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Instruction Manual CombiPro - Amalgamated Pumping Supplies

1. RII i d o Y f u NSSS SSSA SS N DEREN SN Sy zi SET i E D figure 15 Cross section CombiPro with cooling chamber CR EN C Pump parts 39 M onn BH SON PUMP Parts list pump S 1 Description pump casing Material code acc API 610 code S 1 carbon steel A216 grade WCA pump cover carbon steel A216 grade WCA countersunk head screw stainless steel A276 type 316 impeller cast iron A48 class 30 wear plate cast iron A48 class 30 casing wear ring Cr Steel 200 250Br A743 grade CA 40 set screw stainless steel A276 type 304 bracket support steel A108 grade 1020 impeller wear ring Cr steel 300 350Br A743 grade CA 40 set screw stainless steel A276 type 304 gasket plug steel A108 grade 1020 plug steel A108 grade 1020 stud Cr Mo steel A193 grade B7 nut Cr Mo steel A194 grade 2H lock washer steel bolt stainless steel A276 type 304 allen screw steel A108 grade 1020 cap nut stainless steel A276 type 316 set screw stainless steel A276 type 304 impeller key stainl
2. 01 on U ULOU figure 12 Cross section CombiPro with closed impeller CR EN 4C Pump parts 36 Cross section pump with semi open impeller 9 4 no Vol Z OLSE K TM N f N DD Es iS ZIN N N x Di ITS DO AMA PW SCHUIN N A NAR Zn W 2 N DN N A M onn BH SON PUMP 9 5 Cross section pump with half open impeller A DEE 94 JU ZID 2143 2160 21 2190 2110 s gt SAH UND en 3 N MOS KS Less dp figure 14 Cross section CombiPro with half open impeller CR EN 4C 38 Pump parts f PM sounson PUMP CombiPro 9 6 Cross section pump with cooling chamber
3. Pump mounted on a grouted baseplate of carbon steel Fr Mr resultant CR EN 4C Technical data 59 H sonnson PUMP ll 10 8 2 Allowable forces and moments on the discharge flange Allowable forces and moments on the discharge flange based on API 610 2 4 1 Allowable forces N Allowable moments Nm Pump type Discharge Discharge Fy Fz My Mz CR 40A 125 CR 40A 160 CR 40A 200 CR 40A 250 CR 50A 125 CR 50A 160 CR 50A 200 CR 50A 250 CR 50A 315 CR 50B 125 CR 50B 160 CR 50B 200 CR 50B 250 CR 50B 315 CR 80A 125 CR 80A 160 CR 80A 200 CR 80A 250 CR 80A 315 CR 100A 160 CR 100A 200 CR 100A 250 CR 100A 315 CR 100A 400 CR 100B 200 CR 100B 250 CR 100B 315 CR 100B 400 CR 150A 250 CR 150A 315 CR 150A 400 Pump mounted on a grouted baseplate of carbon steel Fr Mr resultant CR EN 4C 60 Technical data Monn BH SON PUMP CombiPro 10 9 Survey curves 200 a m h 6 78910 15 20 30 40 50 60 80 00 150 200 300 figure 18 Survey curve for cast steel pump at 1500 min CR EN C Technical data 61 M onn BH SON PUMP 4434 120 a 40A 250 50A 250
4. 7 50B 125 7 80A 125 figure 24 Survey curve for stainless steel pump at 1800 min CR EN C 64 Technical data ise data mp noise as a function of pump power e following data are based on normal use of the pump driven by an electric otor dB A 4103EN 0 1 1 10 P kw 100 ure 25 Noise as a function of pump power at 1450 min 85 80 75 70 65 60 B A JOHNSON 10 10 2 No 3 0 2 8 2 6 2 4 2 2 2 0 1 8 1 6 1 4 1 2 1 0 0 8 0 6 0 4 0 2 0 0 PUMP ise L dB 4102 O 1 2 3 4 5 6 7 8 9 10 11 12 18 14 15 16 17 18 19 20 L1 L2 dB figure 27 Noise level of the entire pump unit In order to determine the total noise level of the entire pump unit the noise level of the motor must be added to that of the pump This can be easily done by using the graph above 1 NO A A W ND Determine the noise levels L1 and L2 of the pump using figure 25 or 26 and the motor Determine the difference between both levels L1 L2 Look for the differential value on the L1 L2 axis Go up
5. Ls gt Ll 50A 200 60 50 4OA 160 H 40 i N IN 508 160 N 804 N N 50A 160 0A 160 3 40A 125 N N NN PES 80A 125 N 50B 125 QUA 12 N 20 7p ew y N ies 0 2 6 20 30 40 50 60 80 100 120 7150 200 250 300 figure 19 Survey curve for cast steel pump at 3600 min 40A 125 V uu BP 804 125 NN _50B 125 NY M j ma figure 20 Survey curve for cast steel pump at 1800 min CR EN C 62 Technical data il JOHNSON PUMP CombiPro a N NMA 19C _ L ES 504 25 N TS N 1 Z an j 8 7 7 N N 6 Vv 8 10 12 14 16 20 30 40 60 80 100 120 150 200 250 300 400 Q m 1 figure 21 Survey curve for stainless steel pump at 3000 min 5 3 40A 125 50A 125 7 I i AN 2 V 5 6 8 10 5 20 0 40 50 60 80 100 200 300 m h 1 figure 22 Survey curve for stainless steel pump at 1500 min CR EN C Technical data 63 JOHN Al SON PUMP o is A0A 125 N 4439 150A 315 NY 1504 250 404 250 N 50A 250 X zi 804 160
6. gasket bearing cover 48 Pump parts CR EN C il JOHNSON PUMP CombiPro Material code Description acc API 610 code A 8 2180 deflector rubber 2190 set screw stainless steel 2200 pump shaft stainless steel A276 type 316L 2210 coupling key steel A108 grade 1020 2250 roller bearing 2260 angular contact bearing 2300 inner circlip steel 2410 indication plate arrow aluminium 2420 indication plate oil level stainless steel 2560 bearing lock nut steel 2570 retaining ring steel 2810 allen screw steel A108 grade 1020 2815 allen screw steel A108 grade 1020 2820 bolt steel A108 grade 1020 2830 washer steel Recommended spare parts Number depends on pump type 2 4 6 or 8 Number depends on pump type 8 or 12 Number depends on bearing group 4 or 8 Bearing group 1 Allen screw CR EN 4C Pump parts 49 M onn BH SON PUMP Partslist cooling chamber See figure 15 Item nr Number Description plug Material code acc API 610 steel A108 grade 1020 bolt steel A108 grade 1020 heating cooling reservoir nodular cast iron A395 536 gasket 50 Pump parts CR EN C CombiPro MM sonnson PUMP ll v 10 Technical data 10 1 10 2 10 2 1 10 2 2 Recommended liquid locking agents casing wear ring
7. il JOHNSON PUMP CombiPro Material code Description acc API 610 code S 6 2180 deflector rubber 2190 set screw stainless steel 2200 pump shaft Cr Ni steel A276 type 431 2210 coupling key steel A108 grade 1020 2250 roller bearing 2260 angular contact bearing 2300 inner circlip steel 2410 indication plate arrow aluminium 2420 indication plate oil level stainless steel 2560 bearing lock nut steel 2570 retaining ring steel 2810 allen screw steel A108 grade 1020 2815 allen screw steel A108 grade 1020 2820 bolt steel A108 grade 1020 2830 washer steel Recommended spare parts Number depends on pump type 2 4 6 or 8 Number depends on pump type 8 or 12 Number depends on bearing group 4 or 8 Bearing group 1 Allen screw CR EN 4C Pump parts 43 M onn BH SON PUMP Parts list pump S 8 Description pump casing Material code acc API 610 code S 8 carbon steel A216 grade WCA pump cover carbon steel A216 grade WCA countersunk head screw stainless steel A276 type 316 impeller stainless steel A296 grade CC50 wear plate stainless steel A296 grade CC50 casing wear ring stainless steel A351 grade CF 8M set screw stainless steel A276 type 304 bracket support steel A108 grade 1020 impeller wear
8. 2570 retaining ring steel 2810 allen screw steel A108 grade 1020 2815 allen screw steel A108 grade 1020 2820 bolt steel A108 grade 1020 2830 washer steel Recommended spare parts Number depends on pump type 2 4 6 or 8 Number depends on pump type 8 or 12 Number depends on bearing group 4 or 8 Bearing group 1 Allen screw CR EN 4C Pump parts 45 M onn BH SON PUMP Parts list pump C 6 Description pump casing Material code acc API 610 code C 6 Cr steel A296 grade CA 40 pump cover Cr steel A296 grade CA 40 countersunk head screw stainless steel A276 type 316 impeller Cr steel A296 grade CA 40 wear plate Cr steel A296 grade CA 40 casing wear ring Cr Steel 200 250Br A743 grade CA 40 set screw stainless steel A276 type 304 bracket support steel A108 grade 1020 impeller wear ring Cr steel 300 350Br A743 grade CA 40 set screw stainless steel A276 type 304 gasket plug steel A108 grade 1020 plug steel A108 grade 1020 stud Cr Mo steel A193 grade B7 nut Cr Mo steel A194 grade 2H lock washer steel bolt stainless steel A276 type 304 allen screw steel A108 grade 1020 cap nut stainless steel A276 type 316 set screw stainless steel A276
9. Type C Bellows Type A Pusher RL1T 0450 RL1T 0530 Shaft size RL1T 0630 Flexibox AP1D 0476 on request Durametallic PA200 BXHW 1750 1625 BXHW 2125 2000 BXHW 2500 2375 QB 2000 1750 AP1D 0571 PA200 QB 2375 2125 AP1D 0666 PA200 QB 22750 2500 Type B Bellows GL1D 0400 PB200 BX 1750 1500 GL1D 0500 PB200 BX 2125 1875 GL1D 0600 PB200 BX 2500 2250 Type C Bellows RL1D 0450 RL1D 0530 RL1D 0630 on request BXHW 1750 1625 BXHW 2125 2000 BXHW 2500 2375 CR EN 4C Technical data 67 PH sounson PUMP 10 11 2 Dimensions shaft area H u M12 8x Bgr 2 3 es d INN L figure 28 Dimensions shaft area Shaft seal area dimensions according to API 610 API 682 CRIEN C 68 Technical data il JOHNSON PUMP CombiPro E 10 11 3 Pressure in shaft seal area Pressure difference in the shaft seal area above the inlet pressure and at an external circulation of the medium from delivery side calculated for a specific mass of 1000 kg m Pump speed min P bar Pump type 1500 3600 CR 404 125 0 5 2 6 CR 404 160 0 7 3 8 CR 404 200 1 0 5 5 CR 404 250 1 3 7 6 CR 504
10. Apply a drop of Loctite 641 on each set screw 0135 and 0155 and fit them in their positions in the impeller and the pump casing respectively Don t fasten the set screws too tight in order to avoid deformation of the wear rings figure 10 Locking the wear rings 30 CR EN C Disassembly and assembly CombiPro 77 7 7 1 7 7 2 7 7 3 7 8 7 8 1 onn PUMP BH SON PU Mechanical seal Instructions for mounting a mechanical seal First read the following instructions regarding the mounting of a mechanical seal Follow these instructions closely when mounting a mechanical seal e The mechanical seal comes as a full cartridge seal This means that the mechanical seal is mounted as one single piece and that it shall NOT be taken apart e A mechanical seal is a fragile precision instrument Leave the seal in its original packing until you are ready to mount it e Clean all receiving parts properly Make sure your hands and working environment are clean Disassembly of the mechanical seal 1 Re fit the centering tabs on the seal cover into the groove in the seal collar in order to immobilise the seal 2 Disassemble the impeller see 7 6 1 3 Remove the Allen screws and slide the mechanical seal backwards towards the bearing bracket 2100 4 Remove the Allen screws 0850 and knock the pump cover loose from the bearing bracket 5 Pull the entire seal cartridge from the pump shaft Assembly of the mec
11. M onn BH SON PUMP Piping flushing Preparation thermal protection switch Preservation Pressure Pump commissioning Pump casing Pump description R Re use S Safety measures symbols Scrapping Spray clean pump chamber Static electricity Storage Survey curves Switch earth switch operating switch thermal motor protection switch T Temperature Tools Transport Type code U Unit assembling positioning V Voltage different main frequencies different voltages voltage data W Wear rings assembly disassembly replacement 20 20 23 25 40 23 12 11 15 17 29 15 25 17 10 45 21 21 21 40 29 14 18 18 21 21 21 32 31 31 72 Index CR EN 4C M onn N PUMP BH SON PU Order form for spare parts Your order will only be dealt with if this order form has been correctly completed and signed Order date Your order number Pumptype Execution Quantity Article number pump Delivery address Invoicing address BESTFORM 004 EN 73 ul sounson PUMP BESTFORM 004 EN 74 Johnson Pump Group Parent Company SWEDEN Johnson Pump AB Tel 46 0 19 21 83 00 Fax 46 0 19 27 23 30 National Sales Organisations AUSTRALIA Johnson Pump Australia Pty Ltd Tel 61 0 7 3899 9933 Fax 61 0 7 3899 8574 BELGIUM Johnson Pump N V S A Belgium Tel
12. B is in conformity with the following standards EN 292 parts 1 amp 2 EN 809 and that this pump is meant to be incorporated in or combined with another machine electric motor combustion engine and may only be put into use after the complete machine of which the pump under consideration forms part has been made and declared to comply with that directive Assen Janary 1st 2004 P Ressenaar Director I A II B EN CombiPro Monn PUMP BH SON PU Instruction manual CombiPro All technical and technological information in this manual as well as possible drawings made available by us remain our property and shall not be used otherwise than for the operation of this CombiPro pump copied duplicated made available to or brought to the notice of third parties without our prior written consent Johnson Pump Water BV hereafter called Johnson Pump is part of Johnson Pump International AB The core activities of Johnson Pump International AB are the development production sale and maintenance of pumps and pump units Johnson Pump Water BV P O Box 9 9400 AA Assen The Netherlands Tel 31 0 592 376767 Fax 31 0 592 376760 2004 Johnson Pump Water BV CR EN 0402 3 0 CR EN 4C Instruction manual CombiPro 1 M onn ON PUMP BH S U CR EN C 2 Instruction manual CombiPro CombiPro M onn PUMP B SON PU Table of contents 1 Introduction 7 1 1 Introduction 7 1 2 Safet
13. Plan 52 External reservoir providing buffer fluid for the outer seal of an unpressurized dual seal arrangement Plan 53 Pressurized external barrier fluid reservoir supplying clean fluid to the seal chamber CR EN C 14 General CombiPro 2 12 2 13 2 14 sonn N PUMP BH SON PU Application area Overall the application area is as follows Maximum Capacity 350 m h Delivery head 160 m System pressure 3500 kPa 35 bar Temperature range 30 to 350 C Viscosity 300 mm s Re use The pump may only be used for other applications after prior consultation with Johnson Pump or your supplier Because the medium which was pumped last is not always known the following instructions should be observed 1 Flush the pump properly 2 Make sure the flushing liquid is discharged safely environment Take adequate safety measures collection trough and use the correct personal protection equipment rubber gloves spectacles Scrapping If itis decided to scrap a pump then the same steps as 2 13 Re use must be followed first CR EN 4C General 15 M onn BH SON PUMP CRIEN C 16 General f PH sounson PUMP CombiPro a 3 Installation 3 1 Safety 3 1 1 General Read this manual carefully prior to installation and commissioning Non observance of these instructions can result in serious damage to the pump and this will not be covered under the terms of our
14. 0130 Loctite 641 impeller wear ring 0150 Loctite 641 Torques settings Torques settings for bolts and nuts For nuts for pump casing itemnr 0805 see 10 2 3 M6 M8 M10 M12 M16 Torques settings for impeller nut Size Torque Nm 43 104 220 CR EN C Technical data 51 M onn BH SON PUMP 10 2 3 Torques settings for nuts for pump casing Torques settings for nuts for pump casing item nr 0805 Ma greased Washer N mm 8x M10 21x10 5x2 8x M12 24x13x2 5 8x M12 24x13x2 5 12x M12 24x13x2 5 8x M10 21x10 5x2 8x M12 24x13x2 5 8x M12 24x13x2 5 12x M12 24x13x2 5 8x M16 30x17x3 8x M10 21x10 5x2 8x M12 24x13x2 5 8x M12 24x13x2 5 12x M12 24x13x2 5 8x M16 30x17x3 8x M10 21x10 5x2 8x M12 24x13x2 5 8x M12 24x13x2 5 12x M12 24x13x2 5 8x M16 30x17x3 8x M12 24x13x2 5 8x M12 24x13x2 5 12x M12 24x13x2 5 8x M16 30x17x3 12x M16 30x17x3 8x M12 24x13x2 5 12x M12 24x13x2 5 8x M16 30x17x3 12x M16 30x17x3 12x M12 24x13x2 5 8x M16 30x17x3 12x M16 30x17x3 Bolt circle mm Pump type Shaft group CR EN 4C 52 Technical data PM sounson PUMP CombiPro a 10 3 Masses and cubic contents Motor IEC IP54 160 160 180 180 200 225 225 250 280 Nett massj 80 LIMISIM MILIMILILIS MI MIS Pump type pump in kg 38 45 70 81 125 147 1
15. 1 Safety measures 7 1 1 Electrical connections A Take adequate measures to prevent the motor from being started whilst you are working on the pump This is particularly important for electric motors which are remote started e Place the pump operating switch if fitted in the off position e Place the pump switch in the switch box in the off position e f necessary remove the fuses e Fita warning board onto the switch box 7 2 Tools Assembly and disassembly require no special tools However such tools can facilitate certain jobs If such is the case it will be indicated in the text 7 3 Item numbers The item numbers used in the following disassembly and assembly instructions refer to the cross section drawings in chapter 9 7 4 Drain pump 7 4 1 Draining the liquid N If the liquid being pumped is hot then allow the pump to cool down before proceeding Make sure you do not come into contact with the pumped liquid if this is hot or of an unknown composition Before starting any disassembly the pump should be drained by removing the drain plug 0310 If necessary close the valves in the suction and delivery pipe and in the flushing or cooling pipe to the shaft seal Take the following safety precautions if harmful liquids are pumped e Wear protective gloves shoes glasses etc e Flush the pump properly e Make sure no liquid gets into the environment e Re fit the drain plug 0310 CR EN C Disassembl
16. 125 CR 50B 160 CR 50B 200 CR 50B 250 CR 50B 315 CR 80A 125 CR 80A 160 CR 80A 200 CR 80A 250 CR 80A 315 CR 100A 160 CR 100A 200 CR 100A 250 CR 100A 315 CR 100A 400 CR 100B 200 CR 100B 250 CR 100B 315 CR 100B 400 CR 150A 250 CR 150A 315 CR 150A 400 Oo E eo Oo ojo Ooojo jojojo ojoj oj o o o ojoooojo ojooojojolooojojooo CR EN C 34 Dimensions 9 1 Pump parts Ordering parts and spare parts You can use the order form included in this manual for ordering parts You must always state the following on the order 1 Your address information 2 The quantity the item number and the description of the part 3 The pump number ul sounson PUMP Cross section pump with closed impeller 9 3 OLO 07 OLLE UILG on 7 LA Ld VULE TO NIA 0280 OLL 0680 0 Ubri V UVLV 098L an VU
17. 125 0 5 2 6 CR 504 160 0 6 3 4 CR 504 200 1 0 5 7 CR 50A 250 1 4 CR 50A 315 CR 50B 125 0 4 CR 50B 160 0 6 CR 50B 200 CR 50B 250 CR 50B 315 CR 80A 125 CR 80A 160 CR 80A 200 CR 80A 250 CR 80A 315 CR 100A 160 CR 100A 200 CR 100A 250 CR 100A 315 CR 100A 400 CR 100B 200 CR 100B 250 CR 100B 315 CR 100B 400 CR 150A 250 CR 150A 315 CR 150A 400 CR EN 4C Technical data 69 ul sounson PUMP CR EN C 70 Technical data CombiPro M onn BH SON PUMP index A G Allowable forces 42 Guarantee 8 Applications 11 Arrangement H delta arrangement 21 star delta arrangement 22 Hoisting 9 B Back Pull Out unit Impeller 12 assembly 30 assembly 31 Disassembly 30 disassembly 31 Base plate 13 Installation 17 18 19 20 21 22 Bearing drain 25 assembly 34 flushing 25 disassembly 34 foundation 17 instructions for assembly 33 Instructions 7 Bearing construction 13 Bearings L lubrication 25 Liquid C drain 29 Cavitation 24 26 M Check f direction of rotation 24 Maintenance 25 26 fuses 23 mechanical seal 25 Construction 12 Mechanical seal 13 Coupling 13 assembly 33 align tolerances 19 disassembly 33 aligning 18 mounting instructions 33 E N Earth 17 Noise 24 26 Eccentric reducer 20 Electric motor O connectin 21 oil drainin 30 F g Fault 26 P Pallets 9 Permitted moments 42 CR EN C Index 71
18. 32 0 2 422 15 50 Fax 432 0 2 422 15 59 the Netherlands Tel 31 0 592 34 28 33 Fax 31 0 592 40 93 51 DENMARK Johnson Pumper A S Tel 45 43 52 24 00 Fax 45 43 52 15 77 FINLAND Johnson Pump Oy Tel 358 0 9 348 3800 Fax 4358 0 9 348 38495 FRANCE Johnson Pompes Tel 33 0 1 39 20 50 00 Fax 33 0 1 39 56 54 22 GERMANY Johnson Pumpen GmbH Tel 49 0 5731 480 80 Fax 449 0 5731 414 00 Sales Office Essen Tel 49 0 201 23 70 66 ITALY Johnson Pump Italiana S r l Tel 39 039 604 14 63 Fax 39 039 604 90 97 NETHERLANDS Centrifugal Pumps Positive Displacement Pumps contact Belgium Johnson Pump Nederland Tel 31 0 592 37 67 67 Fax 31 0 592 37 67 60 Johnson Pump Horticulture Tel 31 0 174 51 84 10 Fax 431 0 174 51 84 44 NORWAY Johnson Pump A S Tel 47 22 74 08 40 Fax 47 22 28 03 30 SPAIN Johnson Pump Espa a S L Tel 34 972 58 08 01 Fax 34 972 58 08 03 Sales Office Madrid Tel 34 91 328 30 40 SWEDEN Johnson Pump Svenska Tel 46 0 19 21 83 70 Fax 46 0 19 27 23 18 www johnson pump com SWITZERLAND Johnson Pumpen AG Tel 41 0 1 780 90 92 Fax 41 0 1 780 38 32 UNITED KINGDOM JP Pumps Ltd Tel 44 0 1293 55 34 95 Fax 44 0 1293 52 46 35 Northern Regional Office Bradford Tel 44 0 1274 74 22 47 Fax 44 0 1274 74 22 28 Joint Ventures KENYA Johnson Pump Kenya Ltd Tel 254 0 2 556 751 Fax 254 0 2
19. Impeller Closed impeller The back of the closed impeller is provided with back vanes in order to limit the pressure on the shaft seal and to allow the flushing liquid to circulate Contamination of the shaft seal is also prevented On the inlet side the impeller is provided with an interchangeable wear ring The sealing splits of the impeller are conforming to the values in accordance with API 610 In other words these are dependent on the diameter and type of material Semi open impeller The semi open impeller is fully interchangeable with the enclosed impeller The wider bore makes the semi open impeller suitable for liquids with solid particles The rear wall of the semi open impeller is almost fully open at the location of the 12 CR EN C General CombiPro 2 5 3 2 6 2 7 2 8 2 9 2 10 sonn PUMP BH SON PU pump cover The front wall is also partially open between the vanes Therefore an ample bore is created as a result of which impeller blockage occurs less rapidly Half open impeller A half open impeller can be used for special applications A wear plate is fitted into the pump casing along which the vanes rotate at close distance The half open impeller is easy to clean when liquids which easily bond to the wall are being pumped Blockage of the impeller also occurs less rapidly Pump cover The pump is designed to fit any seal type in accordance with API 682 In collaboration with various su
20. Material code acc API 610 code S 6 carbon steel A216 grade WCA pump cover carbon steel A216 grade WCA countersunk head screw stainless steel A276 type 316 impeller Cr Steel A296 grade CA 40 wear plate Cr Steel A296 grade CA 40 casing wear ring Cr Steel 200 250Br A743 grade CA 40 set screw stainless steel A276 type 304 bracket support steel A108 grade 1020 impeller wear ring Cr steel 300 350Br A743 grade CA 40 set screw stainless steel A276 type 304 gasket plug steel A108 grade 1020 plug steel A108 grade 1020 stud Cr Mo steel A193 grade B7 nut Cr Mo steel A194 grade 2H lock washer steel bolt stainless steel A276 type 304 allen screw steel A108 grade 1020 cap nut stainless steel A276 type 316 set screw stainless steel A276 type 304 impeller key stainless steel A276 type 316Ti bearing bracket nodular cast iron A395 536 bearing cover carbon steel A48 class 35 bearing cover carbon steel A48 class 35 oil baffle bronze B271 C93200 oil baffle bronze B271 C93200 oil fill plug steel wire cage steel constant level oiler oil sight glass magnetic drain plug ring gasket bearing cover 42 Pump parts CR EN C
21. a new gasket 0300 in the pump cover and re assemble the complete Back Pull Out unit in the pump casing Tighten the nuts 0805 crossways 2 Fasten the bracket support 0140 at the base 3 Assemble the intermediate stage of the spacer coupling or re position the electric motor 4 Check the alignment of the pump and motor shaft see 3 4 3 If necessary re align in operating position 28 CRIEN C Disassembly and assembly 7 6 7 6 1 7 6 2 7 6 3 Replacing the wear rings The play diameter between the impeller wear ring and the casing wear ring is 0 3 mm on supply Ifthe play has risen to 0 5 0 7 mm due to wear then both wear rings are replaced Disassembly of the impeller 1 Disassemble the Back Pull Out unit see 7 5 2 2 Unlock the set screw 1825 and disassemble the impeller nut 1820 3 Disassemble the impeller 0120 or wrest the impeller free by inserting for instance 2 big screwdrivers between the impeller and the stuffing box cover 0110 4 Disassemble the impeller key 1860 Assembly of the impeller 1 Fitthe impeller key 1860 2 Pushthe impeller 0120 onto the pump shaft 2200 3 Fitthe impeller nut 1820 4 Fitthe Back Pull Out unit see 7 5 3 Disassembly of the wear rings 1 Disassemble the impeller see 7 6 1 2 Disassemble the set screws 0155 that lock up the wear ring 0150 on the impeller 3 Disassemble the set screws 0135 that lock up the wear ring 0130 in the
22. according to classification ISO VG 68 BP HLP 68 Gulf Texaco Chevron EP Industrial Oil 68 Total Azolla 68 Esso Teresso 68 Shell Tellus 68 Mobil Mobil DTE oil heavy medium 10 5 Quantity of oil for bearing CR 40A 125 CR 40A 160 CR 40A 200 CR 40A 250 CR 50A 125 CR 50A 160 CR 50A 200 CR 50A 250 CR 50A 315 CR 50B 125 CR 50B 160 CR 50B 200 CR 50B 250 CR 50B 315 CR 80A 125 CR 80A 160 CR 80A 200 CR 80A 250 CR 80A 315 CR 100A 160 CR 100A 200 CR 100A 250 CR 100A 315 CR 100A 400 CR 100B 200 CR 100B 250 CR 100B 315 CR 100B 400 CR 150A 250 CR 150A 315 CR 150A 400 CR EN 4C Technical data 55 H sonnson PUMP ll 10 6 Permissible pressure and temperature Maximum Maximum allowable Maximum hydrostatic speed at working pressure test pressure CombiP max impeller to 50 C to 50 C an diameter 102 kPa 102 kPa carbon carbon in St min steel siot steel seen CR 40A 125 CR 40A 160 CR 40A 200 CR 40A 250 CR 50A 125 CR 50A 160 CR 50A 200 CR 50A 250 CR 50A 315 CR 50B 125 CR 50B 160 CR 50B 200 CR 50B 250 CR 50B 315 CR 80A 125 CR 80A 160 CR 80A 200 CR 80A 250 CR 80A 315 CR 100A 160 CR 100A 200 CR 100A 250 CR 100A 315 CR 100A 400 CR 100B 200 CR 100B 250 CR 100B 315 CR 100B 400 CR 150A 250 CR 150A 315 CR 150A 400 1 See 10 7 carbon steel 90 80 70 stainless ste
23. guarantee Follow the instructions given step by step 3 1 2 Pump unit e Ensure that the pump can not be started if work has to be undertaken to the pump during installation and the rotating parts are insufficiently guarded e Depending on the design the pumps are suitable for liquids with a temperature of up to 350 C When installing the pump unit to work at 70 C and above the user should ensure that appropriate protection measures and warnings are fitted to prevent contact with the hot pump parts e lf there is danger of static electricity the entire pump unit must be earthed e Ifthe liquid being pumped can cause danger for man or the environment measures must be taken to drain the pump in a safe way 3 2 Protection In order to prevent corrosion the inside of the pump is treated with a preserving agent before leaving the factory Before commissioning the pump remove any preserving agents and flush the pump thoroughly with hot water 3 3 Environment e The foundation must be hard level and flat e The area in which the pump is installed must be sufficiently ventilated An ambient temperature or air humidity which is too high or a dusty environment can have a detrimental effect on the operation of the electric motor e There should be sufficient space around the pump unit to operate and if necessary repair it e Behind the cooling air inlet of the motor there must be a free area of at least 1 4 of the electric motor diamete
24. knocking a lip of the retaining ring into the opening of the bearing lock nut Mount both the inner circlips 2300 into the bearing bracket 2100 Press the outer ring of the roller bearing 2250 into its boring in the bearing bracket using a proper pressure piece Check if the oil baffles 2120 and 2125 are not worn out Replace them if necessary Mount the bearing cover 2110 using a new gasket 2160 Press the pump shaft with the bearings carefully into the bearing bracket until the nearest angular contact ball bearing touches the outer circlip Take care not to damage the rollers of the roller bearing Mount the bearing cover 2115 using a new gasket 2160 Mount the mechanical seal and the impeller see 7 7 2 and 7 6 1 32 CR EN C Disassembly and assembly PM sounson PUMP CombiPro a 8 Dimensions 8 1 Dimension print figure 11 Dimension print CR EN C i Dimensions 33 MW sonnson PUMP alll 8 2 Flange dimensions ANSI B16 5 150lbs ISO7005 PN20 8 3 Flange dimensions ANSI B16 5 300lbs ISO7005 PN50 8 4 Pump dimensions Pump type CR 40A 125 CR 40A 160 CR 40A 200 CR 40A 250 CR 50A 125 CR 50A 160 CR 50A 200 CR 50A 250 CR 50A 315 CR 50B
25. or suction pipe not sufficiently filled or vented Gas or air coming from the liquid Air lock in the suction pipe Suction pipe leaks air The manometric suction head is too high Suction pipe or suction strainer is blocked Insufficient immersion of foot valve or suction pipe during operation of the pump NPSH available too low Speed too high Speed too low Wrong sense of rotation Pump does not work at the correct duty point Liquid density differs from the calculated density Liquid viscosity differs from the calculated viscosity Pump operates with too low liquid flow Wrong pump selection Obstruction in impeller or pump housing Obstruction in the pipe system Wrong installation of the pump unit Pump and motor not correctly aligned Rotating part running out of true Rotating parts out of balance i e impeller pump shaft or coupling Pump shaft is running out of true Bearings faulty or worn Casing wear rings faulty or worn Impeller is damaged Axial retaining of impeller or pump shaft is defective The bearings have been fitted incorrectly Too much or too little ball bearing lubrication Wrong or polluted lubricant Contaminants in the liquid Too high axial force due to excessive inlet pressure CR EN 4C 26 Problem solving il JOHNSON PUMP CombiPro E 7 Disassembly and assembly 7
26. to the curve Go left to the L dB axis Read the value here Add the value found in 6 to the highest noise level L1 or L2 Example 1 2 3 4 Pump 75 dB motor 78 dB 75 78 3 dB 3 dB on the X axis 1 75 dB on the Y axis Highest noise level 1 75 dB 78 1 75 79 75 dB 66 CR EN C Technical data CombiPro Type A Pusher 10 11 Shaft sealing 10 11 1 Specifications mechanical seals arrangement 1 single mechanical seal MM sonnson PUMP ll arrangement 2 dual mechanical seal unpressurized arrangement 3 single mechanical seal pressurized Shaft size Flexibox AP1M 0476 RRAR 036A RRER 036A Durametallic OB 1750 AP1M 0571 RRAR 045A RRER 045A QB 2125 AP1M 0666 RRAR 056A RRER 056A PA100 QB 2500 Type B Bellows GT7B 0400 PB100 BX 1500 GT7B 0500 PB100 BX 1875 GT7B 0600 PB100 BX 2250 Type C Bellows Type A Pusher ST1B 0450 ST1B 0530 Shaft size ST1B 0630 Flexibox AP1T 0476 on request Durametallic PA200 BXRH 1625 BXRH 2000 BXRH 2375 QB 2000 1750 AP1T 0571 PA200 QB 2375 2125 AP1T 0666 PA200 QB 22750 2500 Type B Bellows GL1T 0400 PB200 BX 1750 1500 GL1T 0500 PB200 BX 2125 1875 GL1T 0600 PB200 BX 2500 2250
27. 10 1 10 2 10 2 1 10 2 2 10 2 3 10 3 10 4 10 5 10 6 10 7 10 8 10 8 1 10 8 2 10 9 10 10 10 10 1 10 10 2 10 11 10 11 1 10 11 2 10 11 38 Parts list pump S 8 Parts list pump C 6 Parts list pump A 8 Partslist cooling chamber Technical data Recommended liquid locking agents Torques settings Torques settings for bolts and nuts Torques settings for impeller nut Torques settings for nuts for pump casing Masses and cubic contents Recommanded oil Quantity of oil for bearing Permissible pressure and temperature Eventual higher maximum speed Allowable forces and moments on the flanges Allowable forces and moments on the suction flange Allowable forces and moments on the discharge flange Survey curves Noise data Pump noise as a function of pump power Noise Shaft sealing Specifications mechanical seals Dimensions shaft area Pressure in shaft seal area Index Order form for spare parts 44 46 48 50 51 51 51 51 52 53 55 55 56 57 58 59 60 61 65 65 66 67 67 68 69 71 73 Table of contents CRIEN C M sounson PUMP CombiPro a 1 1 Introduction 1 1 Introduction This manual contains important and useful information for the proper operation and maintenance of this pump It also contains important instructions to prevent potential accidents and damage and to ensure safe and fault free operation of this pump Read this manual carefully before commissioning the pump familiari
28. 23 23 24 24 25 27 27 Table of contents CRIEN C il JOHNSON PUMP CombiPro E 7 1 1 Electrical connections 27 7 2 Tools 27 7 3 Item numbers 27 7 4 Drain pump 27 7 4 1 Draining the liquid 27 7 4 2 Oil draining 28 7 5 Back Pull Out system 28 7 5 1 Principle 28 7 5 2 Disassembly of the Back Pull Out unit 28 7 5 8 Assembly of the Back Pull Out unit 28 7 6 Replacing the wear rings 29 7 6 1 Disassembly of the impeller 29 7 6 2 Assembly of the impeller 29 7 6 3 Disassembly of the wear rings 29 7 6 4 Assembly of the wear rings 30 7 7 Mechanical seal 31 7 7 1 Instructions for mounting a mechanical seal 31 7 7 2 Disassembly of the mechanical seal 31 7 7 3 Assembly of the mechanical seal 31 7 8 Bearing 31 7 8 1 Instructions for assembly and disassembly of bearings 31 7 8 2 Disassembly of the bearing 32 7 8 3 Assembly of the bearing 32 8 Dimensions 33 8 1 Dimension print 33 8 2 Flange dimensions ANSI B16 5 150lbs ISO7005 PN20 34 8 3 Flange dimensions ANSI B16 5 300lbs ISO7005 PN50 34 8 4 Pump dimensions 34 9 Pump parts 35 9 1 Ordering parts and spare parts 35 9 2 Pump number 35 9 3 Cross section pump with closed impeller 36 9 4 Cross section pump with semi open impeller 37 9 5 Cross section pump with half open impeller 38 9 6 Cross section pump with cooling chamber 39 9 7 Parts list pump S 1 40 9 8 Part slist pump S 6 42 CR EN C Table of contents 5 M souNson PUMP a 1 M 9 9 9 10 9 11 9 12 10
29. 532 748 MALAYSIA Johnson Pump M Sdn Bhd Tel 60 0 3 943 2300 Fax 60 0 3 943 6300 SOUTH AFRICA Southern Pumps S A Pty Ltd Tel 27 0 21 551 24 90 Fax 27 0 21 551 30 88 TANZANIA Johnson Pump Tanzania Ltd Tel 255 0 51 865 776 Fax 255 0 51 865 775 ZIMBABWE Johnson Pump Zimbabwe Pvt Ltd Tel 263 0 4 611 681 Fax 263 0 4 611 680 4M JOHNSON PUMP Johnson Pump Water B V Business Units BELGIUM Johnson Pump Brussels N V Tel 32 0 2 422 15 15 Fax 432 0 2 422 15 01 INDIA Johnson Pump India Ltd Tel 91 0 79 287 03 11 Fax 491 0 79 287 25 22 NETHERLANDS Johnson Pump Water B V Tel 31 0 592 37 67 67 Fax 431 0 592 37 67 60 SWEDEN Johnson Pump Marine Tel 46 0 19 21 83 00 Fax 46 0 19 27 23 72 USA Johnson Pumps of America Inc Tel 1 847 671 7867 Fax 1 847 671 7909 ISO 9001 Dr A F Philipsweg 51 P O Box 9 9400 AA Assen The Netherlands Tel 31 0 592 37 67 67 Fax 31 0 592 37 67 60 E mail info nl johnson pump com
30. 80 195 270 284 320 427 562 3 asses in kg and cubic contents in m of pump with motor excl sealpipi and baseplate based on motor make Dutchi CR 40A 125 CR 40A 160 CR 40A 200 CR 40A 250 CR 50A 125 CR 50A 160 CR 50A 200 CR 50A 250 CR 50A 315 CR 50B 125 CR 50B 160 CR 50B 200 CR 50B 250 CR 50B 315 CR 80A 125 CR 80A 160 CR 80A 200 CR EN C Technical data 53 M souNSON PUMP a 1 E Motor IEC IP54 db 160 160 180 180 200 225 225 250 280 Nett mass LIM SIMIM ILIM IL JLITS M i M S Pump type pump in kg 38 45 70 81 125 147 180 195 270 284 320 427 562 asses in kg and cubic contents in m of pump with motor excl sealpipi and baseplate based on motor make Dutchi CR 80A 250 CR 804 315 CR 100A 160 CR 100A 200 CR 100A 250 CR 1004 315 CR 100A 400 CR 100B 200 CR 100B 250 CR 100B 315 CR 100B 400 CR 150A 250 CR 150A 315 CR 150A 400 CR EN 4C 54 Technical data PH sounson PUMP CombiPro a 10 4 Recommanded oil Recommanded oil types for ambient temperatures over 15 C
31. Ce Instruction manual CombiPro Heavy duty process pump according to API 610 8th edition NN In JOHNSON PUMP EC Declaration of conformity Directive 98 37 EC appendix II A Manufacturer Johnson Pump Water B V Dr A F Philipsweg 51 P O Box 9 9400 AA Assen Netherlands hereby declares that the pump in case it is delivered as an assembly with drive last position of serial number A is in conformity with the provisions of Directive 98 37 EC as altered most recently and the following directives and standards e EC directive 73 23 EEC Electric equipment for use within certain voltage limits e standards EN 292 part 1 amp 2 EN 809 The pump to which this declaration refers may only be put into operation after it has been installed in the way prescribed by the manufacturer and as the case may be after the complete system of which this pump forms part has been made to fulfil the requirements of Directive 98 37 EC as altered most recently Manufacturer s declaration Directive 98 37 EC appendix II B Manufacturer Johnson Pump Water B V Dr A F Philipsweg 51 P O Box 9 9400 AA Assen Netherlands hereby declares that the pump in case it is delivered without drive last position of serial number
32. aring and a normal hammer a soft hammer might loose some splinters which could damage the bearing Never mount used retaining rings 2570 always use new rings 7 8 2 Disassembly of the bearing gt First read the instructions regarding assembly and disassembly 4 2 3 Disassemble the impeller and the mechanical seal see 7 6 1 and 7 7 2 Disassemble the coupling key 2210 and the bearing covers 2110 and 2115 Remove the gaskets 2160 Knock the pump shaft 2200 on the impeller side so as to loosen the bearings from the bearing bracket Use a plastic hammer to avoid damage to the thread Remove the pump shaft with the bearings from the bearing bracket Remove both the inner circlips 2300 from the bearing bracket Push the outer ring of the roller bearing 2250 out of the bearing bracket Knock the lip of the retaining ring 2570 out of the bearing lock nut 2560 Loosen the bearing lock nut Use a puller to remove the bearings from the pump shaft 7 8 8 Assembly of the bearing gt First read the instructions regarding assembly and disassembly 4 Mount at the impeller side the inner ring rollers of roller bearing 2250 onto the pump shaft 2200 Mount at drive side the 2 angular contact ball bearings 2260 in back to back position see figure 12 onto the pump shaft Let the bearings cool down Fit the retaining ring 2570 and the bearing lock nut 2560 Tighten the bearing lock nut and secure it by
33. e of ordering spare parts Ordering spare parts This manual contains the spare parts recommended by Johnson Pump as well as the instructions for ordering them A fax order form is included in this manual If you have any questions or require further information with regard to specific subjects then do not hesitate to contact Johnson Pump Pump number The pump number is stamped on the type plate of the pump For correspondence and when ordering spare parts you should always state this number and the other information on the type plate The pump information is also stated on the label on the front of this manual CR EN C Introduction PM sounson PUMP CombiPro a 1 5 Checking goods delivered Check the consignment immediately on arrival for damage and conformity with the advice note In case of damage and or missing parts have a report drawn up by the carrier at once 1 6 Transport instruction 1 6 1 Dimensions and weight The CombiPro range pump units are generally too heavy to be moved by hand Therefore use the correct transport and lifting equipment The weight of this pump unit is shown on the label in the front of this manual For dimensions of the pump unit see chapter 8 1 6 2 Use of pallets The CombiPro is packed on a pallet Leave the pump on the pallet as long as possible This prevents unnecessary damage and makes transporting the pump easier if the pump has to be moved again for installation Use
34. el 80 70 65 CR EN C 56 Technical data A JOHNSON PUMP CombiPro a 10 7 Eventual higher maximum speed Eventual higher maximum speed as mentioned in 10 6 with reduced impeller diameter CR Max speed min 1 impeller diameter mm Dmax 1500 1800 3000 3600 142 142 128 CR 80A 125 CR 100A 160 CR 100A 200 CR 100A 250 CR 100B 200 220 220 202 CR 100B 315 324 324 311 CR 150A 400 404 404 401 CR EN 4C Technical data M souNson PUMP a 1 i 10 8 Allowable forces and moments on the flanges figure 16 Coordinate system according to API 610 2 4 1 CR EN 4C 58 Technical data PM sounson PUMP CombiPro a 10 8 1 Allowable forces and moments on the suction flange Allowable forces and moments on the suction flange based on API 610 2 4 1 Allowable forces N Allowable moments Nm Pump type Suction Suction Fy Fz My Mz CR 40A 125 CR 40A 160 CR 40A 200 CR 40A 250 CR 50A 125 CR 50A 160 CR 50A 200 CR 50A 250 CR 50A 315 CR 50B 125 CR 50B 160 CR 50B 200 CR 50B 250 CR 50B 315 CR 80A 125 CR 80A 160 CR 80A 200 CR 80A 250 CR 80A 315 CR 100A 160 CR 100A 200 CR 100A 250 CR 100A 315 CR 100A 400 CR 100B 200 CR 100B 250 CR 100B 315 CR 100B 400 CR 150A 250 CR 150A 315 CR 150A 400
35. ess steel A276 type 316Ti bearing bracket nodular cast iron A395 536 bearing cover carbon steel A48 class 35 bearing cover carbon steel A48 class 35 oil baffle bronze B271 C93200 oil baffle bronze B271 C93200 oil fill plug steel wire cage steel constant level oiler oil sight glass magnetic drain plug ring gasket bearing cover 40 Pump parts CR EN C il JOHNSON PUMP CombiPro Material code Description acc API 610 code S 1 2180 deflector rubber 2190 set screw stainless steel 2200 pump shaft Cr Ni steel A276 type 431 2210 coupling key steel A108 grade 1020 2250 roller bearing 2260 angular contact bearing 2300 inner circlip steel 2410 indication plate arrow aluminium 2420 indication plate oil level stainless steel 2560 bearing lock nut steel 2570 retaining ring steel 2810 allen screw steel A108 grade 1020 2815 allen screw steel A108 grade 1020 2820 bolt steel A108 grade 1020 2830 washer steel Recommended spare parts Number depends on pump type 2 4 6 or 8 Number depends on pump type 8 or 12 Number depends on bearing group 4 or 8 Bearing group 1 Allen screw CR EN 4C Pump parts 41 M onn BH SON PUMP Part slist pump S 6 Description pump casing
36. gorously a few times by hand Top up the pump as necessary CR EN C Commissioning 21 M onn PUMP BH SON PU 4 5 4 6 Checking the direction of rotation When checking the direction of rotation look out for any unguarded rotating parts 1 The direction of rotation of the pump is shown by an arrow on the bearing housing Check if the direction of rotation of the motor corresponds with that of the pump 2 Only switch the motor on for a brief period and check the direction of rotation 3 Ifthe sense of rotation is not correct alter the sense of rotation See the the instructions in the user manual belonging to the electric motor 4 Fitthe protecting guard Switching on the pump Make sure that the rotating parts are always sufficiently guarded when the pump is running 1 Open the valve in the flushing or cooling liquid supply pipe if the pump is fitted with flushing or jacket cooling 2 Switch on the pump 3 Once the pump is up to pressure slowly open the pressure cock Check the power consumption of the electric motor 4 Now open the outlet valve fully until the pump reaches the correct duty point Check the power consumption again Check If a pump is in operation pay attention to the following The pump should never run dry e Check if the system pressure always remains below the maximum permissible working pressure For the correct values see 10 6 e Never use the stop valve in the suction pipe to con
37. hanical seal 1 Put the bearing bracket in upright position impeller side up 2 Push the seal cartridge onto the pump shaft 3 Mount the pump cover 0110 in the correct position in the fitting edge of the bearing bracket 2100 Check whether the pump cover is at right angles to the pump shaft Fasten the pump cover with Allen screws 0850 4 Mount the mechanical seal against the pump cover 0110 Check the position in view of the connection points 5 Mount the impeller and other parts see 7 6 2 and 7 5 3 6 Release the centering tabs turn them halfway round and secure them again against the seal cover The shaft must now be able to rotate freely Bearing Instructions for assembly and disassembly of bearings Stick closely to the following instructions when assembling and disassembling bearings Disassembly Use a proper puller to remove the bearings from the pump shaft e f no proper puller is available carefully knock on the inner raceway of the bearing Use a normal hammer and a soft metal drift Never knock the bearing with a hammer CR EN 4C Disassembly and assembly 31 M onn BH SON PUMP Assembly Make sure your workplace is clean and leave the bearings in their original packing as long as possible Preheat the bearings to 90 C before mounting them on the pump shaft If preheating is not possible never knock the bearing directly Use a mounting bush positioned against the inner raceway of the be
38. is sprayed clean ail ome run Never spray water on hot pump parts These parts can burst if subject to sudden cooling and the hot pump liquid can then come out figure 7 Oil level 5 1 3 Mechanical seal A mechanical seal generally requires no maintenance however it should never be allowed to run dry If there are no problems it is not advisable to dismantle Because the facing surfaces are running in on one another dismantling always means replacement of the seal When the seal is leaking it has to be replaced 5 2 Lubrication of the bearings e The constant level oiler should never be empty during operation It must therefore be topped up in time e The oil must be replaced every 5000 hours of operation It must be replaced more frequently for higher environmental temperatures e g in the boiler house You can find the recommended oil grades in 10 4 gt Make sure that the used oil is discharged safely See to it that no oil gets into the environment 5 3 Environmental influences e Regularly clean the filter in the suction pipe or the suction strainer at the bottom of the suction pipe because the inlet pressure may become too low if the filter or the suction strainer is blocked e Ifthe unit is out of operation and there is the danger that the pumped liquid will expand as a result of solidifying or freezing it should be drained and if neccessary be flushed e Ifthe pump is put out of opera
39. ist pump A 8 Description pump casing Material code acc API 610 code A 8 stainless steel A351 grade CF 8M pump cover stainless steel A351 grade CF 8M countersunk head screw stainless steel A276 type 316 impeller stainless steel A296 grade CC50 wear plate stainless steel A296 grade CC50 casing wear ring stainless steel A351 grade CF 8M set screw stainless steel A276 type 304 bracket support steel A108 grade 1020 impeller wear ring stainless steel A296 grade CC50 set screw stainless steel A276 type 304 gasket plug stainless steel A276 type 316 plug stainless steel A276 type 316 stud Cr Mo steel A193 grade B7 nut Cr Mo steel A194 grade 2H lock washer steel bolt stainless steel A276 type 304 allen screw steel A108 grade 1020 cap nut stainless steel A276 type 316 set screw stainless steel A276 type 304 impeller key stainless steel A276 type 316Ti bearing bracket nodular cast iron A395 536 bearing cover carbon steel A48 class 35 bearing cover carbon steel A48 class 35 oil baffle bronze B271 C93200 oil baffle bronze B271 C93200 oil fill plug steel wire cage steel constant level oiler oil sight glass magnetic drain plug ring
40. ke place by moving the electric motor 1 Place a ruler A on the coupling Remove or add as many shims as is necessary to bring the electric motor to the correct height so that the straight edge touches both coupling halves over the entire length see figure 3 2 Repeatthe same check on both sides of the coupling at the height of the shaft Move the electric motor so that the straight edge touches both coupling halves over the entire length 3 To be certain the check is also undertaken using external callipers B at 2 diametrically opposed points on the sides of the coupling halves see figure 3 18 CR EN C Installation CombiPro Monn BH SON PUMP 4 Repeat this check at operating temperature and spend time achieving minimum alignment deviation 5 Fit the protecting guard See figure 4 and the corresponding table for the maximum permissible tolerances during setting of the coupling halves External diameter of coupling mm min mm max mm Vamax Vamin Vrmax 81 95 96 110 111 130 131 140 141 160 161 180 181 200 201 225 OO Alea NPININININININ P coupling with spacer figure 4 Alignment tolerances CR EN 4C Installation 19 Monn N PUMP BH SON PU 3 5 Piping The CombiPro is not a self priming pump as a rule the liquid must flow into the pump The suction and pressure pipes must connect perfectly and be free of tension d
41. ng a cooling chamber Base plate and coupling A unique base plate is made for each pump motor combination This is designed in the most optimum way for the relevant combination The base plate is assembled from steel sections and is of an open design so that it can be grouted into concrete This provides maximum rigidity to the structure so that forces from the network of pipes cannot cause any alignment error in the coupling A drip pan under the entire pump collects all leakage liquid and discharges this to the drain point which has a 2 connection Adjustment bolts are provided in the base plate for accurate horizontal adjustment of the entire unit Pump and motor are assembled with a flexible coupling with spacer so called Spacer coupling As a result of this it is possible to disassemble the pump without having to remove the motor and the pump casing from the base plate This is known as the back pull out principle For the coupling a selection can be made between a type with flexible rubber elements or a stainless steel diaphragm set CR EN 4C General 13 Monn PUMP BH SON PU 2 11 Type code The CombiPro range of pumps can be supplied in several designs The main features of the pump are shown in the type code CR 50A 200 A 8 1A 11 Abbreviated designation for CombiPRo Discharge connection mm A and B design pump types have the same designation though they have different hydraulic performances Nominal impelle
42. of a forklift truck always set the forks as far apart as possible and lift the pallet using both forks Avoid jolting the pump when moving it 1 6 3 Hoisting When hoisting a pump or complete pump units the straps must be fixed in accordance with figures 1 and 2 figure 1 Lifting instruction pump unit CR EN C Introduction 9 M onn PUMP BH SON PU 1 7 figure 2 Lifting instruction single pump Never stand underneath a hoisted pump Storage If the pump is not to be used immediately the pump shaft must be turned by hand twice per week 10 CR EN C Introduction CombiPro 2 1 2 2 M onn PUMP BH SON PU General Pump description The CombiPro is a series of horizontal heavy duty centrifugal pumps The design of this pump is based on the guidelines Centrifugal Pumps for General Refinery Services of the American Petroleum Institute otherwise known as the API Standard 610 The CombiPro range therefore meets the high requirements which have been set by the refineries and the petrochemical industry The API 610 contains important technical guidelines in order to guarantee optimum reliability The CombiPro amply complies with these requirements This has been demonstrated through extensive research and can be supported on the basis of advanced methods of calculation Applications In general CombiPro
43. ppliers of mechanical seals the design has been closely evaluated in order to be able to build in the required variants Wear rings Both the impeller and the pump casing are fitted with a renewable wear ring The casing wear ring has a hardness at least 50 Br over the impeller wear ring The rings are secured by three lock screws Mechanical seal The various designs of pumps are created by the addition of shaft seal cartridges These cartridges are standardized in the same three groups as the pump shafts and are designed in accordance with API 682 Bearing e The bearing construction consists of two angular contact bearings in O arrangement combined with a cylindrical bearing The bearings are oil lubricated The oil level is kept constant by means of a constant oil leveler The bearings on the coupling side with which the axial force is taken up are retained on the shaft by a shaft nut The outer ring of these bearings is retained by the bearing cover e The cylindrical bearing on the impeller side takes up radial forces and is mounted floating on the outer ring As a result of this the machining tolerances and expansions can be easily accommodated The bearing arrangement is sealed by labyrinth rings f required the oil bath can be provided with cooling for example when the ambient temperature is higher than 45 C or in other extreme applications The underside of the bearing bracket is provided with an option for creati
44. pump casing In most cases the rings have been fixed so tightly that they cannot be removed undamaged Proceed as follows see also figure 9 e c 4 Measure the thickness d and the width b of the ring Make a centre hole in the middle of the rim of the ring at two opposite points 6 Select a drill with a somewhat smaller diameter than the thickness d of the ring and drill 2 holes in the rim of the ring a Monn BH SON PUMP 7 6 4 Do not drill deeper than the width b of the ring Take care not to damage the fitting edges of the pump casing and the impeller Use a chisel to cut away the remaining part of the ring thickness The rings can then be removed in 2 sections Clean the pump casing and the impeller and carefully remove all drill shavings and metal splinters Assembly of the wear rings 4 2 Clean and degrease the wear rings 0130 en 0150 and the fitting edges of the impeller 0120 and the pump casing 0100 Apply a few drops of Loctite 641 onto the inside of wear ring 0150 and fit the wear ring sliding it over the impeller entrance Apply a few drops of Loctite 641 onto the outside of wear ring 0130 and fit the wear ring sliding it into the pump casing Make sure that they are not inserted obliquely 4 Both wear rings then have to be secured Drill 3 holes 25 mm 9 mm deep right on the seam between impeller and wear ring c q pump casing and wear ring Subsequently cut screw thread M6 see figure 10
45. pumps are suitable for thin clean and lightly contaminated liquids The maximum allowed system pressure and temperature and the maximum speed are dependent upon the pump type and design You can find data concerning this in 10 6 Further information about the application options of your specific pump can be found in the order confirmation and or the accompanying datasheet We advise against using the pump for an application which differs from that for which the pump was originally supplied without discussing this with your supplier first Using a pump in a system or under system conditions liquid system pressure temperature etc for which it has not been designed can create danger for the user CR EN 4C General 11 M onn BH SON PUMP 2 3 2 4 2 5 2 5 1 2 5 2 Construction The CombiPro has been constructed in accordance with a rigorously applied modular construction method e For each pump type the pump casing and the impeller in the various types of materials are structurally the same and interchangeable In principle this means that the hydraulic performances are fixed The required capacity and head are obtained by selecting the pump speed and if necessary by reducing the impeller diameter e The pumps are divided into three bearing groups Each bearing group only has one pump shaft and one bearing arrangement e The pumps are also standardized into six groups with the same connection for the pump ca
46. r to ensure unobstructed air supply CR EN C Installation 17 Monn PUMP BH SON PU 3 4 AN 3 4 1 3 4 2 3 4 3 Pump unit Ensure that the pump can not be started if work has to be undertaken to the pump during installation and the rotating parts are insufficiently guarded Positioning The pump shaft and motor shaft of complete units are fitted accurately together in the factory For permanent installation use shims to ensure that the base plate is level on the foundation Then carefully tighten the nuts on the foundation bolts After that check the setting of the pump and motor shaft and readjust as required It is preferred that the 2 base plate supporting flanges are cast into concrete Assemble If the pump and the electric motor still have to be assembled proceed as follows 1 Fit without impact tool both halves of the coupling to the pump shaft and the motor shaft respectively 2 Position the pump on the foundation and secure it with bolts 3 Place the electric motor on the foundation Mount shims of at least 5 mm between the base plate and the pump and or the electric motor Place copper shims under the feet of the electric motor Secure the electric motor with bolts and ensure there is a gap of 3 mm between both coupling halves 4 Align the coupling in accordance with the following instructions Align the coupling figure 3 Alignment of the coupling Alignment of the coupling halves may only ta
47. r diameter mm Material designation code Material combinations according to API 610 Code API 610 Pump casing material Impeller material S 1 carbon steel cast iron S 6 carbon steel 1396 Cr steel S 8 carbon steel stainless steel 316 C 6 1396 Cr steel 1396 Cr steel A 8 stainless steel AISI 316 stainless steel AISI 316 Mechanical seal code according to API 682 1A Single seal arrangement 1 type A pusher type seal 1B Single seal arrangement 1 type B metal bellows rotating flexible element 1C Single seal arrangement 1 type C metal bellows stationary flexible element DA Arrangement 2 Dual seal with unpressurized buffer lower than product type A pusher type seal 2B Arrangement 2 Dual seal with unpressurized buffer lower than product type B metal bellows rotating flexible element 2C Arrangement 2 Dual seal with unpressurized buffer lower than product type C metal bellows stationary flexible element 3A Arrangement 3 Dual seal with pressurized buffer higher than product type A pusher type seal 3B Arrangement 3 Dual seal with pressurized buffer higher than product type B metal bellows rotating flexible element 3C Arrangement 2 Dual seal with pressurized buffer lower than product type C metal bellows stationary flexible element Mechanical seal flush plan according to API 682 Plan 11 Recirculation from pump discharge through a flow control orifice to the seal
48. revailing regulations of the electricity company Refer to the instruction manual belonging to the electric motor If possible mount a working switch as close as possible to the pump 20 CR EN C Installation p PH sounson PUMP CombiPro a 4 Commissioning 4 1 Preparation e Check if the shaft can rotate freely Do this by turning the shaft end at the coupling a few times by hand e Check if the fuses are fitted e Check that the setting for the thermal protection switch corresponds with the specification on the type plate on the electric motor e The pump is supplied with an oil lubricated bearing construction and is delivered without oil Flush the bearing housing with petrol or benzol first Then fill the bearing housing via the oil filler shut off with oil fill plug 2270 until the oil appears in the constant level oiler 2280 After this fill the constant level oiler See the indication plate see fig 6 for the right oil level See 10 4 for the relevant specifications of the oil to be used oil level indication 4395 Bi Jff onson PUMP figure 6 Oil level indication 4 2 Preparing for commissioning Proceed as follows both when the unit is put into operation for the first time and after the pump has been repaired 1 Fully open the stop valve in the suction pipe Close the delivery stop valve 2 Fillthe pump and the suction pipe with the liquid to be pumped 3 Rotate the pump shaft vi
49. ring stainless steel A351 grade CF 8M set screw stainless steel A276 type 304 gasket plug steel A108 grade 1020 plug steel A108 grade 1020 stud Cr Mo steel A193 grade B7 nut Cr Mo steel A194 grade H2 lock washer steel bolt stainless steel A276 type 304 allen screw steel A108 grade 1020 cap nut stainless steel A276 type 316 set screw stainless steel A276 type 304 impeller key stainless steel A276 type 316Ti bearing bracket nodular cast iron A395 536 bearing cover carbon steel A48 class 35 bearing cover carbon steel A48 class 35 oil baffle bronze B271 C93200 oil baffle bronze B271 C93200 oil fill plug steel wire cage steel constant level oiler oil sight glass magnetic drain plug ring gasket bearing cover 44 Pump parts CR EN C il JOHNSON PUMP CombiPro Material code Description acc API 610 code S 8 2180 deflector rubber 2190 set screw stainless steel 2200 pump shaft stainless steel A276 type 316L 2210 coupling key steel A108 grade 1020 2250 roller bearing 2260 angular contact bearing 2300 inner circlip steel 2410 indication plate arrow aluminium 2420 indication plate oil level stainless steel 2560 bearing lock nut steel
50. s The fault may not be in the pump it may also be caused by the pipe system or the operating conditions Firstly always check that installation has been executed in accordance with the instructions in this manual and that the operating conditions still correspond with the specifications for which the pump was purchased In general breakdowns in a pump installation are attributable to the following causes 1 Faults with the pump 2 Breakdowns or faults in the pipe system 3 Faults due to incorrect installation or commissioning 4 Faults due to incorrect choice of pump A number of the most frequently occurring failures as well as their possible causes are shown in the table below Most common faults Possible causes Pump delivers no liquid 1234567891011 13 14 17 19 20 21 27 29 Pump has insufficient volume flow 1234567891011 1314 15 17 19 20 21 28 29 Pump has insufficient head 24513 14 17 19 28 29 Pump stops after start up 1234567891011 Pump has higher power consumption than normal 12 15 16 17 18 22 23 24 25 26 27 32 34 38 39 Pump has lower power consumtion than normal 13 14 15 16 17 18 20 21 28 29 Pump vibrates or is noisy A adn 15 18 19 20 22 23 24 25 26 27 28 29 37 Bearings wear too much or become hot 23 24 25 26 27 37 38 39 40 42 Pump running rough hot or seizes 18 23 24 25 26 27 34 37 38 39 40 42 CR EN 4C Problem solving 25 M souNnson PUMP a 1 S Possible causes Pump
51. sing and pump cover depending on the nominal impeller diameters For each combination of shaft and nominal impeller diameter there is one pump cover in various materials and one bearing bracket which is made from nodular cast iron or carbon steel e Various material variants can be used for components which come into contact with the pumped liquid The most important parts are e Pump casing e Impeller e Mechanical shaft sealing e Bearing Pump casing On the suction side of the impeller the pump casing is provided with a renewable wear ring An anti rotation partition is fitted into the inlet The centering edge for the pump cover is located on the outside of the packing for the pump casing and does not therefore come into contact with the liquid The suction and discharge flanges are designed in accordance with ANSI B16 5 300 Ibs ISO 7005 PN50 and it is also possible to supply the flanges drilled in accordance with the ANSI B16 5 150 lbs ISO 7005 PN20 The outside diameter and the thickness of the inlet and outlet flanges are in this case in accordance with ANSI B16 5 300 Ibs The flanges can be designed as either raised faced or as flat faced The sealing face of the flanges can be finished in various machining patterns and roughnesses such as stock finished and smooth finished The drain for the pump casing is designed with a screw thread connection or with weld connections such as socket welded and butt welded
52. tion for a longer period it should be treated with a preserving agent and periodically the pump shaft has to be turned several times CR EN C Maintenance 23 Monn N PUMP BH SON PU 5 4 Noise If after some time the pump starts making a noise this may indicate that something is wrong with the pump A crackling noise in the pump may indicate cavitation an excessive motor noise can be an indication of decreasing bearing quality Fault If you want to establish the nature of a fault remember that the pump may be under pressure or the contents may be hot poisonous aggressive or flammable Take the correct safety measures and protect yourself gloves safety goggles Make sure that sufficient safety measures have been taken in area around the pump collection tray fire blankets eye bath etc The cause of electrical faults can also be in the wiring In that case call in a recognized electrical contractor If you are sure that the problem concerns the pump then proceed as follows 1 Firstly switch off the power supply to the pump Secure the operating switch using a lock or remove the fuses 2 Close the stop cocks Take a note of the nature of the fault 4 Using chapter 6 try to trace the cause Then take the appropriate measures Or Contact your installer ow 24 CR EN C Maintenance CombiPro M onn PUMP B SON PU Problem solving Faults in a pump installation can have various cause
53. trol pump capacity This must always be fully open e Check if the differential pressure between the suction and the pressure connections corresponds with the specifications of the working point of the pump e Check if the absolute inlet pressure is sufficient so that no condensation can form in the pump This can result in cavitation The minimum required inlet pressure in m above the vapour pressure of the liquid being pumped at pump temperature must be at least 0 5 1 m above the NPSH values of the pump NPSH Net Positive Suction Head Cavitation must always be prevented since this is very harmful to the pump Noise The noise generated by a pump depends to a large extent on the operating conditions The values stated in paragraph 10 10 are based on normal use of the pump driven by an electric motor When being used outside of the normal area of application with large capacities or with cavitation the noise level can exceed 85 dB A Preventative measures must then be taken such as fitting noise insulation around the pump unit or wearing ear protectors 22 CR EN C Commissioning il JOHNSON PUMP CombiPro E 5 Maintenance 5 1 Daily maintenance ae a NE oil level Sk Chisels indication e Regularly check the oil level see fig 7 e Regularly check the outlet pressure 5 1 2 Cleaning the pump room 0 AN No water should get into the terminal box of the electric motor when the pump room
54. type 304 impeller key stainless steel A276 type 316Ti bearing bracket nodular cast iron A395 536 bearing cover carbon steel A48 class 35 bearing cover carbon steel A48 class 35 oil baffle bronze B271 C93200 oil baffle bronze B271 C93200 oil fill plug steel wire cage steel constant level oiler oil sight glass magnetic drain plug ring gasket bearing cover 46 Pump parts CR EN C il JOHNSON PUMP CombiPro Material code Description acc API 610 code C 6 2180 deflector rubber 2190 set screw stainless steel 2200 pump shaft Cr Ni steel A276 type 431 2210 coupling key steel A108 grade 1020 2250 roller bearing 2260 angular contact bearing 2300 inner circlip steel 2410 indication plate arrow aluminium 2420 indication plate oil level stainless steel 2560 bearing lock nut steel 2570 retaining ring steel 2810 allen screw steel A108 grade 1020 2815 allen screw steel A108 grade 1020 2820 bolt steel A108 grade 1020 2830 washer steel Recommended spare parts Number depends on pump type 2 4 6 or 8 Number depends on pump type 8 or 12 Number depends on bearing group 4 or 8 Bearing group 1 Allen screw CR EN 4C Pump parts 47 Ms BH OHNSON PUMP 9 11 Parts l
55. uarantee Johnson Pump shall not be bound to any guarantee other than the guarantee accepted by Johnson Pump In particular Johnson Pump will not assume any liability for explicit and or implicit guarantees such as but not limited to the marketability and or suitability of the products supplied The guarantee will be cancelled immediately and legally if e Service and or maintenance is not undertaken in strict accordance with the instructions e The pump is not installed and operated in accordance with the instructions e Necessary repairs are not undertaken by our personnel or are undertaken without our prior written permission e Modifications are made to the products supplied without our prior written permission e The spare parts used are not original Johnson Pump parts e Additives or lubricants used are other than those prescribed e The products supplied are not used in accordance with their nature and or purpose e The products supplied have been used amateurishly carelessly improperly and or negligently e The products supplied become defective due to external circumstances beyond our control All parts which are liable to wear are excluded from guarantee Furthermore all deliveries are subject to our General conditions of delivery and payment which will be forwarded to you free of charge on request Service and support This manual is intended for engineering and maintenance staff and for those who are in charg
56. uring operation The maximum permissible forces and torques at the pump flanges are stated in 10 8 The suction pipe bore must be adequately dimensioned This pipe must be as short as possible and lead to the pump in such a way that no air pockets can be created If this is not possible a venting facility must be fitted at the highest point If the suction pipe has a larger bore than the suction connection on the pump then an eccentric reducer must be used so that no turbulence can be created see figure 5 nz 00 sl DO figure 5 Excentric reducer to the suction flange The maximum permissible system pressure is stated in 10 6 If there is a chance that this pressure is exceeded by for instance an excessive inlet pressure take adequate measures against this This can be achieved by installing a safety valve in the piping Due to sudden changes in the flowspeed high pressure surges can occur in the pump and the piping water blow Therefore do not use any rapidly closing shut off valves valves and such like Before the pump is installed thoroughly flush the pipe first in order to remove dirt grease or any particles which are present in the pipes We recommend that you fit a fine gauze temporarily in front of the pump inlet Assemble any loose components Connecting the electric motor The electric motor must be connected to the mains by an approved electrician according to the locally p
57. y 7 1 3 Guarantee 8 1 4 Service and support 8 1 4 1 Ordering spare parts 8 1 4 2 Pump number 8 1 5 Checking goods delivered 9 1 6 Transport instruction 9 1 6 1 Dimensions and weight 9 1 6 2 Use of pallets 9 1 6 3 Hoisting 9 1 7 Storage 10 2 General 11 2 1 Pump description 11 2 2 Applications 11 2 3 Construction 12 2 4 Pump casing 12 2 5 Impeller 12 2 5 1 Closed impeller 12 2 5 2 Semi open impeller 12 2 5 3 Half open impeller 13 2 6 Pump cover 13 2 7 Wear rings 13 2 8 Mechanical seal 13 2 9 Bearing 13 CREN 0 Table of contents 3 M onn BH SON PUMP 2 10 2 11 2 12 2 13 2 14 3 1 3 1 1 3 1 2 3 2 3 3 3 4 3 4 1 3 4 2 3 4 3 3 5 3 6 4 1 4 2 4 3 4 4 4 5 4 6 5 1 5 1 1 5 1 2 5 1 3 5 2 5 3 5 4 5 5 7 1 Base plate and coupling Type code Application area Re use Scrapping Installation Safety General Pump unit Protection Environment Pump unit Positioning Assemble Align the coupling Piping Connecting the electric motor Commissioning Preparation Preparing for commissioning Checking the direction of rotation Switching on the pump Check Noise Maintenance Daily maintenance Check Cleaning the pump room Mechanical seal Lubrication of the bearings Environmental influences Noise Fault Problem solving Disassembly and assembly Safety measures 13 14 15 15 15 17 17 17 17 17 17 18 18 18 18 20 20 21 21 21 22 22 22 22 23 23 23 23 23
58. y and assembly 27 Monn PUMP BH SON PU 7 4 2 7 5 7 5 1 7 5 2 7 5 3 Oil draining e Drain the bearing housing via the drain plug 2150 e Re fit the drain plug If possible wear protective gloves Regular contact with oil products can cause allergic reactions Back Pull Out system Principle If a spacer coupling is used then the coupling spacer can simply be removed After that the Back Pull Out unit comprising the stuffingbox cover and the bearing bracket with the complete rotating section can then be removed In this way the pump can be disassembled for the most part without loosening the inlet and outlet pipe The motor can therefore remain in position If the pump unit does not have a spacer coupling then the motor should be taken off the base before disassembly 4 P 0805 I li m on gt nn I figure 8 Disassembly of the Back Pull Out unit Disassembly of the Back Pull Out unit Disconnect possible flushing and or cooling pipes Remove the spacer Loosen the bracket support 0140 from the base plate see figure 8 Remove the nuts 0805 Tighten alternately both bolts 0820 until the pump cover 0110 is released 5 Pull the entire Back Pull Out unit from the pump casing The entire Back Pull Out unit is particularly heavy Support it with for instance a beam or suspend it with a rope in a hoist Assembly of the Back Pull Out unit A WN 1 Place
59. ze yourself with the operation of the pump and strictly obey the instructions The data published here comply with the most recent information at the time of going to press However they may be subject to later modifications Johnson Pump reserves the right to change the construction and design of the products at any time without being obliged to change earlier deliveries accordingly 1 2 Safety This manual contains instructions for working safely with the pump Operators and maintenance staff must be familiar with these instructions Below is a list of the symbols used for those instructions and their meaning Personal danger for the user Strict and prompt observance of the corresponding instruction is imperative Risk of damage or poor operation of the pump Follow the corresponding instruction to avoid this risk Useful instruction or tip for the user Items which require extra attention are shown in bold print CR EN C Introduction 7 M onn N PUMP BH SON PU 1 3 1 4 1 4 1 1 4 2 This manual has been compiled by Johnson Pump with the utmost care Nevertheless Johnson Pump cannot guarantee the completeness of this information and therefore assumes no liability for possible deficiencies in this manual The buyer user shall at all times be responsible for testing the information and for taking any additional and or deviating safety measures Johnson Pump reserves the right to change safety instructions G

Instruction Manual CombiPro - Amalgamated Pumping Supplies

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