Manual Water Health-W10286

Water
for the future
WATER TECHNOLOGY
MANUAL INDEX
1. Introduction Process description
2. Operation manual Flocculator, type RPF 015
3. Operation manual Coagulant dosing pump
4. Operation manual Caustic soda dosing pump
5. Operation manual Polymer preparation system,

type Polydox AP 1000
6. Operation manual Flocculant dosing pump
7. Operation manual Flotation unit, type GPL 15
8. Operation manual Recirculation pump GPL 15
9. Operation manual Skimmer drive GPL 15
10. Operation manual Sediment discharge valve
11. Operation manual Sludge discharge pump
12. Documents Orgalime
13. Documents Manufacturer’s declaration
14. Documents Recommended spare parts /

wear and tear parts order list RPF 015
15. Operation manual Recommended spare parts /

wear and tear parts order list AP 1000
16. Operation manual Recommended spare parts /

wear and tear parts order list GPL 15
17. Diagrams Pneumatic
18. Drawings
Client : Water Health

Serial No. : W10286
Agent :
LC No. :
Remarks :
Project: Water Health
OHW: W10286
Foreword
Thank you for purchasing a Redox system.

This Manual explains how the system should be installed, started, operated and
maintained, and deals with the safety aspects.
Before the installation work, the entire Manual to be read.
The management staff has to ensure that this manual is available to have this reference
during installation, operation, maintenance and emergencies.
The installation, operation and maintenance of the system should be carried out by
suitably qualified staff (at least average technical level).
This installation should only be used for the purpose for which it is made, namely the
purification of (waste) water, specified in the order confirmation.
The installation is not suitable for use in rooms where an ATEX zone classification
applies unless otherwise stated.
Due guarantee / product liability
The guarantee clause is described in the purchase documents. The standard guarantee
covers one (1) year with a maximum of 1600 operation hours after delivery at site.
Product breakdown of the Redox products which is caused by defects of the Redox
products within the guarantee period and by Redox remarked as a Redox failure will be
replaced by Redox. Only the material will be compensated by Redox. The defect part
can be send to Redox for judgment and eventually repair.
THE FOLLOWING ITEMS ARE EXCLUDED FROM THE GUARANTEE and

LIABILITIES:
 All mistakes caused by not checking the warnings in this manual.

 Damage, caused by poor foundation of the installation.
 Defects caused by normal wear and tear, injudicious handling / operation, incorrect
maintenance or defects which are the result of alterations / modifications by order of
the client or third parties. See „Orgalime".
 Damages and / or defects caused by incorrect operation of the installation.
 Damages and / or defects caused by extreme temperatures like freezing.
 Damages and / or defects caused by dismounting pumps, drives and other parts of
the installation.
 After a defect to pumps and / or drives, dismounting them by anybody other than the
manufacturer automatically makes the guarantee invalid.
 Damages, which are caused by using not original parts, are not included in this
guarantee.
 When components are built in the electrical control panel afterwards by anybody
other than the manufacturer (Redox).
 Wear and tear parts are not included in this guarantee.
 Exchange of materials.
OHW: W10286
Safety instructions
Read the(safety) instructions in this manual carefully.

This Manual highlights security risks during installation, operation and maintenance of
this installation.
In addition to this manual and as a basis for all operations, a comprehensive risk
analysis has to be made under directed lead of a safety officer.
On the basis of this risk analysis a method of working will be created so that the safety
risks will be excluded or minimized, for example by use of personal protective equipment
or other resources.
In carrying out the work, this methodical description is always the basis for the most
safely way to perform the work.
The general rule: Always be alert to safety risks. If necessary, adjust the working
method.
When operating the installation make use of the required personal protective equipment.
Use a minimum of safety shoes, safety helmets, face protection and safety gloves
(chemical resistant).
When using chemicals, the Safety Data Sheets should be requested from the supplier of
the chemicals. The safety sheets should be clearly visible hung in workplaces and
employees need to be informed about the risks of using the chemicals.
OHW: W10286
The following alerts may be placed on the installation:
Electrical Hazard Explosive atmosphere
Automatic starting machine Attention for rotating parts
Biting substance Biting (corrosive) substance
Use safety glasses Use safety gloves
Use safety helmed Use safety shoes
No entry for unauthorized No drinking water

OHW: W10286
PROCESS DESCRIPTION
Treating waste water can be done in several steps. The type of wastewater, the amount
of pollution and the desired effluent quality determines the steps to take.
Here, the following steps will be described:
- the screening step
- the physical chemical step
These steps can be expanded with a biological step and/or an additional sludge
dewatering step by a decanter system.
Screening (not by Redox)

The effluent of the factory is collected in a pump pit.
From here the water is pumped to a screen which is placed above ground.
This first step is to remove larger solids from the water what is necessary for the rest of
the steps. These particles could also block pipes or damage equipment in the rest of the
system. The mesh size of the screen determines the size of the particles which are
flushing through the screen with the waste water.
After passing the screen, the water drops into a buffer equalization tank. This buffer tank
is equipped with mixers (aerators) to create a homogeneous mixture which is necessary
for the physical chemical step.
Physical chemical treatment step

After reaching the start level in the buffer equalization tank, a feed pump in this tank
starts to pump water to the dissolved air flotation unit (DAF unit). Before entering the
DAF, the water flows through a static mixer (flocculator) where the water is treated
chemically. First a coagulant is dosed, which will change the charge of the colloidal parts
inside the waste water. Colloidal parts are not dissolved, but very small particles (< 1
micron) which float through the water. Coagulant will cause agglomeration of these parts
in the form of small flocks.
After this step, a neutralizer is being dosed to change the pH to a neutral value.
A flocculant is added which makes the smaller flocks to agglomerate into bigger, more
solid flocks what will make them easier to separate in the DAF.
In the DAF unit small air bubbles are formed on or adhere to the flocks, increasing there
buoyancy, making them float to the surface of the DAF unit, where it will be removed by
a scraper mechanism to a sludge collection cone. A sludge pump is installed which
pumps the sludge away to a sludge buffer tank.
The micro air bubbles are created by reducing the pressure of recycled effluent that has
been saturated with air at a higher pressure and subsequently exposing this water to the
proper conditions.
Any sediment present in the wastewater will settle to the base of the DAF unit, where it
accumulates in a sediment gutter that stretches the full length of the DAF unit. From
here it will automatically be removed periodically by means of a pneumatically operated
butterfly valve, pulse pause controlled.
The treated water leaves the DAF unit over an overflow weir and flows by gravity into the
sewer system / contact tank.
OHW: W10286
Data concerning waste water
Design parameters:
Type of influent Not applicable
Capacity 15 m³/h design flow
pH We assume 6,5 – 7,5
Water temperature <35ºC (assumed)
Temperature range surrounding: 5 C till 30 °C
Expected reductions
The actual reductions are to be determined by jar tests on flow proportional composite
water samples taken on a representative production day.
REDOX Water Technology B.V. shall not be held responsible for the discharge effluent
quality should the influent parameters differ from the values above.
General
For a good operation and maintenance it is recommended to install the system under a
roof or in a building with a minimal temperature of 10°C.
For optimal performance of the system, a buffer / equalisation tank should be installed
before the flocculation / flotation unit. The purpose of this tank is to balance peak flows
and pollution loads, resulting in a significantly improved performance of the system.
It is recommended to execute the buffer / equalisation tank with a mixer (/ aerator) to

keep the content continuously mixed and to avoid sedimentation.
Voltage : 400 V – 50 Hz – 3 phase + “0” + PE(protected

Earth)
Control voltage panel : 230 V AC
Control voltage field components : 24 V AC
OPERATION MANUAL
Flocculator and chemical dosing
Type : RPF 015
Serial Nr. : W10286-011

Year : 2017
REDOX WATER TECHNOLOGY B.V.

Stevinstraat 11, 7102 DZ Winterswijk
P.O. Box 218, 7100 AE Winterswijk
Phone: 0031 (0)543-531030
Fax: 0031 (0)543-519089
E-mail: info@redox.nl
Edition: 21-02-2017
Type: RRF 015
OHW: W10286-011
TABLE OF CONTENTS: Page

1. Introduction. 1.1
2. Technical information.
2.1. Technical data. 2.1 – 2.2
2.2. Auxiliary equipment. 2.2
2.3. Necessary tools and makeshifts. 2.2
2.4. Flow sheet. 2.3
2.5. Additional information from sub-suppliers. 2.3
3. Safety aspects.
3.1. Incorporated safety measures. 3.1
3.2. Operators and working environment. 3.1
3.3. Personal protection. 3.2
4. Installation.
4.1. Transport instructions. 4.1
4.2. Mounting instructions. 4.2
4.3. Connections. 4.2
5. Directions for use.
5.1. Process description. 5.1
5.2. Item description.
A: Sample points. 5.2
B: Flow-switch. 5.3
C: Coagulant dosing section. 5.3
D: Neutraliser dosing section. 5.3
E: pH-measurement. 5.4
F: Flocculant dosing section. 5.4
G: Aeration points. 5.5
H: Mixing elements pipe flocculator (option) 5.5
5.3. Start up. 5.6
6. Inspection / maintenance.
6.1. Qualification of maintenance personnel. 6.1
6.2. Safety measures and risks during maintenance. 6.1
6.3. Maintenance. 6.2
6.4. Cleaning. 6.2
7. Malfunctioning and repair. 7.1
8. Discard and environment.
8.1. Re-use. 8.1
8.2. Dis-mantling. 8.1
9. Customer service.
9.1. Ordering parts. 9.1
9.2. Helpdesk for process and product information. 9.1
Type: RRF 015
OHW: W10286-011
1. INTRODUCTION
- The scope of this manual is to provide a reference document for operating the
installation.
- In this manual is described how to start up the installation till how to put the installation
out of order.
- After start up special attention is given to:
 Maintenance of the installation.
 Operation of the installation.
 Safety aspects.
- The anticipated operating conditions and procedures defined in this manual are to be
used as guides and are not to be accepted as rigid standards.
- Some maintenance and periodic control is necessary to ensure an optimal and trouble
free operation.
- This manual or a complete copy of this manual should be kept, up to time (without
exception), near the installation.
- Read this manual every month.
- Every month the maintenance personnel and the operators have to be instructed with the
maintenance and the safety aspects in this manual.
- This manual is written compact and as complete as possible. Should there be any
questions left about the installation, please contact your supplier.
Figure 1.1 Flocculator (RPF).
1.1
Type: RRF 015
OHW: W10286-011
2. TECHNICAL INFORMATION.
2.1. TECHNICAL DATA.
Make: Redox
Type: Flocculator RPF 15
Serial number: W10286-011
Capacity: 15 m³/hr.
Noise level: The noise level is minimal and
considerable lower than 70dB(A).
Heat development: Heat development is not present.
Radiation: Radiation is not present.
Vibrations: Vibrations are very low.
Temperature range surrounding: 5 C till 35 C
Temperature range product (wastewater): 5 °C till 30 °C
pH-range at the outlet of the flocculator. 6 till 9
This to prevent serious damage to the installation and pumps!
The solid parts in the incoming wastewater may not be larger than 1 mm.
In case larger parts are present, these parts have to be removed by a
screening system before entering the flotation unit!
Dimensions:
Length x width x height Approx: 4.075 x 495 x 735mm.
Weight:
Weight empty: Approx. 90 Kg.
Weight full: Approx. 205 Kg.
Connections:
Influent: DN 65, PN10 flange
Effluent: DN 65, PN10 flange
Materials:
Frame flocculator: AISI 304
Piping: HDPE
Dosing sections: PVC
Sample:
Material: PVC ½“
Flow-switch:
The flow of the incoming water is controlled by a measuring pin in the effluent
compartment of the GPL 15.
Coagulant (for example FeCl3): ½“

Material: PVC piping
Ball valve (PVC) Art.no.: 1217.00019
Safety valve Art.no.: 1314.00001
Non return valve (PVC) Art.no.: 1716.00009
2.1
Type: RRF 015
OHW: W10286-011
Neutraliser (for example NaOH): ½“

pH: ¾" connection

For more details, see datasheet pH electrode.
Flocculant (for example Poly): 1“

Aeration: ½“
Material: HDPE elbow
2.2. AUXILIARY EQUIPMENT.
Not applicable.
2.3. NECESSARY TOOLS AND MAKESHIFTS.
 For start-up, maintenance and control no special tools are required.
2.2
Type: RRF 015
OHW: W10286-011
2.4. FLOW SHEET.

Aeration (option)
Effluent
Flocculant injection
Influent
Coagulant injection
Neutraliser injection
= Pneumatic valve
= Non return valve
= Valve
Figure 2.1
2.5. ADDITIONAL INFORMATION FROM SUB-SUPPLIERS.
Information about the chemicals you can find on the datasheet of the dosing pumps (in
index) and the datasheets from the sub-supplier.
2.3
Type: RRF 015
OHW: W10286-011
3. SAFETY ASPECTS.
3.1. INCORPORATED SAFETY MEASURES.
Keep all warnings readable, if necessary clean or replace it!
Biting (corrosive) substance.

Figure 3.1
This warning is placed at the front side of the flocculator.
Warnings:
 Coagulants are corrosive (acid) liquids, which causes irritation, if in contact with eyes,
skin and respiratory organs.
 Neutralisers are corrosive (basic) liquids, which causes irritation, if in contact with eyes,
skin and respiratory organs.
 When contact with one of these liquids takes place, immediately wash it with lots of water
and call (if necessary) a doctor.
 THINK OF THE SAFETY CLOTHING AND DO NOT FORGET TO TAKE SAFETY
MEASURES.
Warning for consequences:
 Operating not in accordance with the safety prescriptions.

 Operating by inexperience and / or insufficient instructed personnel.
 Adjustments, modifications or alterations without the knowledge of Redox.
The consequences can be very extensive and in these cases the vendor (supplier) will be
safeguarded against any warranty, guarantee and / or liabilities.
3.2. OPERATORS AND WORKING ENVIRONMENT.
In the first place the operator should always be informed about the kind of processing
substances. The operator also should know the danger of the chemicals which, are used in
the flocculator. On this base the operator has to protect himself.
The allowed temperature for the system is mentioned at chapter 2.1 of this manual. If
temperatures outside this range can be expected, the system needs to be protected, for
example by installing the system inside a heated or cooled building.
The installation has to be placed in a frost-free environment. If not take the measurements
mentioned at chapter 4.1 & 4.2.
3.1
Type: RRF 015
OHW: W10286-011
3.3. PERSONAL PROTECTION.
On the basis of the upper mentioned operators and working environment the operator has to
protect himself with safety-clothes.
For the flocculator the operator needs the following safety clothes:
 Safety clothes (chemical resistant).

 Safety shoes (chemical resistant).
 Safety glasses.
 Working gloves (chemical resistant).
3.2
Type: RRF 015
OHW: W10286-011
4. INSTALLATION.
4.1 TRANSPORT INSTRUCTIONS.
Transport.
For dimensions and weight see chapter 2.1 in this manual.
Transport by truck has to be in accordance with the following conditions:

 The truck needs to have sufficient stability to transport the installation.
 The installation has to be tied with bands or any applicable transport appliances to
guarantee correct and safe transport.
 During transport and hoisting the flocculator needs to be empty.
 The flocculator must be transported in a straight position.
Storage.
The flocculator has to be placed in a frost-free environment. When frost can influence the
process, all valves must be opened and the entire unit including pumps must be drained
empty. It’s also recommended placing a calamity tank under the flocculator. At the same time
the flocculator has to be protected against any corrosive influences like seawater etc. All
electrical components must be protected against all weather influences.
Load and unload.
For (un)loading of the flocculator a forklift truck can be used very well. The flocculator has to
be lifted and approached from the backside of the frame. On this way the injectors on the front
can not be damaged. The flocculator can also be lifted with a crane. For this you'll need duly
hoisting material, what can be tied well on the flocculator (take care that the appendages on
the flocculator do not damage by hoisting ropes etc.). Hoisting accessories have to be of
proven quality. At no situation anybody may come in the hoisting area because falling
products can cause injuries. At no situation the frame of the flocculator, (which is constructed
of stainless steel), may come in contact with carbon steel since carbon steel scratches will
cause corrosion of the stainless steel.
4.1
Type: RRF 015
OHW: W10286-011
4.2 MOUNTING INSTRUCTIONS.
Check the installation for damages, and check whether the functioning of all moving parts is
correct (direction of rotation?). Also check if all (design) conditions are fulfilled to ensure a
correct functioning of the installation. The Transport Company only can leave after inspection
and signing of the transport documents. Redox is not responsible for transport, load, or
unload damages. The Transport Company is responsible for these damages.
Foundation.
The system has to placed in a dry, frost-free environment and has to be levelled on a
horizontal / flat foundation. Install and cramp, the installation with the supplied wall-ties. (See
the enclosed reference general drawing / layout drawing in this manual).
If the installation has to be placed outside then the following measures has to be taken:
 Insulation of the installation, pipes and pumps

 Protection against rain(water)
 Put on heat-tracing on pumps and pipes
 Protect the system against freezing.
The installation is filled with water and is not frost-free, it can be placed outside when the
installation is empty.
Accessibility. (The below mentioned is only valid for standard systems):

There needs to be one (1) meter free space on all sides of the system to allow an unhindered
operation and maintenance. Make allowance for enough space for exchanging parts. This
has to be determined based on the plant and system location.
The supply pipes of the dosing pump(s) are tubes, chosen very carefully by Redox. These
tubes have to be fastened very well on the injectors.
4.3. CONNECTIONS.
 The components, which belong to the flocculator, have to be connected in accordance

with national and local regulations, concerning water, electricity and sewerage etc.
4.2
Type: RRF 015
OHW: W10286-011
5. DIRECTIONS FOR USE.

5.1. PROCESS DESCRIPTION.
The main function of the flocculator (RPF) is to achieve optimal mixing of chemical additives in a
water stream.
The feed pump pumps the wastewater (after coarse filtration) to the inlet of the flocculator. The
flocculator is characterised by the plug flow principle. Chemicals are therefore dosed only if there is
flow. Near the inlet side, coagulant (pos. C) will be dosed. Directly behind the dosing point, a
mixing-unit is installed to mix the coagulant very intensively with the wastewater. Coagulation is the
destabilisation of the polluting matter in the wastewater. Fine particles are formed, which are not
ideal for separation. Before the second mixing unit, flocculant will be dosed to let these particles
grow to flocs. Liquid flocculant is made in a separate poly-electrolyte make-up unit from poly-
electrolyte granulate powder and water, and is then dosed to the flocculator. The floc will be made
in the flocculator-part behind the second mixing-unit. Mixing energy and reaction energy in the
mixing unit and in the pipe are result of turbulence. The flocculator can be provided with optional
fittings for dosing of chemicals for neutralisation and for pH measurement.
effluent
influent
Figure 5.1.
5.1
Type: RRF 015
OHW: W10286-011
5.2. ITEM DESCRIPTION.
A: Sample points.
Before taking a sample read chapter 3 of this manual!
By taking a sample, think of the safety clothes.
Figure 5.2
Pos. A1: Sample point untreated influent.
At sample point A1, a sample of the influent can be taken as it flows into the flocculator, before any
chemical additives are dosed.
Pos. A2: Sample point after coagulant dosing.
At sample point A2, a sample after coagulant dosing can be taken, to check whether coagulant is
dosed optimally.
Pos. A3: Sample point after neutralising agent dosing.
At sample point A3, a sample after neutralising agent dosing can be taken, to check whether
neutraliser is dosed optimally.
Pos. A4: Sample point after flocculant dosing.
At sample point A4, a sample after flocculant dosing can be taken, to check whether flocculant is
dosed optimally.
Pos. A5: Sample point pre-aeration.
At sample point A5, a sample after pre-aeration can be taken, to check whether the preaeration is
optimally.
5.2
Type: RRF 015
OHW: W10286-011
B: Flow-switch.
The flow of the incoming water is controlled by a measuring-pin in the GPL 15.
See manual GPL 15 in manual index chapter 7.
C: Coagulant dosing section.
Pipe flocculator
Safety valve
Figure 5.4
Generally, as a first treatment step coagulant (for example FeCl3) is dosed, to obtain coagulation.
Directly behind the coagulant dosing point, a mixing-unit is installed to mix the coagulant very
intensively with the wastewater. Coagulation is the destabilisation of the polluting matter in the
influent. Fine particles (so called pin flocs) are formed, which are not ideal for separation. To avoid
coagulant to be pumped into the flocculator while the pump is not pumping or pumping an
insufficient amount of wastewater, a safety valve is installed in the injection part. The valve is
controlled by the flow pressure detection unit (see pos B). The valve is controlled by the pneumatic
valve in the pneumatic control panel.
Redox must be informed when another coagulant then FeCl3 42 wt% is dosed.
D: Neutraliser dosing section.
Pipe flocculator
Figure 5.5
Generally neutralising agent (for example NaOH) is dosed to neutralise the wastewater after
coagulant dosing. Neutralisation is often required to obtain the correct pH value to allow discharge
of the treated effluent, to obtain an acceptable pH value for the flotation unit and / or to obtain a
suitable pH value for optimal functioning of the poly-electrolyte for flocculation.
Redox must be informed when another neutraliser then 30 wt% is dosed.
5.3
Type: RRF 015
OHW: W10286-011
E: pH measurement.
Armature with
pH-electrode inside
Pipe flocculator
Figure 5.6
The system is delivered including pH control, at this point the pH value is measured. The pH
measurement and control system can be used for controlling the neutralising or coagulant agent
dosing.
F: Flocculant dosing section.
Pipe flocculator
Figure 5.7
At this point flocculant (generally poly-electrolyte) will be dosed to let grow the pin point flocs
(formed after coagulation) to flocs. Liquid flocculant is made in a separate poly-electrolyte make-up
unit from granulate poly-electrolyte powder (or concentrated liquid) and water and is then dosed to
the flocculator. The floc will further develop in the flocculator part behind the second mixing-unit
after the flocculant dosing point. The optimal type of flocculant (poly-electrolyte) can differ per
application. lt is advised to contact suppliers of flocculant (poly-electrolyte) to perform tests to
determine the optimal type of flocculant.
5.4
Type: RRF 015
OHW: W10286-011
G: Aeration points.
See figure 5.1.
At these points, air saturated water from the recirculation system of the flotation unit can be added
to the pre-treated wastewater. The addition of air saturated water to the flocs in the flocculator can
give a better result in the flotation system.
H: Mixing elements pipe flocculator (option)
The flocculator (figure 5.8) can be equipped with additional mixing elements. The task of the
flocculator is to mix chemicals with the process water. When it appears that more mixing energy is
needed, you can choose to apply these mixing elements.
Mixing
element
Figure 5.8
Figure 5.9a Figure 5.9b
The mixing elements will be placed directly behind the coagulant and flocculant dosing points. The
mixing intensity can be controlled by turning the position of these mixing elements, indicated by an
arrow.
When the arrow points in the direction of the water stream (figure 5.9a), the mixing effect is
minimal. When the arrow is rotated 90° relative to the water stream (figure 5.9b), the mixing effect
is maximal.
Changing the position of these elements will affect the results on the flocculator. These results
must be monitored by taking samples from the sample points at the flocculator and by checking the
results at the flotation unit.
Too little mixing energy can result in higher chemical consumption and worse results.
Too much mixing energy can result in that the created flocks in the flocculator break down again,
with eventually higher dosing rates.
5.5
Type: RRF 015
OHW: W10286-011
5.3. START UP.
 Start up the flocculator:
1) Be sure that the flocculator is clean (no dirt in the flocculator). This to prevent damages on
pumps etc.
2) Be sure that everything is connected according to the drawings.
3) Be sure that the entire installation is checked (working, rotating directions and damages)!
4) Be sure that all samples are closed.
5) Check if the ball valve from the coagulant dosing section is open.
6) Check if the non-return valve from the coagulant dosing section works properly.
7) Check if the ball valve from the neutraliser dosing section is open.
8) Check if the non-return valve from the neutraliser dosing section works properly.
9) For adjusting the pH measurement see the manual of it in the manual index.
10) Check if the ball valve from the flocculant dosing section is open.
11) Check if the non-return valve from the flocculant dosing section works properly.
12) Decide or pre-aeration is necessary.
Too much pre-aeration results in big air bubbles at the influent of the installation.
13) Fill the flocculator with clean water.
For further information about the dosing pumps / poly-electrolyte make-up unit see the manual of it
in the manual index chapter 3,4,5 and 6.
There is no fixed working area required for an operator. For accessibility see paragraph 4.2. Only
regular maintenance and a periodic check to control the correct functioning of the system operation
are required. The operator therefore can also take care of the maintenance of the system; the
requirements for this function are described in chapter 6. 1. Very important for a good and hygienic
operation of the flocculator system is to take care that the equipment and working area are clean.
5.6
Type: RRF 015
OHW: W10286-011
6. INSPECTION / MAINTENANCE.
6.1. QUALIFICATION OF MAINTENANCE PERSONNEL.
Only personnel, who are instructed by Redox, are allowed to carry out operation and
maintenance activities. They are informed with the associated manual.
The operator and/or maintenance engineer must have an average technical level:
This person must have sufficient knowledge of:

 Chemicals working and dangers / process technology when applicable.
 Mechanical engineering, pumps and valves.
 Pneumatical knowledge, follow the working of the installation on the basis of the
pneumatic diagrams and analyse malfunctioning.
 Electrical knowledge, follow the working of the installation on the basis of the electrical
diagrams and analyse malfunctioning. He / she must associate with measuring devices
like ohmmeter, voltmeter and ampere meter for measuring starting- and nominal
currents.
lf a technical service / maintenance department is available, than it is strongly recommended

to have the maintenance carried out by this department.
6.2. SAFETY MEASURES AND RISKS DURING MAINTENANCE.
See manual dosing pumps / poly-electrolyte make-up unit etc. in the manual index chapter
3,4,5 and 6.
 Maintenance, repair, inspection, checking for malfunctioning or removal of parts

(pumps, poly units, etc.) is only allowed when the electric supply has been switched
off and when all drives, pumps etc. are stopped.
 Turn the main switch (figure 6.1, pos 4) in the “off position” on the electric control
panel. Turn the maintenance switch in place in the "off position" (when applicable).
 Secure the main switch (figure 6.1, pos 4) against incompetent switch on!
Figure 6.1
All persons who are working on the machine must have their own padlock with matching key
to lock the main switch (figure 6.1, pos 4) in a “safe position”. Only when all padlocks are
removed from the main switch, the machine can be switched on again. Padlock is no Redox
delivery.
 Before doing maintenance, repair or removal of parts the flocculator has to be empty.
6.1
Type: RRF 015
OHW: W10286-011
6.3. MAINTENANCE.
Daily maintenance:
Daily maintenance consists of the below items:
 Check if the pH value is according to the mentioned range.

 Check the installation for freezing.
 Check the emergency stop circuit.
Weekly maintenance:
Checking / maintenance depends on the amount of working hours and the used substance.
The following points needs to be checked / maintained for at least once a week:
 Check tubes, pipes, valves, non-return valves etc. for fouling, if necessary clean it.
 Check the samples for fouling, if necessary clean it.
 Check if the dosing is all right, if necessary change the dosing.
 Check the working of the coagulant safety valve.
Maintenance for supplied parts:
 If a pH measurement and control system is installed on the flocculator, the pH for optimal
pre-treatment will be adjusted automatically. lf no pH-measurement and control system is
installed, a frequent check is necessary. Take samples of each sample point from the
flocculator and check these samples. Based on these samples the operator can
determine the functioning of the chemical dosing system.
 For maintenance on the aeration points see manual of the GPL 15 in the manual index
chapter 7.
6.4. CLEANING.
Before cleaning the system read chapter 6.2 of this manual. For cleaning the pH electrode
see the manual in the manual index.
6.2
Type: RRF 015
OHW: W10286-011
7. MALFUNCTIONING AND REPAIR.

Before doing maintenance or repair, read chapter 6.2 of this manual very carefully.
7.1
Type: RRF 015
OHW: W10286-011
8. DISCARD AND ENVIRONMENT.

The steels / synthetics / chemicals / medium / substances etc. must be dismantled according
to the national and / or local regulations of that moment.
8.1. RE-USE.
The flocculator is constructed from durable materials and components.

For re-use there must be known which materials are used in the installation, so that can be
considerate for what can be re-used, when and how can be recycled. The stainless steel
frame is made of AISI 304 (werkstoff. Nr:1.4301) and can be re-used for other purposes.
The piping is made of chemical resistant synthetic (HDPE).
The dosing sections are made of PVC.
8.2. DIS-MANTLING.
Drives, pumps, electrical switch and control panel, etc., can be dismantled. The stainless
steel frame is welded in full and cannot be dismantled in parts.
Dismantling of the flocculator has to be executed by professional personnel.
8.1
Type: RRF 015
OHW: W10286-011
9. CUSTOMER SERVICE.
9.1. ORDERING PARTS.
The Redox repeat order procedure is described in the enclosed recommended spare parts /
wear and tear parts order list. See manual index chapter 14. This list has been composed
carefully. Redox doesn’t have all the parts in stock. Therefore it is important that you have
these parts in stock, to prevent possible failures that can cause a long standstill of the
system.
By giving the item number and the description, the correct part with according connection will
be supplied. In case of special / exceptional location etc., parts can be modified.
9.2. HELPDESK FOR PROCESS AND PRODUCT INFORMATION.
The address for all your questions is:

Service department
Phone: 0031 (0)543-531030
Fax: 0031 (0)543-519089
E-mail Service department: info@redoxservice.nl
Internet: http://www.redox.nl
9.1
OHW: W10286-012
Datasheet dosing pumps
1. TECHNICAL INFORMATION
1.1. TECHNICAL DATA
Description: Coagulant dosing pump (for example FeCl3)

Make: Grundfos
Type: DMX221
Electrical motor power: 0,09 kW
Capacity: 0 - 50 l/hr.
1.2 CHEMICALS (OPTION)
 Coagulants (FeCl3, FeClO4, Fe(SO4)3, etc.) are normally delivered in a liquid form and
they have to be stored in non-corroding storage tanks suitable for the medium. They don’t
have to be mixed with other components.
2. SAFETY ASPECTS
2.1 SAFETY MEASURES AND RISKS DURING MAINTENANCE.
 Maintenance, repair, inspection, checking for malfunctioning or removal of parts is only

allowed when the electric supply has been switched off and when all drives, pumps etc.
are stopped.
 Turn the main switch (figure 2.1, pos 4) in the “off position” on the electric control panel.
Turn the maintenance switch in place in the "off position" (when applicable).
Figure 2.1
All persons who are working on the machine must have their own padlock with matching
key to lock the main switch (figure 2.1, pos 4) in a “safe position”. Only when all padlocks
are removed from the main switch, the machine can be switched on again. Padlock is no
Redox delivery.
 To operate separate motors / pumps the below measures has to be taken:

- Turn the service key switch on.
- Press button “Start process”.
- Turn the motor in the position "Hand".
- Attention! The motor is not secured when it’s in the “Hand” position.
1
OHW: W10286-012
3. DIRECTIONS FOR USE

3.1 START UP / TIMER ADJUSTMENTS / ADJUSTMENTS.
Before taking the dosing pump(s) in operation, the below mentioned works have to be done.
 Open the suction and pressure valves.

 Fill the system with clean water.
 De-aerate the system.
 Check the rotating direction of the dosing pump(s)
Let a second person turn the maintenance switch of the pump in the position
“manual" and afterwards off again.
The rotating direction must be equal to the arrow* on the pump.
 Start up the dosing pump.
 Check the function of the dosing pump.
 Mono dosing and sludge pumps are not allowed to dry-run.
In case this happens a thermal dry-running protection is installed as an extra safety.
(*In some cases the arrow indicates the direction of the reaction force. Check the manual of the pump
in the manual index.)
4. MALFUNCTIONING AND REPAIR

Before doing maintenance or repair, read all safety instructions in this manual very
carefully.
Failure Cause Remedy
Dosing pump not accurate Air bubbles in the suction pipe. De-aerate the suction pipe.
Clots or stoppage in suction / Clean the valves, suction /
pressure pipe(s). pressure pipe(s)
At coagulant, neutraliser Oil level to low. Fill the oil level to the right level
dosing pumps (see manual dosing pump)
Membrane of the pump cracked. Replace the membrane.
For further information see manual of the dosing pump in the

manual index.
2
GRUNDFOS INSTRUCTIONS
DMX 221
Dosing pump
Installation and operating instructions

Declaration of conformity
GB: EC declaration of conformity CZ: ES prohlášení o shodě

We, Grundfos, declare under our sole responsibility that the product My firma Grundfos prohlašujeme na svou plnou odpovědnost, že výrobek
DMX 221, to which this declaration relates, is in conformity with these DMX 221, na nějž se toto prohlášení vztahuje, je v souladu s ustanoveními
Council directives on the approximation of the laws of the EC member směrnice Rady pro sblížení právních předpisů členských států Evropského
states: společenství v oblastech:
— Machinery Directive (2006/42/EC). — Směrnice pro strojní zařízení (2006/42/ES).
Standards used: EN 809:1998+A1:2009, EN ISO 12100-1+A1:2009, Použité normy: EN 809:1998+A1:2009, EN ISO 12100-1+A1:2009,
EN ISO 12100-2+A1:2009. EN ISO 12100-2+A1:2009.
— Low Voltage Directive (2006/95/EC). — Směrnice pro nízkonapět’ové aplikace (2006/95/ES).
Standard used: EN 61010-1:2001 (second edition). Použitá norma: EN 61010-1:2001 (druhé vydání).
— EMC Directive (2004/108/EC).* — Směrnice pro elektromagnetickou kompatibilitu (EMC)
* Only for products with control variant AR or AT. (2004/108/ES).*
* Pouze pro výrobky s variantou řízení AR nebo AT.
This EC declaration of conformity is only valid when published as part of
the Grundfos installation and operating instructions. Toto ES prohlášení o shodě je platné pouze tehdy, pokud je zveřejněno
jako součást instalačních a provozních návodů Grundfos.
DE: EG-Konformitätserklärung GR: ∆ήλωση συμμόρφωσης EC

Wir, Grundfos, erklären in alleiniger Verantwortung, dass das Produkt Εμείς, η Grundfos, δηλώνουμε με αποκλειστικά δική μας ευθύνη ότι τα
DMX 221, auf das sich diese Erklärung bezieht, mit den folgenden προϊόντα DMX 221, στα οποία αναφέρεται η παρούσα δήλωση,
Richtlinien des Rates zur Angleichung der Rechtsvorschriften der συμμορφώνονται με τις εξής Οδηγίες του Συμβουλίου περί προσέγγισης
EU-Mitgliedsstaaten übereinstimmt: των νομοθεσιών των κρατών μελών της ΕΕ:
— Maschinenrichtlinie (2006/42/EG). — Οδηγία για μηχανήματα (2006/42/EC).
Normen, die verwendet wurden: EN 809:1998+A1:2009, Πρότυπα που χρησιμοποιήθηκαν: EN 809:1998+A1:2009,
EN ISO 12100-1+A1:2009, EN ISO 12100-2+A1:2009. EN ISO 12100-1+A1:2009, EN ISO 12100-2+A1:2009.
— Niederspannungsrichtlinie (2006/95/EG). — Οδηγία χαμηλής τάσης (2006/95/EC).
Norm, die verwendet wurde: EN 61010-1:2001 (zweite Ausgabe). Πρότυπο που χρησιμοποιήθηκε: EN 61010-1:2001 (δεύτερη έκδοση).
— EMV-Richtlinie (2004/108/EG).* — Οδηγία Ηλεκτρομαγνητικής Συμβατότητας (EMC) (2004/108/EC).*
* Nur für Produkte mit Steuerungsvariante AR oder AT. * Μόνο για προϊόντα με τύπο ελέγχου AR ή AT.
Diese EG-Konformitätserklärung gilt nur, wenn sie in Verbindung mit der Αυτή η δήλωση συμμόρφωσης EC ισχύει μόνον όταν συνοδεύει τις οδηγίες
Grundfos Montage- und Betriebsanleitung veröffentlicht wird. εγκατάστασης και λειτουργίας της Grundfos.
ES: Declaración CE de conformidad FR : Déclaration de conformité CE

Nosotros, Grundfos, declaramos bajo nuestra propia responsabilidad que Nous, Grundfos, déclarons sous notre seule responsabilité, que le produit
el producto DMX 221, al cual se refiere esta declaración, está conforme DMX 221, auquel se réfère cette déclaration, est conforme aux Directives
con las Directivas del Consejo en la aproximación de las leyes de los du Conseil concernant le rapprochement des législations des Etats
Estados Miembros del EM: membres CE relatives aux normes énoncées ci-dessous :
— Directiva de Maquinaria (2006/42/CE). — Directive Machines (2006/42/CE).
Normas aplicadas: EN 809:1998+A1:2009, EN ISO 12100-1+A1:2009, Normes utilisées : EN 809:1998+A1:2009, EN ISO 12100-1+A1:2009,
EN ISO 12100-2+A1:2009. EN ISO 12100-2+A1:2009.
— Directiva de Baja Tensión (2006/95/CE). — Directive Basse Tension (2006/95/CE).
Norma aplicada: EN 61010-1:2001 (segunda edición). Norme utilisée : EN 61010-1:2001 (deuxième édition).
— Directiva EMC (2004/108/CE).* — Directive Compatibilité Electromagnétique CEM (2004/108/CE).*
* Solo para productos con variante de control AR o AT. * Uniquement pour produits avec variante de commande AR ou AT.
Esta declaración CE de conformidad sólo es válida cuando se publique Cette déclaration de conformité CE est uniquement valide lors de sa
como parte de las instrucciones de instalación y funcionamiento de publication dans la notice d'installation et de fonctionnement Grundfos.
Grundfos.
HR: EZ izjava o usklađenosti IT: Dichiarazione di conformità CE

Mi, Grundfos, izjavljujemo pod vlastitom odgovornošću da je proizvod Grundfos dichiara sotto la sua esclusiva responsabilità che il prodotto
DMX 221, na koji se ova izjava odnosi, u skladu s direktivama ovog Vijeća DMX 221, al quale si riferisce questa dichiarazione, è conforme alle
o usklađivanju zakona država članica EU: seguenti direttive del Consiglio riguardanti il riavvicinamento delle
— Direktiva za strojeve (2006/42/EZ). legislazioni degli Stati membri CE:
Korištene norme: EN 809:1998+A1:2009, EN ISO 12100-1+A1:2009, — Direttiva Macchine (2006/42/CE).
EN ISO 12100-2+A1:2009. Norme applicate: EN 809:1998+A1:2009, EN ISO 12100-1+A1:2009,
— Direktiva za niski napon (2006/95/EZ). EN ISO 12100-2+A1:2009.
Korištena norma: EN 61010-1:2001 (drugo izdanje). — Direttiva Bassa Tensione (2006/95/CE).
— Direktiva za elektromagnetsku kompatibilnost (2004/108/EZ).* Norma applicata: EN 61010-1:2001 (seconda edizione).
* Samo za proizvode s vrstom upravljanja AR ili AT. — Direttiva EMC (2004/108/CE).*
* Solo per prodotti con varianti di controllo AR o AT.
Ova EZ izjava o suklađnosti važeća je jedino kada je izdana kao dio
Grundfos montažnih i pogonskih uputa. Questa dichiarazione di conformità CE è valida solo quando pubblicata
come parte delle istruzioni di installazione e funzionamento Grundfos.
LV: EK atbilstības deklarācija HU: EK megfelelőségi nyilatkozat

Sabiedrība GRUNDFOS ar pilnu atbildību dara zināmu, ka produkts Mi, a Grundfos, egyedüli felelősséggel kijelentjük, hogy a DMX 221 termék,
DMX 221, uz kuru attiecas šis paziņojums, atbilst šādām Padomes amelyre jelen nyilatkozik vonatkozik, megfelel az Európai Unió
direktīvām par tuvināšanos EK dalībvalstu likumdošanas normām: tagállamainak jogi irányelveit összehangoló tanács alábbi előírásainak:
— Mašīnbūves direktīva (2006/42/EK). — Gépek (2006/42/EK).
Piemērotie standarti: EN 809:1998+A1:2009, Alkalmazott szabványok: EN 809:1998+A1:2009,
— Zema sprieguma direktīva (2006/95/EK). — Kisfeszültségű Direktíva (2006/95/EK).
Piemērotais standarts: EN 61010-1:2001 (otrā versija). Alkalmazott szabvány: EN 61010-1:2001 (második kiadás).
— Elektromagnētiskās saderības direktīva (2004/108/EK).* — EMC Direktíva (2004/108/EK).*
* Tikai produktiem ar AR vai AT controles variantu. * Csak AR illetve AT vezérlési változat esetén.
Šī EK atbilstības deklarācija ir derīga vienīgi tad, ja ir publicēta kā daļa no Ez az EK megfelelőségi nyilatkozat kizárólag akkor érvényes, ha Grundfos
GRUNDFOS uzstādīšanas un ekspluatācijas instrukcijām. telepítési és üzemeltetési utasítás részeként kerül kiadásra.
2
NL: EC overeenkomstigheidsverklaring PL: Deklaracja zgodności WE
Wij, Grundfos, verklaren geheel onder eigen verantwoordelijkheid dat het My, Grundfos, oświadczamy z pełną odpowiedzialnością, że nasze wyroby
product DMX 221 waarop deze verklaring betrekking heeft, in DMX 221, których deklaracja niniejsza dotyczy, są zgodne z następującymi
overeenstemming is met de Richtlijnen van de Raad in zake de onderlinge wytycznymi Rady d/s ujednolicenia przepisów prawnych krajów
aanpassing van de wetgeving van de EG lidstaten betreffende: członkowskich WE:
— Machine Richtlijn (2006/42/EC). — Dyrektywa Maszynowa (2006/42/WE).
Gebruikte normen: EN 809:1998+A1:2009, EN ISO 12100-1+A1:2009, Zastosowane normy: EN 809:1998+A1:2009,
EN ISO 12100-2+A1:2009. EN ISO 12100-1+A1:2009, EN ISO 12100-2+A1:2009.
— Laagspannings Richtlijn (2006/95/EC). — Dyrektywa Niskonapięciowa (LVD) (2006/95/WE).
Gebruikte norm: EN 61010-1:2001 (tweede editie). Zastosowana norma: EN 61010-1:2001 (drugie wydanie).
— EMC Richtlijn (2004/108/EC).* — Dyrektywa EMC (2004/108/WE).*
* Enkel voor producten met besturingsvariant AR of AT. * Tylko dla produktów w wersji sterowania AR lub AT.
Deze EC overeenkomstigheidsverklaring is alleen geldig wanneer deze Deklaracja zgodności WE jest ważna tylko i wyłącznie wtedy kiedy jest
gepubliceerd is als onderdeel van de Grundfos installatie- en opublikowana przez firmę Grundfos i umieszczona w instrukcji montażu
bedieningsinstructies. i eksploatacji.
PT: Declaração de conformidade CE RU: Декларация о соответствии ЕС

A Grundfos declara sob sua única responsabilidade que o produto Мы, компания Grundfos, со всей ответственностью заявляем, что
DMX 221, ao qual diz respeito esta declaração, está em conformidade com изделия DMX 221, к которым относится настоящая декларация,
as seguintes Directivas do Conselho sobre a aproximação das legislações соответствуют следующим Директивам Совета Евросоюза об
dos Estados Membros da CE: унификации законодательных предписаний стран-членов ЕС:
— Directiva Máquinas (2006/42/CE). — Механические устройства (2006/42/ЕС).
Normas utilizadas: EN 809:1998+A1:2009, Применявшиеся стандарты: EN 809:1998+A1:2009,
— Directiva Baixa Tensão (2006/95/CE). — Низковольтное оборудование (2006/95/EC).
Norma utilizada: EN 61010-1:2001 (segunda edição). Применявшийся стандарт: EN 61010-1:2001 (второе издание).
— Directiva EMC (compatibilidade electromagnética) (2004/108/CE).* — Электромагнитная совместимость (2004/108/EC).*
* Apenas para produtos com sistema de controlo AR ou AT. * Только для насосов с блоком управления AR или AT.
Esta declaração de conformidade CE é apenas válida quando publicada Данная декларация о соответствии ЕС имеет силу только в случае
como parte das instruções de instalação e funcionamento Grundfos. публикации в составе инструкции по монтажу и эксплуатации на
продукцию производства компании Grundfos.
RO: Declaraţie de conformitate CE SI: ES izjava o skladnosti

Noi, Grundfos, declarăm pe propria răspundere că produsele DMX 221, la V Grundfosu s polno odgovornostjo izjavljamo, da so naši izdelki DMX 221,
care se referă această declaraţie, sunt în conformitate cu aceste Directive na katere se ta izjava nanaša, v skladu z naslednjimi direktivami Sveta o
de Consiliu asupra armonizării legilor Statelor Membre CE: približevanju zakonodaje za izenačevanje pravnih predpisov držav članic
— Directiva Utilaje (2006/42/CE). ES:
Standarde utilizate: EN 809:1998+A1:2009, — Direktiva o strojih (2006/42/ES).
EN ISO 12100-1+A1:2009, EN ISO 12100-2+A1:2009. Uporabljeni normi: EN 809:1998+A1:2009,
— Directiva Tensiune Joasă (2006/95/CE). EN ISO 12100-1+A1:2009, EN ISO 12100-2+A1:2009.
Standard utilizat: EN 61010-1:2001 (a doua editie). — Direktiva o nizki napetosti (2006/95/ES).
— Directiva EMC (2004/108/CE).* Uporabljena norma: EN 61010-1:2001 (druga izdaja).
* Numai pentru produsele cu variantă control AR sau AT. — Direktiva o elektromagnetni združljivosti (EMC) (2004/108/ES).*
* Samo za izdelke z kontrolno različico AR ali AT.
Această declarație de conformitate CE este valabilă numai când este
publicată ca parte a instrucțiunilor Grundfos de instalare și funcționare. ES izjava o skladnosti velja samo kadar je izdana kot del Grundfos
instalacije in navodil delovanja.
SE: EG-försäkran om överensstämmelse TR: EC uygunluk bildirgesi

Vi, Grundfos, försäkrar under ansvar att produkten DMX 221, som omfattas Grundfos olarak bu beyannameye konu olan DMX 221 ürünlerinin, AB
av denna försäkran, är i överensstämmelse med rådets direktiv om Üyesi Ülkelerin kanunlarını birbirine yaklaştırma üzerine Konsey
inbördes närmande till EU-medlemsstaternas lagstiftning, avseende: Direktifleriyle uyumlu olduğunun yalnızca bizim sorumluluğumuz altında
— Maskindirektivet (2006/42/EG). olduğunu beyan ederiz:
Tillämpade standarder: EN 809:1998+A1:2009, — Makineler Yönetmeliği (2006/42/EC).
EN ISO 12100-1+A1:2009, EN ISO 12100-2+A1:2009. Kullanılan standartlar: EN 809:1998+A1:2009,
— Lågspänningsdirektivet (2006/95/EG). EN ISO 12100-1+A1:2009, EN ISO 12100-2+A1:2009.
Tillämpad standard: EN 61010-1:2001 (andra upplagan). — Düşük Voltaj Yönetmeliği (2006/95/EC).
— EMC-direktivet (2004/108/EG).* Kullanılan standart: EN 61010-1:2001 (ikinci baskı).
* Endast för produkter med styrenhetsvariant AR eller AT. — EMC Diretifi (2004/108/EC).*
* Sadece AR ve AT kontrol değişkenli ürünler için.
Denna EG-försäkran om överensstämmelse är endast giltig när den
publiceras som en del av Grundfos monterings- och driftsinstruktion. İşbu EC uygunluk bildirgesi, yalnızca Grundfos kurulum ve çalıştırma
talimatlarının bir parçası olarak basıldığı takdirde geçerlilik kazanmaktadır.
CN: EC 产品合格声明书
Pfinztal, 15th May 2012
我们格兰富在我们的全权责任下声明，产品 DMX 221，即该合格证所指之产
品，符合欧共体使其成员国法律趋于一致的以下欧共理事会指令：
— 机械设备指令 (2006/42/EC)。
所用标准 : EN 809:1998+A1:2009, EN ISO 12100-1+A1:2009,
EN ISO 12100-2+A1:2009。
— 低电压指令 (2006/95/EC)。
所用标准 : EN 61010-1:2001 ( 第 2 版 )。
Ulrich Stemick
— 电磁兼容性指令 (2004/108/EC)。* Technical Director
* 仅对控制选项为 AR 或 AT 的型号有效。 Grundfos Water Treatment GmbH
Reetzstr. 85, D-76327 Pfinztal, Germany
本 EC 合格性声明仅在作为格兰富安装与操作指导手册的一部分时有效。
Person authorised to compile technical file and
empowered to sign the EC declaration of conformity.
3
English (GB) Installation and operating instructions
English (GB)
Original installation and operating instructions. 11.3 Cleaning the suction and discharge valves 21
11.4 Maintenance of the relief valve 21
CONTENTS 11.5 Replacing the diaphragm 22
Page 12. Fault finding chart 23
13. Dosing curves 24
1. General information 4
1.1 Introduction 4 14. Disposal 28
1.2 Applications 4
1.3 Warranty 4
Warning
2. Safety 4
These complete installation and operating
2.1 Identification of safety instructions in this manual 4
instructions are also available on
2.2 Qualification and training of personnel 5 www.grundfos.com.
2.3 Risks when safety instructions are not observed 5
Prior to installation, read these installation and
2.4 Safety-conscious working 5
operating instructions. Installation and operation
2.5 Safety instructions for the operator/user 5
must comply with local regulations and accepted
2.6 Safety instructions for maintenance, inspection and
installation work 5 codes of good practice.
2.7 Unauthorised modification and manufacture of spare
parts 5 1. General information
2.8 Improper operating methods 5
2.9 Safety of the system in the event of a failure in the 1.1 Introduction
dosing system 5 These installation and operating instructions contain all the
3. Technical data 5 information required for starting up and handling the DMX 221
3.1 Identification 5 dosing pump.
3.2 Type key 6 If you require further information or if any problems arise, which
3.3 Pump performance 7 are not described in detail in this manual, please contact
3.4 Suction heights 8 Grundfos.
3.5 Ambient and operating conditions 9
3.6 Dosing medium 9 1.2 Applications
3.7 Electrical data 9 The DMX 221 pump is suitable for liquid, non-abrasive and
3.8 AR control unit 9 non-flammable media strictly in accordance with the instructions
3.9 Materials 10 in this manual.
3.10 Weights 10 The DMX 221 dosing pumps have not been approved according
3.11 Dimensional sketches 11 to the EC directive 94/9/EC, the so-called ATEX directive.
4. Transport and storage 12 The application of these pumps in potentially explosive
4.1 Delivery 12 environments according to ATEX directive is therefore not
4.2 Intermediate storage 12 permitted.
4.3 Unpacking 12
Warning
4.4 Return 12
Other applications or the operation of pumps in
5. Installation 13
ambient and operating conditions, which are not
5.1 Optimum installation 13
approved, are considered improper and are not
5.2 Installation tips 13
permitted. Grundfos accepts no liability for any
5.3 Mounting 14
damage resulting from incorrect use.
5.4 Hose / pipe lines 14
5.5 Connecting the suction and discharge lines 14 1.3 Warranty
6. Electrical connections 15 A guarantee claim in accordance with our general terms of sale
6.1 Versions with mains plug 15 and delivery is only valid if the following requirements are fulfilled:
6.2 Versions without mains plug 15
• The product is used in accordance with the information within
7. Commissioning 16 this manual.
7.1 Checks before start-up 16
• The product is not dismantled or incorrectly handled.
7.2 Start-up 16
• The maintenance is carried out by authorised and qualified
8. Operation 16
personnel.
8.1 Description of the pump 16
8.2 Switching on/off 16
8.3 Adjusting the dosing flow via the stroke length 17 2. Safety
8.4 Stroke-length adjustment 17 This manual contains general instructions that must be observed
8.5 Adjustment of stroke rate using a frequency converter 17 during installation, operation and maintenance of the pump.
8.6 Using the AR control unit 17 This manual must therefore be read by the installation engineer
9. Operation with other electronics 17 and the relevant qualified personnel/operators prior to installation
9.1 Electronics version stroke sensor 17 and start-up, and must be available at the installation location of
9.2 Electronic diaphragm leakage sensor 18 the pump at all times.
10. Integral relief valve 20 It is not only the general safety instructions given in this "Safety"
10.1 Function 20 section that must be observed, but also all the specific safety
10.2 Permissible media 20 instructions given in other sections.
10.3 Connections 20 2.1 Identification of safety instructions in this manual
10.4 Setting of opening pressure 20
10.5 Venting 20 If the safety instructions or other advice in this manual are not
10.6 Fault finding chart 21 observed, it may result in personal injury or malfunction and
damage to the pump. The safety instructions and other advice are
11. Maintenance 21
identified by the following symbols:
11.1 General notes 21
11.2 Cleaning and maintenance intervals 21
4
Warning Warning
English (GB)
If these safety instructions are not observed, Electrical connections must only be carried out
it may result in personal injury! by qualified personnel!
The pump housing must only be opened by
If these safety instructions are not observed, personnel authorised by Grundfos!
Caution it may result in malfunction or damage to the
equipment!
2.7 Unauthorised modification and manufacture of
spare parts
Notes or instructions that make the job easier Modification or changes to the pump are only permitted following
Note
and ensure safe operation. agreement with the manufacturer. Original spare parts and
Information provided directly on the pump, e.g. labelling of fluid accessories authorised by the manufacturer are safe to use.
connections, must be observed and must be maintained in a Using other parts can result in liability for any resulting
readable condition at all times. consequences.
2.2 Qualification and training of personnel 2.8 Improper operating methods

The personnel responsible for the operation, maintenance, The operational safety of the supplied pump is only ensured if it is
inspection and installation must be appropriately qualified for used in accordance with section 3. Technical data. The specified
these tasks. Areas of responsibility, levels of authority and the limit values must under no circumstances be exceeded.
supervision of the personnel must be precisely defined by the
operator. 2.9 Safety of the system in the event of a failure in the
If the personnel do not have the necessary knowledge, the dosing system
necessary training and instruction must be given. If necessary, DMX 221 dosing pumps are designed according to the latest
training can be performed by the manufacturer/supplier at the technologies and are carefully manufactured and tested.
request of the operator of the pump. It is the responsibility of the However, a failure may occur in the dosing system. Systems in
operator to make sure that the contents of this manual are which dosing pumps are installed must be designed in such a
understood by the personnel. way that the safety of the entire system is still ensured following a
failure of the dosing pump. Provide the relevant monitoring and
2.3 Risks when safety instructions are not observed control functions for this.
Non-observance of the safety instructions may have dangerous
consequences for the personnel, the environment and the pump. 3. Technical data
If the safety instructions are not observed, all rights to claims for
damages may be lost. 3.1 Identification
Non-observance of the safety instructions may lead to the
following hazards:
• failure of important functions of the pump/system
• failure of specified methods for maintenance 1
DMX 4-10 B-PP/E/T-X-4144X 2
• harm to humans from exposure to electrical, mechanical and 11
96293585 Type: DMX 221
chemical influences S/N:00529211 10
• damage to the environment from leakage of harmful 3 4.00 L/h, 10.00 bar, 50 Hz
5
substances. 230/400V 50/60Hz 440/480V 60 Hz
4
TM03 8599 4313

96293585P11053100529211 9
2.4 Safety-conscious working
6
The safety instructions in this manual, applicable national health 7 8
Made in Germany
and safety regulations and any operator internal working,
operating and safety regulations must be observed.
Fig. 1 DMX nameplate
2.5 Safety instructions for the operator/user
Hazardous hot or cold parts on the pump must be protected to
Pos. Description
prevent accidental contact.
Leakages of dangerous substances (e.g. hot, toxic) must be 1 Type designation
disposed of in a way that is not harmful to the personnel or the 2 Model
environment. Legal regulations must be observed. 3 Maximum capacity [l/h]
Damage caused by electrical energy must be prevented (for more
4 Voltage [V]
details, see for example the regulations of the VDE and the local
electricity supply company). 5 Frequency [Hz]
6 Product number
2.6 Safety instructions for maintenance, inspection
7 Country of origin
and installation work
8 Year and week code
The operator must ensure that all maintenance, inspection and
installation work is carried out by authorised and qualified 9 Marks of approval, CE mark, etc.
personnel, who have been adequately trained by reading this 10 Maximum pressure [bar]
manual. 11 Serial number
All work on the pump should only be carried out when the pump is
stopped. The procedure described in this manual for stopping the
pump must be observed.
Pumps or pump units which are used for media that are harmful
to health must be decontaminated.
All safety and protective equipment must be immediately
restarted or put into operation once work is complete.
Observe the points described in the initial start-up section prior to
subsequent start-up.
5
3.2 Type key
English (GB)
Example: DMX 115 - 3 B PP /E /T -X -E 1 QQ X E0

Type range
Maximum flow [l/h]
Maximum counterpressure [bar] Motor variant
Control variant E0 PTC motor for frequency control
B Standard - manual control Mains plug
AR** Analog/pulse control F EU (Schuko)
AT0 Prepared for servomotor B USA, Canada
AT3 Servomotor, 1 x 230 V, 50/60 Hz supply, I Australia, New Zealand
4-20 mA control E Switzerland
AT5 Servomotor, 1 x 115 V, 50/60 Hz supply, X No plug
4-20 mA control Connection, suction/discharge
AT8 Servomotor, 1 x 230 V, 50/60 Hz supply, 4 Tube 6/9 mm
1 kΩ potentiometer control B1 Tube 6/12 mm/
cementing diameter 12 mm
AT9 Servomotor, 1 x 115 V, 50/60 Hz supply, 6 Tube 9/12 mm
1 kΩ potentiometer control B2 Tube 13/20 mm/
cementing diameter 25 mm
Dosing head variant Q Tube 19/27 mm and 25/34 mm
PP Polypropylene R Tube 1/4" / 3/8"
PV PVDF (polyvinylidene fluoride) S Tube 3/8" / 1/2"
PVC Polyvinyl chloride C5 Hose clamp 1/2"
SS Stainless steel 1.4571* A Threaded Rp 1/4
PV-R PVDF + integrated relief valve A1 Threaded Rp 3/4
PVC-R PVC + integrated relief valve V Threaded 1/4" NPT, female
PP-L PP + integrated diaphragm leakage detection A9 Threaded 1/2" NPT, male
PV-L PVDF + integrated diaphragm leakage detection A3 Threaded 3/4" NPT, female
PVC-L PVC + integrated diaphragm leakage detection A7 Threaded 3/4" NPT, male
SS-L SS + integrated diaphragm leakage detection B3 Welding, diameter 16 mm
PV-RL PVDF + integrated relief valve and B4 Welding, diameter 25 mm
diaphragm leakage detection Valve type
PVC-RL PVC + integrated relief valve and 1 Standard valve
diaphragm leakage detection 3 Spring-loaded
Gasket material 0.05 bar suction opening pressure
0.8 bar discharge opening pressure
E EPDM 4 Spring-loaded, discharge side only
0.8 bar opening pressure
V FKM 5 Valve for abrasive media
T PTFE Supply voltage
Valve ball material G 1 x 230 V, 50/60 Hz
G Glass H 1 x 120 V, 50/60 Hz
T PTFE E 3 x 230/400 V, 50/60 Hz
SS Stainless steel 1.4401* or 3 x 440/480 V, 60 Hz
Control panel position F Without motor, NEMA flange (US)
F Front-mounted (opposite to the dosing head) 0 Without motor, IEC flange
S Side-mounted (same side as the stroke-length adjustment
knob)
Sx Side-mounted (side opposite to the stroke-length adjustment
knob)
W Wall-mounted
X No control panel
* According to EN 10027-2
** Only pumps up to and including 0.37 kW and only pumps with single-phase motors
6
3.3 Pump performance
English (GB)
3.3.1 Accuracy
• Dosing flow fluctuation: ± 1.5 % within the control range 1:10.
• Linearity deviation: ± 4 % of the full-scale value.
Adjustment from max. to min. stroke length, within the control
range 1:5.
Applies to:
• water as dosing medium
• fully deaerated dosing head
• measurement according to Grundfos Water Treatment factory
standard no. 0010/0011
• standard pump version.
3.3.2 Performance
Applies to:
• maximum counterpressure
• water as dosing medium
• flooded suction 0.5 mWC
• fully deaerated dosing head
• three-phase 400 V motor.
Stroke 50 Hz 60 Hz
volume
Pump type V Q** p max.* Max. stroke rate Q** p max.** Max. stroke rate
[cm3] [l/h] [bar]* [n/min] [l/h] [US gph] [bar]* [psi]* [n/min]
DMX 4-10 2.2 4 10 29 5 1.3 10 145 35
DMX 7-10 3.8 7 10 29 8 2.1 10 145 35
DMX 9-10 4.9 9 10 29 11 2.9 10 145 35
DMX 12-10 6.9 12 10 29 14 3.7 10 145 35
DMX 17-4 10.4 17 4 29 20 5.3 4 58 35
DMX 25-3 16 27 3 29 32 8.5 3 43 35
DMX 7.2-16** 1.9 7.2 16 63 10 2.6 16 232 75
DMX 8-10 2.2 8 10 63 10 2.6 10 145 75
DMX 14-10 3.8 14 10 63 17 4.5 10 145 75
DMX 18-10 4.9 18 10 63 22 5.8 10 145 75
DMX 26-10 6.9 26 10 63 31 8.2 10 145 75
DMX 39-4 10.4 39 4 63 47 12.4 4 58 75
DMX 60-3 16 60 3 63 72 19.0 3 43 75
DMX 13.7-16** 1.9 13.7 16 120 19 5.0 16 232 144
DMX 16-10 2.2 16 10 120 19 5.0 10 145 144
DMX 27-10 3.8 27 10 120 32 8.5 10 145 144
DMX 35-10 4.9 35 10 120 42 11.1 10 145 144
DMX 50-10 6.9 50 10 120 60 15.8 8 116 144
DMX 75-4 10.4 75 4 120 90 23.8 3.5 50 144
DMX 115-3 16 115 3 120 138 36.5 2.5 36 144
* Maximum counterpressure
** When operating with a counterpressure of 16 bar, the life of the dosing diaphragm will be reduced.
7
3.4 Suction heights
English (GB)
3.4.1 Media with a viscosity similar to water

Applies to:
• counterpressure of 1.5 to 3 bar
• non-degassing and non-abrasive media
• temperature of 20 °C
• stroke length 100 %.
50 Hz 60 Hz Maximum length of
Pump type Suction height* Intake height** Suction height* Intake height** suction line
[mWC] [mWC] [mWC] [mWC] [m]
DMX 4-10 4 4 4 4 5
DMX 7-10 4 4 4 4 5
DMX 9-10 3 3 3 3 4
DMX 12-10 3 2.5 3 2.5 4
DMX 17-4 1 1 1 1 2
DMX 25-3 1 1 1 1 2
DMX 7.2-16 4 3 4 3 5
DMX 8-10 4 4 4 4 5
DMX 14-10 4 3 4 4 5
DMX 18-10 3 3 3 3 4
DMX 26-10 3 2.5 3 2.5 4
DMX 39-4 1 1 1 1 2
DMX 60-3 1 1 1 1 2
DMX 13.7-16 4 3 3.5 2.5 5
DMX 16-10 4 3 3.5 2.5 5
DMX 27-10 4 3 3.5 2.5 5
DMX 35-10 3 2 2.5 2 4
DMX 50-10 3 2 2.5 1.5 4
DMX 75-4 1 1 0.5 0.5 2
DMX 115-3 1 1 0.5 0.5 2
* Suction line and dosing head filled (continuous operation).
** Suction line and dosing head not filled, but dosing head and valves moistened (start-up).
8
3.4.2 Suction heights for media with maximum permissible 3.6 Dosing medium
viscosity
English (GB)
In the event of questions regarding the material
Applies to:
Caution resistance and suitability of the pump for specific
• Newtonian liquids
dosing media, please contact Grundfos.
• non-degassing and non-abrasive media
The dosing medium must have the following basic characteristics:
• temperature of 20 °C.
• liquid
Maximum viscosity Intake height • non-abrasive
Pump type • non-flammable.
[mPa s] [mWC]
DMX 4-10 400 1 3.6.1 Permissible media temperature
DMX 7-10 400 1
Dosing head Temperature range
DMX 9-10 200 1
material p < 10 bar p < 16 bar
DMX 12-10 200 1
DMX 17-4 200 1 mWC flooded suction PVC 0 °C to 40 °C 0 °C to 20 °C
DMX 25-3 200 1 mWC flooded suction Stainless steel* -10 °C to 70 °C -10 °C to 70 °C
DMX 7.2-16 400 1 PP 0 °C to 40 °C -
DMX 8-10 400 1 -10 °C to 60 °C -10 °C to 20 °C
PVDF
DMX 14-10 400 1 70 °C at 9 bar
DMX 18-10 200 1 * For SIP/CIP applications: A temperature of 145 °C at a
DMX 26-10 200 1 mWC flooded suction counterpressure of max. 2 bar is permitted for a short period
DMX 39-4 100 1 (15 minutes).
DMX 60-3 100 1 Observe the freezing and boiling points of the
Caution
DMX 13.7-16 200 1 dosing medium!
DMX 16-10 200 1
3.7 Electrical data
DMX 27-10 200 1
3.7.1 Enclosure class
DMX 35-10 100 1
The enclosure class depends on the motor variant selected, see
DMX 50-10 100 1 motor nameplate.
DMX 75-4 100 1 mWC flooded suction The specified enclosure class can only be ensured if the power
DMX 115-3 100 1 mWC flooded suction supply cable is connected with the same degree of protection.
Pumps with electronics: The enclosure class is only met if the
3.5 Ambient and operating conditions sockets are protected! The data regarding the enclosure class
• Permissible ambient temperature: 0 °C to +40 °C. applies to pumps with correctly inserted plugs or screwed-on
• Permissible storage temperature: -20 °C to +50 °C. caps.
• Permissible air humidity: max. relative humidity: 3.7.2 Motor
70 % at 40 °C, 90 % at 35 °C. Version: see motor and pump nameplates.
The installation site must be under cover!
3.8 AR control unit
Ensure that the enclosure class of motor and
pump are not affected by the atmospheric Functions of pumps with electronics:
Caution
conditions. • "Continuous operation" button for function test and dosing
Pumps with electronics are only suitable for head deaeration
indoor use! Do not install outdoors! • memory function (stores a maximum of 65000 pulses)
• two-stage tank-empty signal (e.g. via Grundfos tank empty
Warning sensor)
Risk of hot surfaces! • stroke signal/pre-empty signal (adjustable), e.g. as a feedback
Pumps with AC motors may become hot. to the control room
Allow a minimum space of 100 mm above the fan
• dosing controller function (only with sensor - optional)
cover!
• diaphragm leakage detection (only with sensor - optional)
• Sound pressure level: ± 55 dB(A), testing according to
• access-code-protected settings
DIN 45635-01-KL3.
• remote on/off
• Minimum counterpressure: 1 bar at the pump discharge valve.
Pay attention to the pressure losses along the way to the • Hall sensor
injection point inclusively. • operating hours counter
Pumps with AR control unit only • motor monitoring.
Maximum permissible mains impedance: 0.084 + j 0.084 Ω Operating modes:
(testing according to EN 61000-3-11). • manual
Stroke frequency: manually adjustable between zero and
maximum
• contact signal control
Multiplier (1:n) and divisor (n:1)
• current signal control 0-20 mA / 4-20 mA
Adjustment of stroke frequency proportional to the current
signal.
Weighting of current input.
9
3.8.1 Inputs and outputs
English (GB)
Inputs
Contact signal Maximum load: 12 V, 5 mA
Current 0-20 mA Maximum load: 22 Ω
Remote on/off Maximum load: 12 V, 5 mA
Two-stage tank-empty signal Maximum load: 12 V, 5 mA
Dosing controller and diaphragm leakage sensor
Outputs
Current 0-20 mA Maximum load: 350 Ω
Maximum ohmic load:
Error signal
50 VDC / 75 VAC, 0.5 A
Stroke signal Contact time/stroke: 200 ms
Maximum ohmic load:
Pre-empty signal
50 VDC / 75 VAC, 0.5 A
AR control unit factory settings

• Inputs and outputs: NO (normally open)
or
• inputs and outputs: NC (normally closed).
3.9 Materials
• Upper part of enclosure: PPO blend
• Lower part of enclosure: PP, glass-fibre-reinforced
• Stroke-length adjustment knob: ABS.
AR control unit enclosure
• Upper part of enclosure: PPO blend
• Lower part of enclosure: aluminium.
3.10 Weights
Weight
Pump type Plastics Stainless steel
[kg] [kg]
DMX 4-10 5 7
DMX 7-10 5 7
DMX 9-10 5 7
DMX 12-10 5 7
DMX 17-4 7.5 12
DMX 25-3 8 13
DMX 7.2-16 5 7
DMX 8-10 5 7
DMX 14-10 5 7
DMX 18-10 5 7
DMX 26-10 5 7
DMX 39-4 7.5 12
DMX 60-3 8 13
DMX 13.7-16 5 7
DMX 16-10 5 7
DMX 27-10 5 7
DMX 35-10 5 7
DMX 50-10 5 7
DMX 75-4 7.5 12
DMX 115-3 8 13
10
3.11 Dimensional sketches
English (GB)
A3
B4
B3
min. 100 59
14
D1
H1
H3
H2
102.5
C1
TM03 6295 1612

A2 C2 B2
C4 D2 B1
A1
Fig. 2 Dimensional sketches of DMX 221
Pump type A1 A2 A3 B1 B2 B3 B4 C1 C2 C4 D1 D2 H1 H2 H3
DMX 4-10 180 159 275 123 105 175 205 32 10.5 25 R 5/8 6.5 319 179 153
DMX 7-10 180 159 275 123 105 175 205 32 10.5 25 R 5/8 6.5 319 179 153
DMX 7.2-16 180 159 275 123 105 175 205 32 10.5 25 R 5/8 6.5 319 179 153
DMX 9-10 180 159 275 123 105 175 205 32 10.5 25 R 5/8 6.5 319 179 153
DMX 12-10 180 159 275 123 105 175 205 32 10.5 25 R 5/8 6.5 319 179 153
DMX 17-4 180 159 323 123 105 175 205 64 10.5 38 R 1 1/4 6.5 319 192 177
DMX 25-3 180 159 330 123 105 175 205 80 10.5 40 R 1 1/4 6.5 319 197 188
DMX 8-10 180 159 275 123 105 175 205 32 10.5 25 R 5/8 6.5 319 179 153
DMX 13.7-16 180 159 275 123 105 175 205 32 10.5 25 R 5/8 6.5 319 179 153
DMX 14-10 180 159 275 123 105 175 205 32 10.5 25 R 5/8 6.5 319 179 153
DMX 18-10 180 159 275 123 105 175 205 32 10.5 25 R 5/8 6.5 319 179 153
DMX 26-10 180 159 275 123 105 175 205 32 10.5 25 R 5/8 6.5 319 179 153
DMX 39-4 180 159 323 123 105 175 205 64 10.5 38 R 1 1/4 6.5 319 192 177
DMX 60-3 180 159 330 123 105 175 205 80 10.5 40 R 1 1/4 6.5 319 197 188
DMX 16-10 180 159 275 123 105 175 205 32 10.5 25 R 5/8 6.5 319 179 153
DMX 27-10 180 159 275 123 105 175 205 32 10.5 25 R 5/8 6.5 319 179 153
DMX 35-10 180 159 275 123 105 175 205 32 10.5 25 R 5/8 6.5 319 179 153
DMX 50-10 180 159 275 123 105 175 205 32 10.5 25 R 5/8 6.5 319 179 153
DMX 75-4 180 159 323 123 105 175 205 64 10.5 38 R 1 1/4 6.5 319 192 177
DMX 115-3 180 159 330 123 105 175 205 80 10.5 40 R 1 1/4 6.5 319 197 188
Measurements in mm.
11
4. Transport and storage
English (GB)
Do not throw or drop the pump.

Store the pump in a dry and cool place.
Store the pump in upright position so that the
Caution gear grease cannot leak out.
Do not use the protective packaging as transport
packaging.
Observe the permissible storage temperature!
4.1 Delivery
The DMX 221 dosing pumps are supplied in different packaging,
depending on pump type and the overall delivery. For transport
and intermediate storage, use the correct packaging to protect
the pump against damage.
4.2 Intermediate storage

• Permissible storage temperature: -20 °C to +50 °C.
• Permissible air humidity: max. relative humidity: 92 %
(non-condensing).
4.3 Unpacking
Retain the packaging for future storage or return, or dispose of
the packaging in accordance with local regulations.
4.4 Return
Return the pump in its original packaging or equivalent.
The pump must be thoroughly cleaned before it is returned or
stored. It is essential that there are no traces of toxic or
hazardous media remaining on the pump.
Grundfos accepts no liability for damage caused

Caution by incorrect transportation or missing or
unsuitable packaging of the pump!
Before returning the pump to Grundfos for service, the safety
declaration at the end of these instructions must be filled in by
authorised personnel and attached to the pump in a visible
position.
If a pump has been used for a medium which is

Caution injurious to health or toxic, the pump will be
classified as contaminated.
If Grundfos is requested to service the pump, it must be ensured
that the pump is free from substances that can be injurious to
health or toxic. If the pump has been used for such substances,
the pump must be cleaned before it is returned.
If proper cleaning is not possible, all relevant information about
the chemical must be provided.
If the above is not fulfilled, Grundfos can refuse to accept the
pump for service. Possible costs of returning the pump are paid
by the customer.
The safety declaration can be found at the end of these instructions.
The replacement of the supply cable must be

Caution carried out by an authorised Grundfos service
workshop.
12
5. Installation
English (GB)
5.1 Optimum installation
8i
9i
2i
7i
max.
Max.1m
1m 10i
6i
1i 4i 5i
3i
TM03 6296 4506

Fig. 3 Example of optimum installation
• For non-degassing media with a viscosity similar to water, the

Pos. Components pump can be mounted on the tank (observe the maximum
1i Dosing tank suction height).
• Flooded suction preferred.
2i Electric agitator
• For media with a tendency to sedimentation, install the suction
3i Extraction device
line with filter (13i) so that the suction valve remains a few
4i Suction pulsation damper millimetres above the possible level of sedimentation.
5i Dosing pump
p
6i Relief valve
6i 10i
7i Pressure-loading valve
8i Pulsation damper
9i Measuring glass
10i Injection unit
TM03 6299 4506

5.2 Installation tips
13i
• For easy deaeration of the dosing head, install a ball
valve (11i) with bypass line (back to the dosing tank)
immediately after the discharge valve.
• In the case of long discharge lines, install a non-return Fig. 6 Tank installation
valve (12i) in the discharge line.
• Note for suction-side installation: In dosing systems with a
suction line longer than 1 metre, depending on the dosing flow,
11i 12i
it may be necessary to install a properly sized pulsation
damper (4i) immediately before the pump suction valve.
TM03 6297 4506
4i
TM03 6300 4506
Fig. 4 Installation with ball valve and non-return valve
• When installing the suction line, observe the following:

– Keep the suction line as short as possible. Prevent it from
becoming tangled.
– If necessary, use swept bends instead of elbows. Fig. 7 Installation with suction-side pulsation damper
– Always route the suction line up towards the suction valve.
– Avoid loops which may cause air bubbles.
TM03 6298 4506
Fig. 5 Installation of suction line
13
• Note for discharge-side installation: To protect the piping, use • To avoid the siphon effect, install a pressure-loading valve (7i)
a pulsation damper (8i) for rigid piping longer than 3 metres in the discharge line and, if necessary, a solenoid valve (14i) in
English (GB)
and tubing longer than 5 metres. the suction line.
p1 p2p-p p 1≥>
2 -1 _1 bar
1 bar
8i
p2
TM03 6304 4506

14i
TM03 6301 4506

Fig. 11 Installation to avoid the siphon effect
Warning
Fig. 8 Installation with discharge-side pulsation damper
Risk of hot surfaces!
• For degassing and viscous media: flooded suction. Pumps with AC motors may become hot. Allow a
• To protect the dosing pump and the discharge line against minimum space of 100 mm to the fan cover!
excessive pressure build-up, install a relief valve (6i) in the
5.3 Mounting
discharge line.
• Mount the pump horizontally on the tank or on a console using
p four M6 screws.
6i
10i Gently tighten the screws in order not to damage
Caution
the plastic enclosure!
TM03 6302 4506
5.4 Hose / pipe lines

5.4.1 General
Warning
Fig. 9 Installation with relief valve To protect the dosing pump against excessive
pressure build-up, install a relief valve in the
With open outflow of the dosing medium or a
discharge line.
counterpressure below 1 bar
Only use the prescribed line types!
• Install a pressure-loading valve (7i) immediately before the
outlet or the injection unit. All lines must be free from strain!
A positive pressure difference of at least 1 bar must be ensured Avoid loops and buckles in the hoses!
between the counterpressure at the injection point and the Keep the suction line as short as possible to
pressure of the dosing medium at the pump suction valve. avoid cavitation!
• If this cannot be ensured, install a pressure-loading valve (7i) If necessary, use swept bends instead of elbows.
in the discharge line. Observe the chemical manufacturer's safety
instructions when handling chemicals!
pp ≥≥11bar
bar Make sure that the pump is suitable for the actual
7i
dosing medium!
The flow must run in the opposite direction to
gravity!
The resistance of the parts that come into contact

with the media depends on the media, media
temperature and operating pressure. Ensure that
TM03 6303 4506
Caution
parts in contact with the media are chemically
resistant to the dosing medium under operating
conditions!
5.5 Connecting the suction and discharge lines

Fig. 10 Installation with pressure-loading valve
Warning
All lines must be free from strain!
Only use the prescribed line types!
• Connect the suction line to the suction valve.
– Install the suction line in the tank so that the foot valve
remains 5 to 10 mm above the bottom of the tank or the
possible level of sedimentation.
• Connect the discharge line to the discharge valve.
14
Connection of hose lines 6. Electrical connections
English (GB)
• Push the hose firmly onto the connection nipple and, Make sure that the pump is suitable for the electricity supply on
depending on the connection, secure using a connection which it will be used.
counterpart or hose support clip.
• Fit the gasket. Warning
• Screw onto the valve using the union nut. Electrical connections must only be carried out
by qualified personnel!
Disconnect the power supply before connecting
the power supply cable and the relay contacts!
Observe the local safety regulations!
Warning
personnel authorised by Grundfos!
TM03 6456 4506

Warning
Protect the cable connections and plugs against
corrosion and humidity.
Only remove the protective caps from the
sockets that are being used.
Fig. 12 Connection of hose lines
The power supply must be electrically isolated
Connection of DN 20 pipe lines Caution
from the signal inputs and outputs.
• Depending on the pipe material and connection, glue it (PVC),
weld it (PP, PVDF or stainless steel) or press it in (stainless The pump is switched off by switching off the
steel). power supply.
Note
• Fit the gasket. Do not switch on the power supply until the pump
• Screw onto the valve using the union nut. is going to be started.
6.1 Versions with mains plug

• Insert the mains plug in the mains socket.
6.2 Versions without mains plug

• Connect the motor according to the wiring diagram in the
terminal box.
TM03 6457 4506
Observe the direction of rotation!

A motor protector, adjusted to the rated motor
current, must be provided by the customer.
This is also necessary for versions with AR
Fig. 13 Connection of DN 20 pipe lines control unit!
Caution
When the pump is used with a frequency
Using a dosing controller converter, the jumpers in the terminal box have to
• Screw the dosing controller onto the discharge valve. be set according to the converter voltage.
• Connect the discharge line to the dosing controller. The jumpers of three-phase motors are
factory-set for star connection.
flow
2 mm
TM03 6379 0911
Fig. 14 Dosing controller
15
7. Commissioning 8. Operation
English (GB)
7.1 Checks before start-up In the event of a diaphragm leakage, the dosing
• Check that the rated voltage stated on the pump nameplate liquid may leak out of the hole in the intermediate
corresponds to the local conditions! flange between the pump and the dosing head.
The parts inside the housing are protected from
• Check that all connections are secure and tighten,
the dosing liquid for a short time (depending on
if necessary. Caution
the type of liquid) by the housing sealing. It is
• Check that the dosing head screws are tightened with the necessary to check regularly (daily) if liquid is
specified torque and tighten, if necessary. leaking out of the intermediate flange.
• Check that all electrical connections are correct. For maximum safety, we recommend the pump
version with diaphragm leakage detection.
7.2 Start-up
8.1 Description of the pump
Before start-up, open the venting cartridge (pull
cap approx. 5 mm).
Caution 9 1 9
For transport or cleaning, the venting cartridge
must be closed.
After initial start-up and after each time the

diaphragm is changed, tighten the dosing head
screws.
Caution After approximately 6-10 operating hours or two 7 4 3
days, cross-tighten the dosing head screws
using a torque wrench.
Maximum torque: 6 Nm. 8
2
1. Open the suction and discharge isolating valves (15, 16), 5
if installed.
TM03 6308 4506

2. Open the deaeration valve (17), if installed, in the discharge
line, or relieve the pressure on the discharge side so that the 10
medium can run out without a counterpressure.
3. Switch on the power supply. 6
4. Pumps with AR control unit only: Press the "Start/Stop" button
and keep it pressed. Fig. 16 DMX 221
– The pump switches to continuous operation.

5. Set the stroke-length adjustment knob to 100 %. Pos. Components
6. Leave the pump running until the dosed medium is free of air 1 Motor
bubbles.
2 Gears
7. Close the deaeration valve (17), if installed.
3 Eccentric
– The pump is now ready for operation.
4 Dosing diaphragm
17 16 5 Dosing head
6 Suction valve
7 Discharge valve
8 Stroke-length adjustment knob
9 AR control unit (optional)
TM03 6307 4506
10 Stroke sensor
Functional principle
15 • Reciprocating positive displacement pump with electric motor
and mechanical diaphragm control.
Fig. 15 Initial start-up • The rotation of the motor is transformed into the reciprocating
movement of the dosing diaphragm by the eccentric and the
tappet.
• The dosing flow can be set by adjusting the stroke length of
the tappet.
8.2 Switching on/off
Before switching on the pump, check that it is

Caution installed correctly. Refer to sections
5. Installation and 7. Commissioning.
• To start the pump, switch on the power supply.
• To stop the pump, switch off the power supply.
16
8.3 Adjusting the dosing flow via the stroke length 8.5 Adjustment of stroke rate using a frequency
English (GB)
converter
Adjust the stroke length only while the pump is
Caution If a frequency converter is connected, the stroke rate can only be
running!
adjusted in the range 10-100 % of max. stroke rate.
• To increase the dosing flow, turn the stroke-length adjustment See installation and operating instructions for the frequency
knob (8) slowly to the left until the desired dosing flow is converter!
reached.
• To decrease the dosing flow, turn the stroke-length adjustment Warning
knob (8) slowly to the right until the desired dosing flow is Observe the manufacturer’s instructions!
reached. The connections must be carried out according
to these instructions.
50 Settings of frequency converter when used with Grundfos
60 40
dosing pumps
70 30
Pay special attention to the following parameters of the frequency
TM03 6309 4506

80 20 8 converter:
90 10 • P013 (maximum motor frequency):
100% 0 – Set the frequency converter to maximum 100 Hz.
– Due to this setting, the maximum stroke frequency of the
Fig. 17 Stroke-length adjustment knob pump cannot be exceeded.
• P086 (motor current limit):
8.4 Stroke-length adjustment
– Do not change the default setting (150 %).
Warning – The motor is protected by a PTC resistor. Therefore, this
Wear protective clothing (gloves and goggles) parameter is not necessary.
when working on the dosing head, connections • P081 - P085 (motor data):
or lines! – Set these parameters to the values stated on the motor
nameplate.
Caution – Observe the manufacturer’s instructions!
running!
The zero point (no dosing) of the dosing pump is factory-set to a 8.6 Using the AR control unit
counterpressure of 3 bar. See section 13. Dosing curves.
When using the AR control unit, observe the installation and
If the operating counterpressure at the injection unit deviates operating instructions supplied with the unit in addition to the
considerably from this value, it is advisable to readjust the zero instructions in this manual.
point to obtain more precise values.
1. Install a graduated pipe at the suction valve. 9. Operation with other electronics
– If such a pipe is not available, insert the suction line into a
graduated measuring jug. First refer to the general section 8. Operation.
2. Start the dosing pump. Caution This section only describes the additional
functions.
3. Set the dosing flow to 15 %.
4. For pumps with tank-empty indication, remove the electric 9.1 Electronics version stroke sensor
plug of the tank-empty indication.
Pump type with inductive-proximity switch of two-wire design
5. Turn the adjustment knob slowly clockwise (towards the zero according to NAMUR DIN 19234 for signalling the strokes.
point) until the medium level stops falling in the measuring jug
The sensor can be installed in potentially explosive atmospheres
or pipe.
if PTB-approved isolating switching amplifiers with an intrinsically
6. Remove the plug with a small screwdriver without changing safe control circuit [EExia] or [EExib] are connected. The sensor
the position of the adjustment knob and unscrew the can be used up to zone 1 depending on the isolating amplifier.
cheese-head screw together with the flat spiral spring. The specifications in the declaration of conformity for the isolating
7. Gently pull off the adjustment knob and fit it on the adjusting amplifier must be observed.
spindle so that the zero line on the scale and the mark on the Supply voltage UB: 7.7 to 10 V.
adjustment knob coincide.
8. Screw in the cheese-head screw and the spiral spring until the
spring is preloaded, but does not block. Even when adjusted
to 100 %, the spring of the adjustment knob must remain
preloaded.
TM03 6310 4506
Fig. 18 Stroke-length adjustment
17
9.2 Electronic diaphragm leakage sensor To ensure electromagnetic compatibility (EMC), the input cables
and current output cables must be screened.
English (GB)
9.2.1 Technical data

1. Connect the screen at one end to PE.
Model 230 V (+ 10 %/- 10 %)
– Refer to the connection diagram!
Model 115 V (+ 10 %/- 10 %)
2. Route input cables, current output cables and power supply
• Contact load: 250 V / 6 A, max. 550 VA cables in separate ducts.
• Power consumption: 1.15 VA 3. Connect the device to the power supply according to the
• Enclosure class: IP65 connection diagram.
• Permissible temperature range: 0 °C to +40 °C. 4. Connect the electronics with the sensor according to the
9.2.2 Dimensional sketch (electronics enclosure) connection diagram.
Warning
130
The potential-loaded contact 1, terminals 6 and 7,
113.5
is loaded with supply voltage.
Switch off the power supply before connecting
contact 1!
63.5
The contacts have no protective circuits.

80
Only pure ohmic loads may be switched.

Caution
TM03 6381 4506

For switching the pump motor, a contactor has to
be connected inbetween.
5. Connect contacts 1 and 2 according to individual needs.
See section 6. Electrical connections.
Fig. 19 Electronics enclosure 9.2.5 Relay outputs
9.2.3 Function The relay output connection depends on the

Note
Pumps prepared for diaphragm leakage detection: application and the connected actuators.
• Special dosing head flange for inserting the optoelectronic • Interference suppression is required for inductive loads (also
sensor relays and contactors).
• The optoelectronic sensor contains • If this is not possible, protect the relay contacts using a
– infrared sender suppressor circuit as described below.
– infrared receiver. With AC voltage
In case of a leaking diaphragm
Current up to Capacitor C Resistor R
• The dosing liquid penetrates the dosing head flange.
60 mA 10 μF, 275 V 390 Ω, 2 W
– The light refraction will be changed.
• The sensor produces a signal. 70 mA 47 μF, 275 V 22 Ω, 2 W
– The electronics switches two contacts. These contacts can 150 mA 100 μF, 275 V 47 Ω, 2 W
for instance be used to trigger an alarm device or to switch 1.0 A 220 μF, 275 V 47 Ω, 2 W
off the pump.
With DC voltage
• Connect the free-wheeling diode parallel to the relay or
contactor.
+
TM03 6382 4506
DC AC
R
Fig. 20 Diaphragm leakage sensor
TM03 7209 4513
9.2.4 Electrical connection of the electronics C
Warning -
Electrical connections must only be carried out
by qualified personnel! Fig. 21 Suppressor circuit DC/AC
Disconnect the power supply before connecting
the power supply cable and the relay contacts! Provide relay outputs on site with an appropriate
Caution
Observe the local safety regulations! back-up fuse!
Protect the cable connections and plugs from
These connections depend on the type of
corrosion and moisture.
Note actuator used and should only be understood as
Before connecting the power supply cable, guidelines. Refer to actuator documentation.
check that the supply voltage stated on the pump
Caution nameplate corresponds to the local electricity
supply. An incorrect power supply could destroy
the unit!
18
S1 S2
English (GB)
1 1 1 1 1 1 1 1 1 1 1 1 1
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10
Green Yellow White
L N PE PE N
TM03 6385 4506

230 VAC / Contact 1 (non floating Contact 2 Sensor
115 VAC 230 VAC / 115 VAC) (floating)
Fig. 22 Electrical connection of the electronics
9.2.6 Screwing the sensor into the dosing head 9.2.9 Description of the device
• Screw the sensor from the lower side into the hole of the There are a green and a red light-emitting diode (LED) at the
dosing head flange (M14 x 1.5). electronics.
– Now the diaphragm leakage sensor is ready for start-up. • Green LED
9.2.7 Start-up – shows that the system is ready for operation.
– The LED is only on when the sensor is connected to the
Caution Carry out a functional check before start-up! electronics.
If the LED is off in this case, either the sensor or the cable is
Functional check defective or wrongly connected.
• Dip the sensor into water. • Red LED
– Green and red LEDs are on: – shows that a diaphragm leakage has been detected.
Sensor and electronics are ready for operation! – The green LED is still on.
– One or more LEDs are off:
9.2.10 Maintenance
Sensor or electronics is defective!
Call Grundfos service. Warning
• Carefully dry the sensor. Do not open the electronics or sensor!
– Only the green LED is still on: Repairs must only be carried out by authorised
Sensor and electronics are ready for operation! and qualified personnel!
– The red LED is still on:
Sensor
Sensor or electronics is defective!
Call Grundfos service. Optoelectronic sensor with 3 metres cable.
• Clean the sensor in case of malfunction.
Warning
• If the sensor still does not operate correctly, replace it.
Do not open the electronics or sensor!
Electronics
Repairs must only be carried out by authorised
and qualified personnel! • No maintenance is possible by the user.
• If the electronics does not operate correctly, call Grundfos
9.2.8 Using the contacts
service.
• Terminals 6 and 7 (potential-loaded)
– for instance for switching off the pump in case of a
diaphragm leakage.
• Terminals 8, 9 and 10 (potential-free)
– for instance for triggering an alarm device.
19
10. Integral relief valve Warning
English (GB)
10.1 Function When dosing dangerous media, observe the

corresponding safety precautions!
If the pump is the only pump in the system, the integral relief
Wear protective clothing (gloves and goggles)
valve (optional) protects the complete discharge side of the
when working on the dosing head, connections
discharge line system from an excessive pressure build-up.
or lines!
The valve opens if the pressure rises above its set opening
pressure, and the dosing medium can return to the dosing tank. 10.4.2 Setting the valve opening pressure
In contrast to relief valves connected in series, the integral valve To change the factory-set opening pressure, proceed as follows:
also provides pump protection if the discharge valve is dirty or The pump must be running.
blocked. 1. Remove the cap from the top part of the relief valve.
10.2 Permissible media 2. Close the isolating valve after the pressure gauge.
3. When overflowing of the dosing medium is heard, read the
Warning current opening pressure on the pressure gauge.
Dosing heads with integral relief valve must not
be used for abrasive or crystallising media.
10.3 Connections
1. Connect the suction line to the suction valve (A).
2. Connect the discharge line to the discharge valve (B).
TM03 6312 4506

3. Connect the overflow line to the relief valve (C) and allow the
medium to flow by gravity into the tank or to an appropriate
overflow.
B
Fig. 24 Setting of opening pressure
4. Change the pressure as follows:

– To increase the pressure, turn the knob clockwise using
pointed pliers until the desired opening pressure is reached.
– To reduce the pressure, turn the knob counter-clockwise
C
using pointed pliers until the desired opening pressure is
reached.
5. Open the isolating valve after the pressure gauge.
TM03 6311 4506
6. Refit the cap.
10.5 Venting
A The relief valve can also be opened manually, thus serving as a
venting valve at the same time. If manual venting is required (e.g.
Fig. 23 Connections during start-up or when the tank has been replaced), proceed as
follows:
Warning • Turn the knob so that the smaller cut-out rests on the nub of
Never start the pump if the overflow line is not the dosing head (the rotary knob is then further away from the
correctly connected to the relief valve. dosing head). The valve spring is unloaded (position B).
• Once the pump has been completely vented, turn the knob
10.4 Setting of opening pressure back into position A "Operating".
10.4.1 General
The opening pressure can only be set if a pressure gauge is
installed in the system between the pump and the next isolating A Operating
valve or pressure-loading valve.
Warning
TM03 6313 4506
Settings on the relief valve must only be carried

out by authorised and qualified personnel! B Venting
The opening pressure of the relief valve is factory-set to the

maximum pump counterpressure specified in the technical data.
Fig. 25 Knob position
The opening pressure during operation depends on various
factors, e.g. the flow, the stroke frequency of the pump, or the
counterpressure. If an exact setting is required, the relief valve
must be adapted to the local conditions.
Warning
Never set the opening pressure to values higher
than the maximum permissible operating
pressure of the dosing system and dosing pump.
20
10.6 Fault finding chart 11.3 Cleaning the suction and discharge valves
English (GB)
Fault Cause Remedy If possible, rinse the dosing head, e.g. by
Caution
supplying it with water.
Check and possibly
If the pump loses capacity, clean the suction and discharge
Discharge line correct the
valves as follows:
blocked. discharge-side dosing
system. 1. Unscrew the valve.
Permanent
– DN 20
output from Set the relief valve to a
Relief valve incorrectly Unscrew the screw part resp. valve seat with round pliers.
the relief higher opening
set (too low). – DN 8
valve. pressure.
Press out the valve cartridge and remove the valve seat
Replace the
Diaphragm faulty. from the ball cage.
diaphragm.
2. Clean all parts. Replace faulty parts by new ones.
Relief valve dirty. Clean the relief valve.
3. Re-assemble the valve.
4. Replace the O-rings by new ones. Refit the valve.
11. Maintenance
Observe the direction arrow on the valve.
11.1 General notes
DN 8 DN 20
Warning
When dosing dangerous media, observe the
corresponding safety precautions!
Risk of chemical burns!
Wear protective clothing (gloves and goggles)
when working on the dosing head, connections * * *
or lines!
Do not allow any chemicals to leak from the
pump. Collect and dispose of all chemicals
correctly!
Warning
TM04 8384 0911

personnel authorised by Grundfos!
Repairs must only be carried out by authorised
and qualified personnel!
Switch off the pump and disconnect it from the
Fig. 26 Stainless-steel or plastic valve DN 8 / DN 20,
power supply before carrying out maintenance
* spring-loaded as an option
work and repairs!
For transport or cleaning, the venting cartridge The O-rings must be correctly placed in the
must be closed. specified groove.
Caution Caution
Before start-up, open the venting cartridge Observe the flow direction (indicated by an arrow
(pull cap approx. 5 mm). on the valve)!
11.2 Cleaning and maintenance intervals 11.4 Maintenance of the relief valve
11.4.1 Cleaning and maintenance intervals
In the event of a diaphragm leakage, the dosing
liquid may leak out of the hole in the intermediate Clean the relief valve, and replace the diaphragm, if necessary.
flange between the pump and the dosing head. • At least every 12 months or after 8000 operating hours.
The parts inside the housing are protected from • In the event of a fault.
the dosing liquid for a short time (depending on
Caution 11.4.2 Replacing the diaphragm of the relief valve
the type of liquid) by the housing sealing. It is
necessary to check regularly (daily) if liquid is 1. Switch off the pump and disconnect it from the power supply.
leaking out of the intermediate flange. 2. Make it impossible for a return flow or overpressure to occur.
For maximum safety, we recommend the pump
3. Loosen the four screws on the top part of the relief valve.
version with diaphragm leakage detection.
4. Remove the top part of the relief valve.
11.2.1 Changing the gear grease 5. Remove the diaphragm.
Warning 6. Insert a new diaphragm.
The gear grease must only be changed by 7. Refit the top part of the relief valve and cross-tighten the
authorised and qualified personnel. screws.
Maximum torque: 6 Nm.
For this purpose, send the pump to Grundfos or
an authorised service workshop. 8. Start up the dosing system.
To ensure trouble-free operation, it is recommended to have the 9. Tighten the screws on the top part of the relief valve after
gear grease changed after five years or after 20000 operating 48 operating hours.
hours. Maximum torque: 6 Nm.
11.2.2 Cleaning the diaphragm and valves

Clean the diaphragm and valves, and replace if necessary
(with stainless-steel valves: inner valve parts):
• At least every 12 months or after 4000 operating hours.
When operating with a counterpressure of 16 bar, every six
months or after 2000 operating hours.
• In the event of a fault.
21
11.5 Replacing the diaphragm
English (GB)

Caution
running!
For transport or cleaning, the venting cartridge

Caution
must be closed.
If possible, rinse the dosing head, e.g. by

Note
supplying it with water.
11.5.1 Switching off the pump
1. While the pump is running, set the stroke-length adjustment
knob to 100 %.
2. Switch off the pump and disconnect it from the power supply.
3. Depressurise the system.
4. Take suitable steps to ensure that the returning dosing
medium is safely collected.
11.5.2 Replacing the diaphragm
1. Loosen the six dosing head screws.
2. Remove the dosing head.
3. Turn the fan blades until the diaphragm reaches the front
dead centre (the diaphragm detaches itself from the
diaphragm flange).
4. Unscrew the diaphragm by manually turning it
counter-clockwise.
5. Check the parts and replace by new ones, if necessary.
6. Screw in the new diaphragm completely. Then turn it back
until the holes in the diaphragm and the flange coincide.
7. Turn the fan blades until the diaphragm reaches the bottom
dead centre (the diaphragm is pulled onto the diaphragm
flange).
8. Refit the dosing head carefully and cross-tighten the screws.
9. Deaerate and start the dosing pump.
Before start-up, open the venting cartridge (pull

Caution
cap approx. 5 mm).
After initial start-up and after each time the

diaphragm is changed, tighten the dosing head
screws.
Caution After approximately 6-10 operating hours or two
days, cross-tighten the dosing head screws
using a torque wrench.
22
12. Fault finding chart
English (GB)
Fault Cause Remedy
1. Dosing pump does not a) Not connected to the power supply. Connect the power supply cable.
run. b) Incorrect supply voltage. Replace the dosing pump.
c) Electrical failure. Return the pump for repair.
d) The empty indication has responded. Remove the cause.
e) The diaphragm leakage detection has responded. Replace the diaphragm.
2. Dosing pump does not a) Leaking suction line. Replace or seal the suction line.
suck in. b) Cross-section of the suction line too small or
Check with Grundfos specification.
suction line too long.
c) Clogged suction line. Rinse or replace the suction line.
d) Foot valve covered by sediment. Suspend the suction line from a higher position.
e) Buckled suction line. Install the suction line correctly. Check for
damage.
f) Crystalline deposits in the valves. Clean the valves.
g) Diaphragm broken or diaphragm tappet torn out. Replace the diaphragm.
3. Dosing pump does not a) Air in the suction line and dosing head. Wait, until the pump has deaerated.
dose. b) Stroke-length adjustment knob set to zero. Turn the adjustment knob in the "+" direction.
c) Viscosity or density of medium too high. Check the installation.
d) Crystalline deposits in the valves. Clean the valves.
e) Valves not correctly assembled. Assemble the inner valve parts in the right order
and check and possibly correct the flow
direction.
f) Injection point blocked. Check and possibly correct the flow direction
(injection unit), or remove the obstruction.
g) Incorrect installation of lines and peripheral Check the lines for free passage and correct
equipment. installation.
4. Dosing flow of the pump a) Dosing head not fully deaerated. Repeat the deareation.
is inaccurate. b) Degassing medium. Check the installation.
c) Parts of the valves covered in dirt or incrusted. Clean the valves.
d) Zero point misadjusted. Adjust the zero point to the actual
counterpressure.
e) Counterpressure fluctuations. Install a pressure-loading valve and a pulsation
damper.
f) Suction height fluctuations. Keep the suction level constant.
g) Siphon effect (inlet pressure higher than
Install a pressure-loading valve.
counterpressure).
h) Leaking or porous suction line or discharge line. Replace the suction line or discharge line.
i) Parts in contact with the medium are not resistant
Replace with resistant materials.
to it.
j) Dosing diaphragm worn (incipient tears). Replace the diaphragm. Also observe the
maintenance instructions.
k) Supply voltage fluctuations. Decrease the counterpressure of the pump.
l) Variation of the dosing medium (density, Check the concentration. Use an agitator,
viscosity). if necessary.
Caution For further error signals for the control unit, refer to the relevant section.
23
13. Dosing curves ( ) 0
12
English (GB)
The dosing curves on the following pages are trend curves. Q [l/h]
10
They apply to:
8
• performance of simple pump (the flow rate is doubled for the
double pump) 6
• water as dosing medium 4
• suction line with foot valve, 0.5 m flooded suction 33bar
bar
TM03 6319 4506

2 16bar
• zero point of pump Q0 for specified pressure, see table below 16 bar
0
• standard pump version.
0 10 20 30 40 50 60 70 80 90 100
h [%]
Abbreviation Description
Fig. 31 DMX 7.2-16 (50 Hz)
Q Dosing flow
Zero point of the pump ( ) 0
Q0 12
The pumps are calibrated so that Q is 0 at 3 bar.
Q [l/h]
h Stroke length 10
8
6
Q [l/h] 6
5
4
4 3 bar
16bar
TM03 6320 4506

2 16
3bar
bar
3
0
2 0 10 20 30 40 50 60 70 80 90 100
3 bar
TM03 6315 4506
3bar h [%]
1
10 bar
10bar
0 Fig. 32 DMX 7.2-16 (60 Hz)

0 10 20 30 40 50 60 70 80 90 100
h [%]
12
Q [l/h]
Fig. 27 DMX 4-10 (50 Hz) 10
( ) 0 8
6
Q [l/h] 6
5
4
3 bar
3bar
4
TM03 6321 4506

2 10 bar
10bar
3
0
2 0 10 20 30 40 50 60 70 80 90 100
3 bar
10bar
h [%]
TM03 6316 4506
1 10 bar
3bar
Fig. 33 DMX 9-10 (50 Hz)

0
0 10 20 30 40 50 60 70 80 90 100
h [%] 12
Q [l/h]
Fig. 28 DMX 4-10 (60 Hz) 10
8
10
6
Q [l/h]
8 4
3 bar
10bar
TM03 6322 4506
6 2 10
3bar bar
0
4
3 bar
3bar 0 10 20 30 40 50 60 70 80 90 100
h [%]
TM03 6317 4506
2 10 bar
10bar
Fig. 34 DMX 9-10 (60 Hz)

0
0 10 20 30 40 50 60 70 80 90 100
h [%] 18
Q [l/h]
16
Fig. 29 DMX 7-10 (50 Hz)
14
12
10 10
Q [l/h] 8
8 6
3 bar
TM03 6323 4506
4 3bar
6
2 10 bar
10bar
4 0
3 bar
10bar 0 10 20 30 40 50 60 70 80 90 100
h [%]
TM03 6318 4506
2 10 bar
3bar
0 Fig. 35 DMX 12-10 (50 Hz)

0 10 20 30 40 50 60 70 80 90 100
h [%]
Fig. 30 DMX 7-10 (60 Hz)
24
18 12
English (GB)
Q [l/h] Q [l/h]
16
10
14
12 8
10
6
8
6 4
33bar
bar
3 bar
TM03 6329 4506

TM03 6324 4506
4 10bar
2 10bar
10 bar
2 10
3bar bar
0 0
0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100
h [%] h [%]
Fig. 36 DMX 12-10 (60 Hz) Fig. 41 DMX 8-10 (50 Hz)
( ) 0
24 12
Q [l/h] Q [l/h]
20 10
16 8
12 6
4
8 3 bar 310bar
bar
TM03 6330 4506

TM03 6325 4506
3bar
4 4 bar
4bar
2 3bar
10 bar
1.5 bar
1,5bar
0
0
0 10 20 30 40 50 60 70 80 90 100
0 10 20 30 40 50 60 70 80 90 100 h [%]
h [%]
24 24
Q [l/h] Q [l/h]
20 20
16
16
12
12
8
8 3 bar 3 bar
3bar
TM03 6331 4506

TM03 6326 4506
4bar 4 16bar
4 bar 16 bar
4 3bar
1.5
1,5barbar 0
0 0 10 20 30 40 50 60 70 80 90 100
0 10 20 30 40 50 60 70 80 90 100 h [%]
h [%]
Fig. 38 DMX 17-4 (60 Hz) Fig. 43 DMX 13.7-16 (50 Hz)
35 24
Q [l/h] Q [l/h]
30 20
25 16
20 12
15 8
3 bar
16bar
10 31,5bar
bar 4
TM03 6332 4506
TM03 6327 4506
3bar
16 bar
5 1.5
3bar bar
0
0 0 10 20 30 40 50 60 70 80 90 100
0 10 20 30 40 50 60 70 80 90 100 h [%]
h [%]
Fig. 39 DMX 25-3 (50 Hz) Fig. 44 DMX 13.7-16 (60 Hz)
20
35 Q [l/h]
Q [l/h] 18
30 16
25 14
12
20 10
15 8
6
10 33bar
bar 33bar
bar
TM03 6333 4506
4
TM03 6328 4506
5 1.5 bar
1,5bar 2 10 bar
10bar
0
0
0 10 20 30 40 50 60 70 80 90 100
0 10 20 30 40 50 60 70 80 90 100 h [%]
h [%]
Fig. 45 DMX 14-10 (50 Hz)
Fig. 40 DMX 25-3 (60 Hz)
25
20 50
English (GB)
Q [l/h]
18 Q [l/h]
16 40
14
12 30
10
8 20
3 bar
6 3bar
310bar
bar 4 bar
TM03 6339 4506

TM03 6334 4506
4 10 4bar
2 10
3barbar 1,5bar
1.5 bar
0 0
0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100
h [%] h [%]
24 50
Q [l/h] Q [l/h]
20 40
16
30
12
20
8 34bar
bar
33bar
bar
TM03 6340 4506

TM03 6335 4506
4 10bar
10 43bar
bar
10 bar 1,5bar
1.5 bar
0 0
0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100
h [%] h [%]
24 100
Q [l/h] Q [l/h]
20 80
16
60
12
40
8
3 bar
10bar
31,5bar
bar
TM03 6336 4506
TM03 6341 4506

4 3bar 20
10 bar 1.5
3bar bar
0 0
0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100
h [%] h [%]
40 100
Q [l/h]
35 Q [l/h]
30 80
25
60
20
15 40
10 33bar
bar
TM03 6337 4506
20 33bar
bar TM03 6342 4506
5 10 bar
10bar
1.5 bar
1,5bar
0
0
0 10 20 30 40 50 60 70 80 90 100
0 10 20 30 40 50 60 70 80 90 100
h [%]
h [%]
40 24
Q [l/h] Q [l/h]
35
20
30
25 16
20 12
15
8
10 310bar
bar 33bar
bar
TM03 6338 4506
TM03 6343 4506
5 10 bar
3bar 4
10 bar
10bar
0 0
0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100
h [%] h [%]
26
24 70
English (GB)
Q [l/h] Q [l/h]
20 60
16 50
12 40
30
8
3 bar
10bar
20 3 bar
TM03 6344 4506

3bar
TM03 6349 4506

4 3bar
10 bar
10 10 bar
10bar
0
0
0 10 20 30 40 50 60 70 80 90 100
h [%] 0 10 20 30 40 50 60 70 80 90 100
h [%]
40 70
Q [l/h]
36 Q [l/h]
32 60
28 50
24
20 40
16 30
12
3 bar
3bar 20 3 bar
TM03 6345 4506

10bar
8
TM03 6350 4506

4 10 bar
10bar
10 10 bar
3bar
0
0
0 10 20 30 40 50 60 70 80 90 100
0 10 20 30 40 50 60 70 80 90 100
h [%] h [%]
40 100
Q [l/h]
36 Q [l/h]
32 80
28
24 60
20
16 40
12 3 bar
10bar 3 bar
3bar
TM03 6346 4506
TM03 6351 4506

8 3bar 20 4bar
10 bar 4 bar
4
0 0
0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100
h [%] h [%]
100
50 Q [l/h]
Q [l/h]
80
40
30 60
20 40
4 bar
4bar 3 bar
4bar
TM03 6347 4506
10 10 bar
10bar 20 4 bar
3bar TM03 6352 4506
0
0
0 10 20 30 40 50 60 70 80 90 100
h [%] 0 10 20 30 40 50 60 70 80 90 100
h [%]
Fig. 59 DMX 35-10 (50 Hz)
Fig. 64 DMX 75-4 (60 Hz)
50
140
Q [l/h] Q [l/h]
40 120
100
30
80
20
4 bar
10bar
60
TM03 6348 4506
10 10
4bar bar 40 3 bar
1,5bar
TM03 6353 4506
20 1.5
3bar bar
0
0 10 20 30 40 50 60 70 80 90 100 0
h [%] 0 10 20 30 40 50 60 70 80 90 100
h [%]
Fig. 60 DMX 35-10 (60 Hz)
Fig. 65 DMX 115-3 (50 Hz)
27
English (GB)
140
Q [l/h]
120
100
80
60
40 3 bar
3bar
TM03 6354 4506

20 1.5 bar
1,5bar
0
0 10 20 30 40 50 60 70 80 90 100
h [%]
Fig. 66 DMX 115-3 (60 Hz)
14. Disposal
This product or parts of it must be disposed of in an
environmentally sound way. Use appropriate waste collection
services. If this is not possible, contact the nearest Grundfos
company or service workshop.
Subject to alterations.
28
Appendix 1
Appendix
Safety declaration
Please copy, fill in and sign this sheet and attach it to the pump returned for service.
Note Fill in this document using English or German language.
We hereby declare that this product is free from hazardous chemicals,

biological and radioactive substances:
Product type: ________________________________
Model number: _____________________________
No media or water: _____________________________
A chemical solution, name: _________________________
(see pump nameplate)
Fault description
Please make a circle around the damaged part.
In the case of an electrical or functional fault, please mark the cabinet.
GrA3476
Please give a short description of the fault:
_____________________ _____________________
Date and signature Company stamp
29
30
Argentina Denmark Korea Slovenia
Grundfos companies
Bombas GRUNDFOS de Argentina S.A. GRUNDFOS DK A/S GRUNDFOS Pumps Korea Ltd. GRUNDFOS d.o.o.
Ruta Panamericana km. 37.500 Centro Martin Bachs Vej 3 6th Floor, Aju Building 679-5 Šlandrova 8b, SI-1231 Ljubljana-Črnuče
Industrial Garin DK-8850 Bjerringbro Yeoksam-dong, Kangnam-ku, 135-916 Phone: +386 1 568 0610
1619 - Garin Pcia. de B.A. Tlf.: +45-87 50 50 50 Seoul, Korea Telefax: +386 1 568 0619
Phone: +54-3327 414 444 Telefax: +45-87 50 51 51 Phone: +82-2-5317 600 E-mail: slovenia@grundfos.si
Telefax: +54-3327 411 111 E-mail: info_GDK@grundfos.com Telefax: +82-2-5633 725
www.grundfos.com/DK South Africa
Australia Latvia Grundfos (PTY) Ltd.
GRUNDFOS Pumps Pty. Ltd. Estonia SIA GRUNDFOS Pumps Latvia Corner Mountjoy and George Allen Roads
P.O. Box 2040 GRUNDFOS Pumps Eesti OÜ Deglava biznesa centrs Wilbart Ext. 2
Regency Park Peterburi tee 92G Augusta Deglava ielā 60, LV-1035, Rīga, Bedfordview 2008
South Australia 5942 11415 Tallinn Tālr.: + 371 714 9640, 7 149 641 Phone: (+27) 11 579 4800
Phone: +61-8-8461-4611 Tel: + 372 606 1690 Fakss: + 371 914 9646 Fax: (+27) 11 455 6066
Telefax: +61-8-8340 0155 Fax: + 372 606 1691 E-mail: lsmart@grundfos.com
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Austria Finland GRUNDFOS Pumps UAB Spain
GRUNDFOS Pumpen Vertrieb Ges.m.b.H. OY GRUNDFOS Pumput AB Smolensko g. 6 Bombas GRUNDFOS España S.A.
Grundfosstraße 2 Mestarintie 11 LT-03201 Vilnius Camino de la Fuentecilla, s/n
A-5082 Grödig/Salzburg FIN-01730 Vantaa Tel: + 370 52 395 430 E-28110 Algete (Madrid)
Tel.: +43-6246-883-0 Phone: +358-(0)207 889 900 Fax: + 370 52 395 431 Tel.: +34-91-848 8800
Telefax: +43-6246-883-30 Telefax: +358-(0)207 889 550 Telefax: +34-91-628 0465
Malaysia
Belgium France GRUNDFOS Pumps Sdn. Bhd. Sweden
N.V. GRUNDFOS Bellux S.A. Pompes GRUNDFOS Distribution S.A. 7 Jalan Peguam U1/25 GRUNDFOS AB
Boomsesteenweg 81-83 Parc d’Activités de Chesnes Glenmarie Industrial Park (Box 333) Lunnagårdsgatan 6
B-2630 Aartselaar 57, rue de Malacombe 40150 Shah Alam 431 24 Mölndal
Tél.: +32-3-870 7300 F-38290 St. Quentin Fallavier (Lyon) Selangor Tel.: +46 31 332 23 000
Télécopie: +32-3-870 7301 Tél.: +33-4 74 82 15 15 Phone: +60-3-5569 2922 Telefax: +46 31-331 94 60
Télécopie: +33-4 74 94 10 51 Telefax: +60-3-5569 2866
Belarus Switzerland
Представительство ГРУНДФОС в Germany Mexico GRUNDFOS ALLDOS International AG
Минске GRUNDFOS Water Treatment GmbH Bombas GRUNDFOS de México S.A. de Schönmattstraße 4
220125, Минск Reetzstraße 85 C.V. CH-4153 Reinach
ул. Шафарнянская, 11, оф. 56 D-76327 Pfinztal (Söllingen) Boulevard TLC No. 15 Tel.: +41-61-717 5555
Тел.: +7 (375 17) 286 39 72, 286 39 73 Tel.: +49 7240 61-0 Parque Industrial Stiva Aeropuerto Telefax: +41-61-717 5500
Факс: +7 (375 17) 286 39 71 Telefax: +49 7240 61-177 Apodaca, N.L. 66600 E-mail: grundfosalldos-CH@grundfos.com
E-mail: minsk@grundfos.com E-mail: gwt@grundfos.com Phone: +52-81-8144 4000
Telefax: +52-81-8144 4010 Switzerland
Bosnia/Herzegovina Germany GRUNDFOS Pumpen AG
GRUNDFOS Sarajevo GRUNDFOS GMBH Netherlands Bruggacherstrasse 10
Trg Heroja 16, Schlüterstr. 33 GRUNDFOS Netherlands CH-8117 Fällanden/ZH
BiH-71000 Sarajevo 40699 Erkrath Veluwezoom 35 Tel.: +41-1-806 8111
Phone: +387 33 713 290 Tel.: +49-(0) 211 929 69-0 1326 AE Almere Telefax: +41-1-806 8115
Telefax: +387 33 659 079 Telefax: +49-(0) 211 929 69-3799 Postbus 22015
e-mail: grundfos@bih.net.ba E-mail: infoservice@grundfos.de 1302 CA ALMERE Taiwan
Service in Deutschland: Tel.: +31-88-478 6336 GRUNDFOS Pumps (Taiwan) Ltd.
Brazil E-mail: kundendienst@grundfos.de Telefax: +31-88-478 6332 7 Floor, 219 Min-Chuan Road
BOMBAS GRUNDFOS DO BRASIL E-mail: info_gnl@grundfos.com Taichung, Taiwan, R.O.C.
Av. Humberto de Alencar Castelo Branco, Greece Phone: +886-4-2305 0868
630 GRUNDFOS Hellas A.E.B.E. New Zealand Telefax: +886-4-2305 0878
CEP 09850 - 300 20th km. Athinon-Markopoulou Av. GRUNDFOS Pumps NZ Ltd.
São Bernardo do Campo - SP P.O. Box 71 17 Beatrice Tinsley Crescent Thailand
Phone: +55-11 4393 5533 GR-19002 Peania North Harbour Industrial Estate GRUNDFOS (Thailand) Ltd.
Telefax: +55-11 4343 5015 Phone: +0030-210-66 83 400 Albany, Auckland 92 Chaloem Phrakiat Rama 9 Road,
Telefax: +0030-210-66 46 273 Phone: +64-9-415 3240 Dokmai, Pravej, Bangkok 10250
Bulgaria Telefax: +64-9-415 3250 Phone: +66-2-725 8999
Grundfos Bulgaria EOOD Hong Kong Telefax: +66-2-725 8998
Slatina District GRUNDFOS Pumps (Hong Kong) Ltd. Norway
Iztochna Tangenta street no. 100 Unit 1, Ground floor GRUNDFOS Pumper A/S Turkey
BG - 1592 Sofia Siu Wai Industrial Centre Strømsveien 344 GRUNDFOS POMPA San. ve Tic. Ltd. Sti.
Tel. +359 2 49 22 200 29-33 Wing Hong Street & Postboks 235, Leirdal Gebze Organize Sanayi Bölgesi
Fax. +359 2 49 22 201 68 King Lam Street, Cheung Sha Wan N-1011 Oslo Ihsan dede Caddesi,
email: bulgaria@grundfos.bg Kowloon Tlf.: +47-22 90 47 00 2. yol 200. Sokak No. 204
Phone: +852-27861706 / 27861741 Telefax: +47-22 32 21 50 41490 Gebze/ Kocaeli
Canada Telefax: +852-27858664 Phone: +90 - 262-679 7979
GRUNDFOS Canada Inc. Poland Telefax: +90 - 262-679 7905
2941 Brighton Road Hungary GRUNDFOS Pompy Sp. z o.o. E-mail: satis@grundfos.com
Oakville, Ontario GRUNDFOS Hungária Kft. ul. Klonowa 23
L6H 6C9 Park u. 8 Baranowo k. Poznania Ukraine
Phone: +1-905 829 9533 H-2045 Törökbálint, PL-62-081 Przeźmierowo ТОВ ГРУНДФОС УКРАЇНА
Telefax: +1-905 829 9512 Phone: +36-23 511 110 Tel: (+48-61) 650 13 00 01010 Київ, Вул. Московська 8б,
Telefax: +36-23 511 111 Fax: (+48-61) 650 13 50 Тел.:(+38 044) 390 40 50
China Фах.: (+38 044) 390 40 59
Grundfos Alldos India Portugal E-mail: ukraine@grundfos.com
Dosing & Disinfection GRUNDFOS Pumps India Private Limited Bombas GRUNDFOS Portugal, S.A.
ALLDOS (Shanghai) Water Technology 118 Old Mahabalipuram Road Rua Calvet de Magalhães, 241 United Arab Emirates
Co. Ltd. Thoraipakkam Apartado 1079 GRUNDFOS Gulf Distribution
West Unit, 1 Floor, No. 2 Building (T 4-2) Chennai 600 097 P-2770-153 Paço de Arcos P.O. Box 16768
278 Jinhu Road, Jin Qiao Export Process- Phone: +91-44 4596 6800 Tel.: +351-21-440 76 00 Jebel Ali Free Zone
ing Zone Telefax: +351-21-440 76 90 Dubai
Pudong New Area Indonesia Phone: +971-4- 8815 166
Shanghai, 201206 PT GRUNDFOS Pompa Romania Telefax: +971-4-8815 136
Phone: +86 21 5055 1012 Jl. Rawa Sumur III, Blok III / CC-1 GRUNDFOS Pompe România SRL
Kawasan Industri, Pulogadung Bd. Biruintei, nr 103 United Kingdom
Telefax: +86 21 5032 0596
Jakarta 13930 Pantelimon county Ilfov GRUNDFOS Pumps Ltd.
E-mail: grundfosalldos-CN@grundfos.com
Phone: +62-21-460 6909 Phone: +40 21 200 4100 Grovebury Road
China Telefax: +62-21-460 6910 / 460 6901 Telefax: +40 21 200 4101 Leighton Buzzard/Beds. LU7 4TL
GRUNDFOS Pumps (Shanghai) Co. Ltd. E-mail: romania@grundfos.ro Phone: +44-1525-850000
50/F Maxdo Centre No. 8 Xing Yi Rd. Ireland Telefax: +44-1525-850011
Hongqiao Development Zone GRUNDFOS (Ireland) Ltd. Russia
Unit A, Merrywell Business Park ООО Грундфос U.S.A.
Shanghai 200336
Ballymount Road Lower Россия, 109544 Москва, ул. Школьная GRUNDFOS Pumps Corporation
PRC
Dublin 12 39 17100 West 118th Terrace
Phone: +86-21 6122 5222
Phone: +353-1-4089 800 Тел. (+7) 495 737 30 00, 564 88 00 Olathe, Kansas 66061
Telefax: +86-21 6122 5333
Telefax: +353-1-4089 830 Факс (+7) 495 737 75 36, 564 88 11 Phone: +1-913-227-3400
Croatia E-mail grundfos.moscow@grundfos.com Telefax: +1-913-227-3500
GRUNDFOS CROATIA d.o.o. Italy
GRUNDFOS Pompe Italia S.r.l. Serbia Uzbekistan
Cebini 37, Buzin
Via Gran Sasso 4 GRUNDFOS Predstavništvo Beograd Grundfos Tashkent, Uzbekistan The Repre-
HR-10010 Zagreb
I-20060 Truccazzano (Milano) Dr. Milutina Ivkovića 2a/29 sentative Office of Grundfos Kazakhstan in
Phone: +385 1 6595 400
Tel.: +39-02-95838112 YU-11000 Beograd Uzbekistan
Telefax: +385 1 6595 499
Telefax: +39-02-95309290 / 95838461 Phone: +381 11 26 47 877 / 11 26 47 496 38a, Oybek street, Tashkent
www.grundfos.hr
Telefax: +381 11 26 48 340 Телефон: (+998) 71 150 3290 / 71 150
Czech Republic Japan 3291
GRUNDFOS s.r.o. GRUNDFOS Pumps K.K. Singapore Факс: (+998) 71 150 3292
Čapkovského 21 Gotanda Metalion Bldg. 5F, GRUNDFOS (Singapore) Pte. Ltd.
779 00 Olomouc 5-21-15, Higashi-gotanda 25 Jalan Tukang Addresses revised 06.05.2013
Phone: +420-585-716 111 Shiagawa-ku, Tokyo, Singapore 619264
Telefax: +420-585-716 299 141-0022 Japan Phone: +65-6681 9688
Phone: +81 35 448 1391 Telefax: +65-6681 9689
Telefax: +81 35 448 9619
ECM: 1125369
91834765 1213
www.grundfos.com
The name Grundfos, the Grundfos logo, and be think innovate are registered trademarks owned by Grundfos Holding A/S or Grundfos A/S, Denmark. All rights reserved worldwide. © Copyright Grundfos Holding A/S
OHW: W10286-013
1.1. TECHNICAL DATA
Description: Caustic soda dosing pump (for example NaOH)

Make: Grundfos
Type: DDA
 Neutralisers (NaOH, H2SO4) are normally delivered in a liquid form and they have to be
stored in non-corroding storage tanks suitable for the medium. They don’t have to be mixed
with other components.
2. SAFETY ASPECTS

are stopped.
Figure 2.1
Redox delivery.

1
OHW: W10286-013



carefully.

manual index.
2
GRUNDFOS INSTRUCTIONS
SMART Digital - DDA

up to 30 l/h
Installation and operating instructions
English (GB) Installation and operating instructions
English (GB)
Original installation and operating instructions. 6.5 Analog output 26

6.6 SlowMode 27
CONTENTS 6.7 FlowControl 28
Page 6.8 Pressure monitoring 29
6.8.1 Pressure setting ranges 29
1. Safety instructions 3
6.8.2 Calibration of pressure sensor 29
1.1 Symbols used in this document 3
6.9 Flow measurement 30
1.2 Qualification and training of personnel 3
6.10 AutoFlowAdapt 30
1.3 Safety instructions for the operator/user 3
6.11 Auto deaeration 30
1.4 Safety of the system in the event of a
failure in the dosing pump 3 6.12 Key lock 30
1.5 Dosing chemicals 4 6.12.1 Temporary deactivation 30
1.6 Diaphragm breakage 4 6.12.2 Deactivation 30
6.13 Display Setup 31
2. General information 5
6.13.1 Units 31
2.1 Applications 5
6.13.2 Additional display 31
2.2 Improper operating methods 5
6.14 Time+date 31
2.3 Symbols on the pump 6
6.15 Bus communication 32
2.4 Warranty 6
6.15.1 GENIbus communication 32
2.5 Nameplate 6
6.15.2 Possible industrial bus types 32
2.6 Type key 7 6.15.3 Activate communication 32
2.7 Product overview 8 6.15.4 Setting the bus address 32
3. Technical data / Dimensions 9 6.15.5 Characteristics of bus communication 33
3.1 Technical data 9 6.15.6 Deactivate communication 33
3.2 Dimensions 11 6.15.7 Communication faults 33
4. Assembly and installation 12 6.16 Inputs/Outputs 34
4.1 Pump assembly 12 6.16.1 Relay outputs 34
4.1.1 Requirements 12 6.16.2 External stop 35
4.1.2 Align and install mounting plate 12 6.16.3 Empty and Low level signals 35
4.1.3 Engage pump in mounting plate 12 6.17 Basic settings 35
4.1.4 Adjusting control cube position 12 7. Service 36
4.2 Hydraulic connection 13 7.1 Regular maintenance 36
4.3 Electrical connection 14 7.2 Cleaning 36
5. Startup 16 7.3 Service system 36
5.1 Setting the menu language 16 7.4 Perform service 37
5.2 Deaerating the pump 17 7.4.1 Dosing head overview 37
5.3 Calibrating the pump 17 7.4.2 Dismantling the diaphragm and valves 37
7.4.3 Reassembling the diaphragm and valves 38
6. Operation 19
7.5 Resetting the service system 38
6.1 Control elements 19
7.6 Diaphragm breakage 38
6.2 Display and symbols 19
7.6.1 Dismantling in case of diaphragm 39
6.2.1 Navigation 19 breakage
6.2.2 Operating states 19 7.6.2 Dosing liquid in the pump housing 39
6.2.3 Sleep mode (energy-saving mode) 19 7.7 Repairs 39
6.2.4 Overview of display symbols 20
8. Faults 40
6.3 Main menus 21
8.1 List of faults 41
6.3.1 Operation 21
6.3.2 Info 21 8.1.1 Faults with error message 41
6.3.3 Alarm 21 8.1.2 General faults 42
6.3.4 Setup 21 9. Disposal 43
6.4 Operation modes 22
6.4.1 Manual 22 Warning
6.4.2 Pulse 22 Prior to installation, read these
6.4.3 Analog 0/4-20 mA 23 installation and operating instructions.
6.4.4 Batch (pulse-based) 24 Installation and operation must comply
6.4.5 Dosing timer cycle 25 with local regulations and accepted
6.4.6 Dosing timer week 25 codes of good practice.
2
1. Safety instructions 1.3 Safety instructions for the
operator/user
English (GB)
These installation and operating instructions contain
general instructions that must be observed during The safety instructions described in these
installation, operation and maintenance of the pump. instructions, existing national regulations on health
It must therefore be read by the installation engineer protection, environmental protection and for accident
and the relevant qualified operator prior to prevention and any internal working, operating and
installation and start-up, and must be available at the safety regulations of the operator must be observed.
installation location at all times. Information attached to the pump must be observed.
1.1 Symbols used in this document Leakages of dangerous substances must be
disposed of in a way that is not harmful to the
Warning personnel or the environment.
If these safety instructions are not Damage caused by electrical energy must be
observed, it may result in personal prevented, see the regulations of the local electricity
injury. supply company.
Before any work to the pump, the pump

If these safety instructions are not must be in the "Stop" operating state
Caution observed, it may result in malfunction
Caution or be disconnected from the power
or damage to the equipment. supply. The system must be
pressureless!
Note
Notes or instructions that make the job
easier and ensure safe operation. The mains plug is the separator
Note
separating the pump from the mains.
1.2 Qualification and training of personnel
The personnel responsible for the installation, Only original accessories and original spare parts
operation and service must be appropriately should be used. Using other parts can result in
qualified for these tasks. Areas of responsibility, exemption from liability for any resulting
levels of authority and the supervision of the consequences.
personnel must be precisely defined by the operator.
If necessary, the personnel must be trained 1.4 Safety of the system in the event of a
appropriately. failure in the dosing pump
Risks of not observing the safety instructions The dosing pump was designed according to the
Non-observance of the safety instructions may have latest technologies and is carefully manufactured
dangerous consequences for the personnel, the and tested.
environment and the pump and may result in the loss If it fails regardless of this, the safety of the overall
of any claims for damages. system must be ensured. Use the relevant
It may lead to the following hazards: monitoring and control functions for this.
• Personal injury from exposure to electrical, Make sure that any chemicals that are
mechanical and chemical influences. released from the pump or any
• Damage to the environment and personal injury damaged lines do not cause damage to
from leakage of harmful substances. Caution system parts and buildings.
The installation of leak monitoring
solutions and drip trays is
recommended.
3
1.5 Dosing chemicals 1.6 Diaphragm breakage
English (GB)
If the diaphragm leaks or is broken, dosing liquid

Warning escapes from the drain opening (fig. 41, pos. 11) on
Before switching the supply voltage the dosing head. Observe section 7.6 Diaphragm
back on, the dosing lines must be breakage.
connected in such a way that any
chemicals in the dosing head cannot Warning
spray out and put people at risk. Danger of explosion, if dosing liquid
The dosing medium is pressurised and has entered the pump housing!
can be harmful to health and the Operation with damaged diaphragm
environment. can lead to dosing liquid entering the
pump housing.
Warning In case of diaphragm breakage,
When working with chemicals, the immediately separate the pump from
accident prevention regulations the power supply!
applicable at the installation site Make sure the pump cannot be put
should be applied (e.g. wearing back into operation by accident!
protective clothing).
Dismantle the dosing head without
Observe the chemical manufacturer's connecting the pump to the power
safety data sheets and safety supply and make sure no dosing liquid
instructions when handling chemicals! has entered the pump housing.
Proceed as described in section
A deaeration hose, which is routed into 7.6.1 Dismantling in case of diaphragm
Caution a container, e.g. a drip tray, must be breakage.
connected to the deaeration valve.
To avoid any danger resulting from diaphragm
The dosing medium must be in liquid breakage, observe the following:
aggregate state! • Perform regular maintenance. See section
Caution 7.1 Regular maintenance.
Observe the freezing and boiling points
of the dosing medium! • Never operate the pump with blocked or soiled
drain opening.
The resistance of the parts that come – If the drain opening is blocked or soiled,
into contact with the dosing medium, proceed as described in section
such as the dosing head, valve ball, 7.6.1 Dismantling in case of diaphragm
gaskets and lines, depends on the breakage.
medium, media temperature and • Never attach a hose to the drain opening. If a
operating pressure. hose is attached to the drain opening, it is
Ensure that parts in contact with the impossible to recognise escaping dosing liquid.
Caution dosing media are resistant to the • Take suitable precautions to prevent harm to
dosing medium under operating health and damage to property from escaping
conditions, see data booklet! dosing liquid.
Should you have any questions • Never operate the pump with damaged or loose
regarding the material resistance and dosing head screws.
suitability of the pump for specific
dosing media, please contact
Grundfos.
4
2. General information 2.2 Improper operating methods
English (GB)
The DDA dosing pump is a self-priming The operational safety of the pump is only
diaphragm pump. It consists of a housing guaranteed if it is used in accordance with section
with stepper motor and electronics, a 2.1 Applications.
dosing head with diaphragm and valves and the
control cube. Warning
Excellent dosing features of the pump: Other applications or the operation of
pumps in ambient and operating
• Optimal intake even with degassing media, as
conditions, which are not approved,
the pump always works at full suction stroke
are considered improper and are not
volume.
permitted. Grundfos cannot be held
• Continuous dosing, as the medium is sucked up liable for any damage resulting from
with a short suction stroke, regardless of the incorrect use.
current dosing flow, and dosed with the longest
possible dosing stroke. Warning
2.1 Applications The pump is NOT approved for
operation in potentially explosive
The pump is suitable for liquid, non-abrasive, areas!
non-flammable and non-combustible media strictly in
accordance with the instructions in these installation Warning
and operating instructions.
A sunscreen is required for outdoor
Areas of application installation!
• Drinking water treatment
• Wastewater treatment Frequent disengagement from the
mains voltage, e.g. via a relay, can
• Swimming pool water treatment
result in damage to the pump
• Boiler water treatment electronics and in the breakdown of the
• CIP (Clean-In-Place) pump. The dosing accuracy is also
• Cooling water treatment Caution
reduced as a result of internal start
procedures.
• Process water treatment
Do not control the pump via the mains
• Wash plants
voltage for dosing purposes!
• Chemical industry
Only use the "External stop" function to
• Ultrafiltration processes and reverse osmosis start and stop the pump!
• Irrigation
• Paper and pulp industry
• Food and beverage industries
5
2.3 Symbols on the pump
English (GB)
Symbol Description
Indication of universally dangerous spot.
In case of emergency and prior to all maintenance work and repairs, take the mains plug out
of the mains supply!
The device complies with electrical safety class II.
Connection for deaeration hose at dosing head. If the deaeration hose is not correctly
connected, danger will arise due to possible leakage of dosing liquid!
2.4 Warranty
A guarantee claim in accordance with our general terms of sale and delivery is only valid if the following
requirements are fulfilled:
• The pump is used in accordance with the information within this manual.
• The pump is not dismantled or incorrectly handled.
• The maintenance is carried out by authorised and qualified personnel.
2.5 Nameplate

Type Pmax W IP 65
TM04 8144 4313

U f Imax A Q l/h gph
Model P Bar psi NEMA 4X
97694877
Made in France N20683

Fig. 1 Nameplate
Pos. Description Pos. Description
1 Type designation 6 Enclosure class

2 Voltage 7 Mark of approval, CE mark, etc.
3 Frequency 8 Country of origin
4 Power consumption 9 Max. operating pressure
5 Max. dosing flow 10 Model
6
2.6 Type key
English (GB)
The type key is used to identify the precise pump and is not used for configuration purposes.
Code Example DDA 7.5- 16 AR- PP/ V/ C- F- 3 1 U2U2 F G
Pump type
Max. flow [l/h]
Max. pressure [bar]
Control variant
AR Standard
FC AR with FlowControl
FCM FC with integrated flow measurement
Dosing head material

PP Polypropylene
PVC PVC (polyvinyl chloride, only up to 10 bar)
PV PVDF (polyvinylidene fluoride)
SS Stainless steel DIN 1.4401
Gasket material
E EPDM
V FKM
T PTFE
Valve ball material

C Ceramic
SS Stainless steel DIN 1.4401
Control cube position

F Front-mounted (can be changed to the right or left)
Voltage
3 1 x 100-240 V, 50/60 Hz
Valve type
1 Standard
2 Spring-loaded (HV version)
Suction/discharge side connection

U2U2 Hose, 4/6 mm, 6/9 mm, 6/12 mm, 9/12 mm
U7U7 Hose 0.17" x 1/4"; 1/4" x 3/8"; 3/8" x 1/2"
AA Threaded Rp 1/4", female (stainless steel)
VV Threaded 1/4" NPT, female (stainless steel)
XX No connection
Installation set*
I001 Hose, 4/6 mm (up to 7.5 l/h, 13 bar)
I002 Hose, 9/12 mm (up to 60 l/h, 9 bar)
I003 Hose, 0.17" x 1/4" (up to 7.5 l/h, 13 bar)
I004 Hose, 3/8" x 1/2" (up to 60 l/h, 10 bar)
Mains plug
F EU
B USA, Canada
G UK
I Australia, New Zealand, Taiwan
E Switzerland
J Japan
L Argentina
Design
G Grundfos
* including: 2 pump connections, foot valve, injection unit, 6 m PE discharge hose, 2 m PVC suction hose,
2 m PVC deaeration hose (4/6 mm)
7
2.7 Product overview
English (GB)
Control cube
Graphic LC display
(section 6.2.2)
Click wheel (section 6.1)
[Start/stop] key (section 6.1)

100% [100%] key (section 6.1)
Signal inputs/outputs
(section 4.3)
Mains connection
TM04 1129 0110

Mounting plate
Fig. 2 Front view of the pump
Valve, discharge side

Control cube assembly
screws
Deaeration valve
Connection, deaeration Dosing head

hose
Drain opening in case of

diaphragm breakage
Valve, suction side

FlowControl connection
(only DDA-FC/FCM)
TM04 1133 0110
Fig. 3 Rear view of the pump
8
3. Technical data / Dimensions
English (GB)
3.1 Technical data
Data 7.5-16 12-10 17-7 30-4
Turndown ratio (setting range) [1:X] 3000 1000 1000 1000

[l/h] 7.5 12.0 17.0 30.0
Max. dosing capacity
[gph] 2.0 3.1 4.5 8.0
[l/h] 3.75 6.00 8.50 15.00
Max. dosing capacity with SlowMode 50 %
[gph] 1.00 1.55 2.25 4.00
[l/h] 1.88 3.00 4.25 7.50
Max. dosing capacity with SlowMode 25 %
[gph] 0.50 0.78 1.13 2.00
[l/h] 0.0025 0.0120 0.0170 0.0300
Min. dosing capacity
[gph] 0.0007 0.0031 0.0045 0.0080
[bar] 16 10 7 4
Max. operating pressure 6)
[psi] 230 150 100 60
[strokes/
Max. stroke frequency 1) 190 155 205 180
min]
Stroke volume [ml] 0.74 1.45 1.55 3.10
Accuracy of repeatability [%] ±1
Max. suction lift during operation 2) [m] 6
Max. suction lift when priming with wet
[m] 2 3 3 2
valves2)
Mechanical
data Min. pressure difference between suction and
[bar] 1 (FC and FCM: 2)
discharge side
Max. inlet pressure, suction side [bar] 2
Max. viscosity in SlowMode 25 % with [mPas]
2500 2500 2000 1500
spring-loaded valves 3) (= cP)
Max. viscosity in SlowMode 50 % with [mPas]
1800 1300 1300 600
Max. viscosity without SlowMode with [mPas]
600 500 500 200
[mPas]
Max. viscosity without spring-loaded valves 3) 50 300 300 150
(= cP)
Min. internal hose/pipe diameter
[mm] 4 6 6 9
suction/discharge side 2), 4)
Min. internal hose/pipe diameter
[mm] 9
suction/discharge side (high viscosity) 4)
Min./Max. liquid temperature [°C] -10/45
Min./Max. ambient temperature [°C] 0/45
Min./Max. storage temperature [°C] -20/70
Max. relative humidity (non-condensing) [%] 96
Max. altitude above sea level [m] 2000
9
Data 7.5-16 12-10 17-7 30-4
English (GB)
100-240 V, - 10 %/+ 10 %,
Voltage [V]
50/60 Hz
Length of mains cable [m] 1.5
Max. inrush current for 2 ms (100 V) [A] 8
Electrical Max. inrush current for 2 ms (230 V) [A] 25
data
Max. power consumption P1 [W] 24 5)
Enclosure class IP65, Nema 4X
Electrical safety class II
Pollution degree 2
Max. load for level input 12 V, 5 mA
Max. load for pulse input 12 V, 5 mA
Max. load for External stop input 12 V, 5 mA
Min. pulse length [ms] 5
Signal input Max. pulse frequency [Hz] 100
Impedance at 0/4-20 mA analog input [Ω] 15
Accuracy of analog input (full-scale value) [%] ± 1.5
Min. resolution of analog input [mA] 0.05
Max. resistance in level/pulse circuit [Ω] 1000
Max. ohmic load on relay output [A] 0.5
Max. voltage on relay/analog output [V] 30 VDC/30 VAC
Signal
Impedance at 0/4-20 mA analog output [Ω] 500
output
Accuracy of analog output (full-scale value) [%] ± 1.5
Min. resolution of analog output [mA] 0.02
Weight (PVC, PP, PVDF) [kg] 2.4 2.4 2.6
Weight/size Weight (stainless steel) [kg] 3.2 3.2 4.0
Diaphragm diameter [mm] 44 50 74
Sound
Max. sound pressure level [dB(A)] 60
pressure
Approvals CE, CB, CSA-US, NSF61, GOST/TR, C-Tick

1)
The maximum stroke frequency varies depending on calibration
2)
Data is based on measurements with water
3)
Maximum suction lift: 1 m, dosing capacity reduced (approx. 30 %)
4)
Length of suction line: 1.5 m, length of discharge line: 10 m (at max. viscosity)
5)
With E-Box
6)
PVC (polyvinyl chloride), only up to 10 bar
10
3.2 Dimensions
English (GB)
A
110 A1
17.5 G 5/8"
100%
200.8
B
TM04 1103 0110

105 D 161 17
4 x Ø6
120
168
Fig. 4 Dimensional sketch
Pump type A [mm] A1 [mm] B [mm] C [mm] D [mm]
DDA 7.5-16 280 251 196 46.5 24
DDA 12-10/17-7 280 251 200.5 39.5 24
DDA 30-4 295 267 204.5 35.5 38.5
11
4. Assembly and installation 4.1.3 Engage pump in mounting plate
1. Attach the pump to the mounting plate support
English (GB)
For use in Australia: clamps and slide under slight pressure until it
Installation of this product must engages.
comply with AS/NZS3500!
Note
Certificate of suitability number:
CS9431
C-tick number: N20683
TM04 1159 0110

4.1 Pump assembly
Warning
Install the pump in such a way that the
plug can easily be reached by the
operator during operation! This will Fig. 6 Engaging the pump
enable the operator to separate the
pump from the mains quickly in case of 4.1.4 Adjusting control cube position
emergency! The control cube is fitted to the front of the pump on
delivery. It can be turned by 90 ° so that the user can
The pump is delivered with a mounting plate. select to operate the pump from the right or left side.
The mounting plate can be mounted vertically e.g.
on a wall or horizontally e.g. on a tank. It takes just a The enclosure class (IP65/Nema 4X)
few quick steps to firmly secure the pump to the and shock protection are only
mounting plate by means of a slot mechanism. Caution
guaranteed if the control cube is
The pump can easily be released from the mounting installed correctly!
plate for maintenance.
Pump must be disconnected from the
4.1.1 Requirements Caution
power supply!
• The mounting surface must be stable and must
not vibrate. 1. Carefully remove both protective caps on the
• Dosing must flow upwards vertically. control cube using a thin screwdriver.
2. Loosen screws.
4.1.2 Align and install mounting plate
3. Carefully lift off control cube only so far from the
• Vertical installation: Mounting plate slot
pump housing that no tensile stress is produced
mechanism must be above.
on the flat band cable.
• Horizontal installation: Mounting plate slot
4. Turn control cube by 90 ° and re-attach.
mechanism must be opposite the dosing head.
– Make sure the O-ring is secure.
• The mounting plate can be used as a drill
template, please see fig. 4 for drill hole distances. 5. Tighten screws slightly and attach protective
caps.
TM04 1162 0110
Fig. 5 Locate mounting plate

IP65, Nema 4X
Warning
TM04 1182 0110
Make sure that you do not damage any

cables and lines during installation!
1. Indicate drill holes.
2. Drill holes.
3. Secure mounting plate using four screws,
diameter 5 mm, to the wall, on the bracket or the Fig. 7 Adjusting control cube
tank.
12
4.2 Hydraulic connection Hose connection procedure
1. Push union nut and tensioning ring across hose.
English (GB)
Warning 2. Push cone part fully into hose, see fig. 8.
Risk of chemical burns! 3. Attach cone part with hose to corresponding
Wear protective clothing (gloves and pump valve.
goggles) when working on the dosing 4. Tighten union nut manually.
head, connections or lines!
– Do not use tools!
The dosing head may contain water 5. Tighten up union nuts after 2-5 operating hours if
from the factory check! using PTFE gaskets!
Caution When dosing media which should not 6. Attach deaeration hose to the corresponding
come into contact with water, another connection (see fig. 3) and run into a container or
medium must be dosed beforehand! a collecting tray.
Faultless function can only be Cone part

Tensioning ring
Caution guaranteed in conjunction with lines Union nut
supplied by Grundfos!
TM04 1155 0110

The lines used must comply with the
Caution pressure limits as per section
3.1 Technical data!
Hose
Important information on installation
• Observe suction lift and line diameter, see Fig. 8 Hydraulic connection
section 3.1 Technical data.
• Shorten hoses at right angles. Pressure differential between suction
• Ensure that there are no loops or kinks in the Note and discharge side must be at least
hoses. 1 bar/14.5 psi!
• Keep suction line as short as possible.
Tighten the dosing head screws with a
• Route suction line up towards the suction valve. torque wrench once before
• Installing a filter in the suction line protects the Caution
commissioning and again after
entire installation against dirt and reduces the 2-5 operating hours at 4 Nm.
risk of leakage.
Installation example
• Only control variant FC/FCM: For discharge
quantities < 1 l/h we recommend the use of an The pump offers various installation options. In the
additional spring-loaded valve (approx. 3 bar) on picture below, the pump is installed in conjunction
the discharge side for the safe generation of the with a suction line, level switch and multifunction
necessary differential pressure. valve on a Grundfos tank.
Multifunction
valve
Deaeration
hose
Tank
Suction line with

TM04 1183 0110
empty signal
Fig. 9 Installation example
13
4.3 Electrical connection
English (GB)
Warning
The enclosure class (IP65/Nema 4X) is only guaranteed if plugs or protective caps are
correctly installed!
Warning
The pump can start automatically when the mains voltage is switched on!
Do not manipulate mains plug or cable!
The mains plug is the separator separating the pump from the mains.
Note
The rated voltage of the pump, see section 2.5 Nameplate, must conform to local conditions.
Signal connections
Warning
Electric circuits of external devices connected to the pump inputs must be separated from
dangerous voltage by means of double or reinforced insulation!
2 1 2 1
3 4 3 4
4 3 2 1
5
1 2 3 4
TM04 1121 0110
4 1 3
3 3 2 4 2
2 2 4 3 1
1 ► 1 GND
5 BUS
GND
BUS 2
GND 1
Fig. 10 Wiring diagram of the electrical connections
14
Analog, External stop and pulse input
English (GB)
Pins
Function Plug type
1/brown 2/white 3/blue 4/black
Analog GND/(-) mA (+) mA mA signal

External stop GND X Pulse
Pulse GND X Pulse
Level signals: Empty signal and Low-level signal
Pins
Function Plug type
1 2 3 4
Low-level signal X GND Pulse

Empty signal X GND Pulse
GENIbus, Analog output
Danger of damage to the product due to short circuit! Pin 1 supplies 30 VDC.
Caution
Never short-circuit pin 1 with any of the other pins!
Pins
Function Plug type
5/yellow/
green
GENI bus GENI bus

GENIbus +30 V GND Bus
TXD RXD
Analog output (+) mA GND/(-) mA mA signal
Relay outputs
Pins
Function Plug type
Relay 1 X X Pulse
Relay 2 X X Pulse
FlowControl signal connection
Sensor
TM04 1158 0110
Fig. 11 FlowControl signal connection
15
5. Startup
English (GB)
5.1 Setting the menu language

For description of control elements, see section 6.
1. Turn click wheel to highlight the cog symbol.

Operation
7.50 l/h
Manual
2. Press the click wheel to open the "Setup" menu. Operation

7.50 l/h
Manual
3. Turn the click wheel to highlight the "Language"

menu.
Setup
Language English >
Operation mode Manual >
Analog output Actual flow >
SlowMode Off >
FlowControl active ❑
4. Press the click wheel to open the "Language"

menu.
Setup
Language English >
Operation mode Manual >
Analog output Actual flow >
SlowMode Off >
FlowControl active ❑
5. Turn the click wheel to highlight the desired

language.
Language
English
Deutsch ❑
Francais ❑
Espanol ❑
Italiano ❑
6. Press the click wheel to select the highlighted

language.
Language
English
Deutsch ❑
Francais ❑
Espanol ❑
Italiano ❑
7. Press the click wheel again to confirm the "Confirm

settings?" prompt and apply the setting.
Language
TM04 1184 1110
Confirm
settings?
Fig. 12 Set menu language
16
5.2 Deaerating the pump
English (GB)
Warning
The deaeration hose must be
connected correctly and inserted into a
suitable tank!
1. Open deaeration valve by approximately half a

turn.
2. Press and hold down the [100%] key (deaeration
key) until liquid flows continuously without any
bubbles from the deaeration hose.
3. Close deaeration valve.
Press the [100%] key and

simultaneously turn the click wheel
Note
clockwise to increase the duration of
the process to up to 300 seconds.
After setting the seconds, do not press
the key any longer.
5.3 Calibrating the pump

The pump is calibrated in the factory for media with a
viscosity similar to water at maximum pump
backpressure (see section 3.1 Technical data).
If the pump is operated with a backpressure that
deviates or if dosing a medium whose viscosity
deviates, the pump must be calibrated.
For pumps with FCM control variant, it is not
necessary to calibrate the pump if there is deviating
or fluctuating backpressure as long as the
"AutoFlowAdapt" function has been enabled (see
section 6.10 AutoFlowAdapt).
Requirements
• The hydraulics and electrics of the pump are
connected (see section 4. Assembly and
installation).
• The pump is integrated into the dosing process
under operating conditions.
• The dosing head and suction hose are filled with
dosing medium.
• The pump has been deaerated.
17
Calibration process - example for DDA 7.5-16
English (GB)
1. Fill a measuring beaker with dosing medium.

Recommended filling volumes V1:
– DDA 7.5-16: 0.3 l
– DDA 12-10: 0.5 l
– DDA 17-7: 1.0 l V1 = 300 ml
– DDA 30-4: 1.5 l
2. Read off and note down the fill volume V1 (e.g.

300 ml).
3. Place the suction hose in the measuring beaker.
4. Start the calibration process in the "Setup >

Calibration" menu. Calibration
Strokes:
0 START
STOP
Calibrat. volume: 0.0000ml
5. The pump executes 200 dosing strokes and

displays the factory calibration value (e.g. Calibration
125 ml).
Strokes: 200 START
STOP
Calibrat. volume: 125ml
6. Remove the suction hose from the measuring

beaker and check the remaining volume V2 (e.g.
170 ml). V2 = 170 ml
7. From V1 and V2, calculate the actual dosed

volume Vd = V1 - V2
(e.g. 300 ml - 170 ml = 130 ml). Vd = V1 - V2 = 130 ml
8. Set and apply Vd in the calibration menu.

• The pump is calibrated. Calibration
START
Strokes:
200
TM04 1154 1110
STOP
Calibrat. volume: 130 ml
Actual dosed volume Vd
18
6. Operation 6.2 Display and symbols
English (GB)
6.2.1 Navigation
6.1 Control elements
In the "Info", "Alarm" and "Setup" main menus, the
The pump control panel includes a display options and submenus are displayed in the rows
and the following control elements. below. Use the "Back" symbol to return to the higher
menu level. The scroll bar at the right edge of the
display indicates that there are further menu items
which are not shown.
Graphical LC
display The active symbol (current cursor position) flashes.
Operation Press the click wheel to confirm your selection and
7.50 l/h open the next menu level. The active main menu is
Manual 7.49 l/h Click wheel displayed as text, the other main menus are
displayed as symbols. The position of the cursor is
highlighted in black in the sub-menus.
100% When you position the cursor on a value and press
TM04 1104 2111

the click wheel, a value is selected. Turning the click
wheel clockwise increases the value, turning the
click wheel counter-clockwise reduces the value.
When you now press the click wheel, the cursor will
[Start/stop] key [100%] key be released again.
6.2.2 Operating states
Fig. 13 Control panel
The operating state of the pump is indicated by a
Keys symbol and display colour.
Key Function Display Fault Operating state
[Start/stop] Stop Standby

Starting and stopping the pump. White -
key
The pump doses at maximum flow Running
[100%] key Green -
regardless of the operation mode.
Stop Standby Running
Click wheel Yellow Warning
The click wheel is used to navigate through the
menus, select settings and confirm them. Stop Standby
Red Alarm
Turning the click wheel clockwise moves the cursor
clockwise in increments in the display. Turning the
click wheel counter-clockwise moves the cursor 6.2.3 Sleep mode (energy-saving mode)
counter-clockwise.
If in the "Operation" main menu the pump is not
operated for 30 seconds, the header disappears.
After two minutes, the display brightness is reduced.
If in any other menu the pump is not operated for two
minutes, the display switches back to the
"Operation" main menu and the display brightness is
reduced. This state will be cancelled when the pump
is operated or a fault occurs.
19
6.2.4 Overview of display symbols
The following display symbols may appear in the menus.
English (GB)
Top row with main menus (Sect. 6.3)

Operation Back
Info
Alarm Run display
Setup Running - rotates when pump is dosing
Blocked drive - flashing symbol
Operation
7.48 l/h
Manual 7.48l/h
Activated functions Additional display (Sect. 6.13.2)

AR, FC variant: Target flow
SlowMode (Sect. 6.6)
FCM variant: Actual flow
FlowControl (Sect. 6.7)
Remaining batch volume (Batch/Timer)
Key lock (Sect. 6.12) Input current (Analog)
Bus (Sect. 6.15)
Time until next dosing process (Timer)
Auto deaeration (Sect. 6.11)
Total dosed volume
Operation mode Actual backpressure
Manual (Sect. 6.4.1)
Pulse (Sect. 6.4.2) Signal/error display
Analog 0/4-20 mA (Sect. 6.4.3) External stop (Sect. 6.16.2)
Batch (Sect. 6.4.4) Empty signal (Sect. 6.16.3)
Timer (Sect. 6.4.5, 6.4.6) Low-level signal (Sect. 6.16.3)
Operating state (Sect. 6.2.2) and dosing Cable break (Sect. 6.4.3)
flow E-box (Sect. 6.15)
Running Service (Sect. 7.)
Standby
Stop
TM04 1161 1710
100% Deaerating
Diaphragm position "out" (Sect. 7.)
Diaphragm position "in" (Sect. 7.)
Fig. 14 Overview of display symbols
20
6.3 Main menus 6.3.3 Alarm
You can view errors in the "Alarm" main
English (GB)
The main menus are displayed as symbols at the top
of the display. The currently active main menu is menu.
displayed as text.
6.3.1 Operation Alarm
Status information such as the dosing flow, 1 12.02.2010 12:34
selected operation mode and operating state Empty
is displayed in the "Operation" main menu.
2 12.02.2010 12:34
Low level
TM04 1109 1010

Operation
TM04 1157 2011

7.48 l/h
7.48l/h
Delete alarm
messages ❑
Manual
Up to 10 warnings and alarms, together with their

date, time and cause, are listed in chronological
6.3.2 Info order. If the list is full, the oldest entry will be
overwritten, see section 8. Faults.
You can find the date, time and information
about the active dosing process, various 6.3.4 Setup
counters, product data and the service system status The "Setup" main menu contains menus for
in the "Info" main menu. The information can be pump configuration. These menus are
accessed during operation. described in the following sections.
The service system can also be reset from here.
Check all pump settings after any
Note
change in the "Setup " menu.
Info
Th 18.02.2010 12:34 Setup
Backpressure 15.0bar Section
Counters > Language English > 5.1
Service - Operation mode Pulse > 6.4
ServiceKit Pulse memory* ❑ 6.4.2
Reset service system Analog scaling > 6.4.3
TM04 1106 1010
Software rev. V0.20 Batch volume* 1.06 l 6.4.4

Serial no.: Dosing time[mm:ss]* 7:50 6.4.4
Product no.: Dosing timer cycle* > 6.4.5
Type Key: Dosing timer week* > 6.4.6
Analog output Actual flow > 6.5
SlowMode Off > 6.6
Counters FlowControl active* ❑ 6.7
The "Info > Counters" menu contains the following FlowControl* > 6.7
counters: Pressure monitoring* > 6.8
AutoFlowAdapt* ❑ 6.10
Counters Resettable Auto deaeration ❑ 6.11
Calibration > 5.3
Volume Key lock Off > 6.12
Yes
TM04 1110 1010
Total dosed volume [l] or US gallons Display > 6.13

Operating hours Time+date > 6.14
Bus > 6.15
Accumulated operating hours (pump No
Inputs/Outputs > 6.16
switched on) [h] Basic settings > 6.17
Motor runtime
No * These submenus are only displayed for specific
Accumulated motor runtime [h]
default settings and control variants.
Strokes The contents of the "Setup" menu also vary
Accumulated number of dosing No depending on the operation mode.
strokes
Power on/off
Accumulated frequency of switching No
mains voltage on
21
6.4 Operation modes 6.4.2 Pulse
In this operation mode, the pump doses the
English (GB)
Six different operation modes can be set in the

"Setup > Operation mode" menu. set dosing volume for each incoming (potential-free)
pulse, e.g. from a water meter. The pump
• Manual, see section 6.4.1
automatically calculates the optimum stroke
• Pulse, see section 6.4.2 frequency for dosing the set volume per pulse.
• Analog 0-20mA, see section 6.4.3 The calculation is based on:
Analog 4-20mA, see section 6.4.3
• the frequency of external pulses
• Batch (pulse-based), see section 6.4.4
• the set dosing volume/pulse.
• Dosing timer cycle, see section 6.4.5
• Dosing timer week, see section 6.4.6
Operation
6.4.1 Manual
TM04 1126 1110

In this operation mode, the pump constantly
doses the dosing flow set with the click wheel. 0.0400 ml/
The dosing flow is set in l/h or ml/h in the "Operation" Pulse 3.40l/h
menu. The pump automatically switches between the
units. Alternatively, the display can be reset to US
units (gph). See section 6.13 Display Setup.
Fig. 16 Pulse mode
Operation TM04 1125 1110 The dosing volume per pulse is set in ml/pulse in the
"Operation" menu using the click wheel. The setting
3.40 l/h
range for the dosing volume depends on the pump
type:
Manual 3.40l/h
Type Setting range [ml/pulse]
DDA 7.5-16 0.0015 - 14.9

Fig. 15 Manual mode DDA 12-10 0.0029 - 29.0
The setting range depends on the pump type: DDA 17-7 0.0031 - 31.0
DDA 30-4 0.0062 - 62.0
Setting range*
Type The frequency of incoming pulses is multiplied by the
[l/h] [gph] set dosing volume. If the pump receives more pulses
than it can process at the maximum dosing flow, it
DDA 7.5-16 0.0025 - 7.5 0.0007 - 2.0
runs at the maximum stroke frequency in continuous
DDA 12-10 0.012 - 12 0.0031 - 3.1 operation. Excess pulses will be ignored if the
memory function is not enabled.
DDA 17-7 0.017 - 17 0.0045 - 4.5
Memory function
DDA 30-4 0.03 - 30 0.0080 - 8.0
When the "Setup > Pulse memory" function is
* When the "SlowMode" function is active, the enabled, up to 65,000 unprocessed pulses can be
maximum dosing flow is reduced, see section saved for subsequent processing.
3.1 Technical data.
Warning
Subsequent processing of saved
pulses can cause local increase in
concentration!
The contents of the memory will be deleted by:
• Switching off the power supply
• Changing the operation mode
• Interruption (e.g. alarm, External stop).
22
6.4.3 Analog 0/4-20 mA Set analog scaling
In this operation mode, the pump doses Analog scaling refers to the assignment of the
English (GB)
according to the external analog signal. current input value to the dosing flow.
The dosing volume is proportional to the signal input Changes of analog scaling affect also the analog
value in mA. output signal. See section 6.5 Analog output.
Analog scaling passes through the two reference
Operation Input value Dosing flow points (I1/Q1) and (I2/Q2), which are set in the "Setup
mode [mA] [%] > Analog scaling" menu. The dosing flow is
controlled according to this setting.
≤ 4.1 0
4-20 mA Example 1 (DDA 7.5-16)
≥ 19.8 100
Analog scaling with positive gradient:
≤ 0.1 0
0-20 mA
≥ 19.8 100 Q [l/h]
(I2/Q2)
If the input value in operation mode 4-20 mA falls 7.5
below 2 mA, an alarm is displayed and the pump
stops. A cable break or signal transmitter error has
5
occurred. The "Cable break" symbol is displayed in
TM04 1160 2010

the "Signal and error display" area of the display.
(I1/Q1)
1.5
Q [%]
0
100 0 6 16 20 I [mA]
80 A
2 0m Fig. 19 Analog scaling with pos. gradient
60 0-
TM04 1120 2010
In example 1, the reference points I1 = 6 mA,

40
Q1 = 1.5 l/h and I2 = 16 mA, Q2 = 7.5 l/h have been
mA
20 20 set.
4-
0 From 0 to 6 mA analog scaling is described by a line
0 4 8 12 16 20 [mA] that passes through Q = 0 l/h, between 6 mA and
16 mA it rises proportionally from 1.5 l/h to 7.5 l/h
Fig. 17 Analog scaling and from 16 mA onwards it passes through
Q = 7.5 l/h.
Example 2 (DDA 7.5-16)
Operation Analog scaling with negative gradient (Operation
mode 0-20 mA):
6.50
TM04 1127 1110
ml/h Q [l/h]
0-20mA 17.14mA
(I1/Q1)
7,5
TM04 1101 2010

Fig. 18 Analog operation mode
(I2/Q2)
1,3
0
0 2 16 20 I [mA]
Fig. 20 Analog scaling with neg. gradient
In example 2, the reference points I1 = 2 mA,

Q1 = 7.5 l/h and I2 = 16 mA, Q2 = 1.3 l/h have been
set.
From 0 to 2 mA analog scaling is described by a line
that passes through Q = 0 l/h, between 2 mA and
16 mA it drops proportionally from 7.5 l/h to 1.3 l/h
and from 16 mA onwards it passes through
Q2 = 1.3 l/h.
23
Set analog scaling in the "Operation" menu The batch volume (e.g. 75 ml) is set in the "Setup >
Analog scaling can also be modified after a security Batch volume" menu. The minimum dosing time
English (GB)
prompt directly in the "Operation" menu. This is how required for this (e.g. 36 seconds) is displayed and
the dosing flow is directly modified for the current can be increased.
flow input value.
Please observe that changes also have Setup

a direct effect on point I2/Q2
TM04 1134 1110

Caution
Operation mode Batch >
(see fig. 21)!
Batch volume 75.0ml
Dosing time[s] 36.0
Q [%] Analog output Input >
(I2/Q 2) (I2/Q 2) SlowMode Off >
100
new
Fig. 23 Batch mode
Signals received during a batch process or an
TM04 1132 2010

interruption (e.g. alarm, External stop) will be
ignored. If the pump is restarted following an
(I1/Q 1) interruption, the next batch volume is dosed on the
0
next incoming pulse.
0 4 actual mA 20 I [mA]
Fig. 21 Set analog scaling ("Operation" menu) Operation
TM04 1135 1110

6.4.4 Batch (pulse-based)
In this operation mode, the pump doses the
75.0 ml
Batch 43.0ml
set batch volume in the set dosing time (t1).
A batch is dosed with each incoming pulse.
Batch volume Fig. 24 Batch mode
In the "Operation" menu, the total batch volume (e.g.

75 ml) and the remaining batch volume still to be
dosed (e.g. 43 ml) are shown in the display.
TM04 1105 2010
t1 t1
Time
Pulse Pulse
Fig. 22 Batch (pulse-based)
The setting range depends on the pump type:
Setting range per batch

Type
Resolution*
from [ml] to [l]
[ml]
DDA 7.5-16 0.74 999 0.0925
DDA 12-10 1.45 999 0.1813
DDA 17-7 1.55 999 0.1938
DDA 30-4 3.10 999 0.3875
* Thanks to the digital motor control, dosing

quantities with a resolution of up to 1/8 of the
dosing stroke volume can be dosed.
24
6.4.5 Dosing timer cycle The total batch volume (e.g. 125 ml) and the
In this operation mode, the pump doses the remaining batch volume still to be dosed are
English (GB)
set batch volume in regular cycles. displayed in the "Operation" menu. During breaks in
Dosing starts when the pump is started after a dosing, the time until the next dosing process
singular start delay. The setting range for the batch (e.g. 1:21) is displayed.
volume corresponds to the values in section
6.4.4 Batch (pulse-based).
Operation
125
TM04 1136 2011

Warning
When time or date is changed in ml
"Time+date " menu, timer dosing and Timer 1:21
timer relay output functions (Relay 2)
are stopped!
Timer dosing and timer relay output
functions must be restarted manually! Fig. 27 Dosing timer cycle
Changing time or date can cause 6.4.6 Dosing timer week
increase or decrease in concentration!
In this operation mode, up to 16 dosing
procedures are defined for a week.
Batch volume These dosing procedures may take place regularly
on one or several week days. The setting range for
the batch volume corresponds to the values in
section 6.4.4 Batch (pulse-based).
t1 t1 Warning
TM04 1107 1109
When time or date is changed in

t2 "Time+date " menu, timer dosing and
timer relay output functions (Relay 2)
t3
are stopped!
Timer dosing and timer relay output
Fig. 25 Dosing timer cycle diagram functions must be restarted manually!
Changing time or date can cause
t1 Dosing time
t2 Start delay
t3 Cycle time

In the event of an interruption (e.g. interruption of the
mains voltage, External stop), the dosing will be

stopped while the time continues running.
TM04 1108 1109

After suspending the interruption, the pump will
continue to dose according to the actual timeline
position.
The following settings are required in the "Setup >
MO TU WE TH FR SA SU
Dosing timer cycle" menu:
Fig. 28 Example for Dosing timer week function
Timer
If several procedures overlap, the
TM04 1137 1110
Batch volume 125ml Note process with the higher dosing flow has
Dosing time[mm:ss] 1:54 priority!
Cycle time[mm:ss] 3:00
In the event of an interruption (e.g. disconnection of
Start delay[mm:ss] 2:00
the mains voltage, External stop), the dosing is
stopped while the time continues running.
Fig. 26 Dosing timer cycle After suspending the interruption, the pump
continues to dose according to the actual timeline
The batch volume to be dosed (e.g. 125 ml) is set in position.
the "Setup > Dosing timer cycle" menu. The dosing
time required for this (e.g. 1:54) is displayed and can
be changed.
25
The following settings are required in the "Setup > 6.5 Analog output
Dosing timer week" menu for each dosing procedure:
English (GB)
Timer Analog out

Output = Input
TM04 1153 1110

TM04 1138 1110
Procedure 1 Actual flow ❑
Batch volume 80.5ml Backpressure ❑
Dosing time[s] 39.0 Bus control ❑
Start time[hh:mm] 05:00
M❑ T W❑ T F❑ S❑ S
Fig. 31 Configure analog output
Fig. 29 Setting the timer
The analog output of the pump is parametrised in the
The batch volume (e.g. 80.5 ml) is set in the "Setup > "Setup > Analog output" menu. The following
Dosing timer week" menu. The dosing time required settings are possible:
for this (e.g. 39.0) is displayed and can be changed.
In the "Operation" menu, the total batch volume Variant
Description of output
(e.g. 80.5 ml) and the remaining batch volume to be Setting
FCM
signal
AR
FC
dosed is displayed. During breaks in dosing, the time
(e.g. 43:32) until the next dosing is displayed.
Analog feedback signal
(not for master-slave
Output =
Operation Input
application). The analog X X X
input signal is mapped 1:1
TM04 1136 1110
80.5
Timer
ml
to the analog output.
Current actual flow
43:32 • 0/4 mA = 0 %
Actual
• 20 mA = 100 % X X* X*
flow**
see section 6.9 Flow
Fig. 30 Weekly timer dosing (break in dosing) measurement
Backpressure, measured
in the dosing head
• 0/4 mA = 0 bar
Backpres
• 20 mA = Max. X X
sure
operating pressure
see section 6.8 Pressure
monitoring
Enabled by command in
Bus
Bus control, see section X X X
control
6.15 Bus communication
* Output signal is based on motor speed and pump
status (target flow).
** Signal has same analog scaling as the current
analog input signal. See 6.4.3 Analog 0/4-20 mA.
Wiring diagram see section 4.3 Electrical
connection.
In all operation modes, the analog

output has a range of 4-20 mA.
Note Exception: Operation mode 0-20 mA.
Here, the analog output range is
0-20 mA.
26
6.6 SlowMode
English (GB)
When the "SlowMode" function is enabled, the
pump slows down the suction stroke. The function is
enabled in the "Setup > SlowMode" menu and is
used to prevent cavitation in the following cases:
• for dosing media with a high viscosity
• for degassing dosing media
• for long suction lines
• for large suction lift.
In the "Setup > SlowMode" menu, the speed of the
suction stroke can be reduced to 50 % or 25 %.
Enabling the 'SlowMode' function

Caution reduces the maximum dosing flow of
the pump to the set percentage value!
SlowMode
Off
SlowMode (50% max.) ❑ TM04 1153 1110
SlowMode (25% max.) ❑
Fig. 32 SlowMode menu
27
6.7 FlowControl FlowControl works with a maintenance-free sensor
in the dosing head. During the dosing process, the
English (GB)
Applies to DDA-FC/FCM control variant.

sensor measures the current pressure and
This function is used to monitor the dosing process. continuously sends the measured value to the
Although the pump is running, various influences microprocessor in the pump. An internal indicator
e.g. air bubbles, can cause a reduced flow or even diagram is created from the current measured values
stop the dosing process. In order to guarantee and the current diaphragm position (stroke length).
optimum process safety, the enabled "FlowControl" Causes for deviations can be identified immediately
function directly detects and indicates the following by aligning the current indicator diagram with a
errors and deviations: calculated optimum indicator diagram. Air bubbles in
• Overpressure the dosing head reduce e.g. the discharge phase
• Damaged discharge line and consequently the stroke volume (see fig. 33).
• Air in the dosing chamber Requirements for a correct indicator diagram are:
• Cavitation • FlowControl function is active
• Suction valve leakage > 70 % • pressure difference between suction and
discharge side is > 2 bar
• Discharge valve leakage > 70 %.
• No interruption/pause in discharge stroke
The occurrence of a fault is indicated by the "eye"
symbol flashing. The faults are displayed in the • Pressure sensor and cable are functioning
"Alarm" menu (see section 8. Faults). properly
• No leakage > 50 % in suction or discharge valve
If one of these requirements is not met, the indicator
diagram cannot be evaluated.
Pressure
Trouble-free dosing stroke

Faulty dosing stroke: Air
bubbles in the dosing
head
1
3
TM04 1610 1710

4
Stroke length
Fig. 33 Indicator diagram
Sensitivity
1 Compression phase
In "Sensitivity" the deviation in stroke volume, which
2 Discharge phase will result in an error message, is set in percent.
3 Expansion phase
Sensitivity Deviation
4 Suction phase
low approx. 70 %
Setting FlowControl
medium approx. 50 %
The "FlowControl" function is set using the two
parameters "Sensitivity" and "Delay" in the "Setup > high approx. 30 %
FlowControl" menu.
28
Delay 6.8.2 Calibration of pressure sensor
The "Delay" parameter is used to define the time The pressure sensor is calibrated in the factory. As a
English (GB)
period until an error message is generated: "short", rule, it does not need to be re-calibrated. If specific
"medium" or "long". The delay depends on the set circumstances (e.g. pressure sensor exchange,
dosing flow and therefore cannot be measured in extreme air pressure values at the location of the
strokes or time. pump) necessitate a calibration, the sensor can be
calibrated as follows:
Air bubbles
The "FlowControl" function identifies air bubbles 1. Set pump to "Stop" operating state.
> 60 % of the stroke volume. After switching to 2. Make system pressureless and flush.
"Air bubble" warning status, the pump adapts the 3. Dismantle suction line and suction valve.
stroke frequency to approximately 30-40 % of max.
stroke frequency, and starts a special motor drive Warning
strategy. The adaptation of the stroke frequency
Calibrating when the suction valve is
allows the air bubbles to rise from suction to
installed produces incorrect calibration
discharge valve. Due to the special motor drive
and can cause personal injuries and
strategy the air bubbles are displaced from the
damage to property!
dosing head into the discharge line.
Only carry out a calibration if this is
If the air bubbles have not been eliminated after a
technically required!
maximum of 60 strokes, the pump returns to the
normal motor drive strategy. 4. Proceed as described below to calibrate:
6.8 Pressure monitoring Plug in pressure sensor plug or select "Setup >
Applies to DDA-FC/FCM control variant. FlowControl active" menu
A pressure sensor monitors the pressure in the
dosing head. If the pressure during the discharge
phase falls below 2 bar, a warning is generated
(pump continues running). If in the "Setup > Prompt:
Pressure monitoring" menu the function "Min. "Activate FlowContr.?"
pressure alarm" is activated, an alarm is generated FlowControl not
and the pump is stopped. activated
If the pressure exceeds the "Max. pressure" set in
the "Setup > Pressure monitoring" menu, the pump Prompt:
is shut down, enters the standby state and indicates "Sensor calibration?"
an alarm. FlowControl active,
Sensor not calibrated.
The pump restarts automatically once
Caution the backpressure falls below the set Prompt:
"Max. pressure"! "Suction valve removed?"
6.8.1 Pressure setting ranges
Sensor not calibrated.
Fixed min. Adjustable max.
Type Calibration error
pressure [bar] pressure [bar]
OK
DDA 7.5-16 <2 3-17
DDA 12-10 <2 3-11 Message: Message:
"Sensor calib. OK!" "Sensor calib. failed!"
DDA 17-7 <2 3-8 "Current pressure: X "Repeat?"
DDA 30-4 <2 3-5 bar"
TM04 1145 2510
Warning
Install a pressure-relief valve in the
pressure line to provide protection Sensor not calibrated.
against impermissibly high pressure!
The pressure measured in the dosing If a calibration is not successfully possible, check
head is slightly higher than the actual plug connections, cable and sensor and replace
system pressure. defective parts where necessary.
Caution
Therefore the "Max. pressure " should
be set at least 0.5 bar higher than the
system pressure.
29
6.9 Flow measurement Example of "AutoFlowAdapt"
Pressure fluctuations
English (GB)
Applies to DDA-FCM control variant.

The pump accurately measures the actual flow and The dosing volume decreases as backpressure
displays it. Via the 0/4-20 mA analog output, the increases and conversely the dosing volume
actual flow signal can easily be integrated into an increases as the backpressure decreases.
external process control without additional The "AutoFlowAdapt" function identifies pressure
measuring equipment (see section 6.5 Analog fluctuations and responds by adjusting the stroke
output). frequency. The actual flow is thus maintained at a
The flow measurement is based on the indicator constant level.
diagram as described in section 6.7 FlowControl.
The accumulated length of the discharge phase 6.11 Auto deaeration
multiplied by the stroke frequency produces the Dosing degassing media can result in air
displayed actual flow. Faults e.g. air bubbles or pockets in the dosing head during breaks in
backpressure that is too low result in a smaller or dosing. This can result in no medium being dosed
larger actual flow. When the "AutoFlowAdapt" when restarting the pump. The "Setup > Auto
function is activated (see section deaeration" function performs pump deaeration
6.10 AutoFlowAdapt), the pump compensates for automatically at regular intervals.
these influences by correction of the stroke Software-controlled diaphragm movements
frequency. encourage any bubbles to rise and gather at the
discharge valve so that they can be removed on the
Strokes which cannot be analysed next dosing stroke.
(partial strokes, pressure differential
The function works:
Note which is too low) are provisionally
calculated based on the setpoint value • when the pump is not in the "Stop" operating
and displayed. state
• during breaks in dosing (e.g. External stop, no
incoming pulses, etc.).
6.10 AutoFlowAdapt
Applies to DDA-FCM control variant. The diaphragm movements can
displace small volumes into the
The "AutoFlowAdapt" function is activated in the Note discharge line. When dosing strongly
"Setup" menu. It detects changes in various degassing media, this is however
parameters and responds accordingly in order to virtually impossible.
keep the set target flow constant.
Dosing accuracy is increased when 6.12 Key lock

Note
"AutoFlowAdapt" is activated. The key lock is set in the "Setup > Key lock"
menu by entering a four-digit code. It protects the
This function processes information from the
pump by preventing changes to settings. Two levels
pressure sensor in the dosing head. Errors detected
of key lock can be selected:
by the sensor are processed by the software.
The pump responds immediately regardless of the
operation mode by adjusting the stroke frequency or Level Description
where necessary compensating for the deviations
All settings can only be changed by
with a corresponding indicator diagram.
entering the lock code.
If the target flow cannot be achieved by the Settings
The [Start/stop] key and the [100%]
adjustments, a warning is issued. key are not locked.
"AutoFlowAdapt" operates on the basis of the
Settings + The [Start/stop] key and the [100%]
following functions:
keys key and all settings are locked.
• FlowControl: malfunctions are identified (see
section 6.7 FlowControl). It is still possible to navigate in the "Alarm" and "Info"
• Pressure monitoring: pressure fluctuations are main menu and reset alarms.
identified (see section 6.8 Pressure monitoring).
6.12.1 Temporary deactivation
• Flow measurement: deviations from the target
If the "Key lock" function is activated but settings
flow are identified (see section 6.9 Flow
need to be modified, the keys can be unlocked
measurement).
temporarily by entering the deactivation code. If the
code is not entered within 10 seconds, the display
automatically switches to the "Operation" main
menu. The key lock remains active.
6.12.2 Deactivation
The key lock can be deactivated in the "Setup > Key
lock" menu via the "Off" menu point. The key lock is
deactivated after the general code "2583" or a
pre-defined custom code has been entered.
30
6.13 Display Setup The additional display can be set as follows:
English (GB)
Use the following settings in the "Setup > Display"
menu to adjust the display properties: Setting Description
• Units (metric/US) Depending on the operation mode:
• Display contrast
Actual flow (Manual/Pulse) 1), 2)
• Additional display.
Target flow (Pulse)
6.13.1 Units Default
Metric units (litres/millilitres/bar) or US units (US display Input current (analog)
gallons/PSI) can be selected. According to the
operation mode and menu, the following units of Remaining batch volume
measurement are displayed: (Batch, Timer)
Period until next dosing (Timer)
Operation mode /
Metric units US units Dosed Dosed vol. since last reset (see
function
volume Counters on page 21)
Manual control ml/h or l/h gph Actual flow Current actual flow 1)
Pulse control ml/ ml/ Current backpressure in the
Backpressure
0/4-20 mA Analog dosing head 3)
ml/h or l/h gph
control
1)
only DDA-FCM control variant
Batch (pulse- or
ml or l gal 2)
only if indicator diagram can be evaluated (see
timer-controlled)
6.7 FlowControl)
Calibration ml ml
3) only DDA-FCM/FC control variant
Volume counter l gal
Pressure monitoring bar psi 6.14 Time+date
The time and date can be set in the "Setup >
Time+date" menu.
6.13.2 Additional display
The additional display provides additional Warning
information about the current pump status. The value When time or date is changed in
is shown in the display with the corresponding "Time+date " menu, timer dosing and
symbol. timer relay output functions (Relay 2)
In "Manual" mode the "Actual flow" information can are stopped!
be displayed with Q = 1.28 l/h (see fig. 34). Timer dosing and timer relay output
functions must be restarted manually!
Operation Changing time or date can cause

1.30 l/h The conversion between summer and

TM04 1151 2011
Manual Caution winter time does not take place

1.28l/h
automatically!
Additional display
Fig. 34 Display with additional display
31
6.15 Bus communication 6.15.3 Activate communication
1. Set the pump to operating state "Stop" with the
English (GB)
The bus communication enables remote

monitoring and setting of the pump via a [Start/stop] key.
fieldbus system. 2. Switch off the power supply of the pump.
Further manuals, functional profiles and support files 3. Install and connect the E-Box/CIU as described
(e.g. GSD-files) are available on the CD delivered in the respective separate installation and
with the interface hardware and on operating instructions.
www.grundfos.com. 4. Switch on the power supply of the pump.
6.15.1 GENIbus communication The "Activate communication?" prompt is displayed.
The pump is supplied with an integrated module for After confirmation, the "Bus" symbol appears in the
GENIbus communication. The pump identifies the "Activated functions" area of the "Operation" menu,
bus control after connecting to the corresponding no matter if the prompt was accepted or refused.
signal input. The "Activate communication?" prompt If the prompt has been accepted, the bus control
is displayed. After confirmation, the corresponding function is activated. If the prompt has been refused,
symbol appears in the "Activated functions" area in bus control function can be activated in "Setup >
the "Operation" menu. Bus" menu.
In the "Setup > Bus" menu the GENIbus address can
Profibus
be set from 32 to 231 and bus control can be
deactivated.
TM04 1139 2410

Bus control active
Bus address
Bus 126
TM04 1139 2410
Bus control active

Bus address 231
Fig. 36 Example of submenu for Profibus®
6.15.4 Setting the bus address

Fig. 35 Bus menu 1. Enter "Setup > Bus" menu and set desired bus
address:
The maximum cable length for
Caution GENIbus connection is 3 m and must Bus type Address range
not be exceeded!
Profibus® DP 0 - 126
6.15.2 Possible industrial bus types Modbus RTU 1 - 247
The pump can be integrated into several networks
using the additional E-box (Extension-Box). 2. The pump needs to be restarted to initialise the
new bus address. Switch off the power supply of
Interface Retrofitting possible the pump and wait for approximately 20 seconds.
Bus type 3. Switch on the power supply of the pump.
hardware for pump software
The pump is initialised with the new bus address.
Profibus® DP E-Box 150 V2.0 and higher
Modbus RTU E-Box 200 V2.5 and higher
The pump can also be connected to a Grundfos CIU

unit (CIU = Communication Interface Unit) equipped
with one of the following CIM modules (CIM =
Communication Interface Module):
• CIM150 Profibus
• CIM200 Modbus
• CIM270 GRM
• CIM500 Ethernet
For internal communication between the E-Box/CIU
and the dosing pump, GENIbus is used.
The maximum cable length for

Caution GENIbus connection is 3 m and must
not be exceeded!
Prior to installation and start-up, read

Caution the documentation delivered with the
E-Box or CIU unit!
32
6.15.5 Characteristics of bus communication 6.15.7 Communication faults
To start and stop the pump via bus, it needs to be in Faults are only detected, if the respective
English (GB)
operating state "Running". When the pump is "BusWatchDog" (see functional profile on E-Box/CIU
remotely stopped from bus, the "External stop" product CD) is activated.
symbol is displayed and the pump switches to
operating state "Standby". Warning
While bus control function is activated, the "Setup" After a communication fault is repaired,
menu only shows the "Bus" and "Key lock" the pump can start automatically,
submenus. The other main menus, the "External depending on current bus control and
stop" function and the keys are still available. pump settings!
All operation modes (see section 6.4 Operation Before repairing any fault, set the
modes) can still be used when bus control is pump to operating state "Stop"!
activated. This allows to use the bus control only for In case of bus communication faults (e.g.
monitoring and setting the pump. In this case the communication cable break), the pump stops dosing
respective "BusWatchDog" (see funtional profile on and switches to operating state "Standby"
E-Box/CIU product CD) should be deactivated in bus approximately 10 seconds after the fault was
control, because otherwise faults in communication detected. An alarm is triggered, detailing the cause
can stop the pump. of the fault. See section 8. Faults.
To change any settings manually, the
Note bus control function must be
deactivated temporarily.
The analog output can not be used while the pump is
bus-controlled as both functions use the same
electrical connection. See section 4.3 Electrical
connection.
6.15.6 Deactivate communication
Warning
After deactivating the bus control
function, the pump can start
automatically!
Before deactivating the bus control
function, set the pump to operating
state "Stop"!
Bus control function can be deactivated in the "Setup
> Bus" menu. After deactivation all submenus in
"Setup" menu are available.
The "Bus" symbol in the display disappears at next
restart of the pump, after the E-Box/CIU plug was
disconnected.
After disconnecting any plug, always

Caution
refit protective cap!
33
6.16 Inputs/Outputs 6.16.1 Relay outputs
The pump can switch two external signals using
English (GB)
In the "Setup > Inputs/Outputs" menu, you can

configure the two outputs "Relay 1+Relay 2" and the installed relays. The relays are switched by
signal inputs "External stop", "Empty signal" and potential-free pulses. The connection diagram of the
"Low-level signal". relays is shown in section 4.3 Electrical connection.
Both relays can be allocated with the following
signals:
In/Output
Relay 1 Relay 2
TM04 1152 1110

Relay 1 > Description
Relay 2 > signal signal
External stop NO Display red, pump
Empty signal NO Alarm* Alarm stopped (e.g. empty
Low-level signal NO signal, etc.)
Fig. 37 Inputs/Outputs menu Display yellow, pump is

Warning* Warning running (e.g. low-level
signal, etc.)
Warning
When time or date is changed in Stroke Stroke
Each full stroke
"Time+date " menu, timer dosing and signal signal
timer relay output functions (Relay 2) Pump Pump
Pump running and dosing
are stopped! dosing dosing*
Timer dosing and timer relay output Pulse Pulse Each incoming pulse
functions must be restarted manually! input** input** from pulse input
Changing time or date can cause
increase or decrease in concentration! Bus Bus Activated by a command
control control in the bus communication
Timer
See following sections
Cycle
Timer
See following sections
Week
Contact type
NO* NO* Normally open contact

NC NC Normally closed contact
* Factory setting
** The correct transmission of incoming pulses can
only be guaranteed up to a pulse frequency of
5 Hz.
34
Timer Cycle (Relay 2) 6.16.3 Empty and Low level signals
For the "Relay 2 > Timer Cycle" function, set the In order to monitor the filling level in the
English (GB)
following parameters: tank, a dual-level sensor can be connected to the
• On (t1) pump. The pump responds to the signals as follows:
• Start delay (t2)
Sensor signal Pump status
• Cycle time (t3)
• Display is yellow
Low level • Flashes
• Pump continues running
• Display is red
Empty • Flashes
TM04 1124 2110

t1 t1
• Pump stops
t2
When the tank is filled up again, the
Caution
t3 pump restarts automatically!
Both signal inputs are allocated to the normally open
Fig. 38 Diagram contact (NO) in the factory. They can be re-allocated
in the "Setup > Inputs/Outputs" menu to normally
Timer Week (Relay 2)
closed contact (NC).
This function saves up to 16 relay on-times for a
week. The following settings can be made for each 6.17 Basic settings
relay switching operation in the "Relay 2 > Timer
Week" menu: All settings can be reset to the settings default upon
delivery in the "Setup > Basic settings" menu.
• Procedure (No.)
Selecting "Save customer settings" saves the current
• On time (duration) configuration to the memory. This can then be
• Start time activated using "Load customer settings".
• Weekdays. The memory always contains the previously saved
configuration. Older memory data is overwritten.
6.16.2 External stop
The pump can be stopped via an external
pulse, e.g. from a control room. When activating the
external stop pulse, the pump switches from the
operating state "Running" into the operating state
"Standby". The corresponding symbol appears in the
"Signal/error display" area of the display.
Frequent disengagement from the

mains voltage, e.g. via a relay, can
result in damage to the pump
electronics and in the breakdown of the
pump. The dosing accuracy is also
Caution
reduced as a result of internal start
procedures.
Do not control the pump via the mains
voltage for dosing purposes!
Only use the "External stop" function to
start and stop the pump!
The contact type is factory-set to normally open
contact (NO). In the "Setup > Inputs/Outputs >
External stop" menu, the setting can be changed to
normally closed contact (NC).
35
7. Service 7.3 Service system
English (GB)
In order to ensure a long service life and According to the motor runtime or after a defined
dosing accuracy, wearing parts such as period of operation, service requirements will
diaphragms and valves must be regularly checked appear. Service requirements appear regardless of
for signs of wear. Where necessary, replace worn the current operating state of the pump and do not
parts with original spare parts made from suitable affect the dosing process.
materials.
Should you have any questions, please contact your Motor
Time interval
service partner. Service requirement runtime
[months]*
[h]*
Warning
Service soon! 7500 23
Maintenance work must only be carried
out by qualified staff. Service now! 8000 24
* Since the last service system reset

7.1 Regular maintenance
Interval Task
Service soon!
TM04 1131 1110

Check, if liquid leaks from the drain
opening (fig. 41, pos. 11) and if the Please exchange
drain opening is blocked or soiled. diaphragm and valves!
If so, follow the instructions given in Service kit:
section 7.6 Diaphragm breakage. 97xxxxxx
Check, if liquid leaks from the dosing
Fig. 39 Service soon!
head or valves.
If necessary, tighten dosing head
Daily
screws with a torque wrench at 4 Nm.
If necessary, tighten valves and cap
nuts, or perform service (see Service now!
TM04 1131 1110

7.4 Perform service). Please exchange
Check, if a service requirement is diaphragm and valves!
present at the pump display. If so, Service kit:
follow the instructions given in 97xxxxxx
section 7.3 Service system.
Clean all pump surfaces with a dry Fig. 40 Service now!
Weekly
and clean cloth.
For media which result in increased
Check dosing head screws.
Caution wear, the service interval must be
If necessary, tighten dosing head
Every 3 shortened.
screws with a torque wrench at 4 Nm.
months
Replace damaged screws The service requirement signals when the
immediately. replacement of wearing parts is due and displays the
number of the service kit. Press the click wheel to
7.2 Cleaning temporarily hide the service prompt.
If necessary, clean all pump surfaces with a dry and When the "Service now!" message appears
clean cloth. (displayed daily), the pump must be serviced
immediately. The symbol appears in the
"Operation" menu.
The number of the service kit required is also
displayed in the "Info" menu.
36
7.4 Perform service 7.4.2 Dismantling the diaphragm and valves
English (GB)
Only spare parts and accessories from Grundfos Warning
should be used for maintenance. The usage of
non-original spare parts and accessories renders Danger of explosion, if dosing liquid
any liability for resulting damages null and void. has entered the pump housing!
Further information about carrying out maintenance If the diaphragm is possibly damaged,
can be found in the service kit catalogue on our don’t connect the pump to the power
homepage. See www.grundfos.com. supply! Proceed as described in
section 7.6 Diaphragm breakage!
Warning This section refers to fig. 41.
Risk of chemical burns! 1. Make system pressureless.
When dosing dangerous media, 2. Empty dosing head before maintenance and
observe the corresponding precautions flush it if necessary.
in the safety data sheets!
3. Set pump to "Stop" operating state using the
Wear protective clothing (gloves and [Start/stop] key.
goggles) when working on the dosing
4. Press the [Start/stop] and [100%] keys at the
head, connections or lines!
same time to put the diaphragm into "out"
Do not allow any chemicals to leak position.
from the pump. Collect and dispose of
– Symbol must be displayed (see fig. 14).
all chemicals correctly!
5. Take suitable steps to ensure that the returning
Before any work to the pump, the pump liquid is safely collected.
must be in the "Stop" operating state 6. Dismantle suction, pressure and deaeration
Caution or be disconnected from the power hose.
supply. The system must be 7. Dismantle valves on suction and discharge
pressureless! side (5, 6).
7.4.1 Dosing head overview 8. Remove the cover (9).
9. Loosen screws (8) on the dosing head (7) and
1 2 3 5 7 8 9 remove with discs.
10. Remove the dosing head (7).
11. Unscrew diaphragm (4) counter-clockwise and
remove with flange (2).
12. Make sure the drain opening (11) is not blocked
or soiled. Clean if necessary.
13. Check the safety diaphragm (1) for wear and
damage. Replace if necessary.
TM04 1123 2110
If nothing indicates that dosing liquid has entered the

pump housing, go on as described in section
7.4.3 Reassembling the diaphragm and valves.
Otherwise proceed as described in section
11 4 6 10 7.6.2 Dosing liquid in the pump housing.
Fig. 41 Changing the diaphragm and valves
1 Safety diaphragm
2 Flange
3 O-ring
4 Diaphragm
5 Valve on discharge side
6 Valve on suction side
7 Dosing head
8 Screws with discs
9 Cover
10 Deaeration valve
11 Drain opening
37
7.4.3 Reassembling the diaphragm and valves 7.6 Diaphragm breakage
The pump must only be reassembled, if nothing
English (GB)
If the diaphragm leaks or is broken, dosing liquid

indicates that dosing liquid has entered the pump escapes from the drain opening (fig. 41, pos. 11) on
housing. Otherwise proceed as described in section the dosing head.
7.6.2 Dosing liquid in the pump housing.
In case of diaphragm breakage, the safety
This section refers to fig. 41. diaphragm (fig. 41, pos. 1) protects the pump
1. Attach flange (2) correctly and screw on new housing against ingress of dosing liquid.
diaphragm (4) clockwise. When dosing crystallising liquids the drain opening
– Make sure that the O-ring (3) is seated can be blocked by crystallisation. If the pump is not
correctly! taken out of operation immediately, a pressure can
2. Press the [Start/stop] and [100%] keys at the build up between the diaphragm (fig. 41, pos. 4) and
same time to put the diaphragm into "in" position. the safety diaphragm in the flange (fig. 41, pos. 2).
The pressure can press dosing liquid through the
– Symbol must be displayed (see fig. 14).
safety diaphragm into the pump housing.
3. Attach the dosing head (7).
Most dosing liquids don’t cause any danger when
4. Install screws with discs (8) and cross-tighten entering the pump housing. However a view liquids
with a torque wrench. can cause a chemical reaction with inner parts of the
– Torque: 4 Nm. pump. In the worst case, this reaction can produce
5. Attach the cover (9). explosive gases in the pump housing.
6. Install new valves (5, 6). Warning
– Do not interchange valves and pay attention to Danger of explosion, if dosing liquid
direction of arrow. has entered the pump housing!
7. Connect suction, pressure and deaeration hose Operation with damaged diaphragm
(see section 4.2 Hydraulic connection) can lead to dosing liquid entering the
8. Press the [Start/stop] key to leave the service pump housing.
mode. In case of diaphragm breakage,
immediately separate the pump from
Tighten the dosing head screws with a
the power supply!
torque wrench once before
Caution Make sure the pump cannot be put
commissioning and again after
2-5 operating hours at 4 Nm. back into operation by accident!
Dismantle the dosing head without
9. Deaerate dosing pump (see section
connecting the pump to the power
5.2 Deaerating the pump).
supply and make sure no dosing liquid
10. Please observe the notes on commissioning in has entered the pump housing.
section 5. Startup! Proceed as described in section
7.6.1 Dismantling in case of diaphragm
7.5 Resetting the service system breakage.
After performing the service, the service system To avoid any danger resulting from diaphragm
must be reset using the "Info > Reset service breakage, observe the following:
system" function.
• Perform regular maintenance. See section
7.1 Regular maintenance.
• Never operate the pump with blocked or soiled
drain opening.
– If the drain opening is blocked or soiled,
proceed as described in section
7.6.1 Dismantling in case of diaphragm
breakage.
• Never attach a hose to the drain opening. If a
hose is attached to the drain opening, it is
impossible to recognise escaping dosing liquid.
• Take suitable precautions to prevent harm to
health and damage to property from escaping
dosing liquid.
• Never operate the pump with damaged or loose
dosing head screws.
38
7.6.1 Dismantling in case of diaphragm breakage 7.7 Repairs
English (GB)
Warning Warning
Danger of explosion, if dosing liquid The pump housing must only be
has entered the pump housing! opened by personnel authorised by
Do not connect the pump to the power Grundfos!
supply! Repairs must only be carried out by
This section refers to fig. 41. authorised and qualified personnel!
1. Make system pressureless. Switch off the pump and disconnect it
from the voltage supply before carrying
2. Empty dosing head before maintenance and
out maintenance work and repairs!
flush it if necessary.
3. Take suitable steps to ensure that the returning After consulting Grundfos, please send the pump,
liquid is safely collected. together with the safety declaration completed by a
4. Dismantle suction, pressure and deaeration specialist, to Grundfos. The safety declaration can
hose. be found at the end of these instructions. It must be
5. Remove the cover (9). copied, completed and attached to the pump.
6. Loosen screws (8) on the dosing head (7) and The pump must be cleaned prior to
remove with discs. dispatch!
7. Remove the dosing head (7). If dosing liquid has possibly entered
Caution
8. Unscrew diaphragm (4) counter-clockwise and the pump housing, state that explicitly
remove with flange (2). in the safety declaration! Observe
9. Make sure the drain opening (11) is not blocked section 7.6 Diaphragm breakage.
or soiled. Clean if necessary. If the above requirements are not met, Grundfos may
10. Check the safety diaphragm (1) for wear and refuse to accept delivery of the pump. The shipping
damage. Replace if necessary. costs will be charged to the sender.
If nothing indicates that dosing liquid has entered the
pump housing, go on as described in section
7.4.3 Reassembling the diaphragm and valves.
Otherwise proceed as described in section
7.6.2 Dosing liquid in the pump housing.
7.6.2 Dosing liquid in the pump housing
Warning
Danger of explosion!
Immediately separate the pump from
the power supply!
Make sure the pump cannot be put
back into operation by accident!
If dosing liquid has entered the pump housing:
• Send the pump to Grundfos for repair, following
the instructions given in section 7.7 Repairs.
• If a repair isn’t economically reasonable, dispose
of the pump observing the information in section
9. Disposal.
39
8. Faults
English (GB)
In the event of faults in the dosing pump, a

warning or an alarm is triggered.
The corresponding fault symbol flashes in
the "Operation" menu, see section 8.1 List of faults.
The cursor jumps to the "Alarm" main menu symbol.
Press the click wheel to open the "Alarm" menu and,
where necessary, faults to be acknowledged will be
acknowledged.
A yellow display indicates a warning and the pump
continues running.
A red display indicates an alarm and the pump is
stopped.
The last 10 faults are stored in the "Alarm" main
menu. When a new fault occurs, the oldest fault is
deleted.
The two most recent faults are shown in the display,
you can scroll through all the other faults. The time
and cause of the fault are displayed.
Alarm
1 12.02.2010 12:34
Empty
2 12.02.2010 12:34
Low level
TM04 1109 1010
Delete alarm
messages ❑
The list of faults can be deleted at the end of the list.

If there is a service requirement, this appears when
the "Alarm" menu is opened. Press the click wheel to
temporarily close the service prompt (see section
7.3 Service system).
40
8.1 List of faults
English (GB)
8.1.1 Faults with error message
Display in the
Possible cause Possible remedy
"Alarm" menu
Empty • Dosing medium tank empty • Fill tank.

(Alarm) • Check contact setting (NO/NC).
Low level • Dosing medium tank almost empty
(Warning)
• Discharge valve blocked • Replace valve if necessary (see section
• Isolating valve in discharge line 7.4 Perform service).
closed • Check flow direction of valves (arrow) and
• Pressure peaks due to high correct if necessary.
Overpressure
viscosity • Open the isolating valve (on the discharge
(Alarm)
• Max. pressure set too low (see side).
section 6.8 Pressure monitoring) • Enlarge diameter of discharge line.
• Change pressure setting (see section
6.8 Pressure monitoring).
• Faulty diaphragm • Change the diaphragm (see section
• Broken discharge line 7.4 Perform service).
Low • Pressure differential between • Check discharge line and repair if
backpressure suction and discharge side too low necessary.
(Warning/alarm*) • Leakage in the pressure loading • Install additional spring-loaded valve
valve at Q < 1 l/h (approx. 3 bar) on the discharge side.
• Deaeration valve open • Close the deaeration valve.
• Broken/leaky suction line • Check suction line and repair if necessary.
• Strongly degassing medium • Provide positive inlet pressure (place
Air bubble • Tank dosing medium empty dosing medium tank above the pump).
(Warning) • Enable "SlowMode" (see section
6.6 SlowMode).
• Fill tank.
• Blocked/constricted/squeezed • Enable "SlowMode" (see section
suction line 6.6 SlowMode).
Cavitation • Blocked/constricted suction valve • Reduce suction lift.
(Warning) • Suction lift too high • Increase suction hose diameter.
• Viscosity too high • Check suction line and open isolating
valve if necessary.
• Leaky/dirty suction valve • Check valve and tighten it up.
• Deaeration valve open • Flush system.
• Replace valve if necessary (see section
Suct. valve leak
7.4 Perform service).
(Warning)
• Check O-ring position.
• Install filter in suction line.
• Close the deaeration valve.
• Leaky/dirty discharge valve • Check valve and tighten it up.
• Leakage in the pressure loading • Flush system.
valve • Replace valve if necessary (see section
• Deaeration valve open 7.4 Perform service).
Disch. valve leak
• Check O-ring position.
(Warning)
• Install screen in suction line.
• Close the deaeration valve.
• Install spring-loaded valve on the
discharge side.
• Considerable deviation between • Check installation.
Flow deviation
target and actual flow • Calibrate the pump (see section
(Warning)
• Pump not or incorrectly calibrated 5.3 Calibrating the pump).
41
Display in the
Possible cause Possible remedy
English (GB)
"Alarm" menu
• Broken "FlowControl" cable (see • Check plug connection.

fig. 11) • Change sensor if necessary.
Pressure sensor
• Sensor defect • Calibrate pressure sensor correctly (see
(Warning)
• Pressure sensor not correctly section 6.8.2 Calibration of pressure
calibrated. sensor).
• Backpressure greater than • Reduce backpressure.
Motor blocked
nominal pressure • Arrange for repair of gears, if necessary.
(Alarm)
• Damage to gears
• Fieldbus communication error • Check cables for correct specification and
Bus error damage; replace if necessary.
(Alarm) • Check cable routing and shielding; correct
if necessary.
E-Box • E-Box connection error • Check plug connection.
(Alarm) • Faulty E-Box • Replace E-Box if necessary.
• Defect in analog cable 4-20 mA • Check cable/plug connections and
Cable break
(input current < 2 mA) replace, if necessary.
(Alarm)
• Check signal transmitter.
Service now • Time interval for service expired • Perform service (see section 7.4 Perform
(Warning) service).
* Depending on setting
8.1.2 General faults
Fault Possible cause Possible remedy
Install additional spring-loaded valve (approx.

Inlet pressure greater than 3 bar) on the discharge side.
backpressure
Dosing flow too high Increase pressure differential.
Calibrate the pump (see section 5.3 Calibrating
Incorrect calibration
the pump).
Air in dosing head Deaerate the pump.
Change the diaphragm (see section 7.4 Perform
Faulty diaphragm
service).
Leakage/fracture in lines Check and repair lines.
Valves leaking or blocked Check and clean valves.
Check that the arrow on the valve housing is
Valves installed incorrectly pointing in the direction of flow. Check whether all
O-rings are installed correctly.
Blocked suction line Clean suction line/install filter.
No dosing flow or
dosing flow too low Reduce suction lift.
Suction lift too high Install priming aid.
Enable "SlowMode" (see section 6.6 SlowMode ).
Enable "SlowMode" (see section 6.6 SlowMode ).
Viscosity too high Use hose with larger diameter.
Install spring-loaded valve on the discharge side.
Calibrate the pump (see section 5.3 Calibrating
Faulty calibration
the pump).
Deaeration valve open Close the deaeration valve.
42
Fault Possible cause Possible remedy
English (GB)
Tighten up valves, replace valves if necessary
Valves leaking or blocked
(see section 7.4 Perform service).
Irregular dosing
Keep backpressure constant.
Backpressure fluctuations
Activate "AutoFlowAdapt" (only DDA-FCM).
Immediately separate the pump from the power
Liquid escaping from
supply!
the drain opening on Faulty diaphragm
Observe section 7. Service and especially section
the flange
7.6 Diaphragm breakage.
Dosing head screws not Tighten up screws (see section 4.2 Hydraulic
tightened connection).
Liquid escaping
Tighten up valves/union nuts (see section
Valves not tightened
4.2 Hydraulic connection).
Reduce suction lift; if necessary, provide positive
Suction lift too high
inlet pressure.
Pump not sucking in Backpressure too high Open the deaeration valve.
Flush system, replace valves if necessary (see
Soiled valves
section 7.4 Perform service).
9. Disposal
This product or parts of it must be disposed
of in an environmentally sound way.
Use appropriate waste collection services.
If this is not possible, contact the nearest Grundfos
company or service workshop.
Subject to alterations.
43
Appendix 1
Appendix
Safety declaration
Please copy, fill in and sign this sheet and attach it to the pump returned for service.
Note Fill in this document using English or German language.
Product type (nameplate)
Model number (nameplate)
Dosing medium
Fault description
Please make a circle around the damaged parts.
In the case of an electrical or functional fault, please mark the cabinet.
100%
TM04 1185 1110

Please describe the error/cause of the error in brief.
Dosing liquid has possibly entered the pump housing.

The pump must not be connected to the power supply! Danger of explosion!
We hereby declare that the pump has been cleaned and is completely free from chemical, biological and
radioactive substances.
_____________________________________
Date and signature
_____________________________________
Company stamp
44
Declaration of conformity 2
GB: EC declaration of conformity BG: EC декларация за съответствие
We, Grundfos, declare under our sole responsibility that the products Ние, фирма Grundfos, заявяваме с пълна отговорност, че
DDA, DDC and DDE, to which this declaration relates, are in продуктите DDA, DDC и DDE, за които се отнася настоящата
conformity with these Council directives on the approximation of the декларация, отговарят на следните указания на Съвета за
laws of the EC member states: уеднаквяване на правните разпоредби на държавите членки на
ЕС:
CZ: ES prohlášení o shodě DK: EF-overensstemmelseserklæring

My firma Grundfos prohlašujeme na svou plnou odpovědnost, Vi, Grundfos, erklærer under ansvar at produkterne DDA, DDC og DDE
že výrobky DDA, DDC a DDE, na něž se toto prohlášení vztahuje, jsou som denne erklæring omhandler, er i overensstemmelse med disse af
v souladu s ustanoveními směrnice Rady pro sblížení právních Rådets direktiver om indbyrdes tilnærmelse til EF-medlemsstaternes
předpisů členských států Evropského společenství v oblastech: lovgivning:
DE: EG-Konformitätserklärung EE: EL vastavusdeklaratsioon

Wir, Grundfos, erklären in alleiniger Verantwortung, dass die Produkte Meie, Grundfos, deklareerime enda ainuvastutusel, et tooted DDA,
DDA, DDC und DDE, auf die sich diese Erklärung bezieht, mit den DDC ja DDE, mille kohta käesolev juhend käib, on vastavuses EÜ
folgenden Richtlinien des Rates zur Angleichung der Nõukogu direktiividega EMÜ liikmesriikide seaduste ühitamise kohta,
Rechtsvorschriften der EU-Mitgliedsstaaten übereinstimmen: mis käsitlevad:
GR: ∆ήλωση συμμόρφωσης EC ES: Declaración CE de conformidad

Εμείς, η Grundfos, δηλώνουμε με αποκλειστικά δική μας ευθύνη ότι Nosotros, Grundfos, declaramos bajo nuestra entera responsabilidad
τα προϊόντα DDA, DDC και DDE στα οποία αναφέρεται η παρούσα que los productos DDA, DDC y DDE, a los cuales se refiere esta
δήλωση, συμμορφώνονται με τις εξής Οδηγίες του Συμβουλίου περί declaración, están conformes con las Directivas del Consejo en la
προσέγγισης των νομοθεσιών των κρατών μελών της ΕΕ: aproximación de las leyes de las Estados Miembros del EM:
FR: Déclaration de conformité CE HR: EZ izjava o usklađenosti

Nous, Grundfos, déclarons sous notre seule responsabilité, que les Mi, Grundfos, izjavljujemo pod vlastitom odgovornošću da je proizvod
produits DDA, DDC et DDE, auxquels se réfère cette déclaration, sont DDA, DDC i DDE, na koji se ova izjava odnosi, u skladu s direktivama
conformes aux Directives du Conseil concernant le rapprochement ovog Vijeća o usklađivanju zakona država članica EU:
des législations des Etats membres CE relatives aux normes
énoncées ci-dessous:
IT: Dichiarazione di conformità CE LV: EK atbilstības deklarācija

Grundfos dichiara sotto la sua esclusiva responsabilità che i prodotti Sabiedrība GRUNDFOS ar pilnu atbildību dara zināmu, ka produkti
DDA, DDC e DDE, ai quali si riferisce questa dichiarazione, sono DDA, DDC un DDE, uz kuriem attiecas šis paziņojums, atbilst šādām
conformi alle seguenti direttive del Consiglio riguardanti il Padomes direktīvām par tuvināšanos EK dalībvalstu likumdošanas
riavvicinamento delle legislazioni degli Stati membri CE: normām:
LT: EB atitikties deklaracija HU: EK megfelelőségi nyilatkozat

Mes, Grundfos, su visa atsakomybe pareiškiame, kad gaminiai DDA, Mi, a Grundfos, egyedüli felelősséggel kijelentjük, hogy a DDA, DDC
DDC ir DDE, kuriems skirta ši deklaracija, atitinka šias Tarybos és DDC termékek, amelyekre jelen nyilatkozik vonatkozik, megfelelnek
Direktyvas dėl Europos Ekonominės Bendrijos šalių narių įstatymų az Európai Unió tagállamainak jogi irányelveit összehangoló tanács
suderinimo: alábbi előírásainak:
NL: EC overeenkomstigheidsverklaring NO: EU samsvarserklæring

Wij, Grundfos, verklaren geheel onder eigen verantwoordelijkheid dat Vi, Grundfos, erklærer på eget ansvar at produktene DDA, DDC og
de producten DDA, DDC en DDE waarop deze verklaring betrekking DDE, som denne erklæringen gjelder, er i samsvar med disse
heeft, in overeenstemming zijn met de Richtlijnen van de Raad in zake rådsdirektivene slik de omtrentlig samsvarer med lovene for
de onderlinge aanpassing van de wetgeving van de EG Lidstaten EU-medlemlandene:
betreffende:
UA: Декларація відповідності ЄС PL: Deklaracja zgodności WE

Компанія Grundfos заявляє про свою виключну відповідальність за My, Grundfos, oświadczamy z pełną odpowiedzialnością, że nasze
те, що продукти DDA, DDC та DDE, на які поширюється дана wyroby DDA, DDC oraz DDE, których deklaracja niniejsza dotyczy,
декларація, відповідають таким рекомендаціям Ради з уніфікації są zgodne z następującymi wytycznymi Rady d/s ujednolicenia
правових норм країн - членів ЄС: przepisów prawnych krajów członkowskich WE:
PT: Declaração de conformidade CE RU: Декларация о соответствии ЕС

A Grundfos declara sob sua única responsabilidade que os produtos Мы, компания Grundfos, со всей ответственностью заявляем, что
DDA, DDC e DDE, aos quais diz respeito esta declaração, estão em изделия DDA, DDC и DDE, к которым относится настоящая
conformidade com as seguintes Directivas do Conselho sobre декларация, соответствуют следующим Директивам Совета
a aproximação das legislações dos Estados Membros da CE: Евросоюза об унификации законодательных предписаний
стран-членов ЕС:
RO: Declaraţie de conformitate CE SK: Prehlásenie o konformite ES

Noi, Grundfos, declarăm pe propria răspundere că produsele DDA, My firma Grundfos prehlasujeme na svoju plnú zodpovednost’,
DDC şi DDE, la care se referă această declaraţie, sunt în conformitate že výrobky DDA, DDC a DDE, na ktoré sa toto prehlásenie vzt’ahuje,
cu aceste Directive de Consiliu asupra armonizării legilor Statelor sú v súlade s ustanovením smernice Rady pre zblíženie právnych
Membre CE: predpisov členských štátov Európskeho spoločenstva v oblastiach:
SI: ES izjava o skladnosti RS: EC deklaracija o usaglašenosti

V Grundfosu s polno odgovornostjo izjavljamo, da so naši izdelki DDA, Mi, Grundfos, izjavljujemo pod vlastitom odgovornošću da je proizvod
DDC in DDE, na katere se ta izjava nanaša, v skladu z naslednjimi DDA, DDC i DDE, na koji se ova izjava odnosi, u skladu sa direktivama
direktivami Sveta o približevanju zakonodaje za izenačevanje pravnih Saveta za usklađivanje zakona država članica EU:
predpisov držav članic ES:
45
FI: EY-vaatimustenmukaisuusvakuutus SE: EG-försäkran om överensstämmelse

Me, Grundfos, vakuutamme omalla vastuullamme, että tuotteet DDA, Vi, Grundfos, försäkrar under ansvar att produkterna DDA, DDC och
DDC ja DDE, joita tämä vakuutus koskee, ovat EY:n jäsenvaltioiden DDE, som omfattas av denna försäkran, är i överensstämmelse med
lainsäädännön yhdenmukaistamiseen tähtäävien Euroopan neuvoston rådets direktiv om inbördes närmande till EU-medlemsstaternas
direktiivien vaatimusten mukaisia seuraavasti: lagstiftning, avseende:
TR: EC uygunluk bildirgesi CN: EC 产品合格声明书

Grundfos olarak bu beyannameye konu olan DDA, DDC ve DDE 我们格兰富在我们的全权责任下声明，产品 DDA, DDC 和 DDE，即该
ürünlerinin, AB Üyesi Ülkelerin kanunlarını birbirine yaklaştırma 合格证所指之产品，符合欧共体使其成员国法律趋于一致的以下欧共理
üzerine Konsey Direktifleriyle uyumlu olduğunun yalnızca bizim 事会指令：
sorumluluğumuz altında olduğunu beyan ederiz:
JP: EC 適合宣言 KO: EC 적합성 선언

Grundfos は、その責任の下に、 DDA, DDC 製品および DDE 製品が EC Grundfos 에서는 자사의 단독 책임에 따라 이 선언과 관련된 DDA,
加盟諸国の法規に関連する、以下の評議会指令に適合していることを DDC 및 DDE 제품이 EC 회원국 법률에 기반한 다음 이사회 지침을 준
宣言します： 수함을 선언합니다 :
– Machinery Directive (2006/42/EC).

Standards used: EN 809: 1998, DIN EN ISO 12100:2010.
– Low Voltage Directive (2006/95/EC).
Standard used: EN 61010-1: 2001 (second edition).
– EMC Directive (2004/108/EC).
Standards used: EN 61326-1: 2006,
EN 61000-3-2: 2006+A1: 2009+A2: 2009, EN 61000-3-3: 2008.
This EC declaration of conformity is only valid when published as part

of the Grundfos installation and operating instructions.
Pfinztal, 1 December 2014
Ulrich Stemick
Technical Director
Grundfos Water Treatment GmbH
Reetzstr. 85, D-76327 Pfinztal, Germany
Person authorised to compile technical file and

empowered to sign the EC declaration of conformity.
46
47
48
49
Argentina China Germany
Grundfos companies
Bombas GRUNDFOS de Argentina S.A. Grundfos Alldos GRUNDFOS GMBH

Ruta Panamericana km. 37.500 Centro Dosing & Disinfection Schlüterstr. 33
Industrial Garin ALLDOS (Shanghai) Water Technology 40699 Erkrath
1619 - Garin Pcia. de B.A. Co. Ltd. Tel.: +49-(0) 211 929 69-0
Phone: +54-3327 414 444 West Unit, 1 Floor, No. 2 Building (T 4-2) Telefax: +49-(0) 211 929 69-3799
Telefax: +54-3327 411 111 278 Jinhu Road, Jin Qiao Export Pro- E-mail: infoservice@grundfos.de
cessing Zone Service in Deutschland:
Australia Pudong New Area E-mail: kundendienst@grundfos.de
GRUNDFOS Pumps Pty. Ltd. Shanghai, 201206
P.O. Box 2040 Phone: +86 21 5055 1012
Greece
Regency Park Telefax: +86 21 5032 0596 GRUNDFOS Hellas A.E.B.E.
South Australia 5942 E-mail: grundfosalldos-CN@grund- 20th km. Athinon-Markopoulou Av.
Phone: +61-8-8461-4611 fos.com P.O. Box 71
Telefax: +61-8-8340 0155 GR-19002 Peania
China Phone: +0030-210-66 83 400
Austria GRUNDFOS Pumps (Shanghai) Co. Ltd. Telefax: +0030-210-66 46 273
GRUNDFOS Pumpen Vertrieb 50/F Maxdo Centre No. 8 Xing Yi Rd.
Ges.m.b.H. Hongqiao Development Zone
Hong Kong
Grundfosstraße 2 Shanghai 200336 GRUNDFOS Pumps (Hong Kong) Ltd.
A-5082 Grödig/Salzburg PRC Unit 1, Ground floor
Tel.: +43-6246-883-0 Phone: +86-21 6122 5222 Siu Wai Industrial Centre
Telefax: +43-6246-883-30 Telefax: +86-21 6122 5333 29-33 Wing Hong Street &
68 King Lam Street, Cheung Sha Wan
Belgium Croatia Kowloon
N.V. GRUNDFOS Bellux S.A. GRUNDFOS CROATIA d.o.o. Phone: +852-27861706 / 27861741
Boomsesteenweg 81-83 Cebini 37, Buzin Telefax: +852-27858664
B-2630 Aartselaar HR-10010 Zagreb
Tél.: +32-3-870 7300 Phone: +385 1 6595 400
Hungary
Télécopie: +32-3-870 7301 Telefax: +385 1 6595 499 GRUNDFOS Hungária Kft.
Park u. 8
Belarus www.hr.grundfos.com
H-2045 Törökbálint,
Представительство ГРУНДФОС в Czech Republic Phone: +36-23 511 110
Минске GRUNDFOS s.r.o. Telefax: +36-23 511 111
220125, Минск Čapkovského 21
ул. Шафарнянская, 11, оф. 56 779 00 Olomouc
India
Тел.: +7 (375 17) 286 39 72, 286 39 73 Phone: +420-585-716 111 GRUNDFOS Pumps India Private
Факс: +7 (375 17) 286 39 71 Telefax: +420-585-716 299 Limited
E-mail: minsk@grundfos.com 118 Old Mahabalipuram Road
Denmark Thoraipakkam
Bosnia/Herzegovina GRUNDFOS DK A/S Chennai 600 097
GRUNDFOS Sarajevo Martin Bachs Vej 3 Phone: +91-44 4596 6800
Trg Heroja 16, DK-8850 Bjerringbro
BiH-71000 Sarajevo Tlf.: +45-87 50 50 50
Indonesia
Phone: +387 33 713 290 Telefax: +45-87 50 51 51 PT GRUNDFOS Pompa
Telefax: +387 33 659 079 E-mail: info_GDK@grundfos.com Jl. Rawa Sumur III, Blok III / CC-1
e-mail: grundfos@bih.net.ba www.grundfos.com/DK Kawasan Industri, Pulogadung
Jakarta 13930
Brazil Estonia Phone: +62-21-460 6909
BOMBAS GRUNDFOS DO BRASIL GRUNDFOS Pumps Eesti OÜ Telefax: +62-21-460 6910 / 460 6901
Av. Humberto de Alencar Castelo Peterburi tee 92G
Branco, 630 11415 Tallinn
Ireland
CEP 09850 - 300 Tel: + 372 606 1690 GRUNDFOS (Ireland) Ltd.
São Bernardo do Campo - SP Fax: + 372 606 1691 Unit A, Merrywell Business Park
Phone: +55-11 4393 5533 Ballymount Road Lower
Telefax: +55-11 4343 5015 Finland Dublin 12
OY GRUNDFOS Pumput AB Phone: +353-1-4089 800
Bulgaria Mestarintie 11 Telefax: +353-1-4089 830
Grundfos Bulgaria EOOD FIN-01730 Vantaa
Slatina District Phone: +358-(0)207 889 900
Italy
Iztochna Tangenta street no. 100 Telefax: +358-(0)207 889 550 GRUNDFOS Pompe Italia S.r.l.
BG - 1592 Sofia Via Gran Sasso 4
Tel. +359 2 49 22 200 France I-20060 Truccazzano (Milano)
Fax. +359 2 49 22 201 Pompes GRUNDFOS Distribution S.A. Tel.: +39-02-95838112
email: bulgaria@grundfos.bg Parc d’Activités de Chesnes Telefax: +39-02-95309290 / 95838461
57, rue de Malacombe
Canada F-38290 St. Quentin Fallavier (Lyon)
Japan
GRUNDFOS Canada Inc. Tél.: +33-4 74 82 15 15 GRUNDFOS Pumps K.K.
2941 Brighton Road Télécopie: +33-4 74 94 10 51 Gotanda Metalion Bldg. 5F,
Oakville, Ontario 5-21-15, Higashi-gotanda
L6H 6C9 Germany Shiagawa-ku, Tokyo,
Phone: +1-905 829 9533 GRUNDFOS Water Treatment GmbH 141-0022 Japan
Telefax: +1-905 829 9512 Reetzstraße 85 Phone: +81 35 448 1391
D-76327 Pfinztal (Söllingen) Telefax: +81 35 448 9619
Tel.: +49 7240 61-0
Telefax: +49 7240 61-177
E-mail: gwt@grundfos.com
Korea Romania Switzerland
Grundfos companies
GRUNDFOS Pumps Korea Ltd. GRUNDFOS Pompe România SRL GRUNDFOS Pumpen AG
6th Floor, Aju Building 679-5 Bd. Biruintei, nr 103 Bruggacherstrasse 10
Yeoksam-dong, Kangnam-ku, 135-916 Pantelimon county Ilfov CH-8117 Fällanden/ZH
Seoul, Korea Phone: +40 21 200 4100 Tel.: +41-44-806 8111
Phone: +82-2-5317 600 Telefax: +40 21 200 4101 Telefax: +41-44-806 8115
Telefax: +82-2-5633 725 E-mail: romania@grundfos.ro
Taiwan
Latvia Russia GRUNDFOS Pumps (Taiwan) Ltd.
SIA GRUNDFOS Pumps Latvia ООО Грундфос 7 Floor, 219 Min-Chuan Road
Deglava biznesa centrs Россия, 109544 Москва, ул. Школьная Taichung, Taiwan, R.O.C.
Augusta Deglava ielā 60, LV-1035, Rīga, 39 Phone: +886-4-2305 0868
Tālr.: + 371 714 9640, 7 149 641 Тел. (+7) 495 737 30 00, 564 88 00 Telefax: +886-4-2305 0878
Fakss: + 371 914 9646 Факс (+7) 495 737 75 36, 564 88 11
E-mail grundfos.moscow@grundfos.com
Thailand
Lithuania GRUNDFOS (Thailand) Ltd.
GRUNDFOS Pumps UAB Serbia 92 Chaloem Phrakiat Rama 9 Road,
Smolensko g. 6 GRUNDFOS Predstavništvo Beograd Dokmai, Pravej, Bangkok 10250
LT-03201 Vilnius Dr. Milutina Ivkovića 2a/29 Phone: +66-2-725 8999
Tel: + 370 52 395 430 YU-11000 Beograd Telefax: +66-2-725 8998
Fax: + 370 52 395 431 Phone: +381 11 26 47 877 / 11 26 47
496
Turkey
Malaysia Telefax: +381 11 26 48 340 GRUNDFOS POMPA San. ve Tic. Ltd.
GRUNDFOS Pumps Sdn. Bhd. Sti.
7 Jalan Peguam U1/25 Singapore Gebze Organize Sanayi Bölgesi
Glenmarie Industrial Park GRUNDFOS (Singapore) Pte. Ltd. Ihsan dede Caddesi,
40150 Shah Alam 25 Jalan Tukang 2. yol 200. Sokak No. 204
Selangor Singapore 619264 41490 Gebze/ Kocaeli
Phone: +60-3-5569 2922 Phone: +65-6681 9688 Phone: +90 - 262-679 7979
Telefax: +60-3-5569 2866 Telefax: +65-6681 9689 Telefax: +90 - 262-679 7905
E-mail: satis@grundfos.com
Mexico Slovakia
Bombas GRUNDFOS de México S.A. de GRUNDFOS s.r.o. Ukraine
C.V. Prievozská 4D Бізнес Центр Європа
Boulevard TLC No. 15 821 09 BRATISLAVA Столичне шосе, 103
Parque Industrial Stiva Aeropuerto Phona: +421 2 5020 1426 м. Київ, 03131, Україна
Apodaca, N.L. 66600 sk.grundfos.com Телефон: (+38 044) 237 04 00
Phone: +52-81-8144 4000 Факс.: (+38 044) 237 04 01
Telefax: +52-81-8144 4010
Slovenia E-mail: ukraine@grundfos.com
GRUNDFOS d.o.o.
Netherlands Šlandrova 8b, SI-1231 Ljubljana-Črnuče United Arab Emirates
GRUNDFOS Netherlands Phone: +386 1 568 0610 GRUNDFOS Gulf Distribution
Veluwezoom 35 Telefax: +386 1 568 0619 P.O. Box 16768
1326 AE Almere E-mail: slovenia@grundfos.si Jebel Ali Free Zone
Postbus 22015 Dubai
1302 CA ALMERE
South Africa Phone: +971-4- 8815 166
Tel.: +31-88-478 6336 Grundfos (PTY) Ltd. Telefax: +971-4-8815 136
Telefax: +31-88-478 6332 Corner Mountjoy and George Allen
E-mail: info_gnl@grundfos.com Roads United Kingdom
Wilbart Ext. 2 GRUNDFOS Pumps Ltd.
New Zealand Bedfordview 2008 Grovebury Road
GRUNDFOS Pumps NZ Ltd. Phone: (+27) 11 579 4800 Leighton Buzzard/Beds. LU7 4TL
17 Beatrice Tinsley Crescent Fax: (+27) 11 455 6066 Phone: +44-1525-850000
North Harbour Industrial Estate E-mail: lsmart@grundfos.com Telefax: +44-1525-850011
Albany, Auckland
Phone: +64-9-415 3240
Spain U.S.A.
Telefax: +64-9-415 3250 Bombas GRUNDFOS España S.A. GRUNDFOS Pumps Corporation
Camino de la Fuentecilla, s/n 17100 West 118th Terrace
Norway E-28110 Algete (Madrid) Olathe, Kansas 66061
GRUNDFOS Pumper A/S Tel.: +34-91-848 8800 Phone: +1-913-227-3400
Strømsveien 344 Telefax: +34-91-628 0465 Telefax: +1-913-227-3500
Postboks 235, Leirdal
N-1011 Oslo
Sweden Uzbekistan
Tlf.: +47-22 90 47 00 GRUNDFOS AB Grundfos Tashkent, Uzbekistan The Rep-
Telefax: +47-22 32 21 50 (Box 333) Lunnagårdsgatan 6 resentative Office of Grundfos Kazakhstan
431 24 Mölndal in Uzbekistan
Poland Tel.: +46 31 332 23 000 38a, Oybek street, Tashkent
GRUNDFOS Pompy Sp. z o.o. Telefax: +46 31-331 94 60 Телефон: (+998) 71 150 3290 / 71 150
ul. Klonowa 23 3291
Baranowo k. Poznania
Switzerland Факс: (+998) 71 150 3292
PL-62-081 Przeźmierowo GRUNDFOS ALLDOS International AG
Tel: (+48-61) 650 13 00 Schönmattstraße 4 Addresses revised 21.05.2014
Fax: (+48-61) 650 13 50 CH-4153 Reinach
Tel.: +41-61-717 5555
Portugal Telefax: +41-61-717 5500
Bombas GRUNDFOS Portugal, S.A. E-mail: grundfosalldos-CH@grund-
Rua Calvet de Magalhães, 241 fos.com
Apartado 1079
P-2770-153 Paço de Arcos
Tel.: +351-21-440 76 00
Telefax: +351-21-440 76 90
ECM: 1146320
95724708 1114
www.grundfos.com
The name Grundfos, the Grundfos logo, and be think innovate are registered trademarks
owned by Grundfos Holding A/S or Grundfos A/S, Denmark. All rights reserved worldwide. © Copyright Grundfos Holding A/S
Type: AP 1000
OHW: W10286-014
Manual
Polydox AP 1000
Type: AP 1000
OHW: W10286-014

2.1. Technical specifications. 2.1
2.2. Accessories, hoisting points. 2.2
2.3. Tools and accessories needed. 2.2
2.4. Flow diagram. 2.2
3. Safety aspects.
3.1. Safety measures. 3.1 – 3.3
3.2. Conditions of use. 3.3
3.3. Personal protective equipment. 3.3
4. Installation.
4.2. Assembly instructions. 4.2
4.3. Connection instructions. 4.2
5. OPERATING INSTRUCTIONS.
5.1. Process description. 5.1 – 5.5
5.2. Item description. 5.5
5.3. Start up. 5.6 – 5.8
5.4. Polydox operating screen. 5.9
6.1. Requirements for maintenance personnel. 6.1
6.2. Safety measures and risks during maintenance. 6.1
6.3. Maintenance. 6.2
7. FAULTS / REPAIRS.
7.1. Trouble-shooting table. 7.1
8.1. Re-use. 8.1
Type: AP 1000
OHW: W10286-014
1. INTRODUCTION
- The scope of this manual is to provide a reference document for operating the Poly
electrolyte make-up unit Polydox AP 1000.
out of order.
 Safety aspects.
free operation.
Figure 1.1 (Polydox AP 1000).
1.1
Type: AP 1000
OHW: W10286-014
2. TECHNICAL SPECIFICATIONS
2.1. TECHNICAL SPECIFICATIONS.
Supplier: Redox
Type: Polydox AP 1000
Serial Number: W10286-014
Capacity: 1000 L/hour

Maximum water supply: 2500 L/hour *
Noise level: less than 70dB(A).
Heat generation: none
Radiation: none
Vibrations: none
Ambient temperature : 5°C to 35°C
Electrical requirements:
Main power: 400 Volt
Phase: 3+N
Frequency: 50 Hz.
Zero: Yes
Drive voltage: 24V DC
Dimensions:
Length x width x height: Approx. 1400 x 1160 x 2040 mm
Weight:
Tare weight: 470 kg
Gross weight: 1.500 kg
Connections:
Water connection: G ¾”
Polymer connection: NB32 – Ø40
Material:
Polydox AISI 304 (WN 1.4301)
Polypump:
please refer to the polypump manual
* Exceeding the limit could result in failure of the water meter!
2.1
Type: AP 1000
OHW: W10286-014
2.2. ACCESSORIES, HOISTING POINTS
N/A
2.3. TOOLS AND ACCESSORIES NEEDED
No special tools required for maintenance/control or start-up.
2.4. FLOW DIAGRAM
Feed water
Powdered polymer
Polymer make-up unit

Polymer
pump
Figure 2.1
2.2
Type: AP 1000
OHW: W10286-014
3. HEALTH & SAFETY

3.1. SAFETY MEASURES
Ensure that warnings are always clearly visible and clean or replace warnings when
necessary!
 This machine is designed to be stable, with displays and controls positioned within easy
reach. Risks that could occur during normal operation can be solved constructively as far
as possible.
Warning rotating parts.

Figure 3.1
Warning slippery surface.

Figure 3.2
Warning automatic starting installation

Figure 3.3
The warnings above must be clearly visible on the installation.
The polymer is not poisonous and degrades naturally. Please refer to the safety datasheets
provided by your polymer supplier.
If your polymer make-up unit is not operated properly, the following emergency
situations could occur:
the installation could overflow, creating a slipping hazard.
1. Slipping hazard
Improper equipment operation could result in lumps forming in the solution, leading to drain
and overflow pipe blockages.
Inexpert operation of the drain valves could also result pipe blockage.
Spilled polymer CANNOT BE CLEANED WITH WATER, but must be covered with
salt/sawdust and removed.
3.1
Type: AP 1000
OHW: W10286-014
2. Jamming risk
When opening the hopper for polymer powder, there is a jamming risk through contact with
the dosing screw.
After removing the protective cover for the screw in the dosing mouth, jamming could occur
when coming into contact with the screw.
When opening the inspection hatch, jamming could occur when coming into contact with the
agitators.
3. Burn hazard
When coming in contact with the dosing opening, there is a risk of burning parts of the body.
A pump dry run will lead to overheating of some parts
Letting a connected pump run dry could lead to risk of burning parts of the body when
coming into contact with the pump.
4. Danger of electrical shocks

The emergency stop button is located on the switch box.
There is a risk of electrical shock when opening the switch box while the power is still on.
 In situations that could be hazardous for the people or the equipment, the system can be
shut down by pressing the emergency stop button (picture 3.4). This emergency stop
button must be fitted and connected to the switch box.
Figure 3.4
 Restarting the installation after using the emergency stop button

If the installation has been stopped using the emergency stop button, it is NOT possible
to immediately restart it.
The machine must be inspected first to ensure there is nothing wrong with it.
If the installation is stopped manually or for maintenance purposes, safety against
operation is therefore guaranteed.
Unexpected operation could lead to serious injury !
 Locate the cause of the fault.

 Look if somebody is working on the installation.
 Emergency stop switch (Picture 3.4 Pos 5) must be turned in the direction given by the
arrow to reset it.
 Press the Reset Alarm button.
3.2
Type: AP 1000
OHW: W10286-014
Possibly resulting from:
 safety instructions not followed

 operation by untrained/unqualified personnel
 machine modifications performed without the approval of Redox.
The consequences of the above deviations could be extensive. The supplier could in such an
instance decline all responsibility for liability or guarantee.
3.2. CONDITIONS OF USE
The polydox operators must be informed about the polymer selected for their site, as well as
the potential dangers of chemicals being used in the system. Based on this information and the
advice given in this manual, operators can determine which personal measures to implement.
The permitted temperatures for the system are given in chapter 2.1 of this user’s manual. If
temperatures beyond range are expected, the system must be protected by e.g. setting up a
heating or cooling system.
The installation must be used in frost-free environment. If this is not the case measures must
be taken as described in the assembly instructions under 4.2.
3.3. PERSONAL PROTECTIVE EQUIPMENT
In the circumstances described above operators must wear protective equipment

For the polydox, operators must wear the following protective equipment:
 Protective clothing (chemical resistant)

 Safety shoes (chemical resistant)
 Safety goggles
 Work gloves (chemical resistant)
Clothing extensively soaked with polymer must be changed.
3.3
Type: AP 1000
OHW: W10286-014
4. INSTALLATION
4.1 TRANSPORT INSTRUCTIONS
Transport
See chapter 2-1 for measures and weights.
Transport by lorry must comply with the following requirements:

 The lorry must be stable enough to transport the polydox.
 The polydox must be secured with ratchets and other aids that may be considered
necessary for transport in order to guarantee safety.
 The tanks and hopper must be empty to transport the polydox. The bottom of the tank
must be given level support. The production installation must not be tilted or transported
on its side. Shocks must be avoided. Frost-free conditions are required during
transport.
 The polydox must be kept stable while transported.
Installation
The polydox must be installed in frost-free conditions. If there is a chance of sub-zero

temperatures, the complete installation and the pumps must be drained. The polydox must
also be protected against sea/salt and other influences that could harm it or have an impact on
it. All electric components must be protected against weather influence.
Loading/offloading
When loading/offloading, appropriate lifting material which can be properly secured on the
polydox must be used.
Delicate parts must be protected against damage or compression by the lifting system or the
forklift.
This is essential to prevent dangerous situations and damage to the installation. No person
must stand under or in the vicinity of the lifted goods as falling products can be harmful.
During loading, the polydox stainless steel part must not touch other metals (e.g. forklift). Rust
can appear when the stainless steel gets scratched.
4.1
Type: AP 1000
OHW: W10286-014
4.2. ASSEMBLY INSTRUCTIONS
After transport, check the unit for possible damage and ensure that all moving parts work
correctly. Ensure that all requirements which may influence the unit operation have been
complied with.
The truck may only leave after the inspection is complete and all transport documents have
been signed. Redox is not liable for transport, loading or offloading damage, but the transport
company is.
Foundations:
The installation must be set up with a spirit level on a sufficiently strong and solid surface (after
consultation with the producer).
Accessibility: (for standard installations)

A minimum distance of 1 metre must be kept clear around the polymer production unit, to
ensure that inspection and maintenance can be completed unobstructed. This must be
assessed in cooperation with Redox.
Pipes:
Install all pipes and fittings needed as shown on the drawings provided.
4.3. CONNECTION INSTRUCTIONS
Electricity:
 See NEN-EN 60204 for electrical connections between the switch box, main power, valves,
etc. See also the electrical diagram in the manual.
 The machine must be connected as per local and international regulations/directives for
water, electricity and outlet/drain.
 The main power supply must be stable, with a maximum tolerance of ±5%. During
starting and process operation, the power supply must not fall by more than 5%. A cable
with sufficient section must therefore be installed. The main fuse must be tripped by the
power spike when starting up.
 See the electric diagrams in this manual.
4.2
Type: AP 1000
OHW: W10286-014
5. OPERATING INSTRUCTIONS
5.1. PROCESS DESCRIPTION
The Polydox is an self-standing polyelectrolyte production unit. In order to keep the unit active,
a pulse (start process) from the switch box is required. A quantity of polyelectrolyte solution is
in the last compartment that can be used in the process.
Preparation of dry polymer
Hopper (A)
The polyelectrolyte powder is placed in the hopper located above the dosing screw. The lid
must be kept closed as much as possible in order to prevent the powder from forming lumps.
Dosing screw (B)

The polyelectrolyte powder is conveyed from the hopper by the dosing screw. The speed of the
screw is constant and can be adjusted at any time. The dosing screw output can be modified
by adjusting the pulse-time setting during start-up of the polymer production unit. This is
essential as each polymer has its own characteristics (specific gravity, granule size, etc.),
which influence the overall system capacity .
Heating element (C)

The polyelectrolyte powder is highly hygroscopic. In order to avoid moisture absorption, a
heating element is fitted at the dosing mouth. The heating element requires a continuous
power supply, therefore the main power supply should never be switched off.
Hopper (D)
The polyelectrolyte powder gets moistened over a large area in the hopper before entering the
first compartment (F). A lump-free solution is thereby obtained. The water quantity in the
hopper is controlled by valve POS 5 and valve POS 6 (Picture 5.2).
Water supply (E) (see also picture 5.1)

The process water is controlled by a solenoid valve (POS 3). The isolation valve (POS 1) must
be open.
The water pressure must be set via the pressure reducing valve (POS 2) to approx. 2 bars.
The flow can be checked on the water meter (Pos 4). The water meter sends out pulses. Once
the set water quantity has been reached, the polyelectrolyte dosing time starts.
5.1
Type: AP 1000
OHW: W10286-014
Picture 5.1 Process water supply
Start the system by opening the valves (POS 5 and POS 6) completely. The water level in the
hopper will then be adjusted through partial closing of the valve (POS 6) (see picture 5.2).
Set the flow at the value mentioned at “Capacity” in chapter 2.1.

The “Maximum water supply” should never be exceeded!
06
05
Picture 5.2 Water supply to the hopper
Should the process water supply stop due to a fault (e.g. a closed valve or insufficient water
pressure), the production process is automatically halted.
This can be set with the “delay on water pressure alarm”: xx sec. The absence of pulse from
the water meter will activate the alarm. The default value is set on 20 seconds.
Only the mixers will keep running.
5.2
Type: AP 1000
OHW: W10286-014
Upon generation of a fault report, an exclamation mark will appear on the screen or an alarm
on the control box, which can be pressed to see what the fault is.
Alarm Cause Solution

Check if the motor is mechanically
alarm mixer fast poly make-up unit Mixer “fast” overload blocked.
Check the cables
alarm mixer slow poly make-up unit Mixer “slow” overload blocked.
Check the cables
alarm dosing screw poly make-up unit Dosing screw overload blocked.
Check the cables
The water valve is stuck Check the water valve
alarm high level poly make-up unit Level rods need cleaning Clean the level rods
Level relays not properly set Reset the level relays
alarm water supply poly make-up unit Little or no water supply Check the water supply
- water valve
- filter
- pressure reducer
alarm low level poly make-up unit No new polymer is being Check if one of the above faults is
produced. present
The polymer solution is mixed homogeneously by a fast moving mixer in the first compartment
(F). It then gradually flows to the second compartment (G), the maturation cell, where a slow
moving mixer keeps mixing it.
When it is ready, the polymer solution then flows into the third compartment (H), where it is
stored prior to being used.
There are 5 level measurement rods located in the final compartment (picture 5.3).
5.3
Type: AP 1000
OHW: W10286-014
High level alarm
Stop production
Start production
Low level alarm

Stop pump
Earth
Picture 5.3 Level rods
High level alarm Polymer production stops automatically, only the mixers
keep working.
Stop production Solenoid valve (POS 03, Picture 5.1) closed, polymer production
process stops
Start production Solenoid valve (POS 03, Picture 5.1) opened, polymer
production process starts.
Low level alarm Mixers and polymer pump stopped.
The level measurement regulates the automatic polyelectrolyte preparation process.

Production starts when the minimum level is reached. Process water starts flowing, and within
a preset period of time the water meter emits a pulse.
In the absence of water, the production process is halted and an alarm message generated.
Once the set volume of water has flowed into the first cell, dry polymer dosing starts in order to
make up a polyelectrolyte solution.
An alarm message is generated when high or low level alarms are triggered.
The polyelectrolyte pump switches off when the low level is reached.
5.4
Type: AP 1000
OHW: W10286-014
Tap water
Polymer powder
Polymer make
up unit
Polymer dosing
pump
Picture 5.4 Flow diagram
5.2. ITEM DESCRIPTION
Description AP 1000
Type/size
1 Ball valve G3/4“
2 Pressure reducing valve G3/4“
3 Solenoid valve G3/4“
4 Water meter G3/4“
5 Ball valve 25mm
6 Ball valve 25mm
7 Dosing screw
8 Dosing screw motor 0.18kW
9 Heating element 24V 10W
10 Level rods
11 Polymer dosing pump
12 Mixer slow 0.37kW
13 Mixer fast 0.55kW
5.5
Type: AP 1000
OHW: W10286-014
5.3 START-UP
Before starting the polymer production unit, the type of polymer solution and the desired
maturation time (i.e. the time that the polymer solution remains in the production unit) must
be defined.
The dosing screw time interval can be based on the number of pulses emitted by the water
meter. The dosing time of the screw can also be set. A concentration of more than 0.25% PE
must be reported as mixing with the flaking medium will be more difficult due to higher
viscosity.
It is possible to make higher concentrations, but the polymer solution produced must be
subsequently diluted.
Starting the poly production unit for the first time
Before starting, all compartments with a mixer must completely be filled with tap
water manually. To prevent damage, mixers should never run without water!!
When the compartments are filled, the unit can be started and set in auto mode. The mixer
starts to run according timer settings. When the “start production” level in the unit is being
reached due to the running polymer dosing pump, new polymer will be prepared. During this
period, mixers work continuously.
The first batches of mixed polymer will only produce polymer with low concentration. After 2-
3 batches the correct concentration will be reached.
Calculating polymer solutions
Calculations for producing 0.1% solution in a 1000 Litre unit with a maturing time of 60
minutes.
Weight percentage P 0.1 %

Net volume N 1000 L
Maturation time T 60 Min
Calculating the quantity of powder needed (N / 100) x P x (60 / T) = 1 kg / hour
To produce 1000 litre of polymer solution at 0.1% concentration, 1 kg of polymer powder is

needed.
To produce the desired polymer concentration, the unit must be regulated and the timers set.
These timers are located on the “timer adjustments poly make-up unit” screen.
Based on the above-mentioned the unit is regulated as follows:
Setting the water quantity

1) All water supply valves must be closed.
2) Close the drain valves. Open the optional valve between polymer unit and polymer
dosing pump.
3) Start the process at the control panel
4) Open the water supply valve 1 (figure 5.4)
5) Set the water pressure to approx. 2 bar with the pressure reducing valve (2). Check
the value on the pressure gauge.
6) Set the polymer unit in automatic mode at its control panel. The dosing screw will
start rotating and the solenoid valve will open. All compartments with mixers must
5.6
Type: AP 1000
OHW: W10286-014
be filled with clean water first!

7) Open control valve 6 completely. Water will flow into the first compartment.
8) Open control valve 7 partially till a vortex is formed which just hits the breaker plate in
the dosing cone.
9) Stop the polymer dosing unit at its control panel. The dosing screw stops and the
water supply is stopped by the solenoid valve.
Calibrating the dosing screw

Before the polymer powder can be dosed the dosing screw must be calibrated for the
polymer powder being used. This is dependent on the specific gravity and grain size.
 Fill the hopper with polymer powder.

 Start the dosing screw in manual mode; the dosing screw will start rotating and after a
short period polymer powder will start to come out.
 Collect the powder for 2 minutes and weigh it (in grams). Divide this by 120 seconds in
order to determine the capacity of the dosing screw per second.
 Example:
Supposing that 300 grams of powder were dosed in 2 minutes (=120 seconds).
this would correspond to 300/120 = 2.5 gram/sec.
The water meter emits a pulse for each litre of water flowing through it..
The calculations provided earlier showed that for 1000 L of polymer solution at 0.1%,
1000 grams of polymer powder is needed, i.e. 1 gram of polymer powder per litre of
water.
If the “dosing water before dosing poly powder” timer is set to 20 litres the dosing screw
will only start after 20 litres of water have passed.
20 grams of polymer powder must be added to these 20 litres to produce the requested
polymer solution.
2.5 grams are dosed per second, i.e. 20 grams are dosed in 8 seconds.
This means that the “dosing time poly powder” timer must be set to 8 seconds.
For other water quantities or concentrations the formula given below can be used.
Desired solution P %
Preset litres of water Q L
Dosing screw capacity M g/sec.
Dosing screw running time D Sec.
(Q / M) x (P / 0.1) = D
(20 / 2.5) x (0.1 / 0.1) = 8
 After the pulse-pause time has been set, the dosing screw must be calibrated anew.
Setting level measurement sensitivity
Level measurement sensitivity can be modified by adjusting the potentiometers on the

measurement relays in the switch box.
5.7
Type: AP 1000
OHW: W10286-014
Please refer to the electrical diagram for the default settings of the measurement relays.
Adjustments are done as follows:
 Ensure that the electrode for the level to be adjusted is submerged in liquid.
 Turn the potentiometer (02) towards the maximum value until the measurement relay is
activated. If no activation takes place, the sensitivity range (01) must be changed.
 Ensure that the measurement relay switches off correctly once the electrode is no longer
in contact with the liquid.
Mixers
If no start-production signal is received after a preset time (delay on mixers pulse pause
mode) the mixers will switch over to pulse-pause mode. Times can be adjusted at the control
panel.
Polymer dosing pump setting
To obtain problem-free and continuous production of the solution, the polymer preparation
unit capacity must be greater than the pump capacity.
Decommissioning
Ensure that the unit is installed in a frost-free area to avoid freezing of the produced
polyelectrolyte when the unit is not on. Polymer settling or lump formation in the hopper will
also be avoided. If not used for extensive periods of time, the unit should be drained, the
hopper emptied and the complete installation cleaned.
Maintenance
If maintenance is performed on the machine, the power must be disconnected beforehand.

Maintenance and repair activities must only be undertaken by qualified personnel.
5.8
Type: AP 1000
OHW: W10286-014
5.4 POLYDOX OPERATING SCREEN
Automatic process;
 The automatic production cycle can only be released/activated if;

1: The “quick” poly mixer is not faulty.
2: The “slow” poly mixer is not faulty.
3: The poly powder dosing screw is not faulty.
4: There is no water supply fault.
5: There is no high level alarm in the poly unit.
 The quick poly mixer runs when;
1: The mixer is not faulty.
2: The “auto on” selection button is activated.
3: Not in pause mode.
 The slow poly mixer runs when;
1: The mixer is not faulty.
3: Not in pause mode.
 The poly powder dosing screw runs when;
1: The poly powder dosing screw is not faulty.
2: The automated production cycle is activated.
4: The “poly powder dosing time” is activated.
5: The quick poly mixer turns.
6: The “slow” poly mixer turns.
7: The water valve is opened.
 The water valve is open when;
1: The automated production cycle is activated.
2: The start production level is reached.
3: There is no high level alarm.
5.9
Type: AP 1000
OHW: W10286-014
6. INSPECTION/MAINTENANCE
6.1. REQUIREMENTS FOR MAINTENANCE PERSONNEL
Only persons instructed by Redox to operate and maintain the installation are permitted to
undertake maintenance activities.
The operator person and/or repair or maintenance personnel must at least have an
intermediate technical degree.
Such person must have knowledge of the following:

 Chemical reactions and hazards/process technology where applicable.
 Ability to read pneumatic operation diagrams and to analyse faults.
 Electricity : ability to understand an electrical diagram and to analyse faults. Ability to
operate measuring equipment such as resistivity-meters, voltmeters and clamp-on
ammeter to measure incoming and nominal currents.
Maintenance should be performed preferentially by the technical department (if any).
6.2. SAFETY MEASURES AND DANGERS DURING MAINTENANCE
 Maintenance, repairs, inspection, fault repairs or removal of parts may only be

undertaken if the power is disconnected and if the drives, pumps, etc. are not active.
 Switch the lockable main switch (figure 6.1, pos. 4) on the switch box off. Switch the
operating button off locally (if present).
 Secure the main switch (figure 6.1, pos 4) against unauthorised reengagement!
Figure 6.1
Each of the persons involved with the above activities on the machine must have their own
padlock with fitting keys and disconnect the main switch (figure 6.1, pos 4). The machine must
only be reactivated after all padlocks have been removed. Redox does not provide these
padlocks.
 The following is required for the motor/pump to run.

- The motor must be set to the “manual” position
- PLEASE NOTE! The drive/pump are not protected against low level, etc. in
the “manual” setting.
 Before a pump/mixer is removed from a sump/tank, the power must be
disconnected and then be locked in order to prevent unexpected reconnection.
6.1
Type: AP 1000
OHW: W10286-014
6.3. MAINTENANCE
When maintenance activities need to be undertaken on the poly production unit, the power
must be disconnected from the unit.
Maintenance and repairs may only be undertaken by qualified service personnel.
Cleaning the poly production unit

When cleaning, the valves of the outlet pipes can be opened as the compartments are
connected to each other. Encrusted polyelectrolyte can be removed and rinsed away through
the outlet connection.
Cleaning the hopper

Depending on the polyelectrolyte type, as well as the operating conditions, it is possible to
clean the hopper in order to prevent clogging.
Cleaning the dosing screw

Encrusted dry polyelectrolyte can be removed with a brush.
6.2
Type: AP 1000
OHW: W10286-014
7. FAULTS / REPAIRS
First read chapter 6.2 of this user’s manual properly before attempting to resolve any
faults or undertake any repairs.
7.1. Trouble-shooting table
Reset the Polyelectrolyte production  Press the reset button for the automated
unit process to resume .
The production unit does not work  Check if power is present in the switch box.
 Check the temperature switch
 Check if the water supply is working correctly
 Check if there is an active level alarm
Water supply fault  Check if there is water

 Check if the water pressure is sufficient
 Check if the POS 01 valve is open
 Check if solenoid valve POS 03 is working
 Check if there is no high level
 Check filter in pressure reducer
Fault in polyelectrolyte powder  Check if there is sufficient polyelectrolyte

supply powder in the hopper
 Check the hopper for bridge formation
 Check if the dosing screw is clogged
 Check if the dosing opening heater is working
 Environment too moist
Agitator fault  Check if the agitator is working correctly

 Check the temperature switch
Dosing compartment level fault  Check the tank levels

 Check if solenoid valve POS 03 is working
 Check if the level relays are working
 Check filter in pressure reducer
Blocked hopper  Water supply to the hopper too high or too low
Regulate with valve POS 06
Dosing pump fault  Check the low level of the dosing compartment
 Check if the pump is working correctly
 Check the pump temperature switch
7.1
Type: AP 1000
OHW: W10286-014

The steels / synthetics / medium / substances must be dismantled according to the national
and / or local regulations of that moment.
8.1. RE-USE.
The Polydox is constructed from durable materials and components.

considerate for what can be re-used, when and how can be recycled. The stainless steel
frame is made of AISI 304 (werkstoff. Nr:1.4301) and can be re-used for other purposes.
8.2. DIS-MANTLING.
steel frame is welded in full and cannot be dismantled in parts.
Dismantling of the Polydox has to be executed by professional personnel.
8.1
Type: AP 1000
OHW: W10286-014
system.

Service department
Phone: 0031 (0)543-531030
Fax: 0031 (0)543-519089
9.1
OHW: W10286-015
1.1. TECHNICAL DATA
Description: Flocculant dosing pump (for example poly electrolyte )

Make: Mono
Type: C21B
 Flocculants (for instance poly electrolyte) are mostly delivered as a granulate. In general
there will be a solution of 0,1% dosed to let coagulated particles grow to flocs. The effect of
the solution can reduce after two days. Owing to this the activity of the flocculant reduces
very strong and it’s possible that the solution will clot. This causes stoppage in the system.
When the system is not in operation for a longer period, we advise to drain the tank and
clean the dosing system. Please contact your chemical supplier for the right instructions.
2. SAFETY ASPECTS

are stopped.
Figure 2.1
Redox delivery.

1
OHW: W10286-015



carefully.

manual index.
2
English
Original Instructions
Installation, Operation
and Maintenance Instructions
Compact Range
OMMP/032/01
Rev 13, October 2012
Spares & Service Contact Details
Mono UK
Spares +44 (0)161 214 2380 (direct line 8.15 am – 5.00 pm)
E-mail spares@mono-pumps.com
Service +44 (0)161 214 2390 (direct line 8.15 am – 5.00 pm)
E-mail customerservices@mono-pumps.com
Service +44 (0)161 339 9000 (24 hrs)
Mono Australia
Telephone Facsimile
Melbourne (03) 9773 7777 (03) 9773 7400
Sydney (02) 9521 5611 (02) 9542 3649
Brisbane (07) 3350 4582 (07) 3350 3750
Adelaide (08) 8447 8333 (08) 8447 8373
Perth (08) 9479 0444 (08) 9479 0400
Darwin (08) 8984 3099 (08) 8947 0540
Tasmania 0417 345 814 (03) 6330 2051
E-mail ozsales@mono-pumps.com
Mono New Zealand

Spares & Service +64 (0)9 829 0333
E-mail info@mono-pumps.co.nz
Monoflo USA
Spares & Service +1 713 466 7999
E-mail inquire@monoflo.com
Monoflo South America

Spares & Service +54 4296 8997 +54 4284 0323
E-mail inquire@monoflo.com
Mono China
Telephone Facsimile
Beijing +86 (0) 10 5707 0915 +86 (0) 10 5977 6102
Shanghai +86 (0) 21 3990 4588 +86 (0) 21 3990 4535
E-mail monoshanghai@nov.com
Spares & Service

Issued – April 2008
ATEX Warning Statements
PUMPS AND PUMP UNITS Where there may be a risk of an accumulation of
explosive gases or dust non-sparking tools should be
Where a pump or pump unit is to be installed in a used for installation and maintenance.
potentially explosive atmosphere ensure that this
has been specified at the time of purchase and that In addition to causing permanent damage to the
the equipment has been supplied accordingly and stator, dry running of the pump could generate a rapid
displays an ATEX nameplate or is supplied with a rise in the temperature of the stator tube or barrel,
certificate of conformity. If there is any doubt as to which could become an ignition source. It is therefore
the suitability of the equipment please contact Mono essential that a dry run protection device be fitted.
Pumps Limited before commencing with installation This must shut the pump down immediately should a
and commissioning. dry run situation occur. Details of suitable devices are
available from Mono Pumps Limited.
Process liquids or fluids should be kept within
specified temperature limits otherwise the surface of To minimise the risk of sparking or temperature
pump or system components may become an ignition rises due to mechanical or electrical overload the
source due to temperature rises. Where the process following control and safety devices should be
liquid temperature is less that 90ºC the maximum fitted in addition to a dry run protection system. A
surface temperature will not exceed 90ºC provided pressure relief system whereby the pump can not
the pump is installed, operated and maintained in generate pressures in excess of the maximum rated
accordance with this manual. Where the process fluid pressure or an over pressure device which should
temperature exceeds 90ºC the maximum surface shut the pump down when the maximum discharge
temperature will be equal to the maximum process pressure is exceeded. A control system that will shut
fluid temperature. the pump down if the motor current or temperature
exceed specified limits. An isolator switch that will
Cavities that could allow the accumulation of disconnect all electrical supply to the motor and
explosive gases, such as under guards, should where ancillary electrical equipment and be capable of
possible, be designed out of the system. Where this being locked in the off position. All control and safety
is not possible they should be fully purged before any devices should be fitted, operated and maintained in
work is carried out on the pump or system. accordance with the manufacturer’s instructions. All
valves on the system should be open when the pump
Electrical installation and maintenance work is started otherwise serious mechanical overload and
should only be carried out by suitably qualified and failure may result.
competent persons and must be in accordance with

relevant electrical regulations. It is important that the pump rotates in the direction
indicated on the nameplate. This must be checked
All electrical equipment, including control and safety on installation and commissioning and after any
devices, should be suitably rated for the environment maintenance has been carried out. Failure to observe
in to which they are installed. this may lead to dry running or mechanical or
electrical overload.
ATEX – Page 1 of 2
Issued – February 2004
Reference – OMMP/028/01/R1
ATEX Warning Statements
When fitting drives, couplings, belts, pulleys and The use of replacement parts that are not
guards to a pump or pump unit it is essential that manufactured by or approved by Mono Pumps Limited
these are correctly fitted, aligned and adjusted in may affect the safe operation of the pump and it may
accordance with the manufacturer’s instructions. therefore become a safety hazard to both operators
Failure to do so may result in sparking due to and other equipment. In these circumstances
unintended mechanical contact or temperature rises the Declaration provided will become invalid. The
due to mechanical or electrical overload or slipping of guarantee referenced on the Terms and Conditions of
drive belts. Regular inspection of these parts must be Sale will also be invalidated.
carried out to ensure they are in good condition and
replacement of any suspect part must be carried out
immediately.
Mechanical seals should be suitably rated for

the environment. The seal and any associated
equipment, such as a flushing system, must be
installed, operated and maintained in accordance with
the manufacturer’s instructions.
Where a packed gland seal is fitted this must be

correctly fitted and adjusted. This type of seal relies
on the process liquid to cool the shaft and packing
rings so a constant drip of liquid from the gland
section is required. Where this is undesirable an
alternative seal type should be fitted.
Failure to operate or maintain the pump and ancillary

equipment in line with the manufacturer’s instructions
may lead to premature and potentially dangerous
failure of components. Regular inspection, and where
necessary replacement, of bearings and lubrication is
essential.
The pump and its components have been designed

to ensure safe operation within the guidelines
covered by legislation. Accordingly Mono Pumps
Limited have declared the machine safe to use for
the duty specified as defined by the Declaration of
Incorporation or Conformity that is issued with this
instruction manual.
ATEX – Page 2 of 2
Issued – February 2004
Reference – OMMP/028/01/R1
Index
SECTION 1 INSTALLATION
START-UP PROCEDURE
ASSEMBLY AND DISMANTLING ADVICE
SECTION 2 FAULT FINDING
SECTION 3 DRAWING REFERENCE NUMBERS
PUMP CODING SHEET
SECTION 4 DISMANTLING AND ASSEMBLY DIAGRAMS
EXPLODED VIEWS
SECTION 5 TORQUE TIGHTENING FIGURES
EC Declaration as defined by Machinery Directive 2006/42/EC.

The following harmonised standards are applicable: BS EN 809, BS EN ISO 12100 Parts 1 & 2
EC Declaration of Incorporation EC Declaration of Conformity
This declaration is only valid when partly completed This declaration is not valid for partly completed machinery
machinery has been supplied. has been supplied.
In this case, the machinery meets the requirements of the In this case the machinery meets the requirements of the
said directive and is intended for incorporation into other said directive including any amendments which are valid at
machinery or for assembly with other machinery in order the time of supply.
to constitute relevant machinery as defined by the
said directive including any amendments, which are valid We further declare that, where applicable, said machinery also
meets the requirements of:
at the time of supply.
The EMC Directive 2004/108/EC
IMPORTANT The Low Voltage Directive 2006 /95/E
This machinery must not be put into service until the The Pressure Equipment Directive 97/23/EC
The Outdoor Noise Directive 2005/88/EC
relevant machinery into which it is to be incorporated has The Drinking Water Directive 99/83/EC
been declared in conformity to the said directive.
IMPORTANT
This declaration is only valid when the machinery has This declaration is only valid when the machinery has been
been installed, operated and maintained in accordance installed, operated and maintained in accordance with these
with these instructions and safety guidelines contained instructions and safety guidelines contained within as well
within as well as instructions supplied for equipment as instructions supplied for equipment assembled with
assembled with or intended for use with this equipment. or intended for use with this equipment.
Mr C. Q. Griffiths - Engineering Services Manager.

for Mono Pumps Limited, Martin Street, Audenshaw,
Manchester England, M34 5JA
Index
Issued – December 2009
Installation, Operation & Maintenance Instructions
INSTALLATION Normally ‘P’ range pumps will be designed with a sole plate
that will be bolted to the customers framework.
1.1 INSTALLATION AND SAFETY
RECOMMENDATIONS If the pump is to be mounted in any way other than described
above, confirmation of the installation must be agreed
In common with other items of process plant a pump with Mono Pumps Limited. All the pipework should be
must be installed correctly to ensure satisfactory independently supported.
and safe operation. The pump must also be
maintained to a suitable standard. Following these 1.3.1 HANDLING
recommendations will ensure that the safety of
personnel and satisfactory operation of the pump is During installation and maintenance, attention must
achieved. be paid to the safe handling of all items. Where a
1.2.1. GENERAL pump or its components weigh in excess of 20 kg
(45lb) it is recommended that suitable lifting tackle
When handling harmful or objectionable materials, should be used to ensure that personal injury or
adequate ventilation must be provided in order to damage to components does not occur.
disperse dangerous concentrations of vapours. It is
recommended that wherever possible, Mono pumps For safe handling of both bareshaft pumps and pump
should be installed with provision for adequate units (pump/ gearbox/motor etc.) slings should be
lighting, thus ensuring that effective maintenance used. The position of the slings will depend upon
can be carried out in satisfactory conditions. With the specific pump/unit construction and should be
certain product materials, a hosing down facility with carried out by personnel with the relevant experience
adequate draining will simplify maintenance and to ensure that the pump is not damaged and injury to
prolong the life of pump components. personnel does not occur.
Pumps operating on high temperature duties
should be allowed to cool sufficiently before any If eyebolts do exist then these should only be used
maintenance is carried out.
for lifting the individual components for which they
1.2.2. SYSTEM DESIGN & INSTALLATION are supplied.
At the system design stage, consideration must be 1.3.2 STORAGE AND INFREQUENT OPERATION
given to provision of filler plugs, and the installation
of non-return and/or isolating valves. Pumps cannot The situation where a pump is used infrequently is
be reliably used as non-return valves. Pumps in also covered by the instructions in this section.
parallel and those with high static discharge head
must be fitted with non-return valves. SHORT TERM STORAGE
The pumps must also be protected by suitable Where a pump has to be stored for 6 months or less then
devices against over pressure and dry running. the following steps are advised:
i. HORIZONTAL MOUNTING 1. Store pump inside wherever possible or if this is not

feasible then provide protective covering. Do not
All ranges excluding P Range Mono pumps are allow moisture to collect around the pump.
normally installed in a horizontal position with
baseplates mounted on a flat surface, grouted in 2. Remove the drain plug, if fitted. Any inspection
and bolted, thus ensuring firm fixing and a reduction plates fitted should also be removed to ensure that
in noise and vibration. the suction housing can drain and dry completely.
The unit should be checked after bolting down to 3. Loosen the packed gland and inject sufficient grease
ensure that the alignment of the pump to its prime into the stuffing box. Tighten the gland nut hand
mover is correct. tight. If a water flush system is to be used do not
grease, a small amount of light oil is recommended
for these.
ii. VERTICAL MOUNTING
4. See Manufacturers Instructions for motor/gearbox/
P Range Pumps Only drive instructions for storage procedures.
The P range pumps are intended for vertical

installation. Care must be taken when lifting the
pump into the vertical position.
Section 1, Page 1
Issued – October 2009
LONG TERM STORAGE When both are installed it is advised that the relief valve is
positioned closer to the pump than the nonreturn valve.
If the pump is to be kept in storage for more than six
months then in addition to the above the following IMPORTANT
procedures should be carried out regularly (every 2 - 3
weeks if possible): The pump must never run against a closed inlet
or outlet valve, as this could result in mechanical
1. If practicable rotate the pump at least three quarters of failure.
one revolution to avoid the rotor setting in the stator.
1.6 GENERAL SAFETY
2. Note, however, that the pump is not to be rotated for

GREAT CARE MUST BE TAKEN TO PROTECT ALL
more than two revolutions each time because damage
ELECTRICAL EQUIPMENT FROM SPLASHING
could be caused to the rotor/ stator elements.
WHEN HOSING DOWN. WHERE MONO PUMPS
LIMITED HAVE SUPPLIED A BARESHAFT PUMP
IMMEDIATELY PRIOR TO INSTALLATION AND STARTING
THE ONUS IS ON THE USER TO FIT ADEQUATE
GUARDS IN COMPLIANCE WITH THE REQUIRE
Before installing the pump please ensure that all plugs and
MENTS OF THE RELEVANT REGULATIONS.
inspection plates are replaced and that excess grease/oil is
removed from the stuffing box.
All nuts and bolts, securing flanges and base
1.4 ELECTRICAL mounting fixtures must be checked for tightness
before operation. To eliminate vibration, the pump
Electrical connection should only be made using must be correctly aligned with the drive unit, and all
equipment suitable for both rating and environment. guards must be securely fixed in position. When
Where any doubts exist regarding the suitability of commissioning the plant, all joints in the system must
equipment, Mono Pumps Limited, should be consulted be checked thoroughly for leakage.
before proceeding. Normally the Mono pump should If, when starting, the pump does not appear to
be installed with starting equipment arranged to give operate correctly (see 2), the plant must be shut
direct on line starting. down immediately and the cause of the malfunction
established before operations are recommenced. It
Earthing points will be provided on electric drives (if is recommended that depending upon plant system
supplied) and it is essential that these are correctly operation, either a combined vacuum and pressure
connected. When the motor is being wired and gauge, or a vacuum gauge only be fitted to the
checked for rotation, the start/stop sequence must pump inlet port, and a pressure gauge fitted to the
be instantaneous to prevent dry running (see 2) or outlet port, these will then continuously monitor the
pressurising upstream equipment. (Check direction pump operating conditions. May contain substances
arrow on pump nameplate). The electrical installation from the ECHA SVHC Candidates List (REACH -
Regulation (EC) No. 1907/2006)
should include appropriate isolating equipment to
ensure that the pump unit is safe to work on. 1.7 DUTY CONDITIONS
1.5 PRESSURE RELIEF VALVES AND NON-RETURN Pumps should only be installed on duties for which
VALVES Mono Pumps Limited have specified the materials
of construction, flow rates, pressure, temperature,
1. It is recommended that a suitable safety device is speed etc. Where dangerous materials are to be
installed on the discharge side of the pump to prevent pumped, consideration must be given to the safe
over-pressurisation of the system. discharge from relief valves, gland drains etc. IF
THE DUTY SHOULD BE CHANGED, MONO
2. It is also recommended that a non-return valve is in PUMPS LIMITED SHOULD BE CONTACTED
stalled on the discharge side of the pump to prevent AND THEIR RECOMMENDATIONS SOUGHT IN
reverse flow through the system. THE INTEREST OF APPLICATION, SAFETY OF
PLANT, EFFICIENCY AND PUMP LIFE.
Section 1, Page 2
Issued – September 2009
2. START-UP PROCEDURE 2.3.1. GLAND PACKING
Pumps must be filled with liquid before starting. Where a pump is supplied fitted with gland packing
The initial filling is not for priming purposes, but (manufactured from a non-asbestos material), the
to provide the necessary lubrication of the stator gland will require adjustment during the initial running in
until the pump primes itself. When the pump is period. Newly packed glands must be allowed to run-in
stopped, sufficient liquid will normally be trapped in with only finger tight compression on the gland follower
the rotor/stator assembly to provide lubrication upon nuts. This should continue for about 3 days. The gland
restarting. follower should be gradually tightened over the next
week to achieve a leakage rate as shown in the table
If, however, the pump has been left standing for below. Gland
an appreciable time, moved to a new location, or followers should be adjusted at regular intervals to
has been dismantled and re-assembled, it must maintain the recommended leakage flow rate. Under
be refilled with liquid and given a few turns before normal working conditions a slight drip from the gland
starting. The pump is normally somewhat stiff under pressure assists in cooling and lubricating the
to turn by hand owing to the close rotor/stator fit. packing. A correctly adjusted gland will always have
However, this stiffness disappears when the pump small leakage of fluid.
is running normally against pressure.
Typical Leakage Rates from Packed Glands
2.1 DRY RUNNING
Up to 50mm shaft diameter 2 drops per minute 50 …
NEVER RUN THE PUMP IN A DRY CONDITION 75mm shaft diameter 3 drops per minute 75 …
EVEN FOR A FEW REVOLUTIONS OR THE 100mm shaft diameter 4 drops per minute 100 …
STATOR WILL BE DAMAGED IMMEDIATELY. 125mm shaft diameter 5 drops per minute
CONTINUAL DRY RUNNING COULD PRODUCE 125 … 160mm shaft diameter 6 drops per minute
SOME HARMFUL OR DAMAGING EFFECTS.
A gland drip is, however, undesirable when handling
2.2 PUMP ROTATION DETAILS corrosive, degreasing, or abrasive materials. Under
PUMP RANGE BI-DIRECTIONAL COMMENT these conditions the gland must be tightened the
minimum amount whilst the pump is running to ensure
satisfactory sealing when under pressure, or
E Yes ††
Monobloc B Yes to stop entry of air when under suction conditions.
††
ompact Yes †*
Merlin Industrial Yes ** The gland leakage of toxic, corrosive or hazardous
S, SL Yes ** liquids can cause problems of compatibility with the
LF Yes * pumps materials of construction.
W No **
Merlin Widethroat No
MM ML No Provision of a gland drain should be considered,
MS No especially for the leakage of hazardous products.
G No
CB/S B No
Placer No
Grout Injection No ** CARE IS REQUIRED WHEN ADJUSTING THE
P No **
GLAND WHILST PUMP IS RUNNING.
CP0 1 No
CP0025,CP0800,CP1600 No *
* Clockwise when viewed from drive end. 2.3.2 MECHANICAL SEALS - ALL PUMPS
** Anti-clockwise when viewed from drive end.
When a mechanical seal is fitted to the pump it may
† Anti-clockwise gives inlet at drive end. be necessary to provide a barrier fluid to some part of
the seal. This should be provided in line with the
seal manufacturers instructions.
DIRECTIONS OF ROTATION
Where a Monobloc pump is supplied without a drive,
BEFORE THE DIRECTION OF ROTATION IS it is necessary to fit the mechanical seal (supplied
CHANGED, MONO PUMPS LIMITED MUST BE separately) prior to fitting the gearbox and motor.
CONSULTED SO THAT THE SUITABILITY OF
THE PUMP CAN BE CONFIRMED WHEN
OPERATING ON THE NEW DUTY.
Section 1, Page 3
2.4. GUARDS BP LC2 / Mobilgrease XHP 222 or their equivalent
must be used for replenishment.
In the interests of safety, and in accordance with the
U.K. Health and Safety at Work Act 1974, all guards 2.9 PUMP UNITS
must be replaced after necessary adjustments have
been made to the pump. Where a pump unit is dismantled and re-assembled,
consideration must be given to ensure that where
appropriate the following steps are covered.
2.5 WARNING/CONTROL DEVICE
1. Correct alignment of pump/gearbox
Prior to operating the pump, if any warning or control 2. Use of appropriate couplings & bushes
devices are fitted these must be set in accordance 3. Use of appropriate belts & pulleys correctly
with their specific instructions. tensioned.
2.6 PUMP OPERATING TEMPERATURE 2.10 CLEANING PRIOR TO OPERATION
The range of temperatures the pump surfaces will i. Non Food Use
develop is dependent upon factors such as product
temperature and ambient temperature of the During the commissioning of a new pump or
installation. There may be instances where the recommissioning of an overhauled pump, it is
external pump surface can exceed 50oC. advisable to clean the pump prior to the initial
operation of the pump in the process.
In these instances, personnel must be made aware
of this and suitable warnings/guarding used. ii. Food Use
2.7 NOISE LEVELS
When a pump has been supplied for a food
1. The sound pressure level should not exceed 85dB application, it is important to ensure that the pump is
at one metre distance from the pump. clean prior to initial operation of the pump.
Therefore, it is important that a clean-in-place

2. This is based on a typical installation and does treatment is executed on the pump at the following
not necessarily include noise from other sources times:
or any contribution from building reverberation or
installation pipework 1. When the pump is first commissioned for use.
2. When any spare components are fitted into the

3. It is recommended the actual pump unit noise wetted area of the pump.
levels are ascertained once the unit is installed and
A recommended CIP procedure is as follows:
running at duty conditions
This procedure should not be used on the CP

2.8 LUBRICATION
Pump Range. Please consult our application
engineers for a suitable procedure.
Pumps fitted with bearings should be inspected
periodically to see if grease replenishment is Caustic Wash
necessary, and if so, grease should be added until
LQ94 ex Lever Diversey or equivalent
the chambers at the ends of the bearing spacer are
2% concentration
approximately one third full.
Acid Wash
Periodic bearing inspection is necessary to P3 Horolith 617 ex Henkel
maintain optimum bearing performance. The Ecolab or equivalent 1% concentration
most expedient time to inspect is during periods of
regular scheduled equipment downtime - for routine Procedure
maintenance or for any other reason. 1. Caustic wash @ 75°C for 20 mins
2. Water rinse @ 80°C for 20 mins
Under tropical or other arduous conditions, however,
a more frequent examination may be necessary.
It is therefore advisable to establish a correct
maintenance schedule or periodic inspection.
Section 1, Page 4
Issued – August 2009
3. Acid wash @ 50°C for 20 mins 2.13 ACCESS PORTS
4. Water rinse @ 80°C for 20 mins
Where access ports are fitted then the following
CIP flow rates (hence pump speeds) should be steps must be followed prior to removal:
maximised to achieve highest level of cleanability.
1. Pump must be shut down and the electrical supply
A C.I.P. liquid velocity of 1.5 to 2.0 m/s is required isolated.
for removal of solids and soiling.
2. Protective clothing should be worn, especially if the
Pumps fitted with CIP by pass ports will permit pumped product is obnoxious.
higher flow rates without the need to increase pump
speed. 3. Remove access plate with care utilising where
possible drip trays to collect product leakage.
The use of neat active caustic and acid
chemicals is not recommended. Proprietary Access ports are included to assist in removing
cleaning agents should be used in line with blockages and to allow a visual check on the
manufacturers instructions. components within the suction chamber.
All seals and gaskets should be It is not to be considered as an additional method in

replaced with new if disturbed dismantling the pump.
during maintenance.
Re-assembly of the plate should be completed using
Pump internals should be regularly inspected to new gaskets prior to the pump being switched on.
ensure hygienic integrity is maintained, especially
2.14 ADJUSTABLE STATORS
with respect to elastomeric components and seals,
and replaced if necessary.
If adjustable stators are fitted then the following
steps must be followed for adjusting the clamping
The four stages constitute one cycle and we
devices.
recommend that this cycle is used to clean the pump
before use on food.
The adjustable stator assembly is designed to
give an even compression around the stator
Once the pump has been commissioned, the
circumference. It is designed to be used when
cleaning process will depend upon the application.
pump performance reduces through wear to an
The user must therefore ensure that their cleaning
unacceptable level, to restore the required flow rate.
procedures are suitable for the duty for which the
pump has been purchased.
The stator compression is increased using the
following steps:
2.11 WIDETHROAT PUMPS 1. Release the six locking screws half a turn.
Specific pumps may have auger feed screws, with 2. Tighten the eight clamp screws until adjustment
or without a bridge breaker system to feed the allowed by releasing the lock screws has been taken
pumping element. If the pump installation requires up.
that these cannot be enclosed, care must be taken 3. Repeat steps 1 and 2 until the pump performance
to ensure personnel cannot gain access whilst has been restored to its former level.
the pump is operating. If this is not possible an
emergency stop device must be fitted nearby. NOTE
2.12 EXPLOSIVE PRODUCTS/ HAZARDOUS It is imperative that when adjusting the stator that
ATMOSPHERES only sufficient pressure is placed on the stator to
enable the capacity of the pump to be reinstated.
In certain instances the product being pumped may
well be of a hazardous nature. Over tightening of the stator could easily result
in damage to the driver by overload and so
In these installations consideration must be given to extreme care must be taken when carrying out
provide suitable protection and appropriate warnings these adjustments.
to safeguard personnel and plant.
Section 1, Page 5
It is therefore advisable to make the adjustment 2.15.4 FLEXISHAFT DRIVE PUMPS

while the pump is running and power readings can
be monitored. With this design there are no wearing items to replace
in the drive train, however, if during routine inspection
REMOVAL OF ADJUSTABLE STATOR the shaft is visibly damaged / distorted or the
protective coating is damaged, then this item should
The procedure for removal of an adjustable stator be replaced to avoid unexpected breakdowns.
is the same as that of a standard one, except it is
necessary to remove the clamp plates before the 2.16 MECHANICAL SPEED VARIATORS
stator can be twisted off the rotor.
Refer to the manufacturers instructions.
This can be done by undoing the clamp screws;
then releasing the clamp plate by using the locking These machines require regular maintenance, which
screws as jacking screws to remove the clamp typically includes weekly adjustment through the full
plates. speed range.
3.0 ASSEMBLY AND DISMANTLING

Re-assembly will be done using the reverse
procedure.
Section 4 contains the steps to dismantle and re-
2.15 MAINTENANCE OF WEARING COMPONENTS assemble the pump. All fastenings must be tightened
securely and when identified the appropriate torque
2.15.1 ROTOR AND STATOR figures should be used.
The wear rate on these components is dependent 3.1 USE OF ITEMS NOT APPROVED OR
on many factors, such as product abrasivity, speed, MANUFACTURED BY MONO PUMPS LIMITED
pressure etc.
The pump and its components have been designed
When pump performance has reduced to an to ensure that the pump will operate safely within the
unacceptable level one or possibly both items will guidelines covered by the legislation.
need replacing.
As a consequence Mono Pumps Limited
2.15.2 DRIVE SHAFT - PACKED GLAND have declared the machine safe to use for the
duty specified as defined by the Declaration of
The wear rate of the gland area is dependent on Incorporation or Conformity that is issued with this
many factors such as product abrasivity and speed. Instruction Manual.
Regular gland maintenance will maximise the life of
the shaft. Replacement of both the gland packing The use of replacement items that are not approved
and shaft will be necessary when shaft sealing by or manufactured by Mono Pumps Limited
becomes difficult to achieve. may affect the safe operation of the pump and it
may therefore become a safety hazard to both
2.15.3 COUPLING ROD JOINTS operators and other equipment. In these instances
the Declaration provided will therefore become
Regular maintenance and lubrication will maximise invalid. The guarantee referenced in the Terms
life of the joints. and Conditions of Sale will also be invalidated if
replacement items are used that are not approved or
Replacement of one or both joint assemblies and manufactured by Mono Pumps Limited.
possibly the coupling rod may be necessary when
wear is apparent. DISPOSAL OF WORN COMPONENTS
It is essential to replace all the joint items with When replacing wearing parts, please ensure disposal
genuine Mono parts to ensure maximum life. of used parts is carried out in compliance with local
environmental legislation. Particular care should be
taken when disposing of lubricants.
Section 1, Page 6
3.2 RECOMMENDED LIFTING POINTS
120°
CHOKE MAX CHOKE
120°
MAX
CHOKE CHOKE
CHOKE 120° CHOKE

MAX
120°
MAX
CHOKE CHOKE
Kapitel 1, Seite 7
Stand – August 2009
3.3 PUMP AND WEAR PARTS WEIGHTS.
NOTE: Weights are for guidence purpose only. Please refer to the documetation
issued with your pump or spares.
Compact Range
Weight (kg)
Model Coupling
Pump Stator Rotor Shaft
Rod/Joint
C21B 12.5 1.2 0.4 0.2 0.6
C21D 14.5 2.6 0.8 0.2 0.6
C22A 12.5 1.2 0.4 0.2 0.6
C22B 14.5 2.6 0.8 0.2 0.6
C22D 23 5.5 1.6 0.4 0.7
C23A 18 1.3 1.5 0.4 0.7
C23B 20 2.6 1.5 0.4 0.7
C23K 20 2.6 1.5 0.4 0.7
C13D 32 5.3 2.9 1.2 1.7
C2XA 28 2.1 1.6 0.4 0.7
C2XB 31 5.6 2.8 0.4 0.7
C1XD 57 10.4 5.5 2.6 3.1
C1XK 32 5.1 2.7 0.4 0.7
C14A 34 3.5 2.6 1.2 1.7
C14B 46 7.1 4.5 1.2 1.7
C14D 72 14.0 9.2 2.4 3.1
C14K 42 7.1 4.5 1.2 1.7
C15A 50 6.3 4.9 1.2 1.7
C15B 70 12.4 9.1 2.4 3.1
C15D 106 24.5 18.0 4.9 4.4
C15K 57 12.3 8.8 1.2 1.7
C16A 77 11.0 8.4 2.4 3.1
C16B 102 21.5 15.4 4.9 4.4
C16D 180 42.5 30.2 12.3 8.7
C16K 94 5.0 15.3 2.4 3.1
C17A 107 17.4 13.3 4.9 4.3
C17B 150 34.3 24.5 4.6 4.3
C17D 252 68.0 48.9 15.3 8.7
C17K 148 34.3 24.5 4.6 4.3
C18A 113 23.1 17.9 6.2 4.3
C18B 170 24.6 33.7 12.3 8.7
C18D 291 87.0 65.7 15.3 9.5
C18K 172 45.0 33.0 6.2 4.3
C19A 175 41.7 25.8 12.3 8.7
C19B 286 65.9 47.6 12.3 8.7
C19K 270 67.2 47.6 12.3 8.7
C1AA 215 37.4 38.8 12.3 8.7
C1AB 355 74.4 72.4 15.3 9.5
C1AK 301 74.4 71.4 12.3 8.7
C1BA 349 64.5 68.1 15.3 9.5
C1BB 650 130.0 132.5 21.7 35.4
C1BK 473 122.9 126.8 15.3 9.5
C1CA 650 85.0 129.1 21.7 35.4
C1CB 950 186.1 263.6 21.9 35.4
C1CK 950 186.1 263.8 21.9 35.4
C1DA 680 121.4 171.3 21.7 35.4
C1DB 862 176.0 186.0 21.7 35.4
C1EB 1213 451.0 262.0 21.7 35.4
Section 1, Page 8
Diagnostic Chart
SMOTPMYS SESUACELBISOP
1. NO DISCHARGE 1. 2. 3. 7. 26. 28. 29.
2. LOSS OF CAPACITY 3. 4. 5. 6. 7. 8. 9. 10. 22. 13. 16. 17. 21. 22. 23. 29
3. IRREGULAR DISCHARGE 3. 4. 5. 6. 7. 8. 13. 15. 29.
4. PRIMING LOST AFTER START 3. 4. 5. 6. 7. 8. 13. 15
5. PUMP STALLS AT START UP 8. 11. 24.
6. PUMP OVERHEATS 8. 9. 11. 12. 18. 20
7. MOTOR OVERHEATS 8. 11. 12. 15. 18. 20.
8. EXCESSIVE POWER ABSORBED BY PUMP 8. 11. 12. 15. 18. 20
9. NOISE AND VIBRATION 3. 4. 5. 6. 7. 8. 9. 11. 13. 15. 18. 19. 20. 22. 23. 27. 31
10. PUMP ELEMENT WEAR 9. 11.
11. EXCESSIVE GLAND OR SEAL WEAR 12. 14. 25. 30.
12. GLAND LEAKAGE 13. 14.
13. SEIZURE 9. 11. 12. 20.
SESUACFOTSIL SNOITCALAIDEMER
1. INCORRECT DIRECTION OF ROTATION 1. REVERSE MOTOR
2. PUMP UNPRIMED 2. BLEED SYSTEM OF AIR/GAS
3. INSUFFICIENT N.P.S.H. AVAILABLE 3. INCREASE SUCTION HEAD OR REDUCE SPEED/TEMP.
4. PRODUCT VAPORISING IN SUPPLY LINE 4. INCREASE N.P.S.H. AVAILABLE (SEE 3 ABOVE)
5. AIR ENTERING SUPPLY LINE 5. CHECK PIPE JOINTS/GLAND ADJUSTMENT
6. INSUFFICIENT HEAD ABOVE SUPPLY VESSEL OUTLET 6. RAISE VESSEL/INCREASE PIPE SIZE
7. FOOTVALVE/STRAINER OBSTRUCTED OR BLOCKED 7. CLEAN OUT SUCTION LINE/VALVES
8. PRODUCT VISCOSITY ABOVE RATED FIGURE 8. DECREASE PUMP SPEED/INCREASE TEMP.
9. PRODUCT TEMP. ABOVE RATED FIGURE 9. COOL THE PRODUCT
10. PRODUCT VISCOSITY BELOW RATED FIGURE 10. INCREASE PUMP SPEED/REDUCE TEMP.
11. DELIVERY PRESSURE ABOVE RATED FIGURE 11. CHECK FOR BLOCKAGES IN DELIVERY LINE
12. GLAND OVERTIGHT 12. ADJUST GLAND SEE O&M INSTRUCTIONS
13. GLAND UNDERTIGHT 13. ADJUST GLAND SEE O&M INSTRUCTIONS
14. GLAND FLUSHING INADEQUATE 14. CHECK FLUID FLOWS FREELY INTO GLAND
15. PUMP SPEED ABOVE RATED FIGURE 15. DECREASE PUMP SPEED
16. PUMP SPEED BELOW RATED FIGURE 16. INCREASE PUMP SPEED
17. BELT DRIVE SLIPPING 17. RE-TENSION BELTS
18. COUPLING MISALIGNED 18. CHECK AND ADJUST ALIGNMENT
19. INSECURE PUMP/DRIVE MOUNTING 19. CHECK AND TIGHTEN ALL PUMP MOUNTINGS
20. SHAFT BEARING WEAR/FAILURE 20. REPLACE BEARINGS
21. WORN PUMP ELEMENT 21. FIT NEW PARTS
22. RELIEF VALVE CHATTER 22. CHECK CONDITION OF VALVE/RENEW
23. R.V. INCORRECTLY SET 23. RE-ADJUST SPRING COMPRESSION
24. LOW VOLTAGE 24. CHECK VOLTAGE/WIRING SIZES
25. PRODUCT ENTERING PACKING AREA 25. CHECK PACKING CONDITION AND TYPE
26. DRIVE TRAIN BREAKAGE 26. CHECK AND REPLACE BROKEN COMPONENTS
27. NEGATIVE OR VERY LOW DELIVERY HEAD 27. CLOSE DELIVERY VALVE SLIGHTLY
28. DISCHARGE BLOCKED/VALVE CLOSED 28. REVERSE PUMP/RELIEVE PRESSURE/CLEAR BLOCKAGES
29. STATOR TURNING 29. REPLACE WORN PARTS/TIGHTEN UP STATOR BOLTS
30. STUFFING BOX ‘EATS’ PACKING 30. CHECK FOR WORN SHAFT AND REPLACE
31. VEE BELTS 31. CHECK AND ADJUST TENSION OR REPLACE
Section 2, Page 1
Drawing Reference Numbers
C1XK AND ABOVE EXCLUDING 4 - STAGE MODELS
DRG. DESCRIPTION
DRG. DESCRIPTION
REF REF
01A TAPER PLUG

BODY-STD C.I. P201
10A TAPER PLUG
MECHANICAL SEAL P202
15A HEX. SOC. SETSCREW
THROWER GUARD P203
20B
GASKET-GLAND
22A P401 TORL SEAL RING
STATOR-MTM NITRILE RUBBER
23A P402 TORL SEAL RING
SUCTION CHAMBER
23B P403 SPIRAL RET.RING
SUCT CHAMB EXTENSION
24A P404 SPIRAL RET.RING
END COVER
25A P405 TIE-SEALING COVER
ROTOR
26A P406 TIE SEALING COVER
COUPLING ROD
28A
SEALING COVER
28B P501 TAPER PLUG
SEALING COVER P502
29A TAPER PLUG
COUPLING ROD PIN P503
29B HEX. NUT
COUPLING ROD PIN
29C P504 WASHER
SHAFT PIN P505
32A DRIVE SHAFT SNGL. COIL SPR. WASHER
42A P506 HEX. NUT
THROWER
62A P507 WASHER
SUPPORT FOOT P508
65A SNGL. COIL SPR. WASHER
MECH SEAL CARRIER P509
66A TORL SEAL RING
ABUTMENT RING P510
74A TORL SEAL RING
SLEEVE (ROTOR-SHAFT) P519 TAPER PLUG
74B
95A SLEEVE (ROTOR-SHAFT) P520 HEX. HD. BOLT
TIE ROD P521 HEX. NUT
P104 P522 WASHER
P105 HEX. HD. BOLT P523
HEX. NUT SNGL. COIL SPR. WASHER
P106
WASHER P601
P107 HEX HD BOLT
P109 SNGL. COIL SPR. WASHER P602 SNGL. COIL SPR. WASHER
HEX NUT P603 WASHER
P604 HEX. NUT
IMPORTANT NOTE
THE DRAWING REFERENCES SHOWN GIVE THE DESCRIPTION OF ALL THE PARTS DETAILED ON THE SECTIONAL
DRAWINGS IN THIS SECTION OF THE BOOK. THEREFORE SOME OF THE REFERENCES MAY NOT BE SHOWN ON
ANY ONE.
Section 3, Page 1
Issued – September 2008
Drawing Reference Numbers
4 - STAGE MODELS C13D TO C18D
DRG. DRG.
REF. REF.
DESCRIPTION DESCRIPTION
01A BO
DY P501 HEX NU
T
01B BEARI
NG HO
U
SI
NG P502 SPRI
NG W ASHER
01C BO
DY ADAPTO R P503 PLAI
N W ASHER
06A NAMEPLATE (SO G) P504 PLAI
N W ASHER
06B NAMEPLATE (DO G) P505 SPRI
NG W ASHER
10A MECHANICAL SEAL/GLAND PACKING P506 HEX NUT
15A THRO
W ER GU
ARD P507 HEX HEAD SCREW
20A GASK
ET-GLAND P508 PLAI
N W ASHER
20B GASK
ET-GLAND P509 PLAI
N W ASHER
2A STATO R P510 SPRI
NG W ASHER
23A SU
CTI
O N CHAMBER P5 1 HEX NU
T
23B SUCTION CHAMBER EXTENSION P512 STUD
24A END CO VER P513 PLAI
N W ASHER
25A RO
TO R P514 SPRI
NG W ASHER
26A CO
U PLI
NG RO
D P515 HEX NU
T
28A SEALI
NG CO
VER P516 HEAD SCREW
28B SEALI
NG CO
VER P517 PLAI
N W ASHER
29A CO
U PLI
NG RO
D PI
N P518 PLAI
N W ASHER
2 9B CO
U PLI
NG RO
D PI
N P519 SPRI
NG W ASHE R
29C SHAFT PI
N P520 HEX NU
T
32A DRI
VE SHAFT P5 2 PLAI
N W ASHER
42A THRO
W ER P526 TAPER PLU
G
62A SU PO
RT FO
O T P527 TAPER PLU
G
65A MECH SEAL CARRIER/GLAND SECTION P528 TAPER PLUG
6A ABU
TMENT RI
NG P529 SEAL RI
NG
75A RO R/SHAFT SL EVE
TO P530 STU
D
75B RO R/SHAFT SL EVE
TO P531 SPRI
NG W ASHER
76A ADAPTO
R FLANGE P532 PLAI
N W ASHER
95A TI
E BAR P5 3 HEX NU
T
P104 HEX HEAD BO
LT P534 STU
D
P105 HEX NU
T P535 HEX NU
T
P106 PLAI
N W ASHER P536 PLAI
N W ASHER
P107 SPRI
NG W ASHER P537 SPRI
NG W ASHER
P108 SPRI
NG W ASHER P538 TO
RL SEAL RI
NG
P109 HEX NU
T P539 TO
RL SEAL RI
NG
P201 TAPER PLU
G P601 HEX HEAD BO
LT
P202 TAPER PLU
G P602 SPRI
NG W ASHER
P401 SEAL RI
NG P603 PLAI
N W ASHER
P402 SEAL RI
NG P604 HEX NU
T
P403 SPIRAL RETAINING RING
P404 SPIRAL RETAINING RING
P405 TIE - SEALING COVER
P406 TIE - SEALING COVER
IMPORTANT NOTE
ANY ONE.
Section 3, Page 2
C2XB AND BELOW EXCLUDING 4 - STAGE MODELS
DRG. DESCRIPTION DRG.

DESCRIPTION REF. REF.
0 1A BO
DY P2 01 PLU
G
06A NAMEPLATE (SO
G) P202 PLU
G
06B NAMEPLATE (DO
G)
1 0A MECHANI
CAL SEAL P401 SEAL RING
15A THROWER GUARD ASSEMBLY P402 SEAL RING
20A GASK
ET GLAND P 40 3 SPI
RAL RETAI
NI
NG RI
NG
20B GASK
ET GLAND P404 SPI
RAL RETAI
NI
NG RI
NG
20C SEAL RI
NG P405 TI
E
2 A STATO
R P406 TI
E
23A SU
CTI
O N CHAMBER
23B SUCTION CHAMBER EXTENSION P501 PLUG
24A END CO
VER P502 PLU
G
25A RO
TO
R P503 PLU
G
26A CO
U PLI
NG RO
D P504 HEXAGO
NAL NU
T
28A SEALI NG CO
VER P505 SPRI
NG W ASHER
28B SEALI
NG CO
VER P506 FLAT W ASHER
29A CO
U PLI
NG RO
D PI
N P507 HEXAGO
NAL NU
T
29B CO
U PLI
NG RO
D PI
N P508 SPRI
NG W ASHER
29C SHAFT PI
N P50 9 F L A T W AS H E R
32A DRI
VE SHAFT P510 HEXAGO
NAL HEAD BO
LT
42A THRO
W ER P51 SPRI
NG W ASHE R
47A ADAPTER PLATE P512 FLAT W ASHER
47B ADAPTER PLATE P513 HEXAGO
NAL NU
T
62A SU
PPO
RT FO
O T P 5 15 SEAL RI
NG
65A MECHANICAL SEAL CARRIER
6 A ABU
TMENT RI
NG P601 HEXAGO
NAL HEAD BO
LT
75A SLEEVE P602 SPRI
NG W ASHER
75B SL EE VE P 603 F L A T W AS H E R
95A TI
E BAR P604 HEXAGO
NAL NU
T
P101 HEXAGO
NAL HEAD BO
LT
P102 FLAT W ASHER
P104 HEXAGO
NAL HEAD BO
LT
P105 HEXAGONAL NUT
P106 FLAT WASHER
P107 SPRING WASHER
P108 FLAT WASHER
P109 HEXAGONAL NUT
IMPORTANT NOTE
ANY ONE.
Section 3, Page 3
SQUARE INLET - ALL MODELS
DRG. DESCRIPTION DRG.

DESCRIPTION REF. REF.
01A BODY P104 HEX BOLT

06A NAMEPLATE P105 HEX NUT
10A MECHANICAL SEAL P106 FLAT WASHER
15A THROWER GUARD P107 SPRING WASHER
20A INSPECTION COVER GASKET P108 SPRING WASHER
20B GLAND GASKET 22A STA- P109 HEX NUT
P201 TAPER PLUG
TOR
P202 TAPER PLUG
23A THROAT
24A END COVER P203 GRUB SCREW P401 O
25A ROTOR RING
27A COUPLING ROD BUSH P402 O RING
27B COUPLING ROD BUSH P403 SPIRAL RETAINING RING
28A SEALING BOOT P404 SPIRAL RETAINING RING
28B SEALING BOOT P405 SEALING BOOT TIE
29A COUPLING ROD PIN P406 SEALING BOOT TIE
29B C OUPLING ROD PIN P501 TAPER PLUG
29C DRIVE SHAFT PIN P503 HEX NUT
32A DRIVE SHAFT P504 FLAT WASHER
38A CONVEYOR P505 SPRING WASHER
42A THROWER
59A INSPECTION COVER
62A SUPPORT FOOT
65A GLAND SECTION
66A ABUTMENT RING

75A SHAFT SLEEVE
75B ROTOR SLEEVE
95A STATOR TIE BAR
P101 HEX SCREW
P102 FLAT WASHER
P103 STUD
IMPORTANT NOTE
ANY ONE.
Section 3, Page 4
Pump Coding
Monobloc Compact C
Range
Monobloc Compact Square S
Inlet Monobloc C 1
Design Mk No Monobloc (January 2007) 2
1.3m³/h @ 1750 rpm 1 1
3.3m³/h @ 1750 rpm 2
10m³/h @ 1500 rpm 3
13m³/h @ 1500 rpm X
22m³/h @ 1000 rpm 4
Size 37m³/h @ 800 rpm 5
57m³/h @ 700 rpm 6
79m³/h @ 600 rpm 7
97m³/h @ 500 rpm 8
125m³/h @ 450 rpm 9
165m³/h @ 400rpm A
225m³/h @ 350 rpm B
Single stage Two X
stage Four stage A
Stages B
Single stage - extended D
pitch Cast Iron K
Stainless steel C
Casing Material
Code 1 S
Code 5 1
Rotating Parts Code 8 5

1 Mk 0 (Oversized) 8
Mk1 (Standard)
0
Mk3 (Temperature)
1
Rotor Mk No Mk5 (Temperature)
3
5
Stator Material RA, RR etc. R
Mechanical Seal MP
Seal Type
Packed Gland
A
Refer to product manual section 2 & 3, B
Build Op- drive selections
H
tion / /
Variation For special requirements contact Mono Pumps Ltd A1 2 3
Example A C 8 1 R M A
Code 8 Rot Parts
Mechanical Seal
Build Option A
Single Stage
Design Mk 1
Nitrile Stator
Mk 1 Rotor
Cast Iron
C Range
Size 0X
Note: Refer to Pre Selection Table for availability of pump models.

1 : For other material options please contact Mono Pumps Limited.
Section 3, Page 5
Dismantling & Assembly Diagrams
COMPACT RANGE
Section 4, Page 1
C21B - C22B
Section 4, Page 2
ALL 4 - STAGE MODELS

FROM C13D TO C18D
COMPACT RANGE
Section 4, Page 3
COMPACT RANGE
SQUARE INLET MODELS
Section 4, Page 4
SUPPORT - SLING
2
DISMANTLINGROCEDURE
P
Section 4, Page 5
SUPPORT - SLING
C22D
1
DISMANTLINGROCEDURE
C22D
P
Section 4, Page 6
2
C13D TO C18D
4 - STAGE
Section 4, Page 7
MODELS ONLY
Section 4, Page 8
4a
Section 4, Page 3
Only applicable if using packed gland pump

4b
Section 4, Page 10
d
55
c
5a
5b
C1XK AND ABOVE
Section 4, Page 11
5A
5B5C5D
C12 - C22B
Section 4, Page 12
d
5c5
5A
5b
C23A
Section 4, Page 13
Issued – July 2010
SQUARE INLET
Section 4, Page 14
C1XK AND ABOVE
6d
6c
6b
6a
Section 4, Page 15
6A
C21B - C22B
6B6C6D
Section 4, Page 16
C2XA - C2XB
7
C21B - C23K
Section 4, Page 17
NOT APPLICABLE TO SIZES BELOW C1XK
Section 4, Page 18
C18B AND C16D ONLY

OR
8
Section 4, Page 19
9a
Section 4, Page 20
ONLY APPLICABLE IF USING PACKED GLAND PUMP

9b
Section 4, Page 21
BARESHAFT ONLY
10
Section 4, Page 22
1a
ASSEMBLY
Section 4, Page 23

1b
Section 4, Page 24
0.075mm
BARESHAFT ONLY
Section 4, Page 25
C18B AND C16D

OR
3a3b
Section 4, Page 26
NOT APPLICABLE TO SIZES BELOW C1XK
4b
Section 4, Page 27
C2XA - C2XB
OR
C21B - C23K
4b4c
Section 4, Page 28
C21B - C22B 5b
5A

Section 4, Page 29
=
=
CORRECT INCORRECT
stainless steel coupling rod ALIGNMENT MARKS

.or flighted coupling rod
Square Inlet Models.
6
7
EXCLUDING

Section 4, Page 30
9
1011 12
Correct tool available from Mono

Part Number: 80D1331
5
C21B - C22B
ONLY

Section 4, Page 31
=
=
CORRECT INCORRECT
Only applicable if using

stainless steel coupling rod. ALIGNMENT MARKS
6 7 8

C21B - C22B 10 11

Section 4, Page 32
ONLY
11

13
C1XK AND ABOVE
Section 4, Page 33
13
C21B - C22B
ONLY
Section 4, Page 34
13
SQUARE INLET
ONLY
Section 4, Page 35
14a
Section 4, Page 36

14b
Section 4, Page 37
15
4 - STAGE MODELS ONLY
Section 4, Page 38
17
C1XK AND ABOVE
16
Section 4, Page 39
17
4 - STAGE MODELS
16
Section 4, Page 40
17
C22D
16
C22D
Section 4, Page 41
Setting Length - Mechanical Seal
SETTING
LENGTH L
‘X’
DIAMETER
SHAFT
Setting
Shaft Diameter Seal Working
Pump Size Drive Type Seal Part No. Distance ‘X’
mm Length L mm
mm
C21BC12D- 42.5
C2A2CB
NOTE: All seal working lengths are to DIN L1K dimensions.

This table is not to be used for standard or DIN L1N working length seals.
All seals use ‘M’ type seat except for 85mm which uses ‘BS’ type or ‘M’ type.
This table is not necessarily compatible with any other seal type - check with Mono Pumps Technical Dept.
Section 4, Page 42
Setting
mm Length L mm mm
C22D
C23A
C23B
Pin Joint 32 M032139G 42.5 16
C23K
C2XA
C2XB
C1XK
C13D
C14A
C14B 45.0 41
C14K
C15A
C15K
C1XD
C14D
C15B 47.5 34.5
C16A
C16K
C15D
C16B
C17A
C17B
C17K Pin Joint 65 M065139G 52.5 33.5
C18A
C18K

Section 4, Page 43
Setting
mm Length L mm
mm
C16D
C18B
C19A 33
Pin Joint 85 M085139G 60.0
C19B
C19K
C1AA
C1AK
C17D
C1AB
C1BA Pin Joint 85 M085139G 60.0 58
C1BK

Section 4, Page 44
Exploded Views - Packed Gland
01A
08A
10A
65A
32A
20B
23A
Section 4, Page 45
BEARING HOUSING ONLY

Section 4, Page 46
Exploded Views
P407
P122 P120
P123
32A
P109 P105 P121

P108
01B P124
P125
P107
P112
15A
P106
15A
06A/06B P113 11A

P420
P421
01A P111
35A
P101 P110
C1XK AND ABOVE
EXCLUDINGC18B, C1AB, C1BA & C1BK

Section 4, Page 47
22A 29C
32A
Exploded Views
24A P404
P402
P506 75B 23A 42A
P508
P507 28B
P406
26A P203
P201
95A 29B P202
P519 P701
P702 P522P520
P703
P405 59A
P505 62A 28A 20C
75A
P401
P403 29A 20B P106
P503 P504 P107 P101 06A/B
P502 P105
P202
65A P201
01A
25A 10A
66A
P603 P602 P604
P510
15A
P522
P523 15AP102
23B P521 P108
P501 P109
P601 P106 P104

SQUARE INLET

Section 4, Page 48
42A
22A
24A 32A
Exploded Views
29C
95A P403
75A P201
29A P202 65A
27A
62A
P504 P401
P203 P201
29B 28A 66A P202
23A
P503 27B P405 20B
P519 38A
P404 10A
75B
P406
28B
25A P402
P107 P105
P106 P106
P107
P105 P109
P108
P102
01A P103
59A
20A
P703
P501 P702
15A
P701
P704
P101
P106
P104
4 - STAGE
EXCLUDING
C13D C16D
TO C18D

Section 4, Page 49
29C
Exploded Views
22A 32A 23A

42A
P404
24A P402
75B
28B 20B
P406 P202
P523
29B
95A P201 P524
26A
P525
29A P520
P526 P203 P519 06A/B
P405 P518
28A P539 P528
75A P101
62A 65A
P401 23B 01A
P403
10A
P501 66A
P538 15A P601
P502
P503
76A P517
P516
25A P515 P102
P514 P108
P513 P109
P522
P512 P527 P521
P604
P602 15A
P603
4 - STAGE C16D

Section 4, Page 50
32A
22A
P404 29C
P402
75B
Exploded Views
28B
42A
29B 23A
24A
P528
26A
P202
29A P406 P201
95A 65A P519
P526 20B P520

28A P518
P528
75A P528
P536
P501 10A P537
P502 P401 P535
P503 P403 P405 66A
62A P507 P201
P509 P529
P508 P202
P511
23B
P510
06A/B
25A P109
P102
P538 P108 01A
76A
P517
P515P516 15A
P514 P601
P513
P527
P512 01B
20A
P101
P530 P533
P531
P603 P532
15A
P602
P534 P604
COMPACT RANGE
C18B ONLY

Section 4, Page 51
29C
Exploded Views
22A
32A
24A P404
P402
P506 75B 23A 42A
P508
P507 28B
P406
P101 06A/B
26A P203
P201
95A 29B P202 01A
P519 P701
P702 P522P511
P703
P405 59A P603 P602 P604
P505 62A 28A 20C
75A
P401 15A
P403 29A 20A P106
P503 P504 P202 P107
P201 P502 P105 P526 15A P102
P108
65A P109
25A 10A
66A
P510 20B P601 P525 P524
P513
P512
P514
P501 23B P52701BP523
29C
COMPACT RANGE 22A
C1AB ONLY 32A

P404
Section 4, Page 52
P402 29B
75B
24A P501 28B

95A P406
Exploded Views
26A
P522
P520 P405
P504 P521 28A 42A
P503 62A
P401
P403 75A
P505 P519 P101 06A/B P601 P603
15A P602
P604
P105
29A P107
P106
P202
P201
P202
P108
20B
P109
10A
66A 65A P201 P202 01A 15A
23A
P106
P104
P502 P507 P508 P506

29C
22A
32A
COMPACT RANGE
C1BA & C1BK ONLY
P404
29B
Issued –July 2010

P402
Section 4, Page 53
75B
24A
28B
P406
95A
Exploded Views
26A
P405 42A
P501 28A
75A
P504 P401 P101 06A/B P601 P603
P505 P403 15A P602
P503 P604
P105
29A P106
P202 P107
P201
P202 P102
P108
20B P109
10A
66A 65A P201 P202 01A 15A
23A
P106
P104
P502 P507 P508 P506

C21B - C22B
Section 4, Page 54
29C
Issued – November 2011

29A
32A
P109 P108 06A/B 42A

Exploded Views
22A
26A
P501
P403 P406
P604P603P602
24A P202
28A P201
P404
20A
62A
P405
95A
10A
P505
29B 66A
25A
23A 65A01A P107 P106 P105 P601 15A P102 P101
P502
P504P506
P509P508P507 P104P106
COMPACT RANGE
C22D ONLY

Section 4, Page 55
29C
20C
32A
Exploded Views
47B 29A
P403
P401
75A
P109 06A/B42A
28A
22A
P406
P108
26A
95A P601
P405
P201
47A 28B
P202 P102
75B
P402 20A
20B P101
P501 10A
P404
66A
15A
62A 25A
23A
01A
65AP107P106P105P604 P602 P603
29B
P502
24A
P504 P505 P506
P509P507P106
P508 P104
29C
C23A - C23K 95A
32A
24A
P506 P403
P505 P401

29B
Section 4, Page 56
P504
75A
22A
62A 28A
P406
26A
Exploded Views
P501
P405
28B
75B
P402
06A/B
P404 P109 P604 42A
P108
P601
25A P603
29B P602
15A P104
20A P107
P105
65A P102
P101
10A
66A
01A
P202
23A P201 15A
P509
P508
P507
P502
COMPACT RANGE
C2XA - C2XB ONLY

Section 4, Page 57
29C
29A
32A
P10906A/B42A
P403
Exploded Views
P401
95A 75A P604
P108 P603
28A P602
P406
P202
22A 26A P201
P405 20A P102
24A 10A
28B
66A P101
75B 23A
P402
P503
P404
65A 01A P601 P105 P106 P107 15A
25A P515
23B
29B
P504P505P50662AP501 P511P512P513
P502
P512P104P106
P510
P509P508P507
Section 4, Page 58
Drive Shaft (Motor shaft end)
Threads to be
sealed with loctite
or equivalent
5910
Drive Shaft Assembly with Plug
(Coupling Rod end) Cap Head Screw

Grade 12.9
NOTE:
jacking bolt to be used to aid removal

of the drive shaft from the gearbox shaft.
NOTE: ENSURE THE CAP HEAD SCREW IS TIGHTEND &

Torque Tightening Figures
BODY/SUCT. CHAMBER STATOR TIE BARS

PUMP SIZE
Nm Nm
P526 P105 P530 P506 P503
C1XK 10 10
C14A 11 11
C14K 11 11
C14B 11 11
C15A 11 11
C15K 21 11
C15B 21 11
C16A 21 24
C16K 21 24
C16B 36 24
C17A 36 24
C17K 36 24
C17B 36 24
C18A 36 40
C18K 36 40
C18B 50 - 36 40
C19A 90 75
C19K 90 75
C19B 90 75
C1AA 90 75
C1AK 90 75
C1AB 90 75
C1BA 176 120
C1BK 176 120
Note: Torque tolerances are +/-5% of stated nominal figures.
Section 5, Page 1
4 - STAGE C13D TO C18D
PUMP STATOR TIE SCTN.

BODY/SUCTION CHAMBER ADAPTOR
SIZE BARS CHMB./SCTN.
FLANGE
CHMB. EXT.
Nm Nm
m P515 m P520
P533 P105 P535 P501
C13D 1 1 1 1
C1XD 21 1 1 1
C14D 21 21 1 1
C15D 40 40 21 21
C16D 50 - 40 75 40 40
C17D 176 75 75 -
C18D 176 120 75 -
Section 5, Page 2
C2XB AND BELOW
SUCTION CHAMBER/
PUMP SUCTION EXT. STATOR TIE BARS
SIZE mN mN
P105 P504, P507
B12C 01 4
D12C 01 4
A2C 01 4
B2C 01 4
D2C 01 4
A32C 01 4
B32C 01 4
K32C 01 4
AX2C 01 01
BX2C 1 01
Section 5, Page 3
Pin Joint Lubrication
JOINT LUBRICATION NON-FOOD APPLICATIONS ONLY

PUMP FOOD
CAPACITY (APPROX.) PER
MODEL APPLICATIONS
JOINT (ml)* RECOMMENDED SUITABLE ALTERNATIVE
C21B
C21D 6
C22A
C22B
C22D
C23A
C23B
C23K 12
C2XA
C2XB MOBILITH
C1XK SHELL
SHC 007
RETINAX
SEMI-FLUID CSZ
C13D
GREASE
C14A
C14B 22
C14K
C15A
C15K
C1XD
C14D
C15B 45 KLUBERSYNTH
KLUBEROIL
C16A GH6-460
4 UHI 460
C16K OIL
C15D MOBIL GEAR

C16B OIL SHC 320
C17A
C17B 55
C17K
C18A
C18K
C16D
C18B
C19A
95
C19B
C19K
C1AA
C1AK
C17D
C18D
C1AB 175
C1BA
C1BK
C1BB
C1CA 620
C1DA
C1CB
C1CK
C1DB 1600
C1EB
Section 5, Page 4
Issued – January 2012
Recommended Lubrication & Service Intervals
FOOD
ALL APPLICATION SERVICE
COMPONENTS APPLICATIONS
EXCEPT FOOD COMMENTS
ONLY
INSPECT AND
LUBRICATE AS
PUMP DRIVE
SEE SECTION 5 PAGE 4 NECESSARY EVERY
JOINTS
4000 OPERATING
HOURS
INSPECT AND RE
PUMP BEARINGS GREASE IF
BP Energrease LC2 OR EQUIVALENT
(WHERE FITTED) NECESSARY EVERY
12 MONTHS
GEARED DRIVERS
AS RECOMMENDED BY THE MANUFACTURER
(WHERE FITTED)
NOTE: ABOVE SERVICE AND LUBRICATION INTERVALS ARE FOR GUIDANCE ONLY TO
ENSURE MAXIMUM COMPONENT LIFE. PUMP WILL OPERATE FOR CONSIDERABLY LONGER
PERIODS WITHOUT ATTENTION DEPENDING ON SERVICE CONDITIONS
Section 5, Page 5
UK and Europe
Mono Pumps Ltd, Martin Street, Audenshaw

Manchester, M34 5JA, England
T. +44 (0)161 339 9000 E.
info@mono-pumps.com
Americas
Houston, Texas 77040, USA

T. +1 281 854 0300 E.
inquire@mono o.com
Ing. Huergo 2239 - B1842GGW

Monte Grande
Buenos Aires
Argentina
T. +54 4296 8997
F. +54 4284 0323
Australasia
Mono Pumps (Australia) Pty Ltd

75 Frankston Gardens Drive, Carrum Downs
Victoria 3201, Australia
T. +61 (0)3 9773 7777 E. oz-
sales@mono-pumps.com
Mono Pumps (New Zealand) Ltd

PO Box 71-021, Fremlin Place, Avondale
Auckland 7, New Zealand T. +64 (0)9
829 0333 E. info@mono-pumps.co.nz
Asia
Mono Pumps Ltd, Building 4 & 5

No. 1250Sicheng Road
Madong Industrial Park, Malu, Jiading District
Shanghai 201801, P.R. China
T. +86 (0)21 3990
4588 E. monoshanghai@
nov.com
www.mono-pumps.com
OPERATION MANUAL
Wastewater treatment plant
Type : GPL 15
Serial Nr. : W10286-016

Year : 2017

Phone: 0031 (0)543-531030
Fax: 0031 (0)543-519089
Edition: 21-02-2017
Type: GPL 15
OHW: W10286-016

2.1. Technical data. 2.1 – 2.2
2.2. Auxiliary equipment. 2.2
2.3. Necessary tools and makeshifts. 2.2
2.4. Flow sheet. 2.2
3. Safety aspects.
3.1. Incorporated safety measures. 3.1 – 3.2
3.3. Personal protection. 3.2
4. Installation.
4.2. Mounting instructions. 4.2
4.3. Connections. 4.2
5. Directions for use.
5.1. Process description. 5.1 – 5.2
5.2. Item description.
P1: Influent compartment. 5.2
P2: Plate pack (optional). 5.3
P3: Static sludge thickener. 5.4
P4.1: Height adjustable effluent discharge. 5.5
P4.2: Effluent measurement. 5.6
P5: Skimmer drive, chain with skimmer blades. 5.7 – 5.9
P6: Sludge collection cone. 5.9
P7: Sediment discharge valve. 5.10
P8: Recirculation pump. 5.11
P9: Recirculation system. 5.12 – 5.13
P10: Pneumatic control panel. 5.14 – 5.15
5.3. Start up / timer adjustments / adjustments. 5.16 – 5.18
5.5. Putting out of order. 5.19
6.1. Qualification of maintenance personnel. 6.1
6.2. Safety measures and risks during maintenance. 6.1 – 6.2
6.3. Maintenance. 6.2 – 6.3
6.4. Cleaning. 6.3
7. Malfunctioning and repair.
7.1. Complaint table. 7.1 – 7.2
8.1. Re-use. 8.1
Type: GPL 15
OHW: W10286-016
1. INTRODUCTION
- The scope of this manual is to provide a reference document for operating the
installation.
out of order.
 Safety aspects.
free operation.
Figure 1.1 (GPL flotation unit).
1.1
Type: GPL 15
OHW: W10286-016
2. TECHNICAL INFORMATION.
2.1. TECHNICAL DATA.
Make: Redox
Type: Flotation unit GPL 15
Serial number: W10286-016
Capacity: 15 m³/hr.
Noise level: Approx. 72-77 dB(A) / 73-76 dB(C)
Heat development: Heat development is not present.
Radiation: Radiation is not present.
Vibrations: Vibrations are very low.
Temperature range surrounding: 5 C till 35 C
Temperature range product (wastewater): 3 C till 35 C
pH-range of the wastewater at the inlet of 6 till 9 pH
the flotation system:
The solid parts in the incoming wastewater may not be larger than 1 mm.
In case larger parts are present, these parts have to be removed by a
screening system before entering the flotation unit!
Electric:
Voltage: 400 Volt
Phases: 3
Cycles: 50 Hz.
Neutral: Yes
Control voltage: 24 Volt ac
Pneumatic:
Air supply at the inlet of the pneumatic 7 bar.
control panel:
Hose section: Ø15x12
Consumption: 0,5-8 l/min.
Dimensions:
Length x width x height Approx: 3.500 x 1.873 x 1.865mm.
Weight:
Weight empty: Approx. 850 Kg.
Weight full: Approx. 5.600 Kg.
Connections:
Skimmings: DN 100 flange
Influent: DN 80 flange
Effluent: DN 100 flange
Sediment discharge: DN 80 flange
Materials:
GPL GPL 15: AISI 304
2.1
Type: GPL 15
OHW: W10286-016
Sediment discharge valve:

For more details, see datasheet sediment discharge valve.
Recirculation pump:
For more details, see datasheet recirculation pump.
Pneumatic control panel:

Make: Redox
Type: UNI-S-0,5-8
Drive skimmer:
For more details, see datasheet drive skimmer.
2.2. AUXILIARY EQUIPMENT.
To move the system, four (4) hoisting eyes are mounted on the installation.
2.3. NECESSARY TOOLS AND MAKESHIFTS.
 For start-up, maintenance and control no special tools are required.
2.4. FLOW SHEET.
Skimmings
Influent
Sediment discharge Effluent
Figure 2.1
2.2
Type: GPL 15
OHW: W10286-016
3. SAFETY ASPECTS.
3.1 INCORPORATED SAFETY MEASURES.
Keep all warnings readable, if necessary clean or replace it!
 The machine is built extremely stable and the measurement- and control components are
put on the right height and easy accessible places. Risks, which might appear during
normal operation, are eliminated due to constructive solutions as much as possible.
Attention for rotating sprocket wheels (or rolls).

Figure 3.1.1
This warning is placed near by the scraper.
Warning for automatic starting machine!

Figure 3.1.2
This warning is placed at the side of the installation near by the scraper, to prevent risk to get
jammed.
 At all times a maintenance switch must be placed and connected near the scraper
system. The scraper system must always be stopped and locked in a "safe
position" during maintenance, inspection near the scraper system or when the
safety requires this. Limbs can get jammed or ripped off when the installation is not
locked in a "safe position". For this and because of the low scraper speed the place
where the scraper blade passes the static sludge thickener is not shielded.
 When dangerous situations occur for people or installation, the emergency stop button
(figure 3.2) can be pushed for stopping the installation. These emergency stop buttons
must be placed and connected on the electrical control panel and near the scraper
system.
Figure 3.2
3.1
Type: GPL 15
OHW: W10286-016
 Start up the installation after pushing the emergency stop button.

When the installation is stopped because of an inexplicable reason, don’t start up the
installation immediately. It could be that someone has stopped the installation to adjust
something by hand or to maintain the installation and forgot to lock it in a "safe position"
to prevent unawares activation of the installation.
Unawares activation of the installation could cause serious injuries!
 Solve the cause of malfunctioning.

 Check if nobody works at the installation!
 Unlock the emergency stop button (figure 3.2) by turning it in the direction of the arrow.
Warning for consequences:
 Operating not in accordance with the safety prescriptions.

 Operating by inexperience and / or insufficient instructed personnel.
 Adjustments, modifications or alterations without the knowledge of Redox.
The consequences can be very extensive and in these cases the vendor (supplier) will be
safeguarded against any warranty, guarantee and / or liabilities.
In the first place the operator should always be informed about the kind of processing
substances. On this base the operator has to protect himself.
ATTENTION: The cleaned water (effluent) from the GPL flotation unit is NO DRINKING
WATER.
The allowed temperature for the system is mentioned at chapter 2.1 of this manual. If
temperatures outside this range can be expected, the system needs to be protected, for
example by installing the system inside a heated or cooled building.
The installation has to be placed in a frost-free environment. If not take the measurements
mentioned at chapter 4.2. “Mounting instructions”.
3.3. PERSONAL PROTECTION.
On the basis of the upper mentioned operators and working environment the operator has to
protect himself with safety-clothes.
For the GPL the operator needs the following safety-clothes:
 Safety clothes (chemical resistant).

 Safety shoes (chemical resistant).
 Safety glasses.
 Working gloves (chemical resistant).
3.2
Type: GPL 15
OHW: W10286-016
4. INSTALLATION.
4.1 TRANSPORT INSTRUCTIONS.
Transport.
For dimensions and weight see chapter 2.1 in this manual.
Transport by truck has to be in accordance with the following conditions:

 The truck needs to have sufficient stability to transport the installation.
 The installation has to be tied with bands or any applicable transport appliances to guarantee
correct and safe transport.
 During transport and hoisting the GPL needs to be empty.
 The GPL must be transported in a straight position.
Storage.
The GPL has to be placed in a frost-free environment. The entire unit including pumps must be
drained empty when freezing takes place. At the same time the GPL has to be protected against
any corrosive influences like seawater etc. All electrical components must be protected against all
weather influences.
Load and unload.
Redox supplies four (4) hoisting eyes for loading, unloading and erection of the GPL. The hoisting
eyes have to be bolted to the GPL. Before hoisting one has to check and crosscheck the hoisting
eyes and its fastening, to prevent risky situations and possible damage to the equipment during
hoisting. Hoisting accessories have to be of proven quality. The hoisting equipment may not
damage the installation, this to prevent risky situations and possible damage to the equipment
during hoisting. At no situation anybody may come in the hoisting area because falling products
can cause injuries. At no situation the GPL, which is constructed of stainless steel, may come in
contact with carbon steel since carbon steel scratches will cause corrosion of the stainless steel.
Figure 4.1 Figure 4.2
Hoisting Max. workload according to fig. 4.1 Max. workload according to fig. 4.2
eye (Per hoisting eye). (Per hoisting eye)
M16 700 Kg. 500 Kg.
Table 4.1.3
According to figure 4.2 the hoisting-angle may not be smaller then 60!
4.1
Type: GPL 15
OHW: W10286-016
4.2 MOUNTING INSTRUCTIONS.
Check the installation for damages, and check whether the functioning of all moving parts is correct
(direction of rotation?). Also check if all (design) conditions are fulfilled to ensure a correct
functioning of the installation. The Transport Company only can leave after inspection and signing
of the transport documents. Redox is not responsible for transport, load, or unload damages. The
Transport Company is responsible for these damages.
Foundation.
The system has to placed in a dry, frost-free environment and has to be levelled on a horizontal /
flat foundation. Install and cramp, the installation with the supplied wall-ties. (See the enclosed
reference general drawing / layout drawing in this manual).
If the installation has to be placed outside then the following measures has to be taken:
 Insulation of the installation, pipes and pumps

 Protection against rain(water)
 Put on heat-tracing on pumps and pipes
 Protect the system against freezing.
The installation is filled with water and is not frost-free, it can be placed outside when the
installation is empty.
Accessibility. (The below mentioned is only valid for standard systems):

There needs to be one (1) meter free space on all sides of the system to allow an unhindered
operation and maintenance. Make allowance for enough space for exchanging parts. This has to
be determined based on the plant and system location.
Overflow to the sewer:

For emergencies an overflow to sewer is required. With breakdowns it is then possible to work on
without stoppage. lf there is enough wastewater buffer capacity, there is no need to overflow to the
sewer.
Piping:
Take care that everything is connected according to the drawing(s).
4.3. CONNECTIONS.
Electric:
 For electrical connections between the electrical control panel and the drives, valves etc. see
NEN-EN 60204. Further see the electrical diagrams in this manual.
 The components, which belong to the installation, have to be connected in accordance with
national and local regulations, concerning water, electricity and sewerage etc.
 The main voltage must be stable, maximum tolerance ± 5%. During the start up procedure from
the installation, the voltage drop may not exceed the 5%, therefore calculate sufficient cable
cross-section and a circuit breaker suitable to withstand the start up current.
 Further see the electrical diagrams in this manual.
Pneumatic:
 Mount the speed regulator valves on the actuator from the sediment discharge valve.
 For pneumatic connections see chapter 2.1 of this manual and the pneumatic diagram.
4.2
Type: GPL 15
OHW: W10286-016
5. DIRECTIONS FOR USE.

One condition for optimal performance of the installation is a continuous influent flow towards
the installation and a continuous composition of the influent water. This means that the
dictated amount of waste water per minute / hour may not be exceeded since this can result in
a reduction of the effluent quality. This prevents "carry-over" of the installation. The correct
pump capacities and pipe sizes have to be determined.
5.1. PROCESS DESCRIPTION.
Wastewater is collected in a balancing pit or tank, from where the wastewater flows to the
separator (If chemical treatments are used, chemicals will be added to the water before
entering the separator). A recirculation pump (P8) adds some cleaned / treated recirculation
water to the inlet of the separator. The recirculation water is pressurised (approx. 6 bar) and
saturated with air. Under pressurised conditions the air will dissolve into the water. In the
separator de-pressurisation of the recirculation water takes place. As a result, fine air bubbles
of 30-60 microns are formed. These small air-bubbles easily clog to the waste / flocs in the
water and give buoyancy to the flocs. The small size of the air-bubbles is essential for the
efficiency of the flotation unit.
The wastewater enters the separator and passes the plate packs (P2) under laminar
conditions. Part of the floc/air-bubble conglomerate rises spontaneously to the water surface
without entering the plate packs, while the remaining is separated from the water in the plate
packs, leaving them in counter-current.
Side-view View A-A (with pressure pipe for

flocculator)
Figure 5.1 GPL (with manual recirculation system).
5.1
Type: GPL 15
OHW: W10286-016
Counter current
The cleaned water leaves the system over an adjustable weir.
Heavy sediment will sink to the base of the flotation system and will be discharged by the
settled sludge discharge system.
Buoyancy waste / flocs will be discharged by the skimming system (P5) and collected in the
flotation sludge cone (P6).
5.2. ITEM DESCRIPTION.
P1: Influent compartment.
Influent
View according to arrow P
Influentcompartment
Figure 5.2
The influent compartment (figure 5.2) is a compartment with several openings for an even
distribution of the wastewater over the GPL flotation unit.
5.2
Type: GPL 15
OHW: W10286-016
P2: Plate pack (optional).

(upper view)
influent effluent
skimmings
solids
Figure 5.3
The plate pack (figure 5.3) is in the separator to obtain an optimal removal of waste out of the
water.
When the plate pack is fouled, the plate pack needs to be cleaned. In case high-pressure is
applied for cleaning the plate pack, care should be taken that the water beam is never directed
straight on the edges of the plate pack, since this can result in irreparable damage to the plate
pack. A special sprinkle-lance for high-pressure water is designed for cleaning of the plate
pack. This sprinkle-lance can be put between the plates and the lamella plates can be cleaned
by moving this sprinkle-lance up- and downwards.
When the GPL flotation unit is not in operation, the unit needs to be filled with clean water.
Floating sludge removal system
Floated sludge is removed by the skimmer system and transported into the sludge collection
cone. This system contains a:
 Static sludge thickener.

 Effluent weir.
 Skimmer drive and chain with skimmer blades.
 Sludge collection cone.
5.3
Type: GPL 15
OHW: W10286-016
P3: Static sludge thickener.

Upper view
Front view
Figure 5.4
The floating sludge is collected in the sludge thickener (figure 5.4) where the sludge remains
some time to de-water. The longer the sludge remains in the sludge thickener the dryer the
sludge will become. The retention time depends on the amount of produced sludge, the water
level and the skimmer speed.
Attention: The sludge layer may not become thicker than the lowest part of the static
sludge thickener (see figure 5.5), else a carry-over of the sludge flocs can occur.
Chain
Scraper blade
Max. sludge
thickness
Static sludge
thickener
Figure 5.5
5.4
Type: GPL 15
OHW: W10286-016
P4.1: Height adjustable effluent discharge.
Figure 5.6 (Weir pipe)
The effluent weir (figure 5.6) is at the outlet side of the separator. Cleaned water flows towards
the adjustable outlet connection. Lowering and rising the weir can adjust the water level in the
separator. The water level affects the distance between the water level and skimmer blades, in
which the sludge layer is formed, and thus influences the sludge dry solids content.
Adjustments:
 Weir pipe: The weir height can be changed by pushing the upper part of the pipe up or
down.
 By lowering the water level, the de-watering time will increase and the sludge layer
becomes more dry.
 By rising the water level, the de-watering time will decrease and the sludge layer becomes
more wet.
5.5
Type: GPL 15
OHW: W10286-016
P4.2: Effluent measurement.
Figure 5.7 (Stainless steel pin in weir pipe).
One stainless steel measuring pin (figure 5.7) is mounted in the effluent compartment of the
GPL to detect if there is flow. Be sure that the end of the measuring pin is in contact with the
medium and not with steel or plastic. This pin must be connected with a 1 mm2 cross-section
isolated electrical wire to the level control relays in the main panel.
5.6
Type: GPL 15
OHW: W10286-016
P5: Skimmer drive, chain with skimmer blades.
chain pin with

locknut + washer
chain clearance
scraper plate
Figure 5.8
The skimmer drive is a motor that drives the chain with scraper blades (figure 5.8). The
scraper blades move the top layer of the sludge towards the sludge cone, where sludge is
collected. The speed of the skimmer can be in- or decreased depending on the sludge load.
When the skimmer from the GPL flotation unit is not in operation for a longer period
than 5 minutes the skimmer speed must be increased. This to prevent excessive build
up of the sludge layer.
Adjustments:
Skimmer drive:
 The speed of the skimmer drive can be controlled from the electrical control
panel if a frequency control is applied or by means of a manual operated
reducer if a mechanical variator is applied.
 By increasing the speed of the drive, more sludge is skimmed off and the
sludge becomes more wet.
 By decreasing the speed of the drive, less sludge is skimmed off and the
sludge becomes more dry.
Skimmer blades:
Mount the skimmer blades on the chain as mentioned below.

The ends of the skimmer blades are provided with holes. At one side a slotted hole, at the
other side a round hole is provided.
5.7
Type: GPL 15
OHW: W10286-016
 Place the skimmer blade on the chain.

 Mount the washer on the chain pin.
 Tighten the locknut on the chain pin with a tightening moment between
10 and 15 Nm (figure 5.8).
Unscrew the locknut a whole twist at the slotted hole side (figure 5.8.1). Unscrew the
locknut for half a twist at the round hole side (figure 5.8.2).
 After mounting the chain must move freely behind and ahead at the slotted hole side.
 After mounting the chain must move freely at the round hole side.
Figure 5.8.1 Figure 5.8.2
Remark, when the locknuts are tightened too tight the skimmer system can be
damaged!
 The distance between the scraper blades and the scraper plate can
be adjusted.
 The blade clearance can be changed by loosen the bolts and nuts on the
skimmer blades. The clearance between the reinforced glass fibre blades
and the cone must be approx. 0,5 mm. Redox has adjusted this. Heavy
scraping of the blades over the cone has to be avoided at all times.
 When too much sludge leaks under the scraper blades, the distance between
the scraper blades and the scraper plate has to be adjusted.
 If necessary clean the scraper blades with a brush or high-pressure water spray
system.
Chain:
 The chain must have the right tension. At the position between the chain
wheel and chain support, at the cleared waterside the tension can be
observed. At both sides of the unit the vertical clearance must be minimum 10
mm and maximum 40 mm. (see figure 5.8) when scraper is in operation. The
horizontal clearance is approx. 70mm. Redox has adjusted this, however the
chain will stretch in course of time especially in the start up period.
 Be aware that due to temperature the length of the chain can be influenced.
 The chain tension can be adjusted by moving the return chain wheel bearing.
Loosen the bolds and tighten the chain by turning the adjustment bolt.
5.8
Type: GPL 15
OHW: W10286-016
Adjusting the
chain tension
Figure 5.9
Attention: An incorrect tension of the chain can result in damage to the scraper system.
P6: Sludge collection cone.
See figure 5.1 at the beginning of this chapter.
The sludge removed from the top of the separator is collected in the integrated sludge cone.
From here, the sludge must be transported further by a pump or by gravity towards a sludge
buffer tank.
The type of level measurement for the sludge flow depends on the process. Several systems
are available and will not be mentioned here.
Avoid that sludge is building up at the walls of the cone. If necessary clean the cone with a
high-pressure water spray system.
5.9
Type: GPL 15
OHW: W10286-016
P7: Sediment discharge valve.
Figuur 5.10
A sediment discharge valve (figure 5.10) is mounted at the outlet of the sediment discharge
flange. This valve is time controlled and pneumatic operated. The settled sludge will be
discharged from the system by opening the bottom sediment discharge valve for a few
seconds.
Sludge discharge time:
The sludge discharge time is the time that the sediment discharge valve is open. This
discharge time must be set so that the valve is opened completely. This value is indicated in
the table for time adjustments in the electrical diagrams. But just enough to open the valve
(see arrow on the valve). This time depends on the actuating speed of the valve and the
amount of settled sludge that has to be discharged.
Actuating speed of discharge valve
The open / close speed from the valve can be controlled by adjusting the pneumatic speed
controls on the actuator. Opening the valve must be done as fast as possible; this is to cause
a "shock discharge" from the sludge outlet. Closing the valve must be slower; this is to prevent
" water back-slash" in the separator.
5.10
Type: GPL 15
OHW: W10286-016
P8: Recirculation pump.
Figure 5.11
A recirculation pump adds some cleaned / treated recirculation water to the inlet of the
separator. The recirculation water is pressurised and saturated with air. Under pressurised
conditions the air will dissolve into the water.
Pump gaskets:
Where the shaft comes out of the pump (figure 5.11), a gasket is mounted. lf this gasket is of a
rope type it must be tightened to prevent leaking. lt is normal that some water is leaking
through the gasket. This gasket is lubricated with water and should leak a bit to prevent dry
running. lf too much water is leaking, tighten the gasket a bit by fastening the bolds at the
outer side of the gasket clamp. See also specific manual for detail information in the manual
index chapter 8. lf a mechanical seal is mounted, no adjustments can be made (and have to
be made).
5.11
Type: GPL 15
OHW: W10286-016
P9: The recirculation system.
pneumatic control panel
pressure cylinder
aeration valves
recirculation pump
Figure 5.13.1 (Manual recirculation system).
The recirculation system (figure 5.13.1) consists of the following parts:
 The recirculation pump (see chapter before in this user manual)

 The pressure cylinder with the recirculation water distribution system
 The pneumatic control panel (see chapter later on in this user manual)
The recirculation pump pumps the water out of the purified water compartment and towards
the pressure cylinder. The pump brings the recirculation water to a pressure of about 6.5 bars.
The air will be measured out in doses inside or after the pump, and it will saturate the
recirculation water. At these conditions the air will dissolve in the water. At the aeration valves
after the pressure cylinder, the water/air mixture will depressurise to about 1 bar. Very small air
bells will be formed (30-60 micron) as a consequence of this. The dimension of these air bells is
very important for the efficiency of the flotation process. Small air bells stick easily to bigger
particles or particles of the same dimension.
The pressure cylinder:
bleed valve
pressure cylinder
sampling tap
Figure 5.13.2.
As the water is transported through the pressure cylinder (figure 5.13.2) its pressure is
decreased. A pressure decrease takes place because of a drop in pressure in the aeration
valves after the pressure cylinder. The saturated air expands outside the water. This can be
seen when a milky fluid flows through the transparent hoses of the recirculation system. The
5.12
Type: GPL 15
OHW: W10286-016
mechanical effect is that the aeration valve starts vibrating which causes a crackling / rustling
noise.
The bleed valve

At the top of the pressure cylinder there is a bleed valve. This is needed to release the excess
of (large) air bells which build up in the pressure cylinder. This valve must be opened to such
an extent that water/air are constantly released, because, otherwise, the pressure cylinder fills
up with air and a disturbance of the process takes place because of these air bells that are too
large. In any case, a small quantity of water must flow through this valve. The air release tap
must be derated in such a way that the large air bells are slowly expelled through the hose.
The sampling tap

A sampling tap is mounted on the bottom of the pressure cylinder. A sample of the
recirculation water can be taken from here.
The manual aeration system:
Figure 5.14
In order to get the correct aeration, the pressure in the pressure cylinder must be equal to about
5 or 6 bars. The pressure can be regulated by means of the aeration valves. These are
positioned under the pressure cylinder. The stand of the aeration valves must be as uniform as
possible. This requires some experience. The most advantageous position will be found by
opening or closing the valves slowly. The water-air mixture must look like a milky fluid, with
microscopic small air bells. When all the valves are set upwards and the pressure is still higher
than 8 bars, then all the taps must be opened a little bit more.
5.13
Type: GPL 15
OHW: W10286-016
P10: Pneumatic control panel.
PNEUMATIC CONTROL PANEL (TYPE: UNI-S-7-75).
See the pneumatic diagram (drawing W10286-016 page 75).

The pneumatic control panel controls the following components.
 Sediment discharge valve.

 Air supply of the recirculation pump.
 Control valves of the clog-free aeration device.
 Coagulant safety valve.
 Non return valve.
Adjustments:
R1: Pressure switch main air supply set at 6,5 bar.

In case the main air supply pressure drops underneath 6 bar the unit will stop automatically.
Reset on main electrical panel.
R2: Pressure switch for recirculation.

This pressure switch acts on the pressure in the recirculation system. This switch controls the
air to the recirculation system. If there is not enough pressure, it will close the air supply valve
recirculation (pos R3) for a short period. The switch point must be set at 5 bar. This can be
achieved by opening the cover and adjusting the button above the pressure switch. The
setting can be read at the front of the pressure switch. The differential switch must be set at its
minimum (=0 bar).
R3: Control valve air supply recirculation.

R4: Control valve sediment discharge valve.
R8: Control coagulant safety valve.
These are solenoid valves, controlling the airflow. In the front of each solenoid valve is a small
button. By using a screwdriver, this button can be set at the “1” or “0” position, herewith the
valve is actuated manually.
“1” Position: The aeration valve is set in the position "Manual“.

“0” Position: The aeration valve is set in the position "Auto“.
R9: Water separator automatic.

The water filter removes small particles and water droplets (like aerosols) from the airflow.
Water will be discharged automatically under the DAF unit when the separator is full and when
the pressure is off.
When air pressure remains present, draining must be done manually. This can
be done by turning the lower part where the drain hose is fitted to. Clockwise is
loose (seen from below), anti-clockwise is close. There must be adequate
drainage to prevent water from flowing to the downstream system, which can
cause damage to these components.
5.14
Type: GPL 15
OHW: W10286-016
R10: Pressure adjustment airflow to recirculation pump.

The inlet pressure for pneumatic control panel must be 7 bar.
Make sure the airflow is dry and oil free.
The pressure regulator is set at 6,5 bar. By adjusting the red button at the top of the regulator,
the pressure is in- or decreased. The pressure can be read on the gauge, in front of the
pressure regulator.
R11: Pressure indicator main air supply.
R12: Pressure indicator recirculation system.

This pressure gauge, indicates the release pressure in the recirculation system.
This pressure must be set to 6,5 bar.
R13: Needle valve to regulate the airflow to the recirculation pump.
R14: Flow indicator airflow to recirculation pump.

This flow meter regulates the airflow to the recirculation system. The amount of air depends on
the type of separator and recirculation pump.
Non return valve.

In the air supply piping to the recirculation pump, a non-return valve is installed. This to ensure
us that water from the recirculation system doesn’t flow back into the air control panel.
Maintenance:
 Once a week the water separator (pos R9) must be checked.
(check if it drains automatically).
 Check if the hoses are clean and not clogged, renew if necessary.
 Daily check if the necessary pressure is set at the right value.
Pressure indicator recirculation system (pos R12) must be set to 6,5 bar.
 Check daily if the airflow meter is set at the right flow. (See pos R14).
Start up:
 Connect the main air supply to the pneumatic control panel.
 Check if all hoses are firmly tightened and connected at the right position.
 Wire the solenoid valves and pressure switch to the electrical panel.
 Set the pressure regulator (pos R10) at 6,5 bar.
 Be sure that the sediment discharge valve works correctly.
 Be sure that the coagulant safety valve works correctly.
5.15
Type: GPL 15
OHW: W10286-016
5.3. START-UP / TIMER ADJUSTMENTS / ADJUSTMENTS.
Before taking the installation into operation, you have to check the settings of the motor circuit
breaker and verify the value with the current on the motor plate.
You have the obligation to check if your installation diagram / requirements are identical to our
electrical diagram because of the circuit breaker, cable cross-section, voltage drop, short
circuit value, terminals, etc.
Adjust the height of the level measurements (in consultation with the field-engineer). See
chapter 4.2 of this manual for mounting instructions.
Check the rotating directions of the pumps and drives like here is written below.
 Turn all the switches in the position "O".

 Turn the process selection switch in the position “manual / service”.
 Check the rotating direction of the scrapers:
- Let a second person turn the switch of the skimmer drive in the position "manual"
and afterwards off again.
- The "scraping" (lower) scrapers have to move to the sludge collection cone.
 Check the rotation direction of the recirculation pump and feed pumps (when applicable).
Attention, these pumps may only operate when it’s filled with water!
 Check the air controlled sediment discharge valve:
- Let a second person turn the switch of the sediment discharge valve in the
position "manual" and afterwards off again.
- The valve has to open and close again.
(1 The rotating direction of pumps will be indicated by an arrow on the pump. In some cases this arrow will indicate
the reaction force. Therefore check the manual of the supplier in the index.)
Starting the installation:
1) Be sure that the installation is clean (no dirt in the unit). This to prevent damages on
pumps etc.
2) Be sure that everything is connected according to the drawings.
3) Be sure that the entire installation is checked (functioning, rotating directions and
damages)!
4) Be sure that the sediment discharge valve is closed.
5) Be sure that the scraper chain can move freely.
6) Fill the installation with clean water until water flows over the adjustable effluent weir. (lf
the installation will be filled directly with wastewater than there will be untreated
effluent-water for a long time).
7) Set weir height to obtain optimal removal and sludge dry solids content.
Always start up with a to high adjustment of the weir, this to prevent build up
of fouling and attachment of pollution to the unit. The maximum sludge thickness is
approx. 80mm. depending on the kind of floating sludge layer.
8) Check the chain tension.
9) Adjust the run time from the sediment auger and the sludge settle time (for settled sludge)
according to the electrical diagrams.
10) Open the manual valves at suction and pressure pipe from the recirculation pump.
11) Open the aeration valves at the front and base side of the flotation unit till 45 degrees.
12) Turn the main switch in the position “On”.
13) Turn the process selection switch in the position “Auto”.
14) Turn all the selector switches in the position "Auto".
5.16
Type: GPL 15
OHW: W10286-016
15) Unlock the emergency stop if necessary and reset the alarm.
16) Press the button “Start process”.
17) The installation will start according to the below-described start and stop procedure.
18) Reduce the aeration valves until an optimal aeration is achieved at 5 to 6 bar pressure.
19) Adjust the scraper speed to obtain an optimal removal and sludge dry solids content.
Always start with the speed at 50%.
20) Check the gasket from the auger.
21) Set the timers (for the auger) for an optimal result.
22) Set the sludge discharge time to 3 seconds and check if the sediment valve opens 3
seconds actually. The sludge discharge time must be just enough to open the valve
completely (see arrow on the valve). This time depends on the actuating speed of the
valve and the amount of settled sludge that has to be discharged.
23) Adjust closing speed of the valve by adjusting the valve on the actuator.
24) Open the bleed valve till the excess of large air bells are released. This valve will also
operate as a distribution valve. There must be at least some water flow through the valve.
25) Check whether the effluent measuring pin (when applicable) is in contact with the medium
during operation.
Start and stop procedure of the flotation unit.
Start procedure
A level control should be present in the pump pit or buffer/equalisation tank that gives a signal
at high level and stops giving this signal at low level.
If high level is reached in the pump pit / buffer/equalisation tank, a signal is given that:
1. Starts the recirculation pump;
2. Starts, at the same time, the scraper system (the scraper systems remains running as long
as the recirculation pump is operational);
3. After a set time (see timer table sent with the electrical diagrams) after the recirculation
pump has started, the air supply valve is opened. This only happens if the pressure
indicator of the pressure side of the recirculation pump measures sufficient pressure. If,
during operation of the recirculation pump, the pressure of the pump drops, the air control
valve closes to prevent the pump from damaging. If the pressure returns to normal, the air
control valve opens again. Should the pressure drop occur for longer than 15 seconds or
the recirculation pump stops, the entire process (recirculation pump with air supply valve,
feed pump, dosing pumps, scraper, sand discharge valve) stops immediately.
4. The flotation unit is now being aerated and ready to receive and treat wastewater.
5. After a set time (see timer table sent with the electrical diagrams) of aeration, the feed
pump of the flotation unit is started.
6. At the same time the feed pump is started, the dosing pump for coagulant is started (with
coagulant control valve), the dosing pump for neutralisation (pH driven) is started and the
dosing pump for flocculant (poly-electrolyte) is started. The contact pins in the effluent
compartment detect, from this point on, whether there is wastewater flowing through the
flotation unit. If, for a period of three minutes (after the feed pump started), no flow is
detected through the flotation unit, the chemical dosing pumps are stopped and an alarm
“no flow” is given.
7. As long as the feed pump of the flotation unit is running, the sediment discharge cycle is
active.
5.17
Type: GPL 15
OHW: W10286-016
Cycle of the sediment discharge
- Settled materials are transported to the discharge point.

- The pneumatic operated butterfly valve (discharge point) opens for a set time (see
timer table sent with the electrical drawings).
- The pneumatic operated butterfly valve (discharge point) closes and a pause period
starts (see timer table sent with the electrical drawings).
- After this pause period, the cycle of the sediment discharge starts again.
Now the flotation unit is operational.
Stop procedure
If low level is detected in the pump pit / buffer/equalisation tank;
- The feed pump stops immediately.

- The chemical feed pumps stop.
- The sediment discharge cycle stops.
- The recirculation pump, the air supply valve and the scraper stop after a set time from
reaching low level (see timer table sent with the electrical drawings).
Downtime aeration
If, after the stop procedure has taken place, no high level is reached within a certain time
(see timer table sent with the electrical drawings), the downtime aeration cycle starts. The
purpose of the downtime aeration is keeping the sludge layer in tact and floating.
Cycle of the downtime aeration
- After low level has been detected and the recirculation pump stopped, a pause period
starts (see timer table sent with the electrical drawings).
- After this pause period, the recirculation pump starts and 10 seconds after the
recirculation pump has started, the air supply valve opens. The pressure drop security
(see paragraph 4) is also valid here.
- After a set time (see timer table sent with the electrical drawings) the recirculation
pump stops and the air supply valve is closed.
- The cycle continues from here on.
There is no fixed working area required for an operator. Working space is needed in front of all
electrical components and control panel to operate the switches and to be able to make
adjustments. For further accessibility see paragraph 4.2. Only regular maintenance and a
periodic check to control the correct functioning of the system operation are required. The
operator therefore can also take care of the maintenance of the system; the requirements for
this function are described in chapter 6. 1.
5.18
Type: GPL 15
OHW: W10286-016
5.5. PUTTING OUT OF ORDER.
There are several reasons to put the flotation unit out of order, for maintenance / repairs /
vacations / etc.
Putting out of order is going according to the below procedure.
 Put all “Hand-0-Auto” switches in the position "0".

 Put the effluent weir in the highest position as written in chapter 5. In this way the sludge
layer get thicker (with the same influent) or (with decreasing of influent) that the sludge and
sludge layer can be removed by the skimmer.
 Remove the whole sludge layer by turning the scraper switch in the position “Hand”.
 Put the switch for feed pump in the position “Hand”, the whole sludge layer can be
removed now.
Take care for dry running of the feed pump, because with manual serving the level-
servinq does not operate.
 When the entire sludge layer is removed, remove the sediment out of the unit. Make the
installation empty by draining every minute very short and open the sediment discharge
valve (switch in position “Hand”).
 When the plate pack is fouled, clean it.
 When the GPL flotation unit is not in operation for a longer period (more than one
day) by maintenance / repair / cleaning etc., the entire floating sludge layer has to be
skimmed of from the water after that the installation has to be drained empty. After
that always fill the unit with clean water. This prevents fouling and attachment of
pollution to the unit and / or plate pack! Also the flotation unit will start up much
easier when it’s filled up with clean water.
5.19
Type: GPL 15
OHW: W10286-016
6. INSPECTION / MAINTENANCE.
6.1. QUALIFICATION OF MAINTENANCE PERSONNEL.
Only personnel, who are instructed by Redox, are allowed to carry out operation and maintenance
activities. They are informed with the associated manual.
The operator and/or maintenance engineer must have an average technical level:
This person must have sufficient knowledge of:

 Chemicals working and dangers / process technology when applicable.
 Pneumatic knowledge, follow the working of the installation on the basis of the pneumatic
diagrams and analyse malfunctioning.
 Electrical knowledge, follow the working of the installation on the basis of the electrical
diagrams and analyse malfunctioning. He / she must associate with measuring devices like
ohmmeter, voltmeter and amperemeter for measuring starting - and nominal currents.
lf a technical service / maintenance department is available, than it is strongly recommended to

have the maintenance carried out by this department.
6.2. SAFETY MEASURES AND RISKS DURING MAINTENANCE.
 Maintenance, repair, inspection, checking for malfunctioning or removal of parts is only allowed
when the electric supply has been switched off and when all drives, pumps etc. are stopped.
 Turn the main switch (figure 6.1, pos 4) in the “off position” on the electric control panel. Turn
the maintenance switch in place in the "off position" (when applicable).
Figure 6.1
All persons who are working on the machine must have their own padlock with matching key to
lock the main switch (figure 6.1, pos 4) in a “safe position”. Only when all padlocks are
removed from the main switch, the machine can be switched on again. Padlock is no Redox
delivery.

- Attention! The motor is not secured against low level etc. when it’s in the “Hand”
position.
 Before taking a pump / mixer out of a pit / tank it is necessary to make the pump / mixer
voltageless, and locked in safe position to prevent unawares activation of the pump / mixer.
6.1
Type: GPL 15
OHW: W10286-016
6.3. MAINTENANCE.
Daily maintenance:
Once the installation is in normal operation the operation should be checked a few times a day,
especially during start-up.
Daily maintenance consists of the below items:
 Check the pollution of the preliminary filtration, if necessary clean it.

 Check the optical signals on the electrical control panel (alarms).
 Check the installation for leakages (piping, pumps, appendices, etc.).
 Check the flow rate over the installation.
 Check the gaskets of the recirculation pump for leakages.
 Check the sludge layer thickness.
 Check if the scraper blades are not heavy scraping over the scraper plate.
 Check if the scraper blades take along the sludge in a good way.
 Check the scraper blades for fouling, if necessary clean it.
 Check if all valves are partly opened when the recirculation pump is in operation. At all times
some valves must be open.
 Check the recirculation pump for running dry (this may never occur!).
 Check the air distribution valves for fouling, if necessary clean it.
 Check if the mixture of air-water looks like a milky liquid.
 Check if the bleed valve is opened for a bit.
 Check the pressure on the recirculation pump (see chapter 5.2 in this manual.)
 Check the pressure in the pressure cylinder it needs to be checked visually on the pressure
gauge recirculation in the pneumatic control panel. The pressure should be 5 till 6 bar.
 Check the quantity air on the flow meter (see chapter 5.2 in this manual.)
 Rinse the bleed valve with clean water.
 Check the turbidity of the effluent (floc carry-over). See turbidity meter (option).
 Check if the pH value is according to the mentioned range.
 Check the installation for freezing.
 Check the emergency stop circuit.
Weekly maintenance:
 Check the influent compartment for blocking. Drain the installation and inspect it from the top. If
necessary clean it.
 Check the plate pack for fouling (when applicable). Drain the installation and inspect it from the
top. If necessary clean it. Also see chapter 5.2 “P2: Plate pack”.
 Check the sludge thickener for fouling. Drain the installation and inspect it from the top. If
necessary clean it. Clean it for example with a high-pressure water system.
 Check the weir pipe / weir gutter for fouling, if necessary clean it.
 Check the level measurement(s) / measuring pin(s) for fouling, if necessary clean it.
 Check the working of the level measurement(s) / measuring pin(s), also see chapter 4.2 of this
manual.
 Check the chain tension.
 Check the installation and the pump pits (when delivered) for accumulation of pollution, if
necessary clean it.
 Check the working of the valves / filters in the pipes (when applicable).
6.2
Type: GPL 15
OHW: W10286-016
 Check the settings and the readings on the pneumatic control panel / electrical control panel.
 Check if there’s water in the water filter that is placed in the pneumatic control panel. When this
occurs drain the water from the water filter.
Monthly maintenance:
 Check the gasket from the auger. The gland packing should leak for a bit!
Yearly maintenance:
 Check the thickness of the wear and tear liner in the trough for wear out. When the thickness of
the liner is less then 2mm. it needs to be replaced! This can be checked by dismantle the
flange plate and the drive (see below). At the other side the drainpipe with sediment discharge
valve has to be dismantled.
Dismantling the drive and auger:

1. Switch off the electric supply in „safe position“ and lock the main switch with a padlock.
2. Open the junction box on the drive.
3. Write down the colour combination of the electric cable connections in the junction box.
4. Remove the electric connection cables.
5. Remove bolt and washer from the propeller shaft.
6. Remove the nuts from the flange plate.
7. Remove the drive from the shaft.
8. Pay attention to the pin (wedge), don‘t lose it!!
9. Remove the flange plate by removing the bolts.
10. Pull out the auger in a direct line as the trough.
Replacing the wear and tear liner:

1. Remove the drive and auger as written above.
2. Remove the plate pack (when applicable) out of the installation.
3. The wear and tear liner can be removed by pushing a screwdriver behind the cams.
4. Clean the trough carefully.
5. Place the new wear and tear liner in the trough.
6. Mount the drive and auger as written above in a reverse direction.
7. Mount the plate pack in the installation.
8. Check the working of all parts.
Maintenance for supplied parts:
 For maintenance and lubrication of the recirculation pump see the manual in the manual index
chapter 8.
 For maintenance and lubrication of the skimmer drive see manual in the manual index chapter
9.
 For maintenance and lubrication of the sediment discharge valve see the manual in the manual
index chapter 10.
6.4. CLEANING.
Before cleaning the system read chapter 6.2 of this manual. The GPL can be cleaned with a high-
pressure water spray systemIMPORTANT: Pay attention, never spray with high pressure to
the electric junction boxes, drives, working switches and electric switch and control panel.
6.3
Type: GPL 15
OHW: W10286-016
7. MALFUNCTIONING AND REPAIR.

Before doing maintenance or repair, read chapter 6.2 of this manual very carefully.
7.1. Complaint table.
Skimmer does not work Drive is in thermal overload Check if the circuit breaker and
failure. frequency controller are tripped.
Wrong position of the switch. Turn the switch in the right position.
No tension present. Take care for the right tension.
Scraper is blocked. Make the scraper loose and clean it.
Chain is broken. Repair or replace the chain.
Recirculation pump doesn’t Drive is in thermal overload Check the motor circuit breaker.
work. failure.
No tension present. Take care for the right tension.
Aeration isn’t right. Adjust the aeration as mentioned in
this manual.
Pump pressure isn’t right. Set the pump pressure in the right
settings.
Several components don’t The main switch is in the Turn the main switch in the position
work. position “Off”. “On”.
Emergency stops are Check if all four LED’s on the
pushed in. emergency stop relays are burning.
Sediment discharge valve No air pressure present. Take care for the right air pressure.
doesn’t work.
Connections of the air hoses Connect the air hoses in the right way.
are not right.
Air hoses are blocked. Remove the blockage.
7.1
Type: GPL 15
OHW: W10286-016

Aeration is not correct. Bleed valve is blocked. Open valve completely to remove
(Large air bubbles). blockage and readjust to a small flow
through this valve.
Aeration valves not adjusted Check whether all valves are approx. in
properly. the same position, giving equal flow
rates. Readjust if not.
Air supply is too high. Reduce airflow.
No aeration, no milky liquid. No air supply. Check air flow meter for correct
adjustments.
Solids load in effluent water Find the cause in plant operation and
is too high. determine next action accordingly.
Too low pressure in the Check the pressure on manometer in
pressure cylinder. (pneumatic control panel) and reduce
the air flow in the aeration valves. The
pressure is getting higher now. The air
supply is too low when the pressure is
getting below 4 bar. Take care for a
higher air supply.
The recirculation pump is Close some aeration valves and check

worn out. maximum pressure of the pump. If the
pressure is above 6 bar, the pump may
be worn out. (Gasket or impellers). In
this case, replace or repair the pump. If
the operation period had been relatively
short it is worthwhile to find other
causes. When operated at too low pH
or high chloride content will causes
excessive wear out of the pump.
Wet sludge layer. Sludge settle time is too Lower the water level in the flotation
short. unit or decrease the skimmer speed.
Insufficient aeration. Increase steady airflow.

Check aeration valves for blockage, is
necessary clean it.
Too high water supply. Valves in supply pipes are Put the valves in the supply pipes in
not in the right position. the right position.
Flow in the pipes or pumps Accumulation in pipes or Check pipes, pump, pump pit and
are not right. pumps. valves for blockage. If necessary clean
it.
7.2
Type: GPL 15
OHW: W10286-016
The steels / synthetics / medium / substances must be dismantled according to the national
and / or local regulations of that moment.
8.1. RE-USE.
The GPL is constructed from durable materials and components.

considerate for what can be re-used, when and how can be recycled. The stainless steel unit
is made of AISI 304 (werkstoff. Nr:1.4301) and can be re-used for other purposes.
8.2. DIS-MANTLING.
steel unit is welded in full and cannot be dismantled in parts.
Dismantling of the GPL has to be executed by professional personnel.
8.1
Type: GPL 15
OHW: W10286-016
system.

Service department
Phone: 0031 (0)543-531030
Fax: 0031 (0)543-519089
9.1
OHW: W10286-016
Datasheet
recirculation pump
1.1. TECHNICAL DATA
Description: Recirculation pump GPL 15

Make: Johnson
Type: CB32-250
2. SAFETY ASPECTS

are stopped.
Figure 2.1
Redox delivery.

For further information see manual of the recirculation pump in the

manual index.
1
INSTRUCTION MANUAL
CombiBloc
Horizontal centrifugal monobloc pump
Orginal instructions
CB/EN (1501) 6.6
Read and understand this manual prior to operating or servicing this product
EC Declaration of conformity
(Directive 2006/42/EC, appendix II-A)
Manufacturer
SPX Flow Technology Assen B.V.
Dr. A.F. Philipsweg 51
9403 AD Assen
The Netherlands
hereby declares that all pumps member of productfamilies CombiBloc, CombiBlocHorti,
CombiChem, CombiLine, CombiLineBloc and CombiNorm whether delivered without
drive (last position of serial number = B), or delivered as an assembly with drive (last
position of serial number = A), are in conformity with the provisions of Directive 2006/
42/EC (as altered most recently) and where applicable the following directives and
standards:
• EC directive 2006/95/EC, "Electric equipment for use within certain voltage limits"
• standards EN-ISO 12100 part 1 & 2, EN 809
The pumps to which this declaration refers may only be put into operation after they have
been installed in the way prescribed by the manufacturer, and, as the case may be, after
the complete system of which these pumps form part, has been made to fulfil the
requirements of Directive 2006/42/EC (as altered most recently).
EC Declaration of conformity
(Directive 2009/125/EC, Annex VI and Commission Regulation (EU) No 547/2012)
(Implementing Directive 2009/125/EC of the European Parliament and of the Council
with regard to ecodesign requirements for water pumps)
Manufacturer
9403 AD Assen
The Netherlands
Hereby declares that all listed pumps member of product families CombiBloc,
CombiBlocHorti, CombiChem, CombiLine, CombiLineBloc and CombiNorm are in
conformity with the provisions of Directive 2009/125/EC and Commission Regulation
(EU) No 547/2012 and the following standard:
• prEN 16480
EC-ECO/EN (1501) 1.1 1

Declaration of incorporation
(Directive 2006/42/EC, appendix II-B)
Manufacturer
9403 AD Assen
The Netherlands
hereby declares that the partly completed pump (Back-Pull-Out unit), member of
productfamilies CombiBloc, CombiBlocHorti, CombiChem, CombiLine, CombiLineBloc
and CombiNorm is in conformity with the following standards:
• EN-ISO 12100 parts 1 & 2, EN 809
and that this partly completed pump is meant to be incorporated into the specified pump
unit and may only be put into use after the complete machine of which the pump under
consideration forms part has been made and declared to comply with that directive.
Assen, January 1st 2015
G. Santema,
Ad Interim statutory director
2 EC-ECO/EN (1501) 1.1

Instruction manual
All technical and technological information in this manual as well as possible drawings
made available by us remain our property and shall not be used (otherwise than for the
operation of this pump), copied, duplicated, made available to or brought to the notice of
third parties without our prior written consent.
SPX is a Fortune 500, global multi-industry manufacturing leader. SPX divides its
business into four segments and one of these is the SPX Flow Technology segment.
SPX Flow Technology Assen B.V. is part of SPX Flow Technology segment.

P.O. Box 9
9400 AA Assen
The Netherlands
Tel. +31 (0)592 376767
Fax. +31 (0)592 376760
Copyright © 2008 SPX Corporation
INT/EN (1107) 1.1 3

4 INT/EN (1107) 1.1
CombiBloc
Table of Contents
1 Introduction 9
1.1 Preface 9
1.2 Safety 9
1.3 Guarantee 10
1.4 Inspection of delivered items 10
1.5 Instructions for transport and storage 10
1.5.1 Dimensions and weight 10
1.5.2 Use of pallets 10
1.5.3 Hoisting 11
1.6 Storage 11
1.7 Ordering parts 11
2 General 13
2.1 Pump description 13
2.2 Type code 13
2.3 Serial number 13
2.4 Applications 14
2.5 Construction 14
2.5.1 Design 14
2.5.2 Mechanical seal 14
2.5.3 Bearing construction 14
2.6 Ecodesign Minimum Efficiency Requirements Water Pumps 15
2.6.1 Introduction 15
2.6.2 Implementing Directive 2009/125/EC 15
2.6.3 Energy Efficient Pump Selection 18
2.6.4 Scope of Implementing Directive 2009/125/EC 19
2.6.5 Product information 19
2.7 Application area 22
2.8 Re-use 23
2.9 Scrapping 23
3 Installation 25
3.1 Safety 25
3.2 Preservation 25
3.3 Environment 25
3.4 Installation of a pump unit 25
3.5 Piping 26
3.6 Accessories 26
3.7 Connection of the electric motor 26
4 Commissioning 27
CB/EN (1501) 6.6 5

4.1 Inspection of the pump 27
4.2 Inspection of the motor 27
4.3 Preparing the pump unit for commissioning 27
4.4 Checking the sense of rotation 27
4.5 Start-up 27
4.6 Pump in operation 28
4.7 Noise 28
5 Maintenance 29
5.1 Regular maintenance 29
5.2 Mechanical seal 29
5.3 Lubrication of the bearings 29
5.4 Environmental influences 29
5.5 Noise 29
5.6 Motor 29
5.7 Faults 30
6 Problem solving 31
7 Disassembly and assembly 33
7.1 Precautionary measures 33
7.2 Special tools 33
7.3 Liquid draining 33
7.4 Disassembly 34
7.4.1 Back-Pull-Out system 34
7.4.2 Disassembling the Back-Pull-Out unit 34
7.4.3 Assembling the Back-Pull-Out unit 34
7.5 Replacing the impeller and the wear ring 35
7.5.1 Disassembling the impeller 35
7.5.2 Mounting the impeller 35
7.5.3 Disassembling the wear ring 36
7.5.4 Assembling the wear ring 36
7.6 Mechanical seal 37
7.6.1 Instructions for mounting a mechanical seal 37
7.6.2 Disassembling a mechanical seal M1 38
7.6.3 Assembling a mechanical seal M1 39
7.7 Replacing the stub shaft and the motor 40
7.7.1 Disassembling the stub shaft and the motor of pump size 25-... 40
7.7.2 Assembling the stub shaft and the motor of pump size 25-... 40
7.7.3 Disassembling the stub shaft and the motor 41
7.7.4 Assembling the stub shaft and the motor 42
8 Dimensions 43
8.1 Dimension drawings 44
8.2 Motor feet dimensions 45
8.3 Flange dimensions 46
8.3.1 Cast iron and bronze G, B 46
8.3.2 Stainless steel R 46
8.4 Pump dimensions 47
8.5 Overall length (ta) 48
8.5.1 Cast iron and bronze G, B 48
8.5.2 Stainless steel R 49
8.6 Dimension vt 50
8.7 Weight 51
9 Parts 53
6 CB/EN (1501) 6.6

CombiBloc
9.1 Ordering parts 53

9.1.1 Order form 53
9.1.2 Recommended spare parts 53
9.2 Pump with shaft sealing M1 54
9.2.1 Sectional drawing 54
9.2.2 Parts list 55
9.3 Pump sizes 25-125 and 25-160 with shaft sealing M1 56
9.3.1 Sectional drawing 56
9.3.2 Parts list 57
9.4 Additional parts of pump size 200-160 58
10 Technical data 59
10.1 Recommended locking liquids 59
10.2 Tightening moments 59
10.2.1 Tightening moments for bolts and nuts 59
10.2.2 Tightening moments for cap nut 59
10.3 Maximum allowable speed 60
10.4 Maximum allowable working pressures 61
10.5 Hydraulic performance 62
10.5.1 Performance overview cast iron and bronze pumps G, B 62
10.5.2 Performance overview stainless steel pumps R 65
10.6 Permitted forces and torques on the flanges, based on EN-ISO 5199 67
10.6.1 Cast iron and bronze pumps 68
10.6.2 Stainless steel pumps 69
10.7 Noise data 70
10.7.1 Pump noise as a function of pump power 70
10.7.2 Noise level of entire pump unit 71
Index 73
Order form for spare parts 75
CB/EN (1501) 6.6 7

8 CB/EN (1501) 6.6
CombiBloc
1 Introduction
1.1 Preface
This manual is intended for technicians and maintenance staff and for those who are in
charge of ordering spare parts.
This manual contains important and useful information for the proper operation and
maintenance of this pump. It also contains important instructions to prevent potential
accidents and damage, and to ensure safe and fault-free operation of this pump.
! Read this manual carefully before commissioning the pump, familiarize

yourself with the operation of the pump and strictly obey the instructions!
The data published here comply with the most recent information at the time of going to
press. However they may be subject to later modifications.
SPX reserves the right to change the construction and design of the products at any time
without being obliged to change earlier deliveries accordingly.
1.2 Safety
This manual contains instructions for working safely with the pump. Operators and
maintenance staff must be familiar with these instructions.
Installation, operation and maintenance has to be done by qualified and well prepared
personnel.
Below is a list of the symbols used for those instructions and their meaning:
 Personal danger for the user. Strict and prompt observance of the
corresponding instruction is imperative!
! Risk of damage or poor operation of the pump. Follow the corresponding

instruction to avoid this risk.
➢ Useful instruction or tip for the user.
Items which require extra attention are shown in bold print.
This manual has been compiled by SPX with the utmost care. Nevertheless SPX cannot
guarantee the completeness of this information and therefore assumes no liability for
possible deficiencies in this manual. The buyer/user shall at all times be responsible for
testing the information and for taking any additional and/or deviating safety measures.
SPX reserves the right to change safety instructions.
CB/EN (1501) 6.6 Introduction 9

1.3 Guarantee
SPX shall not be bound to any guarantee other than the guarantee accepted by SPX. In
particular, SPX will not assume any liability for explicit and/or implicit guarantees such as
but not limited to the marketability and/or suitability of the products supplied.
The guarantee will be cancelled immediately and legally if:
• Service and/or maintenance is not undertaken in strict accordance with the
instructions.
• The pump is not installed and operated in accordance with the instructions.
• Necessary repairs are not undertaken by our personnel or are undertaken without our
prior written permission.
• Modifications are made to the products supplied without our prior written permission.
• The spare parts used are not original SPX parts.
• Additives or lubricants used are other than those prescribed.
• The products supplied are not used in accordance with their nature and/or purpose.
• The products supplied have been used amateurishly, carelessly, improperly and/or
negligently.
• The products supplied become defective due to external circumstances beyond our
control.
All parts which are liable to wear are excluded from guarantee. Furthermore, all
deliveries are subject to our “General conditions of delivery and payment”, which will be
forwarded to you free of charge on request.
1.4 Inspection of delivered items

Check the consignment immediately on arrival for damage and conformity with the advice
note. In case of damage and/or missing parts, have a report drawn up by the carrier at
once.
1.5 Instructions for transport and storage
1.5.1 Dimensions and weight

A pump or a pump unit is generally too heavy to be moved by hand. Therefore, use the
correct transport and lifting equipment. Dimensions and weight of the pump or pump unit
are shown on the label on the cover of this manual.
1.5.2 Use of pallets

Usually a pump or pump unit is shipped on a pallet. Leave it on the pallet as long as
possible to avoid damages and to facilitate possible internal transport.
! When using a forklift always set the forks as far apart as possible and lift the
package with both forks to prevent it from toppling over! Avoid jolting the
pump when moving it!
10 Introduction CB/EN (1501) 6.6

CombiBloc
1.5.3 Hoisting
When hoisting a pump or complete pump units the straps must be fixed in accordance
with figure 1.
 Never go underneath a hoisted pump!

Figure 1: Lifting instructions.
4185
1.6 Storage
If the pump is not to be used immediately the stub shaft must be turned by hand twice
per week.
1.7 Ordering parts

This manual contains a survey of the spare parts recommended by SPX as well as the
instructions for ordering them. A fax-order form is included in this manual.
You should always state all data stamped on the type plate when ordering parts and in
any other correspondence regarding the pump.
➢ This data is also printed on the label on the front of this manual.
If you have any questions or require further information with regard to specific subjects,
then do not hesitate to contact SPX.
CB/EN (1501) 6.6 Introduction 11

12 Introduction CB/EN (1501) 6.6
CombiBloc
2 General
2.1 Pump description

The CombiBloc is a range of horizontal non-self-priming centrifugal pumps. The pump
and the standard IEC flange motor are assembled by means of a lantern piece and a
stub shaft to one complete unit. The pumps are available in cast iron, bronze and
stainless steel. The cast iron and bronze pump casings comply with EN 733
(DIN 24255), the stainless steel pump casings comply with EN 22858 / ISO 2858
(DIN 24256).
2.2 Type code

Pumps are available in various designs. The main characteristics of the pump are shown
in the type code.
Example: CB 40-200 G2
Pump family
CB CombiBloc
Pump size
40 diameter discharge connection [mm]
200 nominal impeller diameter [mm]
Pump casing material
G cast iron
B bronze
R stainless steel
Impeller material
1 cast iron
2 bronze
6 stainless steel
2.3 Serial number

Serial number of the pump or pump unit are shown on the name plate off the pump and
on the label on the cover of this manual.
Example: 01-1000675A
01 year of manufacture
100067 unique number
5 number of pumps
A pump with motor
B pump with free shaft end
CB/EN (1501) 6.6 General 13

Example horticulture: 11-09 X123500 1/2
11-09 month-year of manufacture
X123500 unique number
1/2 number of pumps
2.4 Applications
• In general, this pump can be used for thin, clean or slightly polluted liquids. These
liquids should not affect the pump materials.
• Further details about the application possibilities of your specific pump are mentioned
in the order confirmation and/or in the data sheet enclosed with the delivery.
• Do not use the pump for purposes other than those for which it is delivered without
prior consultation with your supplier.
 Using a pump in a system or under system conditions (liquid, working

pressure, temperature, etc.) for which it has not been designed may hazard
the user!
2.5 Construction
2.5.1 Design
The design is characterized by a compact construction. The pump is mounted to a
standard IEC flange motor by means of a lantern piece and stub shaft. The pump cover is
clamped between the pump casing and the lantern piece.
The electric motors up to and including frame size 112M have B5 mounting arrangement
and the larger types have B3/B5 mounting arrangement. All vertically placed motors
have mounting arrangement V1.
For each individual pump type there is only one construction of pump casing and
impeller. The pumps are available in cast iron, bronze and stainless steel. The cast iron
and bronze pump casings are according to EN 733 (DIN 24255) and the stainless steel
pump casings according to EN 22858 / ISO 2858 (DIN 24256). The stub shaft is made
of stainless steel.
2.5.2 Mechanical seal

The pump is provided with a mechanical seal with mounting dimensions according to
EN 12756 (L1K) (DIN 24960 (L1K)).
Only 3 diameters are used for the whole range: d1 = 30 mm, 40 mm or 50 mm.
2.5.3 Bearing construction

The pump shaft bearing is provided by the motor bearings. The selection of the pump/
motor combination is such that the bearings of the applied electric motors can absorb
the axial and radial forces without the bearing life being affected.
The electric motors must be provided with a fixed bearing.
14 General CB/EN (1501) 6.6

CombiBloc
2.6 Ecodesign Minimum Efficiency Requirements Water Pumps

• Directive 2005/32/EC of the European Parliament and of the Council;
• Commission regulation (EU) No 547/2012 Implementing Directive 2009/125/EC of
the European Parliament and of the Council with regard to ecodesign requirements for
water pumps.
2.6.1 Introduction
SPX Flow Technology Assen B.V. is an associate member of the HOLLAND PUMP
GROUP, an associate member of EUROPUMP, the organization of European pump
manufacturers.
Europump promotes the interest of the European pump industry with the European
institutions.
Europump welcomes the aim of the European Commission to reduce eco-impact of
products in the European Union. Europump is fully aware of the eco-impact of pumps in
Europe. For many years the ecopump initiative is one of the strategic columns in the work
of Europump. From the first of January 2013 the regulation is coming into force
concerning minimum required efficiencies of rotodynamic water pumps. The regulation
sets minimum efficiency requirements on water pumps set out under the Ecodesign
Directive for energy related products. This regulation mainly addresses manufacturers of
water pumps placing these products on the European market. But as a consequence
customers may also be affected by this regulation. This document gives necessary
information related to the coming into force of the water pump regulation EU 547/2012.
2.6.2 Implementing Directive 2009/125/EC
• Definitions:
“This Regulation establishes eco-design requirements for the placing on the market of
rotodynamic water pumps for pumping clean water, including where integrated in other
products.”
“Water pump” is the hydraulic part of a device that moves clean water by physical or
mechanical action and is of one of the following designs:
1 End suction own bearing (ESOB);
2 End suction close coupled (ESCC);
3 End suction close coupled inline (ESCCi);
4 Vertical multistage (MS-V);
5 Submersible multistage (MSS);”
‘End suction water pump’ (ESOB) means a glanded single stage end suction
rotodynamic water pump designed for pressures up to 1600 kPa (16 bar), with a specific
speed ns between 6 and 80 rpm, a minimum rated flow of 6 m3/h, a maximum shaft
power of 150 kW, a maximum head of 90 m with nominal speed of 1450 rpm and a
maximum head of 140 m with nominal speed of 2900 rpm;
‘End suction close coupled water pump’ (ESCC) is an end suction water pump of which
the motor shaft is extended to become also the pump shaft;
‘End suction close coupled inline water pump’ (ESCCi) means a water pump of which
the water inlet of the pump is on the same axis as the water outlet of the pump;
‘Vertical multistage water pump’ (MS-V) means a glanded multistage (i > 1) rotodynamic
water pump in which the impellers are assembled on a vertical rotating shaft, which is
designed for pressures up to 2500 kPa (25 bar), with a nominal speed of 2900 rpm and
a maximum flow of 100 m3/h;

‘Submersible multistage water pump’ (MSS) means a multistage (i > 1) rotodynamic
water pump with a nominal outer diameter of 4” (10,16 cm) or 6” (15,24 cm) designed to
be operated in a borehole at nominal speed of 2900 rpm, at operating temperatures
within a range of 0°C and 90°C;
This Regulation shall not apply to:

1 water pumps designed specifically for pumping clean water at temperatures below -
10°C or above +120°C;
2 water pumps designed only for fire-fighting applications;
3 displacement water pumps;
4 self-priming water pumps.
• Enforcement:
In order to enforce this there will be a Minimum Efficiency Index (M.E.I.) criteria set for
the above list of pumps.
The MEI is a dimensionless figure that is derived from a complex calculation based on
the efficiencies at BEP (Best Efficiency Point), 75% BEP & 110% BEP, and the specific
speed. The range is used so that manufacturers do not take an easy option of providing
good efficiency at one point i.e. BEP.
The value ranges from 0 to 1,0 with the lower value being less efficient, this provides the
basis of eliminating the less efficient pumps starting with 0,10 in 2013 (the lowest 10%)
and 0,40 (the lowest 40%) in 2015.
The MEI value of 0,70 is classed benchmark for the most efficient pumps in the market at
the time of developing the directive.
The milestones for the MEI values are as follows;
1 1st January 2013 all pumps shall have a minimum MEI value of 0,10;
2 1st January 2015 all pumps shall have a minimum MEI value of 0,40.
The most important point of this is that unless the pumps comply then they
will not be allowed to have a CE marking.
• Part Load Performance

It is common practice that pumps spend much of their time working away from their rated
duty, and efficiency can fall off rapidly below the 50% duty point, any scheme should take
account of this real life performance. However, manufacturers need a pump efficiency
classification scheme that makes it impossible to design pumps with a steep fall off in
efficiency either side of the BEP point in order to claim a higher efficiency than would be
typical of real life operation.
• ‘House of Efficiency’
The decision scheme ‘House of Efficiency’ takes into account design and application
purposes as well as the pump minimum efficiency dependence on flow. The minimum
acceptable efficiency is therefore different for each pump type. The pass-or-fail scheme
is based on two criteria A and B.

CombiBloc
Criterion A is the pass-or-fail minimum efficiency requirement at the best efficiency point
(BEP) of the pump:
η Pump 〈 n s, Q BEP〉 ≥ η BOTTOM
Where
Q BEP
n s = n N × -------------------
H 0.75
BEP
Criterion B is the pass-or-fail minimum efficiency requirement at part load (PL) and at
overload (OL) of the pump:
η BOTTOM – PL, OL ≥ x ⋅ η BOTTOM
Therefore a method is devised what is called a “house of efficiency” scheme that also
requires pumps to pass efficiency thresholds at 75% and 110% of rated flow. The
advantage of this is that pumps will be penalised for poor efficiency away from rated
efficiency, hence it will take account of real life pump duties.
It should be stated that while the scheme may appear complicated at first sight, in
practice it has been easy for the manufacturers to apply the scheme to their pumps.
Figure 2: House of Efficiency

System
Head Curve
BEP
HBEP
η
Pump Eff.
Curve
η BEP
η OL= 0.98 η BEP
η PL= 0.94 η BEP
0 QPL QBEP QOL Flow

2.6.3 Energy Efficient Pump Selection
In selecting the pump, care should be taken to ensure that the duty point required is as
close as possible to the pump’s Best Efficiency Point (BEP). Different heads and flows
can be achieved by changing the diameter of the impeller and thereby eliminating
unnecessary energy loss.
The same pump can be offered at different motor speeds to allow the pump to be used
over a much wider range of duties. For instance, changing from 4-pole motor to 2-pole
motor will enable the same pump to deliver twice as much peak flow at 4 times the head.
Variable speed drives allow the pump to operate efficiently over a wide range of speeds
hence duties in an energy efficient manner. They are particularly useful in systems where
is a variation in required flow.
A very useful tool for energy efficient pump selection is the downloadable software
program “Hydraulic Investigator 2” from the SPX website.
Hydraulic Investigator is the selection guide for centrifugal pumps and search by pump
family and pump type starting from entering required capacity and head. Further refine
the pump curves to find the pump that meets your specification.
The default setting of applicable pump types is prioritized on highest efficiency. In the
standard automated selection procedure the optimum (trimmed) impeller diameter is
calculated already, where applicable. Manually the rotating speed can be adjusted as
well when a variable speed drive is preferred.
Example:
Curve 1: performance at maximum impeller diameter and 2960 rpm;
Curve 2: performance at required duty point (180 m3/h, 30 m) with trimmed impeller,
power consumption 18,42 kW;
Curve 4: performance at required duty point with maximum impeller diameter and
reduced rotating speed (2812 rpm), power consumption 18,21 kW.
Figure 3: Hydraulic Investigator 2

CombiBloc
2.6.4 Scope of Implementing Directive 2009/125/EC

The following SPX Flow Technology products are in the scope of the directive:
• CombiNorm (ESOB)
• CombiChem (ESOB)
• CombiBloc (ESCC)
• CombiBlocHorti (ESCC)
• CombiLine (ESCCi)
• CombiLineBloc (ESCCi)
Pumps with half-open impeller are excluded from the scope of the directive. Half-open
impellers are designed for pumping liquids containing solids.
The vertical multistage pump range MCV(S) is out of the scope of the directive, these
pumps are designed for pressures up to 4000 kPa (40 bar).
Submersible multistage pumps are not available in the SPX product portfolio.
2.6.5 Product information

Name plate, example:
Figure 4: Name plate
1 MEI ≥ 3
SPX Flow Technology Assen B.V. CR Nr. 04029567
Dr. A.F. Philipsweg 51, NL-9403 AD Assen
Ø 5 No. 2 eff. 4
Table 1: Name plate
1 CB 40C-200 G1 Product type and size
2 12-1000675A Year and serial number
3 0,40 Minimum Efficiency Index at max. impeller diameter
4 [xx.x]% or [-,-]% Effciency for trimmed impeller diameter
5 202 mm Fitted impeller diameter
Or
Figure 5: Name plate horticulture
1 MEI ≥ 3
Johnson Pump Horticulture CR Nr. 04029567
De Hondert Margen 23 NL-2678 AC De Lier
Ø 5 No. 2 eff. 4
Table 2: Name plate horticulture
1 CB 40C-200 G1 Product type and size
2 11-09 X123500 1/2 Month-year, serial number and number of pumps

Figure 6: Name plate ATEX certified
SPX Flow Technology Assen B.V. - www.johnson-pump.com

Dr. A.F. Philipsweg 51, NL-9403 AD Assen - CR Nr. 04029567
Type: 1 Ø 6
Code: 2 MEI ≥ 7
No.: 3 eff. 8
4
5
Table 3: Name plate ATEX certified

1 CB 40C-200 Product type and size
2 G1 Smartcode
3 12-1000675A Year and serial number
4 II 2G c T3-T4 Ex marking
5 KEMA03 ATEX2384 Certificate number
1 Minimum efficiency index, MEI:

Table 4: MEI value
Speed
MEI value according prEN16480
[rpm] Remarks
Material Cast iron Bronze1) St.St.2)
25-125 2900 Outside scope
25-160 2900 Outside scope
32-125 2900 > 0,40 > 0,40 > 0,40
32C-125 2900 > 0,40 > 0,40 > 0,40
32-160 2900 > 0,40 > 0,40 > 0,40
32A-160 2900 > 0,40 > 0,40 > 0,40
32C-160 2900 > 0,40 > 0,40 > 0,40
32-200 2900 > 0,40 > 0,40 > 0,40
32C-200 2900 > 0,40 > 0,40 > 0,40
32-250 2900 > 0,40 > 0,40 > 0,40
40C-125 2900 > 0,40 > 0,40 > 0,40
40C-160 2900 > 0,40 > 0,40 > 0,40
40C-200 2900 > 0,40 > 0,40 > 0,40
40-250 2900 > 0,40 > 0,40 > 0,40
50C-125 2900 > 0,40 > 0,40 > 0,40
50C-160 2900 > 0,40 > 0,40 > 0,40
50C-200 2900 > 0,40 > 0,40 > 0,40

CombiBloc
Table 4: MEI value

Speed
MEI value according prEN16480
[rpm] Remarks
Material Cast iron Bronze1) St.St.2)
50-250 2900 > 0,40 > 0,40 > 0,40
65C-125 2900 > 0,40 > 0,40 > 0,40
65C-160 2900 > 0,40 > 0,40 > 0,40
65C-200 2900 > 0,40 > 0,40 > 0,40
65A-250 2900 > 0,40 > 0,40 > 0,40
80C-160 2900 > 0,40 > 0,40 > 0,40
80C-200 2900 > 0,40 > 0,40 > 0,40
80-250 2900 > 0,40 > 0,40 > 0,40
80A-250 2900 > 0,40 > 0,40 > 0,40
100-160 2900 > 0,40 > 0,40 x
100C-200 2900 > 0,40 > 0,40 > 0,40
100C-250 2900 > 0,40 > 0,40 > 0,40
125-125 1450 x Not available
125-250 1450 > 0,40 > 0,40 > 0,40
125-315 1450 > 0,40 > 0,40 > 0,40
150-125 1450 --- --- x Outside scope, ns > 80 rpm
150-200 1450 > 0,40 > 0,40 x
150-250 1450 x Not available
200-200 1450 > 0,40 > 0,40 x
250-200 1450 > 0,40 > 0,40 x
St.St. = stainless steel
¹) impeller or pump in bronze
²) impeller or pump in stainless steel
x = not available in delivery program
2 The benchmark for most efficient water pumps is MEI ≥ 0,70.
3 Year of manufacture; the first 2 positions (= the last 2 positions of the year) of the
serial number of the pump as marked on the rating plate. An example and explanation
is given in paragraph 2.6.5 "Product information" of this document.
4 Manufacturer:
Registration number at Chamber of Commerce 04 029567
9403 AD Assen
The Netherlands
Location Horticulture:

Registration number at Chamber of Commerce 04 029567
Johnson Pump Horticulture
De Hondert Margen 23
2678 AC De Lier
The Netherlands

5 Product type and size identifier are marked on the rating plate. An example and
explanation is given in paragraph 2.6.5 "Product information" of this document.
6 The hydraulic pump efficiency of the pump with trimmed impeller diameter is marked
on the rating plate, either the efficiency value [xx.x]% or [-.-]%.
7 Pump curves, including efficiency characteristics, are published in the downloadable
software program “Hydraulic Investigator 2” from the SPX website. For downloading
“Hydraulic Investigator 2” go to http://www.spx.com/en/johnson-pump/resources/
hydraulic-investigator/ The pump curve for the delivered pump is part of the related
customer order documentation package separate from this document.
8 The efficiency of a pump with a trimmed impeller is usually lower than that of a pump
with the full impeller diameter. The trimming of the impeller will adapt the pump to a
fixed duty point, leading to reduced energy consumption. The minimum efficiency
index (MEI) is based on the full impeller diameter.
9 The operation of this water pump with variable duty points may be more efficient and
economic when controlled, for example, by the use of a variable speed drive that
matches the pump duty to the system.
10 Information relevant for disassembly, recycling or disposal at end-of-life is described
in paragraph 2.8 "Re-use", paragraph 2.9 "Scrapping" and chapter 7 "Disassembly
and assembly".
11 The benchmark efficiency Fingerprint Graphs are published for:
MEI = 0,40 MEI = 0,70
ESOB 1450 rpm ESOB 1450 rpm
ESOB 2900 rpm ESOB 2900 rpm
ESCC 1450 rpm ESCC 1450 rpm
ESCC 2900 rpm ESCC 2900 rpm
ESCCi 1450 rpm ESCCi 1450 rpm
ESCCi 2900 rpm ESCCi 2900 rpm
Multistage Vertical 2900 rpm Multistage Vertical 2900 rpm
Multistage Submersible 2900 rpm Multistage Submersible 2900 rpm
Benchmark efficiency graphs are available under http:\\www.europump.org/
efficiencycharts.
2.7 Application area

The application area globally looks as follows:,
Table 5: Application area.
Maximum value
Capacity 850 m3/h
Discharge head 105 m
System pressure 10 bar
Temperature 120 °C (briefly 140 °C)

CombiBloc
2.8 Re-use
The pump may only be used for other applications after prior consultation with SPX or
your supplier. Since the lastly pumped medium is not always known, the following
instructions should be observed:
1 flush the pump properly.
2 make sure the flushing liquid is discharged safely (environment!)
 Take adequate precautions and use the appropriate personal protection

means like rubber gloves and spectacles!
2.9 Scrapping
If it has been decided to scrap a pump, the same flushing procedure as described for
Re-use should be followed.

CombiBloc
3 Installation
3.1 Safety
• Read this manual carefully prior to installation and commissioning. Non-observance of
these instructions can result in serious damage to the pump and this will not be
covered under the terms of our guarantee. Follow the instructions given step by step.
• Ensure that the pump can not be started if work has to be undertaken to the pump
during installation and the rotating parts are insufficiently guarded.
• Depending on the design the pumps are suitable for liquids with a temperature of up
to 110°C. When installing the pump unit to work at 65°C and above the user should
ensure that appropriate protection measures and warnings are fitted to prevent
contact with the hot pump parts.
• If there is danger of static electricity, the entire pump unit must be earthed.
• If the pumped liquid is harmful to men or the environment, take appropriate measures
to drain the pump safely. Possible leakage liquid from the shaft seal should also be
discharged safely.
3.2 Preservation
In order to prevent corrosion, the inside of the pump is treated with a preserving agent
before leaving the factory.
Before commissioning the pump remove any preserving agents and flush the pump
thoroughly with hot water.
3.3 Environment
• The foundation must be hard, level and flat.
• The area in which the pump is installed must be sufficiently ventilated. An ambient
temperature or air humidity which is too high, or a dusty environment, can have a
detrimental effect on the operation of the electric motor.
• There should be sufficient space around the pump unit to operate and if necessary
repair it.
• Behind the cooling air inlet of the motor there must be a free area of at least ¼ of the
electric motor diameter, to ensure unobstructed air supply.
3.4 Installation of a pump unit

If the unit is delivered as a complete set, pump and motor are assembled in the works. In
that case the impeller has already been properly adjusted axially. In case of permanent
arrangement, level the pump on the foundation by means of shims and carefully tighten
the nuts of the foundation bolts.
CB/EN (1501) 6.6 Installation 25

3.5 Piping
• The piping to the suction and delivery connections must fit exactly and must not be
subject to stress during operation. For the maximum allowable forces and moments on
the pump flanges see paragraph 10.6 "Permitted forces and torques on the flanges,
based on EN-ISO 5199".
• The passage of the suction pipe must be amply dimensioned. This pipe should be as
short as possible and run towards the pump in such a way that no air pockets can
arise. If this is not possible, a venting facility should be provided at the highest point of
the pipe. If the inside diameter of the suction pipe is larger than the suction connection
of the pump, an eccentric reducer should be applied to prevent air pockets and whirls.
See figure 7.
Figure 7: Eccentric reducer to suction flange.
4035_A
• The maximum allowable system pressure is stated in paragraph 2.7 "Application area".
If there is a risk that this pressure might be exceeded, for instance because of an
excessive inlet pressure, appropriate measures should be taken by mounting a safety
valve in the piping.
• Sudden changes in the rate of flow can lead to high pressure impulses in the pump
and the piping (water shock). Therefore, do not use quick-acting closing devices,
valves etc.
3.6 Accessories
• Fit any parts that may have been supplied separately.
• If the liquid does not flow towards the pump, fit a foot valve at the bottom of the
suction pipe. If necessary, combine this foot valve with a suction strainer to prevent
impurities from being drawn in.
• When mounting, place temporarily (for the first 24 operating hours) a fine gauze
between suction flange and suction pipe to prevent internal pump parts from being
damaged by foreign matter. If the risk of damage continues to exist, fit a permanent
filter.
• In case the pump is provided with an isolation, special attention has to be paid To
temperature limits of shaft seal and bearing.
3.7 Connection of the electric motor
 The electric motor must be connected to the mains by an approved

electrician, according to the locally prevailing regulations of the electricity
company.
• Refer to the instruction manual belonging to the electric motor.
• If possible, fit a working switch as close as possible to the pump.
26 Installation CB/EN (1501) 6.6

CombiBloc
4 Commissioning
4.1 Inspection of the pump

• Check whether the stub shaft turns freely. Do this by turning the shaft end at the
coupling a few times by hand.
4.2 Inspection of the motor

• Check whether the fuses have been mounted.
4.3 Preparing the pump unit for commissioning

Proceed as follows, both when the unit is put into operation for the first time and after the
pump has been overhauled:
1 Fully open the stop valve in the suction pipe. Close the delivery stop valve.
2 Fill the pump and the suction pipe with the liquid to be pumped.
3 Turn the stub shaft a few times by hand and add more liquid, if necessary.
4.4 Checking the sense of rotation
 Beware of possible non-screened rotating parts, when checking the sense of

rotation!
1 The sense of rotation of the pump is indicated by an arrow. Check whether the sense
of rotation of the motor corresponds with that of the pump.
2 Let the motor run for only a short time and check the sense of rotation.
3 If the sense of rotation is not correct, alter the sense of rotation. See the instructions
in the user manual belonging to the electric motor.
4 Fit the guard.
4.5 Start-up
1 Start the pump.
2 As soon as the pump is under pressure, slowly open the delivery stop valve until the
working pressure is attained.
 Make sure that when a pump is running, rotating parts are always properly
screened by the guard!
CB/EN (1501) 6.6 Commissioning 27

4.6 Pump in operation
When the pump is in operation, pay attention to the following:
• The pump should never run dry.
• Never use a stop valve in the suction line to control pump output. The stop valve
should always be fully opened during operation.
• Check whether the absolute inlet pressure is sufficient, to prevent vaporization in the
pump.
• Check whether the pressure difference between suction and delivery side
corresponds with the specifications of the pump's duty point.
• A mechanical seal may never show visible leakage.
4.7 Noise
The noise production of a pump depends to a great extent on the operating conditions.
The values stated in paragraph 10.7 "Noise data" are based on normal operation of the
pump, driven by an electric motor. In case the pump is driven by a combustion engine, or
in case it is used outside the normal operation area, as well as in case of cavitation, the
noise level may exceed 85 dB(A). In that case precautions should be taken, like building
a noise-barrier around the unit or wearing hearing protection.
28 Commissioning CB/EN (1501) 6.6

CombiBloc
5 Maintenance
5.1 Regular maintenance

Regularly check the outlet pressure.
 No water should get into the terminal box of the electric motor when the
pump room is sprayed clean!
Never spray water on hot pump parts! The sudden cooling down may cause
them to burst and hot water may flow out!
! Flawed maintenance will result in shorter lifespan, possible break down and
in any event loss of warranty.
5.2 Mechanical seal

A mechanical seal generally requires no maintenance, however, it should never be
allowed to run dry. If there are no problems, do not dismantle the mechanical seal. As
the seal faces have run in on one another dismantling usually implicates replacement of
the mechanical seal. If a mechanical seal shows any leakage it has to be replaced.
5.3 Lubrication of the bearings

For maintenance of the motor bearings we refer to the instructions of the motor supplier
concerned.
5.4 Environmental influences

• Regularly clean the filter in the suction pipe or the suction strainer at the bottom of the
suction pipe, as the inlet pressure may become too low if the filter or the suction
strainer is fouled.
• If there is a risk that the pumped liquid expands during solidification or freezing, the
pump has to be drained and, if necessary, flushed after it has been put out of service.
• If the pump is out of service for a long time, it has to be preserved.
• Check motor for accumulation of dust or dirt, which might influence motor
temperature.
5.5 Noise
If a pump starts making noise, this may point to certain problems with the pump unit. A
crackling noise can indicate cavitation or excessive motor noise can indicate
deterioration of the bearings.
5.6 Motor
Check motor specifications for start-stop frequency.
CB/EN (1501) 6.6 Maintenance 29

5.7 Faults
 The pump, of which you want to determine the fault, may be hot or under
pressure. Take the appropriate precautions first and protect yourself with
the proper safety devices (safety goggles, gloves, protective clothing)!
To determine the source of the malfunctioning of the pump, proceed as follows:
1 Switch off the power supply to the pump unit. Lock the working switch with a padlock
or remove the fuse.
2 Close the stop valves.
3 Determine the nature of the fault.
4 Try to determine the cause of the fault with chapter 6 "Problem solving" and take the
appropriate measures or contact your installer.
30 Maintenance CB/EN (1501) 6.6

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6 Problem solving
Faults in a pump installation can have various causes. The fault may not be in the pump, it
may also be caused by the pipe system or the operating conditions. Firstly, always check
that installation has been executed in accordance with the instructions in this manual and
that the operating conditions still correspond with the specifications for which the pump
was purchased.
In general, breakdowns in a pump installation are attributable to the following causes:
• Faults with the pump.
• Breakdowns or faults in the pipe system.
• Faults due to incorrect installation or commissioning.
• Faults due to incorrect choice of pump.
A number of the most frequently occurring failures as well as their possible causes are
shown in the table below.
Table 6: Most frequently occurring failures.

Most common faults Possible causes, see Table 7.
Pump delivers no liquid 1 2 3 4 8 9 10 11 13 14 17 19 20 21 29
1 2 3 4 8 9 10 11 13 14 15 17 19 20 21
Pump has insufficient volume flow
28 29
Pump has insufficient head 2 4 13 14 17
Pump stops after start up 1 2 3 4 8 9 10 11
Pump has higher power consumption than 12 15 16 17 18 22 23 24 25 26 27 32
normal 38 39
Pump has lower power consumption than
13 14 15 16 17 18 20 21 28 29
normal
Mechanical seal has to be replaced to
23 25 26 30 32 33 36
often
1 9 10 11 15 18 19 20 22 23 24 25 26
Pump vibrates or is noisy
27 29 37 38 39 40
Bearings wear too much or become hot 23 24 25 26 27 37 38 39 40 42
Pump running rough, hot or seizes 23 24 25 26 27 37 38 39 40 42
CB/EN (1501) 6.6 Problem solving 31

Table 7: Possible causes of pump failures.
Possible causes
1 Pump or suction pipe is not sufficiently filled or de-aerated
2 Gas or air coming from the liquid
3 Air lock in the suction pipe
4 Air leak in the suction pipe
8 The manometric suction head is too high
9 Suction pipe or suction strainer is blocked
10 Insufficient immersion of foot valve or suction pipe during operation of the pump
11 NPSH available too low
12 Speed too high
13 Speed too low
14 Wrong sense of rotation
15 Pump does not operate at the right duty point
16 Liquid density differs from the calculated liquid density
17 Liquid viscosity differs from the calculated liquid viscosity
18 Pump operates when the liquid flow is too low
19 Wrong pump selection
20 Obstruction in impeller or pump casing
21 Obstruction in the piping
22 Wrong installation of the pump unit
24 Rotating part running out of true
25 Imbalance in rotating parts (for instance: impeller or stub shaft)
26 Stub shaft is running out of true
27 Bearings faulty or worn out
28 Wear ring faulty or worn out
29 Damaged impeller
30 Seal faces of the mechanical seal are worn out or damaged
32 Bad mounting of the mechanical seal
33 Mechanical seal not suitable for the pumped liquid or operation circumstances
36 Flushing liquid to the mechanical seal is polluted
37 Axial retaining of impeller or stub shaft is defective
40 Wrong or polluted lubricant
42 Too high axial force because of worn dorsal blades or excessive inlet pressure
32 Problem solving CB/EN (1501) 6.6

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7 Disassembly and assembly
7.1 Precautionary measures
 Take adequate measures to avoid that the motor is started while you are
working on the pump. This is especially important for electric motors with
remote control:
• Switch the operating switch near the pump (if available) to "OFF".
• Switch off the pump switch on the switchboard.
• If necessary remove the fuses.
• Hang a danger board near the switchboard cabinet.
7.2 Special tools

Assembly and disassembly work requires no special tools. However, such tools can
make certain jobs easier, for instance replacing the shaft seal. If such is the case it will be
indicated in the text.
7.3 Liquid draining
! Make sure no liquid gets into the environment!

Before starting any disassembly the pump should be drained.
1 If necessary, close the valves in the suction and delivery pipe and in the flushing or
cooling supply lines to the shaft seal.
2 Remove the drain plug (0310).
3 If harmful liquids are pumped wear protective gloves, shoes, glasses, etc., and
thoroughly flush the pump.
4 Refit the drain plug.
CB/EN (1501) 6.6 Disassembly and assembly 33

7.4 Disassembly
7.4.1 Back-Pull-Out system

The pumps are designed with a Back-Pull-Out system. The entire rotating section can be
removed together with the motor. This means that almost the whole pump can be
dismantled without having to detach the suction and delivery piping.
7.4.2 Disassembling the Back-Pull-Out unit

4195_A
0810
0900 0850
Figure 8: Back-Pull-Out principle.
1 Open the terminal box and loosen the wires.
2 If the electric motor has been mounted on a separate foundation, loosen the electric
motor.
3 Remove the nuts (0810).
! NEVER start dismantling by loosening the motor bolts (0850) and nuts (0900).
This may result in irrepairable damage to the mechanical seal and the
impeller!
4 Pull the motor together with the entire lantern piece out of the pump casing. The
Back-Pull-Out unit large pumps is very heavy. Support it with a beam or hang it in a
pulley sling.
7.4.3 Assembling the Back-Pull-Out unit

1 Fit a new gasket (0300) into the pump casing.
2 Mount the complete lantern piece with motor back into the pump casing.
3 Fit the nuts (0810) and tighten them crosswise with the proper tightening torque. See
paragraph 10.2 "Tightening moments".
34 Disassembly and assembly CB/EN (1501) 6.6

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7.5 Replacing the impeller and the wear ring

The play between the impeller and the wear ring is 0,3 mm to the diameter at delivery. In
case the play has increased to 0,5-0,7 mm due to wear, the impeller and the wear ring
should be replaced.
7.5.1 Disassembling the impeller
1820
0120
1860
1100
0110
4192_A
Figure 9: Disassembling the impeller.
The item numbers used are referring to figure 9.
1 Remove the Back-Pull-Out unit, see paragraph 7.4.2 "Disassembling the Back-Pull-
Out unit".
2 Remove the cap nut (1820). Sometimes the nut has to be heated to break the
Loctite-contact.
3 Remove the impeller (0120) with a pulley puller, or wrest the impeller by inserting for
instance 2 big screwdrivers between the impeller and the pump cover (0110).
4 Remove the impeller key (1860).
5 Remove the distance sleeve (1100) with the rotating part of the mechanical seal
(1220).
6 Pump size 200-160 only: Loosen the set screws (1260). Remove the shaft sleeve
(1200) and the rotating part of the mechanical seal (1220).
7.5.2 Mounting the impeller

Pump size 200-160 only:
1 Fit the rotating part of the mechanical seal on the stub shaft.
2 Fit the shaft sleeve (1200) and set the distance to the shaft collar to 44 mm. See
figure 13 of paragraph 7.6.3 "Assembling a mechanical seal M1". Tighten the set
screws (1260).
Other types:
1 Fit the rotating part of the mechanical seal on the distance sleeve.
2 Fit the distance sleeve with the rotating part of the mechanical seal on the stub shaft.

All types:
1 Place the impeller key in the key way of the stub shaft.
2 Push the impeller onto the stub shaft against the distance sleeve.
3 Degrease the thread on the stub shaft and the thread in the cap nut.
4 Put a drop of Loctite 243 on the thread and fit the cap nut. For tightening moment of
the nut see paragraph 10.2.2 "Tightening moments for cap nut".
5 Mount the Back-Pull-Out unit, see paragraph 7.4.3 "Assembling the Back-Pull-Out
unit".
7.5.3 Disassembling the wear ring

After removing the Back-Pull-Out unit the wear ring can be removed. In most cases the
ring has been fixed so tightly that it cannot be removed undamaged.
4043
b d
A B
C D
Figure 10: Removal of wear ring.

1 Measure the thickness (D) and the width (B) of the ring, see figure 10 A.
2 Make a centre hole in the middle of the edge of the ring at two opposite points, see
figure 10 B.
3 Use a drill with a diameter just a little bit smaller than the thickness (D) of the ring and
drill two holes in the ring, see figure 10 C. Don't drill deeper than the width (B) of the
ring. Take care not to damage the fitting edge of the pump casing.
4 Use a chisel to cut the remaining part of the ring thickness. Now you can remove the
ring in two parts from the pump casing, see figure 10 D.
5 Clean the pump casing and carefully remove all bore dust and metal splinters.
7.5.4 Assembling the wear ring

1 Clean and degrease the fitting edge of the pump casing where the wear ring is to be
mounted.
2 Degrease the outer edge of the wear ring and put a few drops of Loctite 641 on it.
3 Fit the wear ring in the pump casing. Take care it is not pushed out of
alignment!

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7.6 Mechanical seal
7.6.1 Instructions for mounting a mechanical seal

➢ First read the following instructions regarding the mounting of a mechanical seal. Follow
these instructions closely when mounting a mechanical seal.
• Leave the assembly of a mechanical seal with PTFE (Teflon) covered O-
rings to a specialist. These rings are easily damaged during assembly.
• A mechanical seal is a fragile precision instrument. Leave the seal in its original
packing until you are ready to fit it!
• Clean all receiving parts properly. Make sure your hands and working environment are
clean!
• Never touch the sliding surfaces with ones fingers!
• Take care not to damage the seal during assembly. Never put the rings down on their
sliding surfaces!
➢ Special tools: Mounting the mechanical seal unit is easier when you use a special
tapered mounting bush. That way, the sharp shaft edges are covered so that the risk of
damaging the seal during assembly is reduced. See figure 11.
4048
Figure 11: Special mounting bush.

7.6.2 Disassembling a mechanical seal M1
4193
Figure 12: Mechanical seal M1.

1 Remove the impeller, see paragraph 7.5.1 "Disassembling the impeller".
2 Pump size 200-160 only: Loosen the set screws (1260). See paragraph Figure 13:
"Adjusting the mechanical seal M1 of pump size 200-160.".
3 Pull the distance sleeve (1100) (Pump size 200-160: spacer sleeve (1200)) and the
rotating part of the mechanical seal (1220) off the shaft.
4 Mark the position of the pump cover (0110) in relation to the lantern piece (0250).
Knock the pump cover loose and remove it.
5 Push the counter-ring of the mechanical seal (1220) out of the pump cover.

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7.6.3 Assembling a mechanical seal M1

1 Make sure the stub shaft (2200) is not damaged. If it is, replace it.
2 Place the electric motor with the shaft upright.
3 Put the pump cover flat down and press the counter-ring of the seal straight into it. If
necessary, use a plastic pressure piece. Never hammer it inside! The maximum
axial turn of the counter-ring is 0,1 mm.
4 Mount the pump cover in the right position in the collar of the lantern piece. Check
whether the pump cover is at right angles to the stub shaft.
5 Push the rotating part of the mechanical seal on the distance sleeve (1100). Put
some glycerine or silicon spray on the bellows to facilitate the assembly!
6 Pump size 200-160 only: Push the rotating part of the mechanical seal and the
spacer sleeve (1200)) on the the stub shaft.
7 Pump size 200-160 only: Set the distance between the spacer sleeve and the shaft
collar at 44 mm. Fix the spacer sleeve by means of set screws (1260). See figure 13.
8 Mount the impeller, see paragraph 7.5.2 "Mounting the impeller".)
1200
1260
4410_A
93.5
44
Figure 13: Adjusting the mechanical seal M1 of pump size 200-160.

7.7 Replacing the stub shaft and the motor
7.7.1 Disassembling the stub shaft and the motor of pump size 25-...
Figure 14: Assembly of the stub shaft of pump size 25-...

1 Dismantle the impeller and the shaft seal. See paragraph 7.5.1 "Disassembling the
impeller" and paragraph 7.6.2 "Disassembling a mechanical seal M1".
2 Loosen the bolts (0850) and nuts (0900) and remove the lantern piece (0250) from
the motor.
3 Remove the seal guards (0276).
4 Loosen the set screws (2280) and pull the stub shaft (2200) from the motor shaft.
7.7.2 Assembling the stub shaft and the motor of pump size 25-...
1 Remove the key from the motor shaft.
2 Put the motor in vertical position, shaft end up. Fit the stub shaft (2200) on the motor
shaft. Make sure the set screws (2280) are positioned over the key way in the motor
shaft. Do not fix the stub shaft yet!
3 Fit the lantern piece (0250) to the electric motor with bolts (0850) and nuts (0900).
4 Mount the pump cover (0110), the mechanical seal (1200) and the impeller (0120),
see paragraph 7.6.3 "Assembling a mechanical seal M1" and paragraph 7.5.2
"Mounting the impeller".
5 Fit the pump casing (0100) to the lantern piece without gasket (0300).
6 Fix the pump casing temporarily with 2 nuts (0810).
7 Push the stub shaft towards the pump casing, until the impeller touches the pump
casing.
8 Fix the stub shaft on the motor shaft with the set screws (2280).

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9 Unscrew the nuts (0810) and remove the pump casing.

10 Place a new gasket (0300) and fit the pump casing. Fix the pump casing with nuts
(0810). Tighten them crossways with the proper tightening moment. See paragraph
10.2 "Tightening moments".
11 Fit the seal guards (0276).
7.7.3 Disassembling the stub shaft and the motor
X
1100 1220 0110 2200
1820 0120 1860 0250 027 6 0850 0900

2280 IE C IE C
80 132S/M
9 0S / L 160M/L
100L 180M/L
112M 200L
225S/M
250M
2200 2200 2280 280S/M
Figure 15: Assembly of the stub shaft
1 Dismantle the impeller and the shaft seal. See paragraph 7.5.1 "Disassembling the
impeller" and paragraph 7.6.2 "Disassembling a mechanical seal M1".
2 Loosen the bolts (0850) and nuts (0900) and remove the lantern piece (0250) from
the motor.
3 Remove the seal guards (0276).
4 Loosen the set screws (2280) and pull the stub shaft (2200) from the motor shaft.

7.7.4 Assembling the stub shaft and the motor
1 For electric motors with IEC-size 80 upto and including 112M: Remove the key from
the motor shaft.
2 Put the motor in vertical position, shaft end up. Fit the stub shaft (2200) on the motor
shaft. Do not fix the stub shaft yet!
3 For electric motors with IEC size 80 upto and including 112M: make sure the set
screws (2280) are positioned over the key way in the motor shaft.
4 Place shims between the lantern piece and the motor flange and fit the lantern piece
(0250) to the electric motor. See Table 8 for the proper thickness X of the shims
Table 8: Shim thickness X for adjusting the stub shaft
Pump type Shim thickness X
32-125 R6 (stainless steel) 2 mm
32-160 R6 (stainless steel) 2,5 mm
40-125 R6 (stainless steel) 3,5 mm
all other types 0,5 mm
5 Mount the pump cover (0110), the mechanical seal (1200) and the impeller (0120).
6 Push the impeller on the stub shaft until the back blades touch the pump cover.
7 Fix the stub shaft on the motor shaft with the set screws (2280).
8 Slightly loosen the fastening bolts (0850) of the electric motor and remove the shims.
9 Tighten the fastening bolts (0850) of the electric motor crossways with the
prescribed tightening moment, see paragraph 10.2.1 "Tightening moments for bolts
and nuts".
10 Place the gasket (0300) and fit the pump casing (0100). Fix the pump casing with
nuts (0810). Tighten them crossways. see paragraph 10.2.1 "Tightening moments for
bolts and nuts".
11 Fit the seal guards (0276).

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8 Dimensions
CB/EN (1501) 6.6 Dimensions 43

8.1 Dimension drawings
ajx∅al
ab
ad
ah
af
ta tu
zb
an
aix∅ak am
zh
dc
ds
db
vf
aa
ac vd
ae vs
ag
vb
vp
vc
vr
vo
ve vt vn
vj
va vm
Figure 16: Pump dimensions.
44 Dimensions CB/EN (1501) 6.6

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8.2 Motor feet dimensions

IEC dc ds vm vn vo vp vr vs
80 80 100
90S 90 100
90L 90 100
100L 100 125
112M 112 125
132S 132 150 202 140 47 216 255 12
132M 132 150 240 178 47 216 255 12
160M 160 175 270 210 60 254 314 15
160L 160 175 314 254 60 254 314 15
180M 180 175 300 241 65 279 346 15
180L 180 175 338 279 65 279 346 15
200L 200 200 385 305 80 318 398 19
225S 225 200 370 286 85 356 441 19
225M 225 200 370 311 85 356 441 19
250M 250 275 439 349 90 406 496 24
280S 280 275 454 368 100 457 557 24
280M 280 275 520 419 100 457 557 24

8.3 Flange dimensions
8.3.1 Cast iron and bronze G, B

ISO 7005 PN6
aa ab ac ad ae af ag ah ai x ak aj x al am an
32 25 64,5 50,8 90 75 117,5 108 4 x 14 4 x 11 12 12
ISO 7005 ≅ EN 1092-2
ISO 7005 PN16
25 25 68 68 86 86 115 115 4 x 14 4 x 14 14 14
50 32 102 78 125 100 165 140 4 x 18 4 x 18 20 18
65 40 122 88 145 110 185 150 4 x 18 4 x 18 20 18
65 50 122 102 145 125 185 165 4 x 18 4 x 18 20 20
80 65 138 122 160 145 200 185 8 x 18 4 x 18 22 20
100 80 158 138 180 160 220 200 8 x 18 8 x 18 22 22
100 100 158 158 180 180 220 220 8 x 18 8 x 18 22 22
125 100 188 158 210 180 250 220 8 x 18 8 x 18 24 22
125 125 188 188 210 210 250 250 8 x 18 8 x 18 24 24
150 125 212 188 240 210 285 250 8 x 23 8 x 18 24 24
150 150 212 212 240 240 285 285 8 x 23 8 x 23 24 24
ISO 7005 ≅ EN 1092-2
ISO 7005 PN10
200 150 268 212 295 240 340 285 8 x 23 8 x 23 26 24
200 200 268 268 295 295 340 340 8 x 23 8 x 23 26 26
250 250 320 320 350 350 395 395 12 x 23 12 x 23 28 28
ISO 7005 ≅ EN 1092-2
8.3.2 Stainless steel R

ISO 7005 PN6
32 25 64,5 50,8 90 75 117,5 108 4 x 14 4 x 11 12 12
ISO 7005 ≅ EN 1092-1
ISO 7005 PN16

25 25 68 68 85 85 115 115 4 x 14 4 x 14 16 16
50 32 99 76 125 100 165 140 4 x 18 4 x 18 22,5 20,5
65 40 118 84 145 110 185 150 4 x 18 4 x 18 22,5 20,5
80 50 132 99 160 125 200 165 8 x 18 4 x 18 22,5 22,5
100 65 156 118 180 145 230 185 8 x 18 4 x 18 26,5 22,5
125 80 184 132 210 160 255 200 8 x 18 8 x 18 26,7 23,1
125 100 184 156 210 180 255 230 8 x 18 8 x 18 26,5 26,9
150 125 216 186 240 210 285 255 8 x 22 8 x 18 28 27,1
ISO 7005 ≅ EN 1092-1

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8.4 Pump dimensions

CB aa* ab* aa** ab** db* db** tu va vb vc vd ve vf* vf** vj zb* zb** zh
25-125 32 25 32 25 100 100 100 100 140 170 12 70 10 10 35 62 62 115
25-160 25 25 25 25 132 132 100 100 190 220 14 70 10 10 35 64,5 64,5 152
32-125 112 112 100 100 140 190 14 70 10 14 50 80 80 140
32C-125 112 112 100 100 140 190 14 70 10 14 50 80 80 140
32-160 132 132 100 100 190 240 14 70 12 14 50 80 80 160
32A-160 132 132 100 100 190 240 14 70 12 14 50 80 80 160
32C-160 50 32 50 32 132 132 100 100 190 240 14 70 12 14 50 80 80 160
32-200 160 160 100 100 190 240 14 70 12 14 50 80 80 180
32C-200 160 160 100 100 190 240 14 70 12 14 50 80 80 180
32-250 180 180 100 125 250 320 14 95 14 14 65 100 100 225
40C-125 112 112 100 100 160 210 14 70 10 14 50 80 80 140
40C-160 132 132 100 100 190 240 14 70 12 14 50 80 80 160
40C-200 65 40 65 40 160 160 100 100 212 265 14 70 12 14 50 100 100 180
40-250 180 180 100 125 250 320 14 95 14 16 65 100 100 225
50C-125 132 132 100 100 190 240 14 70 10 12 50 100 100 160
50C-160 160 160 100 100 212 265 14 70 12 14 50 100 100 180
50C-200 65 50 80 50 160 160 100 100 212 265 14 70 12 14 50 100 100 200
50-250 180 180 100 125 250 320 14 95 14 16 65 100 125 225
65C-125 160 160 100 125 21 280 14 95 10 12 65 100 100 180
65C-160 160 160 100 125 212 280 14 95 12 14 65 100 100 200
65C-200 80 65 100 65 180 180 140 125 250 320 14 95 14 16 65 100 100 225
65A-250 200 200 140 160 280 360 18 120 14 14 80 100 125 250
80C-160 180 180 140 125 250 320 14 95 14 16 65 125 125 225
80C-200 180 180 140 125 280 345 14 95 14 16 65 125 125 250
80-250 100 80 125 80 200 225 140 160 315 400 18 120 15 18 80 125 125 280
80A-250 200 225 140 160 315 400 18 120 15 18 80 125 125 280
100-160 125 100 - - 200 - 100 160 280 360 18 120 15 - 80 125 - 315
100C-200 125 100 125 100 200 200 140 160 280 360 18 120 15 15 80 125 125 280
100C-250 125 100 125 100 225 225 140 160 315 400 18 120 16 16 80 140 140 280
125-125 150 125 - - 225 - 100 125 250 320 14 95 14 - 65 140 - 300
125-250 150 125 150 125 250 250 140 160 315 400 18 120 18 18 80 140 140 355
125-315 150 125 - - 280 - 140 200 400 500 23 150 20 - 100 140 - 355
150-125 150 150 - - 280 - 140 160 315 400 18 120 18 - 80 160 - 400
150-160 150 150 - - 250 - 100 160 315 400 18 120 18 - 80 160 - 315
150-200 150 150 - - 250 - 140 160 315 400 18 120 18 - 80 160 - 315
150-250 200 150 - - 280 - 140 200 400 500 23 150 20 - 100 160 - 400
200-160 200 200 - - 280 - 140 200 400 500 23 150 22 - 100 200 - 400
200-200 200 200 - - 280 - 100 200 400 500 23 150 22 - 100 200 - 400
250-200 250 250 - - 315 - 140 200 450 550 23 150 22 - 100 200 - 450
* cast iron and bronze
** stainless steel

8.5 Overall length (ta)
8.5.1 Cast iron and bronze G, B

Motor 80 90S 90L 100L 112M 132S 132M 160M 160L 180M 180L 200L 225S 225M 250M 280S 280M
CB ta (*)
25-125 491 513 537 - - - - - - - - - - - - - -
25-160 491 513 537 581 607 - - - - - - - - - - - -
32-125 512 534 558 602 628 - - - - - - - - - - - -
32C-125 512 534 558 602 628 - - - - - - - - - - - -
32-160 512 534 558 602 628 706 - - - - - - - - - - -
32A-160 512 534 558 602 628 706 - - - - - - - - - - -
32C-160 512 534 558 602 628 706 - - - - - - - - - - -
32-200 512 534 558 602 628 706 - 834 - - - - - - - - -
32C-200 512 534 558 602 628 706 - 834 - - - - - - - - -
32-250 532 554 578 622 648 726 - 854 898 932 - - - - - -
40C-125 512 534 558 602 628 706 - - - - - - - - - - -
40C-160 512 534 558 602 628 706 - 834 - - - - - - - - -
40C-200 532 554 578 622 648 726 - 854 - - - - - - - - -
40-250 532 554 578 622 648 726 - 854 898 932 - - - - - - -
50C-125 532 554 578 622 648 726 - - - - - - - - - - -
50C-160 532 554 578 622 648 726 - 854 - - - - - - - - -
50C-200 532 554 578 622 648 726 - 854 898 932 - 1060 - - - - -
50-250 532 554 578 622 648 726 - 854 898 932 - 1080 - - - -
65C-125 532 554 578 622 648 726 - 854 - - - - - - - -
65C-160 532 554 578 622 648 726 - 854 898 932 - 1060 - - - - -
65C-200 532 554 578 622 648 726 - 854 898 932 - 1060 - - - - -
65A-250 - 568 592 636 662 740 778 868 912 946 982 1094 - 1142 - - -
80C-160 - 579 603 647 673 751 - 879 923 957 - 1085 - - - - -
80C-200 - 594 618 662 688 766 804 894 938 972 1008 1100 1144 1168 1376 1536 1536
80-250 - 593 617 661 687 765 803 893 937 971 1007 1119 1143 1167 1395 1555 1555
80A-250 - 593 617 661 687 765 803 893 937 971 1007 1119 1143 1167 1395 1555 1555
100-160 - 594 618 662 688 766 - 894 938 972 - 1100 - - - - -
100C-200 - - - 662 688 766 804 894 938 972 - 1100 - 1168 1376 1536 -
100C-250 - - - 676 702 780 818 908 952 986 - 1134 - 1182 1410 1570 1570
125-125 - - 618 662 688 766 894 - - - - - - - - -
125-250 - - - 676 702 780 818 908 952 986 1022 1134 - - - - -
125-315 - - - - - 802 840 930 974 1008 1044 1136 - - - - -
150-125 - - - 682 708 786 - - - - - - - - - - -
150-160 - - - 697 723 801 839 929 973 1007 - 1135 - 1203 1411 - -
150-200 - - - 697 723 801 839 929 - - - - - - - - -
150-250 - - - - - 808 846 936 980 1014 1050 - - - - - -
200-160 - - - 737 763 841 879 969 - - - - - - - - -
200-200 - - - - - 840 878 968 1012 1046 1082 1194 - - - - -
250-200 - - - - - 848 886 976 1020 1054 1090 1202 - - - - -
(*): Motor length based on DIN 42677, could be different due to applied motor make.

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8.5.2 Stainless steel R

Motor 80 90S 90L 100L 112M 132S 132M 160M 160L 180M 180L 200L 225S 225M 250M 280S 280M
CB ta (*)
25-125 491 513 537 - - - - - - - - - - - - - -
25-160 521 543 567 611 637 - - - - - - - - - - - -
32-125 512 534 558 602 628 - - - - - - - - - - - -
32C-125 512 534 558 602 628 - - - - - - - - - - - -
32-160 512 534 558 602 628 706 - - - - - - - - - - -
32A-160 512 534 558 602 628 706 - - - - - - - - - - -
32C-160 512 534 558 602 628 706 - - - - - - - - - - -
32-200 512 534 558 602 628 706 - 834 - - - - - - - - -
32C-200 512 534 558 602 628 706 - 834 - - - - - - - - -
32-250 532 554 578 622 648 726 - 854 898 932 - - - - - -
40C-125 512 534 558 602 628 706 - - - - - - - - - - -
40C-160 512 534 558 602 628 706 - 834 - - - - - - - - -
40C-200 532 554 578 622 648 726 - 854 - - - - - - - - -
40-250 532 554 578 622 648 726 - 854 898 932 - - - - - - -
50C-125 532 554 578 622 648 726 - - - - - - - - - - -
50C-160 532 554 578 622 648 726 - 854 - - - - - - - - -
50C-200 532 554 578 622 648 726 - 854 898 932 - 1060 - - - - -
50-250 557 679 603 647 673 751 - 879 923 957 - 1105 - - - -
65C-125 532 554 578 622 648 726 - 854 - - - - - - - -
65C-160 542 564 588 632 658 736 - 864 908 942 - 1070 - - - - -
65C-200 542 564 588 632 658 736 - 864 908 942 - 1070 - - - - -
65A-250 - 593 617 661 687 765 803 893 937 971 1007 1119 - 1167 - - -
80C-160 - 589 613 657 683 761 - 889 933 967 - 1095 - - - - -
80C-200 - 594 618 662 688 766 804 894 938 972 1088 1100 1144 1168 1376 1536 1536
80-250 - 594 617 661 687 765 803 893 937 971 1007 1119 1143 1167 1395 1555 1555
80A-250 - 594 617 661 687 765 803 893 937 971 1007 1119 1143 1167 1395 1555 1555
100-160 - - - - - - - - - - - - - - - - -
100C-200 - - - 662 688 766 804 894 938 972 - 1100 - 1168 1376 1536 -
100C-250 - - - 676 702 780 818 908 952 986 - 1134 - 1182 1410 1570 1570
125-125 - - - - - - - - - - - - - - - - -
125-250 - - - 676 702 780 818 908 952 986 1022 1134 - - - - -
125-315 - - - - - - - - - - - - - - - - -
150-125 - - - - - - - - - - - - - - - - -
150-160 - - - - - - - - - - - - - - - - -
150-200 - - - - - - - - - - - - - - - - -
150-250 - - - - - - - - - - - - - - - - -
200-160 - - - - - - - - - - - - - - - - -
200-200 - - - - - - - - - - - - - - - - -
250-200 - - - - - - - - - - - - - - - - -
(*): Motor length based on DIN 42677, could be different due to applied motor make

8.6 Dimension vt
Motor 132S 132M 160M 160L 180M 180L 200L 225S 225M 250M 280S 280M
CB vt
25-125 - - - - - - - - - - - -
25-160 - - - - - - - - - - - -
32-125 - - - - - - - - - - - -
32C-125 - - - - - - - - - - - -
32-160 230 - - - - - - - - - - -
32A-160 230 - - - - - - - - - - -
32C-160 230 - - - - - - - - - - -
32-200 230 - 279 - - - - - - - - -
32C-200 230 - 279 - - - - - - - - -
32-250 218 - 267 267 280 - - - - - - -
40C-125 230 - - - - - - - - - - -
40C-160 230 - 279 - - - - - - - - -
40C-200 230 - 279 - - - - - - - - -
40-250 218 - 267 267 280 - - - - - - -
50C-125 230 - - - - - - - - - - -
50C-160 230 - 279 - - - - - - - - -
50C-200 230 - 279 279 292 - 304 - - - - -
50-250 218 - 267 267 280 - 312 - - - - -
65C-125 218 - 267 - - - - - - - - -
65C-160 218 - 267 267 280 - 292 - - - - -
65C-160* 228 - 277 277 290 - 302 - - - - -
65C-200 218 - 267 267 280 - 292 - - - - -
65C-200* 228 - 277 277 290 - 302 - - - - -
65A-250 220 220 269 269 282 282 314 - 340 - - -
80C-160 218 - 267 267 280 - 292 - - - - -
80C-160* 228 - 277 277 290 - 302 - - - - -
80C-200 233 233 282 282 295 295 307 353 353 372 394 394
80-250 220 220 269 269 282 282 314 354 340 379 401 401
80A-250 220 220 269 269 282 282 314 354 340 379 401 401
100-160 221 - 270 270 283 - 295 - - - - -
100C-200 221 221 270 270 283 - 295 - 341 360 382 -
100C-250 220 220 269 269 282 - 314 - 340 379 401 401
125-125 218 - 267 - - - - - - - - -
125-250 220 220 269 269 282 282 314 - - - - -
125-315 226 226 275 275 288 288 300 - - - - -
150-125 205 - - - - - - - - - -
150-160 221 221 270 270 283 - 295 -- 341 360 - -
150-200 221 221 270 - - - - - - - - -
150-250 212 212 261 261 274 274 - - - - - -
200-160 205 205 254 - - - - - - - - -
200-200 205 205 254 254 267 267 299 - - - - -
250-200 212 212 261 261 274 274 306 - - - - -
* stainless steel

CombiBloc
8.7 Weight
Weight [kg] excluding motor
Motor
80
100L 132 160 180 200 225 250 280
CB 90S
112M S/M M/L M/L L S/M M S/M
90L
25-125 27 - - - - - - - -
25-160 29 29 - - - - - - -
32-125 27,5 27,5 - - - - - - -
32C-125 27,5 27,5 - - - - - - -
32-160 31 31 32,5 - - - - - -
32A-160 31 31 32,5 - - - - - -
32C-160 31 31 32,5 - - - - - -
32-200 38,5 40 41 43,5 - - - - -
32C-200 38,5 40 41 43,5 - - - - -
32-250 54,5 54,5 55,5 57,5 57,5 - - - -
40C-125 26 26 28,5 - - - - - -
40C-160 32 32 33,5 36,5 - - - - -
40C-200 40,5 42 43 45,5 - - - - -
40-250 55,5 55,5 56,5 58,5 58,5 - - - -
50C-125 27 27 29,5 37 - - - - -
50C-160 34,5 34,5 35,5 38,5 - - - - -
50C-200 40,5 41,5 43 45,5 45,5 50 - - -
50-250 53,5 53,5 54,5 56,5 56,5 61,5 - - -
65C-125 33 33 35,5 43 - - - - -
65C-160 38,5 38,5 40 43 43 46,5 - - -
65C-200 46 47 48,5 51 51 55,5 - - -
65A-250 59 59 60 62 62 67 68 - -
80C-160 46,5 46,5 47,5 50,5 50,5 54 - - -
80C-200 58,5 60 61 63,5 63,5 68 68 75 75
80-250 67,5 67 68,5 70,5 70,5 75,5 76,5 82,5 82,5
80A-250 67,5 67 68,5 70,5 70,5 75,5 76,5 82,5 82,5
100-160 71,5 72,5 74 76,5 76,5 81 - - -
100C-200 71 72 73,5 76 76 80,5 80,5 87,5 87,5
100C-250 87,5 87,5 88,5 90,5 90,5 95,5 96,5 102,5 102,5
125-125 62,5 62,5 64 67 - - - - -
125-250 108,5 108 109,5 111,5 111,5 116,5 - - -
125-315 - - 135 137 137 139 - - -
150-125 105 106 107,5 - - - - - -
150-160 86,5 87,5 89 91,5 91,5 96 96 103 -
150-200 87 88 89,5 92 - - - - -
150-250 - - 144 146 146 - - - -
200-160 144 145 146,5 149 - - - - -
200-200 141 141 142 144 144 149 - - -
250-200 - - 190 192 192 197 - - -

CombiBloc
9 Parts
9.1 Ordering parts
9.1.1 Order form

You can use the order form included in this manual for ordering parts.
When ordering parts always quote the following data:
1 Your address.
2 The quantity, the item number and the description of the part.
3 The pump number. The pump number is stated on the label on the cover of this
manual and on the type plate of the pump.
4 In the event of different electric motor voltage you should state the correct voltage.
9.1.2 Recommended spare parts

Parts marked with a * are recommended spare parts.
CB/EN (1501) 6.6 Parts 53

54
9.2
9.2.1
2280 IEC IEC

80 132S/M 2405
2405 IEC
90S/L 160M/L IEC
100L 180M/L 80 132S/M
112M 200L 90S/L 160M/L
Figure 17:
225S/M 100L 180M/L
250M 112M 200L
280S/M 225S/M
Sectional drawing
2200 2200 2280 250M

0325 2400 280S/M
0320 2400
0810
0800
Pump with shaft sealing M1
Sectional drawing.
2415
Parts
2410
1220
1100
1820
1860
0120
0130
0100
0315
0310
0110 0300 0250 2200 0276 0850 0900
CB/EN (1501) 6.6

0235/0240
CombiBloc
9.2.2 Parts list

Materials
Item Quantity Description
G1 G2 G6 B2 R6
0100 1 pump casing cast iron bronze st.st.
0110 1 pump cover cast iron bronze st.st.
0120* 1 impeller c.i. bronze st.st. bronze st.st.
0130* 1 wear ring c.i. bronze st.st. bronze st.st.
0235 8 bolt stainless steel
0240 8 washer stainless steel
0250 1 lantern piece cast iron
0276 4 seal guard stainless steel
0300* 1 gasket --
0310 1 plug steel bronze st.st.
0315 1 sealing ring not applicable PTFE
0320 1 plug steel bronze st.st.
0325 1 sealing ring not applicable PTFE
0800 4/8/12 *) stud steel stainless steel
0810 4/8/12 *) nut steel stainless steel
0850 4/8 **) bolt steel
0900 **) nut steel
4/8
1100 1 distance sleeve stainless steel
1220* 1 mechanical seal --
1820* 1 cap nut stainless steel
1860* 1 impeller key stainless steel
2200* 1 stub shaft stainless steel
2280* 2 set screw stainless steel
2400 1 name plate stainless steel
2405 2 rivet stainless steel
2410 1 arrow plate aluminium
c.i. = cast iron, st.st. = stainless steel
*)
Quantity depending on pump type,
**) Quantity depending on motor type
Item 0130:
not for pumps in cast iron and bronze (G1, G2, G6 and B2), except 32-250, 65-250,
80-200, 80-250, 100-160, 100-200, 100-250, 125-250, 125-315, 150-160, 150-
200, 150-250, 200-200 and 250-200.
CB/EN (1501) 6.6 Parts 55

9.3 Pump sizes 25-125 and 25-160 with shaft sealing M1
9.3.1 Sectional drawing
2280
1860 1220 0235/0240 2200

0320 0800 0850 0900
2400 2410
0325 0810 2405 2415
0250
0300 0276
0110
0315
0100
1100
1820
0120
0310
Figure 18: Sectional drawing 25-125, 25-160.
56 Parts CB/EN (1501) 6.6

CombiBloc
9.3.2 Parts list

Materials
G1A R6A
0100 1 pump casing cast iron stainless steel
0110 1 pump cover cast iron stainless steel
0120* 1 impeller cast iron stainless steel
0235 8 bolt stainless steel
0240 8 washer stainless steel
0250 1 lantern piece cast iron
0276 4 seal guard stainless steel
0300* 1 gasket --
0310 1 plug steel stainless steel
0315 1 sealing ring copper PTFE
0320 1 plug steel stainless steel
0325 1 sealing ring copper PTFE
0800 4 stud steel
0810 4 nut steel
0850 4 bolt steel
0900 4 nut steel
1100 1 distance sleeve stainless steel
1220* 1 mechanical seal --
1820* 1 cap nut stainless steel
1860* 1 impeller key stainless steel
2200* 1 stub shaft stainless steel
2280* 2 set screw stainless steel
2400 1 name plate stainless steel
2410 1 arrow plate aluminium
CB/EN (1501) 6.6 Parts 57

9.4 Additional parts of pump size 200-160
Figure 19: Shaft sleeve of 200-160.

Materials
G1 G2 B2
1200 1 shaft sleeve brass
1260 3 set screw stainless steel
58 Parts CB/EN (1501) 6.6

CombiBloc
10 Technical data
10.1 Recommended locking liquids

Table 9: Recommended locking liquids.
Description Locking liquid
cap nut (1820) Loctite 243
wear ring (0130) Loctite 641
10.2 Tightening moments
10.2.1 Tightening moments for bolts and nuts

Table 10: Tightening moments for bolts and nuts.
Materials 8.8 A2, A4
Thread Tightening moment [Nm]
M6 9 6
M8 20 14
M10 40 25
M12 69 43
M16 168 105
10.2.2 Tightening moments for cap nut

Table 11: Tightening moments for cap nut (1820).
Size Tightening moment [Nm]
M12 (bearing bracket 1) 43
CB/EN (1501) 6.6 Technical data 59

10.3 Maximum allowable speed
Table 12: Maximum allowable speed
Max. speed
CB Bearing group
[min-1]
25-125 3600 0
25-160 3600 0+
32-125 3600 1
32C-125 3600 1
32-160 3600 1
32A-160 3600 1
32C-160 3600 1
32-200 3600 1
32C-200 3600 1
32-250 3000 1
40C-125 3600 1
40C-160 3600 1
40C-200 3600 1
40-250 3000 1
50C-125 3600 1
50C-160 3600 1
50C-200 3600 1
50-250 3000 1
65C-125 3600 1
65C-160 3600 1
65C-200 3600 1
65A-250 3000 2
80C-160 3600 1
80C-200 3600 2
80-250 3000 2
80A-250 3000 2
100-160 3600 2
100C-200 3000 2
100C-250 3000 2
125-125 1800 1
125-250 1800 2
125-315 1800 3
150-125 1800 1
150-160 1800 2
150-200 1800 2
150-250 1800 3
200-160 1800 2V
200-200 1800 2
250-200 1800 3
60 Technical data CB/EN (1501) 6.6

CombiBloc
10.4 Maximum allowable working pressures

Table 13: Maximum allowable working pressure [bar]
Materials [bar]
25-125
100-160
125-125
150-125
150-160
6
150-200
150-250
200-160
200-200
250-200
25-160 R 8
all other 10
Test pressure: 1,5 x max. working pressure.

10.5 Hydraulic performance
10.5.1 Performance overview cast iron and bronze pumps G, B

[m] 120
100
80-2
50
80 32-250 40-250 50-250 65A-250
100C-250
70 80A-250
60 10
0C
50 32-200 65C-200 80C-200 -20
40C-200 0
32C-200 50C-200
40
H 30
25-160 32-160 50C-160
32C-160 40C-160 65C-160
32A-160
25 80C-160 100-160
20 50C-125
25-125 32-125 32C-125 65C-125
15 40C-125
10
8
4 6 7 8 10 15 20 30 40 50 60 80 100 150 200 300 400
Q
3
[m/h]
Figure 20: Performance overview 3000 min-1.
[m] 40
30
125-315
25
80-2
50
20 32-250 40-250 50-250 65A-250 100C-250
80A-250 125-250 150-250
15 10
0C
32-200 65C-200 80C-200 -20
40C-200 0
32C-200 50C-200 150-200 200-200
10 250-200
8 25-160 32-160 50C-160 65C-160 80C-160

H 7 32A-160
32C-160 40C-160
100-160
150-160 200-160
6
5
50C-125
4 25-125 32-125 32C-125 65C-125 150-125
40C-125 125-125
2
2 3 4 5 6 7 8 10 15 20 30 40 50 60 80 100 150 200 300 400 600
Q
3
[m/h]

CombiBloc
[m] 20
15
125-315
10 80-2
50
32-250 40-250 50-250 65A-250 100C-250
8 80A-250 125-250 150-250
7
10
6 0C
32-200 65C-200 80C-200 -20
40C-200 0
5 32C-200 50C-200 150-200 200-200
250-200
4
H 25-160 32-160 50C-160 65C-160 80C-160
32C-160 40C-160 150-160 200-160
3 32A-160
100-160
2 50C-125
25-125 32-125 32C-125 65C-125 150-125
40C-125 125-125
1
1 2 3 4 5 6 7 8 10 15 20 30 40 50 60 80 100 150 200 300 400 500
Q
3
[m/h]
[m] 100
80
70 32-200 65C-200 80C-200
40C-200
32C-200 50C-200
60
50
25-160 32-160 50C-160
40 32C-160 40C-160 65C-160 80C-160
32A-160
100-160
30
50C-125
H 25 25-125 32-125 32C-125 65C-125
20 40C-125
15
10
4 5 6 7 8 10 15 20 30 40 50 60 80 100 150 200 300 400
Q
3
[m/h]

[m] 60
50
40 125-315
80-2
30 50
32-250 40-250 50-250 65A-250 100C-250
25 80A-250 125-250 150-250
20 10
0C
32-200 65C-200 80C-200 -20
40C-200 0
15
32C-200 50C-200 150-200 200-200
250-200
25-160 32-160 50C-160 65C-160 80C-160

10 32C-160 40C-160 150-160
32A-160
H 8
100-160
7 50C-125 200-160
6 25-125 32-125 32C-125 65C-125 150-125
40C-125 125-125
5
2
2 3 4 5 6 7 8 10 15 20 30 40 50 60 80 100 150 200 300 400 600 800
Q
3
[m/h]
[m] 30
20
125-315
15 80-2
50
32-250 40-250 50-250 65A-250 100C-250
80A-250 125-250 150-250
10
10
0C
8 32-200 65C-200 80C-200 -20
40C-200 0
7 32C-200 50C-200 150-200 200-200
250-200
6
5 25-160 32-160 50C-160 65C-160 80C-160
H 4
32A-160
32C-160 40C-160
100-160
150-160 200-160
3 50C-125
25-125 32-125 32C-125 65C-125 150-125
40C-125 125-125
2
1
1 2 3 4 5 6 7 8 10 15 20 30 40 50 6 0 80 100 150 200 300 500
Q
3
[m/h]

CombiBloc
10.5.2 Performance overview stainless steel pumps R
[m] 120
100
80-2
50
80 32-250 40-250 50-250 65A-250 100C-250
70 80A-250
60 10
0C
50 32-200 40C-200 65C-200 -20
80C-200 0
32-160 32C-200 50C-200
40
65
C-
25-160 16
30 0
32C-160 40C-160 50C-160
H 25
32A-160
80C-160
20
25-125 32-125 32C-125 50C-125 65C-125
15 40C-125
10
8
4 6 7 8 10 15 20 30 40 50 60 80 100 150 200 300 400
Q
3
[m/h]
[m] 30
25
80-2
50
20 32-250 40-250 50-250 65A-250 100C-250
80A-250 125-250
15 10
0C
32-200 40C-200 65C-200 -20
80C-200 0
32-160 32C-200 50C-200
10
65
C-
8 25-160 16
0
32C-160 40C-160 50C-160
7 32A-160
H 6
80C-160
4 25-125 32-125 32C-125 50C-125 65C-125

40C-125
3
2
2 3 4 5 6 7 8 10 15 20 30 40 50 60 80 100 150 200 300
Q
3
[m/h]

[m] 120
100
80
70 32-200 40C-200 65C-200
32-160 32C-200 80C-200
60 50C-200
65
50 C-
25-160 16
0
32C-160 40C-160 50C-160
40 32A-160
80C-160
30
H 25 25-125 32-125 32C-125 50C-125 65C-125
40C-125
20
15
10
4 5 6 7 8 10 15 20 30 40 50 60 80 100 150 200 250 350
Q
3
[m/h]
[m] 50
40
80-2
30 50
32-250 40-250 50-250 65A-250 100C-250
25 80A-250 125-250
20 10
0C
32-200 40C-200 65C-200 -20
80C-200 0
15 32-160 32C-200 50C-200
65
C-
25-160 16
0
32C-160 40C-160 50C-160
10 32A-160
80C-160
H 8
7
6 25-125 32-125 32C-125 50C-125 65C-125
40C-125
5
2
2 3 4 5 6 7 8 10 15 20 30 40 50 60 80 100 150 200 300
Q
3
[m/h]

CombiBloc
10.6 Permitted forces and torques on the flanges, based on EN-ISO 5199
Forces and moments acting on the pump flanges due to pipe loads can cause
misalignment of the pump, deformation and overstressing of the pump casing, or
overstressing of the fixing bolts between the pump and the baseplate.
The values can be applied simultaneously in all directions with positive or negative signs,
or separately on each flange (suction and discharge).
Z
Y
X
Z
Y
X
Figure 30: Coordinate system.

10.6.1 Cast iron and bronze pumps
Table 14: Permitted forces and torques on the flanges, for cast iron and bronze
pump casings.
Pump unit rigid mounted
Horizontal Pump, End branch, x-Axis Horizontal Pump, Top branch, z-Axis
CB
Force (N) Moment (N.m) Force (N) Moment (N.m)
Fy Fz Fx ΣF My Mz Mx ΣM Fy Fz Fx ΣF My Mz Mx ΣM
25-125 315 298 368 578 263 298 385 560 245 298 263 455 210 245 315 455
25-160 263 245 298 455 210 245 315 455 245 298 263 455 210 245 315 455
32-125 525 473 578 910 350 403 490 718 298 368 315 578 263 298 385 560
32C-125 525 473 578 910 350 403 490 718 298 368 315 578 263 298 385 560
32-160 525 473 578 910 350 403 490 718 298 368 315 578 263 298 385 560
32A-160 525 473 578 910 350 403 490 718 298 368 315 578 263 298 385 560
32C-160 525 473 578 910 350 403 490 718 298 368 315 578 263 298 385 560
32-200 525 473 578 910 350 403 490 718 298 368 315 578 263 298 385 560
32C-200 525 473 578 910 350 403 490 718 298 368 315 578 263 298 385 560
32-250 525 473 578 910 350 403 490 718 298 368 315 578 263 298 385 560
40C-125 648 595 735 1155 385 420 525 770 350 438 385 683 315 368 455 665
40C-160 648 595 735 1155 385 420 525 770 350 438 385 683 315 368 455 665
40C-200 648 595 735 1155 385 420 525 770 350 438 385 683 315 368 455 665
40-250 648 595 735 1155 385 420 525 770 350 438 385 683 315 368 455 665
50C-125 648 595 735 1155 385 420 525 770 473 578 525 910 350 403 490 718
50C-160 648 595 735 1155 385 420 525 770 473 578 525 910 350 403 490 718
50C-200 648 595 735 1155 385 420 525 770 473 578 525 910 350 403 490 718
50-250 648 595 735 1155 385 420 525 770 473 578 525 910 350 403 490 718
65C-125 788 718 875 1383 403 455 560 823 595 735 648 1155 385 420 525 770
65C-160 788 718 875 1383 403 455 560 823 595 735 648 1155 385 420 525 770
65C-200 788 718 875 1383 403 455 560 823 595 735 648 1155 385 420 525 770
65A-250 788 718 875 1383 403 455 560 823 595 735 648 1155 385 420 525 770
80C-160 1050 945 1173 1838 438 508 613 910 718 875 788 1383 403 455 560 823
80C-200 1050 945 1173 1838 438 508 613 910 718 875 788 1383 403 455 560 823
80-250 1050 945 1173 1838 438 508 613 910 718 875 788 1383 403 455 560 823
80A-250 1050 945 1173 1838 438 508 613 910 718 875 788 1383 403 455 560 823
100-160 1243 1120 1383 2170 525 665 735 1068 945 1173 1050 1838 438 508 613 910
100C-200 1243 1120 1383 2170 525 665 735 1068 945 1173 1050 1838 438 508 613 910
100C-250 1243 1120 1383 2170 525 665 735 1068 945 1173 1050 1838 438 508 613 910
125-125 1243 1120 1383 2170 525 665 735 1068 1120 1383 1243 2170 525 665 735 1068
125-250 1575 1418 1750 2748 613 718 875 1278 1120 1383 1243 2170 525 665 735 1068
125-315 1575 1418 1750 2748 613 718 875 1278 1120 1383 1243 2170 525 665 735 1068
150-125 1575 1418 1750 2748 613 718 875 1278 1418 1750 1575 2748 613 718 875 1278
150-160 1575 1418 1750 2748 613 718 875 1278 1418 1750 1575 2748 613 718 875 1278
150-200 1575 1418 1750 2748 613 718 875 1278 1418 1750 1575 2748 613 718 875 1278
150-250 2100 1890 2345 3658 805 928 1138 1680 1418 1750 1575 2748 613 718 875 1278
200-160 2100 1890 2345 3658 805 928 1138 1680 1890 2345 2100 3658 805 928 1138 1680
200-200 2100 1890 2345 3658 805 928 1138 1680 1890 2345 2100 3658 805 928 1138 1680
250-200 2980 2700 3340 5220 1260 1460 1780 2620 2700 3340 2980 5220 1260 1460 1780 2620

CombiBloc
10.6.2 Stainless steel pumps

Table 15: Permitted forces and torques on the flanges, for stainless steel pump
casings.
Pump unit rigid mounted
Horizontal Pump, End branch, x-Axis Horizontal Pump, Top branch, z-Axis
CB
Force (N) Moment (N.m) Force (N) Moment (N.m)
Fy Fz Fx ΣF My Mz Mx Σ M Fy Fz Fx ΣF My Mz Mx Σ M
25-125 630 595 735 1155 525 595 770 1120 490 595 525 910 420 490 630 910
25-160 525 490 595 910 420 490 630 910 490 595 525 910 420 490 630 910
32-125 1050 945 1155 1820 700 805 980 1435 595 735 630 1155 525 595 770 1120
32C-125 1050 945 1155 1820 700 805 980 1435 595 735 630 1155 525 595 770 1120
32-160 1050 945 1155 1820 700 805 980 1435 595 735 630 1155 525 595 770 1120
32A-160 1050 945 1155 1820 700 805 980 1435 595 735 630 1155 525 595 770 1120
32C-160 1050 945 1155 1820 700 805 980 1435 595 735 630 1155 525 595 770 1120
32-200 1050 945 1155 1820 700 805 980 1435 595 735 630 1155 525 595 770 1120
32C-200 1050 945 1155 1820 700 805 980 1435 595 735 630 1155 525 595 770 1120
32-250 1050 945 1155 1820 700 805 980 1435 595 735 630 1155 525 595 770 1120
40C-125 1295 1190 1470 2310 770 840 1050 1540 700 875 770 1365 630 735 910 1330
40C-160 1295 1190 1470 2310 770 840 1050 1540 700 875 770 1365 630 735 910 1330
40C-200 1295 1190 1470 2310 770 840 1050 1540 700 875 770 1365 630 735 910 1330
40-250 1295 1190 1470 2310 770 840 1050 1540 700 875 770 1365 630 735 910 1330
50C-125 1575 1435 1750 2765 805 910 1120 1645 945 1155 1050 1820 700 805 980 1435
50C-160 1575 1435 1750 2765 805 910 1120 1645 945 1155 1050 1820 700 805 980 1435
50C-200 1575 1435 1750 2765 805 910 1120 1645 945 1155 1050 1820 700 805 980 1435
50-250 1575 1435 1750 2765 805 910 1120 1645 945 1155 1050 1820 700 805 980 1435
65C-125 2100 1890 2345 3675 875 1015 1225 1820 1190 1470 1295 2310 770 840 1050 1540
65C-160 2100 1890 2345 3675 875 1015 1225 1820 1190 1470 1295 2310 770 840 1050 1540
65C-200 2100 1890 2345 3675 875 1015 1225 1820 1190 1470 1295 2310 770 840 1050 1540
65A-250 2100 1890 2345 3675 875 1015 1225 1820 1190 1470 1295 2310 770 840 1050 1540
80C-160 2485 2240 2765 4340 1050 1330 1470 2135 1435 1750 1575 2765 805 910 1120 1645
80C-200 2485 2240 2765 4340 1050 1330 1470 2135 1435 1750 1575 2765 805 910 1120 1645
80-250 2485 2240 2765 4340 1050 1330 1470 2135 1435 1750 1575 2765 805 910 1120 1645
80A-250 2485 2240 2765 4340 1050 1330 1470 2135 1435 1750 1575 2765 805 910 1120 1645
100C-200 2485 2240 2765 4340 1050 1330 1470 2135 1890 2345 2100 3675 875 1015 1225 1820
100C-250 2485 2240 2765 4340 1050 1330 1470 2135 1890 2345 2100 3675 875 1015 1225 1820
125-250 3150 2835 3500 5495 1225 1435 1750 2555 2240 2765 2485 4340 1050 1330 1470 2135

10.7 Noise data
10.7.1 Pump noise as a function of pump power

[dB(A)]
98
4103_A
96
94
92 A
90
88
86
84
82 B
80
78
76
74
72
70
68
66
64
62
60
58
56
54
0,1 1 10 P [kW] 100 200
Figure 31: Noise level as function of pump power [kW] at 1450 min-1
A = sound power level, B = sound pressure level.
[dB(A)]
100
4104_A
95
A
90
85
B
80
75
70
65
60
0,1 1 10 P [kW] 100 300
Figure 32: Noise level as function of pump power [kW] at 2900 min-1
A = sound power level, B = sound pressure level.

CombiBloc
10.7.2 Noise level of entire pump unit

L [dB]
3,2
4102
3,0
2,8
2,6
2,4
2,2
2,0
1,8
1,6
1,4
1,2
1,0
0,8
0,6
0,4
0,2
0,0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
|L1 - L2| [dB]
Figure 33: Noise level of entire pump unit.
In order to determine the total noise level of the entire pump unit, the noise level of the
motor must be added to that of the pump. This can be easily done by using the graph
above.
1 Determine the noise level (L1) of the pump, see figure 31 or figure 32.
2 Determine the noise level (L2) of the motor, see documentation of the motor.
3 Determine the difference between both levels |L1 - L2|.
4 Find the differential value on the |L1 - L2|-axis and go up to the curve.
5 From the curve go left to the L[dB] -axis and read out the value.
6 Add this value to the highest value of both noise levels (L1 or L2).
Example:
1 Pump 75 dB; motor 78 dB.
2 |75-78| = 3 dB.
3 3 dB on the X-axis = 1,75 dB on the Y-axis.
4 Highest noise level + 1,75 dB = 78 + 1,75 = 79,75 dB.

CombiBloc
Index
A
Accessories . . . . . . . . . . . . . . . . . . . . . . . . .26 F
Application area . . . . . . . . . . . . . . . . . . . . .22 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Applications . . . . . . . . . . . . . . . . . . . . . . . . .14 Foundation . . . . . . . . . . . . . . . . . . . . . . . . . 25
B G
Back-Pull-Out system . . . . . . . . . . . . . . . .34 Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Back-Pull-Out unit
assembly . . . . . . . . . . . . . . . . . . . . . . .34 H
disassembly . . . . . . . . . . . . . . . . . . . . .34 Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bearing groups . . . . . . . . . . . . . . . . . . . . . .13
Bearings I
lubrication . . . . . . . . . . . . . . . . . . . . . . .29 Impeller
disassembly . . . . . . . . . . . . . . . . . . . . . 35
C mounting . . . . . . . . . . . . . . . . . . . . . . . 35
Construction . . . . . . . . . . . . . . . . . . . . . . . .14 replacement . . . . . . . . . . . . . . . . . . . . . 35
bearing . . . . . . . . . . . . . . . . . . . . . . . . .14 Inspection
mechanical seal . . . . . . . . . . . . . . . . . .14 motor . . . . . . . . . . . . . . . . . . . . . . . . . . 27
pump . . . . . . . . . . . . . . . . . . . . . . . . . . 27
D
Daily maintenance L
mechanical seal . . . . . . . . . . . . . . . . . .29 Lubrificants . . . . . . . . . . . . . . . . . . . . . . . . . 59
Draining
liquid . . . . . . . . . . . . . . . . . . . . . . . . . . .33 M
Maintenance staff . . . . . . . . . . . . . . . . . . . . . 9
E Max. allowable working pressure . . . . . . . 61
Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Maximum allowable speed . . . . . . . . . . . . 60
Ecodesign . . . . . . . . . . . . . . . . . . . . . . . . . .15 Mechanical seal . . . . . . . . . . . . . . . . . . . . . 37
implementing directive . . . . . . . . . . . .15 assembly instructions . . . . . . . . . . . . . 37
introduction . . . . . . . . . . . . . . . . . . . . .15 with Teflon covered O-ring . . . . . . . . 37
MEI . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Mechanical seal M1
minimum efficiency . . . . . . . . . . . . . . .20 assembly . . . . . . . . . . . . . . . . . . . . . . . 39
name plate . . . . . . . . . . . . . . . . . . . . . .19 disassembly . . . . . . . . . . . . . . . . . . . . . 38
product information . . . . . . . . . . . . . . .19 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . 28
pump selection . . . . . . . . . . . . . . . . . .18 Motor
Electric motor replacing . . . . . . . . . . . . . . . . . . . . . . . 40
connection . . . . . . . . . . . . . . . . . . . . . .26
Environment . . . . . . . . . . . . . . . . . . . . . . . .25 N
Environmental influences . . . . . . . . . . . . . .29 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . .28, 29
CB/EN (1501) 6.6 73

O Wear ring
Operational range . . . . . . . . . . . . . . . . . . . .62 assembly . . . . . . . . . . . . . . . . . . . . . . . 36
disassembly . . . . . . . . . . . . . . . . . . . . . 36
P replacement . . . . . . . . . . . . . . . . . . . . . 35
Pallets . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Working switch . . . . . . . . . . . . . . . . . . . . . 26
Performance overview . . . . . . . . . . . . . . . .62
Permitted forces on flanges . . . . . . . . . . . .67
Permitted torques on flanges . . . . . . . . . .67
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Precautionary measures . . . . . . . . . . . . . . .33
Pump description . . . . . . . . . . . . . . . . . . . .13
Pump unit
commissioning . . . . . . . . . . . . . . . . . . .27
installation . . . . . . . . . . . . . . . . . . . . . .25
R
Recommended locking liquid . . . . . . . . . .59
Regular maintenance . . . . . . . . . . . . . . . . .29
Re-use . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
S
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . .9, 25
symbols . . . . . . . . . . . . . . . . . . . . . . . . . 9
Scrapping . . . . . . . . . . . . . . . . . . . . . . . . . .23
Sense of rotation . . . . . . . . . . . . . . . . . . . .27
Serial number . . . . . . . . . . . . . . . . . . . . . . .13
Special tools . . . . . . . . . . . . . . . . . . . . . . . .33
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Static electricity . . . . . . . . . . . . . . . . . . . . .25
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Stub shaft
adjusting . . . . . . . . . . . . . . . . . . . . . . . .42
assembling . . . . . . . . . . . . . . . . . . . . . .42
disassembling . . . . . . . . . . . . . . . . . . .41
replacing . . . . . . . . . . . . . . . . . . . . . . . .40
Stub shaft of pump size 25-...
adjusting . . . . . . . . . . . . . . . . . . . . . . . .40
assembling . . . . . . . . . . . . . . . . . . . . . .40
disassembling . . . . . . . . . . . . . . . . . . .40
T
Technicians . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tightening moments
for bolts and nuts . . . . . . . . . . . . . . . . .59
for impeller nut . . . . . . . . . . . . . . . . . . .59
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Type description . . . . . . . . . . . . . . . . . . . . .13
V
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . .25
W
Wear plate
replacement . . . . . . . . . . . . . . . . . . . . .35
74 CB/EN (1501) 6.6

Order form for spare parts
FAX Nr.
ADDRESS
Your order will only be dealt with if this order form has been correctly completed and signed.
Order date:
Your order number:
Pump type:
Execution:
Quantity Item. No. Part Article number pump
Delivery address: Invoicing address:
Ordered by: Signature: Telephone:
ORDFORM (1107) 3.2 EN 75

76 ORDFORM (1107) 3.2 EN
CombiPrime H
Horizontal self-priming centrifugal pump
CombiBloc
Horizontal centrifugal monobloc pump

Dr. A. F. Philipsweg 51, 9403 AD Assen, THE NETHERLANDS
Phone: + 31 (0) 592 37 67 67 Fax: + 31 (0) 592 37 67 60
E-Mail: johnson-pump.nl@spx.com
www.johnson-pump.com
www.spx.com
For more information about our worldwide locations, approvals, certifications, and local representatives,
please visit www.johnson-pump.com.
SPX Corporation reserves the right to incorporate our latest design and material changes without notice
or obligation. Design features, materials of construction and dimensional data, as described in this bulletin,
are provided for your information only and should not be relied upon unless confirmed in writing.
ISSUED 11/2011 DV-1530

Copyright © 2011 SPX Corporation
OHW: W10286-016
Datasheet drives
1.1. TECHNICAL DATA
Description: Skimmer drive GPL 15

Make: Nord
Type: SK 12063
Electrical power: 0,25 kW
2. SAFETY ASPECTS

allowed when the electric supply has been switched off and when all drives are stopped.
Figure 2.1
Redox delivery.
 To operate separate motors the below measures has to be taken:

For further information see manual of the drive in the manual index.
1
EN
B 1000
Gear units
Operating and Assembly Instructions
Gear units – Operating and Assembly Instructions
General safety and operating instructions
1. General 5. Electrical Connection

Depending on its protection class, the device may have live, bare, When working on live three-phase motors, the applicable
moving or rotating parts or hot surfaces during operation,. national accident prevention regulations must be complied with
Unauthorised removal of covers, improper use, incorrect installation or (e.g. BGV A3, formerly VBG 4).
operation causes a risk of serious personal injury or material damage. The electrical installation must be implemented according to the
All transport, installation, commissioning and maintenance work must be applicable regulations (e.g. cable cross-section, fuses, earth
carried out by qualified specialist personnel (national accident lead connections).
prevention regulations must be observed). Information regarding EMC-compliant installation – such as
Within the meaning of this basic safety information, qualified specialist shielding, earthing and installation of cables – can be found in
personnel are persons who are familiar with the installation, assembly, the three-phase motor documentation. Compliance with the
commissioning and operation of the product and who have the training limiting values specified in the EMC regulations is the
and experience to recognise and avoid any hazards and risks. responsibility of the manufacturer of the system or machine.
2. Correct use 6. Operation
NORD products may only be used according to the information in the Appropriate safety measures must be taken for applications
catalogue and the associated technical documentation. where failure of the device may result in injury.
Compliance with the operating and installation instructions is a Where necessary, systems in which NORD devices are installed
prerequisite for fault-free operation and for the fulfilment of any must be equipped with additional monitoring and protective
warranty claims. These operating and installation instructions must equipment according to the applicable safety requirements, e.g.
be read before working with the device! legislation concerning technical equipment, accident prevention
regulations, etc.
These operating and installation instructions contain important
information about servicing. They must therefore be kept close to the All covers and guards must be kept closed during operation.
device. 7. Maintenance and repairs
All details regarding technical data and permissible conditions at the After the device has been disconnected from the power supply,
installation site must be complied with. live equipment components and power connections should not
3. Transport, storage be touched immediately, because of possible charged
capacitors.
Information regarding transport, storage and correct handling must be
complied with. Further information can be found in this documentation.
4. Installation
The device must be protected against impermissible loads. In particular,
during transport and handling, components must not be deformed or
changed. Touching of electronic components and contacts must be
avoided.
These safety instructions must be kept in a safe place!
2 B 1000 EN-1915
Documentation
Documentation
Name: B 1000
Part No.: 6052802
Series: Gear units and geared motors
Type series:
Gear unit types: Helical gear units
NORDBLOC helical gear units
Standard helical gear units
Parallel shaft gear unit
Bevel gear unit
Helical worm gear units
MINIBLOC worm gear units
UNIVERSAL worm gear units
Version list
Title, Order number Comments
Date
B 1000, 6052802 / 0713 -
February
2013
B 1000, 6052802 / 3814 General corrections
September
2014
B 1000, 6052802 / 1915 New gear unit types SK 10382.1 + SK 11382.1
April 2015
Table 1: Version list B 1000
Copyright notice
As an integral component of the device described here, this document must be provided to all
users in a suitable form.
Any editing or amendment or other utilisation of the document is prohibited.
Publisher
Getriebebau NORD GmbH & Co. KG
Getriebebau-Nord-Straße 1 • 22941 Bargteheide, Germany • http://www.nord.com/
Fon +49 (0) 45 32 / 289-0 • Fax +49 (0) 45 32 / 289-2253
B 1000 EN-1915 3
4 B 1000 EN-1915
Table of Contents
Table of Contents
1 Notes ............................................................................................................................................................ 8
1.1 General information............................................................................................................................ 8
1.2 Safety and information symbols ......................................................................................................... 8
1.2.1 Explanation of labels used.................................................................................................... 8
1.3 Correct use ........................................................................................................................................ 9
1.4 Safety information ............................................................................................................................ 10
1.5 Other documents.............................................................................................................................. 11
1.6 Disposal ........................................................................................................................................... 11
2 Description of gear unit ............................................................................................................................ 12
2.1 Type designations and gear unit types............................................................................................. 12
2.2 Type plate ........................................................................................................................................ 14
3 Assembly instructions, storage, preparation, installation .................................................................... 15
3.1 Transporting the gear unit ................................................................................................................ 15
3.2 Storage ............................................................................................................................................ 16
3.3 Long-term storage ............................................................................................................................ 16
3.4 Preparing for installation .................................................................................................................. 18
3.5 Installing the gear unit ...................................................................................................................... 19
3.6 Fitting hubs on the gear shafts ......................................................................................................... 21
3.7 Fitting push-on gear units................................................................................................................. 22
3.8 Fitting shrink discs............................................................................................................................ 25
3.9 Fitting the covers .............................................................................................................................. 27
3.10 Fitting the covers .............................................................................................................................. 27
3.11 Fitting a standard motor ................................................................................................................... 28
3.12 Fitting the cooling coil to the cooling system .................................................................................... 30
3.13 Subsequent paintwork...................................................................................................................... 30
4 Commissioning ......................................................................................................................................... 31
4.1 Check the oil level ............................................................................................................................ 31
4.2 Activating the Automatic Lubricant Dispenser .................................................................................. 31
4.3 Operation with lubricant cooling ....................................................................................................... 32
4.4 Running-in time for the worm gear unit ............................................................................................ 33
4.5 Checklist .......................................................................................................................................... 33
5 Service and maintenance ......................................................................................................................... 34
5.1 Service and Maintenance Intervals .................................................................................................. 34
5.2 Service and Maintenance Work ....................................................................................................... 35
6 Appendix .................................................................................................................................................... 40
6.1 Configurations and maintenance ..................................................................................................... 40
6.2 Lubricants ........................................................................................................................................ 52
6.3 Lubricant quantities .......................................................................................................................... 54
6.4 Torque values .................................................................................................................................. 61
6.5 Troubleshooting ............................................................................................................................... 62
6.6 Leaks and seals ............................................................................................................................... 63
6.7 Repair information ............................................................................................................................ 64
6.7.1 Repairs ............................................................................................................................... 64
6.7.2 Internet information............................................................................................................. 64
6.8 Abbreviations ................................................................................................................................... 64
B 1000 EN-1915 5
List of illustrations
Fig. 1: Type plate (example) with explanation of the type plate fields.................................................................... 14
Fig. 2: Activating the vent plug............................................................................................................................... 19
Fig. 3: Removing vent plug and fitting the pressure vent ....................................................................................... 19
Fig. 4: Example of a simple pulling device ............................................................................................................. 21
Fig. 5: Applying lubricant to the shaft and the hub ................................................................................................. 22
Fig. 6: Removing the factory-fitted closing cap ...................................................................................................... 23
Fig. 7: Gear unit mounted to shaft with a shoulder using the fastening element.................................................... 23
Fig. 8: Gear unit mounted to shaft without a shoulder using the fastening element............................................... 23
Fig. 9: Dismantling using dismantling device ......................................................................................................... 23
Fig. 10: Mounting the rubber buffer (Option G or VG) on parallel shaft gear units................................................. 24
Fig. 11: Attaching the torque support on bevel gear and worm gear units............................................................. 24
Fig. 12: Hollow shaft with shrink disc ..................................................................................................................... 25
Fig. 13: Fitting the covers, Option SH, Option H, and Option H66 ......................................................................... 27
Fig. 14: Removal and fitting of the cover cap........................................................................................................ 27
Fig. 15: Fitting the coupling onto the motor shaft - various types of coupling ........................................................ 29
Fig. 16: Cooling cover............................................................................................................................................ 30
Fig. 17: Activating the automatic lubricant dispenser with standard motor mounting............................................. 31
Fig. 18: Adhesive label .......................................................................................................................................... 32
Fig. 19: Checking the oil level with a dipstick ........................................................................................................ 37
Fig. 20: Replacing the automatic lubricant dispenser with standard motor mounting ............................................ 37
Fig. 21: Oil level check with oil level tank .............................................................................................................. 41
6 B 1000 EN-1915
List of tables
List of tables
Table 1: Version list B 1000 ..................................................................................................................................... 3
Table 2: Disposal of materials ............................................................................................................................... 11
Table 3: Type designations and gear unit types .................................................................................................... 13
Table 4: Roller bearing greases............................................................................................................................. 52
Table 5: Lubricant table ......................................................................................................................................... 53
Table 6: Lubricant quantities for helical gear units................................................................................................. 55
Table 7: Lubricant quantities for NORDBLOC ....................................................................................................... 56
Table 8: Lubricant quantities: NORDBLOC helical gear units ............................................................................... 57
Table 9: Lubricant quantities for standard helical gear units .................................................................................. 57
Table 10: Lubricant quantities for parallel shaft gear units .................................................................................... 58
Table 11: Lubricant quantities for bevel gear units ................................................................................................ 59
Table 12: Lubricant quantities for helical worm gear units ..................................................................................... 60
Table 13: Torque values ........................................................................................................................................ 61
Table 14: Overview of malfunctions....................................................................................................................... 62
Table 15: Definition of leaks according to DIN 3761 .............................................................................................. 63
B 1000 EN-1915 7
1 Notes
1.1 General information

Read the Operating Manual carefully prior to performing any work on or putting the gear unit into
operation. Strict compliance with the instructions in this Operating Manual is essential. This Operating
Manual and all associated special documentation must be kept in the immediate vicinity of the gear
unit.
Getriebebau NORD accepts no liability for damage to persons, materials or assets as a result of the
non-observance of this Operating Manual, operating errors or incorrect use. General wearing parts,
e.g. radial seals are excluded from the warranty.
If additional components are attached to or installed on or in the gear unit (e.g. motor, cooling system,
pressure sensor etc.) or components (e.g. cooling system) are supplied with the order, the operating
instructions for these components must be observed.
If geared motors are used, compliance with the Motor Operating Manual is also necessary.
If you do not understand the contents of this Operating Manual or additional operating instructions,
please consult Getriebebau NORD!
1.2 Safety and information symbols
1.2.1 Explanation of labels used
DANGER Indicates an immediate danger, which may result in death or serious injury.
WARNING Indicates a possibly dangerous situation, which may result in death or

serious injury.
CAUTION Indicates a possibly dangerous situation, which may result in slight or

minor injuries.
NOTICE Indicates a possibly harmful situation, which may cause damage to the
product or the environment.
Note Indicates hints for use and useful information.
8 B 1000 EN-1915
1 Notes
1.3 Correct use

These gear units generate a rotational movement and are intended for use in commercial systems.
The gear unit must only be used according to the information in the technical documentation from
Getriebebau NORD.
Commissioning (start of proper operation) is prohibited until it has been established that the machine
complies with the local laws and directives. The EMC Directive 2004/108/EC and the Machinery
Directive 2006/42/EC in their currently valid scope of application must be complied with in particular.
DANGER! Explosion hazard

Serious injury and material damage due to explosion are possible.
Use in explosion hazard areas is prohibited.
WARNING Injury to persons

Appropriate safety measures must be taken for applications where failure of a gear unit or geared motor may
result in injury.
Safeguard a wide area around the hazard zone.
WARNING Material damage and personal injury

If the gear unit is not used as designed, this may cause damage to the gear unit or the premature failure of
components. Personal injury as a result of this cannot be ruled out.
Strict compliance with the technical data on the type plate is essential. The documentation must be observed.
B 1000 EN-1915 9
1.4 Safety information

Observe all safety information, including that provided in the individual sections of this Operating
Manual. All national and other regulations on safety and accident prevention must also be observed.
DANGER! Severe personal injury
Serious physical and property damage may result from inappropriate installation, non-designated use, incorrect
operation, non-compliance with safety information, unauthorised removal of housing components or safety covers
and structural modifications to the gear unit.
• All work, e.g. transportation, storage, installation, electrical connection, commissioning, servicing,
maintenance and repair must only be performed by qualified specialist personnel.
• Observe the Operating Manual
• Observe the safety information
• Observe the safety and accident prevention regulations.
• Tighten the drive elements or secure the parallel key before switching on.
• Do not make any structural modifications.
• Do not remove any safety devices.
• If necessary, wear hearing protection when working in the immediate vicinity of the gear unit.
• All rotating components must be provided with guards. In standard cases, covers are fitted by NORD . The
covers must always be used if contact protection is not provided by other methods.
DANGER! Injury to persons
The surfaces of gear units or geared motors may become hot during or shortly after operation. Danger of burns!
• Installation and maintenance work must only be performed when gear unit is at a standstill and has cooled
down. The drive must be isolated and secured to prevent accidental start-up.
• Wear protective gloves.
• Shield hot surfaces with contact guards.
• Do not store inflammable objects or substances in the immediate vicinity of the gear unit.
Serious injury and material damage due to improper transport are possible.
• No additional loads may be attached.
• Transportation aids and lifting gear must have an adequate load-bearing capacity.
• Pipes and hoses must be protected from damage.
10 B 1000 EN-1915
1 Notes
CAUTION Injury to persons

Danger of cuts from exterior edges of attachment adapters, flanges and covers.
Contact freezing with metallic components in case of low temperatures.
In addition to personal protective equipment, wear suitable protective gloves and suitable goggles during
assembly, commissioning, inspection and maintenance, in order to prevent injuries.
It is recommended that repairs to NORD Products are carried out by the NORD Service department.
1.5 Other documents

Further information may be obtained from the following documents:
• Gear unit catalogues (G1000, G1012, G1014, G1035, G1050, G2000),
• Operating and maintenance instructions for the electric motor,
• if applicable, the Operating Manuals for attached or supplied options
1.6 Disposal
Observe the current local regulations. In particular, lubricants must be collected and disposed of
correctly.
Gear unit components Material
Gear wheels, shafts, rolling bearings, parallel keys, locking rings, … Steel
Gear unit housing, housing components, … Grey cast iron
Light alloy gear unit housing, light alloy gear unit housing Aluminium
components, …
Worm gears, bushes, ... Bronze
Radial seals, sealing caps, rubber components,… Elastomers with steel
Coupling components Plastic with steel
Flat seals Asbestos-free sealing material
Gear oil Additive mineral oil
Synthetic gear oil (type plate code: CLP PG) Polyglycol-based lubricants
Cooling spiral, embedding material of the cooling spiral, screw Copper, epoxy, yellow brass
fittings
Table 2: Disposal of materials
B 1000 EN-1915 11
2 Description of gear unit
2.1 Type designations and gear unit types
Gear unit types / Type designations

Helical gear units
SK 11E, SK 21E, SK 31E,SK 41E, SK 51E (1-stage)
SK 02, SK 12, SK 22, SK 32, SK 42, SK 52, SK 62N (2-stage)
SK 03, SK 13, SK 23, SK 33N, SK 43, SK 53 (3-stage)
SK 62, SK 72, SK 82, SK 92, SK 102 (2-stage)
SK 320, SK 172, SK 272, SK 372, SK 472, SK 572, SK 672, SK 772, SK 872, SK 972 (2-stage)
SK 273, SK 373, SK 473, SK 573, SK 673, SK 773, SK 873, SK 973 (3-stage)
SK 072.1, SK 172.1, SK 372.1, SK 572.1, SK 672.1, SK 772.1, SK 872.1, SK 972.1 (2-stage)
SK 373.1, SK 573.1, SK 673.1, SK 773.1, SK 873.1, SK 973.1 (3-stage)
SK 0, SK 01, SK 20, SK 25, SK 30, SK 33 (2-stage)
Parallel shaft gear units
SK 0182NB, SK 0282NB, SK 1282, SK 2282, SK 3282, SK 4282, SK 5282, SK 6282, SK 7282, SK 8282,
SK 9282, SK 10282, SK 11282 (2-stage)
SK 1382NB, SK 2382, SK 3382, SK 4382, SK 5382, SK 6382, SK 7382, SK 8382, SK 9382, SK 10382,
SK 10382.1, SK 11382, SK 11382.1, SK 12382 (3-stage)
Bevel gear units
SK 92072, SK 92172, SK 92372, SK 92672, SK 92772; SK 92072.1, SK 92172.1, SK 92372.1, SK 92672.1,
SK 9012.1, SK 9016.1, SK 9022.1, SK 9032.1, SK 9042.1, SK 9052.1, SK 9062.1, SK 9072.1, SK 9082.1,
SK 9086.1, SK 9092.1, SK 9096.1 (3-stage)
MINIBLOC worm gear units
SK1 S32, SK1 S40, SK 1S50, SK 1S63, SK 1SU..., SK 1SM31, SK 1SM40, SK 1SM50, SK 1SM63 (1-stage)
SK 2S32NB, SK 2S40NB, SK 2S50NB, SK 2S63NB, SK 2SU…, SK 2SM40, SK 2SM50, SK 2SM63 (2-stage)
12 B 1000 EN-1915
2 Description of gear unit
Gear unit types / Type designations
UNIVERSAL worm gear units
SK 1SI31, SK 1SI40, SK 1SI50, SK 1SI63, SK 1SI75,
SK 1SIS31, …, SK 1SIS75,
SK 1SID31, …, SK 1SID63,
SK 1SMI31, …, SK 1SMI75,
SK 1SMID31, …, SK 1SMID63,
SK 1SIS-D31, …, SK 1SIS-D63 (1-stage),
SK 2SMID40, SK 2SMID50, SK 2SMID63, SK 2SID40, …, SK 2SID63 (2-stage)
Versions / Options
- Foot mounting with solid shaft D Torque support IEC Standard IEC motor
A Hollow shaft version K Torque bracket mounting
V Solid shaft version S Shrink disc NEMA Standard NEMA motor
L Solid shaft both sides VS Reinforced shrink disc attachment
Z Output flange B14 EA Hollow shaft with internal spline W With free drive shaft
F Output flange B5 G Rubber buffer 6 Viton radial seals
X Foot mounting VG Reinforced rubber buffer OA Oil expansion vessel
XZ Base and output flange B14 R Back stop OT Oil storage tank
XF Base and output flange B14 W Fixing element SO1 Synthetic oil ISO VG 220
AL Reinforced axial drive bearings H Covering cap as contact guard CC Casing cover with cooling
5 Reinforced output shaft H66 Covering cap IP66 spiral
(Standard helical gear units) VL Reinforced bearings DR Pressure venting
V Reinforced drive shaft VL2 Agitator version H10 Modular contrate pre-stage
(Standard helical gear units) VL3 Drywell agitator version /31 Worm pre-stage
/40 Worm pre-stage
Table 3: Type designations and gear unit types
Double gear units consist of two single gear units. They are to be treated as per the instructions in this
Manual, i.e. as two individual gear units.
Type designation for double gear units: e.g. SK 73 / 22 (consisting of single gear units SK 73 and
SK 22)
B 1000 EN-1915 13
2.2 Type plate

Explanation
1 Matrix or bar code
2 NORD gear unit type
3 Operating mode
4 Year of manufacture
5 Serial number
Rated torque of gear
6
unit output shaft
7 Drive power
Weight according to
8
ordered version
9 Overall gear unit ratio
10 Installation orientation
Rated speed of gear
11
unit output shaft
Lubricant type, viscosity
12
and quantity
Customer’s part
13
number
14 Operating factor
Fig. 1: Type plate (example) with explanation of the type plate fields
14 B 1000 EN-1915
3 Assembly instructions, storage, preparation, installation
Please observe all general safety instructions (please see chapter 1.4 "Safety information"), the safety
information in the individual sections and the proper use (please see chapter 1.3 "Correct use").
3.1 Transporting the gear unit
WARNING Hazard due to heavy loads
Severe injuries and material damage due to falling or tipping heavy loads are possible.
• Standing under the gear unit during transport is extremely dangerous.
• To prevent injury, the danger area must be generously cordoned off.
• Only transport using the eyebolts attached to the gear unit.
• No additional loads may be attached.
• If geared motors have an additional eyebolt attached to the motor, this must also be used.
• The thread of the eyebolt must be fully screwed in.
• Avoid pulling the eyebolts at an angle.
NOTICE Gear unit damage

Damage to the gear unit due to improper use is possible.
• Prevent damage to the gear unit. Impacts to the free ends of the shafts may cause internal damage to the
gear unit.
• Use adequately dimensioned and suitable means of transportation. Lifting tackle must be designed for the
weight of the gear unit. The weight of the gear unit can be obtained from the dispatch documents.
B 1000 EN-1915 15
3.2 Storage
For short-term storage before commissioning, please observe the following:
Store in the installation position (please see chapter 6.1 "Configurations and maintenance") and
secure the gear unit against falling,
• Lightly oil bare metal housing surfaces and shafts
• Store in a dry place.
• Temperature in the range from – 5 °C to + 50 °C without large fluctuations,
• Relative humidity less than 60 %,
• No direct exposure to sunlight or UV light,
• No aggressive, corrosive substances (contaminated air, ozone, gases, solvents, acids, alkalis,
salts, radioactivity etc.) in the immediate vicinity,
• No vibration or oscillation
3.3 Long-term storage

Incorrect, or excessively long storage may result in malfunctions of the gear unit.
Perform an inspection of the gear unit prior to commissioning if the permissible storage time has been exceeded.
Information Long-term storage

For storage or standstill periods in excess of 9 months, Getriebebau NORD recommends the long-term storage
option.
With the long-term storage option and the use of the measures listed below, storage for up to 2 years is possible.
As the actual influences on the unit greatly depend on the local conditions, these times should only be regarded
as guide values.
16 B 1000 EN-1915
Conditions of the gear unit and storage area for long-term storage prior to commissioning:
• Store in the installation position (please see chapter 6.1 "Configurations and maintenance") and
secure the gear unit against falling.
• Transportation damage to the external paint must be repaired. Check that a suitable rust inhibitor is
applied to the flange bearing surfaces. If necessary apply a suitable rust inhibitor to the surfaces.
• Gear units with the long-term storage option are completely filled with lubricant or have VCI
corrosion protection agent mixed with the gear oil (see adhesive label on the gear unit, or are not
filled with oil, but rather with small quantities of VCI concentrate.
• The sealing band in the vent plug must not be removed during storage. The gear unit must remain
sealed tight.
• Store in a dry place.
• In tropical regions, the gear unit must be protected against damage by insects
• Temperature in the range from – 5 °C to + 40 °C without large fluctuations,
• Relative humidity less than 60 %,
• No direct exposure to sunlight or UV light,
• No aggressive, corrosive substances (contaminated air, ozone, gases, solvents, acids, alkalis,
salts, radioactivity etc.) in the immediate vicinity,
• No vibration or oscillation
Measures during storage or standstill periods
• If the relative humidity is <50 % the gear unit can be stored for up to 3 years.
Measures before commissioning
• If the storage or standstill period exceeds 2 years or the temperature during short-term storage has
greatly deviated from the standard range, the lubricant in the gear unit must be replaced before
commissioning.
• If the gear unit is completely filled, the oil level must be reduced before commissioning.
• For gear units without oil filling, the oil level for the version must be filled before commissioning.
The VCI concentrate may remain in the gear unit. Lubricant quantities and types must be filled
according to the details on the type plate.
B 1000 EN-1915 17
3.4 Preparing for installation

Transport damage may cause malfunctions of the gear unit, which may cause material damage or personal
injury.
Please inspect the delivery for transport and packaging damage immediately on receipt. Report any damage to
the carrier immediately. Gear units with transport damage must not be commissioned.
The drive unit must be inspected and may only be installed if no damage is apparent. In particular the radial seals
and the sealing caps must be inspected for damage.
Pay attention to leaked lubricants, they may cause slips.
All bare metal surfaces and shafts of the gear unit are protected against corrosion with oil, grease or
corrosion protection agents before shipping.
Thoroughly remove all oil, grease or corrosion protection agents and any dirt from the shafts and
flange surfaces before assembly.
In applications where an incorrect rotational direction may result in damage or potential risk, the
correct rotational direction of the drive shaft is to be established by test running the drive when
uncoupled and guaranteeing such for subsequent operation.
Gears with integrated return stops are marked with arrows on the driven/driving sides. The arrows
point in the rotation direction of the gear unit. When connecting the motor and during motor control, it
must be ensured that the gear unit can only operate in the direction of rotation. (For further
explanations see catalogue G1000 and WN 0-000 40)

With gear units with an integrated back stop, switching the drive motor to the blocked direction of rotation, i.e.
incorrect direction of rotation, may result in damage to the gear unit.
Take care that the direction of rotation is correct.
Ensure that no aggressive or corrosive substances are present in the area surrounding the installation
site or are subsequently expected during operation, which attack metal, lubricants or elastomers. In
case of doubt, please contact Getriebebau NORD and take the recommended action.
Oil expansion tanks (Option OA) must be fitted in accordance with works standard WN 0-530 04. For
gear units with an M10x1 vent plug, works standard WN 0-52135 must be also be observed during
installation.
Oil expansion tanks (Option OT) must be fitted in accordance with works standard WN 0-521 30.
If venting of the gear unit is provided, the vent or the pressure vent must be activated before
commissioning. To activate, remove the transport securing device (sealing cord). For the position of
the vent plug, refer to (please see chapter 6.1 "Configurations and maintenance").
18 B 1000 EN-1915
Explanation
1 Standard vent plug

2 Transport securing
device
Fig. 2: Activating the vent plug
Special pressure vents are supplied as loose parts. Before commissioning, the vent plug must be
replaced with the pressure vent which is supplied as a loose part. This is achieved by screwing out the
vent fitting and replacing it with the pressure vent and seal (please see chapter 6.4 "Torque values").
Double gear units consist of two single units and are equipped with 2 oil chambers and 2 pressure
vents.
Explanation
1 Standard vent plug 2 Transport securing device 3 Vent screw
Fig. 3: Removing vent plug and fitting the pressure vent
3.5 Installing the gear unit
WARNING Danger of burns

The surfaces of gear units or geared motors may become hot during or shortly after operation.
Hot surfaces which can be touched directly must be protected with a contact guard.
B 1000 EN-1915 19
WARNING Danger to persons

If the foundation or the fastening of the gear unit is not adequately dimensioned, the gear unit may detach, fall
down or rotate in an uncontrolled manner.
The foundation and the gear unit fastening must be appropriately designed for the weight and the torque. All bolts
must be used to fasten the gear unit
NOTICE Damage to the gear unit due to overheating

The gear unit may be damaged by overheating.
When installing, check that the cooling air from the motor fan can circulate around the geared motor and the gear
unit without obstruction.
The eyebolts screwed into the gear units must be used during installation. No additional load may be
attached to the gear unit.
If geared motors have an additional eyebolt attached to the motor, this must also be used. Avoid
pulling the eyebolts at an angle. Observe the safety information (please see chapter 1.4 "Safety
information").
The base and/or flange to which the gear unit is fitted should be vibration-free, torsionally strong and
flat. The smoothness of the mating surface on the base or flange must be according to tolerance class
K according to DIN ISO 2768-2. All contamination to the bolting surfaces of gear unit and base and/or
flange must be thoroughly removed.
The gear housing must always be earthed. With geared motors, earthing via the motor connection
must be ensured.
The gear unit must be precisely aligned with the drive shaft of the machine in order to prevent
additional forces from being imposed on the gear unit due to distortion.
Welding of the gear unit is prohibited. The gear unit must not be used as the earth connection for
welding work, as this may cause damage to the bearings and gear wheels.
The gear unit must be installed in the correct configuration (please see chapter 6.1
"Configurations and maintenance"). (UNIVERSAL SI and SM gear unit types do not depend on the
configuration). Changes to the installation position after delivery require adjustment of the quantity of
oil, and often other measures such as e.g. the installation of encapsulated roller bearings. Damage
may result if the stated installation position is not observed.
All gear unit feet and/or all flange bolts on each side must be used. Bolts must have a minimum quality
of 8.8. The bolts must be tightened with the correct torques (please see chapter 6.4 "Torque values").
Tension-free bolting must be ensured, particularly for gear units with a foot and flange.
The oil inspection screws, oil drain screws and the vent valves must be accessible.
20 B 1000 EN-1915
3.6 Fitting hubs on the gear shafts

The gear unit may be damaged by axial forces.
Do not subject the gear unit to harmful axial forces when fitting the hubs. In particular, do not hit the hubs with a
hammer.
Drive and driven elements, e.g. coupling and chain-wheel hubs must be mounted onto the drive and
driven shaft of the gear unit using suitable pullers that will not apply damaging axial forces onto the
gear unit.
Information Assembly
Use the end thread of the shafts for pulling. Fitting can be aided by coating the hub with lubricant or heating it up
to approx. 100°C beforehand.
Fig. 4: Example of a simple pulling device
DANGER! Severe personal injury

There is a danger of injury due to rapidly rotating drive and driven elements.
Drive and driven elements, such as belt drives, chain drives, shrink disks, fans and couplings must be fitted with
contact protection.
Drive and driven elements may only subject the drive unit to the maximum radial forces FR and
axial forces FA which are specified in the catalogue. Observe the correct tension, particularly on
belts and chains.
Additional loads due to unbalanced hubs are not permitted.
The radial force must be applied to the gear unit as closely as possible.
B 1000 EN-1915 21
3.7 Fitting push-on gear units

The bearings, gear wheels, shafts and housing may be damaged by incorrect fitting.
• Observe the assembly instructions.
• The push-on gear unit must be fitted onto the shaft using a suitable puller, which will not exert damaging axial
forces on the gear unit. In particular, do not hit the gear unit with a hammer.
Assembly and subsequent dismantling is aided by applying an anti-corrosive lubricant to the shaft
before fitting (e.g. NORD Anti-Corrosion Part No. 089 00099). Excess grease or anti-corrosion agent
may escape after assembly and may drip off. Clean these points on the driven shaft after a running-in
time of approx. 24 hours. This escape of grease is not due to a leak in the gear unit.
Fig. 5: Applying lubricant to the shaft and the hub
Information Fixing element

The gear unit can be fitted to shafts with and without a shoulder using the fastening element (Option B). Tighten
the bolt of the fastening element to the correct torque (please see chapter 6.4 "Torque values"). For gear units
with option H66, the factory-fitted closing cap must be removed before assembly.
For push-on gear units with option H66 and fastening element (Option B) the pressed-in closing cap
must be pushed out before fitting the gear unit. The pressed-in closing cap may be destroyed during
dismantling. As standard a second closing cap is supplied as a loose spare part. After fitting the gear
unit, fit the new / new condition closing cap as described in Section 3.9 "Fitting the covers"
22 B 1000 EN-1915
Fig. 6: Removing the factory-fitted closing cap
Fig. 7: Gear unit mounted to shaft with a shoulder using the fastening element
Fig. 8: Gear unit mounted to shaft without a shoulder using the fastening element
A gear unit can be dismantled from a shaft with a shoulder using the following device, for example.
Fig. 9: Dismantling using dismantling device
When assembling push-on gears with torque supports, the support must not be distorted. Tension-free
mounting is aided by the rubber buffer (Option G or VG).
B 1000 EN-1915 23
Fig. 10: Mounting the rubber buffer (Option G or VG) on parallel shaft gear units
To fit the rubber buffer, tighten the screw fastening until there is no play between the contact surfaces
when there is no load.
Then turn the fastening nut (only applies for screw fastenings with adjusting threads) half a turn in
order to pre-tension the rubber buffer. Greater pre-tension is not permissible.
WARNING Risk of injury

The gear unit may suddenly rotate around the shaft if the bolts are loosened.
Secure the screw fastening against loosening, e.g. with Loctite 242 or a second nut.
Explanation
1 Always support torque support
on both sides
Fig. 11: Attaching the torque support on bevel gear and worm gear units
Tighten the fastenings of the torque support with the correct tightening torques (please see
chapter 6.4 "Torque values") and secure against loosening (e.g. Loctite 242, Loxeal 54-03).
24 B 1000 EN-1915
3.8 Fitting shrink discs

:
CAUTION Risk of injury

Risk of injury from incorrect mounting and dismantling of the shrink disc.
Observe the instructions.

If the tensioning bolts are tightened without the solid shaft inserted, the hollow shaft may be permanently
deformed.
Do not tighten bolts if the solid shaft is not inserted!
Explanation
1 Shrink disc, type, part no. and torque

details for tensioning screws
2 Tensioning flanges
3 Solid shaft of machine
4 Shaft and hollow shaft bore FREE OF
GREASE
5 Hollow shaft of gear unit
6 Double half-slotted inner ring
7 Tensioning screws DIN 931 (933) -10.9
Fig. 12: Hollow shaft with shrink disc
The shrink discs are supplied by the manufacturer ready for fitting. They must not be dismantled prior
to fitting.
The solid shaft of the machine runs free of grease in the hollow shaft of the gear unit.
B 1000 EN-1915 25
Assembly sequence
1. Remove any transport securing devices.
2. Loosen but do not remove tightening bolt and tighten gently by hand until there is no play between
the flanges and the inner ring.
3. Slide the shrink disc onto the hollow shaft until the outer clamping flange is flush with the hollow
shaft. The shrink disc is easier to slide on if the bore of the inner ring is lightly greased.
4. Prior to mounting, grease the solid shaft only in the area which will later come into contact with the
bronze bush in the hollow shaft of the gear unit. Do not grease the bronze bush, in order to prevent
grease penetrating the area around the shrink connection.
5. The hollow shaft of the gear unit must be completely de-greased and completely free of grease.
6. In the area of the shrink connection the solid shaft of the machine must be degreased and
completely free of grease.
7. Insert the solid shaft of the machine into the hollow shaft so as to completely fill the area around
the shrink connection.
8. Position the clamping flange by gently tightening the bolts.
9. Tighten the tensioning bolts successively in a clockwise direction by several turns – not crosswise
– with approx. ¼ rotation per turn. Tighten the bolts with a torque wrench to the torque indicated on
the shrink disc.
10. When the tensioning bolts have been tightened, there must be an even gap between the clamping
flanges. If this is not the case, the gear unit must be dismantled and the shrink disc connection
checked for correct fit.
Dismantling sequence:
1. Loosen the tensioning bolts successively in a clockwise direction by several turns with approx. ¼
rotation per turn. Do not remove the bolts from their thread.
2. Loosen the clamping flanges from the cone of the inner ring.
3. Remove the gear unit from the solid shaft of the machine.
If a shrink disk has been in use for a long period or is dirty, it must be dismantled, cleaned and the
conical surfaces coated with Molykote G Rapid Plus or a similar lubricant before it is refitted. The
threads and head surfaces of the screws must be treated with grease without Molykote. Any damaged
or corroded elements must be replaced.
26 B 1000 EN-1915
3.9 Fitting the covers

There is a danger of injury due to shrink discs and freely rotating shaft journals.
• Use a cover (Option H and Option H66) as a guard.
• If this does not achieve sufficient protection against contact according to the required protection type, the
machinery and plant constructor must ensure this by means of special attached components.
All fixing screws must be used and tightened to the correct torque (please see chapter 6.4 "Torque
values"). For covers with Option H66, press in the new / new condition closing cap by tapping it lightly
with a hammer.
Fig. 13: Fitting the covers, Option SH, Option H, and Option H66
3.10 Fitting the covers

There is a danger of injury due to freely rotating shaft journals.
• Use a cover cap as a guard
• If this does not achieve sufficient protection against contact according to the required protection type, the
machinery and plant constructor must ensure this by means of special attached components.
Many versions of the universal worm gear unit are supplied with plastic cover caps as standard. These
cover caps protect the shaft sealing ring against the entry of dust and other possible contamination.
The cover caps can be removed by hand without the use of tools and pushed onto the A or B side.
The cover cap must be removed before installing the universal worm gear unit. After installation is
complete, the cover cap must be pushed into the threaded holes on the output flange on the
corresponding side. Care must be taken that the cover cap is removed and pushed on vertically, in
order not to damage the expansion elements of the cover cap.
Fig. 14: Removal and fitting of the cover cap
B 1000 EN-1915 27
3.11 Fitting a standard motor

The maximum permitted motor weights indicated in the table below must not be exceeded when
attaching the motor to an IEC- / NEMA adapter:
Maximum permitted motor weights

IEC motor size 63 71 80 90 100 112 132 160 180 200 225 250 280 315
NEMA motor size 56C 143T 145T 182T 184T 210T 250T 280T 324T 326T 365T
Max. motor weight [kg] 25 30 40 50 60 80 100 200 250 350 500 700 1000 1500

Severe injuries may be caused by rapidly rotating parts when installing and servicing couplings.
Secure the drive unit against accidental switch-on.
Assembly procedure to attach a standard motor to the IEC adapter (Option IEC)/NEMA adapter
1. Clean the motor shaft and flange surfaces of the motor and the IEC /NEMA adapter and check for
damage. The mounting dimensions and tolerances of the motor must conform to DIN EN
50347/NEMA MG1 Part 4.
2. Push the coupling sleeve onto the motor shaft so that the motor parallel key engages into the
groove in the sleeve on tightening.
3. Tighten the coupling sleeve on the motor shaft in accordance with the motor manufacturer’s
instructions until it touches the collar. With motor sizes 90, 160, 180 and 225, any spacer bushes
must be positioned between the coupling sleeve and the collar. With standard helical gear units,
dimension B between the coupling sleeve and the collar must be observed (see Fig. 35). Certain
NEMA adapters require adjustment of the coupling in accordance with the specifications indicated
on the adhesive plate.
4. If the coupling half contains a threaded pin, the coupling must be secured axially on the shaft. Prior
to use the threaded pin must be coated with a securing lubricant e.g. Loctite 242, Loxeal 54-03 and
tightened to the correct torque (please see chapter 6.4 "Torque values").
5. Sealing of the flange surfaces of the motor and the IEC / NEMA adapter is recommended if the
motor is installed outdoors or in a humid environment. Before the motor is installed, the flange
surfaces must be completely coated with surface sealant Loctite 574 or Loxeal 58-14 so that the
flange seals after mounting.
6. Mount the motor on the IEC / NEMA adapter. Do not forget to fit the gear rim or the splined sleeve
provided (see illustration below).
7. Tighten the bolts of the IEC / NEMA adapter with the correct torque (please see chapter 6.4
"Torque values").
28 B 1000 EN-1915
Fig. 15: Fitting the coupling onto the motor shaft - various types of coupling
I Curved tooth coupling

II Curved tooth coupling, two-part
III Curved tooth coupling, two-part with spacer bush
IV Claw coupling, two-part
V Claw coupling, two-part, observe dimension B:
Standard helical gear unit:
IEC size 63 IEC size 71
Dimension B (Fig. V) B = 4.5 mm B = 11.5 mm
VI Claw coupling two-part with spacer bush
B 1000 EN-1915 29
3.12 Fitting the cooling coil to the cooling system

Possibility of injury due to pressure discharge.
The pressure released from the cooling circuit before carrying out any work on the gear unit.
The cooling coil is installed in the casing cover. Cutting ring screw threads according to DIN 2353 are
located at the casing cover for the connection of a pipe with an external diameter of 10 mm.
Remove the closing cap from the screw neck prior to assembly to avoid any contamination of
the cooling system. The screw necks should be connected with the coolant circuit, which must be
provided by the operator. The flow direction of the coolant is irrelevant.
Make sure not to twist the screw necks during or after assembly as the cooling coil may be
damaged. It must be ensured that no external forces act on the cooling coil.
Explanation
1 Cutting ring screw threads

2 Cooling coil
3 Housing cover
Fig. 16: Cooling cover
3.13 Subsequent paintwork
NOTICE Damage to the device

For retrospective painting of the gear unit, the radial seals, rubber elements, pressure venting valves, hoses, type
plates, adhesive labels and motor coupling components must not come into contact with paints, lacquers or
solvents, as otherwise components may be damaged or made illegible.
For subsequent painting, note that for use in Category II2G Group IIC the paint thickness must not
exceed 0.2 mm.
30 B 1000 EN-1915
4 Commissioning
4 Commissioning
4.1 Check the oil level

The oil level must be checked prior to commissioning (please see chapter 5.2 "Service and
Maintenance Work").
4.2 Activating the Automatic Lubricant Dispenser

Some gear unit types with standard motor (Option IEC/NEMA) have an automatic lubricant dispenser
for the roller bearings. This dispenser must be activated prior to commissioning. The cartridge case
cover of the adapter for attaching an IEC / NEMA standard motor has a red information sign for the
activation of the lubricant dispenser.
Activating the Automatic Lubricant Dispenser:
1. Loosen and remove the cylindrical screws.
2. Remove the cartridge cover.
3. Screw the activation screw into the lubricant dispenser until the lug breaks off at the defined
fracture point
4. Re-fit the cartridge cover and fasten it with the cylindrical screw (please see chapter 6.4 "Torque
values").
5. Mark activation date on the adhesive label indicating month/year
Explanation
1 Cylindrical screw M8 x 16
2 Cartridge cover
3 Activation screw
4 Lug
5 Lubricant sensor
6 Position of adhesive label
Fig. 17: Activating the automatic lubricant dispenser with standard motor mounting
B 1000 EN-1915 31
Adhesive label:
Notice!
Screw in the activation screw until the lug breaks off before
commissioning the gear unit.
Dispensing time: 12 Months
Month Activation date Year
1 2 3 4 5 6 7 8 9 10 11 12 06 07 08 09 10
11 12 13 14 15
Fig. 18: Adhesive label
4.3 Operation with lubricant cooling

Water cooling

The gear unit may be damaged by overheating.
The drive may only be commissioned after the cooling spiral has been connected to the cooling circuit, and the
cooling circuit has been put into operation.
The coolant must have a similar thermal capacity as water (specific thermal capacity at 20 °C
c=4.18 kJ/kgK). Industrial water without any air bubbles or sediments is recommended as a coolant.
The hardness of the water must be between 1 dH and 15 dH; the pH value must be between pH 7.4
and pH 9.5. No aggressive liquids may be added to the coolant!
The coolant pressure must not exceed 8 bar. The required quantity of coolant is 10 litres/minute,
and the coolant inlet temperature must not exceed 40°C; we recommend 10 °C.
We also recommend fitting a pressure reducer or similar at the coolant inlet to avoid damage due to
excessive pressure.
If there is a danger of frost the operator should add a suitable anti-freeze solution to the cooling water.
The temperature of the cooling water and the cooling water flow rate must be supervised and
ensured by the operator.
Air/Oil cooler
The version and all important data for the air/oil cooler can be obtained from Catalogue G1000, or
contact the manufacturer of the cooling unit.
32 B 1000 EN-1915
4 Commissioning
4.4 Running-in time for the worm gear unit
Information Running-in time

In order to achieve maximum efficiency of the worm gear unit, the gear unit must be subjected to a running-in
period of approx. 25 h – 48 h under maximum load.
There may be a reduction in efficiency before the running-in period is complete.
4.5 Checklist
Checklist
Subject of check Date Information
checked: see Section
Is the vent plug activated or the pressure vent screwed in? 3.4
Does the required configuration conform with the actual 6.1
installation?
Are the external gear shaft forces within permitted limits (chain 3.6
tension)?
Is the torque support correctly fitted? 3.7
Are contact guards fitted to rotating components? 3.9
Is the automatic lubricant dispenser activated? 4.2
Is the cooling cover connected to the cooling circuit? 3.12
4.3
B 1000 EN-1915 33
5 Service and maintenance

The surfaces of gear units or geared motors may become hot during or shortly after operation.
• Installation and maintenance work must only be performed when gear unit is at a standstill and has cooled
• Shield hot surfaces with contact guards.
5.1 Service and Maintenance Intervals
Service and Maintenance

Intervals Service and Maintenance Work Information
see Section
At least every six months • Visual inspection 5.2
• Check for running noises
• Check the oil level
• Re-grease / remove excess grease
(only applicable for free drive shaft / Option W and for agitator
bearings / Option VL2 / VL3)
• Replace the automatic lubricant dispenser /
remove excess grease
(For running times < 8 h / day: a replacement interval for
the lubricant dispenser of 1 year is permissible) (only with
attachment of IEC / NEMA standard motors)
For operating temperatures • Change the oil (The interval is doubled if filled with synthetic 5.2
up to 80 °C. products)
every 10000 operating • Cleaning or replacing the vent plug
hours, • Replace shaft sealing rings if worn
at least every 2 years
Every 20000 operating • Re-lubrication of the bearings in the gear unit 5.2
hours,
at least every 4 years
At least every 10 years • General overhaul 5.2
34 B 1000 EN-1915
Information Oil change intervals

The oil change intervals apply for normal operating conditions and operating temperatures up to 80°C. The oil
change intervals are reduced in the case of extreme conditions (operating temperatures higher than 80°C, high
humidity, aggressive environment and frequent fluctuations in the operating temperature).
5.2 Service and Maintenance Work
WARNING Severe personal injury

Severe injury and material damage may be caused by incorrect servicing and maintenance work.
Servicing and maintenance work must only be performed by qualified specialist personnel. Wear the necessary
protective clothing for servicing and maintenance work (e.g. industrial footwear, protective gloves, goggles, etc.)

Risk of injury due to rapidly rotating and hot machine components.
Installation and maintenance work must only be performed when gear units are at a standstill and have cooled

Particles or liquids thrown up during servicing and maintenance can cause injuries.
• Observe the safety information
• Pressure washers and compressed air must not be used for cleaning.

Danger of burns due to hot oil.
• Allow the gear unit to cool down before carrying out maintenance or repair work.
NOTICE Leakages
When cleaning with compressed air or pressure washers, take care that no dirt or water enters the shaft sealing
rings.
Dirt or water in the shaft sealing rings may cause oil leaks
Visual inspection
The gear unit must be checked for leaks. In addition, the gear unit must be inspected for external
damage and cracks in the hoses, hose connections and rubber buffers. Have the gear unit repaired in
case of leaks, e.g. dripping gear oil or cooling water, damage or cracks. Please contact the NORD
service department.
B 1000 EN-1915 35
Information Shaft sealing rings

Shaft sealing rings are rubbing seals and have sealing lips made from an elastomer material. These sealing lips
are lubricated with a special grease at the factory. This reduces the wear due to their function and ensures a long
service life. An oil film in the region of the rubbing sealing lip is therefore normal and is not due to leakage (please
see chapter 6.6 "Leaks and seals").
Check for running noises

If the gear unit produces unusual running noises and/or vibrations, this could indicate damage to the
gear unit. In this case the gear should be shut down and a general overhaul carried out.
Check the oil level
Section 6.1 "Configurations and maintenance" describes the configurations and the corresponding oil
level screws. With double gear units, the oil level must be checked on both units. The vent must be in
the position indicated in Section 6.1 "Configurations and maintenance".
The oil level does not need to be checked on gear units without oil level screw (please see chapter 6.1
"Configurations and maintenance").
Gear unit types that are not supplied full of oil must be filled before the oil level is checked.
Check the oil level with an oil temperature of between 20°C to 40°C.
1. The oil level may only be checked when the gear unit is at a standstill and has cooled down. The
gear unit must be secured to prevent accidental switch-on.
2. Unscrew the oil level screw for the particular configuration (please see chapter 6.1 "Configurations
and maintenance").
Information Checking the oil level

At the first oil level check a small amount of oil may escape, as the oil level may be below the lower edge of the
oil level hole.
3. Gear units with oil level screw: The correct oil level is at the lower edge of the oil level hole. If the
oil level is too low, this must be corrected using the correct type of oil. An oil level glass is available
instead of the oil level screw
4. Gear units with an oil reservoir: The oil level must be checked in the oil reservoir with the aid of
the dipstick plug (thread G1¼). The oil level must be between the upper and lower marking when
the dipstick is fully screwed in (see Fig. 1). Top up the oil level with the relevant type of oil as
necessary. These gear units may only be operated in the configuration stated in Section 6.1
"Configurations and maintenance".
36 B 1000 EN-1915
5. The oil level screw or the cap screw with dipstick and all other loosened screws must be correctly
re-tightened.
Fig. 19: Checking the oil level with a dipstick
Re-greasing
Some gear unit designs (free drive shaft, Option W, agitator designs VL2 and VL3) are equipped with
a re-greasing device.
For agitator versions VL2 and VL3, the vent screw located opposite to the grease nipple must be
unscrewed before re-greasing. Grease should be injected until a quantity of 20 - 25 g escapes from
the vent hole. After this, the vent plug must be reinserted and tightened.
For Option W and some IEC adapters, the outer roller bearing must be re-greased with approx.
20 - 25 g of grease via the grease nipple provided. Excess grease must be removed from the adapter.
Recommended grease: Petamo GHY 133N (please see chapter 6.2 "Lubricants") (Klüber Lubrication).
Replacing the automatic lubricant dispenser
Explanation
1 Cylindrical screws M8 x 16
2 Cartridge cover
3 Activation screw
4 Lug
5 Lubricant sensor
6 Position of adhesive label
Fig. 20: Replacing the automatic lubricant dispenser with standard motor mounting
B 1000 EN-1915 37
The cartridge cover must be unscrewed. The lubrication dispenser is screwed out and replaced with a
new component (Part No. 283 0100). Excess grease must be removed from the adapter. Then carry
out activation (please see chapter 4.2 "Activating the Automatic Lubricant Dispenser").
Change the oil
The illustrations in Section 6.1 "Configurations and maintenance" show the oil drain screw, the oil level
screw and the pressure vent screw (if fitted) for various designs.
Procedure:
1. Place a catchment vessel under the oil drain screw or the oil drain cock.
2. Completely remove oil level screw, screwed sealing plug with dipstick if an oil level tank is being
used and oil drain screw.

Danger of burns due to hot oil.
• Allow the gear unit to cool down before carrying out maintenance or repair work.
3. Drain all the oil from the gear unit.

4. If the sealing ring of the oil drain screw or oil level screw is damaged, a new oil level screw must be
used or the thread cleaned and coated with securing adhesive, e.g. Loctite 242, Loxeal 54-03 prior
to insertion.
5. Insert the oil drain screw into the hole and tighten to the correct torque (please see chapter 6.4
"Torque values").
6. Using a suitable filling device, refill with oil of the same type through the oil level hole until oil
emerges from the oil level hole. (The oil can also be filled through the pressure vent screw or a
sealing plug located higher than the oil level). If an oil level vessel is used, fill the oil through the
upper inlet (thread G1¼) until the oil level is set as described in Section 5.2 "Service and
Maintenance Work"
7. Wait at least 15 minutes, or at least 30 minutes if an oil level tank is used, and then check the oil
level. Then proceed as described in Section 5.2 "Service and Maintenance Work".
Information Oil level

The oil does not need to be changed in gear units without an oil drain screw (please see chapter 6.1
"Configurations and maintenance"). These gear units are lubricated for life.
Standard helical gear units have no oil level screw. Here, the oil is filled through the threaded vent hole using the
quantities listed in the table in Section 6.3 "Lubricant quantities".
Cleaning or replacing the vent plug

Unscrew the vent screw and thoroughly clean it (e.g. with compressed air) and fit the vent screw in the
same place, If necessary, use a new vent screw with a new sealing ring.
38 B 1000 EN-1915
Replacing the shaft sealing ring

Once the shaft sealing ring has reached the end of its service life, the oil film in the region of the
sealing lip increases and a measurable leakage with dripping oil occurs. The shaft sealing ring must
then be replaced. The space between the sealing lip and the protective lip must be filled
approximately 50 % with grease on fitting (recommended grease: PETAMO GHY 133N). Take care
that after fitting, the new shaft sealing ring does not run in the old wear track.
Re-lubricating bearings
For bearings which are not oil-lubricated and whose holes are completely above the oil level, replace
the roller bearing grease (recommended grease: PETAMO GHY 133N). Please contact the NORD
service department.
General overhaul
For this, the gear unit must be completely dismantled. The following work must be carried out:
– Clean all gear unit components
– Examine all gear unit components for damage
– All damaged components must be replaced
– All roller bearings must be replaced
– Replace back stops if fitted
– Replace all seals, radial seals and Nilos rings
– Replace plastic and elastomer components of the motor coupling
The general overhaul must be carried out by qualified personnel in a specialist workshop with
appropriate equipment in observance of national regulations and laws. We recommend that the
general overhaul is carried out by the NORD Service department.
B 1000 EN-1915 39
6 Appendix
6.1 Configurations and maintenance

Explanation of symbols for the following version illustrations:
Venting
Oil level
Oil drain
Information Gear unit - Lubrication

SK 320, SK 172, SK 272, SK 372 as well as SK 273 and SK 373, SK 01282 NB, SK 0282 NB, SK 1382 NB and
UNIVERSAL / MINIBLOC gear units are lubricated for life. These gear units do not have an oil filler screw.
UNIVERSAL / MINIBLOC worm gear units

NORD UNIVERSAL / MINIBLOC worm gear units are suitable for all installation positions. They have
an oil filler which is independent of the the configuration.
As an option, types SI and SMI can be equipped with a vent screw. Gear units with vents must be
installed in the stated position.
Types SI, SMI, S, SM and SU as 2-stage gear unit types and types SI, SMI as worm gear units for
direct motor mounting have an oil filler which depends on the configuration and must be installed in
the stated position.
40 B 1000 EN-1915
6 Appendix
Parallel shaft gear units with oil level vessel

The following applies for SK 9282, SK 9382, SK 10282, SK 10382, SK 11282, SK 11382 parallel gear
units and SK 12382 in the M4 configuration with oil reservoir:
Fig. 21: Oil level check with oil level tank
B 1000 EN-1915 41
42 B 1000 EN-1915
6 Appendix
B 1000 EN-1915 43
44 B 1000 EN-1915
6 Appendix
B 1000 EN-1915 45
46 B 1000 EN-1915
6 Appendix
B 1000 EN-1915 47
48 B 1000 EN-1915
6 Appendix
B 1000 EN-1915 49
50 B 1000 EN-1915
6 Appendix
SK 1S32 – SK 1S63
SK 1SU32 – SK 1SU63
SK 1SM31 – SK 1SM63
SK 1SI31 – SK 1SI75
SK 1SIS31 – SK 1SIS75
SK 1SMI31 – SK 1SMI75
SK 1SID31 – SK 1SID75
SK 1SIS-D31 – SK 1SIS-D63
SK 1SMID31 – SK 1SMID75
SK 2S32NB – SK 2S63NB
SK 2SU32NB- SK 2SU63NB
SK 2SM40 – SK 2SM63
SK 2SIS-D40 – SK 2SIS-D63
SK 2SID40 – SK 2SID63
SK 2SMID40 – SK 2SMID63
B 1000 EN-1915 51
6.2 Lubricants
With the exception of type SK 11282, SK 11382, SK 12382 and SK 9096.1 gear units, all gear units
are filled with lubricant ready for operation in the required installation position when delivered. This
initial filling corresponds to a lubricant from the column for the ambient temperatures (normal version)
in the lubricant table.
Roller bearing greases
This table shows comparable roller bearing greases from various manufacturers. The manufacturer
can be changed for a given grease type. Getriebebau NORD must be contacted in case of change of
grease type or ambient temperature range, as otherwise no warranty for the functionality of our gear
units can be accepted.
Lubricant type Ambient

temperature
Mineral Energrease RENOLIT

oil-based grease LS 2 GP 2 Gadus S2
-30 … 60 °C Longtime PD 2 - Mobilux EP 2
Energrease RENOLIT V100 2
LS-EP 2 LZR 2 H
RENOLIT
-50 … 40 °C - Optitemp LG 2 - - -
JP 1619
Synthetic grease RENOLIT PETAMO
Energrease HLT 2 GHY 133 N Mobiltemp Cassida
-25 … 80 °C Tribol 4747
SY 2202 RENOLIT Klüberplex SHC 32 EPS2
LST 2 BEM 41-132
Biodegradable Mobil SHC
Biogrease PLANTOGEL Klüberbio Naturelle
grease -25 … 40 °C - Grease
EP 2 2S M 72-82 Grease EP2
102 EAL
Foodstuff RENOLIT Klübersynth Mobilgrease
-25 … 40 °C - Obeen UF 2 Cassida RLS2
compatible grease G 7 FG 1 UH1 14-151 FM 222
Table 4: Roller bearing greases
52 B 1000 EN-1915
6 Appendix
Lubricant table
This table shows comparable lubricants from various manufacturers. The manufacturer can be
changed within a particular viscosity or lubricant type. Getriebebau NORD must be contacted in case
of change of viscosity or lubricant type, as otherwise no warranty for the functionality of our gearboxes
can be accepted.
Lubricant type Details on DIN (ISO) /
type plate Ambient
temperature
Mineral oil Alpha EP 680 Renolin CLP
ISO VG 680 Alpha SP 680 680 Klüberoil Mobilgear Omala
CLP 680
0...40 °C Optigear BM 680 Renolin CLP GEM 1-680 N 600 XP 680 S2 G 680
Tribol 1100 / 680 680 Plus
Renolin CLP
Alpha EP 220 220
ISO VG 220
Alpha SP 220 Renolin CLP Klüberoil Mobilgear Omala
CLP 220 -10…40 °C
Optigear BM 220 220 Plus GEM 1-220 N 600 XP 220 S2 G 220
Tribol 1100 / 220 Renolin Gear
220 VCI
Alpha EP 100 Renolin CLP
ISO VG 100 Alpha SP 100 100 Klüberoil Mobilgear Omala
CLP 100
-15…25 °C Optigear BM 100 Renolin CLP GEM 1-100 N 600 XP 100 S2 G 100
Tribol 1100 / 100 100 Plus
Synthetic oil ISO VG 680
Alphasyn GS 680 Renolin Klübersynth Mobil Omala
(Polyglycol) CLP PG 680 -20...40 °C
Tribol 800/680 PG 680 GH 6-680 Glygoyle 680 S4 WE 680
ISO VG 220 Alphasyn GS 220

Renolin Klübersynth Mobil Omala
CLP PG 220 -25…80 °C Alphasyn PG 220
PG 220 GH 6-220 Glygoyle 220 S4 WE 220
Tribol 800 / 220
Synthetic oil Alphasyn EP 460
(hydrocarbons) ISO VG 460 Tribol 1510 / 460 Renolin Unisyn Klübersynth Mobil Omala
CLP HC 460
-30…80 °C Optigear Synthetic CLP 460 GEM 4-460 N SHC 634 S4 GX 460
X 460
Alphasyn EP 220 Renolin Unisyn
ISO VG 220 Tribol 1510 / 220 CLP 220 Klübersynth Mobil Omala
CLP HC 220
-40…80 °C Optigear Synthetic Renolin Unisyn GEM 4-220 N SHC 630 S4 GX 220
X 220 Gear VCI
Bio-degradable ISO VG 680 Plantogear
CLP E 680 - - - -
oil -5…40 °C 680 S
Naturelle
ISO VG 220 Tribol BioTop Plantogear Klübersynth Gear
CLP E 220 -
-5…40 °C 1418 / 220 220 S GEM 2-220 Fluid
EP 220
Foodstuff- Cassida
CLP PG H1 ISO VG 680 Tribol FoodProof Klübersynth Mobil
compatible oil - Fluid
680 -5…40 °C 1800 / 680 UH1 6-680 Glygoyle 680
WG 680
Cassida
CLP PG H1 ISO VG 220 Tribol FoodProof Klübersynth Mobil
- Fluid
220 -25…40 °C 1800 / 220 UH1 6-220 Glygoyle 220
WG 220
Cassida
CLP PG H1 ISO VG 680 Geralyn Klüberoil
Optileb GT 680 - Fluid
680 -5…40 °C SF 680 4 UH1-680 N
GL 680
Mobil Cassida
CLP PG H1 ISO VG 220 Geralyn Klüberoil
Optileb GT 220 SHC Cibus Fluid
220 -25…40 °C SF 220 4 UH1-220 N
220 GL 220
Gear unit liquid Renolit Mobil
MICROLUBE Alvania
grease Longtime Duraplex Chassis
GB 00 EP(LF)2
PD 00 EP 00 Grease LBZ
-25 … 60 °C
Tribol Mobil
3020 / 1000-00 Renolit Klübersynth
Glygoyle -
LST 00 GE 46-1200
Grease 00
Table 5: Lubricant table
B 1000 EN-1915 53
6.3 Lubricant quantities
Information Lubricants
After changing the lubricant, and in particular after the initial filling, the oil level may change during the first few
hours of operation, as the oil galleries and the hollow spaces only fill gradually during operation.
The oil level is still within the permissible tolerance.
If at the express request of the customer, an oil inspection glass is installed at an additional charge, we
recommend that the customer corrects the oil level after an operating period of approx. 2 hours, so that when the
gear unit is at a standstill and has cooled down, the oil level is visible in the inspection glass. Only then, is it
possible to check the oil level by means of the inspection glass.
The filling quantities stated in the following tables are for guidance only. The precise quantities vary depending on
the exact gear ratio. When filling, always observe the oil level screw hole as an indicator of the precise quantity of
oil.
* Gear unit types SK 11282, SK 11382, SK 12382 and SK 9096.1 are normally supplied without oil.
54 B 1000 EN-1915
6 Appendix
Helical gear units
[L]
 6.1 M1 M2 M3 M4 M5 M6 M1 M2 M3 M4 M5 M6
 6.1 B3 V6 B8 V5 B6 B7 B5 V3 B5I V1 B5II B5III
SK11E 0,25 0,50 0,65 0,50 0,40 0,40 0,30 0,50 0,50 0,45 0,40 0,40
SK21E 0,60 1,20 1,30 1,00 1,00 1,00 0,50 1,20 1,30 0,60 0,90 0,90
SK31E 1,10 2,00 2,20 1,70 1,50 1,50 0,90 1,80 1,65 1,30 1,25 1,25
SK41E 1,60 2,60 3,30 2,80 2,30 2,30 1,20 2,30 2,70 2,00 1,90 1,90
SK51E 1,80 3,50 4,10 4,00 3,80 3,80 1,80 3,50 4,10 3,00 3,80 3,80
[L]
SK02 0,20 0,75 0,75 0,65 0,60 0,60 0,25 0,70 0,70 0,70 0,50 0,50
SK12 0,25 0,80 0,85 0,75 0,55 0,55 0,35 0,85 0,90 0,90 0,70 0,70
SK22 0,50 1,90 2,10 1,80 1,40 1,40 0,70 1,80 1,80 1,80 1,40 1,40
SK32 0,90 2,50 3,10 3,10 2,00 2,00 1,20 2,80 3,10 3,10 2,20 2,20
SK42 1,40 4,50 4,50 4,30 3,20 3,20 1,80 4,40 4,50 4,00 3,70 3,70
SK52 2,50 7,00 6,80 6,80 5,10 5,10 3,00 6,80 6,20 7,40 5,60 5,60
[L]
SK62 6,50 15,00 13,00 16,00 15,00 15,00 7,00 15,00 14,00 18,50 16,00 16,00
SK72 10,00 23,00 18,00 26,00 23,00 23,00 10,00 23,00 18,50 28,00 23,00 23,00
SK82 14,00 35,00 27,00 44,00 32,00 32,00 15,00 37,00 29,00 45,00 34,50 34,50
SK92 25,00 73,00 47,00 76,00 52,00 52,00 26,00 73,00 47,00 78,00 52,00 52,00
SK102 36,00 79,00 66,00 102,00 71,00 71,00 40,00 81,00 66,00 104,00 72,00 72,00
[L]
SK03 0,35 1,20 0,80 1,00 0,70 0,70 0,55 0,95 0,90 1,20 0,90 0,90
SK13 0,75 1,30 1,30 1,20 0,75 0,75 1,00 1,30 1,30 1,20 1,00 1,00
SK23 1,20 2,00 1,90 2,40 1,60 1,60 1,40 2,60 2,30 2,80 2,80 2,80
SK33N 1,75 3,00 3,40 4,00 2,30 2,30 2,20 3,00 3,40 4,20 2,30 2,30
SK43 3,00 5,60 5,20 6,60 3,60 3,60 3,50 5,70 5,00 6,10 4,10 4,10
SK53 4,50 8,70 7,70 8,70 6,00 6,00 5,20 8,40 7,00 8,90 6,70 6,70
[L]
SK63 13,00 14,50 14,50 16,00 13,00 13,00 13,50 14,00 15,50 18,00 14,00 14,00
SK73 20,50 20,00 22,50 27,00 20,00 20,00 22,00 22,50 23,00 27,50 20,00 20,00
SK83 30,00 31,00 34,00 37,00 33,00 33,00 31,00 34,00 35,00 40,00 34,00 34,00
SK93 53,00 70,00 59,00 72,00 49,00 49,00 53,00 70,00 59,00 74,00 49,00 49,00
SK103 74,00 71,00 74,00 97,00 67,00 67,00 69,00 78,00 78,00 99,00 67,00 67,00
Table 6: Lubricant quantities for helical gear units
B 1000 EN-1915 55
NORDBLOC
[L] [L]
 6.1 M1 M2 M3 M4 M5 M6  6.1 M1 M2 M3 M4 M5 M6
SK072.1 0,16 0,32 0,21 0,23 0,18 0,20 SK072.1 F 0,16 0,32 0,21 0,23 0,18 0,20
SK172.1 0,27 0,59 0,42 0,45 0,32 0,39 SK172.1 F 0,27 0,59 0,42 0,45 0,32 0,39
SK372.1 0,45 1,05 0,75 1,00 0,60 0,65 SK372.1 F 0,45 1,05 0,75 1,00 0,60 0,65
SK572.1 0,75 1,90 1,50 2,00 1,10 1,15 SK572.1 F 0,75 1,90 1,50 2,00 1,10 1,15
SK672.1 1,10 2,60 2,15 2,70 1,55 1,65 SK672.1 F 1,10 2,60 2,15 2,70 1,55 1,65
SK772.1 1,30 3,80 2,40 3,20 1,60 2,50 SK772.1 F 1,30 3,80 2,40 3,30 1,70 2,40
SK872.1 2,90 7,80 4,60 6,40 2,50 4,00 SK872.1 F 3,20 7,50 5,10 6,70 2,60 4,30
SK972.1 4,50 12,00 7,50 11,50 4,20 7,50 SK972.1 F 4,50 12,50 8,00 12,50 4,50 7,70
SK772.1VL 2,00 3,80 2,40 3,20 1,60 2,50 SK772.1VL F 2,00 3,80 2,40 3,30 1,70 2,40
SK872.1VL 5,00 7,80 4,60 6,40 2,50 4,00 SK872.1VL F 5,00 7,50 5,10 6,70 2,60 4,30
SK972.1VL 8,50 12,00 7,50 11,50 4,20 7,50 SK972.1VL F 8,50 12,50 8,00 12,50 4,50 7,70
[L] [L]
 6.1 M1 M2 M3 M4 M5 M6  6.1 M1 M2 M3 M4 M5 M6
SK373.1 0,45 1,05 0,75 1,00 0,60 0,65 SK373.1 F 0,45 1,05 0,75 1,00 0,60 0,65
SK573.1 0,75 1,90 1,50 2,00 1,10 1,15 SK573.1 F 0,75 1,90 1,50 2,00 1,10 1,15
SK673.1 1,10 2,60 2,15 2,70 1,55 1,65 SK673.1 F 1,10 2,60 2,15 2,70 1,55 1,65
SK773.1 2,30 3,80 3,30 3,20 2,40 3,10 SK773.1 F 2,00 3,50 3,20 2,90 2,30 3,00
SK873.1 4,20 7,80 5,90 6,40 4,10 5,90 SK873.1 F 4,10 7,60 6,90 6,60 5,00 6,60
SK973.1 7,50 12,00 10,50 11,50 7,50 10,50 SK973.1 F 7,40 12,20 11,10 11,60 8,00 10,90
SK773.1VL 2,30 3,80 3,30 3,20 2,40 3,10 SK773.1VL F 2,00 3,50 3,20 2,90 2,30 3,00
SK873.1VL 4,20 7,80 5,90 6,40 4,10 5,90 SK873.1VL F 4,10 7,60 6,90 6,60 5,00 6,60
SK973.1VL 7,50 12,00 10,50 11,50 7,50 10,50 SK973.1VL F 7,40 12,20 11,10 11,60 8,00 10,90
Table 7: Lubricant quantities for NORDBLOC
56 B 1000 EN-1915
6 Appendix
[L]
 6.1 M1 M2 M3 M4 M5 M6 M1 M2 M3 M4 M5 M6
 6.1 B3 V6 B8 V5 B6 B7 B5 V3 B5I V1 B5II B5III
SK172 0,35 0,50 0,50 0,50 0,50 0,50 0,35 0,50 0,50 0,50 0,50 0,50
SK272 0,60 1,00 1,00 1,00 1,00 1,00 0,60 1,00 1,00 1,00 1,00 1,00
SK372 0,60 1,00 1,00 1,00 1,00 1,00 0,60 1,00 1,00 1,00 1,00 1,00
SK472 1,00 1,90 1,90 2,00 1,80 1,80 1,00 1,90 1,90 1,90 1,90 1,50
SK572 1,00 1,90 1,90 2,00 1,80 1,80 1,00 1,90 1,90 1,90 1,90 1,50
SK672 1,40 3,40 3,10 3,15 1,45 3,15 1,15 3,40 2,70 2,80 1,25 2,70
SK772 2,00 3,30 3,50 4,20 2,70 3,30 1,60 3,30 3,50 3,30 3,10 3,10
SK872 3,70 9,60 9,10 7,30 4,70 8,00 3,50 9,00 7,90 7,70 3,90 7,20
SK972 6,50 16,00 15,70 14,70 8,50 14,00 6,50 15,00 13,00 13,50 6,50 12,00
[L]
SK273 0,62 1,10 1,10 1,10 1,10 1,10 0,62 1,10 1,10 1,10 1,10 1,10
SK373 0,55 1,10 1,10 1,10 1,10 1,10 0,55 1,10 1,10 1,10 1,10 1,10
SK473 1,30 2,50 2,10 2,40 2,10 2,10 1,25 2,40 2,10 2,50 2,10 2,10
SK573 1,30 2,50 2,10 2,40 2,10 2,10 1,25 2,40 2,10 2,50 2,10 2,10
SK673 1,80 3,80 3,20 3,40 2,90 3,00 1,70 3,80 3,00 3,20 3,00 3,00
SK773 2,50 4,50 3,70 4,60 3,30 3,30 2,30 5,00 3,60 4,50 3,90 3,90
SK873 6,20 8,40 7,50 9,10 7,50 7,50 5,00 8,80 7,60 8,00 8,00 8,00
SK973 11,00 15,80 13,00 16,00 13,30 13,00 10,30 16,50 13,00 16,00 14,00 14,00
Table 8: Lubricant quantities: NORDBLOC helical gear units
[L] [L]
 6.1 M1 M2 M3 M4 M5 M6  6.1 M1 M2 M3 M4 M5 M6
SK20 0,55 1,00 0,55 1,00 0,55 0,55 SK20 F 0,35 0,60 0,35 0,60 0,35 0,35
SK0 0,13 0,22 0,13 0,22 0,13 0,13 SK0 F 0,13 0,22 0,13 0,22 0,13 0,13
SK01 0,22 0,38 0,22 0,38 0,22 0,22 SK01 F 0,22 0,38 0,22 0,38 0,22 0,22
SK25 0,50 1,00 0,50 1,00 0,50 0,50 SK25 F 0,50 1,00 0,50 1,00 0,50 0,50
SK33 1,00 1,60 1,00 1,60 1,00 1,00 SK33 F 1,00 1,50 1,00 1,50 1,00 1,00
SK30 0,90 1,30 0,90 1,30 0,90 0,90 SK30 F 0,70 1,10 0,70 1,10 0,70 0,70
SK300 1,20 2,00 1,20 2,00 1,20 1,20 SK300 F 1,25 1,50 1,20 1,80 1,30 0,95
SK330 1,80 2,80 1,80 2,80 1,80 1,80 SK330 F 1,60 2,50 1,60 2,90 1,90 1,40
SK200 0,80 1,30 0,80 1,30 0,80 0,80 SK200 F 0,65 0,95 0,70 1,10 0,80 0,50
SK010 0,38 0,60 0,38 0,60 0,38 0,38 SK010 F 0,35 0,65 0,40 0,74 0,50 0,30
SK250 1,20 1,50 1,20 1,50 1,20 1,20 SK250 F 0,90 1,40 1,00 1,60 1,30 0,80
SK000 0,24 0,40 0,24 0,41 0,24 0,24 SK000 F 0,24 0,41 0,24 0,41 0,24 0,24
Table 9: Lubricant quantities for standard helical gear units
B 1000 EN-1915 57
Parallel shaft gear unit
[L] [L]
 6.1 M1 M2 M3 M4 M5 M6  6.1 M1 M2 M3 M4 M5 M6
 6.1 H1 H6 H2 H5 H4 H3  6.1 H1 H6 H2 H5 H4 H3
SK0182NB A 0,40 0,55 0,55 0,40 0,40 0,40
SK0282NB A 0,70 1,10 0,80 1,10 0,90 0,90
SK1382NB A 1,40 2,30 2,20 2,20 2,00 2,00
[L] [L]
SK1282 A 0,95 1,30 0,90 1,30 1,00 1,00 SK2382 A 2,30 2,70 2,10 3,20 2,00 2,00
SK2282 A 1,70 2,30 1,70 2,20 1,90 1,90 SK3382 A 3,80 4,30 3,00 5,50 3,00 3,00
SK3282 A 2,80 4,00 3,30 3,80 3,00 3,00 SK4382 A 6,10 6,90 4,90 8,40 5,00 5,00
SK4282 A 4,20 5,40 4,40 5,00 4,20 4,20 SK5382 A 12,50 12,00 6,70 14,00 8,30 8,30
SK5282 A 7,50 8,80 7,50 8,80 7,20 7,20 SK1382 A 1,45 1,60 1,15 1,70 1,10 1,10
[L] [L]
SK6282 A 17,00 15,50 12,50 17,50 11,00 14,00 SK6382 A 16,00 13,00 10,00 18,00 14,00 12,50
SK7282 A 25,50 21,00 20,50 27,00 16,00 21,00 SK7382 A 22,00 21,00 16,00 25,00 23,00 22,00
SK8282 A 37,50 33,00 30,50 44,00 31,00 31,00 SK8382 A 34,50 32,50 25,00 38,00 35,00 30,00
SK9282 A 74,50 70,00 56,00 80,00 65,00 59,00 SK9382 A 73,50 70,00 43,00 74,50 65,00 60,00
[L] [L]
SK10282 A 90 90 40 90 60 82 SK10382 A 85 90 73 100 80 80
SK11282 A 165 160 145 195 100 140 SK11382 A 160 155 140 210 155 135
SK12382 A 160 155 140 210 155 135
* For further information see page 54
Table 10: Lubricant quantities for parallel shaft gear units
58 B 1000 EN-1915
6 Appendix
Bevel gear unit
[L]
 6.1 M1 M2 M3 M4 M5 M6 M1 M2 M3 M4 M5 M6
 6.1 B3 B6 B8 B3I V5 V6 B5I B5 B5III B5II V1 V3
H1 H4 H2 H3 H5 H6
SK92072 0,40 0,60 0,50 0,55 0,40 0,40 0,40 0,60 0,55 0,55 0,40 0,40
SK92172 0,60 0,90 1,00 1,10 1,10 0,80 0,50 1,00 0,90 1,05 0,90 0,60
SK92372 0,90 1,60 1,50 1,90 1,50 0,90 1,20 1,60 1,50 1,90 1,30 1,30
SK92672 1,80 3,50 3,60 3,40 2,60 2,60 1,60 2,80 2,50 3,30 2,40 2,40
SK92772 2,30 4,50 4,60 5,30 4,10 4,10 2,80 4,40 4,50 5,50 3,50 3,50
[L]
SK9x072.1 0,26 0,49 0,42 0,54 0,29 0,31 0,39 0,93 0,79 1,02 0,49 0,62
SK9x172.1 0,34 0,61 0,55 0,67 0,42 0,48 0,60 1,17 0,94 1,22 0,65 0,85
SK9x372.1 0,43 0,92 0,86 1,10 0,59 0,62 1,00 1,97 1,65 2,14 1,12 1,34
SK9x672.1 0,85 1,60 1,40 1,85 1,05 1,22 1,80 3,23 2,71 4,20 2,02 2,45
SK9x772.1 1,45 2,65 1,95 2,70 1,60 1,70 2,72 4,63 3,70 5,40 2,93 3,25
[L]
SK9012.1 0,70 1,70 1,90 2,10 1,10 1,50 1,00 1,90 1,90 2,20 1,20 1,70
SK9016.1 0,70 1,70 1,90 2,10 1,10 1,50 1,00 1,90 1,90 2,20 1,20 1,70
SK9022.1 1,30 2,90 3,30 3,80 1,70 2,80 1,60 3,50 3,50 4,20 2,30 2,80
SK9032.1 1,80 5,40 6,10 6,80 3,00 4,60 2,10 4,80 6,40 7,10 3,30 5,10
SK9042.1 2,70 9,00 10,00 10,70 5,20 7,70 4,50 10,00 10,00 11,50 6,50 8,20
SK9052.1 6,50 16,00 19,00 21,50 11,00 15,50 7,50 16,50 20,00 23,50 11,50 18,00
SK9062.1 10,00 27,50 32,00 36,00 18,00 24,00 12,00 27,50 33,00 38,50 19,00 26,00
SK9072.1 10,00 27,50 32,00 36,00 18,00 24,00 12,00 27,50 33,00 38,50 19,00 26,00
SK9082.1 17,00 51,50 62,50 71,50 33,00 46,50 21,00 54,00 66,00 80,00 38,00 52,00
SK9086.1 29,00 73,00 85,00 102,00 48,00 62,00 36,00 78,00 91,00 107,00 53,00 76,00
SK9092.1 41,00 157,00 170,00 172,00 80,00 90,00 40,00 130,00 154,00 175,00 82,00 91,00
SK9096.1 70,00 187,00 194,00 254,00 109,00 152,00 80,00 187,00 193,00 257,00 113,00 156,00
[L]
SK9013.1 1,35 2,10 2,15 2,75 1,00 1,80 1,45 2,30 2,10 2,80 1,05 1,80
SK9017.1 1,30 2,00 2,10 2,70 1,00 1,70 1,45 2,30 2,10 2,80 1,05 1,80
SK9023.1 2,20 3,20 3,60 4,70 2,20 2,90 2,30 3,50 3,80 5,30 2,20 3,40
SK9033.1 3,10 5,70 6,30 8,00 3,40 4,80 3,70 5,70 6,70 8,60 3,60 5,30
SK9043.1 5,00 10,10 11,00 13,30 5,70 8,10 6,50 10,50 11,90 14,70 6,70 9,30
SK9053.1 10,00 17,00 20,00 24,50 11,50 16,50 13,00 18,00 21,50 26,50 13,00 17,00
* For further information see page 54
Table 11: Lubricant quantities for bevel gear units
B 1000 EN-1915 59
[L] [L]
 6.1 M1 M2 M3 M4 M5 M6 M1 M2 M3 M4 M5 M6
 6.1 B3 B6 B8 B3I V5 V6 B5I B5 B5III B5II V1 V3
 6.1 H1 H4 H2 H3 H5 H6
SK02040 0,40 0,80 0,75 0,65 0,50 0,50 SK02040 A 0,40 0,70 0,65 0,65 0,55 0,55
SK02050 0,40 1,40 1,10 1,30 0,70 0,70 SK02050 A 0,45 1,40 1,15 1,10 0,75 0,75
SK12063 0,60 1,80 1,20 1,60 1,00 1,00 SK12063 A 0,55 1,45 1,60 1,60 1,10 1,10
SK12080 0,90 3,10 2,40 3,00 1,80 1,80 SK12080 A 0,80 3,10 3,20 2,80 1,80 1,80
SK32100 1,50 6,30 5,60 5,50 3,60 3,60 SK32100 A 1,50 5,60 5,60 5,30 4,00 4,00
SK42125 2,80 11,80 10,20 10,00 6,20 6,20 SK42125 A 3,00 12,50 10,80 10,80 6,50 6,50
[L] [L]
SK13050 0,75 1,75 1,30 1,75 0,75 0,75 SK13050 A 0,90 1,80 1,30 1,65 1,30 1,30
SK13063 1,00 2,30 1,50 2,20 1,10 1,10 SK13063 A 1,05 2,10 1,80 2,10 1,40 1,40
SK13080 1,70 3,50 3,50 3,50 2,00 2,00 SK13080 A 1,60 3,60 2,90 3,75 2,00 2,00
SK33100 2,40 6,40 5,40 6,50 3,40 3,40 SK33100 A 2,60 6,00 5,80 6,00 3,50 3,50
SK43125 4,25 13,00 10,50 13,50 7,20 7,20 SK43125 A 4,60 13,60 11,40 14,30 7,60 7,60
[L] [L]
SK02040 F 0,40 0,70 0,65 0,65 0,55 0,55
SK02050 F 0,40 1,50 1,25 1,20 0,90 0,75 SK13050 F 0,75 1,80 1,50 1,70 1,05 0,90
SK12063 F 0,50 1,95 1,70 1,75 1,20 0,95 SK13063 F 1,00 2,30 1,90 2,20 1,35 1,10
SK12080 F 0,90 3,70 3,20 3,40 2,50 2,30 SK13080 F 1,60 3,80 3,50 3,90 2,70 2,50
SK32100 F 1,40 6,30 6,10 6,10 4,00 3,60 SK33100 F 2,65 7,20 6,40 7,60 4,30 3,80
SK42125 F 3,00 11,50 11,50 11,00 8,40 7,30 SK43125 F 4,70 15,00 13,00 16,00 9,00 7,70
Table 12: Lubricant quantities for helical worm gear units
60 B 1000 EN-1915
6 Appendix
6.4 Torque values
Bolt Torques [Nm]

Screw connections in the strength Screw
classes Threaded pin on connections on
Dimensions Cover screws
coupling protective
8.8 10.9 12.9
covers
M4 3.2 5 6 - - -
M5 6.4 9 11 - 2 -
M6 11 16 19 - - 6.4
M8 27 39 46 11 10 11
M10 53 78 91 11 17 27
M12 92 135 155 27 40 53
M16 230 335 390 35 - 92
M20 460 660 770 - - 230
M24 790 1150 1300 80 - 460
M30 1600 2250 2650 170 - -
M36 2780 3910 4710 - - 1600
M42 4470 6290 7540 - - -
M48 6140 8640 16610 - - -
M56 9840 13850 24130 - - -
G½ - - - 75 - -
G¾ - - - 110 - -
G1 - - - 190 - -
G1¼ - - - 240 - -
G1½ 300 -
Table 13: Torque values
Assembling the hose fittings

Oil the thread of the union nut, the cutting ring and the screw neck. Tighten the union nut with the
wrench until the point where the union nut can only be turned with considerably more force. Turn the
union nut of the screw fitting approx. 30° to 60° further but not more than 90°. For this the screw neck
must be held with a wrench. Remove excess oil from the screw fitting
B 1000 EN-1915 61
6.5 Troubleshooting

There is a slipping hazard in case of leaks.
Clean the soiled floor and machine components before starting troubleshooting.

Risk of injury due to rapidly rotating and hot machine components.
Troubleshooting must only be performed when gear units are at a standstill and have cooled down. The drive
must be isolated and secured to prevent accidental start-up.

Damage to the gear unit is possible in case of faults.
Shut down the drive unit immediately in case of any faults in the gear unit.
Gear unit malfunctions

Fault Possible cause Remedy
Oil too low or
Unusual running noises,
bearing damage Consult NORD Service
vibrations
or gear wheel damage
Oil escaping from the gear unit or
Defective seal Consult NORD Service
motor
Incorrect oil level or
incorrect, contaminated oil Oil change:
Oil escaping from pressure vent
or unfavourable operating Use oil expansion tank (Option OA)
conditions
Unfavourable installation conditions
Gear unit becomes too hot Consult NORD Service
or gear unit damage
Replace the elastomer gear rim,
Defective motor coupling
Shock when switching on, tighten the motor and gear unit
or loose gear unit mounting
vibrations fastening bolts,
or defective rubber element
replace the rubber element
Fracture in gear unit or
Drive shaft does not rotate
defective motor coupling or Consult NORD Service
although motor is running
shrink disc slippage
Table 14: Overview of malfunctions
62 B 1000 EN-1915
6 Appendix
6.6 Leaks and seals

Gear units are filled with oil or grease to lubricate the moving parts. Seals prevent the escape of
lubricants. A complete seal is not technically possible, as a certain film of moisture, for example on the
radial shaft sealing rings is normal and advantageous for a long-term seal. In the region of vents,
moisture due to oil may be visible due to the escape of oil mist because of the function. In the case of
grease-lubricated labyrinth seals, e.g. Taconite sealing systems, used grease emerges from the
sealing gap due to the principle of operation. This apparent leak is not a fault.
According to the test conditions as per DIN 3761, the leak is determined by the medium which is to be
sealed, which in test bench tests exceeds the function-related moisture in a defined test period and
which results in dripping of the medium which is to be sealed. The measured quantity which is then
collected is designated as leakage.
Definition of leakage according to DIN 3761 and its appropriate use

Location of leak
Shaft sealing
Term Explanation in IEC adapter Housing joint Venting
ring
No moisture No reason for No reason for No reason for No reason for
Sealed
apparent complaint complaint complaint complaint
Moisture film locally
No reason for No reason for No reason for No reason for
Damp restricted (not an
complaint complaint complaint complaint
area)
Moisture film beyond
No reason for No reason for Repair if No reason for
Wet the extent of the
complaint complaint necessary complaint
component
Measurable Recognisable Repair Repair Repair Repair
leakage stream, dripping recommended recommended recommended recommended
Temporary
malfunction of the
Temporary No reason for No reason for Repair if No reason for
sealing system or oil
leakage complaint complaint necessary complaint
leak due to
transport *)
Apparent leakage,
e.g. due to soiling,
Apparent No reason for No reason for No reason for No reason for
sealing systems
leakage complaint complaint complaint complaint
which can be re-
lubricated
Table 15: Definition of leaks according to DIN 3761
*) Previous experience has shown that moist or wet radial shaft sealing rings stop leaking later.
Therefore, under no circumstances can replacement be recommended at this stage. The reason for
momentary moisture may be e.g. small particles under the sealing lip.
B 1000 EN-1915 63
6.7 Repair information
For enquiries to our technical and mechanical service departments, please have the precise gear unit
type (type plate) and if necessary the order number (type plate) to hand.
6.7.1 Repairs
The device must be sent to the following address if it needs repairing:
Getriebebau NORD GmbH & Co. KG

Service Department
Getriebebau-Nord-Straße 1
22941 Bargteheide
No guarantee can be given for any attachments, such as encoders or external fans, if a gear unit or
geared motor is sent for repair.
Please remove all non-original parts from the gear unit or geared motor.
Information Reason for return

If possible, the reason for returning the component or device should be stated. If necessary, at least one contact
should be stated in case of queries.
This is important in order to keep repair times as short and efficient as possible.
6.7.2 Internet information

In addition, the country-specific operating and installation instructions in the available languages can
be found on our Internet site: www.nord.com
6.8 Abbreviations
2D Dust explosion protected gear units zone 21 FA Axial force
2G Explosion protected gear units with ignition IE1 Motors with standard efficiency
protection class "c"
3D Dust explosion protected gear units zone 22 IE2 Motors with high efficiency
ATEX ATmospheres EXplosibles IEC International Electrotechnical Commission
B5 Flange fastening with through holes NEMA National Electrical Manufacturers Association
B14 Flange fastening with threaded holes IP55 International Protection
CW Clockwise, right-hand direction of rotation ISO International Standardisation Organisation
CCW Counter-clockwise, left-hand direction of pH pH value
rotation
°dH Water hardness in German hardness PPE Personal Protective Equipment
degrees: 1°dH = 0.1783 mmol/l
DIN German standards institute RL Directive
EC European Community VCI Volatile Corrosion Inhibitor
EN European standard WN Getriebebau NORD factory standard
FR Radial transverse force
64 B 1000 EN-1915
Key word index
Key word index

A Lubricant sensor ........................................... 31
Activating the vent .........................................18 Lubricants ..................................................... 53
Address..........................................................64 M
Assembly .......................................................18 Maintenance ................................................. 64
C Check for running noises .......................... 36
Coolant ..........................................................32 Check oil level ........................................... 36
Cooling cover .................................................30 Lubricant dispenser ................................... 37
Correct use ...................................................... 9 Oil change ................................................. 38
Covers ...........................................................27 Re-greasing VL2, VL3 and IEC ................. 37

Shaft sealing ring....................................... 39
D
Vent screw ................................................. 38
Danger labels .................................................. 8
Visual inspection ....................................... 35
Disposal of materials .....................................11
Maintenance intervals ................................... 34
F
Motor weights for IEC adapters .................... 28
Faults ............................................................. 62
O
G
Option H66 .................................................... 22
Gear unit types ..............................................12
P
General overhaul ...........................................39
Painting the gear unit .................................... 30
General safety information ............................10
Lubricant quantities ....................................... 58
H
Pulling devices .............................................. 21
Hose fitting .....................................................61
Push-on gear unit.......................................... 22
I
R
Inspection intervals ........................................34
Repairs .......................................................... 64
Installing the gear unit ...................................19
Roller bearing greases .................................. 52
Internet...........................................................64
Running-in time ............................................. 33
L
S
Leakage .........................................................63
Safety information ........................................... 2
Long-term storage .........................................16
Service .......................................................... 64
Lubricant quantities
Shrink disc .................................................... 25
bevel gear units ..........................................59
Standard motor ............................................. 28
helical gear units ........................................55
Storage ......................................................... 16
helical worm gear units ..............................60
T
NORDBLOC ...............................................56
Tightening torques ........................................ 61
NORDBLOC helical gear units ..................57
Transport ....................................................... 15
standard helical gear units .........................57
Type plate ..................................................... 14
B 1000 EN-1915 65
66 B 1000 EN-1915
6052802 / 1915
Datasheet valves OHW: W10286-016
1.1. TECHNICAL DATA
Description: Sediment discharge valve GPL 15

Make: Tyco-Keystone
Type: Butterfly valve
Figure: 320-116
Size: DN 80
Actuator: Pneumatic operated
For further information see manual of the valve in the manual index.
1
PED - Operating and Safety Instructions
Resilient Seated Butterfly Valves F320/322
Before installation, these instructions must be fully

read and understood
Please read these instructions carefully. Precautions
This symbol indicates important

messages and safety instructions. WARNING
Hazard potentials For safety reasons, it is important to take the following precautions before you start work on the
valve:
• disregarding of instructions
1. Personnel making any adjustments to the valves should utilize suitable equipment. All required
• improper use of product
personal protection means should be worn.
• insufficiently qualified personnel
2. The line must be depressurized before installing the valve. In case of dangerous pipeline fluids,
Ensure that valve materials are compatible the pipeline should be drained and flushed properly with an appropriate cleaning fluid.
with the pipeline fluid. 3. Personnel trained in all aspects of manual and mechanical handling techniques must carry out
handling of all valves.
Valve application to be within the 4. Misuse of the valve is not allowed. For example: the valve, handles, actuators or other parts
pressure/temperature limits indicated in the may not be used as “climbing tools”.
P/T diagram of the Product Manual. 5. Ensure the valve pressure/temperature specification as indicated on the identification label, is
If in doubt contact factory. within the pressure/temperature limits of the application. A full pressure/temperature diagram
can be obtained from the Product Manual. With the use of the figure and trim number on the
Check the valve’s functionality on a regular valve’s identification label, the correct diagram can be found.
basis. 6. Ensure that valve materials are compatible with the pipeline fluid.
7. The body material is ductile iron, which is a known brittle material and heavy impacts such as
blows with a steel headed hammer should be avoided. This is particularly important for
applications between 0°C and -28°C.
8. The normal shelf life of the F320/322 valve seat is 5 years under clean, dry ambient and
conditions with UV exposure prior to installation.
9. Tighten all flange bolts as per the nominated flange standards using the diagonal sequence
method.
Installation
1. Handling and lifting should be performed according the Maintenance & Installation Instructions.
2. Keystone valves are bi-directional unless fitted with a Flow Direction Arrow. If a directional arrow
is fitted then the valve must be installed with the arrow pointing in the direction of the flow.
3. For detailed installation instructions refer to the Maintenance & Installation Instructions for the
specific product.
Tagplate: for NBR seated valves 4. Preferred installation position of butterfly valves is the shaft horizontal and the lower disc-edge
opening downstream.
5. Do not use the valve to spread the flanges.
Max. permissible 6. Instructions whether to use or to omit flange gaskets are stated in the Maintenance &
working pressure Installation Instructions.
Product designation 7. In case the valve is used as spool piece during erection of piping, do not finish weld the flanges
Nominal to the pipes with the valve bolted between the flanges as this will result in serious heat-damage
Explosive equipment to the seat.
diamete
classification
r 8. Valve operation should be checked for open - close positions. The disc should have enough
Trim number
Body material
clearance from the pipeline in all positions.
Maintenance
!! Read all warning labels fitted to the valve before operation or maintenance !!
Check the valve’s functionality on a regular basis.
No additional routine maintenance is required.
Repair
WARNING
Min/Max The line must be depressurized before carrying out any repairs to the valve. In case of dangerous
temperature pipeline fluids, the pipeline should be drained and flushed with an appropriate cleaning fluid.
limits in °C Failure to do so may cause serious personal injury and/or equipment damage. Before
disassembling the valve ensure the valve has been decontaminated correctly from any harmful
gasses or liquids and that it is within a safe temperature range for handling. Personnel making any
Mass
adjustments to the valves should utilize suitable equipment. All required personal protection
means should be worn. Only qualified personnel trained in all aspects of manual and mechanical
handling techniques must carry out lifting and handling of valves.
Identification
Use Keystone original spare parts only. For detailed information on valve (dis)assembly and part
number of Year of construction
notified body replacement, refer to the Maintenance & Installation Instructions.
Tagplate: for EPDM seated valves http://www.tycovalves.com
Tyco reserves the right to change the contents without notice EBPJV-0771-EN-0312
ATEX - Operating and Safety Instructions
Resilient Seated Butterfly Valves (F320/F322)
Additional Safety instructions for Valves used in

Potentially Explosive Atmosphere under ATEX 94/9
Marking
• ATEX 94/9/EC, Group II, category 2/3, GD.
Reference
These are additional safety instructions to PED document number:
EBPJV-0771.
See also: http://www.tycovalves-eu.com
Selection
• Ensure that the equipment is marked with the correct equipment group, category and type of
atmosphere for the application and that the safety instructions are followed for each item of the
equipment.
• In particular, all items included in an actuated package – valve, actuator, solenoid, limit
switchbox, control panel, etc. – should be CE marked to ATEX in the appropriate and / or
requested category.
Installation
• The installer must only use tooling appropriate to the working area, see EN 1127-1 Annex A.
• Installation has to be carried out at ambient temperature.
• During installation ensure that no metallic shocks / impacts are made to the equipment or the
adjacent pipework.
• Ensure that the equipment is suitably earthed, through the pipe or individually.
• The installer should thoroughly follow the operating and safety instructions provided for each
individual item of an actuated package.
• When the valve is to handle hot fluids or fluids where exothermic reactions may take place, the
end user must take all the necessary measures to ensure that the hot surface of the valve
cannot provide a source of ignition to the surrounding gas, vapor, mist or dust atmosphere.
• Before putting into use or during operation with a dangerous fluid ensure that no release of the
fluid to atmosphere can take place.
Maintenance
• The operator must ensure that only personnel qualified to work in a potentially hazardous area
is allowed to carry out maintenance appropriate to the category of the equipment in use.
• The end user must ensure that only tooling appropriate to the working area is used, see EN
1127-1 Annex A.
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Butterfly valves Figure 320
Installation & Maintenance Instructions
Please read these instructions carefully. 1. Storage & handling
This symbol indicates important 1.1 Protection

messages and safety instructions. Keystone butterfly valves are delivered with protection in accordance with the Keystone
Engineering Instructions, to protect the valve seats and disc from damage. Wrapping and/or
Hazard potentials: covers should be left in place until immediately before fitting to the pipe.
• disregarding of instructions
1.2 Storage
• improper use of product
When valves are to be stored for some time before being fitted, storage should be in the
• insufficiently qualified personnel
original delivery crates or cases. Storage should be off the ground in a clean, dry indoor area.
Valve application to be within the 1.3 Handling
pressure/temperature limits indicated in the 1.3.1 Packed valves
P/T diagram. Lifting and handling of the packed valves in crates should be carried out by appropriate lifting
equipment. If a fork lift truck is used, appropriate fork hitches are required.
Essential points and functions of the valve The lifting and handling of packed valves in cases will be carried out in the lifting points.
should be inspected on a regular basis. The transportation of all packed material should be carried out safely and according the local
safety regulations.
When the valve is used in an end-of-line 1.3.2 Unpacked valves
function, PED Cat-I applications are allowed The lifting and the handling of these valves has to be carried out by using appropriate means
only. For other categories, contact factory. and by respecting the carrying limits. The handling must, preferably, be carried out on pallets,
protecting the machined surfaces and seat to avoid damage.
When lifting the large dimension valves, the sling and the hooking of the load must be carried
out by using the appropriate tools (brackets, hook, fasteners) and load balancing tools in
order to prevent the valves from falling or moving during the lifting and handling.
The valve may be lifted only by slings attached to the flange holes or valve body; never to the
actuator or the valve opening.
2. Installation
WARNING!
For safety reasons, it is important to take the following precautions before you start work on the valve:
1. Personnel making any adjustments to the valves should utilize suitable equipment. All
required personal protection means should be worn.
2. The line must be depressurized before installing the valve.
3. Personnel trained in all aspects of manual and mechanical handling techniques must carry
out handling of the valves.
4. Misuse of the valve is not allowed. For example: the valve, handles, actuators or other parts
may not be used as “climbing tools”.
5. Ensure that valve pressure/temperature limitations marked on the identification tag are within
the service conditions. The trim number on the valve’s tagplate identifies the valve materials.
See Product Manual for valve specific P/T diagram and trim number definition.
6. Ensure that valve materials are compatible with the pipeline fluid.
2.1 Valve inspection

1. Carefully remove the valve from the shipping package (box or pallet) avoiding any damage
to the valve or, in case of automated valves, to the electric or pneumatic/hydraulic actuator
or instrumentation.
2. Confirm that the materials of construction listed on the valve nameplate are appropriate for
the service intended and are as specified.
3. It is not allowed to use third party spare parts. In case of third party spare parts, safe
operation is not guaranteed.
2.2 Flange and pipe compatibility
Check matching of flange drilling pattern of valve and pipe before assembly.
Flanges have to meet the following requirements:
- The face inside diameter should be:
D min. : The valve Q-dimension + adequate disc clearance.
D max. : The inside diameter (ID) of standard pipe for the nominal size ISO 4200.
- If the flange (or pipe) is provided with a raised face, the diameter of this shall be at least
8 mm larger than the YY-dimension of the valve.
D max./min.
The use of the flange-gaskets is not allowed since it might damage the valve.
The Keystone seat-face design eliminates the need for the gaskets.
Use flange bolting in agreement with appropriate standard.
YY
Do not use flange gaskets!
Tyco reserves the right to change the contents without notice EBPJV-0752-EN-0201
2.3 Valve installation

The valves are bi-directional and may be fitted in either direction relative to the flow. The valve
will control flow equally in either direction. The recommended installation position is shaft
horizontal and the lower disc-edge opening down-stream. (Especially for slurry service and
media with a tendency for sedimentation). For optimum valve control and smooth
performance, it is recommended to have a 10 to 20 pipe diameters of straight run inlet piping
and 3 to 5 pipe diameters straight outlet piping.
A valve is no crow-bar. Do not use the valve to spread the flanges. Seat damage might be
the result.
Notes
- The valve can be installed in the pipe-line either with or without the actuator mounted on
top of the valve. Make sure that you can turn the disc cautious so you can feel a mismatch
resulting from a disc touching the adjacent piping.
- Do not use the valve as a support of the pipe line construction.
- Adjacent piping must be positioned so that minimal piping stresses are transmitted to the
valve flanges during or after installation.
- Handling and lifting of the valves during installation MUST be performed following the same
instructions described in previous paragraph “1.3 Handling”.
Important
Mating flange faces should be in good condition and free of dirt and/or inclusions. Both pipe
insides to be well cleaned.
2.3.1. Existing system (see sketch)

1. Check whether the flange distance meets the valve face-to-face dimensions. Spread with
adequate tooling the flanges for easy insertion of the valve.
2. In case of a wafer valve, insert some flange bolts in the pipe flanges, to help you bear the
valve after insertion.
3. Close the valve so far, that the disc-edge is at least 10 mm within the body.
4. Insert the valve between the flanges, center the valve body and insert all flange bolts.
Tighten the flange-bolts hand tight.
5. Slowly open the valve completely. (The disc is in line with parallel flats on stemhead).
6. Maintain the valve flange alignment while gradually removing the flange-spreaders and
tighten the flange-bolts hand tight.
7. Slowly close and open the valve to check for adequate disc clearance.
8. Cross-tighten all bolting to the proper torque. Do not over tighten.
2.3.2. New system (see sketch)

1. With the disc in near-closed position center each mating flange with the valve body.
Fix the body with some flange-bolts and tighten the bolts.
2. Use the flange-valve-flange assembly for fit-up and centering to the pipe.
3. Tack-weld the flanges to the pipe.
4. Remove the bolting and remove the valve from between the flanges.
Important
Do not finish-weld the flanges to the pipe with the valve bolted between the flanges as this
will result in serious heat-damage to the seat.
5. Finish-weld the flanges to the pipe and allow the flanges to cool completely.
6. Install the valve now according to the procedure for installing in existing systems.
2.4. Valve verification

Check the operation of the valve by operating it to “full open” and “full close”. To verify the
valve operation, the disc position indicator on the actuator or the handle should rotate
between the “full open” and “full close” indicators on the actuator or throttle plate. Generally
the valve disc travels clockwise to close.
Tyco reserves the right to change the contents without notice page 2
Existing system New system
1. Spread the flanges with the adequate tooling. 1. Center a flange-valve-flange assembly between
Insert some flange bolts to bear the valve. the pipes.
2. Open the valve and remove the flange spreads 2. Tack weld the flanges to the pipes.
3. Close the valve clockwise, return to open 3. Remove the valve and finish weld. Install the
position and cross-tighten all bolting. valve according to the procedure in the left
column.
2.5. Sources of possible danger

This section contains some examples of possible foreseen danger sources.
2.5.1. Mechanical
When manual operators are used, available space should be checked in order to avoid
hands being clamped.
2.5.2. Electrical
If static charges can initiate explosions, the valve should be grounded.
2.5.3. Thermal
If the valve is used in applications with a fluid temperature above 40°C the outside of the
body might be hot. Sufficient measurements should be taken to avoid burning.
A manual operated valve should be opened and closed with sufficient protection for the
personnel operating the valve. For example: protecting gloves.
2.5.4. Operational
Closing a valve too fast may result in waterhammer in the upstream part of the pipeline.
Waterhammer results in excessive stresses in the valve and will cause severe damage.
Waterhammer should be avoided in all circumstances.
Due to differential pressure across the valve disc, butterfly valves have the tendency to be
closed by the flow. Take care when unlatching the valve operating mechanism.
2.6 Troubleshooting guide

Symptom Possible cause Resolution
Valve would not rotate Actuator has failed Replace or repair
Valve packed with debris Flush or clean valve to remove debris
Valve leaking Valve not fully closed Close valve
Debris trapped in valve Cycle and flush (with valve open) to
remove debris
Seat is damaged Replace valve
Jerky operation Debris trapped in valve Cycle and flush (with valve open) to
remove debris
Air supply actuator Increase air supply pressure and/or
inadequate volume
3. Maintenance
The Keystone butterfly valves figure 320 are designed to require a minimum of maintenance.
WARNING!
Depressurize and, if necessary in case of dangerous fluids, drain the line and flush with
appropriate cleaning fluid before starting any maintenance. Failure to do so may cause serious
personal injury and/or equipment damage.
Before disassembling the valve, ensure the valve has been decontaminated correctly from any
harmful gasses or liquids and that it is within a safe temperature range for handling.
Personnel making any adjustments to the valves should utilize suitable equipment. All required
personal protection means should be worn.
Only personnel trained in all aspects of manual and mechanical handling techniques must
carry out handling of all valves.
3.1 Routine maintenance
Routine maintenance or lubrication is not required other than periodic inspection to ensure
satisfactory operation and sealing.
3.2 Removing the valve

1. Turn the disc to nearly closed position. (The disc is in line with the parallel flats in the stem).
2. Loosen all flange bolts and remove the bolts.
3. Spread the flanges with adequate tooling, and remove the valve.
3.3 Valve disassembly

Disassembly is not possible. The shafts are press-fitted into the disc during the production at
factory.
Figure 320
Parallel flats
Bolt pattern will accept

PN6, PN10, PN16 and
ANSI Class 150
Parts identification
1. Body 7. Upper spacer
2. Disc 8. Lower spacer
3. Seat 9. Packing
4. Top stem 10. Upper bushing
5. Bottom stem 11. Plug
6. Bushing
Tyco PremiAir Pneumatic Actuator
Installation and Maintenance Instructions
Installation and Maintenance Instructions for:

PremiAir Pneumatic Actuators
Introduction
The Tyco PremiAir Pneumatic Actuator is a compact, rack & pinion design, conforming to
European and International standard EN ISO 5211 (preferred dimensions).
General Pneumatic Systems Recommendations

All Tyco PremiAir Actuators are factory lubricated with Molyrace LT2, which is a
molybdenum disulphide (MoS2) grease and, unless the operating environment is extremely
harsh, do not require re-lubrication. To maintain maximum efficiency with this, or other
pneumatic actuators, we advise that the following basic system recommendations are
followed:
1. Where air pipelines are subjected to extremes of temperature, the system should be fitted
with suitable air drying equipment.
2. Air control lines should be fitted in accordance with a ‘Recommended Piping Practice’
and should not have loops, which may trap condensate.
3. All air connection pipe ends should be thoroughly cleaned and deburred after cutting, to
ensure that the pipeline is clear of debris.
Double acting and spring return
actuators are the same size 4. If pipelines are hydraulically tested, then the lines should be “blown down” with
pressurised air to clear all traces of water, prior to connecting lines to the actuator.
5. Where pipe fitting sealants are used, they should be applied to the male threads only, to
avoid excess compound being forced into the actuator control lines.
6. Where Air Filter Equipment is used, the air filters should be situated in positions that allow
easy access to maintain and/or drain.
7. Where pneumatic valve positioners, or pneumatic controllers are fitted to valve actuator
assemblies, oil mist lubricated air should not be used unless the manufacturer states
specifically that the controllers are compatible with lubricated air.
Note: PremiAir actuators are rated for air pressure in the range 2.75barg (40psig) to
8.3barg (120psig) and will withstand a maximum of 10.3barg (150psig).
Note Construction
These instructions refer to all the range, PremiAir actuators are designed to be mounted to quarter turn valves either directly or using
except size 180. the correct mounting brackets/adaptors and sizing procedures.
For Installation & Maintenance instructions
relating to size 180, please refer to All models are of the opposed piston type. Each piston incorporates an integral rack which
document HDLDS-0012. engages with a one piece drive pinion shaft. The drive shaft is Nitrotech(TM) treated for
maximum protection and fitted with “engineered polymer” bearings. The actuator body is of
extruded aluminium, hard anodised and electrostatic powder coated.
The design features bolt on mounting plate and air connection plate for maximum
adaptability. O-rings are used for piston and shaft seals.
For Spring Return actuators, up to four springs per piston can be fitted between the piston
head and end cap to suit the available operating air pressure.
Adjustable travel stops are provided for each end of travel to ensure that the actuator will
open and close the valve precisely.
The output drive is a female double square (star), conforming to EN ISO 5211.
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Standard Installation - Double & Single Acting Units

These instructions assume that the actuators are installed with the cylinder axis parallel to the axis
of the valve bore (In Line) and are fitted to Resilient Seated Butterfly Valves having mounting pads
conforming to EN ISO 5211. Actuator
Single acting actuators are supplied as FAIL-CLOSE units as standard.

Reverse acting, (FAIL-OPEN), must be specified at the time of order.
1. Ensure that the valve and actuator are in the following corresponding positions:
• Double Acting units and Spring Return units, (Fail-closed):
Valve closed, actuator fully clockwise.
• Double Acting units and Spring Return units, (Fail-open): Lockwasher
Valve open, actuator fully counter-clockwise
Mounting to Ball and High Performance Butterfly valves (via bracket)

2a. Secure the mounting bracket to the underside of the actuator, using four bolts and washers, Bolt Coupling
Bolt if required
as shown in Fig 1
3a. Install the appropriate coupling onto the valve stem. The coupling should be lightly tapped or
pressed onto the valve stem. The use of a lubricant is recommended. Bracket
4a. Mount the actuator and bracket onto the valve top flange using the appropriate bolts. if required
Mounting to Resilient Seated Butterfly valves (with EN ISO 5211 mounting)

2b. Screw the actuator mounting studs tightly into the actuator base plate.
3b. Mount the actuator onto the valve top flange and secure using a lockwasher and nut on each
mounting stud.
All 1/4 turn valve types

5. Before installing the valve/actuator assembly in a piping system, the valve operation should be
verified and adjusted, if necessary, using the travel stop screws (see detailed instructions for
travel setting)
6. When installing the valve/actuator assembly into pipeline, ensure that the specific instructions
relating to the valve installation are followed. Figure 1
Typical installation on ball or high performance
butterfly valves, using bracket mounting.
Note: Some valves may require to be fitted into the pipeline prior to mounting the actuator.
Fail Safe butterfly valves are an example of this.
Non Standard Installation - Double & Single Acting Units

All 1/4 turn valve types
In circumstances where the actuator is required to be installed in the transverse position i.e. at
right angles to the valve bore (Across Line), the actuator must be rotated through 90°. Actuator
This is achieved in the following manner:
1. Remove the actuator from the valve or the bracket by removing the 4 fixing bolts/nuts and
withdraw it vertically from the valve. Stud
2. Rotate the actuator through 90°.
Lockwasher
3. Refit actuator to the top of the valve or to the bracket. The output drive of the actuator is a
double square (star) design, with the squares being at 90° to each other. Nut
Figure 2
Typical installation on resilient seated butterfly
valves, with direct EN ISO 5211 mounting.
Installation and Maintenance Instructions - Parts Identification
23
3 22
29
8 15 7
14
9 26 21 13
11 20
24 6
25 4
12
2 10
17 27
16
28
19
18
Materials of Construction
Subject Item Material Finish
1 Body Extruded Aluminium BS 1474 (6000 series) Hard Anodise + ESPC* or SNP**
2 End Cap Die Cast Aluminium DIN 1725 Alloy 231 Chromate + ESPC* or SNP**
3 Piston Die Cast Aluminium DIN 1725 Alloy 231 Anodise or SNP**
4 Pinion Shaft Carbon Steel BS 1490:1983 212 A42 Nitrotech ™*** or SNP**
5 Base Plate Die Cast Aluminium DIN 1725 Alloy 231 Chromate + ESPC* or SNP**
6 Air Connection Plate Aluminium DIN 1725 Alloy 231 Chromate + ESPC* or SNP**
7 Piston Backing Pad Devlon-V ™ Natural
8 Piston Support Ring Devlon-V ™ Natural
9 Top Bearing Devlon-V ™ Natural
10 Bottom Bearing Devlon-V ™ Natural
11 Top Spacer Devlon-V ™ Natural
12 Bottom Spacer Devlon-V ™ Natural
13 Stop Bolt Stainless Steel A2 / 70 Natural
14 Lock Nut Stainless Steel A2 / 70 Natural
15 Sealing Washer Stainless Steel A2 / 70 Natural
16 End Cap Bolt Stainless Steel A2 / 70 Natural
17 End Cap Washer Stainless Steel A2 / 70 Natural
18 Base Plate Bolt Stainless Steel A2 / 70 Natural
19 Base Plate Washer Stainless Steel A2 / 70 Natural
20 Air Connection Plate Bolt Stainless Steel A2 / 70 Natural
21 Air Connection Plate Washer Stainless Steel A2 / 70 Natural
22 Spring Chrome Silicon Spring Steel
BS 2806 685 A55 HD R2 Oil Dip
23 Indicator ABS Natural
24 Piston O-Ring Rubber-NBR or FPM Natural
25 End Cap O-Ring Rubber-NBR or FPM Natural
26 Shaft Top O-Ring Rubber-NBR or FPM Natural
27 Shaft Bottom O-Ring Rubber-NBR or FPM Natural
28 Base Plate O-Ring Rubber-NBR or FPM Natural
29 Air Connection Plate O-Ring Rubber-NBR or FPM Natural
Notes
* ESPC = Electrostatic Powder Coating
** SNP = Special Nickel Protection finish
*** NitrotechTM = Proprietary corrosion resistant finish
Disassembly procedure
CAUTION! Remove air pressure and observe normal safety precautions, including the use of
eye protection.
1. Remove travel stop bolts, (13) after slackening the lock nuts.
2. Remove end caps (2) by unscrewing the four hexagon head bolts on each end cap. For spring return
versions use the progressive diagonal method for unscrewing these bolts.
3. Using a suitable wrench in the top of the pinion shaft (4), turn the shaft counter clockwise to drive the
pistons (3) apart. Remove the pistons from the body (1).
4. Remove the base plate (5) by unscrewing the four cap head bolts and spring washers.
5. The pinion shaft (4) can now be withdrawn from the bottom of the actuator body (1).
6. The top and bottom bearing rings, spacers and o-rings can now be removed from the pinion shaft or
from the recesses in the body and base plate.
7. The air connection plate (6) can be removed from the body if necessary by unscrewing the two cap
head bolts.
8. Remove o-rings and support rings from the piston heads
9. Remove the backing pads from the piston legs
Assembly procedure (refer to illustration on page 3)

1. Clean all disassembled items and replace any damaged items such as o-rings, bearings, support
rings, and backing pads.
2. Grease the body bore with Molyrace LT2 lubricant.
3. Place the base plate (5) flat on the assembly bench and fit the o-ring (28) into the groove on the 1. Position of keyways prior to fitting
top face of the base plate. pistons
4. Fit the bottom spacer (12), then the bottom bearing (10), then the bottom o-ring (27) over the
bottom of the shaft and coat with Molyrace LT2 lubricant.
5. Carefully insert the shaft along with the spacer, bearing and o-ring into the base plate bore,
finishing with a firm push to ensure full location.
6. Fit the top spacer (11), then the top bearing (9), then the top o-ring (26) over the top of the shaft
and coat with Molyrace LT2 lubricant.
7. Carefully lower the body over the shaft and on to the base plate, finishing with a firm push to
ensure that the o-ring and bearing locate fully into the top recess of the body.
8. Secure the base plate to the body using the cap head screws and spring washers (18/19).
9. Grease the pinion shaft teeth with Molyrace LT2 lubricant. Rotate the pinion shaft until the
keyways, in the shaft top, are at 45 degrees as shown in the illustration (opposite 1).
10. Fit o-rings (24), support rings (8) and backing pads (7) to the pistons and then grease the rack
teeth using Molyrace LT2 lubricant.
11. Insert the pistons into the actuator body as follows:
a) Double Acting and Spring To Close models.
With the piston rack on the left side of the body bore, when viewed from the o-ring end of the
piston, as shown (opposite 2). 2. Fitting pistons into body
b) Spring To Open models.
With the piston rack on the right side of the body bore, when viewed from the o-ring end of the
piston.
Locate the assembly on the bench with one piston head on the bench and the other upwards.
Push firmly on the top piston to cause both piston rack profiles to engage with the pinion teeth.
12. Position the assembly with the base plate on the bench. Using a suitable wrench, turn the pinion
shaft clockwise (Double Acting and Spring To Close models), or counter-clockwise (Spring To
Open), as far as it will go. The keyways, at the top of the shaft, should be approximately 4 to 5
degrees clockwise, or counter-clockwise, past the axial and transverse centre lines of the body.
13. Smear the o-ring groove in each end cap with Molyrace LT2 lubricant. Fit the o-rings (24) into the
grooves and position the actuator body with one end downwards on the bench.
14. Double Acting models:
a. Carefully locate one end cap (2) on the uppermost end of the body and secure using four hexagon
head bolts and plain washers (16/17).
b. Repeat for the other end cap.
Spring Return models: 3. Locating of springs in piston head
a. Locate the correct number of springs (22) in the cavities on the piston head which is uppermost. cavities
(See opposite 3)
b. Carefully locate one end cap over the springs so that the springs fit into the cavities in the end cap.
c. Using the four hexagon head bolts and plain washers, compress the springs following the diagonal
progression technique, until the end cap is fully tightened down against the end of the body.
d. Repeat for the other end cap.
15. Locate the o-rings (29) into the recesses on the air connection plate and secure the plate to the
actuator body using the two cap head bolts and spring washers (20/21). Ensure that the port marked
“Port 2” is to the right hand side as shown. (Opposite 4)
2
16. Fit the lock nuts and sealing washers (14/15) to the travel stops and then screw the travel stops into
the body.
17. For double acting versions, ensure that the pinion shaft is rotated fully clockwise and then screw in
the right hand travel stop until the shaft keyways are in line with the major axes of the body and then 4
tighten the lock nut to secure.
4. Fitting air connection plate
18. Turn the pinion shaft fully counter-clockwise and then screw in the left hand travel stop, until
the shaft keyways are in line with the major axes of the body. Tighten the locknut to secure.
Note:- For single acting versions, it is not advisable to use the travel stop screws to
move the pinion as this may damage the cam faces or the stop screw ends.
19. For single acting versions, screw in the left hand travel stop to an estimated position and then
apply pressure to open the actuator. Check the actual position of the pinion shaft, release the
air pressure and re-set the travel stop to compensate for any error. Repeat until the correct
position is achieved. Tighten the lock nut to secure.
20. Apply pressure to open the actuator and screw in the right hand travel stop to an estimated
position and then release the pressure. Check the actual position of the pinion shaft. Re-apply
the pressure and re-set the travel stop to compensate for any error. Repeat until the correct
position is achieved. Tighten the lock nut to secure.
Setting of Internal Travel Stops

PremiAir actuators are fitted with integral end of travel stops to enable setting of exact travel for
the valve being operated.
These stops allow travel adjustment, as follows:
Over Travel (at each end) of ±5°
Under Travel (at each end) of ±10°
Increased under travel is available, on request.
To Set the Stops (Double acting units)

1. Operate valve/actuator assembly to the closed position.
2. Remove air supply.
3. Slacken locknut on the close travel stop.
4. Turn the stop clockwise to reduce travel or anti-clockwise to increase travel.
5. Re-Tighten locknut.
6. Reconnect air supply and check that the position is correct. If not repeat from instruction 2.
7. Apply air to operate to the open position.
8. Remove air supply.
9. Adjust open travel stop screw as per instructions 3 to 6, above.
To Set the Stops (Single acting units) Air Fail Close

1. Remove air supply so that actuator drives to closed position. Note actual position.
2. Apply air to open the actuator. Note actual position.
3. Whilst the air supply is maintained slacken the locknut on the close stop and adjust the stop
screw by an amount estimated to give correct position. (clockwise adjustment decreases
travel).
4. Re-tighten lock nut.
5. Remove air so that actuator closes. If correct closed position is not achieved repeat from
instruction 2.
6. Slacken locknut on the open stop and adjust the travel by an amount estimated to give correct
position. (clockwise adjustment decreases travel).
7. Re-tighten locknut.
8. Apply air and check open position. If correct open position is not achieved, repeat from
instruction 5.
Warnings! To Set the Stops (Single acting units) Air Fail Open
Under no circumstances must the travel stop 1. Remove air supply so that actuator drives to open position. Note actual position.
bolts be totally withdrawn from the actuator 2. Apply air to close the actuator. Note actual position.
whilst compressed air is being applied. 3. Whilst the air supply is maintained slacken the locknut on the open stop and adjust the stop
screw by an amount estimated to give correct position. (clockwise adjustment decreases
Travel stop bolts must not be used for manual travel).
override. 4. Re-tighten lock nut.
5. Remove air so that actuator opens. If correct open position is not achieved repeat from
Accessories mounted to the top of Actuators instruction 2.
must be re-adjusted accordingly after setting 6. Slacken locknut on the close stop and adjust the travel by an amount estimated to give correct
the travel stops. position. (clockwise adjustment decreases travel).
7. Re-tighten locknut.
8. Apply air and check close position. If correct close position is not achieved, repeat from
instruction 5.
Maintenance
Provided that basic pneumatic system procedures are adhered to, the actuator will require little or
no maintenance for many thousands of cycles.
Troubleshooting
If the actuator fails to operate the valve correctly, carry out the following checks.
1. Check that the air supply is at the required pressure.
2. Ensure that the air supply is not restricted in any way.
3. Check for air leakage on supply lines to the actuator.
4. Check for leakage at the top and bottom of the pinion shaft. Such leakage could be caused by
a dirty air supply.
5. Check for leakage across the piston seals by applying pressure to “Port 4” and looking for
leakage from “Port 2”.
6. Check that the valve torque has not increased because of problems with the valve itself.
Note:- refer to disassembly and assembly procedures for gaining access to o-rings and
actuator internals if required.
General information
1. As standard, applying air to “Port 2” will cause the actuator to rotate in a counter clockwise
direction to open the valve.
2. Applying air to “Port 4” will cause the actuator to rotate in a clockwise direction to close the
valve (double acting versions only).
3. Warning:- It is not recommended to “air assist” single acting actuators as this may
apply excess load to the valve stem and cause damage.
Spring ratings versus air pressure

There is one size of spring per actuator for ‘balance’ against air pressures up to 80 psig
(5.5 barg).
Springs are used in multiples depending on the air pressure.
The following table shows the springs needed to give balance at varying air pressures.
‘Balance’ means that air start torque = spring start torque….
and that air finish torque = spring finish torque.
Air pressure Number of springs

Piston 1 Piston 2
40 psig / 2.8 barg 2 2
50 psig / 3.5 barg 3 2
60 psig / 4.2 barg 3 3
70 psig / 4.8 barg 4 3
80 psig / 5.5 barg 4 4
For balance against higher pressures booster springs are fitted inside the standard springs of the
80 psig build as follows.
Air pressure Number of booster springs
Piston 1 Piston 2
90 psig / 6.2 barg 2 2
100 psig / 6.9 barg 4 4
Bolt tightening torques for end caps

When re-assembling the end caps, use the following figures for bolt tightening.
Actuator size Bolt size Tightening torque (Nm)

-002 M5 3,2
-004 M5 3,2
-009 M6 7,3
-014 M6 7,3
-025 M8 13,1
-037 M8 13,1
-045 M10 26,2
-070 M12 45,2
-088 M12 45,2
-180 M16 108,5
Datasheet sludge pumps OHW: W10286-017
1.1. TECHNICAL DATA
Description: Flotate sludge pump

Make: Mono
Type: C1K
Electrical motor power: 0,37kW
Capacity: 1,5 – 5 m³/hr.
2. SAFETY ASPECTS

are stopped.
Figure 2.1
Redox delivery.

1
OHW: W10286-017

Before taking the sludge pump(s) in operation, the below mentioned works have to be done.
 Turn all the switches in the position "O".

 Check the rotating direction of the pump:
- Let a second person turn the switch of the pump in the position "manual" and
afterwards off again.
- The rotating direction must be identical to the direction of the arrow* on the pump.
- Mono dosing and sludge pumps are not allowed to dry-run.
(*In some cases the arrow indicates the direction of the reaction force. Check the manual of the
pump(s) in the manual index.)

carefully.
No right flow in pipes or Blockage of pipes or pumps. Check pipes, pump, pump pit and
pumps. valves for blockage. If necessary
clean it.
For further information see manual of the pump in the manual index.
2
OHW: W10286-017
For manual Mono see chapter 6
3
ORGALIME SI 14
GENERAL CONDITIONS
for the
SUPPLY AND INSTALLATION OF MECHANICAL, ELECTRICAL AND ELECTRONIC PRODUCTS
Brussels, January 2014
PREAMBLE DRAWINGS AND TECHNICAL INFORMATION

1. These General Conditions shall apply when the parties 4. All drawings and technical documents relating to the Works
agree In Writing or otherwise thereto. Any modifications of or submitted by one party to the other, prior or subsequent to the
deviations from them must be agreed In Writing. formation of the Contract, shall remain the property of the submitting
party.
DEFINITIONS Drawings, technical documents or other technical information

2. In these General Conditions the following terms shall have received by one party shall not, without the consent of the other
the meanings hereunder assigned to them: party, be used for any other purpose than that for which they were
provided. They may not, without the consent of the submitting
- “Contract”: the agreement In Writing between the
party, otherwise be used or copied, reproduced, transmitted or
parties concerning delivery and performance of the Works and
communicated to a third party.
all appendices, including agreed amendments and additions In
Writing to the said documents;
5. The Contractor shall, not later than at the date of taking-
- “Contract Price”: the payment to be made for the Works.
over, provide free of charge information and drawings which are
If installation is to be carried out on a time basis and has not been
necessary to permit the Purchaser to commission, operate and
completed, the Contract Price for the purposes of Clauses 21, 43,
maintain the Works. Such information and drawings shall be
44 and 51 shall be the price for the Plant with the addition of 10
supplied in the number of copies agreed upon or at least one
per cent or of any other percentage that may have been agreed by
copy of each. The Contractor shall not be obliged to provide
the parties;
manufacturing drawings for the Plant or for spare parts.
- “Gross Negligence”: an act or omission implying either
a failure to pay due regard to serious consequences, which a
TESTS BEFORE SHIPMENT
conscientious contracting party would normally foresee as likely
to ensue, or a deliberate disregard of the consequences of such 6. Tests before shipment of the Plant provided for in the
an act or omission; Contract shall, unless otherwise agreed, be carried out at the
place of manufacture during normal working hours.
- “In Writing”: communication by document signed by
both parties or by letter, fax, electronic mail and by such other If the Contract does not specify the technical requirements,
means as are agreed by the parties; the tests shall be carried out in accordance with general practice
in the appropriate branch of industry concerned in the country of
- “Plant”: the machinery, apparatus, materials, articles,
manufacture.
documentation, software and other products to be supplied by
the Contractor under the Contract;
7. The Contractor shall notify the Purchaser In Writing of these
- “Site”: the place where the Plant is to be installed,
tests in sufficient time to permit the Purchaser to be represented
including as much of the surrounding area as is necessary for
at the tests. If the Purchaser is not represented, the test report
unloading, storage and internal transport of the Plant and
shall be sent to the Purchaser and shall be accepted as accurate.
installation equipment;
- “Works”: the Plant, installation of the Plant and any other

8. If the tests show the Plant not to be in accordance with
work to be carried out by the Contractor under the Contract. If the
the Contract, the Contractor shall without delay remedy any
Works shall according to the Contract be taken over by separate
deficiencies in order to ensure that the Plant complies with the
sections intended to be used independently from each other,
Contract. New tests shall then be carried out at the Purchaser’s
these Conditions shall apply to each section separately. The term
request, unless the deficiency was insignificant.
“Works” shall then refer to the section in question.
9. The Contractor shall bear all costs for tests before shipment
PRODUCT INFORMATION
of the Plant. The Purchaser shall however bear all travelling and
3. All information and data contained in general product living expenses for his representatives in connection with such
documentation and price lists shall be binding only to the extent tests.
that they are by reference In Writing expressly included in the
Contract.
Licensed for electronic use by Theuma Metal Industries; Licence N° 02/11/07 ORGALIME
PREPARATORY WORK AND WORKING CONDITIONS f) he has made available to the Contractor free of charge
10. The Contractor shall in good time provide drawings necessary storage facilities, providing protection against theft and
showing the manner in which the Plant is to be installed, together deterioration of the Plant, the tools and equipment required for
with all information required for preparing suitable foundations, for installation and the personal effects of the Contractor’s personnel;
providing access for the Plant and any necessary equipment to g) the access routes to the Site are suitable for the required
the Site and for making all necessary connections to the Works. transport of the Plant and the Contractor’s equipment.

11. The Purchaser shall in good time undertake preparatory 15. Upon the Contractor’s request in good time, the Purchaser
work to ensure that the conditions necessary for installation of shall make available to the Contractor, free of charge, such
the Plant and for the correct operation of the Works are fulfilled. labour and operators as may be specified in the Contract or as
This shall not apply to preparatory work which according to the may reasonably be required for the purpose of the Contract. The
Contract shall be performed by the Contractor. persons made available by the Purchaser under this clause shall
provide their own tools. The Contractor shall not be liable for such
12. The preparatory work referred to in Clause 11 shall be labour provided by the Purchaser or for any acts or omissions of
carried out by the Purchaser in accordance with the drawings the persons concerned.
and information provided by the Contractor under Clause 10.
In any case the Purchaser shall ensure that the foundations are 16. If the Contractor so requires, the Purchaser shall give all
structurally sound. If the Purchaser is responsible for transporting necessary assistance required for the import and re-export of
the Plant to the Site, he shall ensure that the Plant is on the Site the Contractor’s equipment and tools, including assistance with
before the agreed date for starting the installation work. customs formalities. The assistance as such shall be provided
free of charge.
13. If an error or omission in the drawings or information referred
to in Clause 10 is discovered by the Contractor or notified to him 17. The Purchaser shall give all necessary assistance to
In Writing before expiry of the period referred to in Clause 59, ensure that the Contractor’s personnel obtain, in good time, visas
the costs of any necessary remedial work shall be borne by the and any official entry, exit or work permits and (if necessary) tax
Contractor. certificates required in the Purchaser’s country, as well as access
to the Site. The assistance as such shall be provided free of
14. The Purchaser shall ensure that: charge.
a) the Contractor’s personnel are able to start work in

accordance with the agreed time schedule and to work during 18. The parties shall, no later than when the Contractor gives
normal working hours. Provided that the Purchaser has been notice that the Plant is ready for dispatch from the place of
given notice In Writing in reasonable time, work may be performed manufacture, each appoint a representative In Writing to act on
outside normal working hours to the extent deemed necessary by their behalf during the work on the Site.
the Contractor; The representatives shall be present on or near the Site
b) he has, in good time before installation is started, informed during working hours. Unless otherwise specified in the Contract,
the Contractor In Writing of all relevant safety regulations in force the representatives shall be authorised to act on behalf of their
at the Site. Installation shall not be carried out in unhealthy or respective party in all matters concerning the installation work.
dangerous surroundings. All the necessary safety and precautionary Wherever these General Conditions stipulate that a notice shall
measures shall have been taken before installation is started and be given In Writing, the representative shall always be authorised
shall be maintained; to receive such notice on behalf of the party he represents.
c) the Contractor’s personnel are able to obtain suitable and

convenient board and lodging in the neighbourhood of the Site PURCHASER’S DEFAULT
and have access to internationally acceptable hygiene facilities 19. If the Purchaser anticipates that he will be unable to fulfil
and medical services; in time his obligations necessary for carrying out installation,
d) he has made available to the Contractor free of charge at including complying with the conditions specified in Clauses 11,
the proper time on the Site all necessary cranes, lifting equipment 12 and 14-17, he shall forthwith notify the Contractor In Writing,
and equipment for transport on the Site, auxiliary tools, machinery, stating the reason and, if possible, the time when he will be able
materials and supplies (including fuel, oils, grease and other to carry out his obligations.
materials, gas, water, electricity, steam, compressed air, heating,
lighting, etc.), as well as the measuring and testing instruments 20. Without prejudice to the Contractor’s rights under Clause 21,
of the Purchaser available on the Site. The Contractor shall if the Purchaser fails to fulfil, correctly and in time, his obligations
specify In Writing his requirements concerning such cranes, lifting necessary for carrying out installation, including to comply with
equipment, measuring and testing instruments and equipment for the conditions specified in Clauses 11, 12 and 14-17, the following
transport on the Site at the latest one month before the agreed shall apply:
date for starting the installation work;
a) The Contractor may at his own discretion choose to
e) he has made available to the Contractor free of charge carry out or employ a third party to carry out the Purchaser’s
sufficient offices on the Site, equipped with telephone and access obligations or otherwise take such measures as are appropriate
to the Internet; under the circumstances in order to avoid or alleviate the effects
of the Purchaser’s default.
2
b) The Contractor may suspend in whole or in part his shall notify the Purchaser In Writing whether and how the variation
performance of the Contract. He shall forthwith notify the Purchaser can be carried out, stating the resulting alteration to the Contract
In Writing of such suspension. Price, the time for taking-over and other terms of the Contract.
c) If the Plant has not yet been delivered to the Site, the The Contractor shall also give such notice to the Purchaser
Contractor shall arrange for storage of the Plant at the Purchaser’s when variations are required as a result of changes in laws,
risk. The Contractor shall also, if the Purchaser so requires, insure regulations and rules referred to in Clause 22.
the Plant.
d) The Purchaser shall pay any part of the Contract Price 28. If taking-over is delayed as a result of disagreement between
which, but for the default, would have become due. the parties on the consequences of variations, the Purchaser shall
pay any part of the Contract Price which would have become due
e) The Purchaser shall reimburse the Contractor for any
if taking-over had not been delayed.
costs not covered by Clause 47 or 48, which are reasonably
incurred by the Contractor as a result of measures under a), b) or
c) of this Clause. 29. Save as provided in Clause 23, the Contractor shall not
be obliged to carry out variations requested by the Purchaser
until the parties have agreed on how the variations will affect the
21. If taking-over is prevented by the Purchaser’s default as
Contract Price, the time for taking-over and other terms of the
referred to in Clause 20 and this is not due to any such circumstance
Contract.
as mentioned in Clause 73, the Contractor may also by notice In
Writing require the Purchaser to remedy his default within a final
reasonable period. PASSING OF RISK
If, for any reason which is not attributable to the Contractor, 30. The risk of loss of or damage to the Plant shall pass to the
the Purchaser fails to remedy his default within such period, the Purchaser in accordance with any agreed trade term, which shall
Contractor may by notice In Writing terminate the Contract in whole be construed in accordance with the INCOTERMS® in force at
or in part. The Contractor shall then be entitled to compensation for the date of formation of the Contract. If no trade term has been
the loss he suffers by reason of the Purchaser’s default, including specifically agreed, delivery of the Plant shall be Free Carrier
any consequential and indirect loss. The compensation shall not (FCA) at the place named by the Contractor.
exceed that part of the Contract Price which is attributable to that Any risk of loss of or damage to the Works not covered by
part of the Works in respect of which the Contract is terminated. the first paragraph of this Clause shall pass to the Purchaser on
taking-over of the Works.
LOCAL LAWS AND REGULATIONS Any loss of or damage to the Plant and Works after the risk
22. The Contractor shall ensure that the Works are carried out has passed to the Purchaser shall be at the risk of the Purchaser,
and are in accordance with any laws, regulations and rules which unless such loss or damage results from the Contractor’s negligence.
are applicable to the Works. If required by the Contractor, the
Purchaser shall provide the relevant information on these laws,
TAKING-OVER TESTS
regulations and rules In Writing.
31. When installation has been completed taking-over tests
shall, unless otherwise agreed, be carried out to determine
23. The Contractor shall carry out any variation work necessary whether the Works are as required for taking-over according to
to comply with changes in laws, regulations and rules, referred to in the Contract.
Clause 22, or in their generally accepted interpretation, occurring
The Contractor shall notify the Purchaser In Writing that
between the date of submission of the tender and taking-over.
the Works are ready for taking-over. He shall in this notice give a
The Purchaser shall bear the extra costs and other consequences
date for taking-over tests, giving the Purchaser sufficient time to
resulting from such changes, including variation work.
prepare for and be represented at these tests.
The Purchaser shall bear all costs of taking-over tests. The

24. If the parties are unable to agree on the extra costs and
Contractor shall however bear all costs relating to his personnel
other consequences of changes in laws, regulations and rules,
and his other representatives.
referred to in Clause 22, the Contractor shall be compensated for
any variation work on a time basis.
32. The Purchaser shall provide free of charge any power,
lubricants, water, fuel, raw materials and other materials required
VARIATIONS
for the taking-over tests and for final adjustments in preparing for
25. Subject to the provisions of Clause 29, the Purchaser is these tests. He shall also install free of charge any equipment and
entitled to request variations to the scope, design and construction provide any labour or other assistance necessary for carrying out
of the Works until the Works have been taken over. The Contractor the taking-over tests.
may suggest such variations In Writing.
33. If, after having been notified in accordance with Clause

26. Requests for variations shall be submitted to the Contractor 31, the Purchaser fails to fulfil his obligations under Clause 32
In Writing and shall contain an exact description of the variation. or otherwise prevents the taking-over tests from being carried
out, the tests shall be regarded as having been satisfactorily
27. As soon as possible after receipt of a request for a variation or completed at the starting date for taking-over tests stated in the
after having himself made a proposal for a variation, the Contractor Contractor’s notice.
3
34. The taking-over tests shall be carried out during normal he shall forthwith notify the Purchaser thereof In Writing, stating
working hours. If the Contract does not specify the technical the reason and, if possible, the time when taking-over can be
requirements, the tests shall be carried out in accordance with expected.
general practice in the appropriate branch of industry concerned If the Contractor fails to give such notice, the Purchaser
in the Purchaser’s country. shall be entitled to compensation for any additional costs which
he incurs and which he could have avoided had he received such
35. The Contractor shall prepare a report of the taking-over notice.
tests. This report shall be sent to the Purchaser. If the Purchaser
has not been represented at the taking-over tests after having
42. The Contractor shall be entitled to an extension of the time
been notified in accordance with Clause 31, the test report shall
for taking-over if delay occurs:
be accepted as accurate.
a) because of any of the circumstances referred to in
Clause 73, or
36. If the taking-over tests show the Works not to be in
b) as a result of variation work under Clause 23, or
accordance with the Contract, the Contractor shall without delay
remedy the deficiencies. If the Purchaser so requires In Writing c) as a result of variations under Clauses 25-29, or
without delay, new tests shall be carried out in accordance with d) as a result of suspension under Clauses 20, 51 or 76, or
Clauses 31-35. This shall not apply when the deficiency was
e) by an act or omission on the part of the Purchaser or any
insignificant.
other circumstances attributable to the Purchaser.
The extension shall be as necessary having regard to all

TAKING-OVER the relevant circumstances. This provision applies regardless of
37. Taking-over of the Works shall be considered to take place: whether the reason for the delay occurs before or after the agreed
a) when the taking-over tests have been satisfactorily time for taking-over.
completed or are regarded under Clause 33 as having been
satisfactorily completed, or
43. If the Works are not completed at the agreed time for
b) where the parties have agreed not to carry out taking- taking-over, the Purchaser shall be entitled to liquidated damages
over tests, when the Purchaser has received a Contractor’s notice from the date on which taking-over should have taken place.
In Writing that the Works have been completed, provided that the
The liquidated damages shall be payable at a rate of 0.5
Works are as required for taking-over according to the Contract.
per cent of the Contract Price for each commenced week of
Minor deficiencies which do not affect the efficiency of the delay. The liquidated damages shall not exceed 7.5 per cent of
Works shall not prevent taking-over. the Contract Price.
The Contractor’s obligation to install the Plant at the Site If only part of the Works is delayed, the liquidated damages
is fulfilled when the Works are taken over pursuant to this Clause shall be calculated on that part of the Contract Price which is
37, notwithstanding his obligation to remedy any remaining minor attributable to such part of the Works as cannot in consequence
deficiencies. of the delay be used as intended by the parties.
The liquidated damages become due at the Purchaser’s

38. The Purchaser is not entitled to use the Works or any part demand In Writing, but not before taking-over has taken place or
thereof before taking-over. If the Purchaser does so without the the Contract is terminated under Clause 44.
Contractor’s consent In Writing, the Works shall be deemed to
The Purchaser shall forfeit his right to liquidated damages
have been taken over. The Contractor is then relieved of his duty
if he has not lodged a claim In Writing for such damages within six
to carry out taking-over tests.
months after the time when taking-over should have taken place.
39. As soon as the Works have been taken over in accordance

44. If the delay is such that the Purchaser is entitled to
with Clause 37 or 38, the period referred to in Clause 59 shall start
maximum liquidated damages under Clause 43 and if the Works
to run. The Purchaser shall, at the Contractor’s request In Writing,
are still not ready for taking-over, the Purchaser may In Writing
issue a certificate stating when the Works have been taken over.
demand completion of the Works within a final reasonable period
The Purchaser’s failure to issue a certificate shall not affect taking-
which shall not be less than one week.
over according to Clauses 37 and 38.
If the Contractor does not complete the Works within
such final period and this is not due to any circumstance which is
CONTRACTOR’S DELAY
attributable to the Purchaser, then the Purchaser may by notice In
40. If the parties, instead of specifying the date for taking-over, Writing to the Contractor terminate the Contract in respect of such
have specified a period of time within which taking-over shall part of the Works as cannot in consequence of the Contractor’s
take place, such period shall start to run as soon as the Contract failure be used as intended by the parties.
is entered into and all agreed preconditions to be fulfilled by
If the Purchaser terminates the Contract he shall be
the Purchaser have been satisfied, such as official formalities,
entitled to compensation for the loss he suffers as a result of the
payments due at the formation of the Contract and securities.
Contractor’s delay, including any consequential and indirect loss.

The total compensation, including the liquidated damages which
41. If the Contractor anticipates that he will not be able to fulfil
are payable under Clause 43, shall not exceed 15 per cent of that
his obligations for taking-over before or at the time for taking-over,
4
part of the Contract Price which is attributable to the part of the and at night shall be charged at special rates. The rates shall be as
Works in respect of which the Contract is terminated. agreed in the Contract or, failing agreement, as normally charged
by the Contractor. Save as otherwise provided, the hourly rates
The Purchaser shall also have the right to terminate the
cover the normal wear and tear of the Contractor’s tools and light
Contract by notice In Writing to the Contractor if it is clear from
equipment;
the circumstances that there will occur a delay in taking-over of
the Works which under Clause 43 would entitle the Purchaser d) time necessarily spent on:
to maximum liquidated damages. In case of termination for this - preparation and formalities incidental to
reason, the Purchaser shall be entitled to maximum liquidated the outward and homeward journeys of the
damages and compensation under the third paragraph of this Contractor’s personnel,
Clause 44. - the outward and homeward journeys and other
journeys to which the personnel are entitled in
45. Liquidated damages under Clause 43 and termination of accordance with current law, regulations or
the Contract with limited compensation under Clause 44 shall be collective agreements in the Contractor’s
the only remedies available to the Purchaser in case of delay on country,
the part of the Contractor. All other claims against the Contractor - daily travel of the Contractor’s personnel
based on such delay shall be excluded, except where the between lodgings and the Site, if it exceeds half
Contractor has been guilty of Gross Negligence. an hour each way and there are no suitable
lodgings closer to the Site,
PAYMENT - waiting when work is prevented by
46. Unless otherwise agreed, payment shall be made within 30 circumstances which are not attributable to the
days after the date of the invoice as follows: Contractor;
a) when installation is carried out on a time basis: e) any expenses incurred by the Contractor in accordance
with the Contract in connection with the provision of equipment
- one third of the agreed price for the Plant at the
by him, including where appropriate a charge for the use of the
formation of the Contract,
Contractor’s own heavy equipment;
- one third when the Contractor notifies the
Purchaser that the Plant or the essential part f) any taxes or dues levied on the invoice and payable by
of it is ready for dispatch from the place of the Contractor in the country where installation takes place;
manufacture and g) any costs which could not reasonably be foreseen by
- the final third on arrival of the Plant at the Site. the Contractor and are caused by a circumstance which is not
attributable to the Contractor;
Payment for installation shall be made against monthly
invoices. h) any extra costs resulting from the applicability of mandatory
rules of the Purchaser’s country in the social field;
b) when installation is included in the lump sum Contract
Price: i) any costs, expenses and time spent resulting from extra
- 30 per cent of the Contract Price at the work which is not attributable to the Contractor.
formation of the Contract,
If these costs are time-related, they shall be charged at the
- 30 per cent when the Contractor notifies the rates referred to in this Clause 47 under c.
Purchaser that the Plant or the essential part
of it is ready for dispatch from the place of
48. When installation is to be carried out for a lump sum, the
manufacture,
Contract Price shall be deemed to include all the items mentioned
- 30 per cent on arrival of the Plant at the Site,
in Clause 47, a) through e). Any items mentioned in Clause 47,
- the remaining part of the Contract Price on f) through i), shall be deemed to be excluded from the Contract
taking-over. Price and shall therefore be charged separately. If these costs
are time-related, they shall be charged at the rates referred to in
47. When installation is carried out on a time basis the following Clause 47 under c).
items shall be separately charged:
a) all travelling expenses incurred by the Contractor in 49. If installation is delayed due to a cause which is attributable
respect of his personnel and the transport of their equipment and to the Purchaser, the Purchaser shall compensate the Contractor
personal effects (within reasonable limits) in accordance with the for any resulting additional costs, including but not limited to:
specified method and class of travel where these are specified in
a) waiting time and time spent on extra journeys;
the Contract;
b) costs and extra work resulting from the delay, including
b) cost of board and lodging and other living expenses,
removing, securing and setting up installation equipment;
including any appropriate allowances of the Contractor’s personnel
for each day’s absence from their homes, including non-working c) additional costs, including costs as a result of the
days and holidays. The daily allowances shall be payable even Contractor having to keep his equipment at the Site for a longer
during incapacity caused by sickness or accident; time than expected;
c) the time worked, which shall be calculated by reference d) additional costs for journeys and board and lodging for
to the number of hours certified as worked in the time-sheets the Contractor’s personnel;
signed by the Purchaser. Overtime and work on Sundays, holidays
5
e) additional financing costs and costs of insurance; LIABILITY FOR DEFECTS
f) other documented costs incurred by the Contractor as a 55. Pursuant to the provisions of Clauses 56-71, the Contractor
result of changes in the installation programme. shall remedy any defect or nonconformity (hereinafter termed
defect(s)) in the Works resulting from faulty design, materials or
If these costs are time-related, they shall be charged at
workmanship.
the rates referred to in Clause 47 under c).
56. The Contractor shall not be liable for defects arising out
50. Whatever the means of payment used, payment shall not
of materials provided or a design stipulated or specified by the
be deemed to have been effected before the Contractor’s account
Purchaser.
has been irrevocably credited for the amount due.
51. If the Purchaser fails to pay by a stipulated date, the 57. The Contractor shall only be liable for defects which appear
Contractor shall be entitled to interest from the day on which under the conditions of operation provided for in the Contract and
payment was due and to compensation for recovery costs. The under proper use of the Works.
rate of interest shall be as agreed between the parties or otherwise
8 percentage points above the rate of the main refinancing facility 58. The Contractor shall not be liable for defects caused by
of the European Central Bank. The compensation for recovery circumstances which arise after the risk has passed to the Purchaser,
costs shall be 1 per cent of the amount for which interest for late e.g. defects due to faulty maintenance or faulty repair by the
payment becomes due. Purchaser or to alterations carried out without the Contractor’s
In case of late payment and in case the Purchaser fails consent In Writing. The Contractor shall neither be liable for normal
to give an agreed security by the stipulated date the Contractor wear and tear nor for deterioration.
may, after having notified the Purchaser In Writing, suspend his
performance of the Contract until he receives payment or, where 59. The Contractor’s liability shall be limited to defects in the
appropriate, until the Purchaser gives the agreed security. Works which appear within a period of one year from taking-over. If
If the Purchaser has not paid the amount due within three the use of the Works exceeds that which is agreed, this period shall
months, the Contractor shall be entitled to terminate the Contract be reduced proportionately. If taking-over has been delayed for
by notice In Writing to the Purchaser and, in addition to the interest reasons which are attributable to the Purchaser, the Contractor’s
and compensation of recovery costs according to this Clause 51, liability for defects shall not, except as stated in Clause 60, be
to claim compensation for the loss he incurs. Such compensation extended beyond 18 months after delivery of the Plant.
shall not exceed the Contract Price.
60. When a defect in a part of the Works has been remedied,
RETENTION OF TITLE the Contractor shall be liable for defects in the repaired or replaced
52. The Plant shall remain the property of the Contractor until part under the same terms and conditions as those applicable to
paid for in full, including payment for installation of the Plant, to the original Works for a period of one year. For the remaining parts
the extent that such retention of title is valid under the relevant of the Works the period mentioned in Clause 59 shall be extended
law. only by a period equal to the period during which and to the extent
The Purchaser shall at the request of the Contractor assist that the Works could not be used as a result of the defect.
him in taking any measures necessary to protect the Contractor’s
title to the Plant. 61. The Purchaser shall without undue delay notify the Contractor
The retention of title shall not affect the passing of risk In Writing of any defect which appears. Such notice shall under no
under Clause 30. circumstances be given later than two weeks after the expiry of the
period given in Clause 59 or the extended period(s) under Clause
60, where applicable.
LIABILITY FOR DAMAGE TO PROPERTY BEFORE
TAKING-OVER The notice shall contain a description of the defect.
53. The Contractor shall be liable for any damage to the Works If the Purchaser fails to notify the Contractor In Writing of a
which occurs before the risk has passed to the Purchaser. This defect within the time limits set forth in the first paragraph of this
applies irrespective of the cause of the damage, unless the damage Clause, he shall lose his right to have the defect remedied.
has been caused by the Purchaser or anyone for whom he is Where the defect is such that it may cause damage, the
responsible in connection with performance of the Contract. If the Purchaser shall immediately inform the Contractor In Writing. The
Contractor is not liable for the damage to the Works in accordance Purchaser shall bear the risk of damage to the Works resulting
with this Clause, the Purchaser may still require the Contractor to from his failure so to notify. The Purchaser shall take reasonable
remedy the damage, be it at the Purchaser’s cost. measures to minimise damage and shall in that respect comply
with instructions of the Contractor.
54. The Contractor shall be liable for damage to the Purchaser’s
property occurring before taking-over of the Works only if it is 62. On receipt of the notice under Clause 61 the Contractor
proved that such damage was caused by negligence on the part of shall at his own cost remedy the defect without undue delay, as
the Contractor or anyone for whom he is responsible in connection stipulated in Clauses 55-71. The time for remedial work shall be
with the performance of the Contract. The Contractor shall chosen in order not to interfere unnecessarily with the Purchaser’s
however under no circumstances be liable for loss of production, activities.
loss of profit or any other consequential or indirect loss.
Remedial work shall be carried out at the Site, unless
6
the Contractor deems it more appropriate, having regard to the is so substantial as to significantly deprive the Purchaser of the
interests of both parties, that the defective part or the Plant is sent benefit of the Contract as regards the Works or a substantial part
to him or a destination specified by him. of it,
Where remedial work is carried out at the Site, Clauses 14- b) the Purchaser may terminate the Contract by notice In
17 and 54 shall apply correspondingly. Writing to the Contractor in respect of such part of the Works as
cannot in consequence of the defect be used as intended by the
If the defect can be remedied by replacement or repair of a
parties. The Purchaser shall then be entitled to compensation for
defective part and if dismantling and re-installation of the part do
his loss, costs and damages up to a maximum of 15 per cent of
not require special knowledge, the Contractor may demand that
that part of the Contract Price which is attributable to the part of
the defective part is sent to him or a destination specified by him.
the Works in respect of which the Contract is terminated.
In such case the Contractor shall have fulfilled his obligations in
respect of the defect when he delivers a duly repaired part or a
part in replacement to the Purchaser. 70. Notwithstanding the provisions of Clauses 55-69 the
Contractor shall not be liable for defects in any part of the Works
for more than one year from the end of the liability period referred
63. The Purchaser shall at his own expense provide access
to in Clause 59 or from the end of any other liability period agreed
to the Works and arrange for any intervention in equipment other
upon by the parties.
than the Works, to the extent that this is necessary to remedy the
defect.
71. Save as stipulated in Clauses 55-70, the Contractor shall
not be liable for defects. This applies to any loss the defect
64. Unless otherwise agreed, necessary transport of the Plant
may cause, including loss of production, loss of profit and other
or parts thereof to and from the Contractor in connection with the
indirect loss. This limitation of the Contractor’s liability shall not
remedying of defects for which the Contractor is liable shall be at
apply if he has been guilty of Gross Negligence.
the risk and expense of the Contractor. The Purchaser shall follow
the Contractor’s instructions regarding such transport.
ALLOCATION OF LIABILITY FOR DAMAGE CAUSED BY
THE WORKS
65. Unless otherwise agreed, the Purchaser shall bear any
additional costs which the Contractor incurs for remedying the 72. The Contractor shall not be liable for any damage to
defect caused by the Works being located in a place other than property caused by the Works after taking-over and whilst the
the Site. Works are in the possession of the Purchaser. Nor shall the
Contractor be liable for any damage to products manufactured by
the Purchaser or to products of which the Purchaser’s products
66. Defective parts which have been replaced shall be made
form a part.
available to the Contractor and shall be his property.
If the Contractor incurs liability towards any third party
for such damage to property as described in the preceding
67. If the Purchaser has given such notice as mentioned in
paragraph, the Purchaser shall indemnify, defend and hold the
Clause 61 and no defect is found for which the Contractor is
Contractor harmless.
liable, the Contractor shall be entitled to compensation for the
costs he incurs as a result of the notice. If a claim for damage as described in this Clause is lodged
by a third party against one of the parties, the latter party shall
forthwith inform the other party thereof In Writing.
68. If the Contractor does not fulfil his obligations under Clause
62, the Purchaser may by notice In Writing fix a final reasonable The Contractor and the Purchaser shall be mutually
period for fulfilment of the Contractor’s obligations, which shall obliged to let themselves be summoned to the court or arbitral
not be less than one week. tribunal examining claims for damages lodged against one of
them on the basis of damage allegedly caused by the Works. The
If the Contractor fails to fulfil his obligations within such final
liability between the Contractor and the Purchaser shall however
period, the Purchaser may himself undertake or employ a third
be settled in accordance with Clause 78.
party to undertake necessary repair work at the risk and expense
of the Contractor. The limitation of the Contractor’s liability in the first
paragraph of this Clause shall not apply where the Contractor has
Where successful repair work has been undertaken by
been guilty of Gross Negligence.
the Purchaser or a third party, reimbursement by the Contractor
of reasonable costs incurred by the Purchaser shall be in full
settlement of the Contractor’s liabilities for the said defect. FORCE MAJEURE
73. Either party shall be entitled to suspend performance of his
69. Where the defect has not been successfully remedied, as obligations under the Contract to the extent that such performance
stipulated under Clause 68: is impeded or made unreasonably onerous by Force Majeure,
meaning any of the following circumstances: industrial disputes
a) the Purchaser shall be entitled to a reduction of the
and any other circumstance beyond the control of the parties,
Contract Price in proportion to the reduced value of the Works,
such as fire, war, extensive military mobilization, insurrection,
provided that under no circumstances shall such reduction
requisition, seizure, embargo, restrictions in the use of power,
exceed 15 per cent of the Contract Price, or, where the defect
7
currency and export restrictions, epidemics, natural disasters, ANTICIPATED NON-PERFORMANCE
extreme natural events, terrorist acts and defects or delays in 76. Notwithstanding other provisions in these General
deliveries by sub-contractors caused by any such circumstance Conditions regarding suspension, each party shall be entitled to
referred to in this Clause. suspend the performance of his obligations under the Contract
A circumstance referred to in this Clause, whether where it is clear from the circumstances that the other party is
occurring prior to or after the formation of the Contract, shall give not going to perform his obligations. A party suspending his
a right to suspension only if its effect on the performance of the performance of the Contract shall forthwith notify the other party
Contract could not be foreseen at the time of the formation of the thereof In Writing.
Contract.
CONSEQUENTIAL LOSSES
74. The party claiming to be affected by Force Majeure shall 77. Save as otherwise stated in these General Conditions there
notify the other party In Writing without delay on the intervention shall be no liability on either party towards the other party for loss
and on the cessation of such circumstance. If a party fails to give of production, loss of profit, loss of use, loss of contracts or for
such notice, the other party shall be entitled to compensation for any other consequential or indirect loss whatsoever.
any additional costs which he incurs and which he could have
avoided had he received such notice.
DISPUTES AND APPLICABLE LAW
If Force Majeure prevents the Purchaser from fulfilling his
78. All disputes arising out of or in connection with the
obligations, he shall compensate the Contractor for expenses
Contract shall be finally settled under the Rules of Arbitration of
incurred in securing and protecting the Works.
the International Chamber of Commerce by one or more arbitrators
appointed in accordance with the said Rules.
75. Regardless of what might otherwise follow from these
General Conditions, either party shall be entitled to terminate the
79. The Contract shall be governed by the substantive law of
Contract by notice In Writing to the other party if performance
the Contractor’s country.
of the Contract is suspended under Clause 73 for more than six
months.
This is an Orgalime publication. Orgalime represents the mechanical, electrical, electronic and metalworking industries in Europe.
All rights reserved ©
Editeur responsable : Adrian Harris, Director General
ORGALIME – The European Engineering Industries Association
Diamant Building, Boulevard A Reyers 80, B – 1030 Brussels
Tel: +32 2 706 82 35 – Fax: +32 2 706 82 50 – secretariat@orgalime.org – www.orgalime.org
Stevinstraat 11 Phone : +31 (0) 543 53 10 30
7102 DZ Winterswijk Fax : +31 (0) 543 51 90 89
P.O. Box 218 IBAN : NL61 RABO 0371277515
Project: Water Health 7100 AE Winterswijk Swift : RABO NL2U
Serial number: W10286-011 The Netherlands K.v.K. : Centr. Gld. 08038650
E-mail: info@redox.nl B.T.W. : NL0064.53.703.B01
Flocculator RPF 015

RECOMMENDED SPARE PARTS / WEAR AND TEAR PARTS ORDER LIST
Pos. Description Art.Nr. Quantity Quantity Drawing
advised ordered
Coagulant dosing ½” (for example FeCl3):

R1 Ball valve ø16 (PVC) 1217.00019 SPT-RPF-01
R2 Non return valve ø16 (PVC) 1716.00009 SPT-RPF-01
R3 Safety valve 1314.00001 SPT-RPF-01
Neutraliser dosing ½” (for example NaOH):

Flocculant dosing 1” (for example Poly):

Sample ½”:
R8 Ball valve ½” (PVC) 1217.00012 SPT-RPF-01
POS R… are spare parts

POS V… are wear and tear parts.
Date of order :
Ordered by :
Polydox AP 1000
RECOMMENDED SPARE PART LIST / PARTS SUBJECT TO WEAR
Pos. Description Art.No. Rec. Quantity Signature
quantity ordered
01 G3/4” ball valve 1217.00031

02 G3/4” pressure reducing valve 1715.00020
0-6bar pressure gauge 1712.00015
03 G3/4” solenoid valve 1312.00015
04 G3/4” water meter 1711.00024
05 25mm ball valve 1217.00027
06 25mm ball valve 1217.00027
07 Spiral dosing screw 1428.00011
08 Dosing screw drive – 0.18kW 1913.00089
09 DHB”MS” heating element 5010.00082 1
Ø42x20mm, 24V, 10W
10 Electrode Holder (Level rods) 1710.00036
11 Polymer dosing pump
12 Mixer drive – 0.37kW, 66rpm 1913.00018
13 Mixer drive – 0.55kW, 910rpm 1910.00009

Date ordered:
Ordered by:
GPL 15
RECOMMENDED SPARE PARTS / WEAR AND TEAR PARTS ORDER LIST
Pos. Description Art.Nr. Quantity Quantity Drawing
advised ordered
In pneumatic control panel (UNI-S-0,5-8):

R1 Pressure switch main air supply 1714.00002
R2 Pressure switch for recirculation 1714.00002
R3,R4, Control valve 5/2 1620.00009
R8
R9, Pressure reducer incl. water filter 1715.00011
R10
R11 Pressure indicator main air supply 1712.00018
¼” 0-10 bar
R12 Pressure indicator recirculation system 1712.00018
¼” 0-10 bar
R13 Needle valve 1316.00004
R14 Flowmeter Hosco 0,5-8 l/min ⅜" 1711.00029
On GPL 15:
V1 Scraper L=1490mm. (polyester) 5015.00053 1 SPT-GPL-02
V2 Chain 5011.00008 1 SPT-GPL-02
V4 Sprocketwheel with flatkey 30*10 5011.00011 2 SPT-GPL-02
V5 Sprocketwheel without flatkey 30*10 5011.00012 2 SPT-GPL-02
V6 Bearing block 3012.00010 4 SPT-GPL-02
V7 Ball valve ½“ bi/bi 1217.00046 2 SPT-GPL-02
R20 Chain pin M8 5011.00036 SPT-GPL-02
R21 Ball valve 1¼" bi/bi 1217.00009 SPT-GPL-02
R22 Rec.pump CB32-250 with drive 1820.00083 SPT-GPL-02
R24 Sediment discharge valve DN80 1318.00042 SPT-GPL-02
R26 Drive scraper, type SK 12063 1913.00002 SPT-GPL-02

Date of order :
Ordered by :

Manual Water Health-W10286

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Water

for the future

2. Operation manual Flocculator, type RPF 015

3. Operation manual Coagulant dosing pump

4. Operation manual Caustic soda dosing pump

5. Operation manual Polymer preparation system,

6. Operation manual Flocculant dosing pump

7. Operation manual Flotation unit, type GPL 15

8. Operation manual Recirculation pump GPL 15

9. Operation manual Skimmer drive GPL 15

10. Operation manual Sediment discharge valve

11. Operation manual Sludge discharge pump

12. Documents Orgalime

13. Documents Manufacturer’s declaration

14. Documents Recommended spare parts /

15. Operation manual Recommended spare parts /

16. Operation manual Recommended spare parts /

17. Diagrams Pneumatic

Client : Water Health

Thank you for purchasing a Redox system.

Due guarantee / product liability

THE FOLLOWING ITEMS ARE EXCLUDED FROM THE GUARANTEE and

 All mistakes caused by not checking the warnings in this manual.

Read the(safety) instructions in this manual carefully.

The following alerts may be placed on the installation:

Electrical Hazard Explosive atmosphere

Automatic starting machine Attention for rotating parts

Biting substance Biting (corrosive) substance

Use safety glasses Use safety gloves

Use safety helmed Use safety shoes

No entry for unauthorized No drinking water

Screening (not by Redox)

Physical chemical treatment step

Data concerning waste water

It is recommended to execute the buffer / equalisation tank with a mixer (/ aerator) to

Voltage : 400 V – 50 Hz – 3 phase + “0” + PE(protected

Flocculator and chemical dosing

Type : RPF 015

Serial Nr. : W10286-011

REDOX WATER TECHNOLOGY B.V.

TABLE OF CONTENTS: Page

Figure 1.1 Flocculator (RPF).

Coagulant (for example FeCl3): ½“

Neutraliser (for example NaOH): ½“

pH: ¾" connection

Flocculant (for example Poly): 1“

2.2. AUXILIARY EQUIPMENT.

2.3. NECESSARY TOOLS AND MAKESHIFTS.

 For start-up, maintenance and control no special tools are required.

2.4. FLOW SHEET.

= Non return valve

2.5. ADDITIONAL INFORMATION FROM SUB-SUPPLIERS.

Keep all warnings readable, if necessary clean or replace it!

Biting (corrosive) substance.

This warning is placed at the front side of the flocculator.

Warning for consequences:

 Operating not in accordance with the safety prescriptions.

3.2. OPERATORS AND WORKING ENVIRONMENT.

3.3. PERSONAL PROTECTION.

 Safety clothes (chemical resistant).

For dimensions and weight see chapter 2.1 in this manual.

Transport by truck has to be in accordance with the following conditions:

Load and unload.

4.2 MOUNTING INSTRUCTIONS.