Centrifugal pump

Original Operating Manual ALLMARINE MELO series

Version BA-2018.03 en-US ALLWEILER GmbH

ID-No. 550 299 Postfach 1140
160-288/B Allweilerstr. 1
78301 Radolfzell
Germany
Phone: +49 (0) 7732-86-0
Fax: +49 (0) 7732-86-436
E-mail: service@allweiler.de
Internet: http://www.allweiler.com

We reserve the right to make technical changes.

Read carefully before use.
Save for future use.
Table of contents

Table of contents
1 About this document ............................... 5 5.5.3 Inspection for stress-free pipe
connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.1 Target groups ................................. 5
5.6 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2 Other applicable documents ................ 5
5.6.1 Connecting the motor . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . 6 5.6.2 Checking the direction of rotation . . . . . . . . . . . 17
2 Safety ................................................. 7 5.7 Installing the coupling guard . . . . . . . . . . . . . . . . 17
2.1 Intended use .................................. 7 6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 General safety instructions . . . . . . . . . . . . . . . . . . 7 6.1 Putting the pump into service for the first
2.2.1 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2.2 Operator's obligations . . . . . . . . . . . . . . . . . . . . . . . . 7 6.1.1 Identifying the pump type . . . . . . . . . . . . . . . . . . . . 18
2.2.3 Obligations of personnel . . . . . . . . . . . . . . . . . . . . . 8 6.1.2 Lubricating the bearings . . . . . . . . . . . . . . . . . . . . . 18
6.1.3 Filling and bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 Specific hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.1.4 Checking the direction of rotation . . . . . . . . . . . 18
2.3.1 Hazardous pumped liquids . . . . . . . . . . . . . . . . . . 8
6.1.5 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 Layout and function ................................ 9 6.1.6 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.1 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 6.2 Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.1.1 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 6.2.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1.2 Pump type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 6.2.2 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.2 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 6.3 Shutting down the pump . . . . . . . . . . . . . . . . . . . . . 20

3.3 Shaft seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 6.4 Restoring the pump to service . . . . . . . . . . . . . . 20

4 Transport, storage and disposal . . . . . . . . . . . . . . . . . . 13 6.5 Operating the stand-by pump . . . . . . . . . . . . . . . 20

4.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.1.1 Unpacking and inspection upon 7.1 Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1.2 Mounting the load-carrying equipment . . . . . 13
7.2.1 Antifriction bearings . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1.3 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.2.2 Cleaning the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Treatment for storage . . . . . . . . . . . . . . . . . . . . . . . . 14
7.3 Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 7.3.1 Returning the pump to the manufac-
4.4 Removing preservative . . . . . . . . . . . . . . . . . . . . . . 14 turer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.3.2 Preparations for dismounting . . . . . . . . . . . . . . . . 22
4.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.4 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5 Setup and connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 7.4.1 Observe the following during the
5.1 Preparing the setup . . . . . . . . . . . . . . . . . . . . . . . . . . 15 installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1.1 Checking the ambient conditions . . . . . . . . . . . 15 7.4.2 Installing the pump in the system . . . . . . . . . . 23
5.1.2 Preparing the installation site . . . . . . . . . . . . . . . 15 7.5 Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1.3 Preparing the container . . . . . . . . . . . . . . . . . . . . . . 15
5.1.4 Removing preservative . . . . . . . . . . . . . . . . . . . . . . 15 8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.2 Installing the flanged motor . . . . . . . . . . . . . . . . . . 15 9 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5.3 Installation in containers . . . . . . . . . . . . . . . . . . . . . 16 9.1 Auxiliary connections . . . . . . . . . . . . . . . . . . . . . . . . 26

5.4 Planning the pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 9.2 Sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5.4.1 Specifying supports and flange 9.2.1 Part numbers and designations . . . . . . . . . . . . . 26
connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 9.2.2 Sectional drawings of MELO
5.4.2 Specifying nominal diameters . . . . . . . . . . . . . . . 16 200/250/300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.4.3 Optimizing changes in cross-section and 9.2.3 Sectional drawings: MELO 400 . . . . . . . . . . . . . 30
direction (recommended) . . . . . . . . . . . . . . . . . . . . 16 9.3 Technical specifications . . . . . . . . . . . . . . . . . . . . . . 31
5.4.4 Discharging leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 9.3.1 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.4.5 Providing safety and control devices 9.3.2 Sound pressure levels . . . . . . . . . . . . . . . . . . . . . . . 31
(recommended) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 9.3.3 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.5 Connecting the pipes . . . . . . . . . . . . . . . . . . . . . . . . 17 9.3.4 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.5.1 Keeping the piping clean . . . . . . . . . . . . . . . . . . . . 17 9.4 Recommended spare parts for two years
5.5.2 Installing the pressure pipe . . . . . . . . . . . . . . . . . . 17 of continuous operation according to DIN
24296 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2 ALLMARINE MELO series BA-2018.03 en-US 160-288/B – 550 299

 Table of contents

9.5 Declaration of harmlessness . . . . . . . . . . . . . . . . 34

9.6 Declaration of conformity according to EC
machine directives . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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Table of contents

List of figures List of tables

Fig. 1 Type plate (example) ........................ 9 Tab. 1 Target groups and their duties .............. 5
Fig. 2 Pump type code (example) .................. 9 Tab. 2 Other applicable documents and their
purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fig. 3 Layout of MELO 200/250/300, 1-stage . . . . . 10
Tab. 3 Warnings and consequences of disregarding
Fig. 4 Layout of MELO 400 . . . . . . . . . . . . . . . . . . . . . . . . . 11
them . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fig. 5 Load-carrying equipment . . . . . . . . . . . . . . . . . . . . 13
Tab. 4 Symbols and their meaning ................. 6
Fig. 6 Fastening the lifting gear to the pump . . . . . . 13
Tab. 5 Treatment for storage . . . . . . . . . . . . . . . . . . . . . . . . 14
Fig. 7 Fastening screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Tab. 6 Measures to be taken if the pump is shut
Fig. 8 Overview sectional drawing: MELO down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
200/250/300 series . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Tab. 7 Measures depending on the behavior of the
Fig. 9 2-stage version, MELO 200/250 series . . . . . 29 pumped liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fig. 10 Version with intermediate bearing, MELO Tab. 8 Measures to be taken after prolonged
200/250/300 series . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 shutdown periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fig. 11 2-stage version, MELO 300 series . . . . . . . . . . 29 Tab. 9 Measures for return . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fig. 12 Overview sectional drawing: MELO 400 Tab. 10 Fault/number assignment . . . . . . . . . . . . . . . . . . . 24
series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Tab. 11 Troubleshooting list . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Tab. 12 Connection designation abbreviations . . . . . . 26
Tab. 13 Designation of components according to part
numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Tab. 14 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Tab. 15 Sound pressure levels . . . . . . . . . . . . . . . . . . . . . . . 31
Tab. 16 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Tab. 17 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Tab. 18 Recommended spare parts for two years of
continuous operation . . . . . . . . . . . . . . . . . . . . . . . . . 33
Tab. 19 Declaration of harmlessness . . . . . . . . . . . . . . . 34
Tab. 20 Declaration of conformity according to EC
machine directives . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4 ALLMARINE MELO series BA-2018.03 en-US 160-288/B – 550 299

 About this document

1 About this document

This manual
• Is part of the pump
• Applies to the afore-mentioned pump series
• Describes safe and appropriate operation during all oper-
ating phases

1.1 Target groups

Target group Duty
Operating company Keep this manual available at the operation site of the system,
including for later use.
Ensure that personnel read and follow the instructions in this
manual and the other applicable documents, especially all safety
instructions and warnings.
Observe any additional rules and regulations referring to the
system.
Qualified personnel, fitter Read, observe and follow this manual and the other applicable
documents, especially all safety instructions and warnings.
Tab. 1 Target groups and their duties

1.2 Other applicable documents

Document Purpose
Order data sheet Technical specifications, conditions of operation
Setup drawing Setup dimensions, connection dimensions etc.
Technical description Technical specifications, operating limits
Sectional drawing Sectional drawing, part numbers, component designations
Supplier documentation Technical documentation for parts supplied by subcontractors
Spare parts list Ordering spare parts
Declaration of conformity Conformity with standards
Contents of the declaration of conformity (→ 9.6 Declaration of
conformity according to EC machine directives, Page 35).
Tab. 2 Other applicable documents and their purpose

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About this document

1.3 Warnings and symbols

Warning Risk level Consequences of disregard
Immediate acute risk Death, serious bodily harm
DANGER
Potentially acute risk Death, serious bodily harm

Potentially hazardous situation Minor bodily harm

CAUTION
Potentially hazardous situation Material damage
NOTE
Tab. 3 Warnings and consequences of disregarding them

Symbol Meaning
Safety warning sign
Take note of all information highlighted by the safety warning sign
and follow the instructions to avoid injury and death.

Instruction
1. , 2. , ... Multiple-step instructions
 Precondition
→ Cross-reference
Information, advice

Tab. 4 Symbols and their meaning

6 ALLMARINE MELO series BA-2018.03 en-US 160-288/B – 550 299


2 Safety
The manufacturer does not accept any liability for any dam-
age caused by disregarding any sections of the entire doc-
umentation.
2.1 Intended use
• Only use the pump to pump the agreed pumped liquids
(→ order data sheet).
• Adhere to the operating limits and size-dependent mini-
mum flow rates.
• Avoid dry running:
Initial damage, such as destruction of seals and plastic
parts, will occur within only a few seconds.
– Make sure the pump is only operated with, and never
without, pumped liquid.
• Avoid cavitation:
– Do not open the pressure-side fitting beyond the
agreed operating point.
• Avoid overheating:
– Do not operate the pump while the pressure-side fitting
is closed.
– Observe the minimum flow rate (→ order data sheet).
• Avoid damage to the motor:
– Do not open the pressure-side fitting beyond the
agreed operating point.
– Note the maximum permissible number of times the
motor can be switched on per hour (→ manufacturer's
specifications).
• Consult the manufacturer about any other use of the pump.
• When a pump is delivered without a motor, the pump unit
must be completed in accordance with the stipulations of
machine directive 2006/42/EC.
Prevention of obvious misuse (examples)
• Note the operating limits of the pump with regard to temper-
ature, pressure, flow rate and motor speed (→ order data
sheet).
• The power consumed by the pump increases with increas-
ing density of the pumped medium. To avoid overloading
the pump, coupling or motor, stay within the agreed density
(→ order data sheet).
Lower densities are allowed. Adapt the auxiliary systems
accordingly.
• Do not pump liquids containing solids or non-lubricating
liquids.
160-288/B – 550 299
Safety
• Pumps used with water as the pumped liquid must not be
used for foodstuffs or drinking water. Use of the pump for
foodstuffs or drinking water must be specified in the order
data sheet.
• Only select the setup type according to this operating man-
ual. For example, the following are not allowed:
– Hanging base plate pumps in the pipe
– Overhead installation
– Installation in the immediate vicinity of extreme heat or
cold sources
– Installation too close to the wall
2.2 General safety instructions
Take note of the following regulations before carrying out
any work.
2.2.1 Product safety
The pump has been constructed according to the latest tech-
nology and recognized technical safety rules. Nevertheless,
operation of the pump can still put the life and health of the
user or third parties at risk or damage the pump or other prop-
erty.
• Only operate the pump if it is in perfect technical condition
and only use it as intended, staying aware of safety and
risks, and in adherence to the instructions in this manual.
• Keep this manual and all other applicable documents com-
plete, legible and accessible to personnel at all times.
• Refrain from any procedures and actions that would pose
a risk to personnel or third parties.
• In the event of any safety-relevant faults, shut down the
pump immediately and have the fault corrected by appro-
priate personnel.
• In addition to the entire documentation for the product,
comply with statutory or other safety and accident-preven-
tion regulations and the applicable standards and guide-
lines in the country where the pump is operated.
2.2.2 Operator's obligations
Safety-conscious operation
• Only operate the pump if it is in perfect technical condition
and only use it as intended, staying aware of safety and
risks, and in adherence to the instructions in this manual.
• Ensure that the following safety aspects are observed and
monitored:
– Adherence to intended use
– Statutory or other safety and accident-prevention reg-
ulations
– Safety regulations governing the handling of haz-
ardous substances
– Applicable standards and guidelines in the country
where the pump is operated
• Make personal protective equipment available.
BA-2018.03 en-US ALLMARINE MELO series 7
Safety

Qualified personnel 2.2.3 Obligations of personnel

• Make sure all personnel tasked with work on the pump • All directions given on the pump must be followed (and kept
have read and understood this manual and all other appli- legible), e.g. the arrow indicating the direction of rotation
cable documents, especially the safety, maintenance and and the markings for fluid connections.
repair information, before they start any work.
• Pump, coupling guard and components:
• Organize responsibilities, areas of competence and the – Do not step on them or use as a climbing aid
supervision of personnel. – Do not use them to support boards, ramps or beams
– Do not use them as a fixing point for winches or sup-
• Ensure that all work is carried out by specialist technicians
ports
only:
– Do not use them for storing paper or similar materials
– Fitting, repair and maintenance work
– Do not use hot pump or motor components as a heating
– Work on the electrical system
point
• Make sure trainee personnel only work on the pump under – Do not de-ice using gas burners or similar tools
supervision of specialist technicians.
• Do not remove the safety guarding for hot, cold or moving
parts during operation.
Safety equipment
• Use personal protective equipment whenever necessary.
• Provide the following safety equipment and verify its func-
tionality: • Only carry out work on the pump while it is not running.
– For hot, cold and moving parts: safety guarding pro-
• Before carrying out any fitting or maintenance work, isolate
vided by the customer for the pump
and safeguard the motor from its supply voltage.
– For potential build up of electrostatic charge: ensure
appropriate grounding. • Reinstall the safety equipment at the pump as required by
regulations after any work on the pump.
Warranty
• Obtain the manufacturer's approval prior to carrying out
any modifications, repairs or alterations during the warranty 2.3 Specific hazards
period.
2.3.1 Hazardous pumped liquids
• Only use genuine parts or parts that have been approved
by the manufacturer. • Follow the safety regulations for handling hazardous sub-
stances when handling hazardous
Drive system (e.g. hot, flammable, poisonous or potentially harmful)
pumped liquids.
For pumps delivered without a drive system, comply with the
following requirements for the drive system: • Use personal protective equipment when carrying out any
work on the pump.
• When using three-phase asynchronous motors, observe
IEC 60034-30-1.
• Power of the drive according to EN ISO 5199 is recom-
mended (EN ISO 5199 also applicable for drives of screw
pumps).
• When using combustion engines, consult Allweiler.
• For pumps with stub shaft, connect drive system and pump
directly with stub shaft.
• Use elastic coupling according to DIN 740-2.
• Use coupling guard with the following requirements:
– Fastening elements must be connected to the pump
unit in undetachable design (cannot get lost).
– Safety distances against the reaching of hazardous
areas according to EN ISO 13857 must be complied
with.

8 ALLMARINE MELO series BA-2018.03 en-US 160-288/B – 550 299

 Layout and function

3 Layout and function

3.1 Labels 3.1.2 Pump type code

3.1.1 Type plate

ALLMARINE MELO 200 - 1 / 01 S 1500 W201

1
2
1 3
2 4
5
13 3 6
4 7
12
11 5
Fig. 2 Pump type code (example)
10 6
1 MELO series
2 Outlet flange DN [mm]
9 8 7 3 Number of stages
4 Hydraulic number
Fig. 1 Type plate (example) 5 Pump version
6 Immersion depth (from bottom edge of sole plate
1 Pump number
to bottom edge of suction casing)
2 Pump type code
7 Material key
3 Year of manufacture
4 Impeller diameter
5 Minimal efficiency index (MEI)
6 Eta efficiency (—.- = not specified)
7 Pump NPSH value
8 Density
9 Kinematic viscosity
10 Motor speed
11 Power consumption
12 Differential head
13 Flow rate

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Layout and function

3.2 Layout

6
8
5
9

10

11

Fig. 3 Layout of MELO 200/250/300, 1-stage

1 Suction casing 1 5 Bell housing 9 Fixed bearing
2 Impeller (first stage) 6 Terminal box 10 Drainage elbow
3 Guide vane housing (first stage) 7 Motor 11 Sole plate
4 Ascending pipe 8 Coupling

10 ALLMARINE MELO series BA-2018.03 en-US 160-288/B – 550 299

 Layout and function

10

11

12

13
14

15
4

3
16
2

Fig. 4 Layout of MELO 400

1 Suction casing 1 7 Ascending pipe 13 Drainage casing
2 Impeller volute casing 8 Drainage elbow 14 Sole plate
3 Volute casing 9 Bell housing 15 Compensator
4 Suction casing 2 10 Motor 16 Connection piece
5 Impeller guide vane housing 11 Coupling
6 Guide vane housing 12 Fixed bearing

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Layout and function

3.3 Shaft seals

These pump versions do not contain shaft seals.
Versions with oil-lubricated antifriction bearing on the drive
side have a radial shaft seal ring to seal the bearing.
Shaft seal rings have functional leaks.

12 ALLMARINE MELO series BA-2018.03 en-US 160-288/B – 550 299

 Transport, storage and disposal

4 Transport, storage and disposal

4.1 Transport 4.1.3 Lifting

Weight specifications (→ documents for the particular

DANGER
order).
Death or crushing of limbs caused by falling or overturning
4.1.1 Unpacking and inspection upon delivery loads!
1. Unpack the pump/pump unit upon delivery and inspect it Use lifting gear appropriate for the total weight to be trans-
for transport damage. ported.
2. Report any transport damage to the manufacturer immedi- Fasten the lifting gear as shown in the following illustra-
ately. tions.
3. Dispose of packaging material according to local regula- Never fasten the lifting gear onto the motor eyebolt (unless
tions. used as a safety device against tipping over for units with
a high center of gravity).
4.1.2 Mounting the load-carrying equipment Do not stand under suspended loads.
1. When transporting using a beam, use the following load-
carrying equipment:
– Use an eye bolt and screw in completely NOTE
– Always transport the pump/pump assembly vertically Material damage when setting down the pump
vertically to avoid side pull (→ Figure Load-carrying Do not set the pump down on the suction casing.
equipment, Page 13).
2. When transporting without a beam, use the following load- Set down the pump properly.
carrying equipment:
– Use rotating safety eye bolt (for example, swiveling ring
bolt) and screw it in completely.
– Before transport, align the rotating safety eye bolt cor-
rectly to avoid side pull.
3. Observe the load bearing capacity of the load-carrying
equipment for axial pull.
4. Ensure that the load-carrying equipment is undamaged
and free of corrosion.

1 2
Fig. 5 Load-carrying equipment
1 Correct alignment without side pull
2 Incorrect alignment with side pull

Fig. 6 Fastening the lifting gear to the pump

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Transport, storage and disposal

4.2 Treatment for storage 4.4 Removing preservative

Not necessary for stainless materials. Only necessary for pumps which have been treated for
Contact the manufacturer for recommendations regarding storage in the event of incompatibility with the pumped liq-
preservatives. uid.

NOTE
Material damage due to inappropriate treatment for stor-
age!
Treat the pump properly, inside and outside, for storage.
1. Preserving pump (observe the processing specifications of
the manufacturers)
WARNING
Risk of poisoning by preservatives and cleaning agents in
the foodstuffs and drinking water sector!
Only use cleaning agents which are compatible with the
pumped liquid (→ 9.3.4 Cleaning agents, Page 32).
Completely remove all preservative.

Duration Measures NOTE

[months]
High water pressure or spray water can damage bearings!
Up to 6 All bare metal parts should be treated, Do not clean bearing areas with a water or steam jet.
inside and outside.
6 – 12 All bare metal parts should be treated,
inside and outside. NOTE
Shrink-wrap the pump in plastic film. Damage to seals by using the wrong cleaning agents!
12 – 24 All bare metal parts should be treated, Ensure the cleaning agent does not corrode the seals.
inside and outside.
1. Choose the cleaning agent according to the application.
Shrink-wrap the pump in plastic film.
(→ 9.3.4 Cleaning agents, Page 32).
Use VCI anticorrosive.
2. Dispose of preservatives according to local regulations.
Tab. 5 Treatment for storage 3. For storage times in excess of 6 months:
– Check all elastomer parts (e.g. O-rings, shaft seals) for
2. Every 6 months: proper elasticity and replace them if necessary.
– Renew the preservative if necessary.

4.5 Disposal
4.3 Storage
Plastic parts can be contaminated by poisonous or radioac-
tive pumped liquids to such an extent that cleaning will be
NOTE insufficient.
Material damage due to inappropriate storage!
Treat and store the pump properly.
WARNING
1. Seal all openings with blind flanges, blind plugs or plastic
Risk of poisoning and environmental damage by the
covers.
pumped liquid or oil!
2. Make sure the storage room meets the following condi-
Use personal protective equipment when carrying out any
tions:
work on the pump.
– Dry
– Dust-free Prior to the disposal of the pump:
– Free from draughts – Collect and dispose of any escaping pumped liquid or
– No corrosive gases oil in accordance with local regulations.
– Frost-free – Neutralize residues of pumped liquid in the pump.
– Vibration-free – Remove the preservative (→ 4.4 Removing preserva-
tive, Page 14).
3. Turn the shaft once a month.
Remove the plastic parts and dispose of them in accor-
4. Make sure the shaft and bearing change their rotational
dance with local regulations.
position in the process.
Dispose of the pump in accordance with local regulations.

14 ALLMARINE MELO series BA-2018.03 en-US 160-288/B – 550 299

 Setup and connection

5 Setup and connection

NOTE 5.2 Installing the flanged motor
Material damage due to distortion or passage of electrical
current in the bearing! NOTE
Do not make any structural modifications to the pump unit
or pump casing. Material damage caused by knocks and bumps!
Do not carry out any welding work on the pump unit or Do not knock or hit any components of the pump.
pump casing. Keep the coupling halves properly aligned when slipping
them on.

NOTE 1. Smear a very thin coat of molybdenum disulfide (e.g.

Molykote) on the shaft ends of the pump and motor.
Material damage caused by dirt!
2. Insert shaft keys.
Do not remove the transport seals until immediately before
3. Without a mounting rig: remove the coupling units and
setting up the pump.
warm both coupling halves up to approx. 100 °C.
Do not remove any covers or transport and sealing covers
4. Slide on the pump-side and motor-side coupling halves
until immediately before connecting the pipes to the pump.
until the shaft ends are flush with the coupling hub.
5. Install the flanged motor:
5.1 Preparing the setup – Place motor on bell housing.
– Screw in the motor bolts and tighten them.
5.1.1 Checking the ambient conditions – Check the prescribed distance between the coupling
Make sure the required ambient conditions are fulfilled halves and adjust it if necessary (→ assembly instruc-
(→ 9.3.1 Ambient conditions, Page 31). tions for the coupling).
6. Tighten the grub screws on both coupling halves.
5.1.2 Preparing the installation site 7. Insert coupling units if necessary.
Ensure the installation site meets the following conditions: 8. Install the coupling guard.
– Sufficient space for the installation/removal of the pipes
and for maintenance and repair work, especially for the
removal and installation of the pump and the motor
– Pump not exposed to external vibrations (damage to
bearings)
– Frost protection

5.1.3 Preparing the container

1. Make sure the container is deep enough (→ setup draw-
ing).
2. Make sure the support surface for the pump fulfills the fol-
lowing conditions:
– Level
– Clean (no oil, dust or other impurities)
– Capable of bearing the weight of the pump unit and all
operating forces
– Stability of the pump ensured

5.1.4 Removing preservative

Remove the preservative (→ 4.4 Removing preservative,
Page 14).

160-288/B – 550 299 BA-2018.03 en-US ALLMARINE MELO series 15

Setup and connection

5.3 Installation in containers 5.4 Planning the pipes

If necessary, insert an appropriate seal between the sole 5.4.1 Specifying supports and flange connections
plate and the cover of the container.
1. Calculate the pipe forces, taking every possible operating
condition into account:
– Cold/warm
NOTE – Empty/full
– Unpressurized/pressurized
Material damage when setting down the pump – Positional changes of the flanges
Do not set the pump down on the suction casing. 2. Ensure the pipe supports have permanent low-friction
properties and do not seize up due to corrosion.

5.4.2 Specifying nominal diameters

1 Keep the flow resistance in the pipes as low as possible.

1. Where possible, make sure the nominal suction pipe diam-

eter is ≥ as possible to the nominal suction flange diameter.
– Recommended flow rate speed < 1 m/s
2. Make sure the nominal pressure pipe diameter is ≥ as pos-
sible to the nominal pressure flange diameter.
– Recommended flow rate speed < 3 m/s

5.4.3 Optimizing changes in cross-section and

direction (recommended)
1. Avoid radii of curvature of less than 1.5 times the nominal
pipe diameter.
2. Avoid abrupt changes of cross-section along the piping.

Fig. 7 Fastening screw 5.4.4 Discharging leaks

1. Insert the fastening screw (1) under the pressure flange
into the sole plate.
2. Raise the pump unit and place it slowly on the tank weld-
ing flange together with the sole plate (→ 4.1 Transport,
Page 13).
3. Tighten the fastening screw under the pressure flange a
little at a time until the pump unit is in full contact.
4. Insert and tighten the remaining fastening screws.
WARNING
Risk of injury and poisoning due to hazardous pumped
liquids!
Safely collect any leaking pumped liquid, then discharge
and dispose of it in accordance with environmental regula-
tions.
1. Provide equipment for collecting and discharging leaking
liquids.
2. Ensure the free discharge of leaking liquids.

16 ALLMARINE MELO series BA-2018.03 en-US 160-288/B – 550 299


5.4.5 Providing safety and control devices
(recommended)
Avoid reverse running
If the pump is not equipped with a check valve, apply a
non-return valve between the pressure flange and stop
valve to make sure the medium does not flow back after
switching off the pump.
Make provisions for isolating and shutting off the pipes
For maintenance and repair work.
Provide shut-off devices in the pressure pipe.
Allow measurements of the operating conditions
Pressure measurements at the control connection
(optional) on the pump do not supply the right pumping
pressure. The control connection is only used for function
control (pumping).
1. Provide manometers for pressure measurements in the
pressure pipe of the system.
2. Provide load monitors (overload and underload) on the
motor side.
5.5 Connecting the pipes
5.5.1 Keeping the piping clean
NOTE
Material damage due to impurities in the pump!
Make sure no impurities can enter the pump.
1. Clean all piping parts and fittings prior to assembly.
2. Ensure no flange seals protrude inwards.
3. Remove any blind flanges, plugs, protective foils and/or
protective paint from the flanges.
5.5.2 Installing the pressure pipe
1. Remove the transport and sealing covers from the pump.
2. Install the pressure pipe.
3. Ensure no seals protrude inwards.
160-288/B – 550 299
Setup and connection
5.5.3 Inspection for stress-free pipe connections
Piping installed and cooled down
NOTE
Material damage due to distorted pump casing
Ensure that all pipes are stress relieved when connected
to the pump.
1. Disconnect the pipe connecting flanges from the pump.
2. Check whether the pipes can be moved freely in all direc-
tions within the expected range of expansion:
– Nominal diameter < 150 mm: by hand
– Nominal diameter > 150 mm: with a small lever
3. Make sure the flange surfaces are parallel.
4. Reconnect the pipe connecting flanges to the pump.
5.6 Electrical connection
DANGER
Risk of death due to electric shock!
Have all electrical work carried out by qualified electricians
only.
DANGER
Risk of death due to rotating parts!
Before carrying out any fitting or maintenance work, isolate
and safeguard the motor from its supply voltage.
5.6.1 Connecting the motor
Follow the instructions of the motor manufacturer.
1. Connect the motor according to the connection diagram.
2. Make sure no danger arises due to electric power.
3. Install an EMERGENCY STOP switch.
5.6.2 Checking the direction of rotation
Only possible when putting the pump into service
(→ 6.1 Putting the pump into service for the first time,
Page 18).
5.7 Installing the coupling guard
Flanged drive
1. If available ,install the coupling guard (two plates) on the
bell housing.
BA-2018.03 en-US ALLMARINE MELO series 17
Operation

6 Operation

6.1 Putting the pump into service 6.1.5 Switching on

for the first time Pump set up and connected properly
Motor set up and connected properly
6.1.1 Identifying the pump type
All connections stress-free and sealed
Identify the pump type (→ order data sheet). All safety equipment installed and tested for functionality
The pump type varies e.g. with regard to the bearing lubri- Pump filled and bled
cation. Container filled up to minimum level

6.1.2 Lubricating the bearings

The antifriction bearings are ready for operation upon deliv-
ery.
6.1.3 Filling and bleeding
The pump is filled automatically after the minimum filling
level is reached. This process can take several minutes,
depending on the viscosity of the pumped liquid.
DANGER
Risk of injury due to running pump!
Do not touch the running pump.
Ensure that the coupling guard is attached.
Do not carry out any work on the running pump.
Allow the pump to cool down completely before starting any
work.

WARNING DANGER
Risk of injury and poisoning due to hazardous pumped Risk of injury and poisoning due to pumped liquid spray-
liquids! ing out!
Safely collect any leaking pumped liquid and dispose of it Use personal protective equipment when carrying out any
in accordance with environmental rules and requirements. work on the pump.

NOTE NOTE
Material damage caused by dry running! Material damage caused by dry running!
Observe the minimum filling level (→ setup drawing). Make sure the pump is filled properly.

1. Open the pressure-side fitting.

2. Verify that no pipe connections are leaking.
6.1.4 Checking the direction of rotation
DANGER
Risk of death due to rotating parts!
Use personal protective equipment when carrying out any
work on the pump.
Keep an adequate distance to rotating parts.
1. Switch the motor on and immediately off again.
2. Check whether the motor's sense of rotation corre-
sponds to the rotation indicator arrow on the drainage
elbow/drainage casing.
3. If the direction of rotation is different: swap two phases
(→ 5.6.1 Connecting the motor, Page 17).
NOTE
Material damage caused by overheating!
Do not operate the pump for long periods with the pressure-
side fitting closed.
Observe the minimum flow rate (→ order data sheet).
1. Close the pressure-side fitting.
2. Switch on the motor and check it for smooth running.
3. Once the motor has reached its nominal speed, open
the pressure-side fitting slowly until the operating point is
reached.
4. Make sure any temperature changes at pumps with hot
pumped liquids are below 5 K/min.
5. After the initial stress due to the pressure and operating
temperature, check that the pump is not leaking.

18 ALLMARINE MELO series BA-2018.03 en-US 160-288/B – 550 299

 Operation

6.1.6 Switching off 6.2 Operating

WARNING 6.2.1 Switching on

Pump initially put into service properly
Risk of injury due to hot pump parts!
Pump filled and bled
Use personal protective equipment when carrying out any
Container filled up to minimum level
work on the pump.

1. Close the pressure-side fitting (recommended).

2. Switch off the motor.
3. Check all connecting bolts and tighten them if necessary.
DANGER
Risk of injury due to running pump!
Do not touch the running pump.
Ensure that the coupling guard is attached.
Do not carry out any work on the running pump.
Allow the pump to cool down completely before starting any
work.

DANGER
Risk of injury and poisoning due to pumped liquid spray-
ing out!
Use personal protective equipment when carrying out any
work on the pump.

NOTE
Material damage caused by dry running!
Make sure the pump is filled properly.

NOTE
Material damage caused by overheating!
Do not operate the pump for long periods with the pressure-
side fitting closed.
Observe the minimum flow rate (→ order data sheet).

1. Close the pressure-side fitting.

2. Switch on the motor and check it for smooth running.
3. Once the motor has reached its nominal speed, open
the pressure-side fitting slowly until the operating point is
reached.
4. Make sure any temperature changes at pumps with hot
pumped liquids are below 5 K/min.

6.2.2 Switching off

1. Close the pressure-side fitting (recommended).
2. Switch off the motor.

160-288/B – 550 299 BA-2018.03 en-US ALLMARINE MELO series 19

Operation

6.3 Shutting down the pump 6.4 Restoring the pump to service
1. If the pump is shut down for over 1 year, take the following
WARNING measures before restoring it to service:
Risk of injury and poisoning due to hazardous pumped Shutdown period Action
liquids!
Safely collect any leaking pumped liquid and dispose of it > 1 year With version with antifriction
in accordance with environmental rules and requirements. bearings which are able to
be relubricated: relubricate.
Take the following measures whenever the pump is shut > 2 years Replace elastomer seals
down: (O-rings, shaft sealing rings).
Replace antifriction bearings.
Pump is Action
Tab. 8 Measures to be taken after prolonged
...shut down Take measures accord- shutdown periods
for a prolonged ing to the pumped liq-
period uid (→ Table 7 Measures 2. Carry out all steps as for the initial start-up (→ 6.1 Putting
depending on the behavior of the pump into service for the first time, Page 18).
the pumped liquid, Page 20).
...emptied Close the pressure-side fitting.
6.5 Operating the stand-by pump
...dismounted Isolate the motor from its power
supply and secure it against Stand-by pump filled and bled
unauthorized switch-on.
...put into Follow the storage instructions Operate the stand-by pump at least once a week.
storage (→ 4.3 Storage, Page 14).
Tab. 6 Measures to be taken if the pump is shut down 1. Open the pressure-side fitting to the extent that the
stand-by pump reaches its operating temperature and is
Behavior of the Duration of shutdown (depending heated evenly.
pumped liquid on process)
2. If a stand-by pump is to be used, put it into service
Short Long (→ 6.1.5 Switching on, Page 18).
Solids Flush the Flush the
sedimenting pump. pump.
Solidifying/ Heat up or Empty the
freezing, empty the pump and
non-corrosive pump and containers.
containers.
Solidifying/ Heat up or Empty the
freezing, empty the pump and
corrosive pump and containers.
containers. Treat the
pump and
containers
with preser-
vative.
Remains liquid, – –
non-corrosive
Remains liquid, – Empty the
corrosive pump and
containers.
Treat the
pump and
containers
with preser-
vative.
Tab. 7 Measures depending on the behavior
of the pumped liquid

20 ALLMARINE MELO series BA-2018.03 en-US 160-288/B – 550 299


7 Maintenance
Trained service technicians are available for fitting and
repair work. Present a pumped medium certificate (DIN
safety data sheet or document of compliance) when
requesting service.
7.1 Inspections
The inspection intervals depend on the operational strain
on the pump.
DANGER
Risk of injury due to running pump!
Do not touch the running pump.
Do not carry out any work on the running pump.
WARNING
Risk of injury and poisoning due to hazardous pumped
liquids!
Use personal protective equipment when carrying out any
work on the pump.
1. Check at appropriate intervals:
– Adherence to the minimum flow rate
– Filling level of the container
– Temperature of antifriction bearings < 100 °C
– Normal operating conditions unchanged
– Condition of the coupling units
2. For trouble-free operation, always ensure the following:
– No dry running
– No leaks
– No cavitation
– No unusual running noises or vibrations
– No excessive leakage at the bearing sealing
– Put the installed stand-by pump into service once a
week
160-288/B – 550 299
Maintenance
7.2 Maintenance
Service life of the antifriction bearings for operation within
the permissible operating range: at least 25,000 h of con-
tinuous operation.
Intermittent operation, high temperatures, low viscosities
and aggressive ambient and process conditions reduce the
service life of antifriction bearings.
DANGER
Risk of injury due to running pump!
Do not touch the running pump.
Do not carry out any work on the running pump.
Before carrying out any fitting or maintenance work, isolate
and safeguard the motor from its supply voltage.
DANGER
Risk of death due to electric shock!
Have all electrical work carried out by qualified electricians
only.
WARNING
Risk of injury and poisoning due to hazardous or hot
pumped liquids!
Use personal protective equipment when carrying out any
work on the pump.
Allow the pump to cool down before commencing any work.
Make sure the pump is depressurized.
Empty the pump, safely collect the pumped liquid and dis-
pose of it in accordance with environmental regulations.
7.2.1 Antifriction bearings
As a precautionary measure, replace antifriction bearings
every 2 years (recommended).
7.2.2 Cleaning the pump
NOTE
High water pressure or spray water can damage bearings!
Do not clean bearing areas with a water or steam jet.
Clean large-scale grime from the pump.
BA-2018.03 en-US ALLMARINE MELO series 21
Maintenance

7.3 Dismounting 7.3.1 Returning the pump to the manufacturer

Pump unpressurized
DANGER Pump completely empty
Electrical connections disconnected and motor secured
Risk of injury due to running pump! against switch-on
Do not touch the running pump. Pump cooled down
Do not carry out any work on the running pump. Manometer lines, manometer and fixtures dismounted
Before carrying out any fitting or maintenance work, isolate Enclose a truthfully (fully) completed document of compli-
and safeguard the motor from its supply voltage. ance when returning pumps or individual parts to the man-
ufacturer (→ 9.5 Declaration of harmlessness, Page 34).
DANGER Repairs Measure for return
Risk of death due to electric shock! ...at the customer's Return the defective
Have all electrical work carried out by qualified electricians premises component to the
only. manufacturer.
...at the Flush the pump and
manufacturer's decontaminate it if it was
WARNING premises used for hazardous pumped
Risk of injury and poisoning due to hazardous or hot liquid.
pumped liquids! Return the complete pump
Use personal protective equipment when carrying out any (not disassembled) to the
work on the pump. manufacturer.
Allow the pump to cool down before commencing any work. ...at the Only in the event of
Make sure the pump is depressurized. manufacturer's hazardous pumped liquid:
premises for flush and decontaminate the
Empty the pump, safely collect the pumped liquid and dis-
warranty repairs pump.
pose of it in accordance with environmental regulations.
Return the complete pump
(not disassembled) to the
WARNING manufacturer.
Tab. 9 Measures for return
Risk of injury due to heavy components!
Pay attention to the component weight. Lift and transport 7.3.2 Preparations for dismounting
heavy components using suitable lifting gear.
Pump unpressurized
Set down components safely and secure them against
overturning or rolling away. Pump completely empty, flushed and decontaminated
Electrical connections disconnected and motor secured
against switch-on
WARNING Pump cooled down
Risk of injury during disassembly! Manometer lines, manometer and fixtures dismounted
Secure the pressure-side gate valve against accidental When dismounting, observe the following:
opening. – Mark the precise orientation and position of all compo-
nents before dismounting them.
Depressurize the blocking pressure system, if available. – Dismount components concentrically without canting.
Wear protective gloves as components can become very – Dismount the pump (→ 9.2 Sectional drawings,
sharp through wear or damage. Page 26).
Remove spring-loaded components carefully (e.g.
mechanical seal, tensioned bearing, valves etc.), as com-
ponents can be ejected by the spring tension.
Observe the manufacturer's specifications (e.g. for the
motor, coupling, mechanical seal, blocking pressure sys-
tem, cardan shaft, drives, belt drive etc.).

NOTE
Material damage when setting down the pump
Do not set the pump down on the suction casing.

22 ALLMARINE MELO series BA-2018.03 en-US 160-288/B – 550 299

 Maintenance

7.4 Installing 7.5 Ordering spare parts

For trouble-free replacement in the event of faults, we rec-
WARNING ommend keeping a supply of spare pumps available on
site.
Risk of injury due to heavy components!
The application guidelines conforming to DIN 24296
Pay attention to the component weight. Lift and transport recommend provisioning for two years of continuous
heavy components using suitable lifting gear. use (→ 9.4 Recommended spare parts for two years of
Set down components safely and secure them against continuous operation according to DIN 24296, Page 33).
overturning or rolling away.
Have the following information ready to hand when order-
ing spare parts (→ type plate):
WARNING – Pump type
– Pump number
Risk of injury during assembly!
– Year of manufacture
Install spring-loaded components carefully (e.g. mechan- – Part number
ical seal, tensioned bearing, valves etc.), as components – Designation
can be ejected by the spring tension. – Quantity
Observe the manufacturer's specifications (e.g. for the
motor, coupling, mechanical seal, blocking pressure sys-
tem, cardan shaft, drives, belt drive etc.).

NOTE
Material damage due to unsuitable components!
Always replace lost or damaged screws with screws of the
same strength (→ 9.3.3 Tightening torques, Page 32).
Only replace seals with seals of the same material.

NOTE
Material damage caused by knocks and bumps!
Do not knock or hit any components of the pump.

7.4.1 Observe the following during the installation

1. Replace worn parts with genuine spare parts.
2. Replace seals, inserting them in such a way that they are
unable to rotate.
3. Adhere to the prescribed tightening torques
4. Clean all parts (→ 9.3.4 Cleaning agents, Page 32). Do
not remove any markings which have been applied.
5. Install the pump (→ sectional drawing).

7.4.2 Installing the pump in the system

Install the pump in the system (→ 5 Setup and connection,
Page 15).

160-288/B – 550 299 BA-2018.03 en-US ALLMARINE MELO series 23

Troubleshooting

8 Troubleshooting
If faults occur which are not specified in the following table or
cannot be traced back to the specified causes, please consult
the manufacturer.
Possible faults are identified by a fault number in the table
below. This number identifies the respective cause and rem-
edy in the troubleshooting list.

Fault Number
Pump not pumping 1
Pumping rate insufficient 2
Pumping rate excessive 3
Pumping pressure insufficient 4
Pumping pressure excessive 5
Pump running roughly 6
Antifriction bearing temperatures too high 7
Bearing sealing leaking 8
Excessive motor power uptake 9
Tab. 10 Fault/number assignment

Fault number Cause Remedy

1 2 3 4 5 6 7 8 9
X – – – – – – – – Pressure pipe closed by fitting Open the fitting.
X – – – – – – – – Transport and sealing cover still in Remove the transport and sealing cover.
place Dismount the pump and inspect it for
dry-running damage.
X – – – – X – – – Tank level is below minimum fill level Observe the minimum filling level (→ setup
drawing).
X X – X – X – – – Pump or suction casing blocked or Clean the pump or suction casing.
encrusted
X X – X – X – – – Air is sucked in Observe the minimum filling level (→ setup
drawing).
Prevent air from entering the pumped
liquid.
X X – X – X – – – Pump running in the wrong direction Swap any two phases at the motor.
X X – X – – – – – Motor speed too low Compare the required motor speed with
the specifications on the pump type plate.
Replace the motor if necessary.
Increase the motor speed if speed control
is available.
X X – X – X – – – Impeller out of balance or blocked Dismount the pump and inspect it for
dry-running damage.
Clean the impeller.
X X – – X X – – – Pressure pipe blocked Clean the pressure pipe.
– X – X – – – – X Viscosity or specific gravity of the Consult the manufacturer.
pumped liquid outside the range
specified for the pump

24 ALLMARINE MELO series BA-2018.03 en-US 160-288/B – 550 299

 Troubleshooting

Fault number Cause Remedy

1 2 3 4 5 6 7 8 9
– X – X – – – – – Geodetic differential head and/or pipe Remove sediments from the pump and/or
flow resistances too high pressure pipe.
Install a larger impeller and consult the
manufacturer.
– X – – X X – – – Pressure-side fitting not opened wide Open the pressure-side fitting.
enough
– X – X – X X – – Pump parts worn Replace the worn pump parts.
– X – X – X – – – Hydraulic parts of the pump dirty, Dismount the pump.
clotted or encrusted Clean the parts.
– X – X – X – – X Motor running on 2 phases Check the fuse and replace it if necessary.
Check the cable connections and
insulation.
– – X X – X – – X Pressure-side fitting opened too wide Throttle down at the pressure-side fitting.
Machine the impeller down. Consult the
manufacturer and adjust the impeller
diameter.
– – X – – X – – X Geodetic differential head, pipe flow Throttle down the flow rate at the
resistances and/or other resistances pressure-side fitting. Observe the
lower than specified minimum flow rate.
Machine the impeller down. Consult the
manufacturer and adjust the impeller
diameter.
– – X – X – – – – Viscosity lower than expected Machine the impeller down. Consult the
manufacturer and adjust the impeller
diameter.
– – X – X X X – X Motor speed too high Compare the required motor speed with
the specifications on the pump type plate.
Replace the motor if necessary.
Reduce the motor speed if speed control
is available.
– – X – X X – – X Impeller diameter too large Throttle down the flow rate at the
pressure-side fitting. Observe the
minimum flow rate.
Machine the impeller down. Consult the
manufacturer and adjust the impeller
diameter.
– – – – – X X – X Antifriction bearing defective Replace the antifriction bearing.
– – – – – X X X X Pump distorted Check the pipe connections and pump
attachment.
– – – – – X – – – Coupling units worn Replace the coupling units.
– – – – – X – – – Flow quantity is below the minimum Increase the flow quantity to the minimum
flow quantity.
– – – – – – X – X Defective antifriction bearing in motor Replace the antifriction bearing
(→ manufacturer's specifications).
– – – – – – X – – Excessive axial load Clean the relief bore in the impeller.
– – – – – – – X – Leakage at bearing cover Tighten the connecting bolts.
– – – – – – – X – Shaft seal ring is defective Replace shaft seal ring.
Tab. 11 Troubleshooting list

160-288/B – 550 299 BA-2018.03 en-US ALLMARINE MELO series 25

Appendix

9 Appendix

9.1 Auxiliary connections Part no. Designation

412.02 O-ring
Abbreviation Connection 412.03 O-ring

G 3/8" Control connection 412.04 O-ring

Tab. 12 Connection designation abbreviations 412.05 O-ring
412.06 O-ring

9.2 Sectional drawings 421.01 Shaft seal ring

504.03 Spacer ring
9.2.1 Part numbers and designations
504.04 Spacer ring
Part no. Designation 506.01 Retaining ring
102.01 Volute casing 509.01 Intermediate ring
106.01 Suction casing 1 524.01 Shaft protection sleeve
106.02 Suction casing 2 529.01 Bearing sleeve
112.01 Guide vane housing, first stage 529.02 Bearing sleeve
112.02 Guide vane housing, second stage 529.03 Bearing sleeve
144.01 Drainage elbow 545.01 Bearing bush
210.01 Shaft 545.02 Bearing bush
230.01 Impeller 545.03 Bearing bush
230.02 Impeller 681.01 Safety guarding
260.01 Impeller cap 710.01 Return pipe
320.01 Angular ball bearings 711.01 Ascending pipe
320.02 Angular ball bearings 711.02 Drainage casing
320.04 Groove ball bearings 711.03 Connection piece
320.05 Groove ball bearing 731.01 Screw-in fitting
341.01 Motor bell housing 731.02 Screw-in fitting
350.01 Bearing housing 735.01 Compensator
360.01 Bearing cover 861.01 Coupling half
400.01 V-ring 861.02 Coupling half
400.02 Seal 867.01 Coupling unit
400.03 Seal 893.01 Sole plate
400.04 Seal 901.01 Hexagon head bolt
400.05 Seal 901.02 Hexagon head bolt
400.07 Seal 901.03 Hexagon head bolt
411.01 Seal ring 901.04 Hexagon head bolt
411.02 Seal ring 901.05 Hexagon head bolt
411.03 Seal ring 901.06 Hexagon head bolt
411.04 Seal ring 901.07 Hexagon head bolt
412.01 O-ring 901.08 Hexagon head bolt

26 ALLMARINE MELO series BA-2018.03 en-US 160-288/B – 550 299

 Appendix

Part no. Designation Part no. Designation

901.09 Hexagon head bolt 940.01 Shaft key
902.01 Stud bolt 940.02 Shaft key
903.01 Screw plug 940.03 Shaft key
903.02 Screw plug 940.04 Shaft key
904.01 Grub screw Tab. 13 Designation of components according
to part numbers
914.01 Cheese head screw
914.02 Cheese head screw
914.03 Cheese head screw
914.04 Cheese head screw
914.05 Cheese head screw
914.06 Cheese head screw
914.08 Cheese head screw
920.01 Hexagon nut
920.03 Hexagon nut
920.04 Hexagon nut
920.05 Hexagon nut
920.06 Hexagon nut
920.08 Hexagon nut
923.01 Slotted nut
923.02 Slotted nut
923.03 Slotted nut
929.01 Supporting washer
929.02 disc
929.03 disc
929.04 disc
929.05 disc
929.06 disc
929.07 disc
929.08 disc
929.09 Supporting washer
929.10 Supporting washer
929.11 disc
931.01 Locking plate
931.02 Locking plate
931.03 Locking plate
932.01 Circlip
932.02 Circlip
932.05 Circlip
932.06 Circlip

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Appendix

9.2.2 Sectional drawings of MELO 200/250/300

Fig. 8 Overview sectional drawing: MELO 200/250/300 series

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 Appendix

Fig. 9 2-stage version, MELO 200/250 series Fig. 11 2-stage version, MELO 300 series

Fig. 10 Version with intermediate bearing, MELO

200/250/300 series

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Appendix

9.2.3 Sectional drawings: MELO 400

Fig. 12 Overview sectional drawing: MELO 400 series

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 Appendix

9.3 Technical specifications 9.3.2 Sound pressure levels

Measuring conditions:
More technical specifications (→ order data sheet).
• Distance to the pump: 1 m
9.3.1 Ambient conditions • Operation: cavitation-free
Operation under any other ambient conditions should be • Motor: IEC standard motor
agreed with the manufacturer. • Tolerance ±3 dB

Tempera- Relative humidity [%] Setup Lower-noise versions of the motors are available if the
ture [°C] height expected noise levels exceed the permissible limits.
Long-term Short-term above sea
level [m] Nominal motor Sound pressure level [dB] for pump
power PM [kW] with motor at speed [rpm]
–20 to +40 ≤ 85 ≤ 100 ≤ 1000
Tab. 14 Ambient conditions 1450 1750
1.5 58 58.5
2.2 60 60.5
3.0 62 62.5
4.0 63 63.5
5.5 65 65.5
7.5 66 66.5
11.0 68 68.5
15.0 69 69.5
18.5 70 70.5
22.0 71 71.5
30.0 72 72.5
37.0 73 73.5
45.0 74 74.5
55.0 75 75.5
75.0 76 76.5
90.0 76 76.5
110.0 77 77.5
132.0 78 78.5
160.0 79 79.5
200.0 80 80.5
230.0 82 82.5
285.0 83 83.5
345.0 84 84.5
Tab. 15 Sound pressure levels

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Appendix

9.3.3 Tightening torques

Thread size Quality Tightening

torque [Nm]
M6 9
M8 22
M10 43
M12 73
M16 8.8 181
M20 353
M24 661
M27 975
M30 1323
Tab. 16 Tightening torques

9.3.4 Cleaning agents

Application area Cleaning agents

Foodstuffs and drinking E.g. spirit, Ritzol 155, strong
water sector alkaline soapy solution,
steam jet (for individual
parts only)
Other Benzine, wax solvents,
diesel, paraffin, alkaline
cleaners
Tab. 17 Cleaning agents

32 ALLMARINE MELO series BA-2018.03 en-US 160-288/B – 550 299

 Appendix

9.4 Recommended spare parts for

two years of continuous operation
according to DIN 24296
Part no. Part designation Number of identical pumps (including stand-by pumps)
2 4 6 8
Set/quantity of spare parts
320.01 Angular ball bearings 1 2 3 4
320.02 Angular ball bearings 1 2 3 4
320.03 Groove ball bearings 1 2 3 4
320.04 Groove ball bearings 1 2 3 4
320.05 Groove ball bearings 1 2 3 4
421.01 Shaft seal ring 3 6 9 12
524.01 Shaft protection sleeve 1 2 3 4
545.01 Bearing bush 1 2 3 4
545.02 Bearing bush 1 2 3 4
545.03 Bearing bush 1 2 3 4
400.01 V-ring 1 2 3 4
412.01 O-ring 1 2 3 4
412.02 O-ring 1 2 3 4
412.03 O-ring 1 2 3 4
412.04 O-ring 1 2 3 4
412.05 O-ring 1 2 3 4
412.06 O-ring 1 2 3 4
904.01 Grub screw 1 2 3 4
Tab. 18 Recommended spare parts for two years of continuous operation

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Appendix

9.5 Declaration of harmlessness

This declaration of harmlessness of the operator is used to ensure work safety Please copy this
and the protection of our employees, the transport company and the environment document and
from harmful effects when handling dangerous materials as well as to protect you send it together
from claims for compensation. with the pump.
Every commercial company is obligated to comply with the legal regulations on work www.allweiler.de/
safety, set forth for example in Germany in the Workplace Ordinance (ArbStättV), en/sales-service/
the Accident Prevention Regulations (UVV), the Hazardous Substances Ordinance downloads
(GefStoffV) and the applicable environmental regulations.
When returning pumps and their accessories, please send them back to us in a properly cleaned condition (safe and harmless
for health and environment) and confirm the safety and harmlessness of the medium used.
If used with toxic, microbiological, explosive, radioactive or other hazardous substances, the safety data sheet must be
provided to us and enclosed to the shipment.
Failure to follow the above instructions will lead to the implementation of measures that ensure the safe handling of the
pump or the device, at your cost. We reserve the right to reject contaminated pumps and accessories and to return them
for cleaning at your cost!
This declaration of harmlessness must be attached clearly visible outside of the packaging of the return shipment, and if
possible sent in advance by e-mail including the safety data sheet, if applicable, to:
service-emea-gr@circor.com. Please understand that return shipments without a declaration of harmlessness cannot be
processed until such declaration is received.
Pump type ❏ The pump has been thoroughly drained and cleaned outside
and inside prior to dispatch or provision.
Serial number:
❏ Special safety precautions are not necessary.
Was the pump operated with hazardous substances or other
media that are hazardous to health or the environment? ❏ Special safety precautions regarding residual liquid, rinsing
❏ No media, personal protective equipment and disposal are
❏ Yes necessary (safety data sheets are required and must be sent
in advance/enclosed).
Medium used:
❏ Aside from the medium specified, are there any other safety
______________________________________________ aspects that need to be observed (for example, the cleaning
medium used)?
UN / CAS number (see safety data sheet): If yes, which:
______________________________________________ _______________________________________________

❏ Up-to-date safety data sheet enclosed.

We do not accept return shipment of pumps or parts thereof that have been exposed to radioactive or microbiological
contamination and that were not properly decontaminated.

Contact:

Tel. / fax / e-mail:

Legally binding declaration:

We hereby certify that we have completed this declaration fully and truthfully to the best of our knowledge. The dispatch
is performed in compliance with all legal requirements that apply to the packaging, shipping, and labeling of hazardous
substances. The sender is liable for all damages caused by unmarked decontaminations of the returned object.

Place, date Signature Stamp

Tab. 19 Declaration of harmlessness

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 Appendix

9.6 Declaration of conformity according

to EC machine directives
The following declaration does not contain serial numbers
or signatures. The original declaration is delivered with the
respective pump.

EC declaration of conformity according to

machine directive, appendix II A
We,
ALLWEILER GmbH, Postfach 1140, 78301 Radolfzell, Germany; Tel. +49 (0)7732 86-0, Fax. +49 (0)7732 86-436,
hereby declare that, when the conditions in the operating manual are observed, the pump unit / pump:
Designation MELO
Equipment no.
Order no.

complies with the following applicable EC directives :

• Machine directive (2006/42/EC)

• The protection targets of the low-voltage directive (2006/95/EC, valid until 19 April 2016, and 2014/35/EU, valid from 20
April 2016) were complied according to appendix I no. 1.5.1 of the machine directive 2006/42/EC.

Applicable harmonized norms:

• EN 809:1998 + A1:2009 + AC:2010

• EN ISO 12100:2010
Person authorized to compile the ALLWEILER GmbH
technical file Allweilerstr. 1
78315 Radolfzell
Date: 06.02.2013 Company stamp / signature:

Head of Development/Construction
Tab. 20 Declaration of conformity according to EC machine directives

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Appendix

36 ALLMARINE MELO series BA-2018.03 en-US 160-288/B – 550 299