AHLSTAR_IOM_ISO_EN

SERIES 2.
15
SPP id: 200401 / Replaces 220221 / en / N32197 / 10
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
Ignition hazard assessment
ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS FINLAND OY

Series 2.15 Page
INSTRUCTIONS ISO
USER'S MANUAL – AHLSTAR April 2020 G
Documents & Dates
SPP id: 200401 / Replaces 220221 / en / N32197 / 10 / Page 2 (2)
Installation, operation and maintenance instruction
G ISO Cover
N32197 Feb - 20
G ISO Table of contents
G ISO N31567 Intended use Feb - 20
G ISO N31568 Safety instructions Nov - 19
G N31569 Hoisting and transportation Feb - 17
G N31570 Commissioning Sep - 11
G ISO N31571 Installation at the site Nov - 19
G ISO N31572 Operation Nov - 19
G ISO N31573 Preventive maintenance Feb - 20
G ISO N32198 Corrective maintenance Feb - 19
G ISO N31575 Spare parts recommendation Sep - 11
G ISO N33727 Ignition hazard assessment Jan - 20

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 February 2020 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.

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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.
• ATEX nameplate (982.01), if the product is designed for use in potentially explosive environments.
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

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INSTRUCTIONS ISO
Intended use
Ex = Explosion protection marking

II = Equipment Group
2G / 3G = Equipment category
h = Non-electrical equipment for explosive atmospheres
IIC = Explosion Group
T4 = Temperature class
Gb / Gc = Equipment protection level
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.

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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
SPP id: Version 14 > / 191104 / Replaces 170201 / en / N31568 / 10
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

Series 2.15 Page
INSTRUCTIONS ISO
USER'S MANUAL – AHLSTAR November 2019 G
Safety instructions
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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INSTRUCTIONS ISO
Safety instructions
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.

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Safety instructions
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.
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.

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INSTRUCTIONS ISO
Safety instructions
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.
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.

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INSTRUCTIONS ISO
Safety instructions
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)
 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.

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Safety instructions
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.
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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INSTRUCTIONS ISO
Safety instructions
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.
 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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Safety instructions
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, Equipment Protection Level Gb, Temperature class T1 – T4, Ex h IIC T1-T4 Gb: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, Equipment Protection Level Gc, Temperature class T1 – T4, Ex h IIC T1-T4 Gc: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 a dynamic seal which is selected
case by case. In the case of mechanical seals, the sliding surfaces are lubricated either by the pumped
liquid, external sealing liquid or grease

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions
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.
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. This ignition hazard assessment document is placed in the
manufacturer’s technical file.
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

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions
Item no. 976.21. Do not run or rotate the seal dry
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.

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions
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).

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions
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

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions
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.

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions
LwA = A-weighted sound power level, dB re 1 pW, if A-weighted sound pressure level exceeds 85 dB.
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
53-250 A 91 87 83 82 79 78 75

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions

Pump size
types 3550 2950 1760 1480 1180 980 880 740 710 590 510 495 445
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
71-400 A 104 102

Series 2.15 Page
INSTRUCTIONS ISO
Safety instructions

Pump size
types 3550 2950 1760 1480 1180 980 880 740 710 590 510 495 445
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
42-200 APP 81 78 74 71 <70

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

Series 2.15 Page
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

Series 2.15 Page
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

Series 2.15 Page
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

Series 2.15 Page
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

Series 2.15 Page
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
In an explosive environment, the suction piping on the self-priming pump must be such that the pump
is filled with liquid when the pump is being started.s
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 regards 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

Series 2.15 Page
INSTRUCTIONS ISO
/
Fig. 6
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

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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.
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

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Fig. 8
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.

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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

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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

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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
4 x DN1 reverse order, they must be as close to
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

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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

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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”.

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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

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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

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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

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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
Dynamic seal (DS):
Use in explosion areas (ATEX) is permitted on a case-by-case basis.
Check that the plates of the appliance and the auxiliary equipment have the required markings.
Gland packing (PG):

Do not use in explosive areas (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 (*

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Operation

type N FR FE QF BF QFFR BFFR QFFE BFFE
GM11 X
GM11 X
GM12 X
GM12 X
GM21 X X
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
NOTE
Lubrication of the shaft seal must be arranged in such a way that the seal always is always lubricated,
irrespective of the pump operating point on the pump curve.
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

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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).

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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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INSTRUCTIONS ISO
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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INSTRUCTIONS ISO
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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INSTRUCTIONS ISO
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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INSTRUCTIONS ISO
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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INSTRUCTIONS ISO
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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INSTRUCTIONS ISO
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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INSTRUCTIONS ISO
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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INSTRUCTIONS ISO
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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INSTRUCTIONS ISO
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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INSTRUCTIONS ISO
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
If the surface temperature of the bearing housing is higher than 185 °F (85 °C) (the permissible maximum is 230 °F
(110 °C)), the fully synthetic oil Mobil SHC 626 or equivalent must be used. In these cases, the oil change interval is
three (3) 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

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Bearing unit Oil volume (l)

2 0.5
3 0.6
4 0.9
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

Series 2.15 Page
INSTRUCTIONS ISO
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
 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

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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.
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.

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INSTRUCTIONS ISO
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
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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INSTRUCTIONS ISO
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.
NOTE
When installing the impeller and the sideplate, replace all O-rings with new ones.

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INSTRUCTIONS ISO
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.
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

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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).
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).

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INSTRUCTIONS ISO
4 Remove the expeller (604.21) from the shaft.

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.
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).

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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).
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.

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Mechanical seal, cartridge double on the shaft without shaft sleeve (type MS41)
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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INSTRUCTIONS ISO
Mechanical seal, ready-fitted single (types MS71 and MS72)

Mechanical seal, ready-fitted double (type MS81)

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.

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INSTRUCTIONS ISO
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.
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).
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.

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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).
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)


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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).
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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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
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”.

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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).
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.

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INSTRUCTIONS ISO
Mechanical seal, cartridge double on the shaft without shaft sleeve (type MS41)
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)

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).

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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)

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.

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INSTRUCTIONS ISO
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.
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)


Series 2.15 Page
INSTRUCTIONS ISO
3 Put the series of compressor rings (487.21) onto the shaft.

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.
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).

Series 2.15 Page
INSTRUCTIONS ISO
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.
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.

Series 2.15 Page
INSTRUCTIONS ISO
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).
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).
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.

Series 2.15 Page
INSTRUCTIONS ISO
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
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.

Series 2.15 Page
INSTRUCTIONS ISO
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
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

Series 2.15 Page
INSTRUCTIONS ISO
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.
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.

Series 2.15 Page
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
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 %

User’s manual
Document No. N33727
Process pump Replaces: -
Safety instruction Release Date: 2020-01-31
Page 1 of 5
Ignition hazard assessment in accordance with standards EN ISO 80079-36:2016 and EN ISO 80079-37:2016
No. 1. 2. 3. 4.
Ignition hazard assessment Assessment of frequency without applying additional measures Measures applied to prevent ignition sources from becoming active Frequency, including all measures
a b a b c d e a b c a b c d e f
Potential ignition Description of the root Reasons for assessment Description of the measure References Technical
During rare malfunctions
During rare malfunctions

source cause (what conditions (standards, documentation
class in relation to this

cause each respective risk technical (including evidence
The resulting device

In normal operation
In normal operation
Essential limitation
of ignition?) principles, of the relevant
During predictable
During predictable
experimental features listed in
Not significant
Not significant
risk of ignition
results from the column 1))
malfunctions
malfunctions
literature)
Hot surface
1 Hot surface Conduction of mechanical x The valve on the discharge side is The maximum surface temperature is determined on EN ISO 80079- Document x Gb T4
energy into heat closed, in which case the friction of the basis of the most unfavourable circumstances. The 36:2016 8.2 concerning the
the liquid may cause the temperature instructions stipulate that operation against a closed maximum
to rise valve is prohibited. temperature N33728
Installation, operation
and maintenance
instructions
2 Hot surface Heating of device due to x Heating of the device as a result of The maximum surface temperature is determined on EN ISO 80079- Document x Ga T4
process heat mechanical operating energy and the basis of the most unfavourable circumstances. The 36:2016 8.2 concerning the
process temperature pump instructions give the maximum temperature of the maximum
pumped liquid. When pumping hot (>100 °C) liquids, the temperature N33728
pump casing heats up to the temperature of the Installation, operation
pumped liquid, in which case the maximum surface and maintenance
temperature does not depend on the pump itself but on instructions
the operating conditions.
3 Hot surface Impeller grinding against x Grinding can cause the temperature The pump case must be filled with liquid when starting EN ISO 80079- Installation, operation x Ga
the fixed parts of the pump to rise the pump, to ensure that there is no air-gas mixture 36:2016 8.2 and maintenance
present. The air-gas mixture exits the pump during instructions
filling. Liquid flow inside the pump ensures adequate
heat transfer, preventing a local heat increase. The
pump shaft and section clearances are dimensioned so
that the impeller does not hit the pump casing even in
the worst possible case.
4 Hot surface Impeller grinding against x Heat caused by friction when The liquid flow inside the pump removes dirt particles EN ISO 80079- x Gb
the fixed parts of the pump particles become wedged in a small from the pump casing. This event is considered a rare 36:2016 8.2
area occurrence.
5 Hot surface Damage to antifriction x The absence of lubricant or excessive The installation, operating and maintenance instructions EN ISO 80079- Installation, operation x Gb
bearings may cause the lubrication may cause the bearings to include instructions on lubricating the bearings and 36:2016 8.2 and maintenance
appliance to heat up and heat up monitoring the correct lubricant level instructions
may also cause sparking
ORIGINAL INSTRUCTION
COPYRIGHT © SULZER PUMPS
N33727 2020-01-31
SULZER CONFIDENTIAL
User’s manual
Document No. N33727
Page 2 of 5
6 Hot surface Heating of the sliding x Lack of lubricant can cause the Several types of mechanical seal are selected for the EN ISO 80079- Pump selection x Gb
surfaces of the mechanical sliding ring seal to heat up. pump–both seals fitted for the pump and general- 36:2016 8.2 instructions.
seal purpose seals. Smooth operation of the seals depends EN ISO 80079- Document N33728
on how well the lubricant reaches the sliding surfaces of 37:2016 A.3 concerning the
the seals (i.e., it depends on the selection of the maximum
lubrication system). temperature.
The temperature,
The lubrication system for the mechanical seal is chosen pressure and
according to the operating conditions, so that lubricant circumferential limit
is always in the seal regardless of the pump operating values and the
point on the pump curve: Plan 02 (no flushing) can only amounts of lubricant
be selected for the application where the pump’s inlet are given in the
pressure is large enough (pump selection instructions). instructions of the
Sealing surfaces can also be lubricated from the pump mechanical seal or in
discharge side with recycled liquid (internal rotation) or the installation,
liquid supplied from outside the pump. Grease can also operation and
be used as a lubricant. maintenance
instructions of the
pump.
For external lubrication, there is an alert function to indicate Document N32687en
if the lubrication fluid input volume is too low. If the alert on the specification
is triggered, the pump must be stopped. Only ATEX- of ignition protection.
approved electrical components may be used in the device.
The pump casing can be equipped with pressure

measurement instrumentation to protect the seal from
running when inadequately lubricated. The measurement
includes an alarm, and if the pressure falls to the negative
level the pump must be stopped. Only ATEX-approved
measuring devices may be used for pressure
measurement.
The ignition protection type for the lubricant alarm is set

to B1.
7 Hot surface Heating of the sliding x At the pump discharge side, clogging In order to avoid obstruction of the pipe, internal rotation EN ISO 80079- Pump selection x Ga
surfaces of the mechanical of the pipe leading to the seal casing may only be used for relatively clean liquids. 36:2016 8.2 EN instructions.
seal results in a lack of lubricant, causing ISO 80079-
the mechanical seal to heat up. 37:2016 A.3
8 Hot surface Friction between the shaft x Without lubricant in the functioning The maximum temperature of the seal components was EN ISO 80079- Document N33669en x Ga T4
wearing sleeve and the seal, friction may cause the parts to determined by tests, which showed that the low coefficient 36:2016 8.2 on determining the
dynamic seal or the thrust heat up of adhesion characteristic of the Teflon material keeps maximum dynamic
ring and the static seal the temperature below the limit value. seal temperature
9 Hot surface Friction between the x Heating caused by friction as dirt The labyrinth rings are protected against dirt particles EN ISO 80079- x Gb
labyrinth ring that serves particles are forced into a small gap by means of deflectors. 36:2016 8.2
as the shaft seal of the
antifriction bearing, and
the shaft
10 Hot surface Friction caused by the x Heating caused by friction in normal The deflectors are lip seals commonly used for this EN ISO 80079- x Ga
deflectors that protect the operation purpose, as their frictional force is low. 36:2016 8.2
antifriction bearing
The lip of the seal causes friction, and the lip comes off
the contact surface as the circumferential speed rises,
whereby no dangerous rise in temperature can occur.
11 Hot surface Flames and hot gases x Ignition hazards caused by flames or hot gases have EN ISO 80079- x Ga
not been identified. 36:2016 6.3
Mechanically generated sparks
12 Mechanical spark Damage to the antifriction x The mechanical grinding of the The bearing is designed for a certain lifetime in EN ISO 80079- The maintenance and x Gb T4
bearing can cause heating impeller in connection with bearing accordance with ISO 281:2007. Bearing damage is 36:2016 6.4 and condition monitoring
of the device and sparking damage cannot be excluded generally accepted as a rare event. C.5 of the bearings are
Early bearing damage can be detected by condition EN ISO 80079- described in the
monitoring. 37:2016 5.7 installation, operation
and maintenance
instructions
N33727 2020-01-31
SULZER CONFIDENTIAL
User’s manual
Document No. N33727
Page 3 of 5
13 Mechanical spark Impeller grinding against x Grinding can cause sparks The pump casing must be filled with liquid when the EN ISO 80079- Installation, operation x Ga
the fixed parts of the pump is running, so that it contains no air-gas mixture. 36:2016 6.4 and maintenance
pumps Liquid flow inside the pump ensures adequate heat instructions
transfer, preventing a local heat increase.
The pump shaft and section clearances are dimensioned
so that the impeller does not hit the pump casing even
in the worst possible case.
14 Mechanical spark Impeller grinding against x The pump is used outside the The flowrate and the lifting height at which the pump is EN ISO 80079- Installation, operation x Gb
the fixed parts of the permissible operating limits, which dimensioned and the rotational speed at which these 36:2016 6.4 and maintenance
pumps can cause abrasion that results in values are reached are marked on the plate attached to instructions
sparking the pump. The installation, operating and maintenance
instructions contain specify limits on where the pump
can be used.
15 Mechanical spark Friction between the x Sparking caused by dirt particles The labyrinth rings are protected from dirt particles by EN ISO 80079- x Gb
labyrinth ring that serves between parts deflection rings 36:2016 6.4
as the shaft seal of the
antifriction bearing and the
shaft
16 Mechanical spark Friction between the x An external factor causes such a major The shaft is protected by a shock-resistant coupling guard EN ISO 80079- Document N15438en x Ga
labyrinth ring that serves change in the shape of the shaft that at the use end. On the impeller side, the shaft is located 36:2016 6.4 on shock resistance
as the shaft seal of the it gets caught inside the spacer. The service openings in the spacer verification
antifriction bearing and the are covered with a protector.
shaft
17 Mechanical spark Grinding of coupling and x The coupling touches the coupling The coupling parts can only become loose as a result of EN ISO 80079- Installation, operation x Gb
coupling guard guard, causing heating or sparks a rare malfunction. Such rare malfunctions may result 36:2016 6.4 and maintenance
from improper installation of the coupling, for example. EN ISO 80079- instructions
The coupling guard is designed to be loose enough that 36:2016 8.3
the parts do not come into contact with each other in Coupling
normal use or in case of predictable disturbances. manufacturer’s
installation instructions
18 Mechanical spark Grinding of coupling and x An external factor causes the coupling The coupling guard is designed to be rigid enough so EN ISO 80079- Document N15438en x Ga
coupling guard guard to deform so much that the that excessive deformation does not occur. 36:2016 6.4 regarding the
coupling guard touches the coupling Impact resistance has been tested. EN ISO 80079- verification of impact
36:2016 8.3 resistance. The test
IEC 60079- has been carried out
0:2011 26.4.2 in accordance with
EN 13463-
1:2001/AC:2002, but
the requirements are
the same as in IEC
60079-0.
19 Mechanical spark Rubbing of the minimum x Sparking caused by rubbing of the Change in liquid flow is the only function that causes EN ISO 80079- x Ga
flow recirculation valve moving parts within the minimum flow components to move. In this case the valve is filled with 36:2016 6.4
components recirculation valve liquid, so there is no flammable air-gas mixture.
20 Mechanical spark Unacceptable vibration x Internal and external sources of Vibrations must be measured upon commissioning the EN ISO 80079- Installation, operation x Ga
due to the foundations of vibration cannot be excluded device, and the foundations need to be corrected if 36:2016 and maintenance
the tank or pump or, for necessary. Measurements must be made at regular EN ISO 80079- instructions. The
example, due to the intervals. 37:2016 5.5 permitted speed of
clogging of the pump, The critical speed of rotation of the device has been rotation is stated on
causes damage to the determined. the device plate and
device in the specification.
21 Mechanical spark Sparks caused by impacts x Impacts caused by transfers during Use permitted lifting accessories. The transfers must be EN ISO 80079- Installation, operation x Ga
when moving the device pump installation, maintenance or carried out so that no collisions or falling can occur. 36:2016 6.4 and maintenance
removal can cause sparks EN 1127- instructions
1:2011 6.4
22 Mechanical spark Sparks caused by the use x Sparks caused by the use of tools The instructions of the device state that the device must EN ISO 80079- Installation, operation x Ga
of tools during installation and maintenance be stopped before repairs and maintenance and that 36:2016 6.4 and maintenance
only such tools and procedures that are appropriate to EN 1127- instructions
the particular conditions must be used. 1:2011 6.4
23 Mechanical spark External parts of the x Light metal parts are not used. Magnesium accounts for EN ISO 80079- x Ga
device containing light less than 7.5 per cent of the weight. Aluminium 36:2016 6.4
metals accounts for less than 10 per cent of the weight. EN 60079-
0:2011 8
Electrical equipment and stray currents
24 Electrical sparking Electric motor x Electrical equipment is a potential The electric motor is treated as a separate device, not EN 60079 EC declaration of x Gb
ignition source as a part of the pump. Only electrical equipment with series conformity (related to
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SULZER CONFIDENTIAL
User’s manual
Document No. N33727
Page 4 of 5
the EC declaration of conformity (related to the ATEX the ATEX directive)
directive) is used. and, if necessary,
control system
(acquired from an
outside supplier)
instructions
25 Electrical sparking Sealing liquid device or its x Electrical equipment is a potential Only electrical equipment with the EC declaration of EN 60079 EC Declaration of x Gb
electrical components ignition source conformity (related to the ATEX directive) is used. series conformity (related to
the ATEX directive)
26 Electrical sparking Accessories: temperature x Electrical equipment is a potential Only electrical equipment with the EC declaration of EN 60079 EC Declaration of x Gb
sensors and other ignition source conformity (related to the ATEX directive) is used. series conformity (related to
electronic measuring the ATEX directive)
devices installed as
accessories
27 Electrical sparking Accessory cabling and x The structure and cables of the coupling Cabling and coupling enclosures are designed according EN 60079 Design instructions for x Gb
coupling enclosures enclosures and their connections can to Exi-class instructions (intrinsically safe construction) series selecting electrical
partly cause ignition sources to arise equipment
28 Electrical stray Bearing currents caused x Harmful bearing currents can break The baseplate of the pump must be grounded. The user EN 60079 Installation, operation x Gb
currents by electric motor drives the pump bearings is responsible for protecting the motor and equipment series and maintenance
and frequency converter against harmful bearing currents. The engine and instruction of electric
drives frequency convertor are selected according to the motor and frequency
manufacturer’s instructions for use of the frequency converter
convertor. Installation, operation
and maintenance
instructions of pump
Static electricity
29 Electrostatic charge Isolated electrically x The discharge of an electrostatic The build-up of electrostatic charges is not possible EN ISO 80079- x Ga
conductive parts charge causes a spark because no plastic parts have been used on the external 36:2016 6.7
surfaces.
30 Electrostatic charge Build-up of electric charge x The pump and the paint layer on the The requirement of explosion group IIA and IIB EN ISO 80079- Installation, operation x Ga
in non-conductive material surfaces of its guards become concerning maximum coating thickness is never 36:2016 6.7 and maintenance
on metal surfaces electrically charged in maintenance exceeded. In the case of explosion group IIC, the limit instructions
and cleaning situations. of 0.2 mm for the paint layer is exceeded slightly, so a
warning concerning cleaning has been added to the
installation, operation and maintenance instruction of
the pump.
31 Electrostatic charge Charging of the dynamic x Charging of static seal by steel In an explosive application, a static seal with PTFE + 25% EN ISO 80079- x Ga
seal’s static seal components rubbing against it C material is used, which does not develop static 36:2016 6.7.5
charge.
32 Electrostatic charge Earthing of electrically x The discharge of an electrostatic The metal parts are fitted together so that differences in EN ISO 80079- Assembly drawings x Ga
conductive parts charge due to a potential difference potential do not occur. 36:2016 6.7.2
causes sparking
33 Electrostatic charge Electrostatic charging of x Use of chargeable liquids tends to Limitation of the intended use: only liquids with a high CLC/TR Warning of limitations x Ga Yes
the liquid during pumping create an electrostatic charge under conductivity (> 1000 pS/m) can be used ( alternatively, 50404:2003 5.7 of intended use in the a)
normal operation inertisation is required). installation, operation
and maintenance
instructions
34 Lightning Ignition hazard caused by x Not a significant ignition source in At the responsibility of the user EN 1127- x
lightning regard to mechanical equipment 1:2011 5.7
35 Radio-frequency Risk of ignition caused by x Not a significant ignition source in At the responsibility of the user EN 1127- x
electromagnetic radio-frequency regard to mechanical equipment 1:2011 5.8
waves electromagnetic waves
36 Electromagnetic Ignition hazard caused by x Not a significant ignition source in At the responsibility of the user EN 1127- x
waves electromagnetic waves regard to mechanical equipment 1:2011 5.9
37 Ionizing radiation Ignition hazard caused by x Ignition hazards caused by ionizing EN 1127- x
ionizing radiation radiation have not been identified 1:2011 5.10
38 Ultrasonics Ignition hazard caused by x Ignition hazards caused by EN 1127- x
ultrasonics ultrasonics have not been identified 1:2011 5.11
39 Adiabatic Ignition hazard caused by x Ignition hazards caused by adiabatic EN ISO 80079- x
compression and adiabatic compression and compression and shock waves have 36:2016 6.8
shock waves shock waves not been identified EN 1127-
1:2011 5.12
40 Reactions caused by Ignition hazard caused by x Ignition hazards caused by EN ISO 80079- x
heat exothermic reactions exothermic reactions have not been 36:2016 6.9
N33727 2020-01-31
SULZER CONFIDENTIAL
User’s manual
Document No. N33727
Page 5 of 5
identified EN 1127-
1:2011 5.13
Resulting equipment category including all existing ignition hazards: Gb T4 a)
a) Limitation of the intended use required
N33727 2020-01-31
SULZER CONFIDENTIAL

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SERIES 2.

SPP id: 200401 / Replaces 220221 / en / N32197 / 10

Installation, operation and maintenance instruction

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS FINLAND OY

Installation, operation and maintenance instruction

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS FINLAND OY

SPP id: 200207 / Replaces 141101 / en / N31567 / 5

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS FINLAND OY

Table 1, Intended use in the process

Table 2, Delivery and design

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS FINLAND OY

Keep these instructions at the place of operation for further reference!

Sulzer product number

Series 2.15 Page

Page number when the document has more than one

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS FINLAND OY

LM = LM design liquid ring pump / mechanical seal

4 Parts number designation

4.1 Part numbers of modules

4.2 Part numbers of parts, connections and documents

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS FINLAND OY

MADE UNDER ONE OR MORE OF

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS FINLAND OY

Ex = Explosion protection marking

6 Capacity and head

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS FINLAND OY

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS FINLAND OY

SPP id: Version 14 > / 191104 / Replaces 170201 / en / N31568 / 10

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS FINLAND OY

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS FINLAND OY

2.2 Essential health and safety requirements

2.2.1 General remarks

2.2.1.2 Principles of safety integration

2.2.1.3 Materials and products

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS FINLAND OY

2.2.1.5 Design of machinery to facilitate its handling

2.2.2.1 Control and stopping devices

2.2.3 Protection against mechanical hazards

2.2.3.2 Risk of break-up during operation

2.2.3.3 Risk due to falling or ejected objects

2.2.3.4 Risks due to sharp edges or angles

2.2.3.5 Risks related to variations in the rotational speed

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS FINLAND OY

2.2.3.6 Prevention of risks related to moving parts

2.2.4 Protection against other hazards

2.2.4.1 Electricity supply

2.2.4.2 Static electricity

2.2.4.3 Errors of fitting

2.2.4.4 Extreme temperatures

2.2.4.5 Fire and explosion

2.2.4.6 Noise and vibration

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS FINLAND OY

2.2.4.9 Slipping, stumbling and falling

2.2.5.1 Machinery maintenance

2.2.5.2 Access to operating position and servicing points

2.2.5.3 Isolation of energy sources

2.2.5.4 Operator intervention

ORIGINAL INSTRUCTION COPYRIGHT © SULZER PUMPS FINLAND OY

2.2.5.5 Cleaning of (internal) parts of machine

2.2.6.1 Information and warning devices