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Range: DBS

Non clogging volute casing pump


PUMP DESCRIPTION: ______________________________
SERIAL NUMBER: ____________________

Operating instructions
Safety issues

Chapter 1

Safety instructions and compliance

Intended application

Chapter 2

Application, description

Planning the installation

Chapter 3

Requirements, piping system, accessories

Unpacking, storage, transport

Chapter 4

Supply, interim storage, corrosion protection

Installing the pump

Chapter 5

Assembly at site, tools, checks

Start-up and shut-down

Chapter 6

Important requirements

Maintenance, dismantling, assembly

Chapter 7

Intervals, cleaning

Troubleshooting

Chapter 8

If something does not work

Technical data

Chapter 9

Dimensions, permissible values

Annex

Chapter 10

Connections, dimensions table, sectional drawings, specific operating limits

Attention: Both the pump and/or the pump set must be installed and commissioned by qualified technical
personnel only and these installation, commissioning and operating instructions must be strictly observed.
Failure to do so could result in:
danger to you and your colleagues,
the pump or the pump unit may be damaged,
Note that the manufacturer is not liable for damages resulting from failure to observe these instructions.
Please be aware of your responsibility to your colleagues when working on the pump or the pump set!
Safety instructions marked with
potentially explosive atmospheres!
For local contact details:
www.sterlingfluidsystems.com

have to be considered in particular when operating this pump in

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice

(Sterling Fluid Systems BV) 2003

Safety issues

Page 1 of 3

Chapter 1

1. Safety issues

Signs affixed to the machine, e.g.

1.1

arrow indicating the direction of rotation

Safety instructions

symbols indicating fluid connections


This manual gives basic instructions which must
be observed during installation, operation and

must be observed and kept legible.

maintenance of the pump.


It is therefore imperative that this manual be read

1.2

by the fitter and the responsible personnel or

Qualification and training


operating personnel

of

operator prior to assembly and start up. It must


always be kept available at the installation site.

The

personnel

responsible

for

operation,

maintenance, inspection and assembly must be


Within this manual, safety instructions are marked

adequately qualified.

with safety symbols.

The responsibilities of the operating personnel


must be exactly defined by the plant operator.
If the staff do not have the necessary knowledge,
they must be trained and instructed, which may be

Safety symbol to ISO 3864-B.3.1

performed by the machine manufacturer or the


supplier on behalf of the plant operator, if

This general hazard symbol highlights information

required.

non-compliance with which could cause a risk to


Moreover, the plant operator is to make sure that

personal safety.

the contents of this manual are fully understood


by the operating personnel and other relevant
personnel such as maintenance staff.
Safety symbol to ISO 3864-B.3.6

1.3
This symbol refers to electrical safety.

Hazards in the event of noncompliance with the safety


instructions

This word gives warning of a hazard to the maNon-compliance with the safety instructions may

chine.
CAUTION

cause a risk to the personnel as well as to the


environment and the machine and may result in a
loss of any right to claim damages.

Safety instructions that have to be considered


when operating this pump in potentially explosive

For example, non-compliance may involve the

atmospheres are marked with the word:

following hazards:
failure of important functions of the equipment
failure of specified maintenance and repair
procedures

For local contact details:


www.sterlingfluidsystems.com

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice.

(Sterling Fluid Systems BV) 2001

Safety issues

Page 2 of 3

electrical, mechanical and chemical hazards


affecting personal safety
release

of

Chapter 1

familiarised themselves with the subject matter by


studying this manual in detail.

environmentally

damaging

substances

Any assembly or maintenance work on the


machine shall only be performed when it is at a
standstill. The procedure for stopping the machine

1.4

Safety at work

described in this manual must be followed.

When operating the pump, the safety instructions

Pumps which handle hazardous fluids must be

contained in this manual, the relevant national

decontaminated.

accident prevention and explosion protection


regulations and any other service and safety

On completion of work all safety and protective

instructions issued by the plant operator must be

facilities must be re-installed and made operative

observed.

again.
Prior to restarting the machine, the instructions

1.5

Safety instructions relevant to


operation

listed under sub-section "Checks before first startup" must be observed.

If hot or cold machine components involve


hazards, the customer must ensure these

1.7

Safety instructions for the use in


areas with explosion hazard

components are guarded against accidental


contact.
Contact guards for moving parts (e.g. coupling)
must not be removed from the machine while

In this paragraph information are given for an


operation in areas with explosion hazard.

in operation.
Any leakage of hazardous (e.g. explosive,

1.7.1 Arrangement of the units

toxic, hot) fluids (e.g. from the shaft seal) must


be drained away so as to prevent any risk to

If the pump is completed with other mechanical or

personal safety or the environment. Statutory

electrical components to one unit, the complete

regulations must be complied with.

unit may be considered only as device category

Hazards resulting from electricity must be


prevented. Local regulations must be complied

according to the directive 94/9 EC which is fulfilled


by all used components.

with.
The operator has always to pay attention to the
conformity of all used components of the pump

1.6

Safety instructions relevant for


maintenance, inspection and
assembly work

unit with the directive 94/9 EC.


1.7.2 Execution of coupling guards for shaft
couplings

It shall be the plant operator's responsibility to


ensure that all maintenance, inspection and

Coupling guards which shall be used in areas with

assembly work is performed by authorised and

explosion hazard have to fulfil the following

qualified

criteria:

personnel

who

For local contact details:


www.sterlingfluidsystems.com

have

adequately

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice.

(Sterling Fluid Systems BV) 2001

Safety issues

Page 3 of 3

Chapter 1

do not use sparking material e.g. brass or

safety. Use of other parts may exempt the

steel plate constructions executed this

manufacturer from any liability.

way that with faults to be foreseen (e.g.


deformation by stepping on the coupling
guard) a contact between the rotating

1.9 Unauthorised use

parts and the coupling guard is excluded.


The reliability of the pump delivered will only be
guaranteed if it is used in accordance with this
1.7.3

Belt-driven pump sets

The belts must include some electrically

1.10 Warranty / guarantee

conductive material.

manual.

The belt-driven pump sets must always be


earthed.

Sterling Fluid Systems guarantee satisfactory

The condition of the belts must be checked

operation if:

regularly.

the pump is

installed and operated in

compliance with these instructions and in


operating conditions approved by Sterling
1.7.4 Priming of the pump

Fluid Systems

The pump is assumed to be filled with liquid at all

modifications

are

only

undertaken

Sterling Fluid Systems written agreement.

times during operation so that no explosive


mixtures can form inside the pump and dry
operation of the mechanical seal is prevented.

1.7.5 Avoidance of exterior impact effect


The operator has to ensure that with an operation
of the machine in areas with explosion hazard no
exterior impact effect to the machine casing may
arise.

1.8 Unauthorised alterations and


production of spare parts
Any modification to the machine is permissible
only within the limits as documented by Sterling
Fluid Systems or after consultation with Sterling
Fluid Systems.
Using genuine spare parts and accessories
authorised by the manufacturer is in the interest of
For local contact details:
www.sterlingfluidsystems.com

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice.

(Sterling Fluid Systems BV) 2001

with

Intended application

Page 1 of 3

Chapter 2

2. Intended application

2.2

2.1

DBS pumps process type are horizontal, single-

General advises

Design and mode of operation

stage volute-casing, free-flow impeller or two


channel impeller or three channel impeller with
dimensions correspond to a large extent to those

CAUTION

of

the

ISO2858/EN22858.

The

process

construction allows the withdrawal of the complete

Observe the pump operating limits docu-

pull-out unit, without the need of removing the

mented by Sterling Fluid Systems (if there is

pump casing from the pipework.

any doubt, please contact Sterling Fluid

Series DBS volute-casing pumps can be used

Systems).

where the requirement is for pumping dirty liquids


or liquids with solids, such as:

According to directive 94/4 EC equipment


group II, category 2, is applicable to the pump.
The

nameplate

bears

the

marking

ex II 2G T1-T5
The operator is to ensure the permissible
maximum temperature of the liquid handled as

Sewage plants
Chemical plants
Rolling mills
Foundries, iron and steel works
Construction industry
Paper and cellulose pulp industry
Sugar mills
Food industry

a function of the temperature class is not


exceeded. Specific limitations or restrictions
resulting from pump design or mode of
operation must be taken into consideration
(see

annex).

Otherwise

temperatures

in

excess of the temperature of the pumped liquid


may occur on the pump casing which could be
hazardous to personnel and environment if the
pump is operated in a potentially explosive
atmosphere.

If the pump is operated in a potentially


explosive atmosphere of temperature class T4,
the ambient temperature must not exceed 40
C (see also 5.2.2).

For local contact details:


www.sterlingfluidsystems.com

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice

(Sterling Fluid Systems BV) 2003

Intended application

Page 2 of 3

Chapter 2

2.3 Product identification


The pump identification on the nameplate covers all essential constructional features

Position
1-3
4
5-9
10
11
12

13-15

16-17
18

Characteristic
Type
Construction
Size
Impeller diameter
Impeller type
Hydraulic
Bearing

Code
DBS
A
032 300
16 50
D
Z
F
A

Explanation
Horizontal, single - stage volute pump of process type

Diameter of discharge nozzle in mm


Diameter of impeller in cm
Triple channel impeller
Double channel impeller
Free-flow impeller

Pump side: one cylindrical roller to DIN 5412

Shaft sealing

Material
Casing design

B
C
S

Motor side: 1 deep groove ball bearing. Grease lubricated

Motor side: Two single-row angular contact ball bearings


paired. Oil lubricated

051
052
071

Uncooled stuffing box, sealing fluid outside source, flushing

BKS
BKW

Burgmann mechanical seal MG1-G60-Q1Q1VGG

0B
0E
4B
B
C

Main parts, and impeller made of cast iron GG 25

Motor side: 1 deep groove ball bearing. Oil lubricated


Motor side: Two single-row angular contact ball bearings
paired. Grease lubricated

Uncooled stuffing box, sealing fluid from an outside source


Uncooled stuffing box with flushing up-stream of packing and
flushing between wear plate and impeller
Burgmann mechanical seal MG1-G60-Q1Q1PGG

Main parts of cast iron GG 25, impeller made stainless steel


Main parts, and impeller made of stainless steel (1.4408)
With wear plate
Without wear plate

19
20

For local contact details:


www.sterlingfluidsystems.com

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice

(Sterling Fluid Systems BV) 2003

Intended application

Page 3 of 3

Chapter 2

2.4 Nameplate
Example pump designations:
In the event of queries, please provide the
1-3

following information as noted on the nameplate:

5-7 8-9 10 11 12 13-15 16-17 18

DBS A 200 32 D A S 051 0B B


- Product identification

Casing design

- Serial number

Materials of
construction
Shaft seal
Bearing lubrication
Hydraulic
Impeller type

2.5 Accessories
The accessories provided with the pump are

impeller cm.

indicated on the order acknowledgement.

Nominal delivery
branch
Estate constrictive

Accessories

subsequently

installed

by

Pump designation

operator must not impair pump function or safety

The fifteenth letter of the pump designation


signifies

the

material

combination

of

the

mechanical seal where applicable.

CAUTION
If the designation of the shaft seal cannot be
found in chapter 2.3 or if the designation is
indicated

by the

letters

QQQ,

please

see

instructions in the data sheet.

For local contact details:


www.sterlingfluidsystems.com

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice

(Sterling Fluid Systems BV) 2003

the

Planning the installation

Page 1 of 3

Chapter 3

3.0

Planning of the installation

3.1.1 Suction or feed line

3.1

Pipework

Feed line. To prevent collection of air or gas the


feed line must be horizontal or show a gradual
slope towards the pump

CAUTION
Suction line. Since the pump is not of the self
Suction branch axial, discharge branch radially

priming type and a foot valve cannot be used in


the case of contaminated liquid, can be started

upwards.
The diameters of the piping are not determined

only after prior evacuation (evacuating unit). The

by those of the pump delivery and suction

suction

line

must

be

horizontal

branches. On short delivery pipe resistance

continuously all the way to the pump.

or

rise

constitutes but a small portion of the delivery


head. For long pipe runs the most economic
pipe diameter must be assessed in each
particular case.
Make sure that the flange gaskets do not
protrude into the bore.
Make sure that the piping is cleaned before
Feed operation

installing the pump.

suction operation

Support the piping in such a way that it is free


of stress (danger of breach of pump parts).
Once the flange bolts have been loosened, the

When handling a fluid containing gas, a suction

flanges must not yield more than the amount

head of at least 0,5 m. should be available to the

corresponding to the gasket thickness, nor

pump, since the under pressure at the entry of the

must they be cut of parallel nor bear against

impeller would otherwise cause a separation of

each other under stress.

gas and a loss prime.

Avoid abrupt changes of the pipe crosssections and changes of direction.

The bore of the feed or suction pipe should be set


as deeply as possible below the suction side liquid

Connect different nominal diameters with an

level. In case the bore should face downwards it

eccentrically taper piece. Thus, the formation

must, however, be so far away from the bottom

of air pockets in the piping will be avoided.

that the inlet losses will not become too great,

Unfavourable installed pipe runs, especially on

thus reducing the delivery performance.

the suction side (i. e. bends in various planes

When delivery sludge, we recommend to lay the

immediately before the suction branch) can

suction line horizontal, preferably immediately at

affect the performance of the pump.

the bottom of the suction side collecting tank

The flow velocity in the piping not be less than


1 m/sec because otherwise there is the danger
of sedimentation.

For local contact details:


www.sterlingfluidsystems.com

(figure 1). The suction line should be as short as


possible.

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice.

(Sterling Fluid Systems BV) 2003

Planning the installation

Page 2 of 3

Chapter 3

3.1.3.1 Sealing liquid connection Xa,b


(a = inlet, b = outlet)
At Xa a sealing liquid line is normally connected
up. The pressure of the connected clear liquid
should be about 1 bar higher than the maximum
operating pressure of the pump (pump delivery
branch, pressure gauge connection I). The sealing
water prevents abrasive particles contained in the
delivery liquid from entering the stuffing box, thus
avoiding premature wear of the shaft sleeves
under the stuffing box packing. When delivering
raw sewage or storm water, an automatic grease
gun may olso be provided for sealing purposes.
The isolating valves in the suction or feed line
must remain fully open during operation. NEVER
use this valves for regulating. If possible, isolating
valves in the suction line should be mounted with
the spindle in horizontal position to avoid air
pockets forming in the spindle cap. To avoid
ingress of air, it is advisable to use isolating
valves with sealing water connection or with water

When delivery biologics sludge or liquids without


abrasive additions under suction head conditions,
no sealing is required. Whilst sealing by a clean
liquid is necessary when handling raw sludge,
putrid sludge or pasteurised sludge and liquids
with abrasive additions, as well as, in the case of
operation under suction lift conditions.
The pipe running to this connection Xa should
incorporate a pressure reducing valve, if the

seal.

pressure in the mains line is far above the


required one. In order to keep the sealing water
consumption as low as possible, we recommend

3.1.2 Delivery line

to install a magnetic valve which will be opened


Install a gate valve in the delivery line close to the

during pump operation only.

pump branch. It is recommended to install a nonreturn valve between pump branch and regulating
valve, thus protecting the pump against reverse
rotation and water hammer which may occur in

3.1.3.2

Flushing
XXIIIa

liquid

connection

the piping in case of sudden shut-down of the


For special applications of delivery liquids with a

pump.

very high content of solids or tendency towards


crystallisation this connection can be additionally

3.1.3 Inlet and outlet connections

drilled. Besides, the lantern ring will then be


situated at the bottom of the stuffing box chamber.

(see also arrangement drawing)


The various connecting points are shown in
Chapter 10.

The flushing liquid is taken directly to the shaft


sleeve before the packing, thus preventing the
entry of solids between stuffing box packing and
shaft sleeve.

For local contact details:


www.sterlingfluidsystems.com

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice.

(Sterling Fluid Systems BV) 2003

Planning the installation

3.1.3.3

Flushing
XXIIIb

liquid

Page 3 of 3

Chapter 3

connection

Here the suction side clearance gap between


wear plate and impeller can be flushed, if required
especially when pumping strongly contaminated
delivery fluids.

3.1.3.4 Leakage water connections IX


The leakage line must be sized amply enough for
the liquid to flow off freely. It should be designed
so that it can be cleaned easily.

3.1.3.5 Pressure gauge connection I


Vent III
Drain VII
Please, see connection dimensions drawing.

3.2

Electrical connections

The electrical connection for the driving motor


must comply with the relevant local rules and
requirements.

For local contact details:


www.sterlingfluidsystems.com

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice.

(Sterling Fluid Systems BV) 2003

Unpacking, storage, transport

Page 1 of 2

4. Unpacking, storage, handling

Chapter 4

The packing should be checked for damage on a


monthly basis.

4.1

General advises
4.4

Handling

The pump or the pump set must be lifted as


shown below:

Do not lift heavy equipment overhead of


personnel.
A safe distance must be kept when lifting and
moving the equipment.
Use only approved and suitable lifting equipment.
The length of the lifting equipment should be
such that the pump or the set are lifted in hori-

zontal position.
Do not attempt to lift the pump or the pump set
using eyebolts on pump components.
CAUTION

Pump without motor

Do not remove protection covers from the


pump branches, as they prevent contamination
of the pump.

4.2 Unpacking
Do not unpack the pump until it has been carefully
checked for damage that may have occurred in
transit. Report any damage on the counterfoil or
delivery note.
Pump unit
Claims must be made immediately on the carrier
or the transport insurance.

4.5

Protection against corrosion

4.3 Intermediate storage

4.5.1 Removal of protection

If the pump or the pump set is not to be installed

In general, a preservation coating is only applied

immediately it should be stored in a dry and vibra-

to 0B and 0E pump material executions.

tion-free room.
For local contact details:
www.sterlingfluidsystems.com

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice

(Sterling Fluid Systems BV) 2003

Unpacking, storage, transport

Page 2 of 2

Chapter 4

To remove the preservative coating, the pump


should be filled and drained several times using
appropriate agents, e.g. solvent naphta, diesel oil,
or an alkaline detergent. Flush with water, if
necessary.
The pump must be installed and put into operation
immediately afterwards.

4.5.2 Renewing corrosion protection


If the pump has been supplied preserved and is to
be stored, a new preservative coating should be
applied after six months.
For suitable preservatives, contact Sterling Fluid
Systems.

For local contact details:


www.sterlingfluidsystems.com

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice

(Sterling Fluid Systems BV) 2003

Installing the pump

Page 1 of 3

Chapter 5

5. Installing the pump

5.2

5.1

Only appropriately trained staff must undertake

General advises

Prerequisites

the work described in this chapter.

5.2.1 Fitting tools

The foundation of the pump must be level and

Standard tools and lifting equipment are used.

have a minimum of vibration. It is recom-

These should be available at the customer's end.

mended to use a baseplate.


Concerning the pipework, the pump must not

5.2.2 Permissible environment

be considered as a fixpoint.
Care should be taken that the pipework forces
and moments acting on the pump branches do

The ambient temperature range should be from

not exceed the permissible pump branch loads

-20 C to +60 C (for restrictions see also chapter

acc. to ISO 5199 (see chapter 9).

2).
The atmospheric humidity should be low in order

The pump must be properly aligned

to avoid corrosion.

The pipework must be properly installed.

5.2.3 Space utilisation

Incorrect pump installation or alignment will

The space required by the pump or the pump set

lead to an overload on the machine which

can be seen from the attached table of dimen-

could

sions or the arrangement drawing.

be

hazardous

to

personnel

and

environment if the pump is operated in a

Clear and easy access to the shut-off and regu-

potentially explosive atmosphere.

lating valves and the measuring instruments must

Leakage due to improper pipe or supply line

be ensured.

connections may lead to the formation of


explosive mixtures and be hazardous to the
personnel and the environment if the pump is

5.2.4 Installation position

operated in a potentially explosive atmosphere.


The coupling must be installed, started-up and

DBS pumps are installed in horizontal position.

operated in accordance with the operating


instructions of the coupling manufacturer.
Misalignment of the coupling may result in
inadmissible temperatures at the coupling and
pump and motor bearings. It has to be
ensured, that the half couplings are correctly
aligned at all times.

For local contact details:


www.sterlingfluidsystems.com

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice

(Sterling Fluid Systems BV) 2003

Installing the pump

Page 2 of 3

Chapter 5

5.2.5 Preparatory checks


5.3

Foundation

The following checks should be made prior to


installation:

5.3.1 Placing the pump set

ease of running (check that the shaft is free to

Prior to placing the pump set on the foundation


which should be well set, the following preparatory
work must be carried out:

rotate by hand)
direction of rotation of the motor
shut-off valve in the suction or feed line and

check the dimensions of the foundation

regulating valve in the discharge line must be

roughen and clean foundation surface

closed

remove shuttering/cores from the anchor holes

power to the equipment must be disconnected

blow the anchor holes clean


check the positions and dimensions of the

5.2.6 Alignment of the pump set

anchor holes against the arrangement drawing


The complete set mounted on the baseplate must
be placed on the foundation with its foundation

After aligning the set the axial clearance between

bolts suspended.

the two coupling halves measured at one point of


the coupling must be the same over the complete

Place shims under the baseplate on both sides

circumference of the coupling, the permissible

of the foundation bolts, 10 mm from the base-

tolerance being 0.05 mm.

plate edge

Carry out the radial alignment of the coupling

Use a spirit level to align the set

using a bevelled straight edge and a feeler gauge.

If necessary, place shims between the foundation bolts to prevent the baseplate from sagging. Care should be taken to minimise distortion of the baseplate during installation
The foundation bolts should be embedded in
concrete using quick-setting grout
Tighten the nuts of the foundation bolts crosswise (when the grout is set)
Re-check the alignment with a spirit level
CAUTION

Aligning the coupling clearance

Care should be taken at every check that the

The indications given before are general rules.

axial play of the pump rotor is taken into con-

Always the operation instruction of the coupling

sideration.

manufacturer must be considered.

Avoid distortions when finally tightening the


bolts.

5.2.7 Pumps with V belt drive


Please, follow the instructions of the V belt
manufacturer.
For local contact details:
www.sterlingfluidsystems.com

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice

(Sterling Fluid Systems BV) 2003

Installing the pump

Page 3 of 3

5.3.2 Grouting the baseplate

Chapter 5

5.6 Cleaning, flushing and pickling of


the pipework

Prior to grouting the baseplate, carry out the folWhen the pipework is cleaned, flushed or pickled,

lowing preparatory work:

the pump should be excluded.


Check the dimensions with regard to height
and adjustment of flanges
Re-adjust baseplate, if necessary
Ram earth-humid concrete under the baseplate or
add shrinkage-free grout until the entire space
under the baseplate is filled. Grouting should be a
continuous process so as to ensure that no air
pockets are left.
When the grout is set re-tighten the foundation
bolts and re-check the alignment of the coupling.

5.4 Pump installation in the piping


system
Remove the protection covers from the pump
flanges and the auxiliary pipeline connections
Correctly insert the flange seals
Connect the suction or feed line
Connect the discharge line

5.5 Hydrostatic test

For the hydrostatic test of pressure containing


pump parts (casing, casing cover), a maximum
pressure of 1.5 x nominal pump pressure

should be applied.
If the piping system is to undergo a hydrostatic
test, the pump must be excluded from such
testing.

For local contact details:


www.sterlingfluidsystems.com

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice

(Sterling Fluid Systems BV) 2003

Starp-up and shut-down

Page 1 of 3

6. Start-up and shut-down


operations

Chapter 6

The operator is to ensure that a dry operation


of the shaft seal is prevented. For pumps
equipped with packing, the gland be tightened

6.1

General advises

until there is a slight leakage and are only


allowed to be operated when primed. Pumps
with a single-acting mechanical seal are only
allowed to be operated when primed. For
pumps

equipped

with

double-acting

mechanical seal, also the seal chamber must


Observe

the

pump

operating

be flushed or sealed.

limits

documented by Sterling Fluid Systems (if there

If the operator cannot warrant this condition,

is any doubt, please contact Sterling Fluid

appropriate monitoring devices must be used.

Systems).

Improper installation (e.g. vertical installation)

Safety measures should be taken at the

may impair the self-venting properties of the

customer's end to ensure (for example by

seal chamber, so that gas bubbles may be

means of a relief valve) that the permissible

collected

pump casing pressure is not exceeded during

mechanical seal to run dry.

in

the

pump

and

cause

the

High negative pressure on the suction side

operation.
If the liquid handled is hot, the pump must be

(e.g. due to clogged suction-side strainers or

filled slowly so as to avoid distortions or heat

low system pressure) may result in air intake at

shocks.

the shaft seal forming gas bubbles in the

The flowrate must be changed at constant

pump. This may also cause the mechanical

speed only on the discharge side. During

seal to run dry. Suitable monitoring facilities

operation the shut-off valve in the suction or

shall be installed, if necessary.

feed line should always be kept open, in order

The direction of rotation of the motor is only


allowed to be checked with the pump primed

not to run the risk of cavitation.


Do not run the pump with the regulating valve

(for pumps with packing and single-acting

closed for any length of time, if there is no

mechanical seal) and, also, with flushed or

bypass line (for restrictions, see also annex).

sealed seal chamber.

6.2
The operator is to ensure the permissible
maximum temperature of the liquid handled as
a function of the temperature class is not

Electrical connections

The motor has to be connected according to the


scheme in the terminal box.

exceeded. Specific limitations or restrictions


resulting from pump design or mode of
operation must be taken into consideration
(see

annex).

Otherwise

temperatures

in

excess of the temperature of the pumped liquid


may occur on the pump casing which could be
hazardous to personnel and environment if the
pump is operated in a potentially explosive

6.3

Control before first start-up

Check the following points before start-up:


1.

Are

all

the

pipes

connected

and

2.

Are pumps and pipework orderly filled?

connections tight?

atmosphere.
For local contact details:
www.sterlingfluidsystems.com

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice.

(Sterling Fluid Systems) 2003

the

Starp-up and shut-down

Page 2 of 3

Chapter 6

3.

Is the control valve in the discharge line

On pumps, which are driven via V belts the

closed?

speed and thus the performance can be changed

4.

Is the isolation valve in the suction or feed

by altering the transmission ratio.

line entirely open?

The coupling alignment should be re-checked

5.

Is the motor ready for operation?

when the pump has reached the operation

6.

Is the direction of rotation of the motor

temperature. If necessary, pump or driver has to

correct? (Check by short start of the motor)

be re-aligned.

7.

Has the coupling been aligned properly?


(see 5.2.6 )

8.

If there is a shaft sealing supply line, is it


entirely open?

9.

Is the bearing housing correctly filled with


oil? (see 7.4.1)

6.5

Operation

6.5.1 Switching frequency


For a start with the regulating valve closed or
slightly

6.4

opened

suction or feed line.


2.

If existing, entirely open the valves of the

3.

Close the discharge valve.

4.

Start motor.

5.

Check the manometer at the pressure

shaft sealing supply line.

gauges. If the pressure does not build up


with

increasing

number

of

revolutions, turn off motor and de-aerate the


pump once more
6.

uniform

start-stop

actuations apply:

Entirely open the isolating valve in the

continually

for

intervals, the following numbers of switching

Start-up

For the start-up, proceed as follows:


1.

and

max switching frequency


equally spaced per hour

P kW

8
8
5

< 12
12 < P <100
>100

6.5.2 Alignment
The alignment of the set should be re-checked at
operating temperature (see 5.2.6). Re-align the
set, if necessary.

Once the pump has reached the operating,


revolution regulates the point of operation by
using the discharge control valve (admissible
operating conditions see data sheet, annex).

6.6

Special notes

Observe the following points during operation:


Control revolutions and head of the pump.

Avoid the maximum casing pressure to be


exceeded due to system failure by means of
safety measures on the installation side (e.g.
overflow valve).
An alteration of the service duty, which might
necessary may be effected by throttling with the
gate valve in the delivery line, to the extent
warrantable taking into account the risk of
clogging due to the nature of the liquid.
For local contact details:
www.sterlingfluidsystems.com

Ensure that the pump runs smoothly without


vibrating.
Control liquid level in the suction or feed tank.
Control the bearing temperature (maximum
temp. 80C)
During the run-in period a slight leakage may
occur.
Should the temperature of the mechanical seal
rise during run-in shut down pump to allow the
seal to cool down.

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice.

(Sterling Fluid Systems) 2003

Starp-up and shut-down

Page 3 of 3

Chapter 6

If the pump is equipped with an external flush


or quench, the supply line has to be opened
before the pump is started up.
After

shutdown of the pump, allow the

mechanical seal to cool down before the shaft


seal supply lines or the intensive cooling are

If e.g. explosive, toxic, hot or crystalline liquids are

closed.

pumped, you have to make sure that no danger

In general, a slight leakage of several cm/h

arises to persons or the environment. Even if the

escapes from the mechanical seal as vapour

pump is completely turned around residues of

or fog. Besides that, few drops may leak from

liquid, remain. If the pump has to be sent back,

the mechanical seal as well.

make sure it is free of any dangerous agents. For


a longer standstill, the pump has to be conserved.

CAUTION
Should the initial leakage rate of the mechanical
seal not reduce considerably after a run-in period
of approx. 5 minutes, shut down the pump as
soon as possible and check the seal.

6.7

Shut-down

If there is no no-return valve flap, close the


regulation valve in delivery line. Do not switch off
driver until then.
Close isolating valve in the feed line only if
necessary. (Removal of pump)
Shut off external sealing.
If a vacuum gauge without relief valve is attached
to the suction branch of the pump, then it must be
isolated before stopping the pump set.
If there is danger of the pump freezing up, the
pump must be drained.

6.8

Restarting

Before restarting the set, take care that the pump


shaft is at rest and does not rotate backwards.
Starting with the shaft rotating in opposite
direction may lead to shaft damage.

For local contact details:


www.sterlingfluidsystems.com

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice.

(Sterling Fluid Systems) 2003

Maintenance, dismantling, assembly

Page 1 of 5

7. Maintenance, dismantling,
assembly

Chapter 7

personnel and environment if the pump is


operated in a potentially explosive atmosphere.
Leakage from a pump equipped with a single-

7.1 General advises

acting mechanical seal may lead to the formation of explosive mixtures and be hazardous to
personnel and environment if the pump is operated in a potentially explosive atmosphere.
Only a pump set, which is properly operated
and maintained in perfect technical condition,

Flush the pump thoroughly before disassembly

will give safe and reliable operation. This also

to purge away the residual liquid left after

applies to the reliable function of the rolling

draining the pump.

element bearings whose actual lifetime largely

Ensure that people and the environment are

depends on the operating mode and operating

not put at risk through explosive, toxic, hot,


crystalline, or acid liquids handled.

The workplace for disassembly or assembly


must be clean.

Ensure trouble-free bearing performance, for


example by regular inspection of bearing temperature or vibration behaviour. The bearing
temperature must not exceed 80C, if oillubricated. Bearing operation must be free from
vibrations. Heat exchange between the bearing
housing and the environment must not be
impaired, insulation is not permissible.

Inspect the mechanical seal leakage at regular


intervals, e.g. by visual inspection. An amount
of a few cm per hour in the form of vapour,
mist or drops is permissible.

conditions.
Regular checks of the lubricant and the
running

noises

will

prevent

the

risk

of

excessive temperatures as a result of bearings


running hot or defective bearing seals.
Any auxiliary systems

installed

must be

monitored, if necessary, to make sure they


function correctly.
Static sealing elements shall be regularly
checked for leakage.
The coupling guard and any other guards of
fast rotating components must be regularly
checked for deformation and sufficient distance
from rotating elements.
Regularly verify the correct position and the
status of plastic components exposed to the
atmosphere.
It is strongly recommended to draw up a
maintenance schedule, which includes the

Assembly and disassembly of this pump must

above-mentioned points.

only be performed by authorised and qualified


personnel who have adequately familiarised
themselves with the subject matter by studying
this manual in detail.
Otherwise the pump could be damaged and

7.2 Maintenance and inspection


7.2.1 Oil lubricated bearings

people and the environment can be put on risk


if the pump is operated in a potentially
explosive atmosphere.

Anti-friction

bearings

which

are

old

or

improperly lubricated may cause the machine

The pump is supplied by the manufacturer


without oilfilling. Before the first start up, fill in oil
into the oil inlet hole until the oil level reaches the
mark in the middle of the oil level sight glass.

temperature to increase and be hazardous to


For local contact details:
www.sterlingfluidsystems.com

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice.

(Sterling Fluid Systems BV) 2003

Maintenance, dismantling, assembly

Page 2 of 5

Chapter 7

Oil change intervals

CAUTION

New bearings need renewal of the oil after about


200 operating hours and then annually, if the

The lubricating oil has to be extremely pure and

bearing temperature is constantly less then 50C

resistant to ageing. It must have good water

and theres no soiling. If the bearing is used at a

separating properties and corrosion protection.

temperature up to 80C and/or if the bearing might


get soiled it requires a renewal of the oil every six
month.

7.2.2 Bearings grease lubricated

Oil Properties

The first filling of the rolling contact bearing and


rolling contact bearing spaces in the bearing
housing is already effected in the works with the
following grease rates per bearing points.

ATTENTION: Should the ambient temperatures


exceed 80C or remain under -30C please
consult the manufacturer.

50C in mm/s

bearing

Ambient

35

50

temperature

temperature

45

75

of bearing

< 0C

55

100

65

150

n 1500

n > 1500

75

200

rpm

rpm

90

250

CL68

CL46

CL22

Re-greasing is effected by means of grease gun

DIN 51517
cinematic viscosity at

Grams per

unit
Operating

up to 80 C

Type of lubrication

Shaft

61.2 to

41.8 to

74.8

50.8

19.8 to 24.2

through the two grease nipples XX. In order to


avoid the entry of impurities into the bearings

Neutralisation number

maximum 0,15 mg KOH/g

together with the grease, take care that the

Ash (Oxide ash)

maximum 0,02% weight

grease container, greasing device and nipple are

Water content

maximum 0,1 % weight

clean and that the lubricant does not become

Suitable motor oil

SAE 20 and 20 W

SAE 10 W

contaminated during the transfer procedure. For


the individual pump speeds, the different regreasing intervals have to be observed:

Oil quantities:

Pump speed: r.p.m


Greasing intervals: hours

1.500
2.500

1.800
2.000

3.000
1.500

Bearing housing size

Shaft end-

amount of oil

35

28

0,35 l

After

45

38

0,6 l

however, after two years at the latest, the rolling

55

48

0,8 l

contact bearings should be removed, cleaned and

65

55

0,9 l

replaced with a fresh grease filling (see Grease

75

65

0,97 l

properties).

90

80

will follow

approximately 10,000

In

the

case

operating

of

hours,

extremely

unfavourable operating conditions (dirty and wet


operation, high ambient temperature) the regreasing must be effected at considerably shorter
intervals. During prolonged standstill periods, the

For local contact details:


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In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice.

(Sterling Fluid Systems BV) 2003

Maintenance, dismantling, assembly

recommendations

given

by

the

Page 3 of 5

respective

Chapter 7

sleeve is damaged and this must be replaced too.


If no pre-shaped packing rings are available cut

lubricant manufacturers must be observed.

packing material to suitable length, e.g. with a

Grease rated/grease types


When installing the rolling contact bearings with a
fresh grease charge, the spaces of the bearings
should always be entirely filled with grease,
however, then housing space on both sides
should only be filled up to one third.
If the bearings are overgreased (too much grease
in the bearings) there is the danger of their

gauging plug of the same diameter as the shaft


sleeve.
A gap of 1 mm between the joints after fitting will,
in

any

case,

prove

less

detrimental

than

squeezing too long pieces together. Pre-shaped


packing must be bent up sidewise and slipped
over the shaft sleeve (fig.: 4)

running hot.

Joint

Use only high-quality lithium soap grease, which


is resin- and acid- free and has a rust inhibiting
effect.
Correct
Consistency n.

Incorrect

Packing ring: L = mean diameter


Fig.: 4

Grease properties:
2

(Work penetration 265-295)


Dropping point 170C

After a certain running-in period, the gland should


be tightened evenly until there is only slight
leakage from the stuffing box.

7.2.3 Mechanical seal

7.2.5 Driver

The mechanical seal shows no or little visible

Carry out maintenance of the driver, according to

leakage. Should the leakage become more

the instructions of the manufacturer.

Usable temperature range up to 120C

intense the mechanical seal has to be checked.


Normally the mechanical seal is a single-acting,

7.3

Disassembly

carbide metal/carbide metal. For it a special


casing cover is required which is not identical with

7.3.1 General

the one used for the packed stuffing box. Normally


for this mechanical seal, no flushing is required.

If the pump has been maintained and services

When

carefully, breakdowns which necessitate the pump

flushing

applications

is

drilled

required
of

the

for

particular

flushing

liquid

connection XXIIIc has to be effected.

being dismantled should not occur (see section 7


maintenance).
If, however, faults occur, then before deciding to
dismantle the pump the plant should be checked

7.2.4 Packing

for possible sources of trouble (see section 8

The pumps are supplied by us with the packing


installed.
If, after prolonged operating time, the inserted
packing material is worn it must be completely
removed, as, other wise, the running surface
For local contact details:
www.sterlingfluidsystems.com

Breakdown Cause Remedy).


If technical personnel are not available, we
recommend that you request the service of an
erection

engineer

or

prevision

of

special

dismantling instructions or despatch of the pump


to our works for checking.

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice.

(Sterling Fluid Systems BV) 2003

Maintenance, dismantling, assembly

If the pump is being stripped by yourselves, all

Page 4 of 5

Chapter 7

7.3.2

Spare parts

parts must be handled with greatest care,


avoiding blows and shocks. All parts must be

The position numbers necessary for ordering

carefully cleaned, tested with new parts. After

spare parts is mentioned in the parts list (see

assembly, the rotor must turn easily by hand.

annex). It is important to indicate the serial

Otherwise the bearings, coupling, shaft seal and

number that can be found on the type plate of the

wear tings opposite the impeller may be damaged

pump as well.

prematurely.
Inspections of all components, especially of the
new ones, to make sure that they do not present

7.4

Special hints

sharp edges or burrs and have completely clean


surfaces. Make certain that the threads are not

In order to facilitate the fitting of the rolling contact

damaged. All grease nipples and plugs must be

bearings on the shaft, these will be warmed up

hermetically sealed with a Teflon tape. Prior to

before on a heating plate. During this procedure

erection all flat gaskets should also be provided

the bearings should, however, not be warned up

with grease.

above 100C because at temperature of 130C

Check of the clearance on semi-open impellers


On

the

semi-open

impellers

the

hydraulic

efficiency is influenced amongst others by the


axial clearance between impeller and wear plate.
Check and correct the setting of the axial
clearance as show on fig. 5

they may already be affected.


After fitting the bearings on the shaft, they and the
grease chambers in the bearing housing have to
be filled with grease according to 7.2.2. Once the
lubricant, this amount of grease will be enough
until the next re-engreasing is due (see 7.2.2).
When fitting the bearings in the hosing take care
that they will have cooled down; we recommend

When measuring clamp by means of


2 opposite wooden wedges

prior warming up of the housing.


When removing the rolling contact bearings from
the housing or from the shaft we recommend
using a pull-off device or a pressing device
Gasket

Clearance
0,5 mm

because otherwise by driving them out with a


hammer the rolling contact bearings may be
damaged.

7.5

After dismantling

fig. 5
Wash out with detergent all lubricants from the
Fixing of the rotor towards the suction side of the

bearings,

impeller by inserting 2 wooden wedges set at

thoroughly by hand or with clean compressed air.

180, measuring of A and B. Required thickness D

Replace bearings that show signs of material

of the gasket (between casing cover and casing)

deterioration on their running surfaces. Apply rust

must be: D = A-B = 0,5 to 1,0 mm

inhibiting oil to the bearings and wrap them in

bearing

housing;

thereafter

paper for protection.

For local contact details:


www.sterlingfluidsystems.com

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice.

(Sterling Fluid Systems BV) 2003

dry

Maintenance, dismantling, assembly

Page 5 of 5

Chapter 7

7.6 Assembly
7.6.1 Tightening torques
Tightening torque of the screws:
Tightening torque of impeller screw 91.41: Nm
size of the bearing housing
shaft material

35

45

55

65

75

90

C45N

25

40

98

190

330

330

X6CrNiMoTi 17 12 2

18

30

72

142

245

245

thread

M10

M12

M16

M20

M24

M30

M36

tightening 12

25

40

90

175

300

500

700

torque

Nm

Nm

Nm

Nm

Nm

Nm

Nm

7.7

M8

Nm

Inspection

After assembly, proceed as follows:


- Check that pump is easy to rotate and leakproof
- Check that the axial clearance of the shaft
assembly is within the permissible range
(0,15 mm 0,75 mm)

For local contact details:


www.sterlingfluidsystems.com

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice.

(Sterling Fluid Systems BV) 2003

Troubleshooting

Page 1 of 1

Chapter 8

8. Help in case of trouble


8.1

Use of trained staff

Trouble shooting must be undertaken only by appropriately trained personnel.

8.2

Symptoms, causes and remedies

Symptom
Delivery at reduced capacity

Cause
- Back-pressure to high.

- Pump or pipework no completely filled.


- Suction head too high or feed head too
low.
- Sealing gap between impeller and wear
plate too great.
- Wrong direction of rotation.
- Pump casing or suction line not tight.
- Impeller clogged.

Pump does not suck at all or


does not suck properly

- Pump casing, shaft seal, strainer or


suction
line not tight.
- Suction head too high or feed head too
low.
- Loose or blocked parts in the pump.
- Casing screws not tight.

Pump leaks

- Gland packing leaks too much.

Remedy
Check if the installation is contaminated
with solid particles.
Regulate the operation point.
Vent and fill the pump and suction or feed
line.
Check the liquid levels, open the isolating
valves on the suction line, clean the
suction filter or strainer.
Exchange the worn out pump parts.
Re-connect electrical supply of the motor.
Exchange casing gasket.
Check the flange connections.
Dismantle the pump and clean the
impeller.
Exchange casing gasket.
Check the shaft seal.
Check the flange connections.
Check the liquid levels, open the isolating
valves on the suction line, clean the
suction filter or strainer.
Open and clean the pump.
Check torque moment of the casing
screws.
Check the packing rings. In case re-tight
the gland. Otherwise renew the packing
rings.

- Mechanical seal leaks.

Temperature increasing in the


pump

- Gaskets defect.
- Pump or pipework no completely filled.
- Suction head too high or feed head too
low.

Pump runs unsteady or noisy

- Gland too tight.

Check the liquid levels, open the isolating


valves on the suction line, clean the
suction filter or strainer.
Loose gland.

- Pump is working against closed valve.

Open the valve on the discharge side.

- Pump or pipework no completely filled.

Vent and fill the pump and suction or feed


line.
Check the liquid levels, open the isolating
valves on the suction line, clean the
suction filter and strainer.
Check the erection of the pump.

- Suction head too high or feed head too


low.

Disconnecting of motor
protection

- Pump is not correctly fitted on the baseplate or foundation or pump is under


stress.
- Foreign bodies in the pump.
Dismantle and clean the pump.
- Erection of the pump not plane or pump is Check the erection of the pump.
under stress.
- Pump is running outside the operating
conditions.
- Loose or blocked parts in the pump.

For local contact details:


www.sterlingfluidsystems.com

Check the seal surfaces and elastomere of


the mechanical seal. In case of damages
exchange mechanical seal.
Renew the gaskets.
Vent and fill the pump and suction or feed
line.

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice.

Observe the operating conditions in the


data sheet.
Open and clean the pump.

(Sterling Fluid Systems BV 2003)

Technical data

Page 1 of 3

Chapter 9

9. Technical Data

Materials: See chapter 2.4

For technical information about the pump or pump

Vibrations:

unit not described in this chapter see data sheet

Vibration level complies with VDI 2056 and ISO

(or delivery note), for the sizes see table of

5199 class K for pumps with a driving power of up

dimensions in the annex.

to 15 kW and class M for driving power of more

This information is overridden by any information

than 15 kW.

given specifically to your order.


Noise emission:
Maximum casing pressure up to 120C:

10 bar

The noise emission of the pump meets the


directive 001/30 - 1992 of the EUROPUMP

ATTENTION: Note the temperature limits of


operation of the mechanical seal.

Commission.

The

following

table

provides

approximate values:

Branch position:
Suction branch axial, discharge branch radially
upwards
Flanges:
The flanges comply with DIN 2501 PN10.
kW

Direction of rotation:
Clockwise viewed from the motor side towards the
pump.

noise level, pump without motor

Please consider that additional noise sources may

Maximum allowed speed, r. p. m:

be:
Pump

Impeller
Type

03216
03220

04016
05016
04020

D/F

Impeller

165
190
173

Bearing
type

driver

Z/F

coupling, if misaligned

B/C
3600

D/F

05020

Maximum
rpm

Piping (note: the larger the pipe diameters, the


lower the noise emission of the pipes)

213/212

06520
05026
08026
10026

D
F

263
260

Z/F

263/260

3000

05032/08032

10032

05032/08032
10032
15032

20032

08040

12540

D/F

20040
30040
12550
20050

D
D

328
325
328

S/T
1800

408

440

960

508

1500

For local contact details:


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In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice.

(Sterling Fluid Systems BV) 2003

Technical data

Page 2 of 3

Chapter 9

Permissible branch forces and moments:


Values according to ISO/DIN 5199 Class II (1997) Annex B, Family N 2 for mounting on sheet metal
baseplates and frames without grouting for pumping temperatures up to 110 C and up to 120 C for grouted
baseplates / frames.

Top branch x-Axis

Top branch z-Axis

Material execution 0B / 0E:

DN
flanges
32
40
50
65
80
100
125
150
200
250
300
50
65
80
100
125
150
200
250
300
350

Fy
(N)
400
400
540
820
820
1080
1620
1620
2160
2700
3220
600
900
900
1200
1800
1800
2400
2980
3580
4180

Fz
(N)
500
500
660
1000
1000
1340
2000
2000
2680
3340
4000
540
820
820
1080
1620
1620
2160
2700
3220
3760

Fx
(N)
440
440
600
900
900
1200
1800
1800
2400
2980
3580
660
1000
1000
1340
2000
2000
2680
3340
4000
4660

F
(N)
780
780
1040
1580
1580
2100
3140
3140
4180
5220
6260
1040
1580
1580
2100
3140
3140
4180
5220
6260
7300

My
(Nm)
360
360
400
460
460
500
700
700
920
1260
1720
400
460
460
500
700
700
920
1260
1720
2200

Mz
(Nm)
420
420
460
520
520
580
820
820
1060
1460
1980
460
520
520
580
820
820
1060
1460
1980
2540

Mx
(Nm)
520
520
560
640
640
700
1000
1000
1300
1780
2420
560
640
640
700
1000
1000
1300
1780
2420
3100

M
(Nm)
760
760
820
940
940
1040
1460
1460
1920
2620
3560
820
940
940
1040
1460
1460
1920
2620
3560
4560

Material execution 4B:

Multiply by = 1,536; which is the relationship of E modules between 1.4408 and GG-25.

For local contact details:


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In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice.

(Sterling Fluid Systems BV) 2003

Technical data

Page 3 of 3

Chapter 9

Operating range: (Continuous operation)

Size

DBSA 03216F
DBSA

03220F

DBSA

04016F

DBSA

04016D

DBSA

04020F

DBSA

04020D

DBSA

05016F

DBSA

05016D

DBSA

05020F

DBSA
DBSA

05020Z
05026F

(1/min)

Qopt

Qmin

Qmax

Size

Factor Factor

2900

(m3/h)
20

0,3

1,3

1450

10

0,3

1,3

2900

26

0,3

1,3

1450

13

0,3

1,3

2900

40

0,4

1,2

1450

24

0,4

1,2

2900

40

0,3

1,3

1450

20

0,3

1,3

2900

36

0,4

1,2

1450

18

0,4

1,2

2900

31

0,3

1,3

1450

15

0,3

1,3

2900

75

0,4

1,2

1450

40

0,3

1,3

2900

63

0,3

1,3

1450

30

0,4

1,2

DBSA

DBSA

DBSA

DBSA

DBSA

DBSA

12540D

12550D

15032Z

20032D

20040D

20050D

Qopt

Qmin

Qmax

(m /h)

Factor

Factor

1450

350

0,4

1,2

960

230

0,4

1,2

1450

350

0,3

1,3

960

250

0,4

1,2

1450

340

0,3

1,3

960

220

0,3

1,3

1450

525

0,3

1,3

960

350

0,3

1,3

1450

550

0,3

1,3

960

365

0,3

1,3

1450

600

0,4

1,2

960

450

0,4

1,2

960

935

0,4

1,2

(1/min)

2900

75

0,4

1,2

1450

40

0,3

1,3

2900

90

0,4

1,2

1450

45

0,4

1,2

2900

90

0,4

1,2

1450

45

0,4

1,2

To calculate Qmin and Qmax, the following process will be

2900

90

0,4

1,2

follow:

1450

45

0,4

1,2

DBSA

30040D

DBSA

05026D

DBSA

05032F

1450

90

0,4

1,2

DBSA

05032Z

1450

90

0,4

1,2

Qmin = Qmin Factor x Qoptimun

DBSA

06520F

Qmax = Qmax Factor x Qoptimun

DBSA

06520Z

DBSA

08026F

2900

110

0,4

1,2

1450

70

0,3

1,3

2900

156

0,4

1,2

1450

78

0,4

1,2

2900

200

0,4

1,2

1450

118

0,4

1,2

Pump size: DBSA 04016D (1450 1/min)

2900

240

0,4

1,2

Qmin = 0,3 x 20 = 6 m /h

120

0,4

1,2

Qmax = 1,3 x 20 = 26 m /h

Example:
3

DBSA

08026Z

1450
960

80

0,4

1,2

DBSA

08032F

1450

118

0,4

1,2

DBSA

08032Z

1450

135

0,4

1,2

960

90

0,4

1,2

DBSA

08040Z

1450

135

0,4

1,2

liquids are pumped. If liquids having distinctly dif-

DBSA

DBSA
DBSA

10026F

10026Z
10032F

DBSA

10032D

DBSA

12540F

This operating range is applicable if waterlike

960

90

0,4

1,2

ferent physical properties are handled, it may be

2900

270

0,4

1,2

1450

150

0,3

1,3

necessary to narrow the permissible operating

2900

325

0,3

1,3

1450

162

0,3

1,3

960

108

0,3

1,3

See the specific permormance curve for more

1450

180

0,4

1,2

details.

1450

195

0,4

1,2

960

130

0,4

1,2

1450

350

0,3

1,3

For local contact details:


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range.

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice.

(Sterling Fluid Systems BV) 2003

Annex

Page 1 of 10

Chapter 10

10. Annex
10.1 Connections

Code

For version with

Connections

Grease

Oil

Pressure gauge connection

II

Pressure/vacuum gauge connection

III

Vent

VII

Drain

IX

Drip and leakage connection

Xa

Inlet connection for sealing liquid

External sealing

Xb

Outlet connection for sealing liquid

External sealing

XV

Oil filling

XVI

Oil drain

XVIIa

Oil level sight glass

XVIIb

Constant level oiler connection

XX

Grease nipple

XXIIIa

Flushing liquid connexion for shaft seal

Flushing before packing

XXIIIb

Flushing liquid connexion for wear plate

Flushing of wear plate

XXIIIc

Seal flushing

External sealing

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Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice

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Annex

Page 2 of 10

Chapter 10

Dimensions of connections
Pumps with shaft unit

35

75

90

Standard

Special

Standard

Special

Standard

Special

Standard

Special

type

type

type

type

type

type

type

type

type

type

(4)

hole

VII

65

Special

Without

III

55

Standard
G 1/2

II

45

G 1/2

G 1/2 (5)
G 1/2

(6)

G 1/2

G 1/2

G 1/2

G 1/2

Without

Without

Without

Without

G 1/2

hole
G 1/2
G 1/2

hole
G3/4

(1)

G 1

(2)

G 1/2

hole

G 1/2

hole

G 1 (3)

G 1

(3)

G 1

G 1

IX

G 1/2

G 1/2

G 1/2

G 3/4

G 3/4

Xa

G 1/4

G 1/4

G 1/4

G 3/8

G 3/8

Xb

G 1/4

G 1/4

G 1/4

G 3/8

G 3/8

XV

20

20

20

20

20

XVI

G 1/4

G 1/4

G 1/4

G 1/4

G 1/4

XVIIa

G 3/4

G 3/4

G 3/4

G 3/4

G 1

XVIIb

G 1/4

G 1/4

G 1/4

G 1/4

G 1/4

XX

M6

M6

M6

M6

M6

XXIIIa

G 1/4

G 1/4

G 1/4

G 3/8

G 3/8

XXIIIb

G 1/2

G 1/2

G 1/2

G 1/2

G 1/2

XXIIIc

G 3/8

G 1/2

G 1/2

G 1/2

G 1/2

G 1/2

On request

Code

1) G 3/4 in 06520
2) G 3/4 in 05032, 08026 and 08032
3) G 3/4 in 08040
4) G 1/4 in 03216 and 03220
5) Pumps 03216, 03220 not drilled
6) G 1/4 in 03216 and 03220

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products at any time without prior notice

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Annex

Page 3 of 10

Chapter 10

10.2 Table of Dimensions

Dimensions in mm
Size Bearing
03216
03220
04016
04020
05016
05020
05026

35
35

45
55

06520

45

08032
08040
10026
10032

55

55
65

12550

75

20032
20040
20050

50

40

50

65
75

h1

Foot dimensions
h2

80

65

100

80

c1 e1 m1 m2 n1

Shaft end
n2

405

90

410

160

180
200

s1

50

100 70

14

265 212

110

14

140 550 225 280 65

12

125 95 345 280

14

125 500 180 225

320 250

13

12

400 315

14

225 280
250 315

38 80
370

125

125 140

550

225 280

12 110

250 315

670 315 400


150 170 720 355 450

150

670

200 200 200

720

30040

280 400
315 450

100

22 15

31

1)
o

140 200 150

41 10

38 80
48

140

41 10
51.5 14

110

59 16

400 315

14 370 48

51.5 14

500 400

55

59 16

550 450

65 140 69 18

500 400

80 200

125 250

280

22 18 500 55 110 59 16 180 150

550 450

355 500
400 530

48 110 51.5 14

670 280 355 80 18 15 140 160 120 435 355 18 18 500 55


100

Spa

295
15

550

13 300

320 250

125

310
295 28 60

240 190

130

15 315

420 160 180

100 405 160


200
65 112
180
500
125
200 250

50

425 132 160

80

65

12540
15032

32

35

05032
08026

Pumps dimensions
DN2 DN1 a

24 15

600 500

300

65 140 69 18

Dimensions on request

DN1/DN2
D
k

32
140
100

d1 x number

d2 x number

18 x 4

Dimensions conections flanges according to DIN 2501 PN - 10


40
50
65
80
100
125
150
165
185
200
220
250
110
125
145
160
180
210
M 16 x 4
M 16 x 4
M 16 x 8
M 16 x 8
M 16 x 8
*) 18 x 4
*) 18 x 4
18 x 4
18 x 4
18 x 4
18 x 8
18 x 8
18 x 8

150
285
240

200
340
295

M 20 x 8

M 20 x 8

22 x 8

22 x 8

*) Only for sizes 32


1) Piece with flanges (on request)

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Annex

Page 4 of 10

Chapter 10

10.3 Parts list


When ordering spare parts give the following information: position number, the complete pump designation
and the serial number, which can be found on the nameplate fixed to the pump.
Pos. Nr. Designation

Pos. Nr. Designation

10.20

Volute casing

50.50

Washer

13.50*

Wear plate

50.70*

Thrower

16.10

Casing cover

52.30*

Shaft sleeve

18.30

Foot

52.40*

Shaft sleeve

21.10*

Shaft

55.40

Washer

23.00*

Impeller

63.60

Conical lubricating nipple

26.00*

Impeller screw

64.20

Oil level sight glass

32.10*

Deep groove ball bearing

67.20

Plug

32.11*

Angular contact ball bearing

90.10

Hexagonal screw

32.20*

Roller bearing

90.11

Hexagonal screw

33.00

Bearing housing

90.12

Hexagonal screw

36.00

Bearing cover

90.13

Hexagonal screw

36.01

Bearing cover

90.20

Stud

40.00*

Flat gasket

90.21

Stud

40.02*

Flat gasket

90.30

Screw plug

41.10*

Flat gasket

90.31

Screw plug

41.11*

Flat gasket

90.32

Screw plug

41.12*

Flat gasket

90.33

Screw plug

41.13*

Flat gasket

90.34

Screw plug

41.14*

Flat gasket

90.35

Screw plug

41.15*

Flat gasket

90.36

Screw plug

41.16*

Flat gasket

90.37

Screw plug

41.17*

Flat gasket

91.40

Allen screw

41.19*

Flat gasket

91.41

Allen screw

42.10*

Retainer

92.00

Hexagonal nut

42.11*

Retainer

92.01

Hexagonal nut

43.30*

Mechanical seal

92.10

Grooved nut

45.20

Stuffing box gland

93.00*

Helicoil insert

45.70*

Follower ring

93.01*

Lockwasher

45.80*

Lantern ring

93.02*

Washer

46.10*

Packing ring

93.20*

Lockwasher

94.00*

Key

94.01*

Key

*recommended spare parts

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Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice

(Sterling Fluid Systems BV) 2003

Annex

Page 5 of 10

Chapter 10

Pump with bearing housing type C (Oil lubrication), shaft seal execution BKS/BKW with mechanical
seal. For grease lubrication please, see pages 2 and 3

23.00

10.20

90.35

16.10 41.15 90.13 41.11 42.11

91.41

40.00 90.20

94.01

26.00 90.30

52.30

41.10 93.00

92.00

21.10

36.01

90.31

40.02

43.30

50.70

50.50

67.20

90.36

64.20 90.37

32.20 41.16

41.17

90.11

90.33
16.10

41.13

46.10

45.70

45.20

93.20

40.02

32.10

36.00

33.00

42.10

18.30 93.02 90.10

90.33
16.10

41.13

46.10

90.21
52.40

45.80 55.40

94.00

90.12

45.70

90.21

92.01

52.40

45.80

55.40

92.01

Code 052

Code 051

For explanation of the different executions, please see chapter 2.


For local contact details:
www.sterlingfluidsystems.com

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products at any time without prior notice

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45.20

Annex

Page 6 of 10

Chapter 10

Pump with bearing housing type S (Grease lubrication), shaft seal execution BKS/BKW with
mechanical seal. For oil lubrication please, see page 1

90.32
90.31
10.20 41.14 13.5041.11 16.10 41.12
91.40

91.41 23.0090.30

90.13 41.15 42.11 40.02

40.00 90.20

41.10 93.00 94.01

26.00

36.01

90.35

52.30

21.10

41.13

90.33
16.10

41.13

45.70

46.10

90.33
46.10

45.70

45.20

16.10

41.13

46.10

45.80 55.40

92.01

45.70

45.20

52.40

45.80

55.40

92.01

Code 052

Code 051

90.21

90.21

90.21
52.40

42.10

90.1293.01 94.00
32.20 33.00
18.30 93.02
90.10
90.11

41.19
16.10

36.00

63.60

92.10

90.34
90.33

40.02

50.70

43.30

92.00

32.11

52.40

45.80

55.40

92.01

Code 071

For explanation of the different executions, please see chapter 2.


For local contact details:
www.sterlingfluidsystems.com

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice

(Sterling Fluid Systems BV) 2003

45.20

Annex

Page 7 of 10

Chapter 10

Pump with bearing housing type B (Grease lubrication), shaft seal execution BKS/BKW with
mechanical seal. For oil lubrication please, see page 1

91.40
10.20 41.14

90.31
13.50 41.11

26.00 90.30
91.41

41.10

90.32
16.10 41.12

93.00
23.00

90.35
90.13 41.15

52.30

94.01

42.11 63.60

90.20
40.00

92.00

36.01

32.10

32.20 21.10

40.02

50.70
43.30

36.00
40.02

41.19
16.10

41.13

33.00

93.02

94.00

90.33
16.10

41.13

45.70

46.10

90.33
46.10

45.70

45.20

16.10

41.13

46.10

45.80 55.40

92.01

45.70

45.20

52.40

45.80

55.40

92.01

Code 052

Code 051

90.21

90.21

90.21
52.40

42.10

18.30 90.12 90.10


90.11

90.34
90.33

93.20

50.50

52.40

45.80

55.40

92.01

Code 071

For explanation of the different executions, please see chapter 2.

For local contact details:


www.sterlingfluidsystems.com

In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice

(Sterling Fluid Systems BV) 2003

45.20

Annex

Page 8 of 10

Chapter 10

Max. permissible temperature of pumping liquid

The highest temperatures usually occur on the pump casing surface, on the bearing housing in the area of
the anti-friction bearings and on the casing cover near the mechanical seal.
The temperature occurring on the pump casing is almost the same as that of the liquid handled.
A maximum temperature of 80 C, if oil-lubricated, can be expected in the area of the anti-friction bearings,
provided the requirements for appropriate pump operation are met and regular maintenance on the bearings
is provided. Insulation of the bearing housing is not permissible.
If the pump is adequately filled with liquid, the temperature of the liquid handled in the shaft seal area should
not increase by more than 20 K for dead end operation with a single-acting mechanical seal. With doubleacting mechanical seals the temperature rise depends largely on the flushing or sealing liquid (if there is any
doubt, please contact Sterling Fluid Systems).
Thus, the following theoretical maximum temperature of the liquid handled as a function of the temperature
class according to EN 13463-1 is obtained. The maximum operating temperature of the pump (see chapter
9) and the operating limits of the mechanical seal must be observed (if there is any doubt, please contact
Sterling Fluid Systems or the mechanical seal manufacturer).

Temperature classes

Permissible

Max. permissible fluid

as per EN 13463-1:

surface

temperature for compliance

temperature
T5

with temperature class

100 C

80 C

T4

135 C

T3

200 C

Temperature limit of pump

115 C

T2

300 C

Temperature limit of pump

T1

450 C

Temperature limit of pump

Make sure that the pump is always started up with the suction-side shut-off valve fully open and the
discharge-side shut-off valve slightly open. However, the pump can also be started up against a closed
swing check valve. Only after the pump has reached full rotational speed shall the discharge-side shut-off
valve be adjusted to comply with the duty point.
Safety note:

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Annex

Page 9 of 10

Chapter 10

The permissible operating temperature of the pump in question is indicated in the technical data. If the pump
is to be operated at a higher temperature, the technical data are missing or if the pump is part of a pool of
pumps, the maximum permissible operating temperature must be requested from the pump manufacturer.

Pump operation with closed shut-off valves in the suction and / or discharge pipes is not permitted. In
this case, there is a risk of the pump casing reaching a high surface temperatures after a very short time, due
to a rapid temperature rise in the pumped fluid inside the pump.
Additionally, the resulting rapid pressure build-up inside the pump may cause excessive stresses on the
pump materials and even cause it to burst.
The minimum flows indicated in the pump operating manual refer to water and water-like liquids. Longer
operating periods with these liquids and at the flow rates indicated will not cause an additional increase in
the temperatures on the pump surface. However, if the physical properties of the fluids handled are different
from water, it is essential to check if an additional heat build-up may occur and if the minimum flow rate must
therefore be increased.
The calculation formula below can be used to check if an additional heat build-up may lead to a
dangerous temperature increase at the pump surface.
To = Tf + DJ
DJ = ((g * H) / (c * h))*(1 - h)
c

Specific heat of liquid [J / kg K]

Acceleration due to gravity [m /s]

Pump head [m]

Tf

Temperature of fluid handled [ C]

To

Temperature of casing surface [ C]

h
DJ

Pump efficiency [-]


Temperature difference [ C]

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products at any time without prior notice

(Sterling Fluid Systems BV) 2003

Annex

Page 10 of 10

Chapter 10

COPYRIGHT WARNING
Please read this notice
The material you are viewing in this document is protected
by Copyright and may only be used in accordance with
Copyright, Designs and Patent legislation.
You are not permitted to copy - either in full or in
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holders or their assignees. Any unlawful use of the
material in this document may result in claims for civil
remedies, including an injunction to restrain further use
and a claim for damages; or may result in criminal penalties.

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In the search to improve continuously its products,


Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice

(Sterling Fluid Systems BV) 2003

Sterling Fluid Systems (Spain), S.A.


Vereda de los Zapateros, s/n
28223 Pozuelo de Alarcon (Madrid) Espaa
Phone: 0034 91 7091310, Fax: 0034 91 7159700

Declaration of Conformity
In the sense of the EU Directive 98/37/EC, Appendix II B
Herewith we declare that the pump type:

In the version supplied by us complies with the following relevant regulations:


EU Machine Directive 98/37/EC, Appendix I No. 1
EU Directive 94/9/EC, Group II, category 2, atmosphere G (Ex II 2 G c T1-T5)
And that is destined for installation in a machine / assembly with other machines to form a
single machine and that it may not be commissioned until it has been determined that the
machine in which this pump is to be installed or with which this pump is to be assembled
complies with the clauses of the EU Machine Directive in the version of 98/37/EC and
94/9/EC.
Harmonised standards used, in particular:
EN 809
EN 292 part 1
EN 292 part 2

ISO 2558 Dimensions

EN 1127 - 1
EN 13463 - 1
prEN 13463 - 5

In the actual version.


National technical standards and specifications used, in particular:
UNE-EN 809
UNE-EN 292-1
UNE-EN 292-2

UNE-EN 1127-1
UNE-EN 13463 - 1

Unauthorised alterations of the pump unit and any use not in accordance with valid
regulations and / or intended use result in a loss of validity of this declaration.
Sterling Fluid Systems, (Spain), S.A.
Business Unit Manager

J. A. Cobo
June 10, 2003