Johnson Pump SPX Flow CombiLineBloc Instruction Manual Download Page 1

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CLB/EN (1901) 6.6

CombiLineBloc

Orginal instructions

Read and understand this manual prior to operating or servicing this product

INSTRUCTION MANUAL

In-line circulation pump in block execution

Summary of Contents for SPX Flow CombiLineBloc

Page 1: ...CLB EN 1901 6 6 CombiLineBloc Orginal instructions Read and understand this manual prior to operating or servicing this product INSTRUCTION MANUAL In line circulation pump in block execution ...

Page 2: ......

Page 3: ...umps 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 EC Declaration of conformity Directive 2009 125 EC Annex VI and Commission Regulation EU...

Page 4: ...tfamilies CombiBloc CombiBlocHorti CombiChem CombiLine CombiLineBloc and CombiNorm is in conformity with the following standards EN ISO 12100 parts 1 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 t...

Page 5: ...ought to the notice of third parties without our prior written consent SPXFLOW is a global multi industry manufacturing leader The company s highly specialized engineered products and innovative technologies are helping to meet rising global demand for electricity and processed foods and beverages particularly in emerging markets SPX Flow Technology Assen B V P O Box 9 9400 AA Assen The Netherland...

Page 6: ...4 INT EN 1512 1 2 ...

Page 7: ...ype code 14 2 4 Serial number 14 2 5 Bearing groups 14 2 6 Construction 15 2 6 1 Design 15 2 6 2 Pump casing impeller 15 2 6 3 Mechanical seal 15 2 6 4 Bearing construction 15 2 7 Ecodesign Minimum Efficiency Requirements Water Pumps 16 2 7 1 Introduction 16 2 7 2 Implementing Directive 2009 125 EC 16 2 7 3 Energy Efficient Pump Selection 19 2 7 4 Scope of Implementing Directive 2009 125 EC 20 2 7...

Page 8: ... piping 33 7 1 4 Liquid draining 33 7 2 Removing the pump 33 7 2 1 Back Pull Out system 33 7 3 Disassembly 34 7 3 1 Disassembling the Back Pull Out unit 34 7 3 2 Assembling the Back Pull Out unit 34 7 4 Impeller 35 7 4 1 Disassembling the impeller 35 7 4 2 Mounting the impeller 36 7 5 Mechanical seal 37 7 5 1 Instructions for mounting a mechanical seal 37 7 5 2 Disassembling a mechanical seal M1 3...

Page 9: ... 55 10 1 Recommended locking liquids 55 10 2 Tightening moments 55 10 2 1 Tightening moments for bolts and nuts 55 10 2 2 Tightening moments for cap nut 55 10 3 Hydraulic performance 56 10 3 1 Performance overview 56 10 4 Noise data 59 10 4 1 Pump noise as a function of pump power 59 10 4 2 Noise level of entire pump unit 60 Index 61 Order form for spare parts 63 ...

Page 10: ...8 CLB EN 1901 6 6 ...

Page 11: ...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 Installation operation and maintenance has to be done by qualified and well prepared personnel Below is a list of the symbols used for those instructions and their meaning Personal danger for the user Strict and prompt observa...

Page 12: ...rishly carelessly improperly and or negligently The products supplied become defective due to external circumstances beyond our control All parts which are liable to wear are excluded from guarantee Furthermore all deliveries are subject to our General conditions of delivery and payment which will be forwarded to you free of charge on request 1 4 Inspection of delivered items Check the consignment...

Page 13: ...ep the bottom and the covering box together Always make sure that the box stands on the floor Wear gloves the straps are under tension and may be sharp 1 Cut the plastic straps 2 Remove the covering box 3 Unscrew the pump from the bottom 4 Rest the pump on the supporting brackets under the suction bend 1 5 5 Storage If the pump is not to be used immediately the stub shaft must be turned by hand tw...

Page 14: ...12 Introduction CLB EN 1901 6 6 ...

Page 15: ... without a foundation being required The pump can also be mounted with the suction bend placed on a fundation by means of the special support device The pumps are available in 2 speeds The flanges are according to EN 1092 2 DIN 2532 PN10 or EN 1092 2 DIN 2531 PN6 2 2 Applications In general this pump can be used for thin clean or slightly polluted liquids These liquids should not affect the pump m...

Page 16: ...ge is divided in a number of bearing groups Pump family CLB CombiLineBloc Pump size 65 diameter discharge connection mm 200 nominal impeller diameter mm Pump casing material G cast iron B bronze Impeller material 1 cast iron 2 bronze Example 19 001160 19 year of manufacture 001160 unique number Table 1 Bearing group division Bearing groups 1 2 2V 3 40C 125 80A 250 200 160 150 250 40 160 100 200 40...

Page 17: ...the same flange size The specially shaped suction bend ensures low noise functioning of the pump and favorable NPSH values The impeller is of the closed type and is mounted directly on the end of the stub shaft The impeller is fixed by means of a cap nut 2 6 3 Mechanical seal The pump is provided with a mechanical seal with mounting dimensions according to EN 12756 L1K DIN 24960 L1K This mechanica...

Page 18: ...information related to the coming into force of the water pump regulation EU 547 2012 2 7 2 Implementing Directive 2009 125 EC Definitions This Regulation establishes eco design requirements for the placing on the market of rotodynamic water pumps for pumping clean water including where integrated in other products Water pump is the hydraulic part of a device that moves clean water by physical or ...

Page 19: ...t pumps starting with 0 10 in 2013 the lowest 10 and 0 40 the lowest 40 in 2015 The MEI value of 0 70 is classed benchmark for the most efficient pumps in the market at the time of developing the directive The milestones for the MEI values are as follows 1 1st January 2013 all pumps shall have a minimum MEI value of 0 10 2 1st January 2015 all pumps shall have a minimum MEI value of 0 40 The most ...

Page 20: ...fficiency thresholds at 75 and 110 of rated flow The advantage of this is that pumps will be penalised for poor efficiency away from rated efficiency hence it will take account of real life pump duties It should be stated that while the scheme may appear complicated at first sight in practice it has been easy for the manufacturers to apply the scheme to their pumps Figure 1 House of Efficiency ηPu...

Page 21: ...A very useful tool for energy efficient pump selection is the downloadable software program Hydraulic Investigator 2 from the SPXFLOW website Hydraulic Investigator is the selection guide for centrifugal pumps and search by pump family and pump type starting from entering required capacity and head Further refine the pump curves to find the pump that meets your specification The default setting of...

Page 22: ...oduct portfolio 2 7 5 Product information Name plate example Or Figure 3 Name plate Table 2 Name plate 1 CLB 65 200 G1 Product type and size 2 19 001160 Year and serial number 3 0 40 Minimum Efficiency Index at max impeller diameter 4 xx x or Effciency for trimmed impeller diameter 5 202 mm Fitted impeller diameter Figure 4 Name plate horticulture Table 3 Name plate horticulture 1 CLB 65 200 G1 Pr...

Page 23: ...mmed impeller diameter Table 5 MEI value Speed rpm MEI value according prEN16480 Remarks Material Cast iron Bronze1 40C 125 2900 0 40 0 40 40 160 2900 0 40 0 40 40 200 2900 0 40 0 40 50 125 2900 0 40 0 40 50 160 2900 0 40 0 40 50 200 2900 0 40 0 40 65 125 2900 0 40 0 40 65 160 2900 0 40 0 40 65 200 2900 0 40 0 40 80 125 2900 0 40 0 40 80 160 2900 0 40 0 40 80 200 2900 0 40 0 40 80A 250 1450 0 40 0...

Page 24: ... en johnson pump resources hydraulic investigator The pump curve for the delivered pump is part of the related customer order documentation package separate from this document 8 The efficiency of a pump with a trimmed impeller is usually lower than that of a pump with the full impeller diameter The trimming of the impeller will adapt the pump to a fixed duty point leading to reduced energy consump...

Page 25: ... 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 2 10 Scrapping If it has been decided to scrap a pump the same flushing procedure as described for Re use should be followed MEI 0 4...

Page 26: ...24 General CLB EN 1901 6 6 ...

Page 27: ... should also be discharged safely Depending on the design the pumps are suitable for liquids with a temperature of up to 140 C When installing the pump unit to work at 65 C and above the user should ensure that appropriate protection measures and warnings are fitted to prevent contact with the hot pump parts 3 2 Preservation In order to prevent corrosion the inside of the pump is treated with a pr...

Page 28: ... the pump is provided with an electric motor B3 B5 or B5 the electric motor must be mounted in horizontal position If the pump is provided with an electric motor V1 the electric motor must be mounted in vertical position When installing the pump proceed as follows 1 Make sure the piping is supported before and after the pump brackets 2 The arrow on the pump casing shows the exact position of the s...

Page 29: ...s damage to the pump 2 Fill the system with liquid until the correct pressure is reached 3 Bleed the system 4 Check the sense of rotation See chapter 4 4 Checking the sense of rotation 5 Start the pump 4 4 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 s...

Page 30: ...heck whether the pressure difference between suction and delivery side corresponds with the specifications of the pump s duty point A mechanical seal may never show visible leakage 4 6 Noise The noise production of a pump depends to a great extent on the operating conditions The values stated in paragraph 10 4 Noise data are based on normal operation of the pump driven by an electric motor In case...

Page 31: ...run in on one another dismantling usually implicates replacement of the mechanical seal If a mechanical seal shows any leakage it has to be replaced 5 3 Lubrication of the bearings For maintenance of the motor bearings we refer to the instructions of the motor supplier concerned 5 4 Environmental influences When a unit is out of operation and there is a risk of freezing it is recommended to drain ...

Page 32: ...p try to determine the cause See chapter 6 Problem solving Then take the necessary measures 3 See chapter 7 Disassembly and assembly in case repair is necessary Always switch off the pump and close the valves before trying to determine a failure First of all try to find what caused the failure In case of electric failure the cause may be in the cabling In that case consult a approved electrician ...

Page 33: ...f pump A number of the most frequently occurring failures as well as their possible causes are shown in the table below Table 7 Most frequently occurring failures Most common faults Possible causes see Table 8 Pump delivers no liquid 1 2 3 4 8 9 10 11 13 14 17 19 20 21 29 Pump has insufficient volume flow 1 2 3 4 8 9 10 11 13 14 15 17 19 20 21 28 29 Pump has insufficient head 2 4 13 14 17 Pump sto...

Page 34: ... viscosity differs from the calculated liquid viscosity 18 Pump operates when the liquid flow is too low 19 Wrong pump selection 20 Obstruction in impeller or pump casing 21 Obstruction in the piping 22 Wrong installation of the pump unit 24 Rotating part running out of true 25 Imbalance in rotating parts for instance impeller or stub shaft 26 Stub shaft is running out of true 27 Bearings faulty o...

Page 35: ... Support of the piping If the entire pump has to be removed you have to make sure that the piping is properly supported If this is not so you should first support and bracket the piping 7 1 4 Liquid draining 1 Close all valves wherever necessary 2 A pump that is used for heating should be left to cool down first 3 Drain the system to the extent that there is no liquid left in the pump Be careful n...

Page 36: ...her with the entire lantern piece out of the pump casing The Back Pull Out unit large pumps is very heavy Support it with a beam or hang it in a pulley sling 7 3 2 Assembling the Back Pull Out unit 1 Grease the outer edge of the impeller entry with Molycote 107 2 Fit the O ring 0300 or a new gasket 0300 3 Mount the complete lantern piece with motor back into the pump casing 4 Fit the nuts 0810 and...

Page 37: ...to break the Loctite contact 4 Remove the impeller 0120 with a pulley puller or wrest the impeller by inserting for instance 2 big screwdrivers between the impeller and the pump cover 0110 5 Remove the impeller key 1860 6 Remove the distance sleeve 1100 with the rotating part of the mechanical seal 1220 7 Pump size 200 160 only Loosen the set screws 1260 Remove the shaft sleeve 1200 and the rotati...

Page 38: ...mechanical seal on the distance sleeve 2 Fit the distance sleeve with the rotating part of the mechanical seal on the stub shaft All types 1 Place the impeller key in the key way of the stub shaft 2 Push the impeller onto the stub shaft against the distance sleeve 3 Degrease the thread on the stub shaft and the thread in the cap nut 4 Put a drop of Loctite 243 on the thread and fit the cap nut For...

Page 39: ...hanical 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 Special tools Mounting the mechanical seal ...

Page 40: ...ly Loosen the set screws 1260 See figure 12 3 Pull the distance sleeve 1100 Pump size 200 160 spacer sleeve 1200 and the rotating part of the mechanical seal 1220 off the shaft 4 Mark the position of the pump cover 0110 in relation to the lantern piece 0250 Knock the pump cover loose and remove it 5 Push the counter ring of the mechanical seal 1220 out of the pump cover Figure 11 Mechanical seal M...

Page 41: ...f the lantern piece Check whether the pump cover is at right angles to the stub shaft 5 Push the rotating part of the mechanical seal on the distance sleeve 1100 Put some glycerine or silicon spray on the bellows to facilitate the assembly 6 Pump size 200 160 only Push the rotating part of the mechanical seal and the spacer sleeve 1200 on the the stub shaft 7 Pump size 200 160 only Set the distanc...

Page 42: ... Disassembling a mechanical seal M1 2 Loosen the bolts 0850 and nuts 0900 and remove the lantern piece 0250 from the motor 3 Remove the seal guards 0276 4 Loosen the set screws 2280 and pull the stub shaft 2200 from the motor shaft Figure 13 Assembly of the stub shaft C E I M S 2 3 1 L M 0 6 1 L M 0 8 1 L 0 0 2 M S 5 2 2 M 0 5 2 M S 0 8 2 C E I 0 8 L S 0 9 L 0 0 1 M 2 1 1 0 8 2 2 0 0 2 2 0 0 2 2 0...

Page 43: ... flange and fit the lantern piece 0250 to the electric motor 5 Mount the pump cover 0110 the mechanical seal 1200 and the impeller 0120 6 Push the impeller on the stub shaft until the back blades touch the pump cover 7 Fix the stub shaft on the motor shaft with the set screws 2280 8 Slightly loosen the fastening bolts 0850 of the electric motor and remove the shims 9 Tighten the fastening bolts 08...

Page 44: ...42 Disassembly and assembly CLB EN 1901 6 6 ...

Page 45: ...CLB EN 1901 6 6 Dimensions 43 CombiLineBloc 8 Dimensions 8 1 Dimensions drawings Figure 14 Pump dimensions drawing O F G H D C B A N J2 J1 K L M E X1 X2 X3 W N P R S x OT N ...

Page 46: ...6 400 200 200 100 131 24 24 5 147 123 146 5 127 136 5 M16 G3 8 G3 8 80 2001 80 574 530 265 265 140 113 22 166 140 151 139 192 M16 G3 8 G3 8 100 160 100 600 560 260 300 140 188 27 27 190 141 184 5 170 172 5 M16 G3 8 G3 8 100 200 100 630 590 280 310 140 174 27 27 195 163 195 169 192 5 M16 G3 8 G3 8 80A 250 100 630 590 280 310 140 214 5 27 200 176 195 169 175 M16 G3 8 G3 8 125 1601 125 794 750 375 37...

Page 47: ...5 557 603 673 751 879 65 160 549 595 665 743 871 65 200 566 612 682 760 932 966 1094 80 125 577 623 693 771 899 80 160 588 634 704 782 954 988 1116 80 200 549 595 665 743 915 949 1077 100 160 683 753 831 1003 1037 1165 100 200 667 737 853 987 1057 1149 1217 1425 1585 80A 250 712 782 898 1032 125 160 748 818 896 1068 1102 1230 125C 200 748 818 934 1068 1102 1230 1298 1506 1666 100A 250 796 912 1046...

Page 48: ...25 29 29 30 33 65 160 33 33 34 36 40 65 200 44 44 45 47 51 51 52 80 125 36 36 37 40 42 80 160 42 42 43 46 49 50 55 80 200 58 58 59 61 65 65 66 100 160 65 66 69 72 73 78 100 200 68 70 74 74 75 76 89 89 80A 250 88 86 89 92 125 160 90 91 93 97 97 98 125C 200 92 93 95 98 99 100 101 114 114 100A 250 118 121 124 125 150 125 160 161 164 150 160 147 149 153 150 200 110 112 115 125A 250 149 151 155 155 150...

Page 49: ...d ISO 7005 N O P R S x T 32 78 100 140 4 x 18 40 88 110 150 4 x 18 50 102 125 165 4 x 18 65 122 145 185 4 x 18 80 138 160 200 8 x 18 100 158 180 220 8 x 18 125 188 210 250 8 x 18 150 212 240 285 8 x 18 200 268 295 340 8 x 22 CLB U1 U2 U3 40C 125 40 160 40 200 50 125 50 160 50 200 35 200 155 65 125 65 160 65 200 80 125 80 160 80 200 35 235 185 80 250A 100 160 100 200 125 160 125C 200 125A 250 35 30...

Page 50: ...48 Dimensions CLB EN 1901 6 6 ...

Page 51: ...te 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 9 1 2 Recommended spare parts Parts marked with a are recommended spare parts ...

Page 52: ...igure 16 Sectional drawing 0350 0100 0310 0120 0320 1820 1860 1100 0110 1220 0250 0235 0240 0276 0800 0810 0850 0900 2200 2280 IEC 132S M 160M L 180M L 200L 225S M 250M 280S M IEC 80 90S L 100L 112M 2400 2400 2405 2405 0300 2410 2415 2280 IEC 80 90S L 100L 112M 0300 ...

Page 53: ...guard stainless steel 0300 1 gasket or O ring 0310 1 plug steel stainless steel 0320 1 plug steel stainless steel 0350 1 plug steel stainless steel 0800 4 8 12 stud steel stainless steel 0810 4 8 12 nut steel stainless steel 0850 4 8 bolt steel 0900 4 8 nut steel 1100 1 distance sleeve stainless steel 1220 1 mechanical seal 1820 1 cap nut stainless steel 1860 1 impeller key stainless steel 2200 1 ...

Page 54: ...B EN 1901 6 6 9 3 Additional parts 200 160 Figure 17 Shaft sleeve of 200 160 Item Quantity Description Materials G1 G2 B2 1200 1 shaft sleeve brass 1260 3 set screw stainless steel 4 4 5 3 9 0 0 2 1 0 6 2 1 4410_A ...

Page 55: ...CLB EN 1901 6 6 Parts 53 CombiLineBloc 9 4 Base plate Figure 18 Base plate Item Quantity Description Materials G1 G2 B2 0410 1 base plate steel 0880 3 bolt steel 0410 0880 ...

Page 56: ...54 Parts CLB EN 1901 6 6 ...

Page 57: ...ts for cap nut Table 9 Recommended locking liquids Description Locking liquid cap nut 1820 Loctite 243 Table 10 Tightening moments for bolts and nuts Materials 8 8 A2 A4 Thread Tightening moment Nm M6 9 6 M8 20 14 M10 40 25 M12 69 43 M16 168 105 Table 11 Tightening moments for cap nut 1820 Size Tightening moment Nm M12 bearing bracket 1 43 M16 bearing bracket 2 105 M24 bearing bracket 3 220 ...

Page 58: ... 30 40 50 60 80 100 150 200 300 4 m 40C 125 50 125 65 125 80 125 80 160 100 160 65 160 50 160 40 160 40 200 50 200 65 200 80 200 100 200 5 6 7 8 10 15 20 30 40 50 60 80 100 150 200 300 4 450 m m h 3 H 1 5 6 7 8 10 15 20 25 30 4 3 2 Q 200 200 150 200 40C 125 50 125 65 125 80 125 80 160 100 160 65 160 50 160 40 160 40 200 50 200 65 200 80 200 100 200 80A 250 100A 250 1 2 5 A 2 5 0 150 250 200 160 12...

Page 59: ...8 10 13 4 3 2 Q 200 200 150 200 40C 125 50 125 65 125 80 125 80 160 100 160 65 160 50 160 40 160 40 200 50 200 65 200 80 200 100 200 80A 250 100A 250 1 2 5 A 2 5 0 150 250 200 160 125C 200 125 160 150 160 150 125 m m h 3 Q H 7 8 10 15 20 25 30 40 50 60 70 80 110 10 15 20 30 40 50 60 80 100 150 200 300 40C 125 50 125 65 125 80 125 80 160 100 160 65 160 50 160 40 160 40 200 50 200 65 200 80 200 100 ...

Page 60: ...5 50 125 65 125 80 125 80 160 100 160 65 160 50 160 40 160 40 200 50 200 65 200 80 200 100 200 80A 250 100A 250 1 2 5 A 2 5 0 150 250 125C 200 125 160 150 160 150 125 m m h 3 Q H 1 5 6 7 8 10 15 5 6 7 8 10 15 20 30 40 50 60 80 100 150 200 300 4 3 400 4 3 2 200 200 150 200 40C 125 50 125 65 125 80 125 80 160 100 160 65 160 50 160 40 160 40 200 50 200 65 200 80 200 100 200 80A 250 100A 250 1 2 5 A 2...

Page 61: ...ump power kW at 1450 min 1 A sound power level B sound pressure level Figure 26 Noise level as function of pump power kW at 2900 min 1 A sound power level B sound pressure level 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 0 1 1 10 100 200 P kW dB A A 4103_A B 60 65 70 75 80 85 90 95 100 0 1 1 10 100 300 P kW dB A 4104_A A B ...

Page 62: ...of the motor 3 Determine the difference between both levels L1 L2 4 Find the differential value on the L1 L2 axis and go up to the curve 5 From the curve go left to the L dB axis and read out the value 6 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 ...

Page 63: ...introduction 16 MEI 21 minimum efficiency 21 name plate 20 product information 20 pump selection 19 Electric motor connecting 26 cooling air inlet 25 terminal box 26 Electricity company 26 Electricity supply disconnecting 33 Environment 25 29 F Faults 30 G Guarantee 10 H Hoisting 11 I Impeller disassembly 35 mounting 36 Inspection motor 27 pump 27 Installation 26 L Lifting eye 11 M Maintenance sta...

Page 64: ... R Recommended locking liquid 56 Re use 23 S Safety 9 25 symbols 9 Scrapping 23 Sense of rotation 27 Serial number 14 Storage 10 Stub shaft adjusting 41 assembling 41 disassembling 40 replacing 40 System de aerating 26 draining apertures 26 T Technicians 9 Tightening moments for bolts and nuts 55 for cap nut 55 Transport 10 Type description 14 V Ventilation 25 W Water hammer pressure 26 Working sw...

Page 65: ...der will only be dealt with if this order form has been correctly completed and signed FAX Nr ADDRESS Order date Your order number Pump type Execution Quantity Item No Part Article number pump Delivery address Invoicing address Ordered by Signature Telephone ...

Page 66: ...64 ORDFORM 1512 3 3 EN ...

Page 67: ...wide locations approvals certifications and local representatives please visit www spxflow com johnson pump SPXFLOW 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 c...

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