the lower edge of the baseplate is at least 50 mm and so that the foundation screws fit into their cavities and the
pump is in its position in the lateral and longitudinal directions.
Grout the foundation screws. Use only non-shrinking solder concrete of high quality. Allow the concrete to set for
about 1 or 2 days.
Remove the mounting blocks and adjust the position of the baseplate by turning the hexagonal nuts until the
assembly lies horizontally and at the correct height.
Table 6, Grouted foundation screws

Foundation screw (mm)
Size
~e Umin U2min
M16 x 250 100 200 160
M20 x 320 125 250 200
M24 x 400 125 300 240
M30 x 450 160 400 300

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Fig. 16, Baseplate for pump and motor, T-base (STD, SLP)
41, 42, 43, 44, 45, 46, 47, 48, 49, 4A, 51, 52, 53, 54, 55, 56, 57, 58, 59, 5A, 5C, 5D,
5E, 5F, 5G, 5H, 61, 62

Series 2.15 Page
INSTRUCTIONS ISO

7D
Foundation
The recommended dimensioning for the foundation is given in Fig. 18 and 19. The dimensions for the baseplate are
given in the dimensional drawing Baseplate for pump and motor.
The suitable concrete reinforcement is recommended because of the concrete shrinkage and the loads of the
foundation. The amount of the concrete reinforcement depends on the size and the loads of the foundation and must
be carefully calculated by the local civil engineer according to local standards and regulations.
Pour concrete into the mold. The recommended strength grade for the concrete is about 35 MPa (design strength K
35).
The upper surface of the foundation is leveled so that it is slanting in accordance with Fig. 18 or 19. In pump
mounting sizes 5J, 5K, 5L, 63, 64, 65, 66, 67, 68, 74, 75, 77, 78, 79, 7A, 7B, 7C and 7D, the casing remaining under
the motor can be covered with concrete up to the mounting level surface of the motor. Water the grouting during its
drying to prevent cracking.
Recheck the alignment of the coupling after the grouting according to section ”Installation and alignment of
coupling”.

Series 2.15 Page
INSTRUCTIONS ISO
L1 + min. 110, when B2 + min. 110, when

L1 ≤ 2000 L1 ≤ 2000
L1 > 2000 L1 > 2000
5 mm
Fig. 18, Baseplate for pump and motor, T-base (STD, SLP)
41, 42, 43, 44, 45, 46, 47, 48, 49, 4A, 51, 52, 53, 54, 55, 56, 57, 58, 59, 5A, 5C, 5D,
5E, 5F, 5G, 5H, 61, 62

Series 2.15 Page
INSTRUCTIONS ISO

L1 ≤ 2000 L1 ≤ 2000
L1 > 2000 L1 > 2000
5 mm

7D
5.3 Steel baseplate installed with mechanical feet

Fasten each machine base (963.61) into the fixing holes in the baseplate and install the washers (554.66) under the
hexagonal nuts. There are 3, 4, 5 or 6 fixing holes. Use the studs in the machine bases to adjust the baseplate to the
correct height and horizontally, and tighten the hexagonal nuts.
Fig. 20

Series 2.15 Page
INSTRUCTIONS ISO
5.4 Concrete baseplate installed with mechanical feet

Mount each machine base (898.61) with a stud bolt (3 pcs) on the bottom of the baseplate. Use the nut in the
mechanical feet to adjust the baseplate so that it is horizontal and at the correct height.
Fig. 21
6 Drive motor
6.1 Installation of the motor on the baseplate

If the motor has not been installed on the baseplate by the pump manufacturer, the installation should be carried out
as follows:
Heat the coupling half on the motor side to approx. 100°C (212 °F) and push it onto the motor shaft in such a way
that the space between the ends of the shaft is according to the dimensional drawing (usually the front face of the
coupling is even with the end of the shaft).
When installing the coupling, also see instructions supplied by the coupling manufacturer.
Fasten the coupling spacer to the coupling half of the motor without the flexible element.
Check that the pump is aligned as accurately as possible to the middle of the fixing holes of the motor. Lift the motor
onto the riser blocks on the baseplate.
Align the coupling in accordance with section 4.1 “Installation and alignment of coupling” and the coupling
manufacturer’s separate installation instructions supplied with this manual. Align the coupling by moving the motor
vertically by means of the riser blocks or shims placed under the feet of the motor and laterally by moving the motor
and its riser blocks sideways. Please note that there is an additional lateral adjustment allowance of a minimum of
3 mm (0.12 in) under the riser blocks or the feet of the motor.
When installing the motor, pay special attention to the clearance of the coupling spacer (see the coupling installation
instruction) so that the spacer can be removed without detaching the motor.

SERIES 2.15
AHLSTAR
PROCESS PUMPS
Operation
1 Safety procedures before start-up

2 Starting the pump
3 Controls during the first run
4 Shut-down procedure
5 Controls after the first run
6 Trouble-shooting - operation

Series 2.15 Page
INSTRUCTIONS ISO
Operation
1 Safety procedures before start-up
Before starting the pump for the first time and after service repairs, the following precautionary measures are always
to be checked carefully to prevent any accidents and to guarantee a trouble-free operation of the pump.
WARNING
Make sure that the motor cannot be started by any means accidentally during the following
procedures.
WARNING
Make sure that the fixing screws of the pump and the motor are tightened according to the instructions.
WARNING
During operation - leakage of hazardous substances can occur - prepare proper means for a safe
waste removal.
NOTE
Pressure containing pump parts are not pressure vessels within the meaning of the regulations for
pressure vessels.
CAUTION
The pump will be damaged if run in the wrong direction.
1.1 Wet end
Leakage test
The pump parts and the piping shall be able to withstand a leakage test before the start-up. Leakage, particularly in
the suction piping, can seriously reduce the performance of the pump and make it impossible to prime the pump
before the start-up.
1.2 Sealing unit
Shaft seal and sealing water

Depending on the shaft seal fitting used, make sure that the shaft seal piping has been mounted correctly and that
the sealing liquid pressures, liquid volumes and service intervals correspond to the table below.

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Operation
Table 1, Sealing unit types (dynamical seal, mechanical seal, gland packing)
Sealing unit Shaft seal fluid
type N FR FC FE QF BF G
DS11 X X
DS12 X X
DS13 X X
DS14 X X
MS11 X X
MS12 X X
MS21 X X
MS31 X
MS32 X X
MS35 X
MS41 X X
MS33 X X
MS34 X X
MS42 X X
MS51 X X
MS52 X X
MS61 X
MS71 X X X
MS72 X X
MS81 X X
MS91 X
PG11 X X X X
Do not use a dynamic seal or gland packing in potentially explosive atmospheres (ATEX).
Table 2, Sealing unit types (liquid ring pump, gas separator, air separating pump)
type N FR FE QF BF QFFR BFFR QFFE BFFE
LM11 X
LM11 X (*
LM21 X
LM21 X
LM21 X (*
LM21 X (*
SM11 X
SM11 X (*
SM21 X
SM21 X
SM21 X (*
SM21 X (*
RM11 X (*
GM11 X
GM11 X
GM12 X
GM12 X
GM21 X X

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INSTRUCTIONS ISO
Operation

type N FR FE QF BF QFFR BFFR QFFE BFFE
GM22 X X
GS11 X
GS12 X
Use in potentially explosive atmospheres is permitted on a case-by-case basis. Make sure that the signs and plates fastened on
the device and auxiliary equipment indicate the required information.
N = No sealing liquid
FR = Internal circulation
FC = Circulation closed loop
FE = External flushing liquid; PT + 0.05 MPa, 3 l/min
*) For high vacuum level external flushing must be doubled or tripled.
BF = Pressurized external flowing sealing liquid; PT + 0.05 MPa (minimum), 3 l/min
Except with the seal pot sealing water equipment, the needed sealant fluid flow is generated by the pumping effect
of the shaft seal. The sealant fluid can be water (Tamb>0ºC) or a suitable water glycol mixture (Tamb< 0ºC) or some
other liquid depending on the process application. Sealing fluid Tmax = 100ºC, Pmax = 1.6 MPa.
QF = Non-pressurized (max 0.05 MPa), 3 l/min
G = Grease once a week. Grease must be suitable for the elastomers of mechanical seal.
QFFR = Quench sealing fluid, Recirculation flushing fluid
BFFR = Barrier sealing fluid, Recirculation flushing fluid
QFFE = Quench sealing fluid, External flushing fluid; PT + 0.05 MPa, 3 l/min
BFFE = Barrier sealing fluid, External flushing fluid; PT + 0.05 MPa, 3 l/min
Impellers with balancing holes
pT= p0-0.005 MPa

Where pT = pressure behind the impeller (MPa)
p0 = inlet pressure (MPa)
Atmospheric pressure used as reference pressure = 0 MPa

Series 2.15 Page
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Operation
Impellers without balancing holes
Where pT = pressure behind the impeller (MPa)

p0 = inlet pressure (MPa)
ρ = density of the liquid being pumped (kg/m3)
H = pump head at the operating point in question (m)
n = rotating speed of the pump (r/min)
d2 = impeller back plate diameter (m)
db = impeller back vane diameter (m)
d5 = impeller hub diameter is 0.04 m in bearing unit no. 1,
in bearing unit no. 2 0.05 m, in bearing unit no. 3 0.06 m,
in bearing unit no. 4 0.07 m, in bearing unit no. 5 0.09 m,
in bearing unit no. 6 0.10 m and in bearing unit no. 7 0.12 m.
Atmospheric pressure used as reference pressure = 0 MPa
The flushing liquid and sealing liquid must fulfill the following quality requirements:
 maximum particle size 50 μm
 maximum solid material content 2 mg/l.
1.3 Bearing unit
Lubrication
WARNING
A pump unit operating without proper lubrication will damage the bearings and cause a pump seizure.
Use grease lubrication always when the pump is mounted in an inclined position.
Check the oil or grease used for the lubrication of both the pump and motor bearings before start-up. Condensation
or ingress of dirt and water may occur if the pump unit is stored for a long time before installation and start-up.
1.4 Drive motor
Direction of rotation
Fig. 1
 Before commissioning, always check the motor for correct rotation.

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Operation
 It is imperative to detach the coupling spacer before checking the rotation direction of the motor.
The motor rotation must be counter-clockwise when viewed from the coupling end (D-end, Fig. 1) of the motor. (The
pump rotation is clockwise when viewed from the coupling end.)
The direction of rotation must correspond to the arrow sign (972.31) on the bearing housing (330.31).
1.5 Coupling unit
Free rotation
Rotate the coupling by hand with the coupling spacer detached.
Coupling alignment
Check that the coupling has been properly aligned according to the instructions in Section ”Installation and alignment
of coupling”.
WARNING
Before starting - all safety devices (e.g. coupling guards) must always be correctly installed. For
explosive areas, guards with non-sparking materials are to be used.
1.6 Baseplate
Vibration of the baseplate should be monitored by means of regular measurements, especially if the baseplate is
equipped with mechanical feet. If the vibration values exceed the highest permissible values, the cause of vibration
should be determined.
2 Starting the pump
WARNING
The product is meant only for the purpose for which it is sold - never operate beyond the intended use
described in these instructions.
WARNING
If your pump has no gas separator (-GM, -GS), liquid ring (-LM, -S) or air separating (-R) pump in the
sealing unit, make sure that the pump is sufficiently filled with the pumped liquid before starting.
CAUTION
Observe immediately after start-up the instrumentation showing the discharge pressure. If the pressure
is not quickly reached, stop the motor and check causes for the low pressure.

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Operation
CAUTION
If it is necessary to adjust the amount of pumped liquid, do it by adjusting the discharge valve. Never
use the suction valve for flow adjustment.
2.1 Pumps equipped with gland packings, mechanical seals or dynamic sealing
units
 Open the valves for sealing water if any, and adjust suitable pressure and flow according to Table 1.
 Check that there is abundant leakage at the gland packing. If there is no continuous leakage, slacken the
stuffing box gland. If this does not help, remove the packings and re-pack the stuffing box less tight.
 Fill the pump so that at least the suction pipe and pump casing are filled with liquid. Let the air come out of
the upper part of the tangential volute casing by opening the screwed plug (903.13) in connection (C54.11).
 Check that the suction valve is fully open and discharge valve closed.
 Start the motor.
 Open the discharge valve gradually until the desired amount of liquid is reached.
 Check that the gland packing leakage is still abundant. If not, slacken the stuffing box gland immediately. If
this does not help and the gland packing becomes hot, stop the pump and find out the reason for the
disturbance. When the gland packing has been operating trouble-free for 10 minutes it may be tightened.
Tighten it by turning the hexagonal nuts approx. 1/6 turns at a time at 5 - 10 minutes’ intervals until the
leakage is at least 30 - 80 drops a minute. While tightening, make sure that the stuffing box gland remains
perpendicular to the shaft.
 Follow the instructions given by the manufacturer of the sealing water equipment for filling, bleeding and
operation setup.
2.2 Pumps equipped with liquid ring pumps (-LM, -S)

 Open the sealing liquid and/or flushing liquid valves and adjust the pressure and the flow rate to a suitable
level in accordance with Table 2.
 Let the flushing liquid flow for about 1 to 2 minutes so that all necessary spaces are filled with the liquid.
 Make sure that the suction valve is fully open and that the discharge valve is closed.
 Adjust the desired vacuum by means of the vacuum relief valve (Fig. 2):
Undo the locking nut (6) which locks the valve spindle (2).
Turn the valve bushing (3) to the desired direction while holding the valve spindle (2) in place. When you turn
the bushing (3) clockwise, the vacuum grows as the force of the spring (4) closing the valve spindle (2)
increases. When you turn the bushing (3) counterclockwise, the vacuum reduces as the force of the spring
(4) decreases.
When the desired vacuum is reached, lock the valve spindle (2) to the bushing (3) with the locking nut (6).

Series 2.15 Page
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Operation
Fig. 2
CAUTION
There is a risk of destroying the suction impeller of a liquid ring pump by cavitation, if the vacuum level
has been adjusted too high or the vacuum relief valve has been taken off and the connection has been
plugged.
 When the pump starts to pump and the pressure on the discharge side rises, open the discharge valve until
the desired liquid volume is reached. If the pump and suction pipe are full of liquid, the pressure will rise
immediately after starting. If the pump is empty when being started, it takes some time for the pressure to
rise.
2.3 Pumps equipped with gas separators (-GM, -GS) or air separating pumps (-R)
 Open the sealing liquid valves of the pump and of the potential degassing pump and adjust the flow rate to a
suitable level in accordance with Table 2.
 Make sure that the suction valve is fully open and that the discharge valve is closed.
 Start the motor of the degassing pump if there is one.
 Adjust the desired vacuum by means of the vacuum relief valve (see pumps equipped with liquid ring
pumps).
 Open the degassing valve between the pump and the potential degassing pump.
 Open the discharge valve carefully until the desired liquid volume is reached.
 If the pump is used as a self-priming pump, do not open the discharge valve until the degassing pump has
sucked the pump full of liquid, the pump starts to pump and the pressure starts to rise on the discharge side.

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Operation
 Make sure that the pumped liquid does not flow out through the degassing connection. If it does, reduce the
vacuum created by the degassing pump by means of a potential vacuum relief valve. The sealing liquid may
flow out through the degassing connection.
3 Controls during the first run
WARNING
Personal injuries may occur if personal protective equipment is not used when servicing the product.
When pumping hazardous liquids, skin and eye protection are required.
CAUTION
Do not operate the pump below the minimum recommended flow or with the discharge valve closed.
Cavitation or recirculation can lead to a quick pump failure.
By controlling the pump operation and output regularly, the possible need for service and repair can be anticipated.
In this way, the pump efficiency is kept high, the process is trouble-free and the maintenance costs are low.
Control the temperature of the gland packing and maintain the leakage at 30 - 80 drops/minute by adjusting the
stuffing box gland.
The flow and pressure of sealing water must be kept at the enclosed values given by the seal manufacturer.
When the seal pot sealing water equipment is operating, check that the sealing fluid is flowing in the correct direction
– the return hose must be warm.
Check the temperature and vibration of bearings through regular measuring. If one or the other increases, it may be
a sign of incorrect lubrication or bearing damage. The measuring studs (SPM, M8 x 24) are in the bearing housing
for controlling the bearings.
Also, any noises from the pump and its vibration have to be controlled and the reasons for unusual noises or
vibration detected.
The condition of the coupling can be monitored with a stroboscope through the perforation in the coupling guard.
4 Shut-down procedure
 Close the discharge valve to prevent the pumped liquid from flowing back.
 Close the degassing valve between the pump equipped with a gas separator (-GM, -GS) or air separating
pumps (-R) and the potential degassing pump.
 Stop the motor.
 Stop the motor of a potential degassing pump.
 Close the suction valve if there is reason to doubt that the pumped liquid will flow out of the suction piping.
 Close the cooling and flushing liquid valves, if any.
 If the pump has a sealing liquid valve, it cannot be closed until the pump has been drained or until at least
the pressure has been relieved from the pump.

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Operation
During longer shut-downs, the pump must be checked every now and then. Turn the shaft manually a few times. If
the pumped liquid congeals or solidifies easily, if it is corrosive, or if the pump is exposed to freezing, drain the pump
and suction piping for the shut-down period. At the same time, flush the pump with clean water.
5 Controls after the first run
NOTE
The correct final alignment of the coupling is important for the pump operation.
When the pump unit has run for a sufficient length of time to bring the pump and motor up to the normal operating
temperature, check the coupling alignment according to Section ”Installation and alignment of coupling”.
With hot liquid pumps, check the tightness of the casing cover fixing screws. Adjust torque in accordance with the
reference values.
With pumps equipped with gland packing, check proper leakage from the stuffing box.
With pumps equipped with mechanical seals, ensure that the flushing or cooling supplies are functioning adequately.
Make sure that the sealing water system is working properly.
Check that there is no overheating in the pump or motor bearings.
6 Trouble-shooting - operation
During the start-up period, problems are mostly caused by pump selection mistakes, poor process design,
operational mistakes or foreign objects in the process.
During the long-term operation of a pump unit, problems are mostly caused by random failures, process changes or
corrosion and wear.
Problems can normally be traced to either poor maintenance or exceeding the limitations for the intended use of the
pump.
The following problem tracing analysis includes the most common malfunctions and their possible causes. If the
pump does not function properly, it is important to trace the actual reasons, so that the repairs and required
modifications can be done without delay. Tables 3-10.
Table 3, Symptom: Pump not delivering liquid

Probable cause: Remedy:
Wrong direction of rotation Change the direction of rotation acc. to the arrow sign on the
bearing unit
Pump not adequately primed or a vapor lock in the suction Reprime the pump and suction piping
pipe
Flushing liquid is not on (liquid ring pumps (-LM, -S)) Open the flushing liquid valve
Difference between inlet pressure and vapor pressure too Check the suction piping arrangements
small
Air leakage in suction opening, suction piping or shaft seal Check the suction piping. Readjust the shaft seal
Suction piping, suction valve or impeller clogged Check the suction piping and the pump for any obstructions
Rotational speed too low Check the speed requirements/limitations
Flow resistance of the piping higher than the head generated Check resistancies and reduce losses
by the pump

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Operation

Unexpected air/gas content in the pumped liquid Consult manufacturer for further instructions
Suction tank level low Check the required inlet/suction head
Table 4, Symptom: Insufficient head

Unexpected viscosity of the pumped liquid Consult manufacturer for further instructions
Wrong direction of rotation Change the direction of rotation acc. to the arrow sign on the
bearing unit
by the pump
Pressure containing pump parts worn/damaged/clogged Check the pump and replace defective parts, if necessary
Suction tank level low Check the required inlet/suction head
Table 5, Symptom: Insufficient (or irregular) flow

Vapor lock in the suction pipe Reprime the pump and suction piping
Suction head too high Check that the suction valve is fully open and that the suction
line is unobstructed
small
Air leakage in suction opening, suction piping or shaft seal Check the suction piping and readjust the shaft seal
Suction piping, suction valve or impeller partially clogged Check the suction piping and the pump for any obstructions
by the pump
Table 6, Symptom: High power consumption

Rotational speed too high Check the speed requirements/limitations
Wrong direction of rotation Change the direction of rotation acc.to the arrow sign on the
bearing unit
Flow resistance of the piping much higher/lower than the head Check the piping arrangements
generated by the pump
Unexpected specific gravity of the pumped liquid Consult manufacturer for further instructions
Pump and motor incorrectly aligned Realign the pump and motor assembly, make sure there is no
strain on the pump.
Crooked or eccentric shaft Reassemble the pump and renew the shaft and bearings, if
necessary
Rotating objects or pump parts chafing inside the pump Reassemble the pump and check the clearances
Mechanical tightness of pump components Reassemble the pump and check the clearances
Table 7, Symptom: Excessive noise and/or vibration

small (cavitation)

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Operation

Air leakage in suction opening, suction piping or shaft seal Check the suction piping/readjust the shaft seal
by the pump
Pump functioning below the recommended minimum flow Check the pumping system requirements
(cavitation)
Pump foundation not rigid enough Strengthen the foundation
Inadequate piping support exerting strain on the pump Check the piping support requirements
Pump and motor incorrectly aligned Realign the assembly, make sure there is no strain on the
pump.
Crooked or eccentric shaft Reassemble the pump and renew the shaft and bearings, if
necessary
Mechanical tightness of pump components Reassemble the pump and check the clearances
Bearings worn or loose Reassemble the pump and replace the bearings, if necessary
Inadequate or excessive lubrication Check the pump for proper lubrication
Impeller damaged or out of balance Reassemble the pump and replace the impeller, if necessary
Table 8, Symptom: Bearings wear rapidly

Pump and motor incorrectly aligned Realign the pump assembly, make sure there is no strain on
the pump. Replace the bearings, if necessary.
Crooked or eccentric shaft Reassemble the pump and straighten or replace the shaft
Inadequate or excessive lubrication Check the pump for proper lubrication
Badly installed and/or dirty bearings Renew bearings, if necessary. Check the quality and amount
of lubricant
Table 9, Symptom: Pump overheats/seizes

Pump not adequately primed Reprime the pump and suction piping
Flushing liquid is not on (liquid ring pumps (-LM, -S)) Open the flushing liquid valve.
Difference between inlet pressure and vapor pressure too Check the suction piping arrangements. The pump may
small operate below the recommended minimum flow (cavitation)
Pump functioning below the recommended minimum flow Check the pumping system requirements
(cavitation)
Pump and motor incorrectly aligned Realign the assembly, make sure there is no strain on the
pump
Bearings worn Reassemble the pump and replace the bearings, if necessary
Crooked or eccentric shaft Reassemble the pump, straighten or renew the shaft
Discharge valve closed Open the discharge valve
Discharge valve clogged Check the pipe and flush it if necessary

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INSTRUCTIONS ISO
Operation
Table 10, The liquid pumped flows out through the degassing connection (pumps equipped with gas
separators (-GM, -GS) and air separating pumps (-R))
Inlet height too high Check the suction height limits
Pump speed too small Check the speed requirements and restrictions
Degassing vacuum too high Adjust the degassing vacuum by means of the vacuum relief
valve

SERIE 2.15
AHLSTAR
PROCESS PUMPS
1 General
2 Wet end
3 Sealing unit
4 Bearing unit

Series 2.15 Page
INSTRUCTIONS ISO
1 General
NOTE
Refer to the sectional drawings when reading through these instructions.
NOTE
Preventive maintenance is also a relevant safety factor.
NOTE
If the pump performance does not fulfill the process requirements, the pump is to be disassembled and
inspected. All worn parts should be changed to new genuine spare parts.
Regular and systematic preventive and predictive maintenance can extend the product lifetime and requires fewer
repairs and spare parts. Monitoring of instrumentation and physical examinations are a vital part of today’s quality
maintenance. We recommend that the maintenance system includes a historical record kept for each pump, its
condition and performance. This will help to prevent sudden failures and aid in case of possible fault tracing
analyses. In the process industries, one process downtime caused by a pump normally costs much more than the
price of the pump.
Preventive maintenance consists of the following actions:
 Bearing lubrication
 Temperature, noise, vibration monitoring and inspections
 Monitoring the discharge pressure, capacity and power demand
 Inspections regarding corrosion and wear
 Shaft seal monitoring
 Regular pump washdowns
 Monitoring the pump and pipings for leakage
 Quarterly checks of the tightness of critical fasteners, such as foundation screws and pump & motor
fasteners onto the baseplate
General measuring instruments for pump operation are presented in Table 1.
Table 1, Measuring instruments

Fixed instruments: Portable instruments:
Pressure gauges & indicators Vibration analysers
Flow meters Tachometers
Ammeters / wattmeters / voltmeters Thermometers
Speed indicators Noise level indicators
Temperature detectors Ultrasonic indicators (wall thickness)
Vibroswitches
Any fixed or portable instruments may in themselves create a possible failure and require regular monitoring to ensure their
correct functioning.

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INSTRUCTIONS ISO
WARNING
In an explosive atmosphere, avoid abrasive cleaning when cleaning the pump to prevent sparking
caused by electrostatic charge (explosion hazard group IIC).
1.1 Temperatures
During operation, the following surface temperatures are to be observed regularly:
 volute casing (102.11)
 bearing housing (330.31)
 shaft sealing, measured from the casing cover (161.21) or from the stuffing box housing (451.21)
 casing (100.21) measured at both the suction impeller and mechanical seal (liquid ring pumps (-LM, -S))
 motor (800.41)
The reasons for any deviations in temperatures are to be checked immediately to prevent further and more serious
damage.
1.2 Noise and vibration analysis

A regular follow-up of the pump noise and vibration gives a good view regarding the condition and wear of bearings
and also other wearing parts of the pump. This enables timely predictive maintenance routines and reduces the
potential for unexpected shut-downs. Admissible vibration severity values are presented in Section ”Safety
instructions/Balance and vibration”.
1.3 Discharge pressure

A regular control of the pressure generated by the pump, the rated flow and the power need of the drive unit gives a
good view regarding the condition and wear of the hydraulic parts of the pump. The follow-up enables such
preventive maintenance actions as clearance adjustments or parts renewals to be scheduled accordingly.
1.4 Pump washdown

The pump is designed to prevent external liquids from entering the bearing unit. However, direct spraying of high-
pressure water to the labyrinth rings (423.31 and 423.32) must be avoided.
2 Wet end
2.1 Corrosion and wear

When the pumps are operating under corrosive and/or abrasive conditions, a regular follow-up of wall thicknesses in
the case and case cover is necessary. When the wall thickness has worn more than the permitted corrosion
allowance of 3.0 mm, the mechanical durability (pressure limits) stated in these instructions is no longer guaranteed.
Due to the casting tolerances (ISO 8062-3: 2007), the nominal wall thicknesses stated in the casting drawings
cannot be used for assessing excessive corrosion and wear. If corrosion and wear are expected, the wall
thicknesses of the volute case and case cover should be measured at specific points before the first start-up. These
values serve later as reference values for assessing excessive corrosion and wear.

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INSTRUCTIONS ISO
2.2 Adjustment of clearance between sideplate and impeller

If the pump has an adjustable sideplate (135.11), the clearance between the impeller and sideplate is adjusted
without disassembling the pump as follows (Fig. 1):
920.11 909.11
135.11
230.11
Fig. 1
 Slacken the hexagonal nuts (920.11) of the adjusting screws (909.11).
 If your pump is provided with a vortex impeller, use the adjusting screws to move the sideplate so that the
clearance between the sideplate and the impeller is 5 mm (A11-40: 4 mm) (pump type: A).
 If the pump is provided with a vortex impeller, move the sideplate using the adjusting screws so that there is
a minimum of stagger between the volute casing and sideplate (pump type: NPP, WPP).
 If your pump is provided with an impeller other than a vortex impeller, turn each adjusting screw alternately
counter-clockwise until the sideplate touches the impeller. Then turn the adjusting screws clockwise 1/3 turns
to obtain a 0.5 mm clearance between the sideplate and impeller.
 After the adjustment, tighten the hexagonal nuts, whereby the adjusting screws will be locked. The adjusting
screw must not turn during tightening.
 By turning the coupling by hand, check that the pump can rotate freely.
 The sideplate can be adjusted altogether 3 - 4 mm towards the impeller. If further adjustment is needed,
change the impeller and sideplate in order to keep the right clearance.
3 Sealing unit
WARNING
Always stop the motor before any of the following maintenance actions to the pump. Make sure that
the motor cannot be started by any means accidentally during the repairs.
WARNING
Always drain the pump before disassembling the shaft seal. When pumping hazardous liquids, make
sure that there is no trapped liquid remaining in pump parts.

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3.1 Gland packing

Gland-packed pumps must be checked regularly to ensure that there is a slight leakage from the gland. An
excessively tight gland causes wear to the shaft sleeve and increased power demand. Refer to the instructions in
Section ”Operation/Controls during the first run”.
WARNING
Never use gland packing material containing asbestos. It may cause a health hazard.
Maintenance of shaft seals

 Remove the used gland packing from the stuffing box housing by using a flexible extraction tool (Fig. 2).
Clean the stuffing box housing and open any clogged sealing liquid holes.
Fig. 2
 If there are scratches or wearing marks on the shaft wearing sleeve (part 524.21 in Table 2) or in the stuffing
box housing, replace the damaged parts.
 We recommend the use of precompressed gland packings. However, if you need to cut the packings from a
sealing band, proceed as follows: turn four rounds of the sealing band around a wooden pattern having the
same thickness as the shaft wearing sleeve (part 524.21 in Table 2) and use a sharp knife to cut the packing
rings straight and axially without overdimensioning or underdimensioning, Fig. 3. The dimensions of the
stuffing box housing and the total length of the band to be cut without working allowances are given in Table
2.
Fig. 3
 When packing new packing rings, be very precise, and keep the parts clean.
 Lubricate the shaft sleeve and packing rings lightly with oil.
 Push the first packing ring tightly against the neck bush. The ends of the rings must be exactly against each
other.
 The second ring is placed against the first one so that the joints are at 180° angle to each other, Fig. 4.
 Next put the lantern ring into the seal chamber.
 Fit also the last two rings with the joints at 180° angle to each other.
 After all the packing rings and the lantern ring have been fitted, tighten the nuts of the stuffing box gland by
hand.
 The shaft seal is taken into use according to Section ”Operation/Controls during the first run”.

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Table 2, Dimensioning of stuffing box
524.21
d D
Stuffing box Total length of the

Shaft size
Ød x ØD x a (mm) packing ring (mm)
1 40 x 60 x 10 640
2 50 x 70 x 10 770
3 60 x 85 x 12.5 930
4 70 x 95 x 12.5 1050
5 90 x 122 x 16 1350
6 100 x 132 x 16 1460
7 120 x 152 x 16 1710
Gland packing
1st ring
2nd ring
lantern ring stuffing box gland
3rd ring
4th ring
Fig. 4
3.2 Mechanical seal

Mechanical seals are normally installed and adjusted at the factory before the delivery. The general principle is that
the mechanical seal does not leak at all. The lifetime of a mechanical seal depends on the cleanliness and
lubricating properties of the pumped liquid and the sealing liquid. If the mechanical seal leaks, stop the pump and
replace the mechanical seal.
CAUTION
The dry running of mechanical seals will damage the sliding surfaces and cause leakage of pumped
liquid.

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Mechanical seals do not normally require any preventive maintenance actions during their operation. If any problems
occur, the whole seal package is normally renewed. For longer-term shutdown, it is recommended that the sealing
space be flushed, preferably using clean water, if possible.
3.3 Dynamic seal
Dynamic seal, ring type (DS11, DS12)

The expeller (604.21) design of the dynamic seal prevents the leakage of pumped liquid through the stuffing box
during operation. During shut-down, the leakage is prevented by the static seal design (435.21).
Dynamic seals do not normally require any preventive maintenance actions. During the first years of operation, the
static seal (435.21) can yet wear so much that some leakage can occur during stoppages. The static seal is again
functional when sliding the thrust ring (475.21) away from the volute casing so long that the leakage stops. The
thrust ring must always be secured with the nuts (920.21) during operation. This adjustment can be done several
times during the lifetime of the static seal. The wear allowance of the static seal is about half of its thickness. If the
seal has worn more or otherwise damaged, it must be replaced with a new one.
Dynamic seal, plate type (DS13, DS14)

The expeller (604.21) design of the dynamic seal prevents the leakage of pumped liquid through the stuffing box
during operation. During shut-down, the leakage is prevented by the static seal design (435.21).
Dynamic seals do not normally require any preventive maintenance actions. During the first years of operation, the
static seal (435.21) can yet wear so much that some leakage can occur during stoppages. The static seal is again
functional when sliding the thrust ring (475.21) towards the volute casing so long that the leakage stops. The thrust
ring must always be secured with the grub screws (904.21) during operation. This adjustment can be done several
times during the lifetime of the static seal. The wear allowance of the static seal is about half of its thickness. If the
seal has worn more or otherwise damaged, it must be replaced with a new one.
4 Bearing unit
4.1 Bearing types

The pump has one cylinder roller bearing unit (deep groove ball bearing on shaft size 7) and two single row angular
contact ball bearings (O-system, Table 3).
Table 3, Pump bearings

Shaft size Impeller side Coupling side
1 NUP 307 ECJ 7308 BECBM
7 6324 7326 BCBM
SKF designation. If bearings by other manufacturers are used, the corresponding bearing types are required.

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4.2 General information on grease lubrication
CAUTION
Never mix different grease grades (consistency, thickeners). The mixed grease becomes softer and
does not lubricate the bearings properly.
NOTE
All greasing equipment and fittings used must be clean to avoid any impurities from entering the
bearing housing.
NOTE
The surface temperature of the bearing unit can temporarily rise after regreasing due to an excess
amount of grease.
All the grease-lubricated bearings have been lubricated before the shipment. The first re-lubrication should be done
before the initial commissioning of the pump.
For normal conditions when the bearing housing surface temperature is below +80°C, we recommend lithium-based
or lithium-calcium-based mineral greases for antifriction bearings, e.g.:
 Shell Gadus S2 V220 2
 Mobil, Mobilgrease XHP 222
If the bearings run hotter and the surface temperatures are above +80°C, we recommend the use of the following
special greases:
 Shell Gadus S3 V550L 1
 Mobil, Mobilgrease XHP 461
These special greases can also be used with surface temperatures below +80°C. If the ambient temperature is
below 0°C, always consult Sulzer about the use of the correct grease. All lubricants may not be suitable for low
temperature use.
Always consult the pump manufacturer about the use of any special greases and their start-up.
4.2.1 Grease lubrication in AHLSTAR

Amounts of lubricants and re-lubrication intervals are described in Table 4 and in Table 5 depending on the speed of
rotation.
Table 4, Initial and re-lubrication (50 Hz speeds of rotation)

Re-lubrication interval 1) (hours, bearing housing
Initial lubrication (g) Re-lubrication (g)
temperature < +55 °C)
Shaft size
Impeller Coupling Impeller Coupling 740 980 1480 2950
495 rpm 590 rpm
side side side side rpm rpm rpm rpm
1 30 50 10 15 - - 16000 12000 8000 3500
2 55 85 15 25 - - 14000 10000 6500 3000
3 85 135 20 30 - - 12000 8000 5500 2500
4 145 210 25 40 - - 10000 7500 4500 -

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Re-lubrication interval 1) (hours, bearing housing

temperature < +55 °C)
Shaft size
Impeller Coupling Impeller Coupling 740 980 1480 2950
495 rpm 590 rpm
side side side side rpm rpm rpm rpm
5 220 390 40 60 - - 8500 6000 3500 -
6 250 450 50 70 - - 8500 6000 - -
7 350 600 70 140 12000 10000 8500 6000 - -
1) Every 15 °C rise in the surface temperature shortens the lubrication interval with a half.
Table 5, Initial and re-lubrication (60 Hz speeds of rotation)

Re-lubrication interval 1) (hours, bearing housing temperature <
+55 °C)
Shaft size
Impeller Coupling Impeller Coupling 445 510 590 710 890 1180 1780 3540
side side side side rpm rpm rpm rpm rpm rpm rpm rpm
1 30 50 10 15 - - - - 15000 10000 7000 3000
2 55 85 15 25 - - - - 13000 8500 5500 2500
3 85 135 20 30 - - - - 11000 7000 4500 2000
4 145 210 25 40 - - - - 9000 6500 3500 -
5 220 390 40 60 - - - - 7500 5000 2500 -
6 250 450 50 70 - - - - 7500 5000 - -
7 350 600 70 140 13000 12000 10000 8500 7500 4500 - -
1) Every 15 °C rise in the surface temperature shortens the lubrication interval with a half.
4.3 General information on oil lubrication
CAUTION
For delivery, the bearing housing of the pump has been emptied of oil. Remember to refill it before
starting.
For lubrication, use only high-quality mineral oils, the viscosity of which is ISO VG 46.
E.g.
 Shell Tellus Oil S46
 Mobil DTE Oil Medium
The viscosity of oil at the operating temperature must not be below 12 cSt (65 SSU). Please take a note that the oil
temperature may be different from the bearing housing surface temperature.
The oil cleanliness requirement is according to ISO 4406, solid contaminant code of oil: -/17/14. The maximum water
concentration in oil is 200 ppm.
If the ambient temperature is below 0°C, always consult Sulzer about the use of the correct synthetic oil. All
lubricants may not be suitable for low temperature use.

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4.3.1 Oil lubrication in AHLSTAR

Bearing unit 1-6 (Oil splash lubrication, Oil bath lubrication)
Lubrication according to “General information of oil lubrication”. If the environment temperature is below 0 °C, oil
splash lubrication shouldn’t be used.
Bearing unit 7 (Oil splash lubrication)
For lubrication, use only lubrication oils of a good quality the viscosity of which in normal conditions is ISO VG 100 -
ISO VG 150.
E.g.
 Shell Tellus Oil S 100
 Mobil DTE Oil Heavy
The viscosity of the oil at operating temperature must not be lower than 16 cSt (84 SSU).The operating temperature
is about 15 °C higher than the surface temperature of the bearing housing.
If the environment temperature is below 0 °C, oil splash lubrication shouldn’t be used.
First oil filling (Oil splash lubrication)

 Remove the venting device (672.31) and add oil so that the level reaches the middle of the sight glass
(642.31).
 Loose the socket head screw (914.31) and remove the constant level oiler (638.31). Fill it with oil and put it
back.
First oil filling (Oil bath lubrication)

Without using the constant level oiler
642.31
Fig. 5
Unscrew the venting device (672.31) and add oil up to the middle of the sight glass (642.31), Fig. 5. When pump is
running oil level in the sight glass can be little variable. With lower speed oil level can go little bit lower and higher
speed go little up (air is mixing into oil). Screw the venting device (672.31) back in place. See the oil volumes in
Table 8.

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With using the constant level oiler
672.31
642.31 638.31
Fig. 6
Install the constant level oiler (638.31) in the bearing unit. Adjust the constant level oiler (638.31) to the correct
height (0 mm) and tighten the locking screw. Unscrew the venting device (672.31), add oil up to the middle of the
sight glass (642.31) and screw the venting device (672.31) back in place. Undo the glass cup of the constant level
oiler (638.31) and fill it with oil, and place the glass cup of the constant level oiler (638.31) back in place.
Oil change
After commissioning, oil should be changed for the first time after about 100 hours of operation and thereafter
according to Table 6 and more often if the operating conditions cause contamination or change in other properties of
the oil used.
Table 6, Oil changes

Surface temperature of bearing housing Oil change interval
65 °C 1 year
75°C 6 months
Table 7, Oil volumes (Oil splash lubrication)

Oil volume (ml)
Shaft size Bearing Constant level
Glass cup
housing oiler
1 ~140 140 100
2 ~350 140 100
3 ~460 140 100
4 ~1030 140 100
5 ~1500 140 100
6 ~2500 140 100
7 ~3900 140 100
Table 8, Oil volumes (Oil bath lubrication)

Bearing unit Oil volume (l)
1 0.2
2 0.5
3 0.6
4 0.9

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Bearing unit Oil volume (l)

5 2.2
6 3.7

SERIES 2.15
AHLSTAR
PROCESS PUMPS
1 General
2 Pump unit
3 Wet end
4 Sealing unit
5 Bearing unit

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1 General
NOTE
Refer to the sectional drawings when reading through these instructions.
1.1 Safety instructions and environmental aspects to be noted before corrective

maintenance
WARNING
When pumping hazardous liquids, secure that there is no trapped liquid remaining in pump parts.
Pumps which convey hazardous media must be carefully decontaminated before any repairs. Skin and
eye protection are required during decontamination. Precautions are needed for personal or
environmental safety.
Some of the disassembled parts and assemblies are heavy, unstable and due to design requirements
they contain sharp edges (e.g. impeller, sideplate, casing cover). Use proper hoistings and supports to
prevent personal injury.
WARNING
Hazardous substances must be kept away from the environment. These substances should be
collected and sent for proper handling. All recyclable components should be taken to a proper
recycling system.
1.2 Necessary equipment / tools
Normally available working tools
 Hoisting accessories. Note the safety requirements!
 Wrenches for hexagonal screws, sizes (mm): 13, 14, 16, 18, 19, 22, 24, 30, 36

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 Allen wrenches for socket head screws, sizes (mm): 2,5, 4, 5, 6, 8, 10, 14
 Torque wrenches for moments (Nm): 30, 50, 130, 250, 420, 800
- for hexagonal, sizes (mm): 18, 24, 30, 36
- for socket head, sizes (mm): 8, 10, 14, 17, 19, 22, 27
 Hooked wrenches, sizes (SKF): HN8, HN10, HN12, HN14, HN18, HN22, HN26
 Extractors
 Bearing heater
 Dial indicators
 Cleaning agents & equipment
 Lubricating agents & equipment
Special tools
 Detachment tool for the casing wear ring/sideplate. Fig. 1.
 Pipe punch series for roller bearings and lubrication rings. Fig. 7.
 Securing tool for impeller head screw. Fig. 3.
2 Pump unit
2.1 Disassembly
NOTE
Ensure that all eventual spare parts are available before the disassembly.
Preliminaries
1 Close the discharge valve.
2 Stop the motor. Make sure that the motor cannot be started by any means during the repair.
3 Close the suction valve.
4 Drain the pump carefully. For this, use the threaded plug (903.11) potentially situated at the bottom of the
volute case (102.11).
5 Disconnect potential guards, pipes and sealing water equipment relating to degassing and shaft seal.

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6 Remove the guard jackets (686.51 and 686.52) and coupling (840.51) spacer.
7 Drain oil from an oil-lubricated bearing housing by unscrewing the threaded plug (903.32).
Detachment of exchange unit
1 Unscrew the hexagon head screws (901.11) and the hexagon head screws (901.62) of the support foot from
the baseplate (890.61).
2 Suspend the exchange unit by a hoist at the maintenance opening of the adapter or underneath the adapter.
3 Pull out the exchange unit by using the hexagon head screws (901.11).
2.2 Reassembly
Preliminaries
 Clean all gasket surfaces and fittings from rust and layers.
 Inspect for unusual erosion, pitting and wear in parts.
 Inspect keyways and bores for damage.
 Inspect the pump and baseplate for cuts and cracks.
Installation of exchange unit
1 Fix the support foot of the bearing unit by means of the hexagon head screws (901.32).
2 Heat the coupling flange to approx. +100°C and push it on the shaft with the front surface at the shaft end
level.
3 Suspend the exchange unit with a hoist at the maintenance opening of the adapter or underneath the
adapter.
4 Fit the gasket (400.21) into the case cover (161.21).
5 Install the exchange unit in its place, lubricate the hexagon head screws (901.11) with Molycote Ti 1200
lubricant and tighten them in a cross bolt pattern little by little; first 30% of moment in Table 1, then 60% of
moment in Table 1 and then 100% of moment in Table 1. Finally tighten the screws screw by screw
clockwise with 100% of moment given in Table 1.
Table 1, Exchange unit fastening screws (901.11)
Moment (Nm)
Screw size
Rating Max. value
M12 50 60
M16 130 160
M20 250 300

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Moment (Nm)
Screw size
Rating Max. value
M24 420 520
6 Check the impeller clearance according to the Section ”Preventive maintenance”.
7 Place adjusting plates under the support foot. The plates must have the same thickness as the gap under
the support foot. Do not close the gap by tightening.
8 Fix the support foot (183.31) to the baseplate (890.61) with the hexagon head screws (901.62).
9 Lubricate the bearing unit with oil or grease according to lubricating instructions in Section ”Operation”.
10 Install the coupling spacer according to the coupling manufacturer’s instructions.
11 Fix the coupling guard jackets (686.51and 686.52). The coupling guard must be adjusted so that the space
between the coupling guard and motor is approx. 5 mm.
12 Install the auxiliary pipings, guards, accessories and sealing unit equipment according to sectional drawings.
WARNING
Proper adjustment of the coupling guard jacket is a relevant safety factor.
3 Wet end
3.1 Disassembly
Detachment of casing wear ring (pump types: APP and EPP / closed impeller)
The casing wear ring (502.11) between the closed impeller and volute casing and also the casing wear ring (502.12)
between the impeller and casing cover in the pump type EPP can be removed with a suitable tool by using the three
notches situated under the casing wear ring, Fig. 1.
Detachment of sideplate
1 Unscrew the three nuts (920.11).
2 Turn the potential adjusting screws (909.11) counter-clockwise. As a result the sideplate protrudes out.
3 The sideplate can now be removed with a proper tool from the volute casing. Fig. 1.

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16
250
2
40
25
Fig. 1
Detachment of impeller
1 Fasten the exchange unit firmly to a vice.
2 Unscrew the cap screw socket head (914.11) of the impeller (230.11).
3 Prevent the shaft (210.31) from rotating at the coupling (840.51) end.
4 Detach the impeller by turning it counter-clockwise. Push e.g. pieces of wood between the impeller vanes to
ease the detachment. Never use metal bars or the like, because they might damage the impeller vanes. Fig.
2.
Fig. 2
3.2 Reassembly
Installation of impeller
WARNING
The socket head screw (914.11) must be secured to avoid loosening of the impeller.

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NOTE
When installing the impeller and the sideplate, replace all O-rings with new ones.
1 Make sure that the o-rings behind the impeller are properly installed.
2 Prevent the shaft from rotating from the coupling end and insert the impeller (230.11) into its place. The
clearance between the impeller and case cover (161.21) is about 1.0 mm.
3 Lock the impeller with the socket head capscrew (914.11) onto which the o-ring (412.14) has been fitted.
4 Tighten the socket head screw to the torque value given in Table 2. Note the special values for the titanium
screws.
Table 2, Impeller locking screw 914.11
Titanium screws (76)

Torque (Nm)
Shaft size Screw size Torque (Nm)
Rating Max. value Rating Max. value
1 M10 30 40 18 22
2 M12 50 60 30 38
3 M16 130 140 70 92
4 M20 250 260 140 180
5 M24 420 440 250 310
6 M30 800 820 490 615
7 M36 1450 1500 850 1070
Secure the socket head capscrew (914.11) by bending its flange into one hole on the impeller. Use a tool
with the head shape and dimensions shown in Fig. 3.
The same socket head screw can be used many times. There are two extra holes on the impeller for
securing later on.

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L D
R
Shaft size L (mm) Ø D (mm) R (mm) Smin (mm)
0
1, 2 6.5 4 2 6
- 0.5
0
3, 4 7.5 6 3 7
- 0.5
0
5, 6, 7 9.0 8 4 8
- 0.5
Fig. 3
Installation of sideplate
APP, NPP, WPP
1 Grease the o-rings (412.11 and 412.13) lightly and fit them into the grooves of the sideplate (135.11).
2 Screw the adjusting screws (909.11) all the way into the sideplate.
3 Install the sideplate into the volute case (102.11).
4 Fix the nuts (920.11) to the adjusting screws.
A, Process pump
1 Grease the o-ring (412.11) lightly and fit it into the groove of the sideplate (135.11).
2 Grease the o-ring (412.12) lightly and fit it into the groove of the adjusting screws (909.11).
3 Screw the adjusting screws (909.11) all the way into the sideplate.
4 Install the sideplate into the volute case (102.11).

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5 Spread Loctite 577 paste (400.13) on the sideplate (135.11) of the low flow impeller just before the
installation of the exchange unit. Push the sideplate (135.11) against the case cover (161.21) by the
adjusting screws (909.11) and tighten the nuts (920.11).
6 Fix the nuts (920.11) to the adjusting screws.
Fixed sideplate of pump type EPP (open impeller)
1 Screw the studs (902.11) tightly into place in the sideplate.
2 Push the back-up rings (516.11) and o-rings (412.12) onto the studs against the sideplate.
3 Install the sideplate into place in the volute case (102.11).
4 Mount and tighten the nuts (920.11).
Installation of casing wear ring (pump types: APP and EPP / closed impeller)
Tap the casing wear ring (502.11) into the volute case (102.11) (and the wear ring (502.12) into the case cover
(161.21) of an EPP pump) with a soft hammer. Check that the wear ring is tightly against the bottom of its groove at
each side.
4 Sealing unit
4.1 Disassembly
CAUTION
The threaded hole in the casing cover is only meant for lifting the casing cover.
Dynamic seal, ring type (types DS11 and DS12)
1 Loosen the hexagon head screws (901.21) and remove the guards (683.21 and 683.22).
2 Unscrew the hexagon head screws (901.21).
3 Detach the case cover (161.21) by levering from the slot between the case cover and adapter (344.31). In
heavier casing covers, there is a threaded hole (size M8) for lifting the cover by using an eye screw. Detach
the gasket (400.22) or o-ring (412.23).
4 Remove the expeller (604.21) from the shaft.

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5 By using the hexagon head screws (901.21) as extractors, pull the stuffing box housing (451.21) out of the
guideway in the adapter. The stuffing box housing (451.21) with its incorporated parts will also come out.
6 Remove the shaft wearing sleeve (524.21) from the shaft.
7 Unscrew the nuts (920.21) and detach the thrust ring (475.21) from the stuffing box housing (451.21).
Detach the o-ring (412.24) from the thrust ring.
8 Remove the static seal (435.21) and o-rings (412.25) from the shaft wearing sleeve (524.21).
9 Unscrew the hexagon head screws (901.33) of the adapter and draw the adapter out by using the same
screws as extractors.
Dynamic seal, plate type (types DS13 and DS14)
2 Uncrew the hexagon head screws (901.21).
heavier case covers, there is a threaded hole (size M8) for lifting the cover by using an eye screw.
4 Detach the expeller (604.21) from the shaft.
5 By using the hexagon head screws (901.21) as extractors, draw the stuffing box housing (451.21) out of the
guiding in the adapter.
6 The cover plate for seal (471.21) and the static seal (435.21) can be detached by unscrewing the nuts
(920.21).
7 Unscrew the grub screws (904.21) and detach the thrust ring (475.21) from the shaft.
8 Unscrew the hexagonal screws (901.33) of the adapter and draw the adapter out by using the same screws
as extractors.
Mechanical seal, standard integrated single (types MS11 and MS12)
3 By using the said screws as extractors, draw the case cover (161.21) out of the adapter (344.31). In heavier
casing covers, there is a threaded hole (size M8) for lifting the cover by using an eye screw. The
components of the mechanical seal (433.21) come off the shaft.
4 Unscrew the hexagon head screws (901.22) of the case cover (161.21) and remove the seal ring (411.21).
5 The mechanical seal can now be removed from the case cover (161.21) and dismantled according to the
seal manufacturer's instructions.

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Mechanical seal, standard integrated double (type MS21, pump types A, APP, NPP and WPP)
4 Unscrew the hexagon head screws (901.22) of the case cover (161.21) and remove the seal ring (411.21).
6 Remove the rotating part on the atmospheric side of the mechanical seal (433.21) from the shaft by opening
the hexagonal retainer screws.
as extractors.
Mechanical seal, standard integrated double (type MS21, pump type EPP)
4 Unscrew the nuts (920.21) of the case cover (161.21).

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Mechanical seal, cartridge single on the shaft without shaft sleeve (types MS31, MS32 and
MS35)
3 Unscrew the nuts (920.21).
casing covers, there is a threaded hole (size M8) for lifting the cover by using an eye screw. All parts
belonging to the mechanical seal (433.21) will remain on the shaft.
5 The mechanical seal can now be removed from the shaft and from the casing cover and dismantled
according to the seal manufacturer's instructions.
Mechanical seal, cartridge single on the shaft sleeve (types MS33 and MS34)
case covers, there is a threaded hole (size M8) for lifting the cover by using an eye screw. All parts
6 Remove the shaft wearing sleeve (524.21) from the shaft with an extractor.
Mechanical seal, cartridge double on the shaft without shaft sleeve (type MS41)

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as extractors.
Mechanical seal, cartridge double on the shaft sleeve (type MS42)
casing covers, there is a threaded hole (size M8) for lifting the cover by using an eye screw. All parts
Mechanical seal, element single (types MS51 and MS52)
Mechanical seal, element double (type MS61)

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Mechanical seal, ready-fitted single (types MS71 and MS72)
Mechanical seal, ready-fitted double (type MS81)

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Mechanical seal, US, outside single (type MS91)
case covers, there is a threaded hole (size M8) for lifting the cover by using an eye screw.
4 The rotating part of the mechanical seal (433.21) will remain on the shaft.
5 The cover plate for seal (471.21) and the static part of the mechanical seal can be detached from the case
cover by unscrewing the screws (914.21).
6 The rotating part can now be removed from the shaft and dismantled according to the seal manufacturer's
instructions.
Gland packing (type PG11)
2 Unscrew the hexagon head screws (901.21) of the case cover (161.21).
belonging to the gland packing, except the shaft wearing sleeve (524.21), will stay in the casing cover.
4 Unscrew the nuts (920.21) and remove the two-piece stuffing box gland (452.21). The neck bush (456.21),
gland packing (461.21) and lantern ring (458.21) can now be drawn out of the casing cover.
Liquid ring pump, standard integrated single (type LM11)
1 Detach the pipe (700.23) with the peripheral equipment from the case (100.21) if a vacuum relief valve
(695.21) is included in the delivery.

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3 Remove the case cover (161.21) by levering from the slot between the case cover and adapter (344.31).
4 Remove the o-ring (412.23) from the case (100.21).
5 Remove the suction impeller (231.21) from the shaft. Notice the compressor rings (487.21) between the
suction impeller and mechanical seal (433.21).
6 Remove the o-rings (412.21 and 412.22).
7 Remove the rotating part on the product side of the mechanical seal from the shaft.
8 Pull the case (100.21) out of the guideway in the adapter (344.31) with the help of hexagon head screws
(901.21).The static parts of the mechanical seal (433.21) will follow.
9 Unscrew the hexagon head screw (901.22) of the case (100.21). Remove the seal ring (411.21).
10 The mechanical seal can now be removed from the case (100.21) and dismantled according to the seal
manufacturer's instructions.
Liquid ring pump, standard integrated double (type LM21)
5 Remove the suction impeller (231.21) from the shaft.
6 Remove the o-rings (412.21 and 412.22).
7 Remove the rotating part on the product side of the mechanical seal from the shaft.
(901.21). The static parts of the mechanical seal (433.21) will follow.
9 Unscrew the hexagon head screw (901.22) of the case (100.21). Remove the seal ring (411.21).
10 The mechanical seal can now be removed from the case (100.21) and dismantled according to the seal
manufacturer's instructions.

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INSTRUCTIONS ISO
Liquid ring pump, element single (type SM11)
5 Remove the suction impeller (231.21) from the shaft. Pull the shaft wearing sleeve (524.21) from the shaft.
The rotating part of the mechanical seal (433.21) will come off, too, and the static part will remain in the
cover plate for seal. Notice the compressor rings (487.21) between the suction impeller and shaft wearing
sleeve.
6 Pull the case (100.21) out of the guideway in the adapter with the help of hexagon head screws (901.21).
Detach the cover plate for seal (471.21) by unscrewing the socket head capscrews (914.21).
7 The rotating part of the mechanical seal can now be removed from the shaft wearing sleeve and the static
part from the cover plate for seal. Make sure not to damage the sliding surfaces.
Liquid ring pump, ready-fitted double (type SM21)
3 Detach the case cover (161.21) by levering from the slot between the case cover and adapter (344.31).
5 Remove the suction impeller (231.21) from the shaft. The rotating part on the product side of the mechanical
seal (433.21) will come off, too, and the static part will remain in the case. Notice the compressor rings
(487.21) between the suction impeller and mechanical seal.
(901.21).
7 The static part of the mechanical seal is detached from the case (100.21) by unscrewing the socket head
capscrews (914.21).

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INSTRUCTIONS ISO
8 The rotating part on the atmospheric side of the mechanical seal can be removed from the shaft by opening
Air separating pump, element single (type RM11)
1 Open the two hexagon head screws (901.21) of the case cover (161.21).
2 By using the above mentioned screws as extractors, push the case cover (161.21) and cover (160.21) out of
the stuffing box housing (451.21).The gasket (400.23) may be replaced if needed.
3 The case cover and cover may be detached from each other, so that the condition of the o-ring (412.23) and
the gasket (400.23) may be checked and replaced if needed.
4 Pull the expeller (235.21) off the shaft by levering against the stuffing box housing. The rotating parts of the
mechanical seal (433.21) follow with the expeller.
5 Special care should be taken not to damage the sliding surfaces of the mechanical seal. The mechanical
seal can be removed from the expeller by detaching the locking screws of the seal.
6 Unscrew the nuts (920.22) of the stuffing box housing (451.21) and lever the stuffing box housing out of the
bearing housing (330.31) guide using the two slots at the interface of the bearing housing.
7 The stationary seat of the mechanical seal (433.21) can be removed from the stuffing box housing. Special
care should be taken not to damage the sliding surfaces of the seal.
Gas separator, standard integrated single (types GM11 and GM12)
2 Detach the case cover (161.21) by levering from the slot between the casing cover and adapter (344.31). In
heavier case covers, there is a threaded hole (size M8) for lifting the cover by using an eye screw. Detach
4 By using the hexagonal screws (901.21) as extractors, pull the stuffing box housing (451.21) out of the
guideway in the adapter. The stuffing box housing (451.21) with its incorporated parts will also push all
components off the shaft.
5 Unscrew the hexagon head screw (901.22) of the stuffing box housing (451.21). Remove the seal ring
(411.21).
6 The static parts of the mechanical seal (433.21) can now be removed from the case cover (161.21).

Series 2.15 Page
INSTRUCTIONS ISO
Gas separator, standard integrated double (types GM21 and GM22)
guideway in the adapter. The stuffing box housing (451.21) with its incorporated parts will also push all
components off the shaft.
5 Unscrew the hexagon head screw (901.22) of the stuffing box housing (451.21). Remove the seal ring
(411.21).
6 The static parts of the mechanical seal (433.21) can now be removed from the stuffing box housing (451.21).
Gas separator, static seal (types GS11 and GS12)
guideway in the adapter. The stuffing box housing (451.21) with its incorporated parts will also come out.
6 Remove the shaft wearing sleeve (524.21) from the shaft.
7 Unscrew the nuts (920.21) and detach the thrust ring (475.21) from the stuffing box housing (451.21).
Detach the o-ring (412.24) from the thrust ring.
8 Remove the static seal (435.21) and o-rings (412.25) from the thrust ring (475.21).

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INSTRUCTIONS ISO
4.2 Reassembly
Dynamic seal, ring type (types DS11 and DS12)
1 Fix the adapter (344.31) to the bearing housing (330.31) with the hexagon head screws (901.33).
2 Grease the o-ring (412.25) slightly and place it into the groove of the static seal (435.21). Push the static seal
(435.21) to the thrust ring (475.21).
3 Grease the o-ring (412.24) slightly and place it into its proper groove in the thrust ring (475.21). Place the
thrust ring (475.21) on the stuffing box housing (451.21) and fix it with the studs (902.21) and nuts (920.21).
Do not tighten the nuts.
4 Push the shaft wearing sleeve (524.21) onto the shaft against the shoulder.
5 Push the stuffing box housing with its parts into its place in the adapter (344.31).
6 Grease the o-ring (412.22) slightly and place it into its proper groove in the expeller (604.21). Place the o-
ring (412.21) in the middle of the expeller and push the expeller onto the shaft.
7 Mount the gasket (400.22) or o-ring (412.23) into its place in the stuffing box housing (451.21).
8 Push the case cover (161.21) into its place in the adapter (344.31) and fasten the hexagon head screws
(901.21). Continue the assembly according to the following section ”Installation of impeller”.
9 When the exchange unit is fully assembled, pull the thrust ring (475.21) and the static seal (435.21) against
the shaft wearing sleeve (524.21). The assembly groove (3 mm x 0.5 mm) in the thrust ring comes out 0.5
mm from the stuffing box housing end. Tighten the nuts (920.21) by hand so that the thrust ring is precisely
aligned with the shaft. Tighten the locking nuts. The distance between the face of the case cover and the
thrust ring is according to Fig. 4.
10 Loosen the hexagon head screws (901.21) and mount the guards (683.21 and 683.22). Tighten the screws.
Shaft size D (mm)

1 17
2 17

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INSTRUCTIONS ISO
Shaft size D (mm)

3 20
4 20
5 24
6 24
Fig. 4
Dynamic seal, plate type (types DS13 and DS14)
2 Slide the thrust ring (475.21) with its o-ring (412.25) and grub screws (904.21) along the shaft to a
preliminary position up to the hindmost shoulder.
3 Install the o-ring (412.24), static seal (435.21) and cover plate for seal (471.21) into the stuffing box housing
(451.21) by using studs (902.21) and nuts (920.21). Observe that the static seal must be placed in the right
way and centrally in its guiding slot in the stuffing box housing.
4 Push the stuffing box housing with its parts into its place in the adapter.
5 Push the expeller (604.21) with the o-rings (412.21, 412.22) fitted in its hub onto the shaft.
6 Install the gasket (400.22) into the stuffing box housing or the o-ring (412.23) into the case cover (161.21).
7 Push the case cover into its place in the adapter and fasten the hexagon head screws (901.21). Continue the
assembly according to the following section "Installation of impeller".
8 When the exchange unit is fully assembled, place the thrust ring (475.21) at the right position on the shaft
and fasten the grub screws (904.21). The distance between the face of the cover plate for seal and the
shoulder of the thrust ring must be 10 mm. Fig. 5.
10 mm
471.21
475.21
Fig. 5

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INSTRUCTIONS ISO
Mechanical seal, standard integrated single (types MS11 and MS12)
2 Push the static part of the mechanical seal (433.21) into the case cover (161.21) by means of the installation
sleeve.
3 Push the seal ring (411.21) onto the hexagon head screw (901.22).
4 Mount the static part of the mechanical seal (433.21) with the hexagon head screw (901.22).
5 Push the case cover (161.21) together with the incorporated parts onto the adapter (344.31). Fix the screws
(901.21, 901.22).
6 Push the rotating part of the mechanical seal onto the shaft against the shoulder. Continue the assembly
according to the following section ”Installation of impeller”.
Mechanical seal, standard integrated double (type MS21, pump types A, APP, NPP and WPP)
2 Mount the rotating part on the atmospheric side of the mechanical seal (433.21) onto the shaft against the
shoulder.
sleeve.
4 Push the seal ring (411.21) onto the hexagon head screw (901.22).
5 Mount the static part of the mechanical seal (433.21) with hexagon head screw (901.22).
(901.21).
7 Push the rotating part of the mechanical seal (433.21) onto the shaft against the shoulder. Continue the
assembly according to the following section ”Installation of impeller”.
Mechanical seal, standard integrated double (type MS21, pump type EPP)
shoulder.
3 Install the static part of the mechanical seal (433.21) into the case cover (161.21).

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INSTRUCTIONS ISO
4 Mount the static part of the mechanical seal (433.21) with studs (902.21), washers (554.21) and nuts
(901.21).
(901.21).
6 Push the rotating part of the mechanical seal (433.21) onto the shaft against the shoulder. Continue the
assembly according to the following section ”Installation of impeller”.
Mechanical seal, cartridge single on the shaft without shaft sleeve (types MS31, MS32 and
MS35)
2 Mount the mechanical seal (433.21) into the case cover (161.21). Follow the instructions provided by the
seal manufacturer.
3 Push the case cover (161.21) together with the incorporated parts onto the shaft. Follow the instructions
provided by the seal manufacturer. Fix the screws (901.21). Tighten the nuts (920.21).
4 Complete all the lockings, fixings and other seal-related jobs as described in the seal manufacturer's
instructions. Continue the assembly according to the following section ”Installation of impeller”.
Mechanical seal, cartridge single on the shaft sleeve (types MS33 and MS34)
seal manufacturer.
3 Push the shaft wearing sleeve (524.21) onto the shaft.
Mechanical seal, cartridge double on the shaft without shaft sleeve (type MS41)

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INSTRUCTIONS ISO
seal manufacturer.
Mechanical seal, cartridge double on the shaft sleeve (type MS42)
1 Fix the adapter (344.31) to the bearing housing (330.31) with the hexagon head screw (901.33).
seal manufacturer.
3 Push the shaft wearing sleeve (524.21) onto the shaft.
Mechanical seal, element single (types MS51 and MS52)
2 Mount the mechanical seal (433.21) parts into the cover plate for seal (471.21) and onto the shaft wearing
sleeve (524.21) according to the seal manufacturer's instructions. Make sure that the cylinder pin (562.22) is
in the proper position.
3 Place the gasket (400.23) in the cover plate for seal (471.21). Fix the cover plate for seal on the case cover
(161.21) with the flange (723.21). Tighten the nuts (920.21).
4 Push the case cover (161.21) together with the incorporated parts onto the shaft. Fix the screws (901.21).
5 Push the shaft wearing sleeve (524.21) together with the incorporated parts onto the shaft against the
shoulder. Continue the assembly according to the following section ”Installation of impeller”.
Mechanical seal, element double (type MS61)

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INSTRUCTIONS ISO
2 Mount the mechanical seal (433.22) onto the shaft against the shoulder.
3 Mount the mechanical seal (433.21 and 433.22) parts into the cover plate for seal (471.21) and onto the
shaft wearing sleeve (524.21) according to the seal manufacturer's instructions. Make sure that the cylinder
pins (562.22 and 562.23) are in the proper position.
4 Place the gasket (400.23) in the cover plate for seal (471.21). Fix the cover plate for seal on the case cover
(161.21) with the nuts (920.21).
6 Push the shaft wearing sleeve (524.21) together with the incorporated parts onto the shaft against the
shoulder. Continue the assembly according to the following section ”Installation of impeller”.
Mechanical seal, ready-fitted single (types MS71 and MS72)
2 Install the gasket (400.21) if included in the delivery
3 Mount the static part of the mechanical seal (433.21) into the case cover (161.21), and the outer rotating part
onto the shaft according to the seal manufacturer’s instructions. Tighten the nuts (920.21).
Mechanical seal, ready-fitted double (type MS81)
2 Install the gasket (400.21) if included in the delivery.
3 Mount the static part of the mechanical seal (433.21) into the case cover (161.21), and the outer rotating part
onto the shaft according to the seal manufacturer’s instructions. Tighten the nuts (920.21).
Mechanical seal, US, outside single (type MS91)

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INSTRUCTIONS ISO
2 Mount the static part of the mechanical seal (433.21) into the case cover (161.21) with the cover plate for
seal (471.21). Follow the instructions provided by the seal manufacturer. Tighten the socket head capscrews
(914.21).
4 Push the rotating part of the mechanical seal (433.21) almost to its proper place on the shaft wearing sleeve.
Follow the instructions provided by the seal manufacturer.
6 Mount the mechanical seal (433.21) into its final place according to the seal manufacturer's instructions.
Complete all the lockings, fixings etc. as described in the manufacturer's instructions. Continue the assembly
Gland packing (type PG11)
2 Place the case cover (161.21) on a horizontal surface with the sealing cavity upwards.
3 Place the neck bush (456.21) to the bottom of the sealing cavity.
4 Put the shaft wearing sleeve (524.21) in an upright position to the middle of the sealing cavity.
5 Insert the first two gland packings (461.21), the lantern ring (458.21), the other two gland packings and the
two-piece stuffing box gland (452.21). Tighten the nuts (920.21) by hand.
6 Push the casing cover with gland packing parts onto the shaft. Check that the shaft wearing sleeve is placed
towards the shaft shoulder.
7 Attach the case cover to the adapter with hexagon head screws (901.21). Continue the assembly according
to the following section ”Installation of impeller”.
Liquid ring pump, standard integrated single (type LM11)
2 Push the case (100.21) into its guideway into the adapter (344.31). Fix the hexagon head screws (901.21).
3 Put the series of compressor rings (487.21) onto the shaft.
4 Push the rotating part of the mechanical seal (433.21) onto the shaft against the shoulder.
5 Push the suction impeller (231.21) onto the shaft. Do not insert the o-ring (412.21) at this stage.

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INSTRUCTIONS ISO
6 Measure the gap between the suction impeller (231.21) and case (100.21), and adjust it according to Table 3
by taking off or adding compressor rings (487.21). While measuring the gap, make sure that both the casing
and the suction impeller are tightly in their guideway pressed all the way to the bottom. Measure the gap
between the end of the suction impeller hub and the casing because the front face of the vanes is slightly
conical.
Table 3, Gap between the suction impeller and casing
Shaft size Gap (mm)

1 0.2 - 0.3
2 0.2 - 0.3
3 0.2 - 0.3
4 0.25 - 0.35
5 0.3 – 0.4
6 0.3 – 0.4
7 After adjusting the gap, remove the parts again so as to perform the actual assembly.
8 Push the static part of the mechanical seal (433.21) into the case (100.21) by means of the installation
sleeve. Follow the instructions provided by the seal manufacturer.
9 Place the seal ring (411.21) onto the hexagon head screw (901.22) and mount the static part of the
mechanical seal (433.21) using this screw.
11 Push the compressor rings (487.21) onto the shaft against the shoulder.
12 Push the rotating part of the mechanical seal (433.21) onto the shaft.
13 Grease the o-ring (412.22) slightly and place it into its proper groove in the suction impeller (231.21). Push
the suction impeller onto the shaft.
14 Push the cylinder pin (562.21) into its hole in the case (100.21).
15 Place the o-ring (412.23) into its groove in the case.
16 Install the case cover (161.21) into its guideway into the adapter (344.31). Tighten the hexagon head screws
Liquid ring pump, standard integrated double (type LM21)
3 Put the series of compressor rings (487.21) onto the shaft.

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INSTRUCTIONS ISO
by taking off or adding compressor rings (487.21). While measuring the gap, make sure that both the casing
between the end of the suction impeller hub and the casing because the front face of the vanes is slightly
conical.
shoulder.
10 Place the seal ring (411.21) onto the hexagon head screw (901.22) and mount the static part of the
mechanical seal (433.21) using this screw.
12 Push the compressor rings (487.21) onto the shaft against the shoulder.
13 Push the rotating part of the mechanical seal (433.21) onto the shaft.
14 Grease the o-ring (412.22) slightly and place it into its proper groove in the suction impeller (231.21). Push
the suction impeller onto the shaft.
16 Place the o-ring (412.23) into its groove in the case.
Liquid ring pump, element single (type SM11)
1 Fix the adapter (344.31) into the bearing housing (330.31) with hexagonal screws (901.33).
2 Push the case (100.21) into its guideway into the adapter (344.31).
3 First, push the shaft wearing sleeve (524.21) and then the series of compressor rings (487.21) onto the
shaft.
4 Push the suction impeller (231.21) onto the shaft. Do not install the o-rings (412.21), the parts of the
mechanical seal (433.21) nor the cover plate for seal (471.21) yet.
by taking off or adding compressor rings (487.21). While measuring the gap, make sure that both the case
and the suction impeller are tightly in their guideway pressed all the way to the bottom.

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INSTRUCTIONS ISO
Measure the gap between the end of the suction impeller hub and the case. The gap is bigger at the vanes
of the suction impeller, since the front face of the vanes is slightly conical.
Once the gap between the suction impeller and case is correct, the gap between the suction impeller and the
case cover (161.21) will also become automatically correct.
6 After adjusting the gap, remove the suction impeller, shaft wearing sleeve and case again so as to perform
the actual assembly.
7 Fasten the cylinder pins (562.22 and 562.21) into the cover plate for seal (471.21) and case (100.21).
8 Install the static part of the mechanical seal (433.21) into the cover plate for seal (471.21). Make sure that
the position of the static part in relation to the cylinder pin is correct. Place the o-ring (412.24) into the groove
in the cover plate for seal. Install the cover plate for seal into the case (100.21) with socket head capscrews
(914.21).
9 Install the case (100.21) with its parts into its guideway into the adapter (344.31).
10 Install the rotating part of the mechanical seal (433.21) into place into the shaft wearing sleeve (524.21) and
push the shaft wearing sleeve onto the shaft.
11 Install the needed the compressor rings (487.21) onto the shaft.
12 Place the o-ring (412.21) into its groove and then push the suction impeller (231.21) onto the shaft.
13 Install the o-ring (412.23) into its groove in the case (100.21).
14 Install the case cover (161.21) into its guideway into the adapter (344.31). Make sure that the cylinder pin
(562.21) goes into its hole in the case cover. Fix the screws (901.21). Continue the assembly according to
the following section ”Installation of impeller”.
Liquid ring pump, ready-fitted double (type SM21)
1 Fix the adapter (344.31) into the bearing housing (330.31) with hexagonal screws (901.33).
3 Push the inner rotating part of the mechanical seal (433.21) on the shaft against the shoulder. Remove the
o-ring from the periphery of the part.
4 Put the series of compressor rings (487.21) onto the shaft against the front face of the part of the mechanical
seal.

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INSTRUCTIONS ISO
by taking off or adding compressor rings (487.21). While measuring the gap, make sure that both the case
between the end of the suction impeller hub and the case because the front face of the vanes is slightly
conical.
8 Push the outer rotating part of the mechanical seal onto the shaft against the shoulder.
9 Install the static part of the mechanical seal into the case (100.21). Fasten the socket head capscrews
(914.21).
11 Push the inner rotating part of the mechanical seal (433.21) onto the shaft. Put the o-ring (which was
removed in item 3) back into its groove to the periphery of the part.
12 Push the compressor rings (487.21) onto the shaft against the front face of the part of the mechanical seal.
13 Place the o-ring (412.21) into its groove inside the suction impeller and then push the suction impeller
(231.21) onto the shaft.
15 Place the o-ring (412.23) into its groove in the case (100.21).
Air separating pump, element single (type RM11)
1 Press the stationary seat of the mechanical seal (433.21) with its o-ring into the adapter (344.31) without
damaging the sliding surface of the seal.
2 Fix the stuffing box housing (451.21) to the bearing housing (330.31) with the nuts (920.22) of the studs
(902.22). Do not damage the sliding surface of the seal.
3 Fix the rotating part of the mechanical seal (433.21) on the expeller (235.21), making sure it fits tightly
against the shoulder and lock it with the locking screws of the seal. The sliding surfaces must not be
damaged.
4 Push the expeller with seal onto the shaft.
5 Fit the o-ring (412.23) on the cover (160.21).
6 Fit the gaskets (400.23) in their places between the cover (160.21) and the case cover (161.21) and between
the cover (160) and the stuffing box housing (451.21).

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INSTRUCTIONS ISO
7 Fix the combination of cover and case cover to the adapter with hexagon head screws (901.21). Continue
the assembly according to the following section ”Installation of impeller”.
Gas separator, standard integrated single (types GM11 and GM12)
3 Place the seal ring (411.21) onto the hexagon head screw (901.22). Mount the static part of the mechanical
seal (433.21) to the stuffing box housing (451.21) using the screw.
7 Install the gasket (400.22) or o-ring (412.23) into its place in the stuffing box housing (451.21).
Gas separator, standard integrated double (types GM21 and GM22)
2 Mount the rotating part on the atmospheric side of the mechanical seal (433.21) against the shaft sleeve.
4 Place the seal ring (411.21) onto the hexagon head screw (901.22). Mount the static part of the mechanical
seal (433.21) to the stuffing box housing (451.21) using the screw.
8 Install the gasket (400.22) or o-ring (412.23) into its place in the stuffing box housing (451.21).

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INSTRUCTIONS ISO
Gas separator, static seal (types GS11 and GS12)
2 Grease the o-ring (412.25) slightly and place it into the groove of the static seal (435.21). Push the static seal
(435.21) to the thrust ring (475.21).
3 Grease the o-ring (412.24) slightly and place it into its proper groove in the thrust ring (475.21). Place the
thrust ring (475.21) on the stuffing box housing (451.21) and fix it with the studs (902.21) and nuts (920.21).
Do not tighten the nuts.
7 Mount the gasket (400.22) or o-ring (412.23) into its place in the stuffing box housing (451.21).
9 When the exchange unit is fully assembled, pull the thrust ring (475.21) and the static seal (435.21) against
the shaft wearing sleeve (524.21). The assembly groove (3 mm x 0.5 mm) at the thrust ring comes out 0.5
mm from stuffing box housing end. Tighten the nuts (920.21) by hand so that the thrust ring is precisely
aligned with the shaft. Tighten the locking nuts. The distance between the face of the casing cover and the
thrust ring is according to Fig. 6.
Shaft size D (mm)

1 17
2 17
3 20
4 20

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INSTRUCTIONS ISO
Shaft size D (mm)

5 24
6 24
Fig. 6
5 Bearing unit
NOTE
The bearing unit may be grease-lubricated, splash oil lubricated or bath oil lubricated.
5.1 Disassembly
NOTE
Always renew the bearings once they have been removed from the shaft.
1 Fasten the bearing unit firmly to a vice at the bearing housing (330.31).
2 Detach the coupling (840.51) using an extractor.
3 Unscrew the hexagon head screws (901.31) and washers (554.31) of the bearing cover (360.31). Remove
the guard end (685.51).
4 Draw the bearing cover out by using the hexagon head screws (901.31). As a result, the deflector (507.31)
will also come off.
5 Strike the pump side end of the shaft (210.31) with a soft hammer, where upon the shaft with its bearings will
come off the bearing housing. Simultaneously the other deflector (507.31) also comes off. Note that the lugs
in the oil ring (644.31, not in the bath oil lubricated bearing) should fit into the grooves in the bearing housing
(330.31).
6 Fasten the shaft with its bearings to a vice and detach the bearing nut (923.31) and lockwasher (931.31).
7 Detach the antifriction bearings (320.31 and, 320.32) and oil ring (644.31, not in the bath oil lubricated
bearing) from the shaft with an extractor or by means of a hammer and a punch.
5.2 Reassembly

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INSTRUCTIONS ISO
NOTE
It is absolutely necessary to place the bearings correctly according to the O-system (so called Back-
To-Back-Design).
1 Inspect the shaft (210.31) with its shaft wearing sleeve (524.21) using a measuring tool for radial run-out.
The radial run-out between these parts may not exceed 0.05 mm.
2 Fasten the shaft to a vice with the impeller end of the shaft upwards. Use soft sheets between the vice clamp
jaws to avoid shaft damage. Use a punch to push the oil ring (644.31, not in the bath oil lubricated bearing)
onto the shaft. Heat the cylinder roller bearing (320.31) (deep groove ball bearing on shaft size 7) to ca
+100°C and push it onto the shaft. Remember to place the spacer ring of the bearing on the shaft shoulder
side. Fig. 7.
L
ØD
Ød
Shaft size (mm) 1 2 3 4 5 6 7

Ød 37 47 57 67 87 105 125
ØD 50 60 71 80 100 115 135
Lmin 185 205 220 280 320 360 400
Fig. 7
3 Let the bearing cool down. Then tap it tightly by the inner ring against the shoulder using a pipe punch.
Rotate the pipe punch between the blows.

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INSTRUCTIONS ISO
4 Turn the shaft so that the coupling side is upwards, fasten it to a vice.
5 Heat the two angular contact ball bearings (320.32) to approx. +100°C and push them onto the shaft. Let the
bearings cool down.
6 Place the lockwasher (931.31) on the shaft.
7 Tighten the angular contact ball bearings by means of the bearing nut (923.31) tightly against the shaft
shoulder, use a suitable hooked wrench.
8 Bend the lockwasher tooth into the bearing nut slots.
9 Tighten the bearing housing (330.31) vertically to the vice with the coupling side upwards.
10 Grease the O-rings (412.32) of the labyrinth rings (423.31) lightly and stretch them into their grooves. Tap
the labyrinth rings (423.31) with a soft mallet into the bearing housing (330.31) and bearing cover (360.31).
Note that the drain holes in the labyrinth rings come underneath.
11 Heat the bearing housing first slightly (max. +80°C) to ease the installation of the shaft unit.
12 Lower the shaft carefully into the bearing housing. Make sure not to damage the labyrinth ring in the bearing
housing. Note that the lugs in the oil ring (644.31, not in the bath oil lubricated bearing) should fit into the
grooves in the bearing housing (330.31).
13 Grease the o-ring (412.31) of the bearing cover lightly and stretch it into its groove.
14 Set the bearing cover into its place. Note that the drain holes in the labyrinth ring come underneath. Place
the guard end (685.51) on the bearing cover, mount the washers (554.31) and fix it with the hexagon head
screws (901.31) into the bearing housing. Tighten the hexagonal screws of the bearing cover.
15 Place the deflectors (507.31) with care onto the shaft by using e.g. a special pipe punch shown in Fig. 8.
Grease the rubber lip before installation.

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INSTRUCTIONS ISO
Fig. 8
Tool Coupling side Impeller side

Tolerance +0,2 +0,4 +-0,1 +0,2 +0,4 +-0,1
Bearing B Alpha L L2 C1 C2 C3 C4 P1 P2 P3 P4
1 53 160 160 106 24 37 2 3,5 30 37 2 0,5

Series 2.15 Page
INSTRUCTIONS ISO
2 60 160 180 120 32 47 1,3 3 40 47 2 0,5

3 70 160 195 120 42 57 2 3 50 57 2 0,5
4 80 160 250 160 48 67 2,2 3 60 66 2,2 0,5
5 110 160 290 170 75 86 0 3 80 86 1,5 1
6 120 - 320 - 90 102 6 3 90 102 2 1
7 158 - 360 - 110 121 2 3 110 121 1,7 1
Coupling Side Impeller Side

Shaft Size
Ød ØD Ød ØD
1 24 35 30 35
2 32 45 40 45
3 42 55 50 55
4 48 65 60 65
5 75 85 70 85
6 90 100 80 100
7 110 120 90 120

SERIES 2.15
SPP id: 110901 / en / N31575 / 1
AHLSTAR
PROCESS PUMPS
1 Recommended spare parts

Series 2.15 Page
INSTRUCTIONS ISO
SPP id: 110901 / en / N31575 / 1 / Page 2 (3)
1 Recommended spare parts
To avoid long and expensive outages, we recommend that the following spare parts be kept in store preferably as
spare part units, spare part kits and maintenance kits rather than as individual parts. The number of spare parts is
evaluated for two year’s use in normal operating conditions, Table 1 - Table 4.
1.1 Wet end

Table 1, Spare parts recommendation (APP, EPP, NPP, WPP)
Number of identical parts and units in various pumps
6 8
WEEN.1 Wet end 1 2 3 4 5 >10
7 9
Number of recommended spare parts
Spare part kit 1 1 1 1 2 2 3 30 %
Service kit 2 4 6 8 8 9 12 150 %
102.11 Volute case 1 10 %
135.11 Sideplate 1 1 1 1 2 2 3 30 %
230.11 Impeller 1 1 1 1 2 2 3 30 %
502.11 Casing wear ring 1 2 2 2 3 3 4 50 %
412 O-rings 2 4 6 8 8 9 10 100 %
Refer to the parts lists of the pumps when estimating the number of needed spare parts.
Table 2, Spare parts recommendation (A, Process pump)

6 8
WEEN.1 Wet end 1 2 3 4 5 >10
7 9
Spare part kit 1 1 1 1 2 2 3 30 %
Service kit 2 4 6 8 8 9 12 150 %
102.11 Volute case 1 10 %
135.11 Sideplate 1 1 1 1 2 2 3 30 %
230.11 Impeller 1 1 1 1 2 2 3 30 %
412 O-rings 2 4 6 8 8 9 10 100 %
1.2 Sealing unit

Table 3, Spare parts recommendation
6 8
SEUN.2 Sealing unit 1 2 3 4 5 >10
7 9
Spare part kit 1 2 3 4 5 6 7 90 %
Service kit 2 4 6 8 8 9 12 150 %
100.21 Case 1 10 %
161.21 Case cover 1 10 %
231.21 Suction impeller 1 1 1 1 2 2 3 30 %
400 Gaskets 2 4 6 8 8 9 12 150 %
412 O-rings 2 4 6 8 8 9 10 100 %
433.21 Mechanical seal 1 2 3 4 5 6 7 90 %
435.21 Static seal 1 2 3 4 5 6 7 90 %

Series 2.15 Page
INSTRUCTIONS ISO
SPP id: 110901 / en / N31575 / 1 / Page 3 (3)

6 8
SEUN.2 Sealing unit 1 2 3 4 5 >10
7 9
451.21 Stuffing box housing 1 10 %
452.21 Stuffing box gland 1 10 %
456.21 Neck bush 1 10 %
458.21 Lantern ring 1 10 %
461.21 Gland packing 24 32 400 %
475.21 Thrust ring 1 2 3 4 5 6 7 90 %
487.21 Compressor ring 1 10 %
524.21 Shaft wearing sleeve 1 2 2 2 3 3 4 50 %
542.21 Throttle bushing 1 10 %
604.21 Expeller 1 1 1 1 2 2 3 30 %
1.3 Bearing unit

Table 4, Spare parts recommendation
6 8
BEUN.3 Bearing unit 1 2 3 4 5 >10
7 9
Spare part kit 1 1 1 2 2 3 4 50 %
Service kit 2 4 6 8 8 9 10 100 %
183.31 Support foot 1 10 %
210.31 Shaft 1 1 1 2 2 2 3 30 %
320.31 Antifriction bearing 1 1 1 2 2 3 4 50 %
320.32 Antifriction bearing 2 4 6 8 50 %
330.31 Bearing housing 1 10 %
344.31 Adapter 1 10 %
412 O-rings 2 4 6 8 8 9 10 100 %
423 Labyrinth ring 1 10 %
507.31 Deflector 4 8 8 10 100 %
923.31 Bearing nut 1 1 1 2 2 2 3 30 %
931.31 Lockwasher 1 1 1 2 2 2 3 30 %
940.31 Key 1 1 1 2 2 2 3 30 %

SPP id: 151022 / Replaces 111220 / en / C10151 / 5
1 (27)
20000461en
John Crane Safematic Oy

P.O. Box 10
FI-40951 MUURAME, FINLAND
Tel. +358 10 8525 611 Fax: +358 10 8525 600
E-mail: safematic@johncrane.fi
Internet: www.johncrane.com
INSTALLATION AND OPERATION INSTRUCTIONS, EN
No. 20000461
Date 23.6.2008
Revision no. 2
Revision date 30.4.2013
UP
AHLSTAR PUMP
SEALS JCS1, JCS1F, JCS1G, JCS1A, JCS2P, JCS2AP AND JCS2EP
Should you have any questions about the products, please get in touch with the nearest supplier or a
representative of John Crane Safematic Oy.
A part of Smiths Group plc VAT reg. No. FI10985536

Residence: Muurame
Business Identity Code: 1098553-6
INSTALLATION AND OPERATION 2 (27)
INSTRUCTION
20000461en
CONTENTS
1 GENERAL DESCRIPTIONS ....................................................................................................................... 4

1.1 JCS1 seal .................................................................................................................................................... 4
1.2 JCS1F seal .................................................................................................................................................. 4
1.3 JCS1G seal ................................................................................................................................................. 4
1.4 JCS1A seal ................................................................................................................................................. 4
1.5 JCS2P seal .................................................................................................................................................. 5
1.6 JCS2AP seal ............................................................................................................................................... 5
1.7 JCS2EP seal ............................................................................................................................................... 5
2 SAFETY ....................................................................................................................................................... 5
3 STORAGE ................................................................................................................................................... 5
4 MATERIALS AND DESIGN ........................................................................................................................ 6

1. Table Tightening torque values................................................................................................................. 6
5 INFORMATION ON OPERATING CONDITIONS ....................................................................................... 6
5.1 JCS1, JCS1F, JCS1G and JCS1A seal ..................................................................................................... 6
2. Table Permissible seal operating conditions. ........................................................................................... 7
5.2 JCS2P, JCS2AP and JCS2EP seal ........................................................................................................... 7
3. Table Permissible seal operating conditions. ........................................................................................... 7
4. Table SmartFlow IG operation with JCS2P and JCS2AP seals. ............................................................... 7
5. Table Recommended sealant fluid quality values..................................................................................... 8
6 INSTALLATION........................................................................................................................................... 8
6.1 Preparations ............................................................................................................................................... 8
6.2 Installation of JCS1 and JCS1F seals ...................................................................................................... 9
6.3 Installation of JCS1G seal ....................................................................................................................... 11
6.4 Installation of JCS1A seal ....................................................................................................................... 13
6.5 Installation of JCS2P seal ....................................................................................................................... 15
6.6 Installation of JCS2AP seal..................................................................................................................... 17
6.7 Installation of JCS2EP seal ..................................................................................................................... 20
7 DETACHING.............................................................................................................................................. 21
7.1 Detaching JCS1, JCS1G and JCS1F seals ............................................................................................ 23
7.2 Detaching JCS1A seal ............................................................................................................................. 23
7.3 Detaching JCS2P seal ............................................................................................................................. 23
7.4 Detaching JCS2AP seal........................................................................................................................... 23
7.5 Detaching JCS2EP seal ........................................................................................................................... 23
8 ADJUSTMENT AND CONTROL ............................................................................................................... 24
8.1 Flush water control and monitoring for the JCS1F and JCS1A seals’ stuffing box ......................... 24
6. Table Use with Safeunit Ultima. .............................................................................................................. 24
8.2 Seal fluid control and monitoring for the JCS2P and JCS2AP seals ................................................. 24
7. Table Use with SmartFlow IG. ................................................................................................................ 24
8. Table Use with Safeunit Ultima. .............................................................................................................. 24
9. Table Use with Safesiphon 10. ............................................................................................................... 24
8.3 Seal water control and monitoring for the JCS2EP seal ...................................................................... 24
10. Table Use with Safeunit Ultima. ............................................................................................................ 24
8.4 Using the JCS2P and JCS2AP seals in a closed seal fluid system .................................................... 25
11. Table Use with Safesiphon 10. ............................................................................................................. 25
9 SERVICE AND MAINTENANCE ............................................................................................................... 26

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10 DISPOSAL ................................................................................................................................................. 27
12. Table Seal disposal............................................................................................................................... 27
13. Table Packaging disposal. .................................................................................................................... 27
11 APPENDICES ............................................................................................................................................ 27

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INSTRUCTION
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1 GENERAL DESCRIPTIONS
1.1 JCS1 seal
The Safeseal JCS1 is a single-acting seal integrated in the target device. It has been developed
for use with environmentally clean lubricant liquids with low consistency (0–8%), such as water,
UP
different oils, solvents and pulp. The JCS1 is specifically designed for Sulzer AHLSTAR
pumps. The seal faces receive their lubrication and cooling from the pumped product. The
balanced design of the seal allows trouble-free operation, even with sudden pressure
fluctuations. This design ensures reliable and long-lasting operation under the most demanding
conditions. The seal is designed to guarantee long-lasting and trouble-free use, reduce seal
fluid consumption and prevent environmental emissions.
1.2 JCS1F seal
The Safeseal JCS1F is a single-acting seal integrated in the target device. It is used in hot
water targets where the JCS1 seal cannot be used. The JCS1F seal always uses recirculation
of process fluid in the seal space or external flushing in order to prevent dry running or to cool
UP
the seal. The JCS1F is specifically designed for Sulzer AHLSTAR pumps. Pressurized,
continuous water flushing through throttle bushing design to the process produces clean
lubrication on seal faces. This also prevents any dry running during pump start-up. The seal is
designed for demanding conditions in which clean fluid lubricates the seal faces. Typical uses
include high-temperature condensed steam pumps. The seal is designed to guarantee long-
lasting and trouble-free use, reduce seal fluid consumption and prevent environmental
emissions.
1.3 JCS1G seal
The Safeseal JCS1G is a single-acting seal integrated in the target device. It has been
developed for use with environmentally clean lubricant fluids with low consistency (0–8%), such
as water, different oils, solvents and pulp, in applications with the risk of dry running. The
UP
JCS1G is specifically designed for Sulzer AHLSTAR pumps. The seal faces receive most of
the lubrication and cooling from the pumped product. Lubrication is further ensured by grease in
the space between the seal and the shaft. The balanced design of the seal allows trouble-free
operation, even with sudden pressure fluctuations. This design ensures reliable and long-lasting
operation under the most demanding conditions. The seal is designed to guarantee long-lasting
and trouble-free use, reduce seal fluid consumption and prevent environmental emissions.
1.4 JCS1A seal
The Safeseal JCS1A is a single-acting seal integrated in the target device. It has been
developed for use with environmentally clean lubricant liquids with low consistency (0–8%),
such as water, different oils, solvents and pulp. The JCS1A is specifically designed for Sulzer
UP
AHLSTAR liquid ring pumps and gas separators. The seal faces receive their lubrication and
cooling from the pumped product or from an external flushing system. The balanced design of
the seal allows trouble-free operation, even with sudden pressure fluctuations. This design
ensures reliable and long-lasting operation under the most demanding conditions. The seal is
designed to guarantee long-lasting and trouble-free use, reduce seal fluid consumption and
prevent environmental emissions.

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INSTRUCTION
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1.5 JCS2P seal
The Safeseal JCS2P is a double-acting seal integrated in the devicet. It is designed to be used
in pumps for environmentally hazardous and abrasive liquids when operating limits for single-
UP
acting seals are exceeded. The JCS2P is specifically designed for Sulzer AHLSTAR pumps.
When designing the JCS2P, use of the seal in a closed seal fluid system was a priority. The
seal structure offers adequate seal fluid circulation in the system, and thus a separate
circulating pump is not needed. The seal faces receive their lubrication and cooling from the
sealant fluid. The double-balanced design of the seal allows the use of both pressurized and
non-pressurized sealant fluid. This design ensures reliable and long-lasting operation under the
most demanding conditions. The seal is designed to guarantee long-lasting and trouble-free
use, reduce seal fluid consumption and prevent environmental emissions.
1.6 JCS2AP seal
The Safeseal JCS2AP is a double-acting seal integrated in the device. It is designed to be used
UP
acting seals are exceeded. The JCS2AP is specifically designed for Sulzer AHLSTAR liquid
ring pumps and gas separators. When designing the JCS2AP, use of the seal in a closed seal
fluid system was a priority. The seal structure offers adequate seal fluid circulation in the
system, and thus a separate circulating pump is not needed. The seal faces receive their
lubrication and cooling from the sealant fluid. The double-balanced design of the seal allows the
use of both pressurized and non-pressurized sealant fluid. This design ensures reliable and
long-lasting operation under the most demanding conditions. The seal is designed to guarantee
long-lasting and trouble-free use, reduce seal fluid consumption and prevent environmental
emissions.
1.7 JCS2EP seal
The Safeseal JCS2EP is a double-acting seal integrated in the device. It is designed to be used
acting seals are exceeded. The seal faces receive their lubrication and cooling from the sealant
fluid. The cooling design integrated with the seal improves the cooling of the seal. The double-
balanced design of the seal allows the use of both pressurized and non-pressurized sealant
fluid. This design ensures reliable and long-lasting operation under the most demanding
conditions. The seal is designed to guarantee long-lasting and trouble-free use, reduce seal
fluid consumption and prevent environmental emissions.
2 SAFETY
John Crane Safematic products are designed and manufactured to operate safely if used
properly. Installation and operating instructions follow the general requirements set for product
use. General and mill-specific safety regulations must also be followed. The user must also take
into account the possible dangers that can arise from eventual fault situations.
3 STORAGE
John Crane Safematic products must be stored in their original protective packaging in a dry
place. When stored properly, the products and their parts will remain undamaged and in
working order. The product packaging should be opened as close to the device device as
possible for ease of installation and less risk of damage to the products.
Caution After a long storage period (more than 6 months), the seal should be
checked carefully and, if possible, pressure-tested with pressurized air or
water before being put into service.

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INSTRUCTION
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4 MATERIALS AND DESIGN
The materials and design of the product are shown in the attached bill of materials of the
assembly drawing. The seal type and identifying information are marked on the product.
Warning A burnt fluorinated rubber seal (FKM, such as Viton, FFKM, such as
Chemraz or FPM) must be handled in the same way as highly corrosive
substances.
1. Table Tightening torque values.
Thread size Torque Unit

M4 1.5 Nm
M5 3 Nm
M6 4 Nm
M8 11 Nm
M10 16 Nm
M12 40 Nm
5 INFORMATION ON OPERATING CONDITIONS
Warning Information about any abnormal seal operating conditions is marked on the
assembly drawing.
5.1 JCS1, JCS1F, JCS1G and JCS1A seal
Caution The seal may not be run without the liquid to be pumped.
Caution The JCS1F may not be run without recirculation of process liquid or external
flushing.
Caution The JCS1G must be filled with grease before start-up. Ensure that air has
been drained from inside the fluid when filling. Category NLG 1-2 greases
may be used for lubrication. The manual lubrication interval is approximately
one month. The seal may also be connected to an automatic lubrication
system.

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INSTRUCTION
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2. Table Permissible seal operating conditions.
Explanation Quantity Value Unit

Product temperature Tmax 90 (195) °C (°F)
(JCS1, JCS1G and JCS1A)
Product temperature (JCS1F) Tmax 120 (250) °C (°F)
Stuffing box pressure pmax 16 (225) bar (psi)
Velocity v 20 (65) m/sec (ft/sec)
5.2 JCS2P, JCS2AP and JCS2EP seal
Fluids, condensates, lye, masses, silts and various chemicals. Pumps in applications
susceptible to wear and environmentally hazardous products, such as pumps used in pulp mill
cooking departments, evaporating plants and causticizing plants, and paper mill additive pumps.
Caution Do not use the seal without sealant fluid. Use only water as sealant fluid. If
it’s necessary to use other fluid, make sure it’s compliant with the elastomers
of the seal. If needed, contact the seal manufacturer.
Note When pumping abrasive and poorly lubricating fluids, the sealant fluid
pressure should exceed the pressure of the product pumped by
approximately 10%.
3. Table Permissible seal operating conditions.
Explanation Quantity Value Unit

Product temperature Tmax 180 (350) °C (°F)
Stuffing box pressure pmax 25 (360) bar (psi)
Sealant fluid pressure pmax 15 (215) bar (psi)
Velocity v 20 (65) m/sec (ft/sec)
4. Table SmartFlow IG operation with JCS2P and JCS2AP seals.
Explanation, value and unit

SmartFlow IG automatically controls and regulates sealant fluid flow in accordance with the
cooling needs of the seal.
o o
SmartFlow IG does not close if the liquid coming from the outlet side exceeds 45 C (113 F).
For detailed instructions on SmartFlow IG operation, please see manual 20000402.
Caution Ensure that air has been carefully removed from SmartFlow IG before start-
up. The system pressure is the same as the supply pressure of the sealant
fluid system.
Note For seal fluid flow and pressure control with the JCS2EP seal, we
recommend the Safeunit Ultima sealant fluid control and monitoring unit.

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INSTRUCTION
20000461en
5. Table Recommended sealant fluid quality values
Explanation Value Unit

Solids content; may not contain clay or similar fine-grained max10 mg/l
materials
Solids particle size max 50 µm
Silicate content max 10 mg/l
Permanganate number max 30 -
Iron content max 1 mg/l
Total hardness < 10 °dH
Note Exceeding these values will shorten the life span of the seal.
6 INSTALLATION
6.1 Preparations
Check that no product damage has occurred during transportation. During installation, follow
the assembly and installation instructions for the target device and exercise care and
cleanliness.
Avoid touching the seal faces. If you have to touch the seal faces, clean them with a cleaning
solvent and a soft cloth before pressing the faces against each other.
Remove sharp burrs from all shoulders that have elastomers slid over them during installation.
Lubricate component mating surfaces and elastomers prior to installation.
Note The components can be manually pressed in place. Do not install them by
hitting them!
Caution Use silicone oil or a soap solution for lubrication. Mineral-based oil or grease
cannot be used with EPDM rubber.

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INSTRUCTION
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6.2 Installation of JCS1 and JCS1F seals
Figure 1. 46101_JCS1_1.pdf
• The seal is installed to the stuffing box cover from the impeller end.
• Lubricate the elastomers on the seal body using soap solution, for example.
• Insert the seal in the stuffing box so that the M10 hole on the seal body is aligned with the
hole (unthreaded Ø 12 mm hole) used to attach the seal.
• Attach the seal body onto the stuffing box cover with an M10 hexagonal screw (1 pc).
Note Install the screw seal under the screw head.

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INSTRUCTION
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• Attach the stuffing box cover with the seal to the bearing unit.
• Install the thrust ring and thrust ring elastomers. If the slot seal of the thrust ring is not in
place inside the thrust ring, insert it in place so that the spring inside it will not touch the
product to be pumped; i.e., place the spring on the bearing side.
• Check that the impeller hub at the seal end is well rounded or beveled.
• Lubricate the slot seal with a soap solution, for example.
• Tighten the thrust ring against the shaft shoulder on the impeller.

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INSTRUCTION
20000461en
6.3 Installation of JCS1G seal
Figure 5. 46105_JCS1G_1.pdf

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INSTRUCTION
20000461en
• Pack grease into the seal so that there is grease at least up to the seal ring’s seal face.

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INSTRUCTION
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• Install the thrust ring and thrust ring elastomers. If the slot seal packing of the thrust ring is
not in place inside the thrust ring, insert it in place so that the spring inside it will not touch
the product to be pumped; i.e., place the spring on the bearing side.
• Ensure that the seal has been fully packed with grease by pumping more grease into the
seal until grease starts to leak out in between the seal body and the shaft.
6.4 Installation of JCS1A seal
Figure 10. 46110_JCS1A_1.pdf

• The seal is installed to the stuffing box from the impeller end.

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INSTRUCTION
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• Lock the seal body to the stuffing box with one (1) M10 hexagonal screw.

• Attach the stuffing box with the seal to the bearing unit.

• Install the shaft thrust ring.
• Continue the installation process in accordance with the instructions from the pump
manufacturer.

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6.5 Installation of JCS2P seal
Figure 14. 46114_JCS2P_1.pdf

• Slide the locking ring and the thrust ring on the shaft against the shaft shoulder in such a
way that the locking ring pin enters the thrust ring hole as shown.
• Tighten the two (2) locking ring retainer screws evenly.


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INSTRUCTION
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product to be pumped; i.e., place the spring on the bearing side.
6.6 Installation of JCS2AP seal
Figure 19. 46119_JCS2AP_1.pdf


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INSTRUCTION
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• The seal is installed to the stuffing box from the impeller end.

• Lock the seal body to the stuffing box with one (1) M10 hexagonal screw.

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INSTRUCTION
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• Attach the stuffing box with the seal to the bearing unit.

• Install the shaft thrust ring.
• Continue the installation process in accordance with the instructions from the pump
manufacturer.

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6.7 Installation of JCS2EP seal
Figure 24. 46124_JCS2EP_1.pdf

Figure 25. 46125_JCS2EP_2.pdf and 46126_JCS2EP_2.1.pdf

• The seal is installed to the stuffing box cover from the bearing end.
• Push the seal inside the pump cover so that the plane surface machined on the seal body
points upward when the cover is fastened to the pump.
• Fasten the seal to the cover with the stud bolts located on the cover.

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INSTRUCTION
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Figure 26. 46127_JCS2EP_3.pdf

• Make sure that the seal is correctly mounted to the cover. The machined plane surface on
the seal body must point upwards after the cover has been installed.
Figure 27. 46128_JCS2EP_4.pdf and 46129_JCS2EP_4.1.pdf

product to be pumped; in other words, place the spring on the bearing side.
• Lubricate the packing with a soap solution, for example.
7 DETACHING
Note To detach and re-install the seal, follow the instructions given in the
installation and operation manual.

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INSTRUCTION
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INSTRUCTION
20000461en
7.1 Detaching JCS1, JCS1G and JCS1F seals

• Dismantle the pump in accordance with the instructions from the pump manufacturer.
• Pull the thrust ring package off the shaft.
• Detach the stuffing box cover from the bearing unit.
• Remove the M10 fastening screw (1 screw).
• Pull the seal out.
7.2 Detaching JCS1A seal

• Detach the stuffing box from the bearing unit.
7.3 Detaching JCS2P seal

• Disconnect the seal water device and hoses.
• Unscrew the two (2) locking ring set screws.
• Pull the thrust ring on the atmosphere side and the locking ring off the shaft.
7.4 Detaching JCS2AP seal

• Detach the stuffing box from the bearing unit.
7.5 Detaching JCS2EP seal

• Detach the seal from the stuffing box cover.

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INSTRUCTION
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8 ADJUSTMENT AND CONTROL
8.1 Flush water control and monitoring for the JCS1F and JCS1A seals’ stuffing box
For flush water flow control, we recommend the John Crane Safematic Safeunit Ultima flow
meter. For additional information, please contact the closest supplier or a John Crane
Safematic representative.
6. Table Use with Safeunit Ultima.

For detailed instructions on Safeunit Ultima use, see instruction 20000402.
8.2 Seal fluid control and monitoring for the JCS2P and JCS2AP seals
For seal fluid flow control, we recommend the John Crane Safematic SmartFlow IG. The JCS2P
and JCS2AP seals may also be used with a John Crane Safematic Safeunit Ultima flow meter
and a John Crane Safematic Safesiphon 10 sealant fluid system. For additional information,
please contact the closest supplier or a John Crane Safematic representative.
7. Table Use with SmartFlow IG.

For detailed instructions on SmartFlow IG use, see instruction 20000402.

9. Table Use with Safesiphon 10.

For detailed instructions on Safesiphon 10 use, see instruction 20000465.
8.3 Seal water control and monitoring for the JCS2EP seal
For seal fluid flow control, we recommend the John Crane Safematic Safeunit Ultima flow
meter.


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INSTRUCTION
20000461en
8.4 Using the JCS2P and JCS2AP seals in a closed seal fluid system
The JCS2P and JCS2AP seals have been designed for use in a closed sealant fluid system,
such as the John Crane Safematic Safesiphon 10 system. The design of these seals ensures
adequate fluid flow in a closed system by means of pumping, and thus a separate circulating
pump is not needed. The fluid flow direction in the system is defined based on the pump
rotation direction: when the pump rotates clockwise, the fluid goes out of the right-side
connection, and when the situation is studied from the bearing side, the fluid goes out of the left-
side connection.
Figure 28. 46130.pdf

• Safesiphon 10 flow direction.
Note Please note the instructions from the manufacturer of the closed fluid system
regarding connections and take into account the above-mentioned fluid flow
direction when installing the system.
11. Table Use with Safesiphon 10.

For detailed instructions on Safesiphon 10 use, see instruction 20000465.

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INSTRUCTION
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9 SERVICE AND MAINTENANCE
To maintain John Crane Safematic Safeseal in the best operating condition, we recommend
that the seals always be checked in connection with equipment maintenance. Before
disassembling the device, check the seal for tightness and possible leaks. Seal maintenance
intervals depend on the process used, and no exact time can be determined (one to ten years).
When device maintenance is performed, a seal that has been in use for a long period should be
replaced, as it will have to be detached from the device (even though no seal leakages were
apparent). If you want to re-install the seal that was removed, you should check the condition of
the seal faces and elastomers, clean the device stuffing box and the seal thoroughly and
lubricate the O-ring faces with silicone grease.
When service or maintenance is required, please contact the seal manufacturer or its
representative. John Crane Safematic Oy belongs to John Crane Group, whose worldwide
service outlets are also at your service.
Note Before contacting them, find out the type and identification information from
the seal or from the Installation and Operation Instructions stored in the
vicinity of the device.
We use a customer-specific information file, which makes it possible to provide a fast, precise
and sensible service and rebuilding of old seals. On the basis of the monitoring reports, it is
possible to perform necessary service and maintenance work as well as material and
construction updates on the seal.

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INSTRUCTION
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10 DISPOSAL
John Crane Safematic products have been designed in such a way that their components can
be reused and rebuilt at an authorized John Crane service outlet. John Crane Safematic Oy
belongs to John Crane Group, whose worldwide service outlets are also at your service. If
something is unclear, please contact the manufacturer or its representative.
12. Table Seal disposal.
Seal components can be recycled and disposed of as follows:

Seal The materials of John Crane Safematic seals are shown in the attached
components bill of materials of the assembly drawing and they can be recycled
according to local instructions and regulations.
Metal Local instructions and regulations.
components
Elastomers A burnt fluorinated rubber seal (FKM e.g. Viton, FFKM e.g. Isolast or
FPM) should be handled in the same way as strong corrosive
substances.
Seal faces The carbon used in the seals is antimony (element Sb) impregnated and
it should be sent to hazardous waste treatment according to local
instructions and regulations.
13. Table Packaging disposal.
Seal packaging can be recycled and disposed of as follows:

Wood, cardboard, paper or plastic packaging is used to pack John Crane
Safematic products John Crane Safematic Oy has attended to its
recycling obligations related to its packaging in accordance with the
European Union directive 94/67/EC and, nationally, in accordance with
the Decision 962/97 of the Finnish Council of State, by joining the joint
organ of packaging producer organizations known as the Environmental
Register of Packaging (PYR Ltd).
Wood, Can be recycled according to local instructions and regulations.
cardboard and
paper
Padding plastic Padding plastic made of recycled polyethylene plastic (PE) can be
recycled or incinerated according to local instructions and regulations.
11 APPENDICES
Assembly drawing and bill of material

Residence: Muurame
18
17
2 21
O-ring
A
9 3 10 4 11 12 1
Fastening screw
Sealing washer
This constructional drawing applies for following seal models:

Bearing unit A1 A2 A3 A4 A5 A6 A7
Shaft size [mm] 30 40 50 60 80 90 110
Seal model 309140 309141 309142 309143 309144 309145 309577
NIMITYS LAATU MITAT . MALLI MÄÄRÄ / OSA

PIIR NO
OSA AINES ( MASSA KG ) KPL
NO
OSAN ERITTELY
SUUNN.
KaL PIIRT.
KaL SAFESEAL
KORVAA KORVATTU
JCS1 PVM.
12.6.2008
SUHDE PIIR. NO REV.
MUURAME - FINLAND
AHLSTAR UP A MS11 309210X A
16
3.1 4.1
15 18
2
O-ring
8 3 9 4 10 11 1
Fastening screw
A Sealing washer
Bearing unit A1 A2 A3 A4 A5 A6
Shaft size [mm] 30 40 50 60 80 90
Seal model 307780 307758 307730 307701 308002 308206
PIIR NO
NO
OSAN ERITTELY
SUUNN.
KaL PIIRT.
KaL TARK.
SAFESEAL KORVAA KORVATTU
JCS1A PVM.
09.09.2005
SUHDE PIIR. NO REV.
MUURAME - FINLAND AHLSTAR UP A LM11, GM11, GM12 307904 X

18
17
2 21
O-ring
A
9 3 10 4 11 12 1
Fastening screw
Sealing washer

Shaft size [mm] 30 40 50 60 80 90 110
Seal model 309146 309147 309148 309149 309150 309151 309578

PIIR NO
NO
OSAN ERITTELY
SUUNN.
KaL PIIRT.
KaL SAFESEAL
KORVAA KORVATTU
JCS1F PVM.
21.9.2009
SUHDE PIIR. NO REV.
MUURAME - FINLAND
AHLSTAR UP A MS12 309211X A
17
2 18 21
O-ring
9 3 10 4 11 12 1 14
Fastening screw
Sealing washer

Shaft size [mm] 30 40 50 60 80 90 110
Seal model 309152 309153 309154 309155 309156 309157 309579
DESCRIPTION MATERIAL DIMENSIONS, TYPES QTY/ITEM

DETAIL DRAW
ITEM MATERIAL DESCRIPTION ( WEIGHT KG ) PCS
SPECIFICATION OF ITEM
DESIGNED
KaL DRAWN
KaL SAFESEAL PREVIOUS DRG NEW DRG
JCS1G DATE
12.6.2008
SCALE DRAWING NUMBER REV.
MUURAME - FINLAND AHLSTAR UP A MS11 309212X A

17
15 16 18 5 14
O-ring
2 8 3 9 4 10 11 1 12 13 6 7 19
Fastening screw
Sealing washer

Bearing unit A1 A2 A3 A4 A5 A6
Shaft size [mm] 30 40 50 60 80 90
Seal model 309101 309102 309103 309104 309105 309106
DESCRIPTION MATERIAL DIMENSIONS, TYPES QTY/ITEM
DETAIL DRAW
ITEM MATERIAL DESCRIPTION ( WEIGHT KG ) PCS
SPECIFICATION OF ITEM
DESIGNED
KaL DRAWN
KaL SAFESEAL PREVIOUS DRG NEW DRG
JCS2AP DATE
8.5.2008
SCALE DRAWING NUMBER REV.
MUURAME - FINLAND AHLSTAR UP A LM21, GM21, GM22 309187X

29
24
27
14 23
29 26
18 22
17
A
Seal water OUT
O-ring
2
4 11 1 5 13 15 21 16 20
25 19 6 7 8
9 3 10 12
SECTION A-A
Bearing unit E3 E4 E5 E6
Shaft size [mm] 50 60 80 90
Seal model 309111 309112 309113 309114
PIIR NO
NO
Seal water IN OSAN ERITTELY
SUUNN.
KaL PIIRT.
KaL SAFESEAL
KORVAA KORVATTU
JCS2EP PVM.
13.6.2008
SUHDE PIIR. NO REV.
A MUURAME - FINLAND
SULZER AHLSTAR UP E MS21 309216X
A
3.1 4.1 7.1 8.1
17 20
2 18 5 13 15 21 16 22
O-ring
A 9 3 10 4 11 12 1 14 19 6 7 8
Fastening screw
Sealing washer

Shaft size [mm] 30 40 50 60 80 90 110
Seal model 309062 309063 309064 309065 309066 309070 309580
PIIR NO
NO
OSAN ERITTELY
SUUNN.
Kal PIIRT.
KaL TARK.
SAFESEAL KORVAA KORVATTU
JCS2P PVM.
07.03.2008
SUHDE PIIR. NO REV.
MUURAME - FINLAND AHLSTAR UP A MS21 309069 X

BILL OF MATERIALS (EN)
Code 2005X1XXXX Date 11.06.2008

Revision Designed SSa
Description JCS1-XX-XXXX
309210
Equipment AHLSTAR UP A1 MS11
Part Code Pcs Draw no. Description Material Dimensions

01 1 BODY
02 1 INTERMEDIATE RING
03 1 THRUST RING
03.1 1 FACE
04 1 SEALING RING
04.1 1 FACE
09 1 SLOT SEAL
10 1 O-RING
11 1 SLOT SEAL
12 1 SLOT SEAL
17 3 DRIVE PIN
18 3 DRIVE SCREW
21 1 SPRING
23 20000461 1 INSTALLATION INSTRUCTION
23.1 309210X 1 ASSEMBLY DRAWING

Description JCS1A-XX-XXXX-
307904
Equipment AHLSTAR UP

01 1 BODY
03 1 THRUST RING
03.1 1 FACE
04 1 SEALING RING
04.1 1 FACE
08 1 SLOT SEAL
09 1 O-RING
10 1 SLOT SEAL
11 1 SLOT SEAL
15 3 DRIVE PIN
16 3 DRIVE SCREW
18 1 SPRING

Description JCS1F-XX-XXXX
309211X

01 1 BODY
03 1 THRUST RING
03.1 1 FACE
04 1 SEALING RING
04.1 1 FACE
09 1 SLOT SEAL
10 1 O-RING
11 1 SLOT SEAL
12 1 SLOT SEAL
17 1 DRIVE PIN
18 3 DRIVE SCREW
21 1 SPRING

Description JCS1G-XX-XXXX-
309212

01 1 BODY
03 1 THRUST RING
03.1 1 FACE
04 1 SEALING RING
04.1 1 FACE
09 1 SLOT SEAL
10 1 O-RING
11 1 SLOT SEAL
12 1 SLOT SEAL
14 1 O-RING
17 3 DRIVE PIN
18 3 DRIVE SCREW
21 1 SPRING

Description JCS2AP-XX-XXXX
309187

01 1 BODY
03 1 THRUST RING
03.1 1 FACE
04 1 SEALING RING
04.1 1 FACE
05 1 SEALING RING
05.1 1 FACE
06 1 THRUST RING
06.1 1 FACE
07 1 LOCKING RING
08 1 SLOT SEAL
09 1 O-RING
10 1 SLOT SEAL
11 1 SLOT SEAL
12 1 O-RING
13 1 O-RING
14 1 O-RING
15 3 DRIVE PIN
16 3 DRIVE SCREW
17 1 DRIVE PIN
18 1 SPRING
19 2 SET SCREW

Revision Designed JuV
Description JCS2EP-XX-XXXX-
309216

01 1 BODY
03 1 THRUST RING
03.1 1 FACE
04 1 SEALING RING
04.1 1 FACE
05 1 PRESSURE RING
06 1 SEALING RING
06.1 1 FACE
07 1 THRUST RING
07.1 1 FACE
08 1 LOCKING RING
09 1 SLOT SEAL
10 1 O-RING
11 1 SLOT SEAL
12 1 SLOT SEAL
13 1 O-RING
14 1 O-RING
15 1 O-RING
16 1 O-RING
17 3 DRIVE PIN
18 3 DRIVE SCREW
19 3 DRIVE PIN
20 1 DRIVE PIN
21 1 SPRING
22 2 SET SCREW
26 1 FLOW GUIDE
27 1 FLOW GUIDE
29 2 CLINCH NAIL

Revision A Designed MaT
Description JCS2P-XX-XXXX-
309069

01 1 BODY
03 1 THRUST RING
03.1 1 FACE
04 1 SEALING RING
04.1 1 FACE
05 1 PRESSURE RING
06 1 SEALING RING
06.1 1 FACE
07 1 THRUST RING
07.1 1 FACE
08 1 LOCKING RING
09 1 SLOT SEAL
10 1 O-RING
11 1 SLOT SEAL
12 1 SLOT SEAL
13 1 O-RING
14 1 O-RING
15 1 O-RING
16 1 O-RING
17 3 DRIVE PIN
18 3 DRIVE SCREW
19 3 DRIVE PIN
20 1 DRIVE PIN
21 1 SPRING
22 2 SET SCREW
23.1 309069x 1 ASSEMBLY DRAWING
Installation Instructions ~ Rexnord® Viva® Elastomer Couplings

(Page 1 of 6) Type V, VS and VSX Sizes 110-460
This is the Original Document in English Language
The designation ATEX (Atmosphere Explosibles) has established itself for the new guidelines. ATEX controls all
regulations for the condition of explosion-proof equipment.
Model No. _____________________ Category ______________________ Reference _____________________

Mfg Year_______________________ Max Temperature _______________
1. General Information
1.1. Viva Couplings are designed to provide a mechanical connection between the rotating shafts of mechanical equipment, using
a torsionally soft flexible element to accommodate inherent misalignment while transmitting the power and torque between the
shafts.
1.2. These instructions are intended to help you install and maintain your Viva coupling. Please read these instructions prior to installing the
coupling, and prior to maintenance of the coupling and connected equipment. Keep these instructions near the coupling installation
and available for review by maintenance personnel.
1.3. Rexnord Industries, LLC owns the copyright of this material. These Installation and Maintenance instructions may not be reproduced in
whole or in part for competitive purposes.
1.4. Symbol descriptions:
Danger of injury to persons.
Damages on the machine possible.
Pointing to important items.
2. Safety and Advice Hints
DANGER!
2.1. Safety should be a primary concern in all aspects of coupling installation, operation, and maintenance.
2.2. Proper lockout-tag out procedures must be followed to safeguard against unintentional starting of the equipment.
2.3. Because of the possible danger to person(s) and/or property, from accidents which may result from improper use or installation of these
products, it is extremely important to follow the proper selection, installation, maintenance and operational procedures.
2.4. All personnel involved in the installation, service, operation, maintenance, and repair of this coupling and the connected
equipment must read, understand and comply with these Installation and Maintenance instructions.
2.5. All rotating power transmission products are potentially dangerous and can cause serious injury. They must be properly guarded in
compliance with OSHA, ANSI, ATEX, European machine safety standards and other local standards. It is the responsibility of the user to
provide proper guarding.
PRECAUTION! For this coupling to meet the ATEX requirements, you must precisely follow these
installation and maintenance instructions, and the supplement form 0005-08-49-01. This supplement
outlines the ATEX requirements. If the operator does not follow these instructions, the coupling will
immediately be considered non-conforming to ATEX.
2.6. For ATEX requirements the guard must have a minimum of 12.7 mm (1/2 inch) radial clearance to the coupling outside diameter
(coupling sizes shown in Table 1 are equivalent to the coupling outside diameter in millimeters) and allow for proper ventilation.
2.7. Make sure to disengage the electrical power and any other sources of potential energy before performing work on the coupling.
2.8. Do not make contact with the coupling when it is rotating and/or in operation.
2.9. All work on the coupling must be performed when the coupling is at rest under no load.
Rexnord Industries, LLC, 5555 S. Moorland Rd., New Berlin, WI 53151-7953 508-510
Telephone: 262-796-4060 Fax: 262-796-4064 November 2010
e-mail: info@rexnord.com web: www.rexnord.com Supercedes 02/10

3. Rexnord Viva Coupling Design and Part Numbers

Type V Type VS and VSX
7 3 6
1 2
1
5
5
Figure 1
Table 1 – Viva Part Numbers

Elastomer Element Hubs
Element High
Coupling Rough Taper Bushed British Standard
Type V Type VS Type VSX QD Hubs* Capscrews Speed Rings
Size Bore Steel Hubs – Inch* Whitworth Threads
1 1 1 7 5
5 66
22 33 (BSW)
110 7392646 7392702 7392702X 7392746 7392768 7392770 7392766 7393097 7393046
125 7392650 7392706 7392706X 7392774 7392797 7392799 7392795 7393097 7393049
130 7392654 7392710 7392710X 7392803 7392827 7392829 7392825 7393097 7393052
150= 7392656 7392712 7392712X 7392833 7392856 7392858 7392854 7393101 7393055
170= 7392658 7392714 7392714X 7392833 7392856 7392858 7392854 7393101 7393055
190 7392662 7392718 7392718X 7392862 7392884 7392886 7392882 7393101 7393058
215 7392666 7392722 7392722X 7392890 7392912 7392914 7392910 7393105 7393061
245 7392670 7392726 7392726X 7392918 7392933 7392935 7392931 7393105 7393064
290 7392674 7392730 7392730X 7392939 7392954 7392956 7392952 7393109 7393067
365 7392678 7392734 7392734X 7392960 7392966 7392969 7392964 7393120 7393070
425 7392682 7392738 7392738X 7392972 7392978 7392981 7392976 7393120 7393073
460 7392686 7392742 7392742X 7392984 7392990 7392993 7392988 7393120 7393076
Note: Hubs are interchangeable with standard or spacer flex elements.

* Bushings are not included.
= V150/V170 utilize same hubs, high speed rings and capscrews
4. Hub mounting
DANGER!
Be sure to disengage the electrical power and any other sources of potential
energy before you perform work on the hub and coupling assembly.
4.1. Examine the coupling assembly to insure there is no visible damage.

4.2. Clean the hub bores and shafts using lint free cloth. Remove any nicks or burrs.
4.3. When assembled, the key(s) should have a close side-to-side fit in the keyway in both the hub and shaft, with a slight clearance over the
top of the key.
CAUTION: When heating hubs is required, use of an oven is preferred. An open flame is not
recommended. If flame heating is considered mandatory, it is important to provide uniform heating to
avoid distortion and excessive temperature. A thermal stick (crayon marker) applied to the hub surface
will help determine the hub temperature.
DANGER!
Touching hot hubs causes burns. Wear safety gloves to avoid contact with hot surfaces.
508-510 Rexnord Industries, LLC, 5555 S. Moorland Rd., New Berlin, WI 53151-7953
November 2010 Telephone: 262-796-4060 Fax: 262-796-4064
Supercedes 02/10 e-mail: info@rexnord.com web: www.rexnord.com

4.4. Rexnord Viva hubs can be installed: D E F
~ flush with the shaft end (D)

~ extended beyond the end of the shaft (E)
~ recessed behind the shaft end (F) Figure 2
ATTENTION! Shaft engagement length should be >0,8 times shaft diameter, bushed hubs must engage 100%.
5. Straight Bore with Clearance/Slip Fit

5.1. Install the key(s) in the shaft.
5.2. Check to be sure that the set screw(s) in the hub does not protrude into the keyway and/or the bore. If needed, loosen the set screw to
provide clearance during assembly.
5.3. Slide the hub up the shaft to the desired axial position.
ATTENTION! Use half element to set proper hub spacing.

5.4. Assemble and tighten the set screw(s), using a calibrated torque wrench, to the values shown in Table 2.
Table 2 - Set Screw Tightening Torque
Set Screw Tightening torque Internal Hex Size Set Screw Tightening torque Internal Hex Size
Thread Size Thread Size
inch lb-in lb-ft Nm inch mm lb-in lb-ft Nm mm
1/4 66 6 7 1/8 M6 55 5 6 M3
5/16 132 11 15 5/32 M8 110 9 12 M4
3/8 240 20 27 3/16 M10 220 18 25 M5
1/2 600 50 68 1/4 M12 440 37 50 M6
ATTENTION! Never use two set screws with one on top of the other in the same tapped hole.
6. Straight Bore with Interference Fit

6.1. Accurately measure the bore and shaft diameters to assure proper fit.
6.2. Install the key(s) in the shaft.
6.3. Heat the hub in an oven until the bore is sufficiently larger than the shaft.
6.4. 350°F (177°C) is usually sufficient for carbon steel hubs. Do not exceed 500°F (260°C).
6.5. Higher temperatures may be required for higher interference fit levels where alloy steel hubs may be encountered. A general rule to
consider is that for every 160°F increase in temperature, steel will expand 0.001 inch for every inch of shaft diameter (or .029 mm/100°C).
When calculating temperatures, also consider additional expansion to provide clearance and allow for a loss of heat and subsequent
shrinkage during the handling process.
6.6. With the hub expanded, install it quickly on the shaft to the desired axial position. A pre-set axial stop device can be helpful.
7. Tapered bushed hubs
7.1. When using tapered bushings, follow bushing manufacturers instructions.
8. Rexnord Viva “Type V” coupling hub / element mounting options (see table 3)
C C C
Arrangement Arrangement Arrangement

A (IN) (IN) B (OUT) (IN) C (OUT) (OUT)
Figure 3
Table 3 – Type V Mounting Options

Coupling Sizes
Hub
110 125 130 150 170 190 215 245 290 365 425 460
Arrangement
Dimension C (mm)
A 9 9 7 9 9 7 11 7 8 20 19 19
B 32 32 31 35 35 34 38 40 54 76 76 76
C 55 55 55 60 60 60 64 73 94 131 133 132

9. Rexnord Viva “Type VS” coupling hub / element mounting Options (See table 4)
Shaft
Gap
Table 4 - Spacer coupling (VS) Hub mounting options for industry shaft gaps
Rexnord Viva ISO (mm) Ansi (inch)
coupling size 100 140 180 250 300 3,5 5 7 9,5 12
C2-B1 C1-C1 B1-B1 C2-C1
Both hubs mounted VS 110
101 139 3,47 4,98
outward B1-B1 C1-C2* B1-B2 C2-C2*
Shaft VS 125
Gap 101 139 3,42 4,93
C2-C2 C1-C1 B1-B1 C2*-C2*
VS 130
100 140 3,50 5,12
B1-B1 C1-C1 D1-D1 B1*-D1* D1*-D1* D1-D2*
VS 150
102 140 179 3,52 5,04 6,87
One hub mounted outward B1-B1 C1-C1 D1-D1 B1*-D1* D1*-D1* D1-D2*
VS 170
One hub mounted inward 102 140 179 3,52 5,04 6,87
Shaft B1-B1 C1-C1 D1-D1 C1*-C1* D1*-D1* D1-D1
Gap VS 190
102 141 179 3,50 4,94 7,04
B1-B1 C1-C1 D1-D1 C1*-C1* D1*-D1* D1-D1
VS 215
103 142 181 3,50 5,06 7,14
B1-B2 D1-C1* D2-D1 B1*-D1* B2-C1 D1-C1
VS 245
106 142 185 3,50 4,95 6,89
Both hubs mounted
inward B2*-B2* B2*-B1 C1-B2* C1-C1 B1*-B2* C2*-B1* B2-B1 C1-C2
VS 290
100 143 179 257 3,54 4,92 6,94 9,70
DCBA ABCD
C1*-C1* B1-B1 C1-C1 D1-D1 B1-B1* B1-B1 C1-C1 D1-D1
VS 365
137 180 250 300 4,86 7,09 9,85 11,81
21 12
C2*-C2* B1-B1 C1-C1 D1-D1 B1-B2* B1-B1 C1-C1 D1-1D
X X VS 425
137 180 250 299 4,86 7,08 9,84 11,77
C2*-C2* B1-B1 C1-C1 D1-D1 B1-B2* B1-B1 C1-C1 D1-D1
VS 460
X X 137 180 250 299 4,86 7,08 9,84 11,77
* hub mounted inward

Figure 4
10. Rexnord Viva element mounting

10.1. Mount first half element to the hubs using only original Rexnord Viva fasteners provided (do not substitute with non-approved
capscrews).
10.2. Rotate the shaft 180 degrees and secure second half element.
10.3. If shaft cannot be rotated, mount half elements at 90 degrees.
Figure 5
ATTENTION! Elements are weight balanced and must be used in pairs as packaged.

DANGER!
Incorrectly tightened capscrews could cause coupling component(s) to dislodge during operation and result in
personal injury. TIGHTEN CAPSCREWS BY USING TORQUE WRENCH.
10.4. Ensure that all capscrews are tightened to the torques specified in Table 5.

Figure 6
Table 5 – Capscrew Torque

Wrench Wrench
Viva Bolt Torque Viva Bolt Torque
Part No. Size Part No. Size
Size Size Size Size
mm Nm ft lb in lb mm Nm ft lb in lb
110 7393097 M8 13 27 20 240 215 7393105 M10 13 53 39 468
125 7393097 M8 13 27 20 240 245 7393105 M10 13 53 39 468
130 7393097 M8 13 27 20 240 290 7393109 M12 15 92 68 816
150 7393101 M10 13 53 39 468 365 7393120 M14 19 158 117 1404
170 7393101 M10 13 53 39 468 425 7393120 M14 19 158 117 1404
190 7393101 M10 13 53 39 468 460 7393120 M14 19 158 117 1404
ATTENTION! When installing the element, first seat all the capscrews with a light torque, then tighten all
capscrews to proper torque using a torque wrench.
ATTENTION! Do not lubricate capscrew threads
ATTENTION! Capscrews must have a thread-locking adhesive applied.
ATTENTION! Capscrews must be replaced with original Rexnord Viva fastener kit after three installations or when
replacing elastomer element.
DANGER!
Incorrectly tightened capscrews could cause coupling component(s) to dislodge during operation and result in
personal injury.
11. Shaft Alignment

11.1. Move the equipment into place.
ATTENTION! Soft Foot – The equipment must rest flat on its base. If one or more feet of the machine are shorter, longer, or
angled in some way to prevent uniform contact (a condition commonly known as “soft foot”) it must now be corrected.
11.2. Move the connected equipment to achieve acceptable alignment.
11.3. Table 6 shows recommended installation limits for Parallel and Angular alignment limits.
11.4. These dimensions are suggested for initial installation. Additional capacity is available to compensate for thermal and structural
equipment movement.

b
B
Figure 7 b (max)__________ mm
a (min)___________ mm
360º ΔKW (actual) x 100
a
ΔKW% =
A
ΔKW (max limit table 6)
ΔK
r
r
ΔKr (actual) x 100

ΔKr% =
100% 360 ΔKr (max limit)
90%
80%
ΔKw% + ΔKr % ≤ 100%
70% Table 6 - Drive Alignment Limits (max)
angular displacements ΔK %
B
(b-a) mm Δ Kr mm (b-a) inch Δ Kr inch
Angular displacements ΔKw% w
60%
110 4,2 1,6 0.165 0.063
50%
125 4,9 1,6 0.193 0.063
ΔD 40%
A 130 5,5 1,6 0.217 0.063
30% 150= 6,1 1,6 0.240 0.063
20% 170= 6,6 1,6 0.260 0.063
10%
190 6,1 2,4 0.240 0.095
215 7,3 2,4 0.287 0.095
10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 245 8,9 2,4 0.350 0.095
Parallel displacements ΔK %
radial displacements ΔKr % r
290 11,2 2,4 0.441 0.095
365 8,2 3,2 0.323 0.126
425 9,9 3,2 0.390 0.126
Δr
460 9,4 3,2 0.370 0.126
ATTENTION! Improper alignment of the equipment or hubs may result in hub contact with equipment or guard and sparking.
12. Preventative Maintenance
DANGER!
Do not make contact with the coupling when it is rotating and/or in operation
12.1. Periodic visual inspection is necessary to evaluate the condition of the flex element. Inspection can be done during the operation
using a strobe light.
12.2. When inspecting the element look for:

~5PcXVdTRaPRZbPcT[T\T]cb_[Xcb Inspect Here
~DaTcWP]T3XbR^[âPcX^]
~BdaUPRTRaPRZX]VX]Q^ShÛ DaTcWP]TT[T\T]c
ATTENTION! Replace Element if necessary.

Figure 8
13. Element Replacement
DANGER!
Stop the motor and lock it out to prevent start-up during installation of coupling.
13.1. Always replace both half elements.
13.2. Install both half elements from the same box.
13.3. Follow installation instructions (see Section 5, Rexnord Viva Element Installation).
DANGER!
Tighten element capscrews to proper torque by using a torque wrench (see Table 3).
Low voltage motors

Installation, operation, maintenance and safety manual
Installation, operation, maintenance and safety manual............................................................................................ EN 3
Montage-, Betriebs-, Wartungs- und Sicherheitsanleitung....................................................................................... DE 21
Manuel d’installation, d’exploitation, de maintenance et de sécurité........................................................................ FR 41
Manual de instalación, funcionamiento, mantenimiento y seguridad........................................................................ ES 61
Manuale d’installazione, funzionamento e manutenzione........................................................................................... IT 81
Manual de instalação, operação, manutenção e segurança...................................................................................PT 101
Installations-, driffts-, underhålls- och säkerhetsmanual........................................................................................ SV 123
Asennus-, käyttö-, kunnossapito- ja turvallisuusohje. .............................................................................................. FI 141
Kurulum, işletim, bakım ve emniyet kılavuzu............................................................................................................. TR 159
More languages – see web site www.abb.com/motors&generators > Motors > Document library
Low voltage motors

Installation, operation, maintenance and safety manual
Contents Page
1. Introduction................................................................................................................................................5
1.1 Declaration of Conformity.....................................................................................................................5
1.2 Validity.................................................................................................................................................5
2. Safety considerations................................................................................................................................5
3. Handling......................................................................................................................................................6
3.1 Reception............................................................................................................................................6
3.2 Transportation and storage..................................................................................................................6
3.3 Lifting...................................................................................................................................................6
3.4 Motor weight........................................................................................................................................6
4. Installation and commissioning................................................................................................................7
4.1 General................................................................................................................................................7
4.2 Motors with other than deep groove ball bearings................................................................................7
4.3 Insulation resistance check..................................................................................................................7
4.4 Foundation...........................................................................................................................................7
4.5 Balancing and fitting coupling halves and pulleys.................................................................................8
4.6 Mounting and alignment of the motor...................................................................................................8
4.7 Radial forces and belt drives................................................................................................................8
4.8 Motors with drain plugs for condensation.............................................................................................8
4.9 Cabling and electrical connections.......................................................................................................8
4.9.1 Connections for different starting methods................................................................................9
4.9.2 Connections of auxiliaries..........................................................................................................9
4.10 Terminals and direction of rotation........................................................................................................9
5. Operation .................................................................................................................................................10
5.1 General..............................................................................................................................................10
Low voltage motors manual, 3GZF500730-85 Rev. G 07-2016 | ABB Motors and Generators 3
6. Low voltage motors in variable speed operation ................................................................................11

6.1 Introduction........................................................................................................................................11
6.2 Winding insulation..............................................................................................................................11
6.2.1 Selection of winding insulation for ABB converters...................................................................11
6.2.2 Selection of winding insulation with all other converters ...........................................................11
6.3 Thermal protection ............................................................................................................................11
6.4 Bearing currents.................................................................................................................................11
6.4.1 Elimination of bearing currents with ABB converters.................................................................11
6.4.2 Elimination of bearing currents with all other converters............................................................12
6.5 Cabling, grounding and EMC.............................................................................................................12
6.6 Operating speed................................................................................................................................12
6.7 Motors in variable speed applications.................................................................................................12
6.7.1 General....................................................................................................................................12
6.7.2 Motor loadability with AC_8_ _ – series of converters with DTC control....................................12
6.7.3 Motor loadability with AC_5_ _ – series of converter.................................................................12
6.7.4 Motor loadability with other voltage source PWM-type converters............................................12
6.7.5 Short time overloads................................................................................................................13
6.8 Rating plates......................................................................................................................................13
6.9 Commissioning the variable speed application...................................................................................13
7. Maintenance.............................................................................................................................................14
7.1 General inspection.............................................................................................................................14
7.1.1 Standby motors ......................................................................................................................14
7.2 Lubrication.........................................................................................................................................14
7.2.1 Motors with permanently greased bearings..............................................................................14
7.2.2 Motors with regreasable bearings.............................................................................................15
7.2.3 Lubrication intervals and amounts............................................................................................15
7.2.4 Lubricants................................................................................................................................17
8. After Sales Support..................................................................................................................................18
8.1 Spare parts........................................................................................................................................18
8.2 Dismantling, re-assembly and rewinding............................................................................................18
8.3 Bearings............................................................................................................................................18
9. Environmental requirements...................................................................................................................18
10. Troubleshooting.......................................................................................................................................19
4 ABB Motors and Generators | Low voltage motors manual, 3GZF500730-85 Rev. G 07-2016
1. Introduction 2. Safety considerations

The motor is intended for installation and use by qualified
NOTE!
personnel, familiar with health and safety requirements and
These instructions must be followed to ensure
national legislation.
safe and proper installation, operation and
maintenance of the motor. They should be brought Safety equipment necessary for the prevention of accidents
to the attention of anyone who installs, operates at the installation and operating site must be provided in
or maintains the motor or associated equipment. accordance with local regulations.
The motor is intended for installation and use by
qualified personnel, familiar with health and safety
requirements and national legislation. Ignoring these WARNING!
instructions may invalidate all applicable warranties. Emergency stop controls must be equipped with
restart lockouts. After emergency stop a new start
command can take effect only after the restart
lockout has been intentionally reset.
1.1 Declaration of Conformity
The conformity of the end product according to Directive
2006/42/EC (Machinery) has to be established by the
Points to be observed:
commissioning party when the motor is fitted to the
machinery. 1. Do not step on the motor.
2. The temperature of the outer casing of the motor
1.2 Validity may be hot to the touch during normal operation and
especially after shut-down.
These instructions are valid for the following ABB electrical 3. Some special motor applications may require additional
machine types, in both motor and generator operation: instructions (e.g. when supplied by frequency
converter).
series MT*, MXMA, 4. Observe rotating parts of the motor.
series M1A*, M2A*/M3A*, M2B*/M3B*, M4B*, M2C*/M3C*,
5. Do not open terminal boxes while energized.
M2F*/M3F*, M2L*/M3L*, M2M*/M3M*, M2Q*, M2R*/M3R*,
M2V*/M3V*
in frame sizes 56 - 450.
There is a separate manual for e.g. Ex motors ‘Low voltage

motors for explosive atmospheres: Installation, operation
and maintenance and safety manual (3GZF500730-47)
Additional information is required for some machine types

due to special application and/or design considerations.
Additional manual is available for the following motors:

– roller table motors
– water cooled motors
– smoke extraction motors
– brake motors
– motors for high ambient temperatures
– motors in marine applications for mounting on open deck
of ships or offshore units
3. Handling
3.1 Reception Lifting eyebolts must be tightened before lifting. If needed,
the position of the eyebolt can be adjusted using suitable
Immediately upon receipt, check the motor for external washers as spacers.
damage (e.g. shaft-ends, flanges and painted surfaces)
and, if found, inform the forwarding agent without delay. Ensure that proper lifting equipment is used and that the
sizes of the hooks are suitable for the lifting lugs.
Check all rating plate data, especially voltage and winding
connections (star or delta). The type of bearing is specified Care must be taken not to damage auxiliary equipment and
on the rating plate of all motors except the smallest frame cables connected to the motor.
sizes. Remove eventual transport jigs fixing the motor to the
In the case of a variable speed drive application check pallet.
the maximum loadability allowed according to frequency Specific lifting instructions are available from ABB.
stamped on the motor’s second rating plate.
3.2 Transportation and storage WARNING!

During lifting, mounting or maintenance work, all
The motor should always be stored indoors (above necessary safety considerations shall be in place
–20 °C), in dry, vibration-free and dust-free conditions. and special attention to be taken that nobody will be
During transportation, shocks, falls and humidity should be subject to lifted load.
avoided. In other conditions, please contact ABB.
Unprotected machined surfaces (shaft-ends and flanges)

should be treated against corrosion. 3.4 Motor weight
It is recommended that shafts are rotated periodically (once The total motor weight can vary within the same frame size
per quarter) by hand to prevent grease migration. (center height) depending on different output, mounting
arrangement and auxiliaries.
Anti-condensation heaters, if fitted, are recommended to
be used to avoid water condensing in the motor. The following table shows estimated maximum weights
for machines in their basic versions as a function of frame
The motor must not be subject to any external vibrations at material.
standstill so as to avoid causing damage to the bearings.
The actual weight of all ABB’s motors, except the smallest
Motors fitted with cylindrical-roller and/or angular contact frame sizes (56 and 63), is shown on the rating plate.
bearings must be fitted with locking devices during
transport. Frame size Aluminum Cast iron Add.
for brake
Weight kg Weight kg
3.3 Lifting 56 4.5 – –
63 6 – –
All ABB motors above 25 kg are equipped with lifting lugs
71 8 13 5
or eyebolts.
80 14 20 8
Only the main lifting lugs or eyebolts of the motor should be 90 20 30 10
used for lifting the motor. They must not be used to lift the 100 32 40 16
motor when it is attached to other equipment. 112 36 50 20
132 93 90 30
Lifting lugs for auxiliaries (e.g. brakes, separate cooling 160 149 130 30
fans) or terminal boxes must not be used for lifting the 180 162 190 45
motor. Because of different output, mounting arrangements 200 245 275 55
and auxiliary equipment, motors with the same frame may 225 300 360 75
have a different center of gravity. 250 386 405 75
280 425 800 –
Damaged lifting lugs must not be used. Check that 315 – 1700 –
eyebolts or integrated lifting lugs are undamaged before 355 – 2700 –
lifting. 400 – 3500 –
450 – 4500 –
If the motor is equipped with a separate fan, contact ABB

for the weight.
4. Installation and commissioning

Insulation resistance should be used as a trend indicator
WARNING! to determine changes in the insulation system. In new
Disconnect and lock out before working on the machines the IR is usually thousands of Mohms and thus
motor or the driven equipment. following the change of IR is important so as to know
the condition of the insulation system. Typically, the IR
should not be below 10 MΩ and in no case below 1 MΩ
4.1 General (measured with 500 or 1000 VDC and corrected to 25 °C).
The insulation resistance value is halved for each 20 °C
All rating plate values must be carefully checked to ensure increase in temperature.
that the motor protection and connection will be properly
done. Figure 1, in chapter 11, can be used for the insulation
correction to the desired temperature.
When starting the motor for the first time or after it has
been in storage more than 6 months, apply the specified
quantity of grease. WARNING!
To avoid risk of electrical shock, the motor frame
See section “7.2.2 Motors with re-greasable bearings” for must be grounded and the windings should be
more details. discharged against the frame immediately after each
measurement.
When fitted in a vertical position with the shaft pointing
downwards, the motor must have a protective cover
to prevent foreign objects and fluid from falling into the If the reference resistance value is not attained, the
ventilation openings. This task can also be achieved by winding is too damp and must be oven dried. The oven
a separate cover not fixed to the motor. In this case, the temperature should be 90 °C for 12-16 hours followed by
motor must have a warning label. 105 °C for 6-8 hours.
If fitted drain hole plugs must be removed and closing

4.2 Motors with other than deep valves must be opened during heating. After heating, make
groove ball bearings sure the plugs are refitted. Even if the drain plugs are fitted,
it is recommended to disassemble the end shields and
Remove transport locking if employed. Turn the shaft of the terminal box covers for the drying process.
motor by hand to check free rotation, if possible.
Windings drenched in seawater normally need to be
rewound.
Motors equipped with cylindrical roller bearings:
Running the motor with no radial force applied to the shaft
may damage the roller bearing due to “sliding”, 4.4 Foundation
The end user has full responsibility for preparation of the
Motors equipped with angular contact ball bearing: foundation.
Running the motor with no axial force applied in the right
direction in relation to the shaft may damage the angular Metal foundations should be painted to avoid corrosion.
contact bearing. Foundations must be even and sufficiently rigid to
withstand possible short circuit forces.
WARNING! They must be designed and dimensioned to avoid the
For motors with angular contact bearings the axial transfer of vibration to the motor and vibration caused by
force must not by any means change direction. resonance. See figure below.
The type of bearing is specified on the rating plate.

Ruler
4.3 Insulation resistance check

Measure insulation resistance (IR) before commissioning, Note! Height difference shall
after long periods of standstill or storage when winding not exceed ± 0,1mm referred
to any other motor foot
dampness may be suspected. IR shall be measured
directly on the motor terminals with the supply cables
disconnected in order to avoid them affecting the result.
Foot location
4.5 Balancing and fitting 4.7 Radial forces and belt drives
coupling halves and pulleys Belts must be tightened according to the instructions of the
supplier of the driven equipment. However, do not exceed
As standard, balancing of the motor has been carried out the maximum belt forces (i.e. radial bearing loading) stated
using half key. in the relevant product catalogs.
Coupling halves or pulleys must be balanced after
machining the keyways. Balancing must be done in WARNING!
accordance with the balancing method specified for the Excessive belt tension will damage bearings and can
motor. cause shaft damage.
Coupling halves and pulleys must be fitted on the shaft by
using suitable equipment and tools which do not damage
the bearings and seals. 4.8 Motors with drain plugs for
Never fit a coupling half or pulley by hammering or condensation
removing it by using a lever pressed against the body of the
motor. Check that drain holes and plugs face downwards. In
vertical position mounted motors, the drain plugs may be in
horizontal position.
4.6 Mounting and alignment of
Motors with sealable plastic drain plugs are delivered in an
the motor open position. In very dusty environments, all drain holes
should be closed.
Ensure that there is enough space for free airflow around
the motor. It is recommended to have a clearance between
the fan cover and the wall etc. of at least ½ of the air 4.9 Cabling and electrical
intake of the fan cover. Additional information may be
found from the product catalog or from the dimension connections
drawings available on our web pages: www.abb.com/ The terminal box on standard single speed motors normally
motors&generators. contains six winding terminals and at least one earth
Correct alignment is essential to avoid bearing, vibration terminal.
and possible shaft failures. In addition to the main winding and earthing terminals, the
Mount the motor on the foundation using the appropriate terminal box can also contain connections for thermistors,
bolts or studs and place shim plates between the heating elements or other auxiliary devices.
foundation and the feet. Suitable cable lugs must be used for the connection of all
Align the motor using appropriate methods. main cables. Cables for auxiliaries can be connected into
their terminal blocks as such.
If applicable, drill locating holes and fix the locating pins into
position. Motors are intended for fixed installation only. Unless
otherwise specified, cable entry threads are metric. The IP
Mounting accuracy of coupling half: check that clearance class of the cable gland must be at least the same as those
b is less than 0.05 mm and that the difference a1 to a2 is of the terminal boxes.
also less than 0.05 mm. See figure 2.
Certified conduit hub or cable connector has to be used at
Re-check the alignment after final tightening of the bolts or the time of installation.
studs.
Do not exceed permissible loading values for bearings as NOTE!

stated in the product catalogs. Cables should be mechanically protected and
clamped close to the terminal box to fulfill the
Check that the motor has sufficient airflow. Ensure that no appropriate requirements of IEC/EN 60079-0 and
nearby objects or direct sunshine radiate additional heat to local installation standards.
the motor.
For flange mounted motors (e.g. B5, B35, V1), make sure Unused cable entries must be closed with blanking
that the construction allows sufficient air flow on the outer elements according to the IP class of the terminal box.
surface of the flange.
The degree of protection and diameter are specified in the
documents relating to the cable gland.
4.9.1 Connections for different starting

WARNING! methods
Use appropriate cable glands and seals in the cable
entries according to the type and diameter of the The terminal box on standard single speed motors normally
cable. contains six winding terminals and at least one earth
terminal. This enables the use of DOL- or Y/D –starting.
Earthing must be carried out according to local regulations For two-speed and special motors, the supply connection
before the motor is connected to the supply voltage. must follow the instructions inside the terminal box or in the
motor manual.
The earth terminal on the frame has to be connected to PE
(protective earth) with a cable as shown in Table 5 of IEC/ The voltage and connection are stamped on the rating
EN 60034-1: plate.
Minimum cross-sectional area of protective Direct-on-line starting (DOL):

conductors Y or D winding connections may be used.
Cross-sectional area of phase Minimum cross-sectional area For example, 690 VY, 400 VD indicates Y-connection for
conductors of the installation, of the corresponding protective 690 V and D-connection for 400 V.
S, [mm2] conductor, S, [mm2]
4 4 Star/Delta (Wye/Delta) starting (Y/D):
6 6 The supply voltage must be equal to the rated voltage of
10 10 the motor when using a D-connection.
16 16
Remove all connection links from the terminal block.
25 25
35 25 Other starting methods and severe starting
50 25 conditions:
70 35
95 50
In cases where other starting methods e.g. converter or
120 70
soft starter will be used in the duty types of S1 and S2, it
150 70
is considered that the device is “isolated from the power
185 95
system when the electrical machine is running” as in the
240 120
standard IEC 60079-0 and thermal protection is optional.
300 150
400 185 4.9.2 Connections of auxiliaries
In addition, earthing or bonding connection facilities on If a motor is equipped with thermistors or other RTDs
the outside of electrical apparatus must provide effective (Pt100, thermal relays, etc.) and auxiliary devices, it is
connection of a conductor with a cross-sectional area of at recommended they be used and connected by appropriate
least 4 mm2. means. For certain applications, it is mandatory to use
thermal protection. More detailed information can be found
The cable connection between the network and motor
in the documents delivered with the motor. Connection
terminals must meet the requirements stated in the
diagrams for auxiliary elements and connection parts can
national standards for installation or in the standard
be found inside the terminal box.
IEC/EN 60204-1 according to the rated current indicated
on the rating plate. The maximum measuring voltage for the thermistors is
2.5 V. The maximum measuring current for Pt100 is 5 mA.
NOTE! Using a higher measuring voltage or current may cause
When the ambient temperature exceeds +50 °C, errors in readings or a damaged temperature detector.
cables having permissible operating temperature
The insulation of thermal sensors fulfills the requirements of
of +90 °C as minimum shall be used. Also all other
basic insulation.
conversion factors depending on the installation
conditions shall be taken into account while sizing
the cables. 4.10 Terminals and direction of
Ensure that the motor protection corresponds to the rotation
environment and weather conditions. For example, make The shaft rotates clockwise when viewing the shaft face at
sure that water cannot enter the motor or the terminal the motor drive end, and the line phase sequence – L1, L2,
boxes. L3 – is connected to the terminals as shown in figure 3.
The seals of terminal boxes must be placed correctly in To alter the direction of rotation, interchange any two
the slots provided to ensure the correct IP class. A leak connections on the supply cables.
could lead to penetration of dust or water, creating a risk of
flashover to live elements. If the motor has a unidirectional fan, ensure that it rotates in
the same direction as the arrow marked on the motor.
5. Operation
5.1 General
The motors are designed for the following conditions unless
otherwise stated on the rating plate:
– Motors are to be installed in fixed installations only.

– Normal ambient temperature range is from –20 °C to
+40 °C.
– Maximum altitude is 1000 m above sea level.
– The variation of the supply voltage and frequency may
not exceed the limits mentioned in relevant standards.
Tolerance for supply voltage is ±5 %, and for frequency
±2 % according to the figure 4 (EN / IEC 60034-1,
paragraph 7.3, Zone A). Both extreme values are not
supposed to occur at the same time.
The motor can only be used in applications for which

it is intended. The rated nominal values and operation
conditions are shown on the motor rating plates. In
addition, all requirements of this manual and other related
instructions and standards must be followed.
If these limits are exceeded, motor data and construction

data must be checked. Please contact ABB for further
information.
WARNING!
Ignoring any instructions or maintenance of the
apparatus may jeopardize safety and thus prevent
the use of the motor.
6. Low voltage motors in variable speed operation

6.1 Introduction 6.2.2 Selection of winding insulation with
all other converters
This part of the manual provides additional instructions for
motors used in frequency converter supplies. The motor The voltage stresses must be limited below accepted limits.
is intended to operate from a single frequency converter Please contact the system supplier to ensure the safety of
supply and not motors running in parallel from one the application. The influence of possible filters must be
frequency converter. Instructions given by the converter taken into account while dimensioning the motor.
manufacturer shall be followed.
Additional information may be required by ABB to decide 6.3 Thermal protection

on the suitability for some motor types used in special Most of the motors covered by this manual are equipped
applications or with special design modifications. with PTC thermistors or other type of RTD’s in the stator
windings. It is recommended to connect those to the
6.2 Winding insulation frequency converter. Read more in chapter 4.9.2.
Variable speed drives create higher voltage stresses

than the sinusoidal supply on the winding of the motor. 6.4 Bearing currents
Therefore, the winding insulation of the motor as well as Insulated bearings or bearing constructions, common
the filter at the converter output must be dimensioned mode filters and suitable cabling and grounding methods
according following instructions. must be used according to the following instructions and
using table 6.1.
6.2.1 Selection of winding insulation for
ABB converters 6.4.1 Elimination of bearing currents with
In the case of ABB e.g. AC_8_ _-series and AC_5_ _-series ABB converters
single drives with a diode supply unit (uncontrolled DC In case of ABB frequency converter e.g. AC_8_ _- and
voltage), the selection of winding insulation and filters can AC_5_ _-series with a diode supply unit, the methods
be made according to table 6.1. according to table 6.1 must be used to avoid harmful
bearing currents in motors.
PN < 100 kW PN ≥ 100 kW or PN ≥ 350 kW or

IEC315 ≤ Frame size ≤ IEC355 IEC400 ≤ Frame size ≤ IEC450
UN ≤ 500 V Standard motor Standard motor Standard motor
+ Insulated N-bearing + Insulated N-bearing
+ Common mode filter
500V > UN ≤ 600V Standard motor Standard motor Standard motor
+ dU/dt –filter (reactor) + dU/dt –filter (reactor) + Insulated N-bearing
OR + Insulated N-bearing + dU/dt –filter (reactor)
Reinforced insulation OR + Common mode filter
Reinforced insulation OR
+ Insulated N-bearing Reinforced insulation
+ Insulated N-bearing
500V > UN ≤ 600V Standard motor Standard motor Standard motor
(cable length > 150 m) + Insulated N-bearing + Insulated N-bearing
600V > UN ≤ 690V Reinforced insulation Reinforced insulation Reinforced insulation

+ dU/dt –filter (reactor) + dU/dt –filter (reactor) + Insulated N-bearing
+ Insulated N-bearing + dU/dt –filter (reactor)
600V > UN ≤ 690V Reinforced insulation Reinforced insulation Reinforced insulation
(cable length > 150 m) + Insulated N-bearing + Insulated N-bearing
Table 6.1 Selection of winding insulation for ABB converters
Please contact ABB for more information on resistor braking and converters with controlled supply units.
NOTE!
6.7 Motors in variable speed
Insulated bearings which have aluminum oxide applications
coated inner and/or outer bores or ceramic rolling
elements are recommended. Aluminum oxide
coatings shall also be treated with a sealant to 6.7.1 General
prevent dirt and humidity penetrating into the porous With ABB’s frequency converters, the motors can be
coating. For the exact type of bearing insulation, see dimensioned by using ABB’s DriveSize dimensioning
the motor’s rating plate. Changing the bearing type program. The tool is downloadable from the ABB website
or insulation method without ABB’s permission is (www.abb.com/motors&generators).
prohibited.
For application supplied by other converters, the motors
must be dimensioned manually. For more information,
6.4.2 Elimination of bearing currents with please contact ABB.
all other converters
The loadability curves (or load capacity curves) are based
The user is responsible for protecting the motor and driven
on nominal supply voltage. Operation in under or over
equipment from harmful bearing currents. Instructions
voltage conditions may influence on the performance of the
described in chapter 6.4.1 can be used as guideline, but
application.
their effectiveness cannot be guaranteed in all cases.
6.7.2 Motor loadability with AC_8_ _ – series

6.5 Cabling, grounding and EMC of converters with DTC control
To provide proper grounding and to ensure compliance The loadability curves presented in Figures 5a – 5d are
with any applicable EMC requirements, motors above valid for ABB AC_8_ _-series converters with uncontrolled
30 kW shall be cabled by shielded symmetrical cables and DC-voltage and DTC-control. The figures show the
EMC glands, i.e. cable glands providing 360° bonding. approximate maximum continuous output torque of the
motors as a function of supply frequency. The output
Symmetrical and shielded cables are highly recommended torque is given as a percentage of the nominal torque of
also for smaller motors. Make the 360° grounding the motor. The values are indicative and exact values are
arrangement at all the cable entries as described in the available on request.
instructions for the glands. Twist the cable shields into
bundles and connect to the nearest ground terminal/bus
bar inside the terminal box, converter cabinet, etc. NOTE!
The maximum speed of the motor and application
may not be exceeded!
NOTE!
Proper cable glands providing 360° bonding must
be used at all termination points such as motor, 6.7.3 Motor loadability with AC_5_ _ – series
converter, possible safety switch, etc.
of converter
The loadability curves presented in Figures 6a – 6d are
For motors of frame size IEC 280 and above, additional valid for AC_5_ _ -series converters. The figures show
potential equalization between the motor frame and the the approximate maximum continuous output torque of
driven equipment is needed, unless both are mounted on the motors as a function of supply frequency. The output
a common steel base. In this case, the high frequency torque is given as a percentage of the nominal torque of
conductivity of the connection provided by the steel the motor. The values are indicative and exact values are
base should be checked by, for example, measuring the available on request.
potential difference between the components.
More information about grounding and cabling of variable NOTE!

speed drives can be found in the manual “Grounding and The maximum speed of the motor and application
cabling of the drive system” (Code: 3AFY 61201998). may not be exceeded!
6.6 Operating speed

For speeds higher than the nominal speed stated on the
motor’s rating plate or in the respective product catalog,
ensure that either the highest permissible rotational speed
of the motor or the critical speed of the whole application is
not exceeded.
6.7.4 Motor loadability with other voltage 6.9 Commissioning the variable
source PWM-type converters
For other converters, with uncontrolled DC voltage and
speed application
minimum switching frequency of 3 kHz (200…500 V), the
The commissioning of the variable speed application must
dimensioning instructions as mentioned in chapter 6.7.3
be done according to the instructions of the frequency
can be used as guidelines. However, it shall be noted that
converter and local laws and regulations. The requirements
the actual thermal loadability can also be lower. Please
and limitations set by the application must also be taken
contact the manufacturer of the converter or the system
into account.
supplier.
All parameters needed for setting the converter must be
NOTE! taken from the motor rating plates. The most often needed
The actual thermal loadability of a motor may be parameters are:
lower than shown by guideline curves.
– nominal voltage
– nominal current
6.7.5 Short time overloads – nominal frequency
ABB motors can usually be temporarily overloaded as well – nominal speed
as used in intermittent duties. The most convenient method – nominal power
to dimension such applications is to use the DriveSize tool.
6.8 Rating plates NOTE!

In case of missing or inaccurate information, do not
The usage of ABB’s motors in variable speed applications operate the motor before ensuring correct settings!
do not usually require additional rating plates. The
parameters required for commissioning the converter
can be found from the main rating plate. In some special ABB recommends using all the suitable protective features
applications, however, the motors can be equipped with provided by the converter to improve the safety of the
additional rating plates for variable speed applications. application. Converters usually provide features such as
Those include the following information: (names and availability of features depend on manufacturer
and model of the converter):
– speed range
– power range – minimum speed
– voltage and current range – maximum speed
– type of torque (constant or quadratic) – acceleration and deceleration times
– and converter type and required minimum switching – maximum current
frequency. – maximum torque
– stall protection
7. Maintenance
2. The bearing must be greased while rotating the shaft
WARNING! every year (to be reported). If the motor has been
Voltage may be connected at standstill inside the provided with roller bearing at the driven end, the
terminal box for heating elements or direct winding transport lock must be removed before rotating the
heating. shaft. The transport locking must be remounted in case
of transportation.
3. All vibrations must be avoided to prevent a bearing from

7.1 General inspection failing. All instructions in the motor instruction manual for
commissioning and maintenance have to be followed.
1. Inspect the motor at regular intervals, at least once a The warranty will not cover the winding and bearing
year. The frequency of checks depends on, for example, damages if these instructions have not been followed.
the humidity level of the ambient air and on the local
weather conditions. This can initially be determined
experimentally and must then be strictly adhered to. 7.2 Lubrication
2. Keep the motor clean and ensure free ventilation
airflow. If the motor is used in a dusty environment,
WARNING!
the ventilation system must be regularly checked and
Beware of all rotating parts!
cleaned.
3. Check the condition of shaft seals (e.g. V-ring or radial
seal) and replace if necessary.
WARNING!
4. Check the condition of connections and mounting and Grease can cause skin irritation and eye
assembly bolts. inflammation. Follow all safety precautions specified
5. Check the bearing condition by listening for any unusual by the manufacturer of the grease.
noise, vibration measurement, bearing temperature,
inspection of spent grease or SPM bearing monitoring.
Pay special attention to bearings when their calculated Bearing types are specified in the respective product
rated life time is coming to an end. catalogs and on the rating plate of all motors, except
smaller frame sizes.
When signs of wear are noticed, dismantle the motor,
check the parts and replace if necessary. When bearings Reliability is a vital issue for bearing lubrication intervals.
are changed, replacement bearings must be of the same ABB uses mainly the L1 -principle (i.e. that 99 % of the
type as those originally fitted. The shaft seals have to be motors are certain to make the life time) for lubrication.
replaced with seals of the same quality and characteristics
as the originals when changing bearings.
7.2.1 Motors with permanently greased
In the case of the IP 55 motor and when the motor bearings
has been delivered with a plug closed, it is advisable to Bearings are usually permanently greased bearings of 1Z,
periodically open the drain plugs in order to ensure that 2Z, 2RS or equivalent.
the way out for condensation is not blocked and allows
condensation to escape from the motor. This operation As a guide, adequate lubrication for sizes up to 250 can
must be done when the motor is at a standstill and has be achieved for the following duration, according to L1.
been made safe to work on. For duties with higher ambient temperatures, please
contact ABB. The informative formula to change the
7.1.1 Standby motors L1 values roughly to L10 values: L10 = 2.0 x L1.
If the motor is in standby for a longer period of time on

a ship or in other vibrating environment the following
measures have to be taken:
1. The shaft must be rotated regularly every 2 weeks (to

be reported) by means of starting up of the system. In
case a start-up is not possible, for any reason, at least
the shaft has to be turned by hand in order to achieve
a different position once a week. Vibrations caused by
other vessel's equipment will cause bearing pitting which
should be minimized by regular operation/hand turning.
Duty hours for permanently greased bearings at ambient Regreasing while the motor is at a standstill
temperatures of 25 °C and 40 °C are: If it is not possible to re-grease the bearings while the
motors are running, lubrication can be carried out while the
Duty hours Duty hours motor is at a standstill.
Frame size Poles at 25 °C at 40 °C – In this case, use only half the amount of grease and then
56 2 52 000 33 000 run the motor for a few minutes at full speed.
56 4–8 65 000 41 000 – When the motor has stopped, apply the rest of the
63 2 49 000 31 000 specified amount of grease to the bearing.
63 4–8 63 000 40 000 – After 1–2 running hours, close the grease outlet plug or
71 2 67 000 42 000 closing valve, if fitted.
71 4–8 100 000 56 000 B. Automatic lubrication
80–90 2 100 000 65 000
80–90 4–8 100 000 96 000 The grease outlet plug must be removed permanently with
100–112 2 89 000 56 000 automatic lubrication or open closing valve, if fitted.
100–112 4–8 100 000 89 000
ABB recommends only the use of electromechanical
132 2 67 000 42 000
systems.
132 4–8 100 000 77 000
160 2 60 000 38 000 The amount of grease per lubrication interval stated in the
160 4–8 100 000 74 000 table should be multiplied by three if a central lubrication
180 2 55 000 34 000 system is used. When using a smaller automatic re-grease
180 4–8 100 000 70 000 unit (one or two cartridges per motor) the normal amount of
200 2 41 000 25 000 grease can be used.
200 4–8 95 000 60 000 When 2-pole motors are automatically re-greased, the note
225 2 36 000 23 000 concerning lubricant recommendations for 2-pole motors in
225 4–8 88 000 56 000 the Lubricants chapter should be followed.
250 2 31 000 20 000
250 4–8 80 000 50 000 The used grease should be suitable for automatic
lubrication. The automatic lubrication system deliverer and
Data is valid up to 60 Hz. the grease manufacturer’s recommendations should check.
7.2.2 Motors with regreasable bearings Calculation example of amount of grease for
automatic lubrication system
Lubrication information plate and general lubrication Central lubrication system: Motor IEC M3_P 315_ 4-pole in
advice 50 Hz network, re-lubrication interval according to Table is
If the motor is equipped with a lubrication information plate, 7600 h/55 g (DE) and 7600 h/40 g (NDE):
follow the given values.
(DE) RLI = 55 g/7600 h*3*24 = 0,52 g/day
Greasing intervals regarding mounting, ambient
temperature and rotational speed are defined on the (NDE) RLI = 40 g/7600 h*3*24 = 0,38 g/day
lubrication information plate.
Calculation example of amount of grease for single
During the first start or after a bearing lubrication a automation lubrication unit (cartridge)
temporary temperature rise may appear, approximately 10 (DE) RLI = 55 g/7600 h*24 = 0,17 g/day
to 20 hours.
(NDE) RLI = 40 g/7600 h*24 = 0,13 g/day
Some motors may be equipped with a collector for old
grease. Follow the special instructions given for the RLI = Re-lubrication interval, DE = Drive end,
equipment. NDE = Non drive end
A. Manual lubrication
7.2.3 Lubrication intervals and amounts
Regreasing while the motor is running
– Remove grease outlet plug or open closing valve if fitted. Lubrication intervals for vertical motors are half of the values
– Be sure that the lubrication channel is open. shown in the table below.
– Inject the specified amount of grease into the bearing.
As a guide, adequate lubrication can be achieved for the
– Let the motor run for 1-2 hours to ensure that all excess
following duration, according to L1. For duties with higher
grease is forced out of the bearing. Close the grease
ambient temperatures please contact ABB. The informative
outlet plug or closing valve, if fitted.
formula to change the L1 values roughly to L10 values is L10
= 2.0 x L1, with manual lubrication.
The lubrication intervals are based on a bearing operating

temperature of 80 °C (ambient temperature +25 °C).
Higher speed operation, e.g. in frequency converter

NOTE!
applications, or lower speed with heavy load will require
An increase in the ambient temperature raises the
shorter lubrication intervals.
temperature of the bearings correspondingly. The
interval values should be halved for a 15 °C increase
in bearing temperature and may be doubled for a WARNING!
15 °C decrease in bearing temperature. The maximum operating temperature of the grease
and bearings, +110 °C, must not be exceeded.
The designed maximum speed of the motor must
not be exceeded.
Amount
Frame 3600 3000 1800 1500 1000 500-900
of grease kW kW kW kW
size r/min r/min r/min r/min r/min r/min
g/bearing
Ball bearings, lubrication intervals in duty hours
112 10 all 10 000 13 000 all 18 000 21 000 all 2 5 000 all 28 000
132 15 all 9 000 11 000 all 17 000 19 000 all 23 000 all 26 500
160 25 ≤ 18,5 9 000 12000 ≤ 15 18 000 21 500 ≤ 11 24 000 all 24 000
160 25 > 18,5 7 500 1 0000 > 15 15 000 18 000 > 11 22 500 all 24 000
180 30 ≤ 22 7 000 9 000 ≤ 22 15 500 18 500 ≤ 15 24 000 all 24 000
180 30 > 22 6 000 8 500 > 22 14 000 17 000 > 15 21 000 all 24 000
200 40 ≤ 37 5 500 8 000 ≤ 30 14 500 17 500 ≤ 22 23 000 all 24 000
200 40 > 37 3 000 5 500 > 30 10 000 12 000 > 22 16 000 all 20 000
225 50 ≤ 45 4 000 6 500 ≤ 45 13 000 16 500 ≤ 30 22 000 all 24 000
225 50 > 45 1 500 2 500 > 45 5 000 6 000 > 30 8 000 all 10 000
250 60 ≤ 55 2 500 4 000 ≤ 55 9 000 11 500 ≤ 37 15 000 all 18 000
250 60 > 55 1 000 1 500 > 55 3 500 4 500 > 37 6 000 all 7 000
2801) 60 all 2 000 3 500 – – – – – – –
2801) 60 – – – all 8 000 10 500 all 14 000 all 17 000
280 35 all 1 900 3 200 – – – –
280 40 – – all 7 800 9 600 all 13 900 all 15 000
315 35 all 1 900 3 200 – – – –
315 55 – – all 5 900 7 600 all 11 800 all 12 900
355 35 all 1 900 3 200 – – – –
355 70 – – all 4 000 5 600 all 9 600 all 10 700
400 40 all 1 500 2 700 – – – –
400 85 – – all 3 200 4 700 all 8 600 all 9 700
450 40 all 1 500 2 700 – – – –
450 95 – – all 2 500 3 900 all 7 700 all 8 700
Roller bearings, lubrication intervals in duty hours

160 25 ≤ 18,5 4 500 6 000 ≤ 15 9 000 10 500 ≤ 11 12 000 all 12 000
160 25 > 18,5 3 500 5 000 > 15 7 500 9 000 > 11 11 000 all 12 000
180 30 ≤ 22 3 500 4 500 ≤ 22 7 500 9 000 ≤ 15 12 000 all 12 000
180 30 > 22 3 000 4 000 > 22 7 000 8 500 > 15 10 500 all 12 000
200 40 ≤ 37 2 750 4 000 ≤ 30 7 000 8 500 ≤ 22 11 500 all 12 000
200 40 > 37 1 500 2 500 > 30 5 000 6 000 > 22 8 000 all 10 000
225 50 ≤ 45 2 000 3 000 ≤ 45 6 500 8 000 ≤ 30 11 000 all 12 000
225 50 > 45 750 1 250 > 45 2 500 3 000 > 30 4 000 all 5 000
250 60 ≤ 55 1 000 2 000 ≤ 55 4 500 5 500 ≤ 37 7 500 all 9 000
250 60 > 55 500 750 > 55 1 500 2 000 > 37 3 000 all 3 500
2801) 60 all 1 000 1 750 – – – – – – –
2801) 70 – – – all 4 000 5 250 all 7 000 all 8 500
280 35 all 900 1 600 – – – –
280 40 – – all 4 000 5 300 all 7 000 all 8 500
315 35 all 900 1 600 – – – –
315 55 – – all 2 900 3 800 all 5 900 all 6 500
355 35 all 900 1 600 – – – –
355 70 – – all 2 000 2 800 all 4 800 all 5 400
400 40 all – 1 300 – – – –
400 85 – – all 1 600 2 400 all 4 300 all 4 800
450 40 all – 1 300 – – – –
450 95 – – all 1 300 2 000 all 3 800 all 4 400
1)
M3AA
7.2.4 Lubricants The following high performance greases can be used:

– Mobil Unirex N2 or N3 (lithium complex base)
– Mobil Mobilith SHC 100 (lithium complex base)
WARNING! – Shell Gadus S5 V 100 2 (lithium complex base)
Do not mix different types of grease. – Klüber Klüberplex BEM 41-132 (special lithium base)
Incompatible lubricants may cause bearing damage. – FAG Arcanol TEMP110 (lithium complex base)
– Lubcon Turmogrease L 802 EP PLUS
(special lithium base)
When re-greasing, use only special ball bearing grease with
– Total Multis Complex S2A (lithium complex base)
the following properties:
– good quality grease with lithium complex soap and with NOTE!
mineral- or PAO-oil Always use high speed grease for high speed 2-pole
– base oil viscosity 100-160 cST at 40 °C motors where the speed factor is higher than
– consistency NLGI grade 1.5 - 3 *) 480,000 (calculated as Dm x n where Dm = average
– temperature range –30 °C - +120 °C, continuously bearing diameter, mm; n = rotational speed, r/min).
*) A stiffer end of scale is recommended for vertical

mounted motors or in hot conditions. The following greases can be used for high speed cast iron
motors but not mixed with lithium complex greases:
The above mentioned grease specification is valid if the
ambient temperature is above –30 °C or below +55 °C, – Klüber Klüber Quiet BQH 72-102 (polyurea base)
and the bearing temperature is below 110 °C; otherwise, – Lubcon Turmogrease PU703 (polyurea base)
consult ABB regarding suitable grease.
If other lubricants are used, check with the manufacturer
Grease with the correct properties is available from all major that the qualities correspond to those of the above
lubricant manufacturers. mentioned lubricants. The lubrication intervals are based
on the listed high performance greases above. Using other
Admixtures are recommended, but a written guarantee
greases can reduce the interval.
must be obtained from the lubricant manufacturer,
especially concerning EP admixtures, that admixtures do
not damage bearings or the properties of lubricants at the
operating temperature range.
WARNING!
In general, lubricants containing EP admixtures are
not recommended. In some cases it can cause harm
in the bearing, therefore its use has to be evaluated
case by case together with lubricant suppliers.
8. After Sales Support 9. Environmental

8.1 Spare parts requirements
Unless otherwise stated, spare parts must be original parts Most of ABB’s motors have a sound pressure level not
or approved by ABB. exceeding 82 dB (A) (± 3 dB) at 50 Hz.
When ordering spare parts, the motor serial number, full Values for specific motors can be found in the relevant
type designation and product code, as stated on the rating product catalogs. At 60 Hz sinusoidal supply, the values are
plate, must be specified. approximately 4 dB(A) higher compared to 50 Hz values
stated in the product catalogs.
8.2 Dismantling, re-assembly For sound pressure levels at frequency converter supplies,
please contact ABB.
and rewinding
When motor(s) need to be scrapped or recycled,
Rewinding should always be carried out by qualified repair appropriate means, local regulations and laws must be
shops. followed.
Smoke venting and other special motors should not be
rewound without first contacting ABB.
8.3 Bearings
Special care should be taken with the bearings.
These must be removed using pullers and fitted by heating

or using special tools.
Bearing replacement is described in detail in a separate

instruction leaflet available from the ABB Sales Office.
Any directions placed on the motor, such as labels, must

be followed. The bearing types indicated on the rating plate
must not be changed.
NOTE!
Any repair by the end user, unless expressly
approved by the manufacturer, releases the
manufacturer from responsibility to conformity.
10. Troubleshooting
These instructions do not cover all details or variations
in equipment nor provide information for every possible
condition to be met in connection with installation,
operation or maintenance. Should additional information be
required, please contact the nearest ABB Sales Office.
Motor troubleshooting chart

Your motor service and any troubleshooting must be
handled by qualified persons who have the proper tools
and equipment.
TROUBLE CAUSE WHAT TO DO

Motor fails to start Blown fuses Replace fuses with proper type and rating.
Overload trips Check and reset overload in starter.
Improper power supply Check to see that power supplied agrees with motor rating plate
and load factor.
Improper line connections Check connections against diagram supplied with motor.
Open circuit in winding or Indicated by humming sound when switch is closed. Check for loose
control switch wiring connections and ensure that all control contacts are closing.
Mechanical failure Check to see if motor and drive turn freely.
Check bearings and lubrication.
Short circuited stator Contact ABB
or
Ensure that the supply is disconnected and grounding for work done,
disconnect the cables and measure the insulation resistance.
Poor stator coil connection Indicated by blown fuses. Motor must be rewound.
Remove end shields and locate fault.
Motor may be overloaded Reduce load.
Motor stalls One phase may be open Check lines for open phase.
Wrong application Change type or size. Consult equipment supplier.
Overload Reduce load.
Low voltage Ensure the rating plate voltage is maintained. Check connection.
Open circuit Fuses blown. Check overload relay, stator and push buttons.
Motor runs and Power failure Check for loose connections to line, fuses and control.
then dies down
Motor does not Not applied properly Consult equipment supplier for proper type.
accelerate up to Voltage too low at motor terminals Use higher voltage or transformer terminals or reduce load.
nominal speed because of line drop Check connections. Check conductors for proper size.
Starting load too high Check the motor’s starts against “no load”.
Broken rotor bars or loose rotor Look for cracks near the rings. A new rotor may be required, as
repairs are usually temporary.
Open primary circuit Locate fault with testing device and repair.
TROUBLE CAUSE WHAT TO DO

Motor takes too Excessive load Reduce load.
long to accelerate Low voltage during start Check for high resistance. Make sure that an adequate cable size
and/or draws high is used.
current
Defective squirrel cage rotor Replace with new rotor.
Applied voltage too low Correct power supply.
Wrong rotation Wrong sequence of phases Reverse connections at motor or at switchboard.
direction
Motor overheats Overload Reduce load.
while running Frame or ventilation openings may be Open vent holes and check for a continuous stream of air
full of dirt and prevent proper ventilation from the motor.
of motor
Motor may have one phase open Check to make sure that all leads and cables are well connected.
Grounded coil Motor must be rewound.
Unbalanced terminal voltage Check for faulty leads, connections and transformers.
Motor vibrates Motor misaligned Realign.
Weak support Strengthen base.
Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective bearings Replace bearings.
Bearings not in line Repair motor
Balancing weights shifted Rebalance rotor.
Contradiction between balancing of Rebalance coupling or rotor.
rotor and coupling (half key - full key)
Poly phase motor running single phase Check for open circuit.
Excessive end play Adjust bearing or add shim.
Scraping noise Fan rubbing end shield or fan cover Correct fan mounting.
Loose on bedplate Tighten holding bolts.
Noisy operation Air gap not uniform Check and correct end shield fits or bearing fits.
Rotor unbalance Rebalance rotor.
Hot bearings Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension.
Pulleys too far away from shaft Move pulley closer to motor bearing.
shoulder
Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of the drive.
Insufficient grease Maintain proper quality and amount of grease in bearing.
Deterioration of grease or lubricant Remove old grease, wash bearings thoroughly in kerosene and
contaminated replace with new grease.
Excess lubricant Reduce quantity of grease, bearing should not be more than half full.
Overloaded bearing Check alignment, side and end thrust.
Broken ball or rough races Replace bearing, clean housing thoroughly first.
11. Figures Key

X-axis: Winding temperature, Celsius Degrees
Y-axis: Insulation Resistance Temperature Coefficient, ktc
100 1) To correct observed insulation resistance, Ri, to 40 °C
multiply it by the temperature coefficient ktc. Ri 40 °C = Ri x
50
Passfeder
x-Achse: Wicklungstemperatur, Grad Celsius
y-Achse: Temperaturkoeffizient des Isolationswiderstandes,
ktc
10 1) Zur Korrektur des ermittelten Isolationswiderstandes,
Ri, bis 40 °C, multiplizieren Sie ihn mit dem
5
Temperaturkoeffizient ktc. Ri 40 °C = Ri x
Légende
Axe X : Température du bobinage, degrés Celsius
Axe Y : Coefficient de température de la résistance
1.0 d'isolation, ktc
1) Pour corriger la résistance d'isolation observée, Ri,
à 40 °C, la multiplier par le coefficient de température
0.5
ktc. Ri 40 °C = Ri x
Clave
Eje X: Temperatura de devanado, grados centígrados
1)
0.1 Eje Y: Coeficiente de temperatura de resistencia de
aislamiento, ktc
1) Para corregir una resistencia de aislamiento observada,
0.05
Ri, a 40 °C, multiplíquela por el coeficiente de temperatura
ktc. Ri 40 °C = Ri x
-10 0 10 20 30 40 50 60 70 80 90 100
Legenda
Figure 1. Diagram illustrating the insulation resistance Asse X: Temperatura dell'avvolgimento, in gradi Celsius
dependence from the temperature and how to correct the Asse Y: Coefficiente di temperatura della resistenza
measured insulation resistance to the temperature of 40 °C. d'isolamento, ktc
1) Per correggere la resistenza d'isolamento osservata,
Abb. 1. Diagramm, das die Abhängigkeit des Ri, per 40 °C, moltiplicarla per il coefficiente di temperatura
Isolationswiderstandes von der Temperatur anzeigt und ktc. Ri 40 °C = Ri x
angibt, wie der gemessene Isolationswiderstand für die
Temperatur von 40 °C korrigiert wird. Explicação
Eixo X: Temperatura dos enrolamentos, Graus Celsius
Figure 1. Diagramme illustrant la dépendance de la résistance Eixo Y: Coeficiente de Temperatura da Resistência de
d'isolation à la température et la façon de corriger la Isolamento, ktc
résistance d'isolation mesurée à la température de 40 °C. 1) Para corrigir a resistência de isolamento observada, Ri,
para 40 °C, deverá ser multiplicada pelo coeficiente de
Figura 1. Diagrama que ilustra la dependencia de la temperatura ktc. Ri 40 °C = Ri x
resistencia de aislamiento respecto a la temperatura y cómo
corregir la resistencia de aislamiento medida a la temperatura Nyckel
de 40 °C. X-axeln: Lindningstemperatur, grader Celsius
Y-axeln: Isolationsresistans, temperaturkoefficient, ktc
Figura 1. Diagramma che mostra la resistenza d'isolamento 1) För att korrigera observerad isolationsresistans, Ri,
in funzione della temperatura e come correggere la resistenza till 40 °C ska den multipliceras med temperaturkoefficienten
d'isolamento misurata per la temperatura di 40 °C. ktc. Ri 40 °C = Ri x
Figur 1. I schemat visas isolationsresistansens beroende av Selitys

temperaturen och hur den uppmätta isolationsresistansen X-akseli: Käämin lämpötila, celsiusastetta
korrigeras till en temperatur på 40 °C. Y-akseli: Eristysvastuksen lämpötilakerroin, ktc
1) Korjaa havaittu eristysvastus, Ri, 40 °C:n lämpötilaan
Kuva 1. Kaavio, joka kuvaa, miten eristysvastus riippuu kertomalla se lämpötilakertoimella ktc. Ri 40 °C = Ri x
lämpötilasta ja miten mitattu eristysvastus korjataan 40 °C:n
lämpötilaan Tuş
X ekseni: Sargı sıcaklığı, Santigrat Derece
Tablo 1. Yalıtım direncinin sıcaklık ile olan bağıntısını ve ölçülen Y ekseni: Yalıtım Direnci Sıcaklık Katsayısı, ktc
yalıtım direncinin 40 °C sıcaklığa göre nasıl düzeltileceğini gösteren 1) Gözlenen yalıtım direncini düzeltmek için,
diyagram. Ri, 40 °C'ye ktc sıcaklık katsayısı ile çarpın. Ri 40 °C = Ri x
Low voltage motors manual, 3GZF500730-85 Rev G 07-2016 | ABB Motors and Generators 177
Figure 2. Mounting of half-coupling or pulley

a1 b
Abb. 2. Montage von Kupplungshälften und
Riemenscheiben
Figure 2. Montage d'un demi-accouplement

ou d'une poulie
Figura 2. Montaje de acoplamiento o polea
Figure 2. Montaggio di semigiunto o puleggia
Figura 2. Montagem dos meios-acoplamentos

ou polias
Figur 2. Montering av kopplingshalva eller remskiva
Kuva 2. Kytkinpuolikkaan tai hihnapyörän

a2 kiinnittäminen
Tablo 2. Yarım kaplin veya kasnağın montajı
Figure 3. Connection of terminals for main supply
Abb. 3. Anschlussklemmen für Hauptversorgung
Figure 3. Raccordement des bornes pour l'alimentation principale
Figura 3. Conexión de terminales de la alimentación principal
Figura 3. Collegamento dei morsetti per l'alimentazione di rete
Figura 3. Ligação de terminais para alimentação
Figur 3. Anslutning av terminaler för elnätet
Kuva 3. Verkkosyötön liitäntöjen muodostaminen
Tablo 3. Ana besleme için terminal bağlantıları
178 ABB Motors and Generators | Low voltage motors manual, 3GZF500730-85 Rev G 07-2016
Y Key
1.10
X axis frequency p.u.
Y axis voltage p.u.
1 zone A
2 zone B (outside zone A)
3 rating point
1.05
Passfeder
x-Achse Frequenz p.u.
1.03
1
y-Achse Spannung p.u.
1 Zone A
3
1.09
2 Zone B (außerhalb Zone A)
X 3 Bewertungspunkt
0.95 0.98 1.00 1.02
2 Légende
0.93 Axe X fréquence p.u.
Axe Y tension p.u.
1 zone A
0.95
2 zone B (hors zone A)
3 point nominal
Clave
Eje X frecuencia p.u.
0.90 Eje Y tensión p.u.
1 zona A
2 zona B (fuera de la zona A)
3 punto nominal
Figure 4. Voltage and frequency deviation
Legenda
in zones A and B
Asse X frequenza p.u.
Asse Y tensione p.u.
Abb. 4. Spannungs- und Frequenzabweichung 1 zona A
in den Zonen A und B 2 zona B (fuori dalla zona A)
3 punto nominale
Figure 4. Écart de tension et de fréquence Explicação

dans les zones A et B Eixo X frequência p.u.
Eixo Y tensão p.u.
1 zona A
Figura 4. Desviación de tensión y frecuencia
2 zona B (fora da zona A)
en zonas A y B 3 ponto de avaliação
Figura 4. Deviazione di tensione e frequenza Nyckel

X-axeln frekvens p.u.
nelle zone A e B
Y-axeln spänning p.u.
1 zon A
Figura 4. Desvio de tensão e frequência 2 zon B (utanför zon A)
nas zonas A e B 3 märkpunkt
Selitys
Figur 4. Spännings- och frekvensavvikelse X-akseli taajuus yksikköä kohti
i zoner A och B Y-akseli jännite yksikköä kohti
1 vyöhyke A
2 vyöhyke B (vyöhykkeen A ulkopuolella)
Kuva 4. Jännite- ja taajuuspoikkeama
3 arvopiste
vyöhykkeillä A ja B
Tuş
Tablo 4. Zon A ve B'de voltaj ve frekans sapması X ekseni frekans p.u.
Y ekseni voltaj p.u.
1 zon A
2 zon B (zon A dışında)
3 değerlendirme noktası
Guideline loadability curves with converters with DTC control

Richtlinie Belastbarkeitskurven mit Frequenzumrichtern mit DTC-Regelung
Courbes de capacité de charge de référence avec convertisseurs à contrôle DTC
Curvas indicativas de capacidad de carga con convertidores dotados de control de DTC
Curve di funzionamento con alimentazione da convertitore di frequenza, controllo DTC
Curvas de capacidade de carga orientadoras com conversores com controlo DTC
Riktlinjer: lastbarhetskurvor för omriktare med DTC-styrning
Ohjeelliset kuormitettavuuskäyrät DTC-ohjatuilla taajuusmuuttajilla
DTC kontrollü konvertörler ile kılavuz yüklenebilirlik eğrileri
Figures/Abbildungen/Figures/Figure/Figure/Figuras/Figur/Kuvat/Eğriler 5a, 5b, 5c, 5d
Conventer with DTC control, 50/60 Hz, temperature rise B/F

Convertisseur à contrôle DTC, 50/60 Hz, élévation de température B/F
Convertidor con control de DTC, 50/60 Hz, aumento de temperatura B/F
Convertitore con controllo DTC, 50/0 Hz, sovra-temperatura classe B/F
Conversor com controlo DTC, 50/60 Hz, aumento de temperatura B/F
Omriktare med DTC-styrning, 50/60 Hz, temperaturstegring B/F
DTC-ohjattu taajuusmuuttaja, 50/60 Hz, lämpötilan nousu B/F
DTC kontrollü konverter, 50/60 Hz, sıcaklık artışı B/F
Figure 5a Figure 5b
Figure 5c Figure 5d
180 ABB Motors and Generators | Low voltage motors manual, 3GZF500730-85 Rev G 07-2016
Guideline loadability curves with other voltage source PWM type

Belastbarkeitskurven als Richtlinie für PWM-Frequenzumrichter mit anderen Spannungsquellen
Courbes de capacité de charge de référence avec d’autres convertisseurs PWM de source de tension
Curvas indicativas de capacidad de carga con otros convertidores de fuente de tensión de tipo PWM
Curve di funzionamento con convertitori di frequenza PWM
Curvas de capacidade de carga orientadoras com outros conversores de alimentação tipo PWM
Riktlinjer: belastbarhetskurvor för annan spänningsomriktare av PWM-typ
Ohjeelliset kuormitettavuuskäyrät muilla PWM-tyyppisillä jännitelähdetaajuusmuuttajilla
Diğer voltaj kanyağı PWM tipi ile kılavuz yüklenebilirlik eğrileri
Figures/Abbildungen/Figures/Figure/Figure/Figuras/Figur/Kuvat/Eğriler 6a, 6b, 6c, 6d
Other voltage source PWM type converter, 50/60 Hz, temperature rise B/F
PWM-Frequenzumrichter mit anderen Spannungsquellen, 50/60 Hz, Temperaturanstieg B/F
Autre convertisseur PWM de source de tension, 50/60 Hz, élévation de température B/F
Otro convertidor de fuente de tensión de tipo PWM, 50/60 Hz, aumento de temperatura B/F
Convertitore PWM, 50/60 Hz, sovra-temperatura classe B/F
Outros conversores de alimentação tipo PWM, 50/60 Hz, aumento de temperatura B/F
Annan spänningsomriktare av PWM-typ, 50/60 Hz, temperaturstegring B/F
Muu PWM-tyyppinen jännitelähde-taajuusmuuttaja, 50/60 Hz, lämpötilan nousu B/F
Diğer voltaj kaynağı PWM tipi konverter, 50 Hz, sıcaklık artışı B
Figure 6a Figure 6b
Figure 6c Figure 6d
Contact us
3GZF500730-85 Rev G ML 07-2016

Manufacturing units: We reserve the right to make technical changes or modify
the contents of this document without prior notice. With
ABB Shanghai Motors Co. Ltd. regard to purchase orders, the agreed particulars shall
No 88. Tianning Road prevail. ABB does not accept any responsibility what so ever
Minhang
for potential errors or possible lack of information in this
Shanghai 200245
document.
China
ABB Oy, Motors and Generators We reserve all rights in this document and in the subject
Strömbergin puistotie 5 A matter and illustrations contained herein. Any reproduction,
FI-65320 Vaasa disclosure to third parties or utilization of its contents – in
Finland whole or in parts – is forbidden without prior written consent
of ABB.
ABB India Ltd.
Plot No 5&6, 2nd Stage
Peenya industrial Area © Copyright 2016 ABB.
Peenya 560058, Bangalore All rights reserved.
Karnataka, India
ABB India Limited www.abb.com/motors&generators

32, Industrial area, NIT,
Faribadad - 121001
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ABB Sp. z o.o.

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95-070 Aleksandrow Lodski
Poland
Series Page
Balancing test certificate, 1-plane CERTIFICATION

November 2018 H03a
SPP id: 181108 / Replaces 180108 / en / N05669_100204001 / 10
Customer Customer Order No. Customer Item/Tag
MARCOBRE S.A.C. 0030020022 3241-PU-301

Project name Sulzer Order No. / Position Witnessed
Mina Justa (Marcobre) 495727 / 10 Yes / No
Manufacturer Test date Impeller
Sulzer Pumps Finland Oy 06.09.2019 920543 / 410,0 mm

Product type Serial Number Impeller speed Test standard
A43-350 100204001 1480 rpm 1-Plane 6.3
Residual unbalance measured Residual unbalance allowed
1599 gmm 1825 gmm
Pump balancing test has been made acc. to the above results. The test results meet the standard requirements and balancing is
accepted.
Kotka 06.09.2019
Enno Danke

Series Page
Hydrostatic pressure test certificate CERTIFICATION

November 2018 H04
Customer Customer Order No. Customer Item/Tag
MARCOBRE S.A.C. 3241-PU-301

Project name Sulzer Order No. / Position Witnessed
Mina Justa (Marcobre) 0000495727 / 10 Yes / No

Manufacturer Test date
Sulzer Pumps Finland Oy 09.09.2019

Product type Serial Number Pump material Test water temperature is ambient
temperature, min.
A43-350 100204001 4U 7ºC (45ºF) for ferrous materials.
Test pressure Max allowed operating pressure at Test duration Test standard
20oC (68oF)
24,00 bar 16,00 bar 10 min ISO 5199
The pump hydrostatic pressure test has been made acc. to the above conditions without any visible leakage during the test. The test is
acceptable.
Kotka 09.09.2019
Enno Danke

N30397en_100204001
N30398en_100204001
PERFORMANCE TEST REPORT
Guaranteed Results Measured
Client MARCOBRE S.A.C. Speed [rpm] 874 874 874
Project Mina Justa (Marcobre) Flow [l/s] 321,9 332,4 332,4
Pump Service Head [m] 14,4 14,9 14,9
Pump Type A43-350 Power [kW] 51,7 56,0 56,0
Tag No. 3241-PU-301 Efficiency [%] 87,9 86,5 86,5
Manufacturers Order No. 0000495727 / 10 Testing conditions
Serial No. 100204001 Temperature [°C] 22,1
Impeller 920543 / 410,0 mm Specific Gravity 0,99792
Test date 13.09.2019 Kinematic Viscosity [m2/s] 9,53E-07
Test standard ISO 9906 / HI 14.6 Grade 2B
20
18
16
14
12
Head (m)
10
8
6
4
2
0
0 50 100 150 200 250 300 350 400 450 500
60
55
Power (kW)
50
45
40
0 50 100 150 200 250 300 350 400 450 500
100
90
80
70
Efficiency (%)
60
50
40
30
20
10
0
0 50 100 150 200 250 300 350 400 450 500
© SULZER Ltd. 2019
Flow (l/s)
SULZER CONFIDENTIAL
Series Page
CERTIFICATE
February 2019 H07a
Declaration of compliance with the order EN 10204 2.1
We certify that this product is manufactured in compliance with the requirements of the order and the materials used
in the construction of the product are in accordance with the specifications.
Kotka 20.2.2019
Enno Danke

Series Page
CERTIFICATION ISO
February 2019 H14m
Certificate of surface treatment
SPP id: 190612 / en / n33613en/ 1 / Page 1 (4)
We certify that AHLSTAR pump has been finished according to the option mentioned in the product specification.
1 Product outside surface treatment

Atmospheric-corrosivity category C5M, ISO 12944-2, temperatures <150 °C, 2-pack epoxy primer
1.1 Wet end outside surface treatment

• Relates to part numbers 102.11 (volute case) and 175.11 (flow straightener)
1.1.1 Painting, marine method

• Painting of wet end is made according to EN-ISO 12944-5 standard
• Preparation of steel substrates grade Sa 2 ½ according to standard ISO 8501-1
Painting of cast iron and carbon steel components:

• Atmospheric corrosivity category C5M according to standard 12944-2 "Classification of environment"
• Paint system A5M.02/H-EP 320/4
1 x priming coat (EP) 80 m
1 x intermediate coat (EP) 60 m
2 x top coat (EP) 90 m
Nominal dry film thickness 320 m
• Machined surfaces paint system EP200/2
Teknos Data Sheet 197, INERTA 51 MIOX, Epoxy Paint

Teknos Data Sheet 113, TEKNOPLAST PRIMER HS150, Epoxy Paint
ORIGINAL INSTRUCTION SULZER CONFIDENTIAL COPYRIGHT © SULZER PUMPS FINLAND OY

Series Page
CERTIFICATION ISO
February 2019 H14n
SPP id: 190612 / en / n33613en/ 1 / Page 2 (4)
1.1.2 Painting, standard method

• Painting of wet end is made according to EN-ISO 12944-5 standard
Painting of stainless steel components:

• Paint system EP80/1
1.2 Sealing unit outside surface treatment

• Relates to part numbers 100.21 (case), 161.21 (case cover) and 451.21 (stuffing box housing)

• Painting of sealing unit is made according to EN-ISO 12944-5 standard
Painting of cast iron and carbon steel components:
• Atmospheric corrosivity category C5M according to standard 12944-2 "Classification of environments"
1.2.2 Painting, standard method

• Painting of sealing unit is made according to EN-ISO 12944-5 standard

Series Page
CERTIFICATION ISO
February 2019 H14o
SPP id: 190612 / en / n33613en/ 1 / Page 3 (4)
Painting of stainless steel components:
• Paint system EP80/1
1.3 Bearing unit outside surface treatment

• Relates to part numbers 183.31 (support foot), 330.31 (bearing housing), 344.31 (adapter) and 360.31
(bearing cover)

• Painting of bearing unit is made according to EN-ISO 12944-5 standard
Painting of cast iron components:

• Atmospheric corrosivity category C5M according to standard 12944-2 "Classification of environments"
• Machined surfaces paint system EP200/2

• Bearing housing unmachined innersurfaces paint system EP80/1


Series Page
CERTIFICATION ISO
February 2019 H14p
SPP id: 190612 / en / n33613en/ 1 / Page 4 (4)
1.4 Coupling guard surface treatment

• Relates to part numbers 685.51 (guard end), 686.51 (guard jacket) and 686.52 (guard jacket)
1.4.1 Stainless steel guards

Stainless steel guards are painted with
• 1 x top coat (EP) 80 m

Brass guard are painted with
• Paint system Liquid paint EP240/3
1 x priming coat (EP) 80 μm
1 x intermediate coat (EP) 80 μm
1x top coat (EP) 80 μm
Paint system ISO 12944-5/ A7.10/M-EP (2-pack epoxy paint,

240/3), dry film thickness 240 μm. Typical coat thicknesses: primer coat
80 μm, intermediate coat 80 μm, and top coat 80 μm.
1.5 Baseplate surface treatment

• Relates to part number 890.61 (baseplate)

• Painting of baseplate is made according to EN-ISO 12944-5 standard
• Preparation of steel substrates grade Sa 2 ½ according to standard EN-ISO 8501-1
• Preparation of steel substrates grade P2 according to standard EN-ISO 8501-3
Baseplates are painted with

• 1 x top coat (EP) 80 m
Teknos Data Sheet 113, TEKNOPLAST HS150, Epoxy Paint
Kotka 12.6.2019
Enno Danke

V-101946-0075a-0178 - 3241-Pu-301 - 100204001

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Sulzer Pumps

Solution Pumps MDR

Sulzer Bombas Chile Limitida Contact Person Ian Pena

Sulzer Bombas Chile Limitida Contact Person Ian Pena

Motor frequency: 60 Hz Specialities of Drive motor: INERTA51 MIOX-TEKNOPLAST HS150

Sulzer Bombas Chile Limitida Contact Person Ian Pena

D01.01 1 QUALITY OF CONFORMITY N15715EN

D02.01 1 DIMENSIONAL DRAWING, PUMP P12923EN

D02.02 1 DIMENSIONAL DRAWING, DRIVE MOTOR P12465EN

D02.03 1 DIMENSIONAL DRAWING, ASSEMBLY P30486EN

D02.11 1 DIMENSIONAL DRAWING, WET END CONNECTIONS P13098EN

D02.12 1 Dimensional drawing P02184EN

D02.21 1 DIM.DRAW.,SEAL.UNIT CONNECT. P12459EN

D02.31 1 DIM. DRAW., BEARING UNIT CONNECT. P30572EN

D02.61 1 DIMENSIONAL DRAWING, FOUNDATION SCREW P12525EN

D03.11 1 CHARACTERISTIC CURVE K52771EN

D04.01 1 SECTIONAL DRAWING, PUMP N15579EN

D04.11 1 SECTIONAL DRAWING, WET END N15583EN

D04.21 1 SECTIONAL DRAWING, SEALING UNIT N15596EN

D04.25 1 SECTIONAL DRAWING, GUARDS N30338EN

D04.31 1 SECTIONAL DRAWING, BEARING UNIT N31010EN

D04.51 1 SECTIONAL DRAWING, COUPLING UNIT N31039EN

D04.61 1 SECTIONAL DRAWING, BASEPLATE N30768EN

D04.62 1 SECTIONAL DRAWING, FOUNDATION SCREW N15634EN

D05.00 1 INSTRUCTION, CONTENTS N32197ES

D05.01 1 INSTRUCTION, INTENDED USE N31567ES

D05.02 1 INSTRUCTION, SAFETY INSTRUCTIONS N31568ES

D05.03 1 INSTRUCTION, HOISTING AND TRANSPORT. N31569ES

D05.04 1 INSTRUCTION, COMMISSIONING N31570ES

D05.05 1 INSTRUCTION, INSTALLATION N31571ES

D05.06 1 INSTRUCTION, OPERATION N31572ES

D05.07 1 INSTRUCTION, PREVENTIVE MAINTENANCE N31573ES

D05.08 1 INSTRUCTION, CORRECTIVE MAINTENANCE N32198ES

D05.09 1 INSTRUCTION, SPARE PARTS RECOMM. N31575ES

D06.21 1 INSTRUCTION, SHAFT SEAL C10151ES

D06.51 1 INSTRUCTION, COUPLING C10014ES

D06.81 1 INSTRUCTION, DRIVE MOTOR C10017ES

D07.011 1 Cert. ISO1940 G1.0/G2.5/G6.3 Static N05669EN_100204001

D07.012 1 CERTIFICATE HYDROSTATIC TEST N05670EN_100204001

D07.018 1 PAINTING CERTIFICATE N30397EN_100204001

D07.019 1 PAINTING CERTIFICATE N30398EN_100204001

D07.02 1 Performance Certificate N04386EN_100204001

D07.022 1 CERTIFICATE EN10204-2.1 N30527EN

D07.09 1 CERTIFICATE, SURFACE TREATMENT N33613EN

Sulzer Bombas Chile Limitida Contact Person Ian Pena

C40.11 CON-C40 1 DRAINING OF PUMP ISO 7/1-Rp 3/8

C41.31 CON-C41 2 GREASE FILLING ISO 7/1-Rp 1/8

C43.31 CON-C43 1 DRAINING OF LUBRICAT ISO 7/1-Rp 1/2

C54.11 CON-C54 1 BLEED CONNECTION ISO 7/1-Rp 3/8

102.11 920663014U-C 1 VOLUTE CASE A43-350 (4U) 654 SMO

Material and NDT tests: Material test EN 10204-2.1

Flange drilling: ASME B16.5-2009 CLASS 150

Wet end connections: Yes Wet end drain. C40, bottom

We.inside surface treatment: Standard surface treatment

102V 920662014U-1 1 VOLUTE CASE CASTING A43-350 (4U) 654 SMO

135.11 920674014U-C 1 SIDEPLATE O A43-350 (4U) 654 SMO

Material and NDT tests: Material test EN 10204-2.1

We.inside surface treatment: Standard surface treatment

135V 920673014U-1 1 SIDEPLATE CASTING O A43-350 (4U) 654 SMO