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FreFlow - Tapflo

1. Motorlength based on DIN 42673 could be different due to applied motor make Base plate dimensions mm EEE A SE AA AA EN 2 15 5 340 384 90 450 630 35 275 3 19 6 385 433 120 560 800 45 305 58 Dimensions FRE EN 0912 9 0 MW sounson PUMP alll AN SPX BRAND FreFlow zh ff fg Figure 25 FRE pump unit A6 with ISO 7005 PN20 connections IEC motor 90 100 112 L M 345 402 432 ae according to PN20 0 2 mm Motorlength based on DIN 42673 could be different due to applied motor make Base plate dimensions mm baseplate nr X FRE EN 0912 9 0 Dimensions 59 MW sounson PUMP alll AN SPX BRAND ff fg Figure 26 FRE pump unit A6 with ISO 7005 PN20 connections IEC motor 100 112 132 L MIS 402 432 486 ae according to PN20 0 2 mm Motorlength based on DIN 42673 could be different due to applied motor make Base plate dimensions mm basep
2. IEC motor 80 F165 Figure 31 FRES with ISO 7005 PN20 connections t a 90L F165 112M F215 80 F165 112M F215 132M F265 IEC motor 80 F165 motor make 90L F165 112M F215 80 F165 112M F215 132M F265 FRE EN 0912 9 0 Dimensions 65 MW sounson PUMP alll AN SPX BRAND Figure 32 FRES with ISO 7005 PN20 connections IEC motor i ta 90S F165 90L F165 50 125b 120 7 100L F215 112M F215 90L F165 50 125 120 7 112M F215 50 205 160M F300 120 7 Et 139 7 132S F265 i 112M F215 65 135 139 7 132S F265 70 90S F165 90L F165 132S F265 132M F265 65 230 160L F300 112M F215 1325 F265 1325 F265 132M F265 139 7 100 225b 100 225 ae according to PN20 0 2 mm Motorlength based on DIN 42678 could be different due to applied motor make 66 Dimensions FRE EN 0912 9 0 MW sounson PUMP alll AN SPX BRAND FreFlow Figure 33 FRES with ISO 7005 PN20 connectio
3. 56 Dimensions FRE EN 0912 9 0 MW sounson PUMP alll AN SPX BRAND FreFlow 4 x fa 5 i i t Figure 23 FRE pump unit A6 IEC motor 132 160 M M 520 652 100 250 150 290 Motorlength based on DIN 42673 could be different due to applied motor make ISO 7005 PN 16 connections Base plate dimensions mm papan fa f M fe f ml 8 f a vw se 595 178 900 1250 0 425 6 19 8 475 525 425 145 710 1000 63 385 7 24 10 610 678 175 900 1250 90 500 FRE EN 0912 9 0 Dimensions 57 MW sounson PUMP alll AN SPX BRAND 8 5 FRE pump unit A6 with ISO 7005 PN20 connections ai x dak zh sb Figure 24 FRE pump unit A6 with ISO 7005 PN20 connections IEC motor 90 90 1100 112 S LIL M 345 402 432
4. 1 2 3 4 5678 10 20 30 40 5060 80100 Q Figure 54 Performance overview 1500 min 500 000 m h 98 Technical data FRE EN 0912 9 0 M sounson PUMP alll AN SPX BRAND FreFlow im 20 Q p m h Figure 55 Performance overview 3600 min 100 250 50 125b 1 2 3 4 5678910 20 30 40 5060 80 100 500 000 Q gt m h Figure 56 Performance overview 1800 min FRE EN 0912 9 0 Technical data 99 sounson PUMP alll AN SPX BRAND 10 5 Permissible forces and moments on the flanges The forces and torques acting on the flanges cause deformations in the pump unit These are manifested in a displacement of the shaft journal of the pump in relation to the shaft journal of the motor The permissible forces and moments on the flanges should be based on the following maximum values for the radial displacement of the shaft journal of the pump pumps of bracket group 1 0 15 mm pumps of bracket group 2 0 20 mm pumps of bracket group 3 0 25 mm pumps of bracket group 4 0 25 mm When determinating the forces the weight of the piping and of the liquid must be taken into account Irrespective of the direct
5. 72 FRE EN 0912 9 0 FreFlow 9 1 9 1 1 M sounson PUMP alll AN SPX BRAND Parts Ordering parts Order form You can use the order form included in this manual for ordering parts When ordering parts always quote the following data 1 Your address 2 The quantity the item number and the description of the part 3 The pump number The pump number is stated on the label on the cover of this manual and on the type plate of the pump 4 In the event of different electric motor voltage you should state the correct voltage Recommended spare parts Parts marked with a are recommended spare parts FRE EN 0912 9 0 Parts 73 MW sounson PUMP alll AN SPX BRAND 9 2 Pump FRE bearing group 1 9 2 1 Sectional drawing FRE bearing group 1 O O N CN D S N un CN D Mm LN CN ON O X 2 N ae oO N D O F D CN NG N O N O O om LA N No pie N O O on O O CO CO SO EM N CO O Eg R m O O O Ln un O N N N AV FR nx D OS O Figure 39 Sectional drawing FRE bearing group 1 0115 0120 1820 0310 74 Parts FRE EN 0912 9 0 MW sounson PUMP alll AN SPX BRAND FreFlow 9 2 2 Parts list FRE bearing group 1 Material Quantity Description G6 1 pump casing cast iron bronze stainless steel 2 countersun
6. 4 ed Figure 16 FRE with ISO 7005 PN20 connections 50 Dimensions FRE EN 0912 9 0 MW sounson PUMP alll AN SPX BRAND FreFlow Figure 17 FRE with ISO 7005 PN20 connections 50 125b 120 7 50 125 120 7 50 205 120 7 65 135b 139 7 65 135 139 7 65 155 139 7 65 230 139 7 100 225b 190 5 100 225 190 5 Oo By A A A A Aj j CO 00 ae according to PN20 0 2 mm 50 125b 50 125 50 205 65 135b 65 135 65 155 65 230 100 225b 100 225 FRE EN 0912 9 0 Dimensions 51 PM sonson PUMP AN SPX BRAND eb 6 eg Figure 18 FRE with ISO 7005 PN20 connections 80 135 152 5 192 M16 40 337 132 312 80 135 152 5 192 M16 40 416 160 60 8 31 28 368 80 FE va 30 149 495 13
7. FRE EN 0912 9 0 Disassembly and assembly 31 y PM sons 7 5 7 5 1 7 5 2 ON PUMP AN SPX BRAND Back Pull Out system The pumps are designed with a Back Pull Out system This means that almost the whole pump can be dismantled without having to detach the suction and delivery piping The motor has to be removed from the foundation before disassembly The item numbers refer to figure 52 and figure 49 Disassembly Back Pull Out unit 1 a ROD 8 Disassemble bolts 0230 and nuts 0231 and remove them with washers 0232 and spring washers 0233 Carefully bend the coupling guards 0270 open and remove them Remove the protection plate 0280 at motor side Remove the electric motor If provided with a Plan 11 on the shaft sealing Unscrew screw joints 1410 and 1450 and remove the by pass line 1420 Remove the Allen screws 0800 Pull the entire bearing bracket 2100 off the pump casing The entire bearing bracket of large pumps is very heavy Support it with a beam or hang it in a pulley sling Remove the coupling halve and remove the key 2210 Assembly Back Pull Out unit 1 2 3 4 Mount with a little grease a new gasket 0300 into the pump casing Mount the entire bearing bracket back into the pump casing Tighten the Allen screws 0800 crosswise If provided with a Plan 11 on the shaft sealing Fit the by pass line 1420 and tighten screw joints 1410 and 1450 Place
8. 89 Parts FRE EN 0912 9 0 sounson PUMP alll AN SPX BRAND 9 9 2 Parts list FREM Quantity Description pump casing Material G1 cast iron countersunk screw stainless steel impeller cast iron wear plate cast iron wear ring cast iron lantern piece cast iron gasket plug cast iron gasket plug cast iron cleaning cover cast iron stud stainless steel nut Allen screw stainless steel spring washer bolt steel spring washer steel Allen screw stainless steel countersunk screw stainless steel spring washer stainless steel washer stainless steel impeller key stainless steel tolerance ring stub shaft stainless steel stainless steel set screw steel name plate stainless steel combustion engine 1 For pumps with semi open impeller 2 For pumps with closed impeller 3 For FREM 80 140 only 4 For bearing group 1 5 For bearing group 2 Material not specified 90 Parts FRE EN 0912 9 0 Ba aff sounson pump 9 10 Parts Mechanical seal MQ1 9 10 1 Sectional drawings Mechanical seal MQ1 1280 0110 Figure 47 Sectional drawing Mechanical seal MG12 1280 0110 sounson PUMP alll AN SPX BRAND 9 10 2 Parts list Mechanical seal MQ1 Material G2 G6 B2 R6 intermediate cover cas
9. Pump not filled with liquid Inlet or suction pipe insufficiently submerged NPSH available too low 1 2 3 4 5 6 Pump not up to rated speed Foreign particles in the pump Air leak in the suction pipe Liquid viscosity differs from the calculated liquid viscosity Gas or air coming from the liquid Speed too high Total head lower than rated Total head higher than rated Liquid density differs from the calculated liquid density Obstruction in the piping Pump and motor not well aligned Bearings faulty or worn out Impeller blocked or damaged Bent shaft Improper location of discharge valve Foundation not rigid The bearings have been mounted wrongly Vibration Speed too low Pump does not operate at the right duty point Pump operates when the liquid flow is too low Obstruction in impeller or pump casing Dragging of rotating part Imbalance in rotating parts for instance impeller or coupling Casing wear ring or wear plate faulty or worn out Running faces of the mechanical seal are damaged Mechanical seal has been mounted wrongly Mechanical seal is not suitable for the operation circumstances Liquid in oil chamber of the mechanical seal polluted 30 Problem solving FRE EN 0912 9 0 FreFlow 7 2 7 3 7 3 1 7 4 MW sounson PUMP alll AN SPX BRAND Disassembly and assembly
10. 65 135b 150 290b 65 155 80 140 Disassembly of the impeller bearing bracket 1 1 Remove the Back Pull Out unit see paragraph 7 5 1 Disassembly Back Pull Out unit Disassemble the impeller bolt 1820 and spring washer 1825 Pull the impeller 0120 off the pump shaft using a proper puller 4 Remove the tolerance ring 1880 34 Disassembly and assembly FRE EN 0912 9 0 FreFlow M sounson PUMP alll AN SPX BRAND Assembly of the impeller bearing bracket 1 1 Place the tolerance ring 1880 into the shaft recess of the pump shaft 2200 2 For bronze and stainless steel pumps the tolerance ring must be isolated from the liquid In order to do this apply Loctite 572 on the impeller stop face 0120 the shaft end and the rearmost part of the tolerance ring 3 Push the impeller over the tolerance ring onto the shaft Make sure its position is square with the shaft 4 Put a drop of Loctite 243 on the thread and mount the impeller bolt and spring washer 1825 See chapter 10 Technical data for the correct fastening moment Disassembly of the impeller other bearing brackets 1 Remove the Back Pull Out unit see paragraph 7 5 1 Disassembly Back Pull Out unit Bearing bracket 4 Tap the lips of the locking ring 1825 straight Disassemble the impeller nut or the impeller bolt 1820 Bearing brackets 2 and 3 Remove the washer 1830 Pull the impeller 01 20 off the pump shaft
11. For this use Loctite 243 to lock the screws FRE EN 0912 9 0 Disassembly and assembly 35 MW sounson PUMP alll AN SPX BRAND 7 6 9 Disassembling the wear ring For pump with a closed impeller the wear occurs between the impeller and the wear ring This wear may not exceed 1 2 mm to the diameter After removing the Back Pull Out unit the wear ring can be removed In most cases the ring has been fixed so tightly that it cannot be removed undamaged S pa Figure 9 Removal of wear ring NI wm S 5 Measure the thickness d and the width b of the ring see figure 9 A Make a centre hole in the middle of the edge of the ring at two opposite points see figure 9 B Use a drill with a diameter just a little bit smaller than the thickness d of the ring and drill two holes in the ring see figure 9 C Don t drill deeper than the width b of the ring Take care not to damage the fitting edge of the pump casing Use a chisel to cut the remaining part of the ring thickness Now you can remove the ring in two parts from the pump casing see figure 9 D Clean the pump casing and carefully remove all bore dust and metal splinters 7 6 10 Assembling the wear ring 1 w N Clean and degrease the fitting edge of the pump casing where the wear ring is to be mounted Degrease the outer edge of the wear ring and put a few drops of Loctite 641 on it Fit the wear ring in the pump casing Take care it is
12. Place the adjustment ring 2335 onto it Push the shaft with both bearings through the bore at the back of the bearing bracket until the bearing at impeller side touches the inner circlip The adjustment ring is now locked between the bearing and the inner circlip Place the shim ring 2330 onto the bearing at drive side and the waved ring 2355 and the shim ring 2331 Fit the inner circlip 2300 at drive side 10 Mount the bearing cover 2115 at drive side and protect the bearing at impeller side by mounting the laminated seal 2165 11 Mount the shaft seal and the impeller see paragraph 7 7 3 Assembly of the mechanical seal MG1 2 and paragraph 7 6 6 Assembly of the impeller other bearing brackets 42 Disassembly and assembly FRE EN 0912 9 0 FreFlow MW sounson PUMP alll AN SPX BRAND 7 8 8 Disassembly of the bearings FRE 80 210 and 100 250 The item numbers refer to figure 42 1 O wa N Q Disassemble the impeller and the shaft seal see paragraph 7 6 5 Disassembly of the impeller other bearing brackets and paragraph 7 7 2 Disassembly of the mechanical seal MG1 2 Disassemble the lip seal 2180 Disassemble the Allen screws 2815 and remove the bearing cover 2115 Disassemble the inner circlip 2305 and remove the adjustment ring 2330 if present Use a plastic hammer and knock on the impeller side of the shaft with the bearings as to remove it from the back of the bearing bra
13. 2200 at impeller side Mount the preheated bearing 2250 carefully on the pump shaft at impeller side with the largest part of the inner ring facing the outer circlip and push it firmly against the shaft shoulder Let the bearing cool down The Nilos ring 2310 is now locked between the bearing and the shaft shoulder Mount the preheated bearing 2260 carefully on the pump shaft at drive side and push it firmly against the outer circlip Let the bearing cool down Pull the rubber closure ring gently aside and apply a small amount of grease at both sides of the angular contact bearing 2250 Push the closure ring back in its correct position Place the adjustment ring 2335 into the bearing bore at impeller side Place the Nilos ring 2315 Push the shaft with both bearings through the bore at the back of the bearing bracket until the bearing at impeller side touches the bearing seat The adjustment ring if present and the Nilos ring are now locked up between the bearing and the bearing seat Place the adjustment ring 2330 and fit the inner circlip 2305 Mount the bearing cover 2115 at drive side using Allen screws 2815 10 Mount the lip seal 2180 at impeller side 11 Mount the shaft seal and the impeller see paragraph 7 7 3 Assembly of the mechanical seal MG1 2 and paragraph 7 6 6 Assembly of the impeller other bearing brackets 44 Disassembly and assembly FRE EN 0912 9 0 MW sounson PUMP alll AN
14. B ma GA a 7 3 6 385 433 560 800 45 305 4 6 425 473 630 900 56 345 54 Dimensions FRE EN 0912 9 0 MW sounson PUMP alll AN SPX BRAND FreFlow al x ak Figure 21 FRE pump unit A6 IEC motor 100 112 132 L M S 402 432 486 Motorlength based on DIN 42673 could be different due to applied motor make ISO 7005 PN 16 connections Base plate dimensions mm baseplate nr X FRE EN 0912 9 0 Dimensions 55 M sounson PUMP alll AN SPX BRAND al x ak Figure 22 FRE pump unit A6 IEC motor 100 112 L M 402 432 100 225 Motorlength based on DIN 42673 could be different due to applied motor make ISO 7005 PN 16 connections Base plate dimensions mm baseplate nr X
15. Installation of a pump unit Pump and motor shafts of complete pump units are adjusted perfectly in line in the works 1 In case of permanent arrangement place the base plate level on the foundation with the aid of shims Carefully tighten the nuts on the foundation bolts Check the alignment of pump and motor shafts and if necessary realign see paragraph 3 4 3 Alignment of the coupling Assembling a pump unit If the pump and the electric motor still have to be assembled do the following 1 2 3 5 Fit both halves of the coupling to the pump shaft and the motor shaft respectively Place the pump on the base plate Fix the pump to the base plate Place the electric motor on the base plate Move the motor to obtain a gap of 3 mm between both coupling halves Place copper shims under the feet of the electric motor Fix the electric motor to the base plate Align the coupling in accordance with the following instructions Alignment of the coupling 1 Place a ruler A on the coupling Place or remove as many copper 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 4 Figure 4 Aligning the coupling by means of a ruler and a pair of outside calipers 2 Repeat the 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
16. Precautionary measures Take adequate measures to avoid that the motor is started while you are working on the pump This is especially important for electric motors with remote control Switch the operating switch near the pump if available to OFF Switch off the pump switch on the switchboard If necessary remove the fuses Hang a danger board near the switchboard cabinet Special tools Assembly and disassembly work requires no special tools However such tools can make certain jobs easier for instance replacing the shaft seal If such is the case it will be indicated in the text Draining Make sure no liquid or oil gets into the environment Liquid draining Before starting any disassembly the pump should be drained 1 If necessary close the valves in the suction and delivery pipe and in the flushing or cooling supply lines to the shaft seal Remove the drain plug 0310 or cleaning cover 0370 If harmful liquids are pumped wear protective gloves shoes glasses etc and thoroughly flush the pump 4 Refit the drain plug or cleaning cover If possible wear protective gloves Regular contact with oil products may result in allergic reactions Constructive variants The pumps can be supplied in various constructive variants Each variant has a code which is stated in the type identification on the name plate on the pump See paragraph 2 2 Type code for further explanation about the type identification
17. 155 EH34DU 161 212 327 195 135 107 332 445 3 80 DY41DU 161 212 334 250 150 107 337 450 3 90 EY28DU 199 212 295 210 200 126 322 450 3 75 80 140 EH35DU 199 212 318 220 190 126 334 462 3 80 DY35DU 199 212 335 220 140 126 342 470 3 95 70 Dimensions FRE EN 0912 9 0 MW sounson PUMP alll FreFlow AN SPX BRAND C d e 25 35 15 f 50 50 100 vm see previous page a a EE I PP Pp ft 6 6 4 1G 5b p verse erre ere foer ama 3 1 vm c l Figure 37 Frame dimensions FRE EN 0912 9 0 Dimensions 71 y PM sons zd ze ON PUMP AN SPX BRAND 4 x Dvd Figure 38 80 F130 FREF o 4 db 90L F165 80 F130 90S F165 Rp 2 90L F165 Rp 2 100L F215 65 100L F215 65 112M F215 aa gt 50 ISO 7005 PN 16 connections Motorlength based on DIN 42677 could be different due to applied motor make 80 F130 90L F165 80 F130 90S F165 90L F165 100L F215 100L F215 112M F215 100L F215
18. 5 bar higher than the pressure at the impeller hub 22 Installation FRE EN 0912 9 0 FreFlow 3 9 3 9 1 3 9 2 M sounson PUMP alll AN SPX BRAND Connection of the electric motor The electric motor must be connected to the mains by an approved electrician according to the locally prevailing regulations of the electricity company Refer to the instruction manual belonging to the electric motor If possible fit a working switch as close as possible to the pump Combustion engine Safety If the pump set is designed with a combustion engine the manual for the engine should be included in the delivery If the manual is missing we urgently request you to contact us immediately Irrespective of the manual the following points should be observed for all combustion engines Comply with the local safety regulations The exhaust of combustion gases must be screened off to prevent incidental contact The starting device should automatically be disengaged after the engine has been started The maximum speed of the engine set by us should not be changed Before starting the engine check the oil level Sense of rotation The sense of rotation of combustion engine and pump is indicated by means of an arrow on the combustion engine and the pump casing Verify whether the sense of rotation of the combustion engine is the same as that of the pump FRE EN 0912 9 0 Installation 23 sounson P
19. Parts list FRE 80 210 and 100 250 Quantity Description pump casing Material G2 G6 cast iron stainless steel intermediate cover cast iron stainless steel countersunk screw stainless steel impeller cast iron bronze stainless steel wear plate steel stainless steel gasket rubber non return valve synthetic material spring plate steel valve seat synthetic material gasket gasket plug stainless steel gasket plug cast iron stainless steel Allen screw distance sleeve steel stainless steel stainless steel mechanical seal cap nut stainless steel lock plate n a impeller key stainless steel AUN AO LG 2100 bearing bracket cast iron 2115 bearing cover steel filling plug synthetic material aluminium oil drain plug ast iron oil seal pump shaft steel alloy stainless steel coupling key angular contact bearing ball bearing inner circlip inner circlip nilos ring EN AA MES PD LA MER nilos ring VY adjusting ring ah adjusting ring adjusting ring adjusting ring steel name plate stainless steel Aj Allen screw steel FRE EN 0912 9 0 Parts 81 JOHNSON PUMP M AN SPX BRAND 9 6 Pump parts FRE 150 290
20. SPX BRAND FreFlow 7 9 FRES 7 9 1 Assembly of the electric motor The electric motor must be provided with a fixed bearing 1 Check if the axial clearance of the motor shaft does not exceed 0 3 mm 2 Place the motor vertically support the shaft on fan side so that it is pushed to motor flange side and the axial clearance is absorbed For motors up to and including IEC 112 remove the key from the shaft end Push the stub shaft 2200 over the shaft end Fit the 2 set screws 2280 into the sub shaft hub using Loctite 243 till they are inside the keyway but do not tighten the screws For motors of IEC 112 upwards fit only one set screw at the pump casing side 6 Place the lantern piece 0250 on the motor using the bolts 0850 and nuts 0900 7 9 2 Adjusting the impeller 1 Fit the intermediate cover 0110 the mechanical seal 1220 and the impeller 0120 2 Adjust the impeller to size A between the rear of the impeller and the intermediate cover See figure 12 and Table 6 below Preferably use 2 calibrated rulers Table 6 Bearing bracket A 0 05 6 10 Figure 12 Adjusting the impeller FRES 3 Push the rulers snugly against the impeller and tighten the set screws 2280 4 For motors upwards of IEC 112 mark a drilling point on the motor shaft in the free tapped hole of the stub shaft fit the second set screw using Loctite 243 Properly tighten both set screws FRE EN 0912 9 0 D
21. The pumps to which this declaration refers may only be put into operation after they have been installed in the way prescribed by the manufacturer and as the case may be after the complete system of which these pumps form part has been made to fulfil the requirements of Directive 2006 42 EC as altered most recently Declaration of incorporation valid from 30 12 2009 Directive 2006 42 EC appendix II B Manufacturer SPX Process Equipment NL B V Dr A F Philipsweg 51 9403 AD Assen The Netherlands hereby declares that the partly completed pump Back Pull Out unit member of productfamilies CombiBloc CombiBlocHorti CombiChem CombiDirt CombiFlex U B CombiPrime H CombiLine CombiLineBloc CombiMag CombiMagBloc CombiNorm CombiPro M V CombiPrime V FRE FRES FREF FREM KGE L KGEF HCR PHA MDR is in conformity with the following standards EN ISO 12100 parts 1 4 2 EN 809 and that this partly completed pump is meant to be incorporated into the specified pump unit 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 November 1st 2009 G A Schaafsma General Manager 2 EC EN 0911 5 0 FreFlow M sounson PUMP alll AN SPX BRAND Instruction manual FreFlow All technical and technological information in this manual as well as possible drawings made available by us remain our p
22. a bata VIA TT FRE EN 0912 9 0 Sectional drawing FRES Parts Figure 44 84 MW sounson PUMP alll AN SPX BRAND FreFlow 9 7 2 Parts list FRES Material Quantity Description y p G6 cast iron bronze stainless steel pump casing countersunk screw stainless steel impeller cast iron bronze stainless steel bronze stainless steel wear plate cast iron stainless steel bronze stainless steel wear ring cast iron bronze stainless steel bronze stainless steel lantern piece cast iron gasket plug cast iron stainless steel gasket n a gasket plug cast iron stainless steel gasket n a cleaning cover cast iron bronze stainless steel stud steel nut steel Allen screw stainless steel bolt steel bolt steel nut steel nut steel Allen screw stainless steel countersunk screw stainless steel spring washer washer stainless steel stainless steel impeller key tolerance ring stainless steel stainless steel stub shaft stainless steel set screw stainless steel name plate stainless steel uplift section ANKRA profile steel elevation piece steel nut stainless steel washer stainless steel bolt stud stainless steel support stee
23. halves over the entire length Check the alignment once again using a pair of external callipers B at 2 diametrical opposite points on the sides of the coupling halves see figure 4 Fit the guard 20 Installation FRE EN 0912 9 0 M sounson PUMP alll FreFlow AN SPX BRAND 3 4 4 Tolerances for aligning the coupling The maximum allowable tolerances for the alignment of the coupling halves are shown in Table 2 See also figure 5 Table 2 Alignment tolerances v External diameter of Va max Vamin Vrmax mm coupling mm min mm max mm mm 81 95 2 4 0 15 0 15 96 110 0 18 0 18 111 130 0 21 Sa 131 140 0 24 0 24 0 27 0 27 0 30 0 30 0 34 0 34 0 38 0 38 Va min Vr Vamax Figure 5 Alignment tolerances 3 5 Installation of pumps with flanged on motors Pumps with flanged on motors FRES FREF FREM can be mounted directly on a foundation realignment of pump and motor shaft is not necessary 3 6 Main piping connection For connection of suction and discharge piping there are different possibilities 1 Screwed female connections to 2 for cast iron pumps to 1 1 2 for stainless steel pumps 2 Drilled holes in pump casing for connections gt Rp50 FRE EN 0912 9 0 Installation 21 y PM sons 3 7 ON PUMP AN SPX BRAND A C D Figure 6 Connection main piping on pump casing bolt flange of connecte
24. locked up between the bearing and the inner circlip 10 For FRE 100 250 only Place the adjustment ring 2330 11 Fit the inner circlip 2305 12 Mount the bearing cover 2115 at drive side using Allen screws 2815 13 Mount the lip seal 2180 at impeller side 14 Mount the shaft seal and the impeller see paragraph 7 7 3 Assembly of the mechanical seal MG12 and paragraph 7 6 6 Assembly of the impeller other bearing brackets FRE EN 0912 9 0 Disassembly and assembly 43 sounson PUMP alll AN SPX BRAND 7 8 10 Disassembly of the bearings FRE 150 290b and 150 290 The item numbers refer to figure 43 1 a A WON 7 8 Disassemble the impeller and the shaft seal see paragraph 7 6 5 Disassembly of the impeller other bearing brackets and paragraph 7 7 2 Disassembly of the mechanical seal MG1 2 Disassemble the lip seal 2180 Disassemble the Allen screws 2815 and remove the bearing cover 2115 Disassemble the inner circlip 2305 and remove the adjustment ring 2330 Use a plastic hammer and knock on the impeller side of the shaft with the bearings as to remove it from the back of the bearing bracket Use a proper puller to remove the bearings from the pump shaft Remove the Nilos ring 2310 Remove the Nilos ring 2315 and the adjustment ring 2335 from the bearing bore 7 8 11 Assembly of the bearings 150 290b and 150 290 1 2 8 9 Place the Nilos ring 2310 over the pump shaft
25. must always be filled with a lubricating liquid which will not attack the liquid to be pumped nor the mechanical seal See paragraph 10 1 Oil chamber for the appropriate oil type Drain the oil or the liquid every 2000 hours of operation or once a year and replace it by fresh oil or liquid For the recommanded quantities see paragraph 10 1 Oil chamber Make sure the drained oil or liquid is discharged safely See to it that it doesn t get into the environment If there are no problems it is not advisable to dismantle the seal As the facing surfaces are running in on one another Dismantling always means replacement of the mechanical seal When the shaft seal is leaking it has to be replaced If the mechanical seal should start to leak the oil chamber will overflow via the hole in the oil filler cap and the pump must be immediately stopped to replace the mechanical seal Double mechanical seal Regularly check the pressure of the flushing liquid This pressure must be 1 5 bar higher than the pressure at the impeller hub FRE EN 0912 9 0 Maintenance 27 y PM sons 5 5 5 6 ON PUMP AN SPX BRAND Environmental influences Regularly clean the filter in the suction pipe or the suction strainer at the bottom of the suction pipe as the inlet pressure may become too low if the filter or the suction strainer is fouled If there is a risk that the pumped liquid expands during solidification or freezing the pump has
26. the mechanical seal General FRE EN 0912 9 0 FreFlow 2 10 2 12 2 13 2 14 MW sounson PUMP alll AN SPX BRAND Materials Fre Flow pumps are available in the following materials all cast iron cast iron with bronze impeller cast iron with stainless steel impeller all bronze all stainless steel The pump shaft is always made of stainless steel with the exception of bearing group 4 and the bearing bracket or lantern piece of cast iron There are a number of factors which can be decisive for the material selection Corrosion resistance of the materials is the most common One of the reasons to opt for a stainless steel pump is to avoid pollution of the liquid handled by the pump material A bronze impeller is advisable for pumps which are frequently out of operation to prevent the pump from getting jammed due to corrosion in the seal clearances around the impeller Another reason to choose a bronze impeller is that the flow velocity and consequently corrosion are highest here Connections Pump size FRE 32 110 40 110 32 150 and 40 170 are standard provided with thread connection Starting with pump size 50 125 alSO 7005 PN16 flange connection can be provided Pumps of bearing group 4 are provided with ISO 7005 PN10 flange connections All pumps are also available with flange connections to ISO 7005 PN20 ANSI B16 5 Class 150 Ibs With FRE 32 110 40 110 32 150 and 40 170 in bronze connectio
27. to be drained and if necessary flushed after it has been put out of service If the pump is out of service for a long time it has to be preserved Noise If a pump starts making noise this may point to certain problems with the pump unit A crackling noise can indicate cavitation or excessive motor noise can indicate deterioration of the bearings Faults The pump of which you want to determine the fault may be hot or under pressure Take the appropriate precautions first and protect yourself with the proper safety devices safety goggles gloves protective clothing To determine the source of the malfunctioning of the pump proceed as follows 1 Switch off the power supply to the pump unit Lock the working switch with a padlock or remove the fuse In case of a combustion engine switch off the engine and close the fuel supply to the engine Close the stop valves Determine the nature of the fault Try to determine the cause of the fault with chapter 6 Problem solving and take the appropriate measures or contact your installer 28 Maintenance FRE EN 0912 9 0 FreFlow MW sounson PUMP alll AN SPX BRAND Problem solving Faults in a pump installation can have various causes 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 opera
28. using a proper puller oa BRB O N Remove the impeller nut 1860 from the pump shaft Assembly of the impeller other bearing brackets 1 Place the impeller key 1860 into the key way of the pump shaft 2200 Slide the impeller onto the pump shaft Bearing brackets 2 and 3 Fit the washer 1830 Bearing bracket 4 Fit the locking ring 1825 Degrease the thread of the pump shaft and impeller nut 1820 or impeller bolt 1820 6 Put a drop of Loctite 243 on the thread and mount the impeller nut or impeller bolt See chapter 10 Technical data for the correct fastening moment a BO N 7 Bearing bracket 4 Tap the edges of the locking ring 1825 into the recesses of the pump shaft and the impeller nut or the impeller bolt Disassembly of the wear plate After disassembly of the Back Pull Out unit the wear plate can be removed The item numbers refer to figure 51 1 Loosen the screws 0115 2 Remove the wear plate 0125 from the pump casing including the possible cutting blade 0105 if the pump is provided with a cutting mechanism Assembly of the wear plate 1 Clean the edge of the pump casing where the wear plate has to be fitted 2 Fit the wear plate including the possible cutting blade 0105 if the pump is provided with a cutting mechanism in the pump casing When doing this make sure that it is not pushed out of alignment Pay attention to the position of the holes 3 Tighten the wear plate with screws 0115
29. 0 from the pump shaft Remove the intermediate cover 0110 from the bearing bracket 2100 4 Remove the oil catcher 1235 and push the counter ring of the mechanical seal out of the intermediate cover Assembly of the mechanical seal M7N 1 Put some grease on the oil catcher 1235 and fit it into the intermediate cover 0110 2 Put the intermediate cover flat down Put some glycerine or silicon spray into the seal compartment of the intermediate cover and press the counter ring of the mechanical seal straight into it The opening in the counter ring must correspond to the position of the locking pin 1270 otherwise the counter ring will break 3 Fita conical assembling bush onto the pump shaft or onto the stub shaft Fit the intermediate cover over the pump shaft into the bearing bracket 2100 Slide the rotating part of the mechanical seal onto the pump shaft Put some glycerine or silicon spray on the O ring to prevent it from rolling on the shaft sleeve 6 Adjust the rotating part of the mechanical seal to distance X see figure 10 and corresponding table and lock it by fixing the set screw 1220 Remove the assembling bush 8 Fit the impeller and the other parts see paragraph 7 6 4 Assembly of the impeller bearing bracket 1 and paragraph 7 6 6 Assembly of the impeller other bearing brackets h ZIZZD K en 4 i WW Qn li Figure 10 Adjusting the mechanical seal M7N Shaft 16 25 30 40 50 X 23 3 7 0
30. 10 8 38 Disassembly and assembly FRE EN 0912 9 0 FreFlow MW sounson PUMP alll AN SPX BRAND Diassembly of double mechanical seal MD1 The item numbers refer to figure 50 1 Disassemble the impeller 0120 see paragraph 7 6 3 Disassembly of the impeller bearing bracket 1 and paragraph 7 6 5 Disassembly of the impeller other bearing brackets Remove bolts 1800 and slide the mechanical seal cover 1230 backward Mark the position of the intermediate cover 0110 in relation to the bearing bracket 2100 Knock the intermediate cover loose and remove it Unscrew both set screws 1250 and remove the shaft sleeve 1200 from the pump shaft Unscrew the set screw and remove the rotating parts of the mechanical seal 1220 from the pump shaft Unscrew the set screw and remove the rotating parts of the mechanical seal 1225 from the shaft sleeve Push the counter ring of mechanical seal 1225 out of the intermediate cover Remove the mechanical seal cover from the pump shaft and push the counter ring of mechanical seal 1220 out Remove the O ring 1300 Assembly double mechanical seal MD1 1 Put the mechanical seal cover 1230 flat down Put some glycerine or silicon spray into the seal compartment and press the counter ring of the mechanical seal 1220 straight into it The opening in the counter ring must correspond to the position of the locking pin 1260 otherwise the counter ring will b
31. 50 290b and 150 290 44 7 8 11 Assembly of the bearings 150 290b and 150 290 44 7 9 FRES 45 7 9 1 Assembly of the electric motor 45 7 9 2 Adjusting the impeller 45 7 10 FREF 46 7 10 1 Assembly of the electric motor 46 7 11 FREM 46 7 11 1 Assembly combustion engine 46 7 11 2 Adjusting the impeller 46 8 Dimensions 47 8 1 FRE bearing groups 1 2 and 3 47 8 2 FRE bearing group 4 49 8 3 FRE with ISO 7005 PN20 connections 50 8 4 FRE pump unit A6 53 8 5 FRE pump unit A6 with ISO 7005 PN20 connections 58 8 6 FRES 63 8 7 FRES with ISO 7005 PN20 connections 65 8 8 FREM 69 8 9 FREF 72 9 Parts 73 9 1 Ordering parts 73 9 1 1 Order form 73 9 1 2 Recommended spare parts 73 9 2 Pump FRE bearing group 1 74 9 2 1 Sectional drawing FRE bearing group 1 74 9 2 2 Parts list FRE bearing group 1 75 9 3 Pump FRE bearing group 2 76 9 3 1 Sectional drawing FRE bearing group 2 76 9 3 2 Parts list FRE bearing group 2 77 9 4 Pump FRE bearing group 3 78 9 4 1 Sectional drawing FRE bearing group 3 78 9 4 2 Parts list FRE bearing group 3 79 9 5 Pump parts FRE 80 210 and 100 250 80 9 5 1 Sectional drawing FRE 80 210 and 100 250 80 9 5 2 Parts list FRE 80 210 and 100 250 81 9 6 Pump parts FRE 150 290b and 150 290 82 9 6 1 Sectional drawing FRE 150 290b and 150 290 82 9 6 2 Parts list FRE 150 290b and 150 290 83 9 7 Pump parts FRES 84 9 7 1 Sectional drawing FRES 84 9 7 2 Parts list FRES 85 9 8 Pump parts FREF 87 FRE EN 0912 9 0 7 souns
32. 6 ara 292 14 80 12 at 79 766 329 aso 282 70 80 170 573 143 250 360 14 80 15 48 115 187 408 510 340 108 52 Dimensions FRE EN 0912 9 0 MW sounson PUMP alll AN SPX BRAND FreFlow 8 4 FRE pump unit A6 Figure 19 FRE pump unit A6 IEC motor 90 100 L L 345 402 Rp 11 4 Rp 11 Rp 11 Motorlength based on DIN 42673 could be different due to applied motor make Base plate dimensions mm 3 19 6 385 433 120 560 800 45 305 FRE EN 0912 9 0 Dimensions 53 PM sounson PUMP AN SPX BRAND Figure 20 FRE pump unit A6 IEC motor 90 100 112 L L M 345 402 432 Rp2 Motorlength based on DIN 42673 could be different due to applied motor make R6 aa 50mm Base plate dimensions mm paaien fa f fe f f Mm
33. DU DY23DU EY15DU z z z 50 125b EY15DU Rp2 125 125 4 M16 566 E 300 408 EY20DU Rp2 125 125 4 M16 584 317 432 30129 DY23DU Rp 2 125 125 4 M16 596 379 438 EY28DU 65 145 145 4 M16 663 386 480 65 135b DY27DU 65 145 145 4 M16 621 E 379 440 DY30DU 65 145 145 4 M16 718 370 490 EY28DU 65 145 145 4 M16 663 386 480 65 135 DY27DU 65 145 145 4 M16 621 379 440 DY30DU 65 145 145 4 M16 718 370 490 60 158 EMS4DU 65 145 145 4 M16 647 z 395 534 DY41DU 65 145 145 4 M16 850 370 520 EY28DU 80 160 160 8 M16 699 386 498 80 140 EH35DU 80 160 160 8 M16 715 418 541 DY35DU 80 160 160 8 M16 754 370 500 aa gt 50 ISO 7005 PN 16 connections FRE EN 0912 9 0 Dimensions 69 pr PM sons ON PUMP AN SPX BRAND pO vj Figure 36 FREM EY20DU 2 DY23DU 2 EY15DU 1 50 125b EY15DU 160 190 244 162 130 100 260 370 2 50 EY20DU 160 190 242 162 140 100 245 370 2 55 ol DY23DU 160 190 289 240 130 100 285 390 2 65 EY28DU 170 190 288 210 190 107 294 407 2 58 65 135b DY27DU 170 190 295 240 210 107 302 415 2 64 DY30DU 170 190 328 220 180 107 322 435 3 74 EY28DU 170 190 288 210 190 107 294 407 2 58 65 135 DY27DU 170 190 295 240 210 107 302 415 2 64 DY30DU 170 190 328 220 180 107 322 435 3 74 65
34. F165 225 195 50 32 150 ma 190 12 tL 30 15 73 330 235 22 112M F215 275 245 100 40 110 80 F165 200 165 12 170 30 15 78 300 220 22 38 112M F215 275 12 245 30 15 424 315 22 90 40 170 222 78 132M F265 330 14 200 20 20 414 305 25 140 90S F165 60 225 195 90L F165 65 BO 25 A TO O ig bo 1 80 15 100 360 250 35 100L F215 90 275 245 112M F215 110 90L F165 225 195 60 50 125 190 12 30 15 100 360 250 35 112M F215 275 245 110 50 205 160M F300 440 230 14 200 20 20 105 460 320 35 140 100L F215 275 12 245 30 15 395 282 65 65 135b 190 107 35 132S F265 310 14 200 20 20 385 272 120 112M F215 275 12 245 30 15 395 282 75 65 135 190 107 35 132S F265 310 14 200 20 20 385 272 130 90S F165 75 275 12 245 30 15 425 312 90L F165 80 65 155 212 107 35 112M F215 105 330 14 200 20 20 415 302 132M F265 125 65 230 160L F300 480 250 14 250 20 30 115 495 345 40 215 90S F165 65 90L F165 275 12 245 30 15 440 312 35 70 80 140 212 126 112M F215 90 132M F265 500 14 250 20 30 430 302 29 140 80 170 160M F300 500 250 14 250 33 30 127 490 360 33 210 112M F215 200 100 225b 500 315 14 320 20 30 156 615 450 37 132S F265 230 132S F265 200 100 225 500 315 14 320 20 30 156 615 450 37 132M F265 220 64 Dimensions FRE EN 0912 9 0 FreFlow 8 7 MW sounson PUMP alll AN SPX BRAND FRES with ISO 7005 PN20 connections al x ak
35. M bl JOHNSON PUMP AN SPX BRAND Instruction Manual FreFlow Horizontal centrifugal pump Orginal instructions Read and understand this manual prior to operating or servicing this product FRE EN 091 2 9 0 M sounson PUMP alll AN SPX BRAND EC Declaration of conformity aid until 30 12 2009 Directive 98 37 EC appendix II A Manufacturer SPX Process Equipment NL B V Dr A F Philipsweg 51 P O Box 9 9400 AA Assen The 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 EC directive 2006 95 EG Electric equipment for use within certain voltage limits standards EN ISO 12100 part 1 4 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 valid until 30 12 2009 Directive 98 37 EC appendix II B Manufacturer SPX Process Equipment NL B V Dr A F Philipsweg 51 P O Box 9 9400 AA Assen The Netherlands hereby declares that the pump in case it is delivered without drive last position o
36. UMP alll AN SPX BRAND 24 Installation FRE EN 0912 9 0 FreFlow 4 1 4 2 MW sounson PUMP alll AN SPX BRAND Commissioning Inspection of the pump Check whether the pump shaft turns freely Do this by turning the shaft end at the coupling a few times by hand Inspection of the motor Pump driven by an electric motor Check whether the fuses have been mounted Pump driven by a combustion engine Check whether the room in which the engine is placed is well ventilated Check whether the exhaust of the engine is not obstructed Before starting the engine check the oil level Never run the engine in a closed room Oil chamber The pumps are being delivered without any liquid in the oil chamber Fill the oil chamber with oil see paragraph 10 1 Oil chamber for the appropriate type and quantity If the liquid to be pumped may not come into contact with oil fill the oil chamber with another suitable liquid Checking the sense of rotation Beware of possible non screened rotating parts when checking the sense of rotation 1 The sense of rotation of the pump is indicated by an arrow Check whether the sense of rotation of the motor corresponds with that of the pump Let the motor run for only a short time and check the sense of rotation If the sense of rotation is not correct alter the sense of rotation See the instructions in the user manual belonging to the electric motor 4 Fit the
37. ase on the oil catcher 1235 and fit it into the intermediate cover 0110 Put the intermediate cover flat down Wet the seal chamber of the intermediate cover with some low surface tension water add detergent and fit the counter ring of the mechanical seal straight into it Fit a conical assembling bush onto the pump shaft or onto the stub shaft Fit the intermediate cover over the pump shaft into the bearing bracket 2100 Wet the pump shaft with some low surface tension water add detergent Do not use oil or grease Feed the rotating part of the seal with a slight twist in clockwise direction onto the shaft until the rear end of the bellows is at equal level with the shaft shoulder Apply pressure or tension during assembly via the rear end of the bellows only Remove the assembling bush Only for FRE 150 290 and 150 290b Fit the distance ring 0370 Fit the impeller and the other parts see paragraph 7 6 4 Assembly of the impeller bearing bracket 1 and paragraph 7 6 6 Assembly of the impeller other bearing brackets FRE EN 0912 9 0 Disassembly and assembly 37 MW sounson PUMP alll 7 7 4 AN SPX BRAND Disassembly of the mechanical seal M7N The item numbers refer to figure 47 1 Remove the impeller 0120 see paragraph 7 6 3 Disassembly of the impeller bearing bracket 1 and paragraph 7 6 5 Disassembly of the impeller other bearing brackets Remove the rotating part of the mechanical seal 122
38. ast iron bronze or stainless steel construction FreFlow pumps can be used for handling clean and polluted liquids 2 2 Type code Pumps are available in various designs The main characteristics of the pump are shown in the type code Example FRE 50 125 G1 MQ1 Pump construction pump with bearing bracket pump with flanged electric motor and extended shaft pump with flanged motor IEC standard pump with flanged combustion engine Pump size suction and discharge connections mm impeller diameter mm Pump casing and impeller material cast iron pump casing and impeller cast iron pump casing bronze impeller cast iron pump casing stainless steel impeller bronze pump casing and impeller stainless steel pump casing and impeller Shaft sealing mechanical seal unbalanced non EN standard with oil quench mechanical seal unbalanced EN 12756 with oil quench mechanical seal double unbalanced EN 12756 FRE EN 0912 9 0 General 13 sounson PUMP alll 2 3 2 4 2 5 2 6 AN SPX BRAND Serial number Serial number of the pump or pump unit are shown on the name plate off the pump and on the label on the cover of this manual Example 01 1000675A 01 year of manufacture 100067 unique number number of pumps pump with motor pump with free shaft end Pump motor group There is also a designation for the pump motor gro
39. ation
40. b and 150 290 9 6 1 Sectional drawing FRE 150 290b and 150 290 1200 1220 2130 2180 2315 2335 2250 2310 2100 2260 2400 2330 2300 2815 2115 2210 A Aer gt Y ye ons 0125 1860 1825 1820 0120 Sua o 2 z E 3 o o o o Figure 43 Sectional drawing FRE 150 290b and 150 290 0310 82 Parts FRE EN 0912 9 0 FreFlow MW sounson PUMP alll AN SPX BRAND 9 6 2 Parts list FRE 150 290b and 150 290 Quantity Description pump casing Material G2 G6 cast iron stainless steel intermediate cover cast iron stainless steel countersunk screw stainless steel impeller cast iron bronze stainless steel wear plate steel stainless steel gasket rubber non return valve synthetic material spring plate steel valve seat synthetic material gasket gasket plug steel stainless steel gasket plug cast iron stainless steel Allen screw steel stainless steel distance sleeve stainless steel mechanical seal cap nut bronze stainless steel lock plate brass n a impeller key stainless steel bearing bracket cast iron bearing cover steel filling plug oil drain plug synthetic material cast iron oil seal pump shaft steel alloy stain
41. cast iron stainless steel gasket n a cleaning cover cast iron stainless steel stud nut stainless steel stainless steel Allen screw steel stainless steel countersunk screw stainless steel washer stainless steel impeller key stainless steel bearing bracket cast iron bearing cover steel coupling key angular contact bearing angular contact bearing retaining ring adjusting ring adjusting ring steel adjusting ring steel waved ring steel gasket rubber SAN py name plate stainless steel 1 For pumps with semi open impeller 2 For pumps with closed impeller 3 For FRE 80 170 and FRE 100 225 b only Material not specified n a Not applicable FRE EN 0912 9 0 Parts 79 ON PUMP Aff sours Pump parts FRE 80 210 and 100 250 9 5 Sectional drawing FRE 80 210 and 100 250 9 5 1 00L0 0060 OLLO 0080 osz SEZ 50E 50E0 0022 azz SZ 582 00EZ 0922 0077 OVEZ OOC OLEZ OSZCZ SLET VELT OBZ Cz y 00zL En gt NEA 05Z 00L 384 0ZE0 SEO N HEZA 052 001 384 Sectional drawing FRE 80 210 and 100 250 Figure 42 FRE EN 0912 9 0 Parts 80 MW sounson PUMP alll AN SPX BRAND FreFlow 9 5 2
42. cket Use a proper puller to remove the bearings from the pump shaft Remove the Nilos ring 2310 Remove both outer circlips 2340 and 2345 Remove the Nilos ring 2315 and the adjustment ring 2335 if present from the bearing bore 10 Disassemble the inner circlip 2300 7 8 9 Assembly of the bearings FRE 80 210 and 100 250 1 2 3 O wa N Q Fit the outer circlips 2340 and 2345 Place the Nilos ring 2310 over the pump shaft 2200 at impeller side Mount the preheated bearing 2250 carefully on the pump shaft at impeller side with the largest part of the inner ring facing the outer circlip and push it firmly against the outer circlip Let the bearing cool down The Nilos ring 2310 is now locked between the bearing and the outer circlip Mount the preheated bearing 2260 carefully on the pump shaft 2200 at drive side and push it firmly against the outer circlip Let the bearing cool down Pull the rubber closure ring gently aside and apply a small amount of grease at both sides of the angular contact bearing 2250 Push the closure ring back in its correct position Fit the inner circlip 2300 For FRE 100 250 only Place the adjustment ring 2335 onto the inner circlip Place the Nilos ring 2315 Push the shaft with both bearings through the bore at the back of the bearing bracket until the bearing at impeller side touches the inner circlip The adjustment ring if present and the Nilos ring are now
43. cover in the proper position into the centring rim of the bearing bracket 2100 9 Fit the mechanical seal cover 1230 to the intermediate cover Ensure it is fitted in the right position with regard to the connections Tighten bolts 1800 crosswise The cover may not be placed oblique 10 Fit the impeller and other parts see paragraph 7 6 6 Assembly of the impeller other bearing brackets Bearing Instructions for assembly and disassembly of bearings First read the following instructions regarding assembly and disassembly Follow these instructions closely when assembling and disassembling bearings Disassembly Use a proper puller to remove the bearings from the pump shaft If no proper puller is available carefully knock at the inner raceway of the bearing Use an ordinary hammer and a mild steel drift for this Never knock at the bearing with a hammer Assembly Make sure your working place is clean Leave the bearings in their original packing as long as possible Make sure the pump shaft and the bearing seats do have a smooth surface free of burrs Slightly oil the pump shaft and the other relevant parts before assembly Preheat the bearings to 110 C before mounting them on the pump shaft If preheating is not possible knock the bearing onto the pump shaft Never knock at the bearing directly Use a mounting bush positioned against the inner raceway of the bearing and a normal hammer a soft ham
44. d piping pump casing gasket Table 3 Choose proper bolts according to the table below Pump size Pump size M1 6x40x4 M16x40x8 M1 6x40x8 40 170 80 210 M16x40x8 50 125b M16x40x4 100 225b M16x40x8 50 125 M16x40x4 100 225 M16x40x8 50 205 M16x40x4 100 250 M16x40x8 65 135b M16x40x4 100 290b M20x45x8 65 135 M16x40x4 100 290 M20x45x8 3 65 230 M16x40x4 ANSI connections for pump sizes 80 Piping The piping to the suction and delivery connections must fit exactly and must not be subject to stress during operation The maximum allowable forces and moments on the pump flanges are stated in chapter 10 Technical data The passage of the suction pipe must be amply dimensioned This pipe should be as short as possible Sudden changes in the rate of flow can lead to high pressure impulses in the pump and the piping water shock Therefore don t use quick acting closing devices valves etc A foot valve in the suction line is not required for this selfpriming pump unless this line is so voluminous or the operating conditions are so unfavourable that suction times longer than approximately 8 minutes have been calculated or measured Avoid the entry of big or hard particles by installing a strainer In case of a pump with a double mechanical seal shaft sealing variant MD1 connect the flushing chamber to the flushing system The pressure of the flushing system must be 1
45. e the adjustment ring 2330 onto the bearing at drive side and fit the inner circlip 2305 with its teeth facing the adjustment ring Mount the bearing cover 2115 at drive side and protect the bearing at impeller side by mounting the laminated seal 2165 Mount the shaft seal and the impeller see paragraph 7 7 3 Assembly of the mechanical seal MG12 and paragraph 7 6 4 Assembly of the impeller bearing bracket 1 Disassembly of the bearings FRE bearing bracket 2 The item numbers refer to figure 40 1 a A WON 7 8 Disassemble the impeller and the shaft seal see paragraph 7 6 5 Disassembly of the impeller other bearing brackets and paragraph 7 7 2 Disassembly of the mechanical seal MG1 2 Disassemble the laminated seal 2165 Remove the bearing cover 2115 Disassemble the inner circlip 2305 and remove the adjustment ring 2330 Use a plastic hammer and knock on the impeller side of the shaft with the bearings as to remove it from the back of the bearing bracket Use a proper puller to remove the bearings from the pump shaft Remove the rubber closure ring 2390 Remove the adjustment ring 2335 from the bearing bore Disassemble the inner circlip 2300 Assembly of the bearings FRE bearing bracket 2 1 Mount the rubber closure ring 2390 onto the pump shaft at impeller side with its largest part facing the impeller Mount the preheated bearing 2250 carefully on the pump shaft 2200 at im
46. ed motor make Base plate dimensions mm baseplatenr x fa f f fa f a m B 7 fy vo eo ov 178 900 1250 500 62 Dimensions FRE EN 0912 9 0 FreFlow pr PM sonson PUMP AN SPX BRAND db Figure 29 FRES 90L F165 112M F215 80 F165 112M F215 132M F265 90S F165 90L F165 100L F215 112M F215 90L F165 112M F215 50 205 160M F300 100L F215 132S F265 112M F215 132S F265 90S F165 90L F165 132S F265 132M F265 160L F300 90S F165 90L F165 112M F215 132M F265 80 170 160M F300 112M F215 132S F265 132S F265 132M F265 aa gt 50 ISO 7005 PN 16 connections R6 aa 50 Motorlength based on DIN 42673 could be different due to applied motor make 50 125b 50 125 65 135b 65 135 100 225b 100 225 FRE EN 0912 9 0 Dimensions 63 MW sounson PUMP alll AN SPX BRAND zd Figure 30 FRES IEC motor 32 110 80 F165 200 165 12 170 30 15 73 300 215 22 30 90L
47. eet enclosed with the delivery Please do not use the pump for purposes other than those for which it is delivered without prior consultation with your supplier Using a pump in a system or under system conditions liquid working pressure temperature etc for which it has not been designed may hazard the user General FRE EN 0912 9 0 M sounson PUMP alll AN SPX BRAND FreFlow 2 7 Selfpriming action FreFlow pumps are of the selfpriming type A separate air pump or any other equipment is not required Suction lifts up to 7 m are possible The selfpriming action relies on the principle of injection The pump has to be filled with liquid once When it has been switched on the air or gas is evacuated from the suction line The aspirated air is mixed with the liquid contained in the impeller Through the centrifugal force the liquid air mixture from the volute flows to the upper half of the pump casing In the generously sized pump casing the liquid can be de aerated The air escapes to the discharge line The de aerated liquid has a higher specific gravity than the liquid with air contained the volute This causes the liquid to return to the volute with some pumps bearing group 4 the liquid flows back through the impeller inlet where it is aerated and then de aerated again in the upper part of the pump casing The air is evacuated from the suction line and the liquid level in this piping rises Once all air has been e
48. en impeller and wear plate FRE bearing group 1 33 Measuring clearance between impeller and wear plate other bearing groups Disassembly of the impeller bearing bracket 1 Assembly of the impeller bearing bracket 1 Disassembly of the impeller other bearing brackets Assembly of the impeller other bearing brackets Disassembly of the wear plate Assembly of the wear plate Disassembling the wear ring Assembling the wear ring Mechanical seal Instructions for mounting a mechanical seal Disassembly of the mechanical seal MG12 Assembly of the mechanical seal MG12 Disassembly of the mechanical seal M7N Assembly of the mechanical seal M7N Diassembly of double mechanical seal MD1 Assembly double mechanical seal MD1 34 34 35 35 35 35 35 36 36 37 37 37 37 38 38 39 39 FRE EN 0912 9 0 FreFlow pr PM sons ON PUMP AN SPX BRAND 7 8 Bearing 40 7 8 1 Instructions for assembly and disassembly of bearings 40 7 8 2 Disassembly of the bearings FRE bearing bracket 1 40 7 8 3 Assembly of the bearings FRE bearing bracket 1 41 7 8 4 Disassembly of the bearings FRE bearing bracket 2 41 7 8 5 Assembly of the bearings FRE bearing bracket 2 41 7 8 6 Disassembly of the bearings FRE bearing bracket 3 42 7 8 7 Assembly of the bearings FRE bearing bracket 3 42 7 8 8 Disassembly of the bearings FRE 80 210 and 100 250 43 7 8 9 Assembly of the bearings FRE 80 210 and 100 250 43 7 8 10 Disassembly of the bearings FRE 1
49. f serial number B is in conformity with the following standards EN ISO 12100 parts 1 4 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 November 1st 2009 G A Schaafsma General manager EC EN 0911 5 0 sounson PUMP alll AN SPX BRAND EC Declaration of conformity valid trom 30 12 2009 Directive 2006 42 EC appendix II A Manufacturer SPX Process Equipment NL B V Dr A F Philipsweg 51 9403 AD Assen The Netherlands hereby declares that all pumps member of productfamilies CombiBloc CombiBlocHorti CombiChem CombiDirt CombiFlex UXB CombiPrime H CombiLine CombiLineBloc CombiMag CombiMagBloc CombiNorm CombiPro MXV CombiPrime V CombiSump CombiWell FRE FRES FREF FREM KGE L KGEF HCR MCH W S MCHZ W S MCVXS PHA MDR whether delivered without drive last position of serial number B or delivered as an assembly with drive last position of serial number A are in conformity with the provisions of Directive 2006 42 EC as altered most recently and where applicable the following directives and standards EC directive 2006 95 EG Electric equipment for use within certain voltage limits standards EN ISO 12100 part 1 4 2 EN 809
50. fied n a Not applicable stainless steel FRE EN 0912 9 0 Parts 77 AN SPX BRAND ON PUMP Sectional drawing FRE bearing group 3 Pump FRE bearing group 3 9 4 9 4 1 JJ sons 0lZZ LEET SSE 00LZ SEET SIT 0981 00 0 0ZL0 SLEO OLEO OELO O 8L 0281 0022 SALO SILG SLLO STED OZE0 El UW 90 XEN OVET DEEZ 0072 0902 UbEZ OSZE 00EZ Jj LC A 0010 0080 OLED S80 080 ez SLEO FRE EN 0912 9 0 Sectional drawing FRE bearing group 3 Parts Figure 41 78 FreFlow 9 4 2 Quantity Description pump casing MW sounson PUMP alll AN SPX BRAND Parts list FRE bearing group 3 Material G6 cast iro bronze stainless steel countersunk screw stainless steel impeller cast iron bronze stainless steel bronze stainless steel wear plate cast iron stainless steel bronze stainless steel wear ring cast iron bronze stainless steel bronze stainless steel gasket plug cast iron stainless steel gasket n a gasket plug
51. g lifted If the electric motor is provided with a lifting eye this lifting eye is intended only for the purpose of carrying out service activities to the electric motor The lifting eye is designed to bear the weight of the electric motor only It is NOT permitted to lift a complete pump unit at the lifting eye of an electric motor Figure 1 Lifting instructions for pump unit Figure 2 Lifting instructions for single pump Figure 3 Lifting instructions FRES FRE EN 0912 9 0 Introduction 11 sounson PUMP alll AN SPX BRAND 1 5 4 Storage If the pump is not to be used immediately the pump shaft must be turned by hand twice per week 1 6 Ordering parts This manual contains a survey of the spare parts recommended by Johnson Pump as well as the instructions for ordering them A fax order form is included in this manual You should always state all data stamped on the type plate when ordering parts and in any other correspondence regarding the pump gt This data is also printed on the label on the front of this manual If you have any questions or require further information with regard to specific subjects then do not hesitate to contact Johnson Pump 12 Introduction FRE EN 0912 9 0 MW sounson PUMP alll AN SPX BRAND FreFlow 2 General 2 1 Pump description FreFlow pumps are self priming centrifugal pumps with a half open or closed impeller and a mechanical seal The pumps come in c
52. guard FRE EN 0912 9 0 Commissioning 25 MW sounson PUMP alll 4 5 4 6 4 7 AN SPX BRAND Start up Proceed as follows both when the unit is put into operation for the first time and after the pump has been overhauled 1 Fill the pump with the liquid to be handled through the filling plug at the pump front until the liquid starts to overflow 2 Open the stop valve in the supply piping for flushing liquid if the pump is supplied with a flushing system When flushing a double mechanical seal version MD1 the appropriate pressure of the flushing liquid must be set This pressure must be 1 5 bar higher than the pressure at the impeller hub 3 Open any pressure cut off entirely During the self priming phase it is necessary that the air escapes unobstructed and without any back pressure in the discharge pipe Start the pump As soon as the pump is under pressure if necessary adjust the delivery stop valve in order to obtain the desired the working pressure Make sure that when a pump is running rotating parts are always properly screened off by the guard Pump in operation When the pump is in operation pay attention to the following The pump should never run dry The flushing liquid of a double mechanical seal versions MD1 always must have the appropriate pressure set This pressure must be 1 5 bar higher than the pressure at the impeller hub Never use a stop valve in the suction line to control pum
53. iciently guarded Depending on the design the pumps are suitable for liquids with a temperature of up to 95 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 If there is danger of static electricity the entire pump unit must be earthed If the pumped liquid is harmful to men or the environment take appropriate measures to drain the pump safely Possible leakage liquid from the shaft seal should also be discharged safely Preservation 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 Environment The foundation must be hard level and flat 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 There should be sufficient space around the pump unit to operate and if necessary repair it Behind the cooling air inlet of the motor there must be a free area of at least 1 4 of the electric motor diameter to ensure unobstructed air supply FRE EN 0912 9 0 Installation 19 pr PM sons 3 4 3 4 1 3 4 2 3 4 3 ON PUMP AN SPX BRAND Mounting
54. ion of the forces and torques and their components on the flanges the permissible values should comply with the following equation E J Ys v max Es max max ies Il 2 3 F F lt F Index v in vertical direction y axis v v press v suct v max Fy Fj press t273 Fh suot S Fh max Index h in horizontal direction x axis and z axis M M ress Mout EM press suc M torque in the plane of the flange max Fy max Fh max and M max are given in the table A distinction is made here between a pump unit with a base plate not grouted and a pump unit with a base plate which is grouted 100 Technical data FRE EN 0912 9 0 FreFlow pr PM sons ON PUMP AN SPX BRAND Table 11 Permissible forces and moments on the flanges based on EN ISO 5199 Pump unit non grouted base plate Pump unit grouted base plate Fy max N Fh max N Mmax Nm Fy max N Fh max N Mmax Nm 50 125b 50 125 50 205 65 135b 65 135 65 155 65 230 80 140 80 170 80 210 100 225b 100 225 100 250 150 290b 150 290 Pump casing material Cast iron Stainless steel stated values x 1 0 stated values x 2 0 FRE EN 0912 9 0 Technical data 101 alll JOHNSON PUMP 10 6 10 6 1 AN SPX BRAND Noise data Pump noise as a function of pum
55. isassembly and assembly 45 sounson PUMP alll 7 10 7 10 1 7 11 7 11 1 7 11 2 AN SPX BRAND FREF Assembly of the electric motor 1 Place the motor vertically with the shaft pointing upwards 2 Place the lantern piece 0250 on the motor using the bolts 0850 and nuts 0900 FREM Assembly combustion engine 1 Check if the axial clearance of the motor shaft does not exceed 0 3 mm 2 Place the combustion engine vertically with the shaft pointing upwards 3 Apply some Loctite 648 on the motor shaft end Never use quick drying Loctite 4 Push the stub shaft 2200 over the motor shaft Take care the hole for the set screw corresponds with the keyway of the motor shaft 5 Fit the set screw 2280 using Loctite 243 but do not tighten the screw 6 Place the lantern piece 0250 on the motor using the bolts 0850 and nuts 0900 Adjusting the impeller 1 Fit the intermediate cover 0110 the mechanical seal 1220 and the impeller 0120 2 Adjust the impeller to size A between the rear of the impeller and the intermediate cover See figure 13 and Table 7 below Preferably use 2 calibrated rulers Table 7 Bearing bracket A 0 05 1 6 Figure 13 Adjusting the impeller FREM 3 Push the rulers snugly against the impeller and tighten the set screw 2280 46 Disassembly and assembly FRE EN 0912 9 0 MW sounson PUMP alll AN SPX BRAND FreFlow 8 Dimensions 8 1 FRE bearing gro
56. k screw stainless steel 1 impeller cast Iron bronze stainless steel bronze stainless steel 1 wear plate cast iron stainless steel bronze stainless steel 1 gasket 1 plug cast iron stainless steel 1 gasket n a 1 plug cast iron stainless steel 1 gasket n a 4 Allen screw steel stainless steel 1 Allen screw stainless steel 1 spring washer stainless steel 1 tolerance ring stainless steel 1 bearing bracket cast iron 1 bearing cover steel 1 sealing washer steel 1 pump shaft stainless steel 2210 1 coupling key steel 2260 1 ball bearing steel 2300 1 inner circlip steel 2305 1 inner circlip steel 2330 1 adjusting ring steel 2400 1 name plate stainless steel Material not specified n a Not applicable FRE EN 0912 9 0 Parts 75 ON PUMP Aff sours Pump FRE bearing group 2 9 3 Sectional drawing FRE bearing group 2 9 3 1 0022 OLZT SLC OEEZ 0S22 D0EZ ECH 2225 gt DOLZ D0 0 0ZL0 SLEO DELO SOEZ 0072 0922 06 Z SEEZ S9LZ 0080 0981 0Z8L DESL SCL0 SLLO SCEO 02 0 A 0010 Sectional drawing FRE bea
57. l support steel FRE EN 0912 9 0 Parts 85 MW sounson PUMP alll AN SPX BRAND D ipti Material ERE G1 G2 G6 B2 R6 1 For pumps with semi open impeller 2 For pumps with closed impeller 3 For pumps with a connection of DN80 and upwards 4 For bearing group 1 5 For bearing group 2 and 3 6 Assembly depends on pump and motor size Material not specified n a Not applicable 86 Parts FRE EN 0912 9 0 ON PUMP JIE sours FreFlow Pump parts FREF 9 8 Sectional drawing FREF 9 8 1 0060 0580 S6cl 06cl OZEL 0981 OCC SELL fo JU OLLO Seel 00 0 EN 0281 5281 0520 0821 0080 0072 OLEO OELO 0ZL0 0 8l 0Z8l SZL0 SLLO 0010 02E0 Sectional drawing FREF Figure 45 87 Parts FRE EN 0912 9 0 sounson PUMP alll AN SPX BRAND 9 8 2 Parts list FREF Quantity Description pump casing Material G1 cast iron intermediate cover cast iron countersunk screw stainless steel impeller cast iron wear pla
58. latenn x fa f fe f a Mm B 2 f 8 320 384 80 450 630 35 275 3 19 6 385 433 560 800 45 305 120 6 19 8 475 525 145 710 1000 63 385 60 Dimensions FRE EN 0912 9 0 MW sounson PUMP alll AN SPX BRAND FreFlow sp fe ff fe fg Figure 27 FRE pump unit A6 with ISO 7005 PN20 connections IEC motor 90 100 112 LI LIM 345 402 432 Motorlength based on DIN 42673 could be different due to applied motor make Base plate dimensions mm baseplate mex fa tb fe tat MGM BE 3 19 6 385 433 120 560 800 45 305 6 19 8 475 525 145 710 1000 63 385 FRE EN 0912 9 0 Dimensions 61 M sounson PUMP alll AN SPX BRAND zh ff fg Figure 28 FRE pump unit A6 with ISO 7005 PN20 connections IEC motor 100 112 L M 402 432 100 225b 100 225 Motorlength based on DIN 42673 could be different due to appli
59. less steel coupling key angular contact bearing ball bearing retaining ring steel nilos ring steel o nilos ring steel a adjusting ring steel adjusting ring steel E name plate stainless steel S Allen screw 1 FRE 150 290b no G1 execution steel 2 For construction with suction valve only Material not specified n a Not applicable FRE EN 0912 9 0 83 ON PUMP Pump parts FRES Sectional drawing FRES 9 7 9 7 1 Aff sours Lu 0955 I 0005 0756 0859 1 N S005 0005 EE SOLS 5580 3 001s 0025 0025 5060 0060 0580 0022 00 0 SZLO SLEO OLEO A 0210 DELO DEBI E ft 0281 0981 5710 D SLLO ba Vi Ji STED vil ETNA i gt 070 777720 7 OBZZ 0520 00472
60. mer might loose some splinters which could damage the bearing Disassembly of the bearings FRE bearing bracket 1 The item numbers refer to figure 39 1 Disassemble the impeller and the shaft seal see paragraph 7 6 3 Disassembly of the impeller bearing bracket 1 and paragraph 7 7 2 Disassembly of the mechanical seal MG12 Disassemble the laminated seal 2165 Remove the bearing cover 2115 Disassemble the inner circlip 2305 and remove the adjustment ring 2330 a A O N Use a plastic hammer and knock on the impeller side of the shaft with the bearings as to remove it from the back of the bearing bracket Use a proper puller to remove the bearings from the pump shaft 7 Disassemble the inner circlip 2300 40 Disassembly and assembly FRE EN 0912 9 0 FreFlow 7 8 3 7 8 4 7 8 5 M sounson PUMP alll AN SPX BRAND Assembly of the bearings FRE bearing bracket 1 1 Mount the preheated bearing 2250 carefully on the pump shaft 2200 at impeller side and push it firmly against the shaft shoulder Let the bearing cool down Mount the preheated bearing 2260 carefully on the pump shaft at drive side and push it firmly against the shaft shoulder Let the bearing cool down Fit the inner circlip 2300 into the bearing bore at impeller side Push the shaft with both bearings through the bore at the back of the bearing bracket until the bearing at impeller side touches the inner circlip Plac
61. mportant 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 familiarize 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 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 bu
62. n pieces flange and thread pipe are made of stainless steel Application area The application area globally looks as follows Table 1 Application area Maximum value 350 m h Discharge head 80 m System pressure 9 bar Temperature 95 C Self priming up to 7 m Viscosity 150 mPa s Re use The pump may only be used for other applications after prior consultation with Johnson Pump or your supplier Since the lastly pumped medium 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 precautions and use the appropriate personal protection means like rubber gloves and spectacles Scrapping If it has been decided to scrap a pump the same flushing procedure as described for Re use should be followed FRE EN 0912 9 0 General 17 sounson PUMP si AN SPX BRAND 18 General FRE EN 0912 9 0 FreFlow 3 3 1 3 2 3 3 MW sounson PUMP alll AN SPX BRAND Installation Safety 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 guarantee Follow the instructions given step by step Ensure that the pump can not be started if work has to be undertaken to the pump during installation and the rotating parts are insuff
63. not pushed out of alignment 36 Disassembly and assembly FRE EN 0912 9 0 FreFlow MW sounson PUMP alll AN SPX BRAND 7 7 Mechanical seal 7 7 1 Instructions for mounting a mechanical seal gt First read the following instructions regarding the mounting of a mechanical seal Follow these instructions closely when mounting a mechanical seal Leave the assembly of a mechanical seal with PTFE Teflon covered O rings to a specialist These rings are easily damaged during assembly A mechanical seal is a fragile precision instrument Leave the seal in its original packing until you are ready to fit it Clean all receiving parts properly Make sure your hands and working environment are clean Never touch the sliding surfaces with ones fingers Take care not to damage the seal during assembly Never put the rings down on their sliding surfaces 7 7 2 Disassembly of the mechanical seal MG12 The item numbers refer to figure 47 1 Remove the impeller 0120 see paragraph 7 6 3 Disassembly of the impeller bearing bracket 1 and paragraph 7 6 5 Disassembly of the impeller other bearing brackets Remove the rotating part of the mechanical seal 1220 from the pump shaft Remove the intermediate cover 0110 from the bearing bracket 2100 Remove the oil catcher 1235 and push the counter ring of the mechanical seal out of the intermediate cover 7 7 3 Assembly of the mechanical seal MG12 1 Put some gre
64. ns IEC motor 90S F165 90L F165 100L F215 112M F215 90L F165 112M F215 50 205 160M F300 100L F215 1325 F265 112M F215 132S F265 90S F165 90L F165 1325 F265 132M F265 65 230 160L F300 112M F215 1325 F265 132S F265 132M F265 50 125b 50 125 65 135b 65 135 100 225b 100 225 FRE EN 0912 9 0 Dimensions 67 y PM sons IEC motor 90S F165 Figure 34 90L F165 112M F215 ON PUMP AN SPX BRAND z FRES with ISO 7005 PN20 connections 152 5 162 132M F265 152 278 932 80 170 160M F300 80 135 1525 192 4 M16 40 180 368 334 1093 Motorlength based on DIN 42677 could be different due to applied motor make IEC motor 90S F165 90S F165 112M F215 132M F265 160M F300 68 Dimensions FRE EN 0912 9 0 MW sounson PUMP alll AN SPX BRAND FreFlow Figure 35 FREM EY20
65. nsport aaa Ka eden trend NAY KLANG KGG 10 Type Code ibi 13 W Wear ring assembly wiii 36 disassembly aa 36 replacement a aaa 33 Working switch aaa 23 106 FRE EN 0912 9 0 M sounson PUMP alll AN SPX BRAND Order form for spare parts ADDRESS Your order will only be dealt with if this order form has been correctly completed and signed Order date Your order number Pump type Execution Item No Article number pump Delivery address Invoicing address ORDFORM 0804 3 1 EN 107 sounson PUMP si AN SPX BRAND 108 ORDFORM 0804 3 1 EN WHERE IDEAS MEET INDUSTRY Your local contact SPX Process Equipment NL B V Dr A F Philipsweg 51 9403 AD Assen THE NETHERLANDS P O Box 9 9400 AA Assen THE NETHERLANDS Phone 31 0 592 37 67 67 Fax 31 0 592 37 67 60 E Mail johnson pump nl processequipment spx com For more information about our worldwide locations approvals certifications and local representatives please visit www johnson pump com www spxpe com SPX Corporation reserves the right to incorporate our latest design and material changes without notice or obligation Design features materials of construction and dimensional data as described in this bulletin are provided for your information only and should not be relied upon unless confirmed in writing Copyright 2005 2009 SPX Corpor
66. nt on the pump size the pump is fitted with a half open or closed impeller The half open impellers have 3 or 4 blades with a generously sized passage Pumps with a half open impeller come with a renewable wear plate between pump casing wall and impeller blades Pumps with a closed impeller have a renewable wear ring fitted in the pump casing around the impeller entry This wear plate wear ring enables the pump to be overhauled at minimum cost Bearing bracket construction In the FRE configuration pumps are fitted with a shaft supported in two generously sized grease lubricated ball bearings Pumps of the FRES and FREM types come with a stub shaft which can be mounted on the mother shaft without play Pumps of the FREF range have the impeller fitted on the extended motor shaft In the FRES FREF and FREM configurations the motor is fitted to the pump casing using a lantern piece Mechanical seal All pump types of FRE FRES and FREM are equipped with a mechanical seal according to EN 12756 DIN 24960 FREF types are equipped with a short built mechanical seal The mechanical seal is almost leakproof Besides it is maintenance free When air is aspirated the mating faces of the mechanical seal are hardly cooled or lubricated by the liquid handled To ensure adequate lubrication the intermediate cover is provided with a chamber which must be filled with a lubricant e g oil This liquid must not attack the liquid handled nor
67. on 19 3 1 Safety 19 3 2 Preservation 19 3 3 Environment 19 3 4 Mounting 20 3 4 1 Installation of a pump unit 20 3 4 2 Assembling a pump unit 20 3 4 3 Alignment of the coupling 20 3 4 4 Tolerances for aligning the coupling 21 FRE EN 0912 9 0 5 pr PM sons 3 5 3 6 3 7 3 8 3 9 3 9 1 3 9 2 4 4 1 4 2 4 3 4 4 4 5 4 6 4 7 5 5 1 5 2 5 3 5 4 5 5 5 6 5 7 6 7 7A 7 2 7 3 7 3 1 7 4 7 5 7 5 1 7 5 2 7 6 7 6 1 7 6 2 7 6 3 7 6 4 7 6 5 7 6 6 7 6 7 7 6 8 7 6 9 7 6 10 7 7 7 7 1 7 7 2 7 7 3 7 7 4 7 7 5 7 7 6 7 7 7 ON PUMP AN SPX BRAND Installation of pumps with flanged on motors Main piping connection Piping Connection of the electric motor Combustion engine Safety Sense of rotation Commissioning Inspection of the pump Inspection of the motor Oil chamber Checking the sense of rotation Start up Pump in operation Noise Maintenance Daily maintenance Combustion engine Mechanical seal Double mechanical seal Environmental influences Noise Faults Problem solving Disassembly and assembly Precautionary measures Special tools Draining Liquid draining Constructive variants Back Pull Out system Disassembly Back Pull Out unit Assembly Back Pull Out unit Replacing the impeller and the wear ring 21 21 22 23 23 23 23 25 25 25 25 25 26 26 26 27 27 27 27 27 28 28 28 29 31 31 31 31 31 31 32 32 32 33 Measuring clearance betwe
68. on PUMP alll 9 8 1 9 8 2 9 9 9 9 1 9 9 2 9 10 9 10 1 9 10 2 9 11 9 11 1 9 11 2 9 12 9 12 1 9 12 2 9 13 9 13 1 9 13 2 9 14 9 14 1 9 14 2 10 10 1 10 2 10 3 10 4 10 5 10 6 10 6 1 10 6 2 AN SPX BRAND Sectional drawing FREF Parts list FREF Pump parts FREM Sectional drawing FREM Parts list FREM Parts Mechanical seal MQ1 Sectional drawings Mechanical seal MQ1 Parts list Mechanical seal MQ1 Parts FRE plan 11 Sectional drawing FRE plan 11 Parts list FRE plan 11 Parts Double mechanical seal MD1 Sectional drawing Double mechanical seal MD1 Parts list Double mechanical seal MD 1 Parts Cutting mechanism Sectional drawing Cutting mechanism Parts list Cutting mechanism Parts Coupling guard Sectional drawing Coupling guard Parts list Coupling guard Technical data Oil chamber Recommended locking liquids Tightening moments for bolts and nuts Hydraulic performance Permissible forces and moments on the flanges Noise data Pump noise as a function of pump power Noise level of entire pump unit Index Order form for spare parts 87 88 89 89 90 91 91 92 93 93 93 94 94 94 95 95 95 96 96 96 97 97 97 97 98 100 102 102 103 105 107 FRE EN 0912 9 0 MW sounson PUMP alll AN SPX BRAND FreFlow 1 Introduction 1 1 Preface This manual is intended for technicians and maintenance staff and for those who are in charge of ordering spare parts This manual contains i
69. p output The stop valve should always be fully opened during operation Check whether the absolute inlet pressure is sufficient to prevent vaporization in the pump Check whether the pressure difference between suction and delivery side corresponds with the specifications of the pump s duty point Noise The noise production of a pump depends to a great extent on the operating conditions The values stated in paragraph 10 6 Noise data are based on normal operation of the pump driven by an electric motor In case the pump is driven by a combustion engine or in case it is used outside the normal operation area as well as in case of cavitation the noise level may exceed 85 dB A In that case precautions should be taken like building a noise barrier around the unit or wearing hearing protection 26 Commissioning FRE EN 0912 9 0 FreFlow 5 1 5 2 5 3 5 4 MW sounson PUMP alll AN SPX BRAND Maintenance Daily maintenance Regularly check the outlet pressure No water should get into the terminal box of the electric motor when the pump room is sprayed clean Never spray water on hot pump parts The sudden cooling down may cause them to burst and hot water may flow out Combustion engine Never top up with fuel while the motor is running Mechanical seal A mechanical seal generally requires no maintenance however it should never be allowed to run dry So the oil chamber behind the mechanical seal
70. p power dB A 8 lt 96 2 94 x 92 D 90 88 86 84 82 80 78 76 74 72 70 68 66 64 62 60 58 56 54 0 1 1 10 P kW 100 200 Figure 57 Noise level as function of pump power kW at 1450 min A sound energy B sound pressure dB A AHAHAHAHA ol II Biga SEH 100 4104 A oe LL o IT est 1 LIU TAG TT III sol IHI 0 1 1 10 P kW 100 300 Figure 58 Noise level as function of pump power kW at 2900 min A sound energy B sound pressure 102 Technical data FRE EN 0912 9 0 FreFlow MW sounson PUMP alll AN SPX BRAND 10 6 2 Noise level of entire pump unit L dB 3 2 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 4102 0 12 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 L1 L2 dB Figure 59 Noise level of 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 Determine the noise level L1 of the pump see figure 57 or figure 58 Determine the noise level L2 of the motor see documentation of the motor Determine the difference between both levels L1 L2 Find the differential value on the L1 L2 axis and go
71. paragraph 7 6 5 Disassembly of the impeller other bearing brackets and paragraph 7 7 2 Disassembly of the mechanical seal MG12 Disassemble the laminated seal 2165 Remove the bearing cover 2115 Disassemble the inner circlip 2300 at drive side and remove the shim ring 2331 the waved ring 2355 and the other shim ring 2330 Use a plastic hammer and knock on the impeller side of the shaft with the bearings as to remove it from the back of the bearing bracket Use a proper puller to remove the bearings from the pump shaft Remove both the rubber closure rings 2390 Remove the adjustment ring 2335 from the bearing bore Disassemble the inner circlip 2300 7 8 7 Assembly of the bearings FRE bearing bracket 3 1 Mount both the rubber closure rings 2390 onto the pump shaft its largest sides turned away from each other The bearing are to be mounted in X set up 2 9 Mount the preheated bearing 2250 carefully on the pump shaft 2200 at impeller side and push it firmly against the shaft shoulder Let the bearing cool down Mount the preheated bearing 2260 carefully on the pump shaft at drive side and push it firmly against the shaft shoulder Let the bearing cool down Pull the rubber closure rings gently aside and apply a small amount of grease at both sides of the bearings Push the closure rings back in their correct position Fit the inner circlip 2300 into the bearing bore at impeller side
72. peller side and push it firmly against the rubber closure ring Let the bearing cool down Mount the preheated bearing 2260 carefully on the pump shaft at drive side and push it firmly against the shaft shoulder Let the bearing cool down Pull the rubber closure ring gently aside and apply a small amount of grease at both sides of the angular contact bearing 2250 Push the closure ring back in its correct position Fit the inner circlip 2300 into the bearing bore at impeller side Place the adjustment ring 2335 onto it Push the shaft with both bearings through the bore at the back of the bearing bracket until the bearing at impeller side touches the inner circlip The adjustment ring is now locked between the bearing and the inner circlip Place the adjustment ring 2330 onto the bearing at drive side and fit the inner circlip 2305 with its teeth facing the adjustment ring FRE EN 0912 9 0 Disassembly and assembly 41 sounson PUMP alll 9 AN SPX BRAND Mount the bearing cover 2115 at drive side and protect the bearing at impeller side by mounting the laminated seal 2165 10 Mount the shaft seal and the impeller see paragraph 7 7 3 Assembly of the mechanical seal MG12 and paragraph 7 6 6 Assembly of the impeller other bearing brackets 7 8 6 Disassembly of the bearings FRE bearing bracket 3 The item numbers refer to figure 41 1 7 8 Disassemble the impeller and the shaft seal see
73. r see figure 7 4 Calculate the size of the shim 0220 to be fitted using formula E B C E should be between minimum 0 3 mm and maximum 0 6 mm If the calculated shim thickness exceeds 0 6 mm impeller and wear plate must be replaced FRE EN 0912 9 0 Disassembly and assembly 33 y PM sons ON PUMP AN SPX BRAND Measuring clearance between impeller and wear plate other bearing groups Figure 8 Clearance between impeller and wear plate 1 Remove the Back Pull Out unit see paragraph 7 5 1 Disassembly Back Pull Out unit 2 Remove the gasket 0300 and clean the edges of pump casing and intermediate cover N DO OF BR 0 Find the appropriate gasket thickness D in the table below Measure the distance B between wear plate and pump casing see figure 8 Measure the distance C between impeller and intermediate cover see figure 8 Calculate the size of the clearance E using formula E B C D In case the clearance due to wearing has increased more than the maximum permitted value the impeller and the wear plate should be replaced For FRES or FREM it may be useful to check distance A see paragraph 7 9 2 Adjust ing the impeller or paragraph 7 11 2 Adjusting the impeller wrong adjustment of the impeller can also be a cause of too much clearance gasket thickness mm 80 170 0 3 50 125 80 210 100 225 50 125b 100 250 100 225b 65 135 150 290
74. re 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 Inspection of delivered items 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 Instructions for transport and storage Dimensions and weight A pump or a pump unit is generally too heavy to be moved by hand Therefore use the correct transport and lifting equipment Dimensions and weight of the pump or pump unit are shown on the label on the cover of this manual Use of pallets Usually a pump or pump unit is shipped on a pallet Leave it on the pallet as long as possible to avoid damages and to facilitate possible internal transport When using a forklift always set the forks as far apart as possible and lift the package with both forks to prevent it from toppling over Avoid jolting the pump when moving it Introduction FRE EN 0912 9 0 FreFlow 1 5 3 M sounson PUMP alll AN SPX BRAND Hoisting When hoisting a pump or complete pump units the straps must be fixed in accordance with figure 1 figure 2 and figure 3 When lifting a pump or a complete pump unit always use a proper and sound lifting device approved to bear the total weight of the load Never go underneath a load that is bein
75. reak Put the intermediate cover 0110 flat down Put some glycerine or silicon spray into the seal compartment and press the counter ring of the mechanical seal 1225 straight into it The opening in the counter ring must correspond to the position of the locking pin 1270 otherwise the counter ring will break Fit the O ring 1320 into the shaft sleeve Fit the rotating part of the mechanical seal 1225 onto the shaft sleeve Tighten the set screw Place the bearing bracket with the shaft in upright position Fit the mechanical seal cover onto the pump shaft Fit the O ring 1300 Fit the rotating part of the mechanical seal 1220 onto the shaft Adjust the rotating part of the mechanical seal to distance X1 from figure 11 and corresponding table Lock it by fixing the set screw A E dl X1 Figure 11 Adjusting the mechanical seal MD1 FRE EN 0912 9 0 Disassembly and assembly 39 sounson PUMP alll 7 8 7 8 1 7 8 2 AN SPX BRAND Shaft 16 25 30 X 43 18 8 30 7 Fit the shaft sleeve 1200 with the rotating part of the shaft sealing 1225 onto the shaft 8 Fit the intermediate
76. ring group 2 Figure 40 FRE EN 0912 9 0 Parts 76 FreFlow 9 3 2 Quantity Description pump casing Parts list FRE bearing group 2 MW sounson PUMP alll AN SPX BRAND Material cast iron G6 bronze stainless steel countersunk screw stainless steel impeller cast iron bronze stainless steel bronze stainless steel wear plate cast iron stainless steel bronze stainless steel wear ring cast iron bronze stainless steel bronze stainless steel gasket plug cast iron stainless steel gasket gasket plug cast iron stainless steel gasket n a E cleaning cover cast iron bronze stainless steel stud stainless steel nut stainless steel Allen screw countersunk screw steel stainless steel stainless steel washer stainless steel impeller key stainless steel bearing bracket cast iron bearing cover sealing washer steel steel pump shaft stainless steel coupling key steel angular contact bearing steel ball bearing steel retaining clip steel retaining clip steel adjusting ring steel adjusting ring steel gasket rubber name plate 1 For pumps with semi open impeller 2 For pumps with closed impeller 3 For FRE 80 140 only Material not speci
77. roperty and shall not be used otherwise than for the operation of this pump copied duplicated made available to or brought to the notice of third parties without our prior written consent SPX Process Equipment NL B V hereafter called Johnson Pump is part of SPX Process Equipment AB The core activities of SPX Process Equipment AB are the development production sale and maintenance of pumps and pump units SPX Process Equipment NL B V P O Box 9 9400 AA Assen The Netherlands Tel 31 0 592 376767 Fax 31 0 592 376760 www johnson pump com or www spxpe com 2008 SPX Process Equipment NL B V FRE EN 0912 9 0 sounson PUMP si AN SPX BRAND 4 FRE EN 0912 9 0 FreFlow pr PM sons Table of Contents ON PUMP AN SPX BRAND 1 Introduction 9 1 1 Preface 9 1 2 Safety 9 1 3 Guarantee 10 1 4 Inspection of delivered items 10 1 5 Instructions for transport and storage 10 1 5 1 Dimensions and weight 10 1 5 2 Use of pallets 10 1 5 3 Hoisting 11 1 5 4 Storage 12 1 6 Ordering parts 12 2 General 13 2 1 Pump description 13 2 2 Type code 13 2 3 Serial number 14 2 4 Pump motor group 14 2 5 Bearing groups 14 2 6 Applications 14 2 7 Selfpriming action 15 2 8 Configurations 16 2 9 Construction 16 2 9 1 Pump casing and impeller 16 2 9 2 Bearing bracket construction 16 2 9 3 Mechanical seal 16 2 10 Materials 17 2 11 Connections 17 2 12 Application area 17 2 13 Re use 17 2 14 Scrapping 17 3 Installati
78. s FRE EN 0912 9 0 FreFlow 10 Technical data 10 1 Oil chamber Table 8 Recommended oil type SAE 20 MW sounson PUMP alll AN SPX BRAND Oil contents Pump types 0 12 litre 32 110 and 40 110 32 150 50 125b 50 125 65 135 025 line 65 155 and 80 140 40 170 50 205 65 230 80 170 0 45 litre 100 225b and 100 225 0 75 litre 80 210 1 5 litre 100 250 2 0 litre 150 290b and 150 290 10 2 Recommended locking liquids Table 9 Recommended locking liquids Description Locking liquid locking of the impeller bolt set screws of the stub shaft Loctite 243 fastening screws FREM securing the stub shaft onto the motor shaft of the FREM Loctite 648 securing the wear ring in the pump casing on closed impeller pumps Loctite 641 sealing the tolerance ring of stainless steel and bronze pumps Loctite 572 10 3 Tightening moments for bolts and nuts Table 10 Tightening moments for bolts and nuts Materials 12 9 Thread Tightening moment N bearing bracket Application lantern piece set screws impeller wear plate FRE EN 0912 9 0 Technical data 97 PM sonson PUMP AN SPX BRAND 10 4 Hydraulic performance Figure 53 Performance overview 3000 min 80 100 m h
79. steel locking pin stainless steel plug cast iron stainless steel plug cast iron stainless steel O ring 1320 O ring 1800 tap bolt stainless steel 1 Bearing group 1 G1 G2 and G6 configuration is the same as R6 2 7 1 1 1 1 1 O Material not specified 94 Parts FRE EN 0912 9 0 AN SPX BRAND FreFlow pr PM sonson PUMP 9 13 Parts Cutting mechanism 9 13 1 Sectional drawing Cutting mechanism Figure 51 Sectional drawing Cutting mechanism 9 13 2 Parts list Cutting mechanism Material G6 R6 cutting blade stainless steel impeller stainless steel Quantity Description wear plate stainless steel FRE EN 0912 9 0 Parts 95 MW sounson PUMP alll AN SPX BRAND 9 14 Parts Coupling guard 9 14 1 Sectional drawing Coupling guard 0275 0270 0270 0280 I I SJ 0235 0232 0230 0232 Figure 52 Sectional drawing Coupling guard 9 14 2 Parts list Coupling guard Quantity Description Material 3 tap bolt stainless steel 3 nut stainless steel 6 washer stainless steel 3 spring washer stainless steel 4 tap bolt stainless steel 2 guard aluminium 0275 1 assembly plate steel 0280 1 plate motor side steel 96 Part
80. t voii BAR 20 assembly oser eee e dees aa 39 alignment tolerances 21 disassembly a essa 39 Mechanical seal MG12 D assembly aaa 37 Daily maintenance s ssia peie eea 27 disassembly s vm r ae seek se nkor 37 double mechanical seal 27 mechanical seal 27 N Draining 2 24 28284 Rd Krade era a 31 NOISE oicsriicsriicsrniss sites 26 28 Fo 01 gt EE 31 O E Oil chamber 000000 25 Electric motor oil contents aa 97 CONNECTION eiii ahat ewes 23 Order instructions 12 Environment aaa 19 Ordering parts a 12 F P Faults iii TA KA 28 Piping dang eid ee te beta te heey 22 Fax order form 0 cece eee eee 12 Precautionary measures 31 Preservation cece eee 19 FRE EN 0912 9 0 105 sounson PUMP alll AN SPX BRAND Pump description o oo ooooooo o 13 Pump unit assembly aaa GRAN akse knee 20 installation a 20 R REUSE sanere bes bi 17 S Safety ss r nen vanes aren views sae des 19 symbols assed aio o 9 Scrapping serve 00 cece eee eee 17 Sense of rotation 25 Serial number 2 00000 eee 14 Special tools 00 00 ee eee eee 31 SIAP cia n RR RAN EP TE 26 Static electricity 19 Storage aaa 10 11 12 T Technicians aaa 9 Tightening moments for bolts and nuts 97 Tra
81. t iron bronze stainless steel Quantity Description mechanical seal oil seal locking pin stainless steel plug plastic plug stainless steel gasket For M7N only Material not specified 92 Parts FRE EN 0912 9 0 Ba ff sounson pump 9 11 Parts FRE plan 11 9 11 1 Sectional drawing FRE plan 11 Figure 49 Sectional drawing FRE plan 11 9 11 2 Parts list FRE plan 11 Material G6 pipe nipple stainless steel connector straight female stainless steel Quantity Description pipe stainless steel reducing ring stainless steel connector straight male stainless steel FRE EN 0912 9 0 Parts 93 MW sounson PUMP alll AN SPX BRAND 9 12 Parts Double mechanical seal MD1 9 12 1 Sectional drawing Double mechanical seal MD1 1800 1280 1200 1300 oo N mm N p pa ba e r 1 P 1220 7 1260 BN 1250 gt e 0110 Figure 50 Sectional drawing Double mechanical seal MD1 9 12 2 Parts list Double mechanical seal MD1 Material G1 G2 G6 R6 0110 1 intermediate cover cast iron stainless steel 1200 1 shaft sleeve stainless steel 1 mechanical seal 1 Item Quantity Description mechanical seal i o mechanical seal cover cast iron stainless steel set screw stainless steel locking pin stainless
82. te cast iron wear ring cast iron lantern piece cast iron gasket plug cast iron gasket plug cast iron cleaning cover cast iron stud nut stainless steel stainless steel Allen screw bolt steel nut slide ring counter ring oil seal plug plastic plug steel gasket Allen screw stainless steel countersunk screw stainless steel spring washer stainless steel washer stainless steel impeller key stainless steel tolerance ring stainless steel name plate stainless steel motor 1 For pumps with semi open impeller 2 For pumps with closed impeller 3 For FREF 80 140 only 4 For bearing group 1 5 For bearing group 2 Material not specified steel 88 Parts FRE EN 0912 9 0 ON PUMP JIE sours FreFlow Pump parts FREM 9 9 Sectional drawing FREM 9 9 1 0Z4Z 5980 00ZZ ed if 0580 0040 0981 CC 0080 0072 05Z0 0180 Mg OELO 0210 0e8L 0Z8l STL SLLO 0010 0ZE0 Sectional drawing FREM Figure 46
83. the coupling key 2210 and fit the coupling half to onto the pump shaft Place the protection plate 0280 around the motor shaft and fit the electric motor Carefully bend the coupling guards 0270 open and place them around the coupling Ensure plates 0275 and 0280 fit into the centring rims Fit bolts 0230 and nuts 0231 with washers 0232 and spring washers 0233 Check the alignment of pump and motor shaft see chapter 3 Installation If necessary realign 32 Disassembly and assembly FRE EN 0912 9 0 FreFlow 7 6 7 6 1 M sounson PUMP alll AN SPX BRAND Replacing the impeller and the wear ring The clearance between the half open impeller and the wear plate may be 0 3 mm minimum and 0 6 mm maximum If there is a decline in the performance characteristics of the pump this can be an indication of wear of the impeller and in the wear plate To check this the pump must be dismantled in order to measure the clearance between the impeller and the wear plate Measuring clearance between impeller and wear plate FRE bearing group 1 A LTE E W a Figure 7 Clearance between impeller and wear plate FRE bearing group 1 1 Remove the Back Pull Out unit see paragraph 7 5 1 Disassembly Back Pull Out unit Measure the distance B between wear plate and pump casing see figure 7 Measure the distance C between impeller and intermediate cove
84. ting 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 Faults with the pump Breakdowns or faults in the pipe system Faults due to incorrect installation or commissioning 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 Table 4 Most frequently occurring failures Most common faults Possible causes see Table 5 Pump delivers no liquid 1 2 3 4 5 Pump has insufficient volume flow 4 5 7 8 12 17 31 Pump has insufficient head 1 5 8 9 11 17 31 Motor is overloaded 8 10 11 12 13 17 22 Pump vibrates or is noisy 3 4 7 8 9 14 15 16 17 18 19 20 23 Bearings wear too much or become hot 15 18 21 22 23 Motor is running hot 8 13 24 Pump got stuck 2 6 17 22 Irregular delivery 4 7 9 14 Pump does not prime 1 2 5 7 Pump has higher power consumption than 1 8 10 13 15 16 18 20 21 24 25 normal 27 28 32 Pump has lower power consumption than normal 1 8 13 14 23 24 25 26 29 31 Mechanical seal have to be replaced to often 15 18 21 28 30 31 32 33 FRE EN 0912 9 0 Problem solving 29 pr PM onns ON PUMP AN SPX BRAND Table 5 Possible causes of pump failures Possible causes Wrong sense of rotation
85. up Pumps with bare shaft are designated by an A FRE Pumps complete with all parts to be assembled with the motor but supplied without the motor are designated by A5 FRE Pumps assembled with three phase electric motor are designated by A6 FRE FRES and FREF single phase electric motor are designated by A7 FREF petrol engine are designated by A10 FREM diesel engine are designated by A11 FREM Bearing groups FreFlow pumps can be divided into 4 categories of bearing bracket groups i e groups 1 2 3 and 4 Groups 1 2 and 3 are of modular construction Pumps that are part of one such group share their bearing bracket Pumps of group 4 higher capacity each have their own bearing bracket but will for con venience sake be identified as bearing bracket group 4 Applications FreFlow pumps are suitable for handling clean polluted and thin liquids The maximum particle size of impurities depends on the pump size In handling viscous liquids you should make allowance for a decrease in hydraulic performance and an increase in power consumption Please ask us for advice The maximum allowed system pressure and temperature and the maximum speed depend on the pump type and the pump construction For relevant data see the tables in chapter 10 Technical data Further details about the application possibilities of your specific pump are mentioned in the order confirmation and or in the data sh
86. up to the curve From the curve go left to the L dB axis and read out the value oar OUO DN Add this value to the highest value of both noise levels L1 or L2 Example 1 Pump 75 dB motor 78 dB 2 75 78 3 dB 3 3 dB on the X axis 1 75 dB on the Y axis 4 Highest noise level 1 75 dB 78 1 75 79 75 dB FRE EN 0912 9 0 Technical data 103 sounson PUMP alll AN SPX BRAND 104 Technical data FRE EN 0912 9 0 FreFlow Index MW sounson PUMP alll AN SPX BRAND A Application area eee eee 17 H HOIStING ca diske a e 11 B Back Pull Out unit I assembly cases eb grn ir 32 Impeller disassembly sx sket se kons ee 32 replacement sss x os kors sek oas KRA Aa 33 Back Pull Out system 32 Inspection Bearing iia ries 40 MO a 25 Bearing groups aaa 14 PUMP 4787243 PEER EKAGG AGANG nen 25 Bearings assembly instructions 40 L disassembly instructions 40 Liting eye csse e AA 11 Cc M Combustion engine 23 Maintenance staff aaa 9 SAY ura GG kaa eee 23 Mechanical seal oomoooo 37 sense of rotation 23 assembly instructions 37 Commissioning 00 eee eee 25 Mechanical seal M7N Connections aaa 17 assembly 270770033383343 rr 38 Construction variants 31 disassembly 00 essa 38 Coupling Mechanical seal MD1 alignmen
87. ups 1 2 and 3 ze Figure 14 FRE bearing groups 1 2 and 3 FRE EN 0912 9 0 Dimensions 47 PM sounson PUMP AN SPX BRAND 50 125b Rp 2 50 125 50 205 Rp 2 65 135b 65 135 65 155 65 230 80 140 80 170 100 225b 0 O AI A A A A BR 100 225 CO CO CO CO CO CO OT OM 00 R6 aa 50mm aa gt 50 ISO 7005 PN 16 connections 50 125b 50 125 50 205 65 135b 65 135 65 155 65 230 80 140 80 170 100 225b 100 225 48 Dimensions FRE EN 0912 9 0 MW sounson PUMP alll AN SPX BRAND FreFlow 8 2 FRE bearing group 4 Figure 15 FRE bearing group 4 80 210 100 250 150 290b 150 290 ISO 7005 PN 16 connections 80 210 100 250 150 290b 150 290 FRE EN 0912 9 0 Dimensions 49 sounson PUMP alll AN SPX BRAND 8 3 FRE with ISO 7005 PN20 connections eb
88. vacuated the pump starts to run as a normal centrifugal pump A precondition for good functioning is that it should be possible for the aspirated air to escape without back pressure in the discharge line The pump does not have a non return valve so the suction and discharge lines can be siphoned empty when the pump has been stopped The remaining liquid in the pump casing is always sufficient for the next suction phase In case voluminous suction piping causing too long suction times it is recommended to install a non return valve in the pumps suction inlet O O OG ST O TO A Water air separation B Pump casing Cc Volute D Impeller E Back flow opening FRE EN 0912 9 0 General 15 sounson PUMP alll 2 8 2 9 2 9 1 2 9 2 2 9 3 AN SPX BRAND Configurations There are 4 different configurations in the FreFlow range Type FRE Pump with bearing bracket Type FRES Pump with stub shaft and lantern piece coupled to an IEC flange motor Type FREF Pump with lantern piece coupled to a flange motor with extended shaft end Type FREM Pump with stub shaft and lantern piece coupled to a petrol or diesel engine Construction Pump casing and impeller The pump casing is a combination of a volute and aeration chamber to ensure the selfpriming action There is a generously sized drain hole at the bottom of the pump casing which can also be used for cleaning Depende
89. yer 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 FRE EN 0912 9 0 Introduction 9 sounson PUMP alll 1 3 1 4 1 5 1 5 1 1 5 2 AN SPX BRAND Guarantee 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 Service and or maintenance is not undertaken in strict accordance with the instructions The pump is not installed and operated in accordance with the instructions Necessary repairs are not undertaken by our personnel or are undertaken without our prior written permission Modifications are made to the products supplied without our prior written permission The spare parts used are not original Johnson Pump parts Additives or lubricants used are other than those prescribed The products supplied are not used in accordance with their nature and or purpose The products supplied have been used amateurishly carelessly improperly and or negligently The products supplied become defective due to external circumstances beyond our control All parts which a

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