BAS6808 Operating Instructions BRINKMANN
Contents
1. drain the medium in the block ing chamber through the screw plug 27 2 Loosen the socket head cap screws 60 and remove the connection cover 52 2 Loosen the Socket head cap screws 82 and re move the agitator 81 with the Serrated lock washer 84 4 Loosen the socket head cap screws 58 and remove the shim ring 55 and the chip breaker 56 5 Loosen the shaft nut 80 and remove the suction screw 78 6 Loosen the socket head cap screws 54 and remove the intake cover with o ring 67 7 Use two screwdrivers to push the impeller 75 from the insert shaft 91 Insert the screwdrivers between the impeller 75 and the pump body 50 2 Remove the woodruff key 53 from the insert shaft 91 Loosen the socket head cap screws 65 and remove the bushing cartridge assembly 61 with the shim ring 83 Remove the circlip 25 and the shim ring 22 Remove the rotating axial face seal unit 24b 24e 2g 10 Loosen the Socket head cap screws 31 and remove the pump body 50 11 Remove circlip 25 and shim ring 22 and remove the rotating axial face seal unit 24b 24e To replace the insert shaft see position BAS6808 Edition 03 2014 11 2 When changing an axial face seal remove the sta tionary axial face seal unit 24a from the pump body 50 and pump foot 12 Clean the seat of the seal and the pump parts The mechanical seal 24 should now be completely replaced If necessa2. removing the pump exists Proper and secured lifting tools must be used Risk of burns The pump must have cooled down sufficiently prior to commencing any repair maintenance or installation BAS6808 Edition 03 2014 3 4 Qualification and training of operating person nel The personnel responsible for operation maintenance inspection and assembly must be adequately qualified Scope of responsibility and supervision of the personnel must be exactly defined by the plant operator If the staff does not have the necessary knowledge they must be trained and instructed which may be performed by the machine manufacturer or supplier on behalf of the plant operator Moreover the plant operator is to make sure that the contents of the operating manual are fully understood by the personnel 3 5 Safety instructions relevant for operation e f hot or cold machine components involve hazards they must be guarded against accidental contact e Guards for moving parts e g coupling must not be removed from the machine while in operation e Any leakage of hazardous e g explosive toxic hot fluids e g from the shaft seal must be drained away so as to prevent any risk to persons or the environ ment Statutory regulations are to be complied with e Hazards resulting from electricity are to be prevented see for example the VDE Specifications and the bye laws of the local power supply utilities e The pumps are only secured safe
3. start no motor noise At least two of the power supply leads have failed Overload has tripped Check fuses terminals and supply leads Inspect overload Motor does not start humming noise One of the supply leads has failed Impeller faulty Motor bearing faulty See above Replace impeller Replace bearing Overload trips Pump locked up mechanically High on of cycling frequency Inspect pump hydraulics Check application Power consumption is too high Wrong direction of rotation of impeller Lime or other deposits mechanical friction See above Clean pump mechanism repair pump Motor overheats High on off cycling frequency Wrong power supply voltage or cycles Insufficient cooling See above Power supply must correspond with name plate rating Check air flow at motor fan Pump does not pump liquid level too low Pump mechanism faulty Pipe blocked Fill up liquid replace pump mechanism Clean pipe Insufficient flow and pressure Wrong direction of rotation of impeller Pump mechanism silted up Worn pump mechanism Change over two power supply leads Clean pump mechanism Replace pump mechanism Incorrect flow or pressure Wrong power supply voltage or cycles Power supply must correspond with name plate rating Running noise Vibration BAS6808 Edition 03 2014 Foreign objects in pump end Impeller damaged Bearing Bushing broken Re
4. the direction of rotation is correct Tightening torques for screwed connections Thread M5 M6 M8 M16 Strength 48 8 8 12 9 8 8 classes Tightening 2 2 3 3 11 7 15 44 torque ft lbs 3 45 16 20 60 Nm Item 82 12 Disposal When disposing of the pump or the packaging mate rials the local and national regulation for proper disposal must be complied with Prior to its disposal the pump must be completely drained and decontaminated if necessary Page 9 of 10 13 WARRANTY Brinkmann Pumps Inc warrants that the product contained herein conforms to the descrip tion in Brinkmann s catalog and that if this product shall fail to conform to the description thereof or to any express or implied warranty Brinkmann shall upon written notice of such nonconformity within one year of the date of its shipment from BRINKMANN S plant repair or replace such non conforming material at the original point of delivery Brinkmann will fur nish instructions for disposition of the goods If however Brinkmann provides a written war ranty as to this specific product which is not in conformity to the above warranty then as to such specific product the specific written warranty shall prevail In addition to the warranty that this product will conform to the description in Brinkmann s catalog and that any such non conforming material will be repaired or replaced as above stated BRINKMANN further warrants that it conveys g
5. 25 PN1 Dimensions inmm Dimensions for motors up 7 4 HP ATTENTION Maximum tightening torque for piping connections NPT 2 is 130 ft Ibs 770 Nm When installed the space around the pump must be large enough to provide sufficient cooling of the motor The pump must never under any circumstances be used as a point for securing the piping No forces or torques from the piping may be allowed to affect the pump Pipes must be intercepted directly before the pump and connected with no tension A e The pump may only be operated if installed to a suitable tank e A suction screw is in the suction side of the pump risk of injury e Touching the rotating parts is forbidden e Reaching of the suction screw in the suction side of the pump must be prevented by fitting preventive measures e As particles and or chips can be redirected from the pump suction at a high velocity the tank design must incorporate appropriate pro tection i e a tank cover that prevents such objects from being ejected out off the tank When pumping cooling and cutting oils the following is to be adhered to e The geometry of the tank must be designed and executed in such a way that no flammable aerosol can develop i e through velocity dur ing operation of the pump The necessity of mist collection exhaustion must be investigated and determined Danger of fire and explosion if ignition spark is present e In order to avoi
6. BAS6808 EJBRINKMANN Operating Instructions BRINKMANN Horizontal End Suction Pumps SBC820S 1120S BRINKMANN PUMPS Inc 47060 Cartier Drive Wixom MI 48393 USA Phone 1 248 926 9400 www brinkmannpumps com Fax 1 248 926 9405 sales brinkmannpumps com Subject to change without prior notice Order No BAS6808 ENGLISH Brinkmann Pumpen Edition 03 2014 Page 1 of 10 Brinkmann Horizontal End Suction Pumps Series SBC820S 1120S Contents 1 Indication to the manual ceeeeeteeeeeees 2 2 Description of the Product cceeeeeee 2 3 3 Safety instructions ereere 3 4 4 Transportation and Storage cceeeeeeeeeeeeee 4 5 Installation and Connection cccccceeee 4 5 6 Start up Shut down oe ee eeeeeeeeeeeeeeeeeeeeeeeee 5 7 Operation 2 tye cited E OEE 5 1 Indication to the manual This operating manual gives basic instructions which are to be observed during installation operation and maintenance of the pump It is therefore imperative that this manual be read by the responsible person nel and operator prior to assembly and commission ing It is always to be kept available at the installa tion site 1 1 Identification of safety instructions in the operating manual Safety instructions given in this manual non compliance with which would affect safety are identified by the following symbol A Safety sign according with ISO 3864 B 3 1 or where electric
7. al safety is involved with AN Safety sign according with ISO 3864 B 3 6 Where non compliance with the safety instructions may cause a risk to the machine and it s function the word ATTENTION is inserted 2 Description of the Product 2 1 General description of the pump Pumps of the series SBC are one stage rotary pumps The impellers are fixed on the driving shaft extension The pump shaft and motor shaft are interconnected by means of a shaft clamp The cutting unit is cutting the chips and the semi open impeller with its large clearances allows to pump the particles along with the coolant fluid from the machine back to the filter The SBC pumps are capable of handling chip to coolant ratios of up to 1 5 by weight Pump and motor form a compact and space saving unit All pumps are equipped with double mechanical seal These pumps are for horizontal installations next to or underneath a tank The pumps are foot mounted and must be screwed down in order to ensure a secure stance BAS6808 Edition 03 2014 8 Servicing and Maintenance ceseeeee 6 9 Troubleshooting Guide esseeseeseeeeeeeeeeee 6 10 Spare Parse eee aae a aE ii eaa 7 11 Repair Instructions eeen 8 9 12 Disposal ey cnc cae T 9 13 WARRANTY 0 eeecceecceeeeeeeeeeeeeeeeeeneeeeneeeeaees 10 2 2 Intended use These pumps are not self priming and must be gravity fed They are suited for cutting aluminum ch
8. d the formation of an ignition spark no foreign particles may enter the tank Page 4 of 10 5 2 Electric wiring A All service work must be carried out by qualified service personnel Pump must be disconnected from the power source and all rotating parts must stand still Reassure that pump is disconnected from power source and cannot be switched on Verify that there is no voltage at the terminal board According to the European Standard EN809 a motor overload must be installed and properly set to the full load amps stated on the pump name plate It is the responsibility of the machine operator to decide whether or not an additional emergency switch must be installed 5 2 1 Circuit LN Tension voltage and frequency must correspond with the shown specification on the nameplate The pump must be wired so that a solid longterm elec trical connection is ensured Establish a solid ground connection The electrical wiring must be performed according to the wiring diagram shown inside the terminal box cover Please see above sample wiring diagrams Wiring diagram e g Voltage changing 1 2 YY Y e g 230 460 V 60 Hz o_o i o _ f CDO YY Y Low Voltage High Voltage There may be no foreign objects such as dirt particles or humidity inside the terminal board Mount terminal board cover to motor tight against dust and humidity and close up all unused wiring ports ATTENTION When Variab
9. e other Do not under any circumstances remove the screws completely danger of injury 6 Pull the extension shaft 2 and the shaft clamp 1 off the motor shaft 3 11 3 Assembling the insert shaft and motor shaft ATTENTION Clean the contact surfaces of the insert shaft 2 inside and the motor shaft 3 They must not be lubricated or oiled 7 Set the pump down on the end of the shaft 8 Position the shaft clamp 1 use a new shaft clamp in the centre of the cranked clamping di ameter 2 of the insert shaft 9 Insert the motor shaft 3 into the insert shaft 2 10 Tighten Mark the first screw and tighten all the screws evenly by hand one after the other in a clockwise direction not cross ways 11 Use a torque screwdriver to tighten each screw first with 1 5 ft lbs 2 Nm then with 2 6 ft Ibs 3 5 Nm and finally with 3 7 ft Ibs 5 Nm in a clock wise direction again BAS6808 Edition 03 2014 12 Mount the pump foot and the pump body The remainder of the reassembly process is to be completed in the opposite order of the prior described dismantling process ATTENTION Note torques for the screw connections 13 Position the pump laterally and fill the pump blocking chamber GD with oil until it reaches the oil inspection window 27 0 45 litres Fit the sealing ring 28 and screw on the screw plug 27 When putting the pump back into use make sure
10. ions weight 1 Type PSI bar GPM l min H Inch h Inch I Inch HP kW SBC8208 1000 54 40 SBC1120S 70 2 1 310 1150 31 4 20 4 13 6 205 7 4 5 5 DN125 PN16 Discharge Port NPT2 G2 The motor is surface cooled and compliant with DIN IEC 34 and EN 60034 protection degree IP 55 Pipe connection Suction Port 3 Safety instructions When operating the pump the safety instructions con tained in this manual the relevant national accident prevention regulations and any other service and safety instructions issued by the plant operator are to be observed 3 1 Hazards in the event of non compliance with the safety instructions Non compliance with the safety instructions may pro duce a risk to the personnel as well as to the environ ment and the machine and results in a loss of any right to claim damages For example non compliance may involve the following hazards e Failure of important functions of the machines plant e Failure of specified procedures of maintenance and repair e Exposure of people to electrical mechanical and chemical hazards e Endangering the environment due to hazardous substances being released 3 2 Unauthorized modes of operation A e Pump may not be used in potentially explosive environments e Pump and discharge piping are not designed to hold any weight and may not be used as a step ladder 3 3 Remaining Risk Risk of Injury Risk of squeezing or crushing body parts when installing or
11. ips or similar materials and for pumping these materials along with the coolant fluid An agitator located at the pump suction helps to break up and separate any large bundles of chips or birds nests which reach the pump suction Pay attention of the limit of application in table 1 Limit of Application Table 1 Type SBC Mediums Coolants Cooling and cutting oil upon request Flashing point of 302 F 150 C the medium to be pumped Chip material Aluminum max chip to coolant ratio 1 5 Chip geometry Chip bundles to max 3 94 Inch 100 mm Kinetic viscosity 200SSU 45 mm s of the medium Temperature of 30 175 F 0 80 medium min delivery 1 5 of Q max volume Dry running Dry running causes increased wear and should be avoided During the test of the direction of rotation lt 30 s permissible Switching on The pump SBC should be oper frequency per ated in continual operation mode hour not pulsed mode Ambient tem 104 F 40 TC perature Set up altitude 3280 ft 1000 m ATTENTION The pumps are to be operated within their design limits Applications outside of these limits are not approved The manufacturer is not responsible for any damages resulting from use of the pumps in such applications Page 2 of 10 2 3 Technical data Max del Max del Dimen Length Weight Power Pressure spec volume s
12. le Frequency Drives are used interfering signals might occur Non sinus shaped supply voltage from a variable fre quency drive might result in elevated motor tempera tures 6 Start up Shut down 6 1 Start up ATTENTION Switch off at the mains After connection the electrical wires close the terminal box BAS6808 Edition 03 2014 Briefly start the motor max 30 sec and check the rotation according to the arrow on the top of the motor If the direction is incorrect change over two of the power leads 6 2 Shut down All service work must be carried out by qualified service personnel Pump must be disconnected from the power source and all rotating parts must stand still Reassure that pump is disconnected from power source and cannot be switched on Verify that there is no voltage at the terminal board Open terminal box and disconnect the power leads Empty out the pump 7 Operation Liquid level These pumps are not self priming and must be gravity fed Possible leakage must be drained away so as to prevent any risk to persons or the environment Oil inspection Screw plu window pag Leakage G 1 8 ATTENTION The SBC pump should be operated in continual operation mode not pulsed mode Pulsed mode causes increased wear due to the return flow of chips and additional load on the bearings The pump should transport medium without chips for 1 2
13. ly if properly at tached to the floor or underneath a tank e The female threads on the motor MUST NOT be used to lift the entire pump and motor assembly 3 6 Safety instructions relevant for maintenance inspection and assembly work Any work on the machine shall only be performed when itis at a standstill it being imperative that the procedure for shutting down the machine described in this manual be followed Pumps and pump units which convey hazardous media must be decontaminated On completion of work all safety and protective facilities must be re installed and made operative again Prior to restarting the machine the instructions listed under Start up are to be observed 3 7 Signs on the pump It is imperative that signs affixed to the machine e g e arrow indicating the direction of rotation e symbols indicating fluid connections be observed and kept legible Page 3 of 10 3 8 Unauthorized alterations and production of spare parts Any modification may be made to the machine only after consultation with the manufacturer Using spare parts and accessories authorized by the manufacturer is in the interest of safety Use of other parts may exempt the manufacturer from any liability 4 Transportation and Storage Protect the pump against damage when transporting The pumps may only be transported in a horizontal position and hooks or straps must be attached on the motor and pump end Do not use the pu
14. minutes before being switched off A The fluid level should be above the suction mouth of the pump during pumping of cooling and cutting oils in order to avoid ignitions sparks Danger of fire and explosion if flammable aerosol is present Unwanted objects such as broken tools or indexing plates which still lie under the pump after stopping the working process must be taken out in regular intervals Any repair or maintenance work must be performed after the pump has been turned off and the shaft has come to a complete stop Risk of injury See provided warning label If the pump should lock up and cease shut pump down see 6 2 and disconnect from power supply Pump must be uninstalled and removed from the system prior to its repair Page 5 of 10 8 Servicing and Maintenance ATTENTION The surface of the motor must be kept free of dirt The motor shaft is spinning in permanently greased ball bearings with special grease and increased bearing play and does not require any special 8 1 Pumps with double mechanical seal GD Pumps with double mechanical seal GD are identi fied by the letters GLRD stamped in on the motor side of the pump foot and must include an oil receiver with a capacity of 0 45 litres Check this through the inspection window Oil receiver Castrol WHITEMOR WOM14 or equiva maintenance 9 Troubleshooting Guide Fault lent oil Cause Remedy Motor does not
15. move foreign objects Replace impeller Replace bearing bushing Page 6 of 10 10 Spare part 10 1 Spare part list for Brinkmann Horizontal End Suction Pumps Series SBC820S 1120S 7 19 3 814115 4 11 16 2 3196 97 92 93 94 95 50 918351547955 78 60 82 52 13 30 6 102916 21 Item Description Stator with terminal board Motor flange End shield Terminal box up to 5 4 HP 4 1 Terminal box frame up 7 4 HP 4 2 Terminal box cover up 7 4 HP 5 Bearing cover 6 Compensation disk 7 Fan 8 9 ROM Fan cover Ball bearing DIN 10 Ball bearing DIN 11 Gasket 11 1 Gasket up 7 4 HP 12 Pump foot 13 Retaining ring 14 Spiral shaped screw DIN 15 Socket head cap screw DIN 16 Socket head cap screw with lock DIN 19 Parallel pin DIN 20 Shaft nut 21 Motor shaft with rotor 22 Shim ring 23 Socket head cap screw DIN 24 Mechanical seal 25 Circlip 27 Oil inspection window 27 Screw plug DIN 28 Sealing ring DIN 29 O ring 30 Shaft seal 31 Socket head cap screw with lock DIN BAS6808 628 625 7500 912 912 908 7603 912 Edition 03 2014 23 5 9 2012 77 9027 2824 22 25 24 616567 755367685856 80 81 84 Description Pump body Intake cover Connection cover Woodruff key DIN Socket head cap screw with lock DIN Shim ring Chi
16. mp shaft for connecting any transpor tation aids such as hooks or straps Pumps must be drained prior to their storage Store pump in dry and protected areas and protect it against penetration of foreign bodies Always store pump above the freezing point 5 Installation and Connection 5 1 Mechanical installation The pumps must be properly fastened The pipework must be installed so that no distortion of the pump can occur The fluid inlet is on the face side of the flange connected pump mechanism The clearance between the suction opening and the tank floor should be large enough to prevent the suction opening from becoming blocked even if the coolant is heavily polluted and the pump has not been operated for long periods In order to reach the maximum flow rate it is recom mended that the pipe diameter is as close as possible to the nominal pump connection diameter Avoid the introduction of pipe bends no angled sections The installed pipes must be rated for the hydraulic pressures which occur during operation The positions of the foot and pressure connection can be moved around the circumference to 3 different positions On the S type the pipe connection can also be set to normal or parallel alignment to the pump axis BAS6808 Edition 03 2014 9218 2584 Flonsch DN125 PNI6 Flange DN1
17. ood title to this product free of all liens of any kind whatever unknown to the first Buyer These are the sole warranties of BRINKMANN with respect to this product BRINKMANN MAKES NO FURTHER WARRANTY OF ANY KIND EXPRESS OR IMPLIED ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS ARE HEREBY DISCLAIMED BY BRINKMANN AND EXCLUDED FROM THIS SALE The Buyer s exclusive and sole remedy on account or in respect of the product herein con tained that does not conform to the description thereof or to any express or implied warran ty shall be to secure replacement thereof as aforesaid BRINKMANN shall not in any event be liable for the cost of any labor expended on any such material or for any special direct indirect incidental or consequential damages to anyone by reason of the fact that such goods do not conform to the description thereof or to any express or implied warranty BAS6808 Edition 03 2014 Page 10 of 10
18. p breaker with bearing bush Socket head cap screw with lock DIN Socket head cap screw with lock DIN Bushing cartridge assembly Socket head cap screw DIN O ring O ring Impeller O ring Suction screw Woodruff key DIN Shaft nut Agitator Socket head cap screw with lock DIN Shim ring Serrated lock washer Shaft clamp Insert shaft Joining socket Socket head cap screw DIN Spring washer DIN O ring Screw plug DIN Sealing ring DIN 6888 912 7984 912 912 6888 912 912 7980 908 7603 Page 7 of 10 10 2 Indications to the spare part order Spare parts are available from the supplier Standard commercially available parts are to be pur chased in accordance with the model type The ordering of spare parts should contain the following details 1 Pumptype e g SBC1120S 2 Pump No e g 03146808 The date of the construction year is a component of the pumps type number 3 Voltage Frequency and Power Take item 1 2 and 3 from the nameplate 4 Spare part with item No e g connection cover item No 52 11 Repair Instructions Replacing the rotary mechanical seal the shaft clamp 11 1 Replacing the rotary mechanical seal A Wear safety gloves Risk of injury due to sharp edges on pump components i e impeller blades 1 Disconnect the pump electrically and mechanically Note the markings on the pump components prior to dismantling When completely dismantling a unit with dual axial face seals
19. ry replace the o rings 67 77 and impeller 75 12 Fit a new mechanical seal The sliding surfaces of the axial face seal must be free of dirt and grease Lightly moisten the collar 24a with prill water and press the stationary axial face seal unit 24a into the pump body 50 and pump foot 12 Slide the rotating axial face seal unit 24b 24e onto insert shaft 91 and fix in position using shim ring 22 and circlip 25 13 The remaining assembly steps are Pos 2 to 8 in reverse order ATTENTION Assembly help and detailed instruction is demanded for the assembly of the pump and adjusting of the cutting unit 24a 24b 24c 24d 91 24a 24b 24c 2kd yw i yoy J He UNS AD Sr ZAP 50 Uke et OP 25 i Poi Dee 97 75 Page 8 of 10 11 2 Dismantling the insert shaft 1 4 1 Disconnect the inline pump from the mains both electrically and mechanically Ss 1 Shaft clamp 2 Insert shaft 3 Motor shaft 2 Remove the pump 3 Empty out the Pump and dismantle the pump unit A Wear safety gloves Risk of injury due to sharp edges on pump compo nents i e impeller blades 4 Dismantle the pump body and the pump foot 5 Loosen the screws on the shaft clamp 1 one after th
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