Johnson Controls TopClean AS User's Manual
Contents
1. Execution Q 610 710 6Q 10 7 IM AS 02 00 GB 0412 Execution V 87V 86V 71V 70V 1V 2 N lt RD NS 85V 66V 65V 68V 21 22 12 6 Spare part list AS 42 52 Pos Q ty Denomination Material 1 1 Casing pump CF 3M 1 4409 1Q 1 Casing pump Q execution CF 3M 1 4409 1V 1 Casing pump V execution CF 3M 1 4409 2 1 Cover casing CF 3M 1 4409 3 2 Impeller CF 3M 1 4409 4 1 Shaft AISI 316 L 1 4404 4v 1 Shaft V execution AISI 316 L 1 4404 5 1 Housing bearing Cast iron 25 396Ni 6 1 Mechanical seal 6Q 1 Mechanical seal Q execution 7 1 Bearing Steel 8 1 Bearing cover Aluminum 2011 11 2 Key impeller AISI 316 1 4401 13 1 O ring EPDM 14 1 Thrower NBR 15 1 Shaft plug NBR 17 1 Nut ring Galvanized iron 20 1 Foot front CF 8 1 4308 21 2 Foot adjustable AISI 304 1 4301 23 1 2 Foot rear CF 8 1 4308 AISI 304 1 4301 25 1 2 Foot adjustable AISI 304 1 4301 26 4 Screw socket head AISI 304 1 4301 27 3 Screw socket head AISI 304 1 4301 22. Dimensions not binding DN DIN 11851 male threaded connection exec with standard IEC EN motors 26 IM AS 02 00 GB 0412 14 0 Trouble shooting chart The pump does not prime Air has entered the suction piping check the seals on the fittings and tighten them sufficiently Suction pipe not submerged in liquid Clearances between impeller cover and impeller body have increased Check and correct No liquid in the pump Introduce liquid Reduce loss of suction head reduce the suction height Formation of air pockets eliminate and if necessary fit a valve on discharge No flow Pump not primed see point 8 and previous point Pump turning in wrong direction Suction port obstructed On off valves closed Insufficient flow Increased system back pressure on discharge side increase piping diameter Air entering mechanical seal check its condition Viscosity of fluid greater than that specified in the order Contact manufacturer Clearances between impeller cover and impeller body have increased Check and correct Loss of head Back pressure on discharge side has fallen throttle the suction pipe Clearances between impeller cover and impeller body have increased Check and correct Increase in absorbed power Flow rate is lower than required Pump is turning at higher speed The impeller does not turn freely Check it Viscosity and or spe
3. IM AS 02 00 GB 0412 7 8 2 8 3 8 4 9 0 Operating checks e Ifthe pump does not generate the required discharge head rapidly facilitate priming by stopping the pump and adding liquid e Check that the absorption of the motor does not exceed the value specified on the plate The pump must always work smoothly and without vibrations e Do not operate without liquid and in any case avoid prolonged operation with the discharge gate valve closed e With series AS pumps never close discharge side completely e Mechanical seal check that there is no leakage along the shaft Extended stop When stopping the pump for a longer time empty the pump completely and wash it accurately in order to avoid the formation of scales and or encrustations When starting the pump again please follow the above mentioned instructions Cleaning the pump The pump does not require any special washing procedures The washing cycles normally used for the plant in which it is installed are quite satisfactory When using the pump for liquids that tend to harden or crystallize always make sure it is washed before periods when the machine is to be taken out of operation This will ensure durability of the seal and of the pump itself It is the user s responsibility to ensure that the washing liquids are compatible with the process liquid and the pump Spare parts Denomination Number of pumps Including reserve 1 2 3 4 5 Me
4. 13 1 AS 40 50 60 65 80 with shroud 1450 rpm K A Weight Pumps kW DN A B Cc C1 E E1 F G K H J I n Y L L1 kg 1 1 40 238 168 190 222 143 438 581 160 110 305 297 195 178 29 AS 40 1 5 40 238 168 190 222 143 438 581 160 110 305 297 195 178 31 2 2 40 298 169 301 179 143 506 649 190 110 335 354 225 225 45 2 2 50 298 196 301 186 175 509 684 213 115 364 377 249 225 50 AD 4 50 298 196 301 186 175 509 684 213 115 364 377 249 225 59 4 65 370 216 301 186 205 499 704 212 135 392 429 257 225 625 AS 60 5 5 65 370 226 324 226 225 551 776 228 135 408 445 273 225 175 75 5 5 65 370 226 324 226 225 551 776 228 135 408 445 273 225 175 76 5 AS 65 7 5 65 370 226 324 226 225 551 776 228 135 408 445 273 225 175 82 5 11 80 360 267 485 347 248 851 1099 230 158 446 520 288 225 220 129 s 15 80 360 267 485 347 248 851 1099 230 158 446 520 288 225 220 140 Dimensions not binding DN DIN 11851 male threaded connection exec with standard IEC EN motors 13 2 AS 40 50 60 65 80
5. 6 7 3 Electrical connectiOn Ai tr et leen steve teet yell de re at eet be ve in 7 8 0 Operation TY EN aa ied rack NSF FN FO EON FT FA NPRN 1 8 1 Preliminary operations and starting ss 7 82 Operatmg checks eii den Ty dT tonio e eo c einer 8 83 Extended stOp see ire e nn eec eme voee va beg dren 8 8 4 Cleaning the pump einenatiae neta ett hoe Re Hep ade t iba 8 9 0 PT e 8 ERE EE _ _ __ 9 11 0 Disassembly and Assembly AS series ss 10 111 General 1n structiOnl u ceo eee een tee hi OO ERREUR Ee Ee de Fr dn 10 12 Oxnngsandlp seals nee y Y FYW YY FOR 10 1 35 Shutdown anean AOE PR 10 114 Disassembly 2nsseese teen eee entente tea penis vela tee tre oY 11 11 41 Removal of pump casing and impeller AS 40 50 60 65 and 80 11 11 42 Removal of pump casing and impeller AS 42 and AS 52 11 11 43 Seal disassembly avden Dr rr tinh re t OR Dre dti sedeat 12 11 4 3 1 T executiOn caei ie Pere Y ne 12 11 4 3 2 AV CXCCUUION Me ES 12 11 4 3 3 Q X CUTION EO sen WN WB 12 11 4 4 Bearing removal sig re eto E p b Re re 13 15 Assembly cluuenpne A desine ode ed sa 13 11 51 ClearanceS cacnnesecmetenenin rei iae HE UR t t DUREE Pep SER 13 11 5 2 Pump assembly AS 40 50 60 05 cosi cap o raa P Pacers 14 11 53 Se lassembly 14 5 esee p o HE HO RE ree etn 14 IM AS 02 00 GB 0412 11 5 3 1 T exe cutlOB eee nenne bud ees 14 1153
6. the above mentioned values do not take into account external noise sources e g valves abrupt hydraulic deflections Pump type dB A AS 40 80 AS 42 81 85 AS 50 81 85 AS 52 86 90 AS 60 86 90 AS 65 86 90 AS 80 86 90 IM AS 02 00 GB 0412 5 6 0 7 0 Tal 1 2 Non permitted uses Do not use the pump with a suction pressure greater than the specified value 0 5 times the discharge head generated by the pump The pump must always be used in an environment appropriate to the level of protection of the motor Always check this on the motor plate before installation The pump may not be used in environments which require a higher level of protection or a higher specification motor or electrical parts Components complying with the safety standards for the environment in question must be used Installation Suction and inflow conditions NPSH Net Positive Suction Head NPSH of system available NPSH In order to ensure that pump operation is free from cavitation it is essential to observe the maximum permitted suction lift ha geo max or the minimum allowable head hc geo min NPSH of pump required NPSH The centrifugal pumps can operate correctly only if vapour has not formed inside For this reason the static head at the reference point for the NPSH is the centre of the impeller that is the point of intersection of the pump shaft axis with the vertical plane that passes through
7. 02 00 GB 0412 18 12 3 AS 50 Execution T O V Execution T NEEDS me LM I Execution O Execution V 66V 71V 65V 1V 62Q 600 6Q 1Q j ff SN INGE ss Se y 2 N TT Yo SAWN 3 4 L iy Y Z N CVE 1 NS 61Q 710 4V 70V 68V IM AS 02 00 GB 0412 19 20 12 4 AS 60 65 Execution T O V Execution T 16 P J EM N 25 23 23 25 8 27 26 5 Execution Q 71Q 4 30 29 20 21 Execution V IM AS 02 00 GB 0412 T a A A A 11 10 12 5 _ AS 80 Execution T O V Execution T
8. 8 E 26 45 46 43 15 14 1 6 13 34 35 N X n 3 S DN k L NON a AY d E M zr N x wa L PES B k NS NINI NE GARN v a k lt n ARE ya CT p i IE g f E y Fe V IF f A Lar 4 i Y i G W Z n u TD IN Sly x 25 44 38 Execution Q 600 610 6Q 1Q IM AS 02 00 GB 0412 23 24 12 8 ASS2 Execution T Q V Execution T 7 N NS SN zm A L S N f i 7 Execution O 620 600 6Q 1Q Z TD B Execution V 66 v TIN ae 1V 7 sy S S 4V ny 68 V IM AS 02 00 GB 0412 13 0 Dimensions and weights
9. only Fit the ring retainer 31 on the shaft 4 Compress the spring on the rotating seal with the ring retainer and lock it with the circlip 32 11 5 3 2 V execution Press the radial seal 66 into the mechanical seal cover 65 Fasten the stud bolt 68 on the pump casing 1 Slide the mechanical seal cover 65 on the stud bolts 68 and tighten them Insert the stationary seal part into the pump casing 1 by gently pushing it Assemble the pump casing 1 together with the bearing housing 5 Be careful not to damage the radial seal 66 Tighten the pump casing with screws 26 Fit the rotating part of the seal on the shaft 4 N B Assemble the mechanical seal carefully to avoid damages on the seal faces and O rings AS 42 and AS 52 only Fit the ring retainer 31 on the shaft 4 Compress the spring on the rotating seal with the ring retainer and lock it with the circlip 32 IM AS 02 00 GB 0412 11 5 3 3 Q execution 1 Position the O ring 61 on the mechanical seal cover 60 2 Position the secondary stationary seal in the mechanical seal cover 60 and hex head screws 62 3 Slide the mechanical seal cover 60 onto the shaft 4 and position it on the back end of the shaft 4 Gently slide the rotating seals onto the shaft 4 5 Check the A length as it is essential for an equal working load on both seal faces ZA A measures as foll
10. without shroud 1450 rpm le Eun G DN m a 44 DN n UH nl L B ND L s Weight Pumps kW DN A B c D E F G K H J I Y L M N o kg 1 1 40 200 296 100 9 22 143 380 523 90 110 235 125 140 26 AS 40 1 5 40 200 296 125 9 22 143 380 523 90 110 235 125 140 28 2 2 40 250 308 140 12 18 143 416 559 100 110 245 135 160 41 AS 50 2 2 50 250 343 140 12 18 175 419 594 100 115 251 136 160 45 4 50 250 351 140 12 18 175 441 616 112 115 263 148 190 54 AS 60 4 65 250 372 140 12 20 205 431 636 112 134 293 159 190 57 5 5 65 300 412 140 12 20 204 492 696 132 134 312 179 216 68 AS 65 5 5 65 300 412 140 12 20 204 492 696 132 134 312 179 216 69 5 7 5 65 300 423 178 12 20 215 492 707 132 184 312 179 216 76 AS 80 11 80 350 555 210 14 23 248 677 925 160 190 376 218 254 118 15 80 350 555 254 14 23 248 677 925 160 190 376 218 254 129 Dimensions not binding DN DIN 118
11. 01 46 3 Screw flat head AISI 304 1 4301 50 1 Motor electric 60 Q 1 Mechanical seal cover Q execution AISI 304 1 4301 61Q 1 O ring Q execution NBR 62 Q 2 Screw hex head Q execution AISI 304 1 4301 65V 1 Mechanical seal cover V execution AISI 304 1 4301 66V 1 Seal radial shaft V execution 68 Q 2 Stud bolt Q execution AISI 304 1 4301 68 V 2 Stud bolt V execution AISI 304 1 4301 70V 1 O ring V execution NBR 71Q 2 Mechanical seal flushing pipe Q execution AISI 304 1 4301 71V 2 Mechanical seal flushing pipe V execution AISI 304 1 4301 85 V 1 Ceramic hardened bush V execution AISI 304 1 4301 86 V 1 O ring V execution NBR 87 V 3 Dowel V execution AISI 304 1 4301 IM AS 02 00 GB 0412 17 12 2 AS 40 Execution T O V Execution T 44 1 6 12 11 10 2 i 4 v pA 4 pod Lg W S LA og X B Ee B g N NG m d T Ene 16 20 Execution V Execution Q 66V 71V 1a 60Q 61Q 6Q ST IS IDI Y A mw 68Q SN 710 IM AS
12. 2 Ve amp xecuton sene M tte 14 11 5 3 3 OCXCCULION isi S 15 11 5 4 Assembly of pump casing and impeller assembly AS 40 AS 50 AS 60 AS 65 and AS 80 15 11 5 5 Pump cover and Impeller assembly AS 42 and AS 52 16 120 Spare parts lists and sectional drawings Laien broker enti eire deba 17 12 1 Spare part list AS 40 50 60 65 80 seen rire esten on erii 17 12 2 _ AS 40 Execution T O Veense a es ans aai aeea ieie 18 12 3 AS50 Execution T Q Vue em ea ee o C OR I Dd 19 12 4 AS 60 65 Execution T O V errrenrrernvrnnvrernvrenvrennrsenvrennnrsnvrennnssnvessnnnsnvnensrssnnsennenenes 20 12 5 S80 Execution T O V 4 ccce ae a D A FY ERE NUR 21 12 6 Spare p rt list AS 42 52 a aie mime re Debe P Ie bereiten 22 12 7 AS42 Execution T Q V onde aita o ie WYN ERR ras 23 12 8 AS 52 Execution T Q Van tameo e e e E E EE Ed 24 130 Dimensions and weishts 4 tite baiser ebbe Feel kon GO EG 23 13 1 AS 40 50 60 65 80 with shroud 1450 rpm ss 25 13 2 AS 40 50 60 65 80 without shroud 1450 rpm ss 25 13 3 ANS 42 52 with Shroud 1450 TDI iiie ett rd etn tti rto Coni eee 26 13 4 AS 42 52 with shroud 1450 rpm ss 26 140 Troubleshoo ng chart uus rbi Qo ods bas k Concio cU 27 150 Dispos l f th pump Le ete 28 IM AS 02 00 GB 0412 1 0 Introduction Serial No Read the instructions carefully and keep them for future consu
13. 51 male threaded connection exec with standard IEC EN motors IM AS 02 00 GB 0412 25 13 3 AS 42 52 with shroud 1450 rpm WN i H C1 lE Lo NI c Le 4 Weight Pumps kW DN A B C C1 E E1 F G K H J I H Y L L1 kg AS 42 2 2 40 298 220 231 203 205 520 725 190 110 335 354 225 225 56 3 40 298 220 231 203 205 520 725 190 110 335 354 225 225 60 AS 52 5 5 50 370 258 292 267 237 580 817 230 115 381 417 266 225 85 Dimensions not binding DN DIN 11851 male threaded connection exec with standard IEC EN motors 13 4 AS 42 52 with shroud 1450 rpm G DN O I DE a B Weight Pumps kW DN A B c D E F G K H J I Y L M N O kg AS 42 2 2 140 250 365 140 12 18 200 416 616 100 110 245 135 160 51 3 40 250 365 140 12 18 200 416 616 100 110 245 135 160 55 AS 52 5 5 50 300 454 140 12 20 237 502 739 132 115 283 168 216 77
14. 6 SE 701 14 Orebro Sweden Tel 46 0 19 21 83 00 Fax 46 0 19 27 23 72 E mail Industry se johnson pump com Web www johnson pump com
15. 8 4 Screw hex head Steel 29 2 Screw socket head AISI 304 1 4301 30 2 Nut AISI 304 1 4301 31 1 Ring retainer AISI 316 L 1 4404 32 1 Circlip AISI 304 1 4301 34 1 Inter suction casing CF 3M 1 4409 35 1 Inter discharge casing CF 3M 1 4409 36 2 O ring EPDM 38 2 Rag bolt AISI 304 1 4301 39 2 Rag bolt pin AISI 304 1 4301 43 1 Shroud adapter AISI 304 1 4301 44 1 Shroud AISI 304 1 4301 45 3 Screw hex hollow AISI 304 1 4301 46 3 Screw flat head AISI 304 1 4301 50 1 Motor electric 60 Q 1 Mechanical seal cover Q execution AISI 304 1 4301 61Q 1 O ring Q execution NBR 62 Q 2 Screw hex head Q execution AISI 304 1 4301 65 V 1 Mechanical seal cover V execution AISI 304 1 4301 66 V 1 Seal radial shaft V execution 68 Q 2 Stud bolt Q execution AISI 304 1 4301 68 V 2 Stud bolt V execution AISI 304 1 4301 70V 1 O ring V execution NBR 71Q 2 Mechanical seal flushing pipe Q execution AISI 304 1 4301 71V 2 Mechanical seal flushing pipe V execution AISI 304 1 4301 IM AS 02 00 GB 0412 12 7 AS 42 Execution T O V Execution T 50 17
16. Instruction Manual TopClean AS Hygienic Self priming Liquid Ring Pumps In JOHNSON PUMP CE Declaration of conformity Manufacturer Johnson Pump Box 1436 SE 701 14 Orebro Sweden We declare under our sole responsibility that the product Pump Series AS CE declaration of conformity Ann II A 98 37 EEC to wich this declaration refers is conform to safety requirements according to 98 37 EEC norms and amendments Manufacturer declaration Ann ILB 98 37 EEC cannot be operated before the machine in which is assembled will be decla red in conformity with safety requirements according to 98 37 EEC norms and amendments Orebro Sweden 01 03 2007 St fan Ring Manager Quality amp Environment 1 0 O CO LN haec FFYN cta A n p YN FY FON FR m 3 2 0 DOS non dei done nid 3 3 0 Safety PAPE edda ne one 3 4 0 Transportation receipt and transferring of goods sss 4 4 1 TianspOEtatlOtl sc acer aee epe Eten tne nr en ad ei qu CUD FN Dee va eed vicus 4 4 2 Jes P 4 4 3 TEADSIOTEHIB idcirco ipee Ceg Y Te BY RUA T YM van 4 5 0 DEP see YY E RYN AAT RY FFY RAW O 5 51 Sound pressure levellisg aia cai nbi anm I He rede va a doni o 5 6 0 Non permitted use rA 6 7 0 Installation NFED FARN FFF FERF FFY MR FON NFED Y HNN 6 71 suction and imflowconditions eseese neriie eere reete eere eire GAF 6 7 2 PIPING MM
17. ake the shroud off before moving the pump motor set in order to avoid damages IM AS 02 00 GB 0412 5 0 Description The pumps of series AS are centrifugal side channel self priming with star shaped impeller the ports are located on the longitudinal axe with the suction located on the front of the pump cover All models have threaded connections for fittings according to DIN 11851 standard unless otherwise requested The pump front cover is easy to open to improve cleaning and inspection operations all models are fitted with mechanical seals and the materials used for the components of mechanical seal are chosen according to the liquid to be pumped Designed in close coupled version fitted with indepandant standard electric motors B5 shape IP 55 protection unless otherwise requested These pumps are designed for applications where the liquid to be pumped e is not subject to pollution of any kind e is at a temperature between 30 C and 140 C e must under no circumstances come into contact with the outside environment e is chemically aggressive 5 1 Sound pressure level The sound pressure level of self priming pumps is the following see table The measurement has been made by means of a phon meter placed at 1 m distance from the pump and at a height of 1 6 m from the ground Preliminary condition is that the pump is fixed correctly
18. als are clean and tight and not under stress When starting the motor s current absorption increases briefly to 5 6 times the nominal value If the mains supply is unable to sustain this increase in absorption use a star delta starter or other kind of device e g an autotransformer Johnson Pump will accept no responsibility for damage to property and or injury to persons caused by failure to comply with technical standards and regulations in force Lower N voltage Higher voltage 8 0 Operation 8 1 Preliminary operations and starting When first starting fill the pump with liquid so as to create the pressure drop required for suction When starting subsequently the quantity of liquid that remains in the pump will be sufficient to ensure self priming even if the pipe is empty Make sure that the pump does not become completely empty in the event of installation under a vacuum or to a siphon If necessary fit a check valve e Check that the pump turns freely under hand pressure e Check that the clamp joining the pump casing and the cover is well tightened and that it cannot be easily unscrewed by hand The tightening of the clamp must be carried out by means of a key and not by hand e Check that the pump turns in the market direction e Check that any gate valves installed on the suction and discharge pipelines are open e Start the pump and check the turns direction before restarting it is extremely important to
19. by means of a key and not by hand Non observance of inspection and maintenance can cause damages to persons and objects especially when dangerous or toxic liquids are pumped When pumping liquids at a temperature over 60 C adequate protection and warning signals are required When you buy a pump with bare shaft motor coupling operations have to be carried out according to technical directions and law providing adequate rotections for joints gear belts etc Operations on the electric parts have to be carried out by skilled personnel according to technical directions and law on authorisation of the responsible installer Installation must ensure adequate ventilation in order to cool the engine as well as enough space for maintenance operations 4 0 4 1 4 2 Before carrying out any operation which requires to disassembly of the pump inspection cleaning seal replacement etc the following preliminary operations have to be carried out e Switch off engine tension and disinsert electric connection e Close valves on suction and outlet pipelines in order to avoid the risk of inundation e Use adequate protection for hands and face if the pump contains liquids which are hazardous to health for example acids solvents etc e Consider whether the liquid which flows out of the pump when disassembling is dangerous and arrange for adequate safety measures Transportation receipt and transferring of goods Transp
20. cement A warmed up O ring becomes softer thus easier to install Be aware of that PTFE has no thermal memory Shutdown Before starting the maintenance or inspection follow the next steps to shut down the pump 1 Stop the pump To prevent the motor from starting while you are working on the pump follow the procedure below e Turn off the pump at the electrical cabinet e Set the pump circuit breaker to off e Switch off and lock the operating switch e Remove the fuse e Sign the electrical cabinet danger 2 Remove if necessary the protection around the shaft coupling when the pump has stopped completely 3 Letthe pump cool down to ambient temperature IM AS 02 00 GB 0412 Isolate and depressurize flushing quench system Close the inlet and discharge valves Drain and purge the pump casing and pipe work moe DA Gm Clean the pump externally before disassembly 11 4 Disassembly 11 4 1 Removal of pump casing and impeller AS 40 50 60 65 and 80 See sectional drawings AS40 page 18 AS 50 page 19 Remove the mechanical seal flushing pipes 71 on V and O executions Remove the shroud 44 with screws 46 if shroud is assembled 1 2 3 Loosen screws 28 to remove the motor 50 4 Gently pull the motor 50 away from the bearing housing 5 5 Motor sizes up to IEC 112 If necessary remove the adjustable foot frame by loosening the two nuts 30 and the screws 29 6 Motor sizes larger t
21. chanical seal 1 2 3 4 4 Pump bearing 1 1 1 2 2 O ring seal 2 3 5 6 7 O ring seal nut 2 3 5 6 7 Recommended spare part for two years of operation according to the number of pumps installed vdma standard Johnson Pump declines all responsibility for damage or injury resulting from the use of non original spare parts IM AS 02 00 GB 0412 10 0 Seals All centrifugal pumps of the AS series are fitted with unified mechanical seals according to DIN 24960 ISO 3069 standards in order to grant the interchangeability subject to verification of axial space The type of mechanical seal and material are chosen according to the liquid to be pumped Mechanical seal types conforming to DIN 24960 e T execution Standard Internal single mechanical seal e V execution External single mechanical seal with external flushing quench e Q execution Compact double mechanical seal back to back high pressure flush LE Warning before using the pump for any liquids other than those specified when selecting and ordering ensure that mechanical seals and gaskets are suitable for the new product IM AS 02 00 GB 0412 10 11 0 Disassembly and Assembly AS series 11 1 11 2 11 3 General instructions Assembly and disassembly may be preformed by qualified personnel only Always wear appropriate safety clothing Make sure that personnel are instructed and educated Insufficient or wrong assembly and disassembly ca
22. cific weight are higher than stated Bearings are not in good condition Increase in absorbed current IM AS 02 00 GB 0412 The power required has increased see previous point Main voltage value has fallen There is a fault in the electrical system 27 28 15 0 Disposal of the pump For disposing the pump please observe the following instructions e Disconnect electrical and hydraulic connections according to technical rules and laws in force e Disassemble all components of the pump for separate dismantling wash the components and clean the structure accurately The main components of the pump are made from the following materials e Pump casing cover impeller S S AISI 316L shaft impeller nut e Elastomeres NBR EPDM Viton Teflon e Motor Aluminium Cast iron Copper Components made from amianthus or lead are not used in our production The components of the pump should be properly disposed of according to the corresponding rules in force in receiver s country IM AS 02 00 GB 0412 Johnson Pump Industry Group National Sales Organisations AUSTRALIA Johnson Pump Australia Pty Ltd Tel 461 0 7 3899 9933 Fax 461 0 7 3899 8574 BELGIUM Johnson Pump N V S A Tel 32 0 2 422 15 50 Fax 32 0 2 422 15 59 DENMARK Johnson Pumper A S Tel 45 43 52 24 00 Fax 45 43 52 15 77 FINLAND Johnson Pump Oy Tel 358 0 9 348 3800 Fax 358 0 9 348 38495 FRANCE Johnson Pompes T
23. el 33 0 1 39 20 50 00 Fax 33 0 1 39 56 54 22 GERMANY Johnson Pumpen GmbH Tel 49 0 5731 480 80 Fax 49 0 5731 414 00 ITALY Johnson Pump Italiana S r l Tel 39 039 604 14 63 Fax 39 039 604 90 97 NETHERLANDS Johnson Pump B V Tel 31 0 592 37 67 67 Fax 31 0 592 37 67 06 Johnson Pump Horticulture Tel 31 0 174 51 84 10 Fax 31 0 174 51 84 44 NORWAY Johnson Pump Norway Tel 47 22 74 08 40 Fax 47 22 22 70 30 www johnson pump com SPAIN Johnson Pump Espaiia S L Tel 34 972 58 08 01 Fax 434 972 58 08 03 Sales Office Madrid Tel 34 91 888 79 22 SWEDEN Johnson Pump Svenska AB Tel 46 0 19 21 83 70 Fax 46 0 19 27 23 18 SWITZERLAND Johnson Pumpen AG Tel 41 0 43 477 7122 Fax 41 0 43 477 71 20 UNITED KINGDOM JP Pumps Ltd Tel 44 0 1293 55 34 95 Fax 44 0 1293 52 46 35 Northern Regional Office Bradford Tel 44 0 1274 74 56 10 Fax 44 0 1274 74 56 11 MM JOHNSON PUMP Johnson Pump Industry AB Business Units BELGIUM Johnson Pump Brussels N V Tel 32 0 53 60 27 15 Fax 32 0 53 60 27 01 INDIA Johnson Pump India Ltd Tel 91 0 79 287 03 11 Fax 491 0 79 287 25 22 NETHERLANDS Johnson Pump Water B V Tel 31 0 592 37 67 67 Fax 31 0 592 37 67 60 SWEDEN Johnson Pump Industry AB Tel 46 0 19 21 83 00 Fax 46 0 19 27 23 72 SS EN ISO 9001 SS EN ISO 14001 Nastagatan 19 P O Box 143
24. g seals along the shaft 4 Remove the mechanical seal cover 60 by gently pulling it over the shaft 4 Push out the secondary stationary seal from the mechanical seal cover 60 Remove the O ring 61 10 Pull off the thrower 14 12 IM AS 02 00 GB 0412 11 4 4 Bearing removal 1 Remove shroud adapter 43 if assembled by loosening the screws 45 Unscrew the screws 27 Remove the bearing cover 8 Press out the shaft and bearing assembly from the bearing housing 5 SSN Unscrew the ring nut 17 Press out the shaft 4 from the bearing 7 11 5 Assembly Remark It is recommended to pre assemble the pump without the seal Shim the pump according to the clearance table to obtain the correct impeller clearance and thereafter assemble the pump with seal Exception AS 42 and AS 52 two stage pumps which have floating impellers shim free 11 5 1 Clearances Defined clearances for AS range to be shimmed e A Behind impeller Clearance between Impeller and Pump casing e B Front of impeller Clearance between Impeller and Cover e C Clearance between Pump Casing and Cover To remember C clearance is machined B will be given depending on the shims put under A Behind impeller should be correct If problems occur concentrate on the A clearance it is the most important if there will be a deviation make sure that it will be at B clearance If it is other problems please contact Johnson pump or deale
25. h back the ring retainer 31 to remove the circlip 32 from the shaft 4 Remove the rotating seal half by turning the spring clockwise and at the same time pull the spring and the seal over the shaft end If necessary use a pair of pliers Loosen the screws 26 Slowly remove the pump casing 1 from the bearing housing 5 Remove the stationary seal part from its seat in the pump casing 1 Pull off the thrower 14 11 4 3 2 V execution il SOS GM PR AS 42 and AS 52 only Push back the ring retainer 31 to remove the circlip 32 from the shaft 4 Remove the rotating seal half by turning the spring clockwise and at the same time pull the spring and the seal over the shaft end If necessary use a pair of pliers Loosen the screws 26 Slowly remove the pump casing 1 from the bearing housing 5 Loosen the stud bolt 68 Gently pull off the mechanical seal cover 65 from the pump casing 1 Remove the radial seal 66 from the mechanical seal cover 65 11 4 3 3 Q execution T O D So A K D D AS 40 42 60 65 80 Loosen and remove the stud bolts 68 AS 50 52 on the stud bolts 62 Separate the mechanical seal cover 60 from the pump casing 1 by pushing it backwards Loosen the screws 26 Pull the pump casing 1 gently from the bearing housing 5 Remove the primary stationary seal from the rear of the pump casing 1 Loosen the grub screws on the rotating seal Slide off the rotatin
26. han IEC 112 If necessary remove the adjustable foot frame by loosening the screws 29 to remove the front foot 20 and the rear foots 23 7 Loosen and remove the casing clamp 9 8 Remove the casing cover 2 9 Unscrew the impeller nut 10 anti clockwise and slide off the impeller 3 10 Remove the impeller key 11 11 Remove the clearance shims 19 11 4 2 Removal of pump casing and impeller AS 42 and AS 52 See sectional drawings AS 42 page 23 and AS 52 page 24 Remove the mechanical seal flushing pipes 71 on V and Q executions Remove the shroud 44 with screws 46 if shroud is assembled Loosen the screws 28 to remove the motor 50 Gently pull the motor 50 away from the bearing housing 5 A P M gu ug Motor sizes up to IEC 112 If necessary remove the adjustable foot frame by loosening the two nuts 30 and the socket head screw 29 6 Motor sizes larger than IEC 112 If necessary remove the adjustable foot frame by loosening the socket head screw 29 to remove front foot 20 and the rear foots 23 7 Loosen and remove the rag bolt 38 8 Remove the casing cover 2 9 Remove the first impeller 3 as well as the impeller key 11 10 Remove the inter discharge casing 35 and the intersuction casing 34 11 Remove the second impeller 3 as well as the impeller key 11 IM AS 02 00 GB 0412 11 11 4 3 Seal disassembly 11 4 3 1 T execution T AS 42 and AS 52 only Pus
27. he adapter 43 with the screws 46 10 V and O executions Assemble the mechanical seal flushing pipes 71 and 71 respectively on the mechanical seal cover 65 and 60 respectively IM AS 02 00 GB 0412 15 16 11 5 5 Pump cover and Impeller assembly AS 42 and AS 52 See drawing 1 2 Fit the first impeller key 11 and push on the impeller 3 on the shaft 4 Fit the O ring in the pump casing 1 groove and assemble the inter suction casing 34 Fit the O ring 36 in the inter suction casing 34 and assemble the inter discharge casing 35 Fit the second impeller key 11 and push on the impeller 3 on the shaft 4 Fit the O ring 36 in the inter discharge casing 35 Assemble the cover casing 2 with the rag bolts 38 Motors up to size IEC 112 Fit the adjustable foot frame and lock it with the nuts 30 and the screws 29 Motor sizes larger than IEC 112 or Fit the adjustable foot frame and fasten the screws 29 for the front foot 20 and the rear foots 23 Assemble the motor 50 by entering the motor shaft into the pump shaft 4 and lock it with the screws 28 Slide the shroud 44 over the motor 50 and assemble it on the adapter 43 with the screws 46 10 V and Q executions Assemble the mechanical seal flushing pipes 71 and 71 respectively on the mechanical seal cover 65 and 60 respectively IM AS 02 00 GB 0412 12 0 Spare parts lists and secti
28. he liquid Avoid creating obstacles which could increase suction losses disrupting smooth fluid flow Make sure that there are no restrictions YES MH JOD i IM AS 02 00 GB 0412 7 3 Electrical connection Make the electrical connection only after the hydraulic connection has been completed set up A the motor control system in conformity with the technical standards and regulations in force EN 60204 1 in particular a manual electric power switch must be installed with adequate current switching capacity devices for overcurrent and overload protection e g fuses automatic switches etc must also be fitted plus if necessary a device to prevent accidental restarting Check that the main frequency and voltage and the available power are suitable for the motor installed All the material used for the electrical connection cables cable clamps switches and shielding must have a suitable level of protection for the environment in which it is installed Be sure to use cables of sufficient cross section for the current shown on the motor plate so as to prevent them from overheating Before doing anything else make the motor s earth connection using the terminal on the motor and a cable of sufficient cross section The cables may be connected to the terminal board using either a delta or star arrangement Follow the data given on the motor plate for the main voltage as shown in the diagram in fig 2 ensure that the termin
29. ltation Johnson Pump reserves the right to make any changes to the documentation it deems necessary without being obliged to update publications that have already been issued When requesting information spare parts or assistance always specify the pump type and serial number in order to ensure fast and efficient service the complete code is given on the plate and in the purchase documents Ie TopClean JOHNSON PUMP O Item Pump type No r p m kW Volt Hz Nastagatan 19 rebro Sweden Tel 46 0 19 21 83 00 Name plate 2 0 Symbols i Warning Pay great attention to the text parts indicated by this symbol AN Danger The non observance of instructions can cause serious damage to persons and or objects Danger Only skilled personnel is allowed to carry out operations concerning the electric parts 3 0 Safety warnings When the pump is working the following occurs y AC IM AS 02 00 GB 0412 Electric parts are in tension Mechanical parts are moving Pump body pipelines and articulations are under internal pressure Therefore do not remove any protection or locking do not loosen screws or clampings as this can cause serious damages to persons or objects The clamp joining the pump casing and the cover must be well tightened and it should not be easily unscrewed by hand The tightening of the clamp must be carried out
30. n lead to the pump malfunction Johnson Pump is not liable for accidents and or damage caused by non compliance with the guidelines Always work in a clean surrounding Keep all highly sensitive parts such as seals O rings bearings etc in their original packing as long as possible Use a clean work surface Check that the parts to be used have not been damaged during transport Never work on the pump in operation In case of a disassembled pump avoid any contact with the impeller when turning the shaft manually Do not forget that the pump can be started even when the pump casing has been remo ved for e g cleaning Never run the pump without the pump casing Follow the instructions for shutdown before performing any maintenance or service After disassembly carefully clean the parts and check them for damage especially the mounting surfaces and replace all damaged parts All parts fitted together at the disassembly must stay together when reinstalled especially the impeller shaft shim and back plate O rings and lip seals When working with lip seals or O rings take care not to damage them as they pass over sharp edges of splines threads etc Be sure that the O rings are not twisted in the groove when installing All O rings and sealing lips should be lubricated with a suitable lubricant before fitting e g soap and water or silicone spray For O rings made of PTFE it is advised to heat them up in hot water before pla
31. onal drawings 12 1 Spare part list AS 40 50 60 65 80 Pos Qty Description Material 1 1 Casing pump CF 3M 1 4409 1Q 1 Casing pump Q execution CF 3M 1 4409 1V 1 Casing pump V execution CF 3M 1 4409 2 1 Cover casing CF 3M 1 4409 3 1 Impeller CF 3M 1 4409 4 1 Shaft AISI 316 L 1 4404 4V 1 Shaft V execution AISI 316 L 1 4404 5 1 Housing bearing Cast iron 25 3 Ni 6 1 Mechanical seal 6Q 1 Mechanical seal Q execution 7 1 Bearing Steel 8 1 Bearing cover Aluminum 2011 9 1 Clamp casing AISI 304 1 4301 10 1 Nut impeller AISI 316 L 1 4404 11 1 Key impeller AISI 316 1 4401 12 1 Pin AISI 304 1 4301 13 1 O ring EPDM 14 1 Thrower NBR 15 1 Shaft plug NBR 16 1 O ring EPDM 17 1 Nut ring Galvanized iron 18 1 Grease nipple Galvanized iron 19 2 Shim AISI 316 L 1 4404 20 1 Foot front CF 8 1 4308 21 2 Foot adjustable AISI 304 1 4301 23 1 Foot rear CF 8 1 4308 AISI 304 1 4301 25 1 Foot adjustable AISI 304 1 4301 26 4 Screw socket head AISI 304 1 4301 27 3 Screw socket head AISI 304 1 4301 28 4 Screw hex head Steel 29 2 Screw socket head AISI 304 1 4301 30 2 Nut AISI 304 1 4301 33 1 Gaco ring NBR 40 2 Lantern guard AISI 304 1 4301 43 1 Shroud adapter AISI 304 1 4301 44 1 Shroud AISI 304 1 4301 45 3 Screw hex hollow AISI 304 1 43
32. ortation The packings of all AS pumps are defined when making the order Unless prior arrangements are given goods will be packed only for transit conditions and not for long term storage in case it should be necessary to store the pumps outside you are requested to cover the pumps appropriately in order to protect the electrical parts motor from rain dust humidity etc Receipt Upon receipt of goods the integrity of the packaging must be verified in order to identify possible damages to the content during transfer and to claim immediately from the carrier Should any damage be ascertained the following procedure must be observed e Collect the goods with receipt e Take the necessary pictures showing the damages e Notify the carrier of the suffered damages by registered airmail including the pictures taken Transferring Carry the packed pumps as close as possible to the place of installation by means of appropriate lifting devices and unpack them During this operation take care as unsteady parts could fall down The material used for packing wood paper cellophane etc should be properly disposed of according to the corresponding rules in force in receiver s country After unpacking the pump use special lifting belts and move the pump motor set to the place of installation never use the eyebolts on the motor to move the pump as the eyebolts are for moving the motor only In versions complete with shroud t
33. ows 577 UE MS e AS40 160mm 5 Es a AS 50 17 5mm AS 60 15 5mm NUR AS 65 15 5mm VP GARE 74 Li gt At A ILL AS 80 19 5 mm 6 Tighten the grub screws on the rotating seal 7 Fit the primary stationary seal part in the back of the pump casing 1 8 Assemble the pump casing 1 onto the bearing housing 5 Be careful not to damage the seal Tighten with the screws 26 9 Fitthe mechanical seal cover 60 together with the pump casing 1 and lock it with the 62 11 5 4 Assembly of pump casing and impeller assembly AS 40 AS 50 AS 60 AS 65 and AS 80 Fit the correct clearance shims 19 adjusted from pre fitting Fit the impeller key 11 and push on the impeller 3 Fit the O ring 16 in the impeller nut 10 and tighten the impeller 3 Assemble the O ring 13 in the pump casing 1 groove Assemble the cover casing 2 and lock it with the casing clamp 9 Qv MW B SNE Motors up to size IEC 112 Fit the adjustable foot frame and lock it with the nuts 30 and the screws 29 7 Motor sizes larger than IEC 112 Fit the adjustable foot frame and fasten the screws 29 for the front foot 20 and the rear foots 23 8 Assemble the motor 50 by entering the motor shaft into the pump shaft 4 and lock it with the screws 28 9 Slide the shroud 44 over the motor 50 and assemble it on t
34. r for advice Pump clearances defined and shimmed AS pumps A B C AS 40 0 15 15 AS 50 0 15 0 15 2 85 AS60 65 0 2 0 2 2 80 AS 80 0 3 0 3 4 20 IM AS 02 00 GB 0412 13 14 11 5 2 Pump assembly AS 40 50 60 65 Before assembly read chapters 11 1 General Instructions and 11 2 O rings and lip seals N B Make sure that all surfaces are clean and without damage If necessary polish using 600 degrees emery cloth lubricate all O rings and contact surfaces with soap and water or silicone spray ot GON gm dps d quod Check the shaft condition no tracks of wear etc Clean it carefully Press the bearings 7 on to the shaft 4 Assemble the ring nut 17 and tighten it Press the shaft 4 and bearing assembly into the bearing housing 5 Assemble the bearing cover 8 Tighten it with the screws 27 Push the thrower 14 on the shaft 4 Assemble the shroud adapter 43 if shroud should be assembled with screws 46 11 5 3 Seal assembly 11 5 3 1 T execution I 2 Insert the stationary seal part into the pump casing 1 by gently pushing it Assemble the pump casing 1 together with the bearing housing 5 Be careful with the seal when sliding it over the shaft Tighten the pump casing with the screws 26 Fit the rotating part of the seal on the shaft 4 N B Assemble the mechanical seal carefully to avoid damages on the seal faces and O rings AS 42 and AS 52
35. the external points of the blade inlet corners NPSHnec is the value required by the pump expressed in metres obtained from the performance curve In practice 0 5 m should be added to this value as a safety margin Piping In order to prevent the creation of harmful stresses the suction and discharge pipes must be connected to the pump ports without the use of force These pipes must also be supported independently avoiding causing stresses on the pump The internal diameter must be the same size as the pump connections It must in any case not be smaller to avoid head loss and or poor performances Always use elbows with large radius If the pipe diameter changes along the line use reduction cones choosing the ones that are most suitable for avoiding the formation of air pockets Fig 1 The suction pipe must be as short as possible and rise as it moves towards the pump if it is sucking from a tank if on the other hand the pump is below the level of the liquid the pipe should descend slightly If the pump is used for transporting hot liquids fit expan sion joints to compensate any expansion of the piping The maximum velocity of the liquid in the suction pipe must not be greater than 3 m s Velocities between 1 and 2 m s are recommended The suction pipe must be designed in such a way as to prevent air from entering the pump For this reason when sucking from a tank located at a lower level the pipe must reach below the free surface of t
Download Pdf Manuals
Related Search