Instruction Manual TopClean AS Hygienic, Self-priming Liquid Ring Pumps IM-AS/02.
CE – Declaration of conformity Manufacturer Johnson Pump Box 1436 SE- 701 14 Örebro Sweden We declare under our sole responsibility that the product: Pump Series AS CE declaration of conformity (Ann.II.A, 98/37/EEC) to wich this declaration refers, is conform to safety requirements according to 98/37/EEC norms and amendments Manufacturer declaration (Ann. II.
Index 1.0 2.0 3.0 4.0 Introduction ...................................................................................................... 3 Symbols ...................................................................................................... 3 Safety warnings ................................................................................................ 3 Transportation, receipt and transferring of goods ....................................... 4 4.1 4.2 4.3 5.0 Description .....................
11.5.3.1 T execution .......................................................................... 14 11.5.3.2 V execution .......................................................................... 14 11.5.3.3 Q execution .......................................................................... 15 11.5.4 Assembly of pump casing and impeller assembly ........................................ – AS 40, AS 50, AS 60, AS 65 and AS 80 ................................................... 15 11.5.
1.0 Introduction • Read the instructions carefully and keep them for future consultation. • Johnson Pump reserves the right to make any changes to the documentation it deems necessary without being obliged to update publications that have already been issued. • When requesting information, spare parts or assistance, always specify the pump type and serial number in order to ensure fast and efficient service: the complete code is given on the plate and in the purchase documents.
Before carrying out any operation which requires to disassembly of the pump (inspection, cleaning, seal replacement, etc.), the following preliminary operations have to be carried out: • Switch off engine tension and disinsert electric connection. • Close valves on suction and outlet pipelines, in order to avoid the risk of inundation. • Use adequate protection for hands and face, if the pump contains liquids which are hazardous to health (for example acids, solvents, etc.).
5.0 Description The pumps of series AS are centrifugal side channel self-priming with star-shaped impeller; the ports are located on the longitudinal axe with the suction located on the front of the pump cover. All models have threaded connections for fittings according to DIN 11851 standard (unless otherwise requested).
6.0 Non-permitted uses Do not use the pump with a suction pressure greater than the specified value (0.5 times the discharge head generated by the pump). The pump must always be used in an environment appropriate to the level of protection of the motor. Always check this on the motor plate before installation. The pump may not be used in environments which require a higher level of protection or a higher specification motor or electrical parts.
7.3 Electrical connection Make the electrical connection only after the hydraulic connection has been completed; set up the motor control system in conformity with the technical standards and regulations in force (EN 60204-1): in particular a manual electric power switch must be installed with adequate current switching capacity; devices for overcurrent and overload protection (e.g. fuses, automatic switches, etc.) must also be fitted, plus, if necessary, a device to prevent accidental restarting.
8.2 8.3 Operating checks • If the pump does not generate the required discharge head rapidly, facilitate priming by stopping the pump and adding liquid. • Check that the absorption of the motor does not exceed the value specified on the plate. • The pump must always work smoothly and without vibrations. • Do not operate without liquid and in any case avoid prolonged operation with the discharge gate valve closed. • With series AS pumps never close discharge side completely.
10.0 Seals All centrifugal pumps of the AS series are fitted with unified mechanical seals according to DIN 24960 - ISO 3069 standards, in order to grant the interchangeability (subject to verification of axial space). The type of mechanical seal and material are chosen according to the liquid to be pumped. Mechanical seal types conforming to DIN 24960 • T execution: Standard – Internal single mechanical seal • V execution: External single mechanical seal with external flushing/quench.
11.0 Disassembly and Assembly AS-series 11.1 General instructions Assembly and disassembly may be preformed by qualified personnel only. Always wear appropriate safety clothing. Make sure that personnel are instructed and educated. Insufficient or wrong assembly and disassembly can lead to the pump malfunction. Johnson Pump is not liable for accidents and/or damage caused by non-compliance with the guidelines. Always work in a clean surrounding.
4. Isolate and depressurize flushing/quench system. 5. Close the inlet and discharge valves. 6. Drain and purge the pump casing and pipe work. 7. Clean the pump externally before disassembly. 11.4 Disassembly 11.4.1 Removal of pump casing and impeller – AS 40, 50, 60, 65 and 80 See sectional drawings AS40 page 18, AS 50 page 19 1. Remove the mechanical seal flushing pipes 71 on V and Q executions. 2. Remove the shroud (44) with screws (46) (if shroud is assembled). 3.
11.4.3 Seal disassembly 11.4.3.1 T execution 1. AS 42 and AS 52 only. Push back the ring retainer (31) to remove the circlip (32) from the shaft (4). 2. Remove the rotating seal half by turning the spring clockwise and at the same time pull the spring and the seal over the shaft end. If necessary use a pair of pliers. 3. Loosen the screws (26). 4. Slowly remove the pump casing (1) from the bearing housing (5). 5. Remove the stationary seal part from its seat in the pump casing (1).
11.4.4 Bearing removal 1. Remove shroud adapter (43) (if assembled) by loosening the screws (45). 2. Unscrew the screws (27). 3. Remove the bearing cover (8). 4. Press out the shaft and bearing assembly from the bearing housing (5). 5. Unscrew the ring nut (17). Press out the shaft (4) from the bearing (7). 11.5 Assembly Remark: It is recommended to pre-assemble the pump without the seal.
11.5.2 Pump assembly AS 40, 50, 60, 65 Before assembly read chapters 11.1 General Instructions and 11.2 O-rings and lip seals. N.B. Make sure that all surfaces are clean and without damage. If necessary polish using (600 degrees) emery cloth, lubricate all O-rings and contact surfaces with soap and water or silicone spray. 1. Check the shaft condition – no tracks of wear etc. Clean it carefully. 2. Press the bearings (7) on to the shaft (4). 3. Assemble the ring nut (17) and tighten it. 4.
11.5.3.3 Q execution 1. Position the O-ring (61) on the mechanical seal cover (60). 2. Position the secondary stationary seal in the mechanical seal cover (60) and hexhead screws (62). 3. Slide the mechanical seal cover (60) onto the shaft (4) and position it on the back end of the shaft. 4. Gently slide the rotating seals onto the shaft (4). 5. Check the “A” length as it is essential for an equal working load on both seal faces, A measures as follows: • AS 40 = 16.0mm • AS 50 = 17.5mm • AS 60 = 15.
11.5.5 Pump cover and Impeller assembly – AS 42 and AS 52 See drawing 1. Fit the first impeller key (11) and push on the impeller (3) on the shaft (4). 2. Fit the O-ring in the pump casing (1) groove and assemble the inter-suction casing (34). 3. Fit the O-ring (36) in the inter-suction casing (34) and assemble the inter-discharge casing (35). 4. Fit the second impeller key (11) and push on the impeller (3) on the shaft (4) 5. Fit the O-ring (36) in the inter-discharge casing (35).
12.0 Spare parts lists and sectional drawings 12.1 Spare part list AS 40, 50, 60-65, 80 Pos Qty Description Material 1 1Q 1V 1 1 1 Casing, pump Casing, pump Q-execution Casing, pump V-execution CF-3M / 1.4409 CF-3M / 1.4409 CF-3M / 1.4409 2 3 4 4V 1 1 1 1 Cover, casing Impeller Shaft Shaft V-execution CF-3M / 1.4409 CF-3M / 1.4409 AISI 316 L / 1.4404 AISI 316 L / 1.
12.2 AS 40 – Execution T, Q, V Execution T 44 50 20 27 17 25 8 26 28 45 5 7 Execution Q 60 Q 71 Q 18 61 Q 46 14 43 15 29 4 21 1 30 6 19 12 13 11 9 10 3 2 16 Execution V 6Q 68 Q 1Q 66 V 65 V 71 V 68 V 70 V 1V 4V IM-AS/02.
12.3 AS 50 – Execution T, Q, V Execution T 44 23 50 17 25 7 8 26 27 Execution Q 62 Q 60 Q 61 Q IM-AS/02.
12.4 AS 60-65 – Execution T, Q, V Execution T 44 25 23 23 25 Execution Q 60 Q 71 Q 50 17 7 8 27 26 28 45 5 4 20 68 Q 30 43 15 29 14 20 1 21 19 3 6 13 12 9 16 2 11 10 Execution V 1Q 66 V 61 Q 46 6Q 65 V 71 V 70 V 1V 4V 68 V IM-AS/02.
12.5 AS 80 – Execution T, Q, V Execution T 44 50 8 26 5 45 46 43 15 14 40 1 6 9 12 4 16 2 23 25 17 27 28 Execution Q 61 Q 60 Q IM-AS/02.
12.6 22 Spare part list AS 42, 52 Pos. Q.
12.7 AS 42 – Execution T, Q, V Execution T 50 17 44 25 8 7 26 45 23 28 Execution Q 60 Q 71 Q IM-AS/02.
12.8 AS 52 – Execution T, Q, V Execution T 44 23 50 17 25 8 45 26 7 27 28 5 Execution Q 62 Q 60 Q 61 Q 24 43 46 4 15 30 14 6 29 20 1 32 21 3 13 31 35 34 38 36 11 39 Execution V 6Q 71 Q 1Q 66 V 4V 71 V 70 V 65 V 1V 68 V IM-AS/02.
13.0 Dimensions and weights 13.
13.3 AS 42-52 with shroud 1450 rpm A K DN G F J DN I1 I Y H C1 E1 C B L L1 E Pumps kW 2,2 AS 42 3 DN 40 40 A 298 298 B 220 220 C - C1 231 231 E - E1 203 203 F 205 205 G 520 520 K 725 725 H 190 190 J 110 110 I 335 335 I1 354 354 Y 225 225 L 225 225 L1 - Weight kg 56 60 AS 52 50 370 258 292 - 267 - 237 580 817 230 115 381 417 266 225 - 85 5,5 Dimensions not binding – DN = DIN 11851 male threaded connection – exec. with standard IEC/EN motors 13.
14.0 Trouble shooting chart The pump does not prime • Air has entered the suction piping; check the seals on the fittings and tighten them sufficiently. • Suction pipe not submerged in liquid. • Clearances between impeller/cover and impeller/body have increased. Check and correct. • No liquid in the pump. Introduce liquid. • Reduce loss of suction head; reduce the suction height. • Formation of air pockets; eliminate and if necessary fit a valve on discharge.
15.0 Disposal of the pump For disposing the pump please observe the following instructions: • Disconnect electrical and hydraulic connections according to technical rules and laws in force. • Disassemble all components of the pump for separate dismantling; wash the components and clean the structure accurately. The main components of the pump are made from the following materials: • Pump casing, cover, impeller, shaft, impeller nut } S.S.
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