SIHISuperNova Programme

Range: ULN
Self-primming volute casing pump to EN 733 / DIN 24255*
PUMP DESCRIPTION: ______________________________
SERIAL NUMBER: ____________________

Operating instructions
Safety issues

Chapter 1

Safety instructions and compliance

Intended application

Chapter 2

Application, description

Planning the installation

Chapter 3

Requirements, piping system, accessories

Unpacking, storage, transport

Chapter 4

Supply, interim storage, corrosion protection

Installing the pump

Chapter 5

Assembly at site, tools, checks

Start-up and shut-down

Chapter 6

Important requirements

Maintenance, dismantling, assembly

Chapter 7

Intervals, cleaning

Troubleshooting

Chapter 8

If something does not work

Technical data

Chapter 9

Dimensions, permissible values

Annex

Chapter 10

Technical data, dimensions table, sectional drawings

*

With certain exceptions see Technical Catalogue

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

Safety instructions marked with

included in this Operating Instructions and in the
Supplementary Operating Instructions, which must be attached to this Operating Instruction, have to
be considered in particular when operating this pump in potentially explosive atmospheres!
For local contact details:
www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Safety issues

Page 1 of 3

Chapter 1

1. Safety

the identification plate

This operating manual gives basic instructions,

and that these are kept legible.

which must be observed during installation,

operation and maintenance of the pump. It is

1.2

therefore imperative that this manual is read by

Qualification and training of

personnel

the responsible personnel / operator(s) prior to

The

assembly and commissioning. It must always be

maintenance, inspection and assembly must be

kept available at the site of pump installation.

adequately qualified. The scope of responsibility

It is not only the general safety instructions

and supervision of the personnel must be exactly

contained in this chapter Safety which must be

defined by plant management. If the staff do not

observed,

have the necessary knowledge, they must be

but

also

the

specific

information

provided in the other chapters.

trained

personnel

and

responsible

instructed.

This

for

task

operation,

may

be

performed by the machine manufacturer or

1.1

Identification of safety
symbols in the operating
instructions

supplier on behalf of the plant management.

Moreover, plant management must ensure that
the contents of the operation instructions are fully

Safety symbols are given in these operating

understood by plant operators and other relevant

instructions. Non compliance with these would

personnel such as maintenance staff.

affect safety and are identified by the following

1.3

symbol

Hazards in case of non

compliance with safety
instructions

Non compliance with the safety instructions may

result in risk to personnel as well as to the
Danger symbol as per DIN 4844-W9
(ISO 3864 - B.3.1)

environment and the pump/pump set and result in

the loss of any right to claim damages.
For example, non-compliance may result from, or

Or in case of danger of electric current with:

lead to, the following:

failure of important functions of the pump/pump
set/plant
failure of specified procedures of maintenance
and repair

Danger symbol as per DIN 4844 W-8

(ISO 3864 - B.3.6)

exposure of people to electrical, mechanical

and chemical hazards
danger to the environment owing to hazardous

The word
ATTENTION

substances being released.

identifies those safety regulations where noncompliance may pose a danger to the pump and
its function. It is imperative that the appropriate
safety information is attached to the pump/pump
set, for example:
an arrow indicating the direction of rotation
symbols indicating fluid connections
For local contact details:
www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Safety issues

1.4

Page 2 of 3

Compliance with regulations

relating to safety at work

Chapter 1

operative again. Prior to re-starting the machine,

the instructions listed under first commissioning

When operating the pump the safety instructions

are to be observed.

contained in this manual, the relevant national

accident prevention regulations and any other

1.7

service and safety instructions issued by plant

Safety instructions for the use in

areas with explosion hazard

management must be observed.

1.5

Safety instructions relating to

operation

If high or low temperature pump/pump set

components involve hazards, steps must be
taken to avoid accidental contact.
Guards for moving parts (e.g. couplings) must

In this section information is given for operation in

areas where an explosion hazard exists.

1.7.1 Complete pump sets

not be removed from the pump/pump set while

If the pump is combined with other mechanical or

in operation.

electrical components in one set, the category of

Any leakage of hazardous (e.g. explosive,

the complete unit will correspond, based upon the

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

Directive 94/9/EC, only to that category with which

be drained safely so as to prevent any risk to

all of its components comply.

persons

or

the

environment.

Statutory
Note:

regulations are to be complied with.

Hazards from electricity are to be avoided by

These comments are of particular importance

VDE-

when pumps, which conform to a given category

specifications and the bye-laws of the local

of Directive 94/9/EC, are powered by a driver

power supply utilities).

which is not in the same category.

the

user

(see

for

example

the

Although the pump may bear the Ex sign, the set

1.6

Safety instructions relevant for

maintenance, inspection and
assembly work

should not be used in areas with an explosion

hazard when the motor is not classified for this
application.

It is the plant managements responsibility to

This means that plant management personnel

ensure that all maintenance, inspection and

should always check that all elements of the set

assembly

work

is

comply with the Directive 94/9/EC.

personnel

who

have

performed

by

adequately

authorized
familiarised

themselves with the subject matter by studying

1.7.2 Execution of coupling guards

this manual in detail.

Coupling guards that are to be used in areas with

Any work on the machine must only be performed

an explosion hazard, have to fulfil one of the

when it is at a standstill. It is imperative that the

following criteria:

procedure

for

shutting

down

the

machine

described in this manual is followed.

consist of non-sparking material, e.g. brass.

if they consist of sparking material, e.g. steel

Pumps and pump sets, which convey hazardous

sheet, they must be designed in such a way

media, must be decontaminated.

that the rotating parts will not come in contact

On completion of the work all safety and

with any part of the guard if errors, that could

protective guards must be re-installed and made

be foreseen, are committed by the user, e.g if

a person steps on the guard.

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Safety issues

Page 3 of 3

Chapter 1

1.7.3 Monitoring technical

parameters

1.10 Warranty / guarantee

When using pumps in areas with an explosion

operation if:

risk, the operator must check the following

the

Sterling Fluid Systems guarantee satisfactory

pump

is

installed

and

operated

in

parameters regularly:

compliance with these instructions and in

leakage of shaft seals

operating conditions approved by Sterling Fluid

bearing temperature

Systems

that the pump is always filled with liquid during

operation

modifications are only undertaken with Sterling

Fluid Systems written agreement.

that the pump does not operate against a

closed valve for any length of time.
The operator must ensure that pumps, which
show evidence of abnormal operation, are
switched off and not started again until the cause
of the abnormal operation has been eliminated.

1.7.4 Avoiding external damage

In areas with a risk of explosion the operator must
ensure that the pumps and or pump set is not
subjected to external impacts e.g by heavy
objects.

1.8

Unauthorized alterations and

production of spare parts

Modifications may be made to the pump/pump set

only after consultation with,and written approval
from, the manufacturer. Using spare parts and
accessories authorized by the manufacturer are in
the interests of safety. Use of other parts may
exempt the manufacturer from any liability.

1.9

Unauthorized mode of operation

The reliability of the pump/pump set can only be

guaranteed if it is used in the manner intended
and in accordance with the instructions of this
manual. The specified limit values must under no
circumstances be exceeded.

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Intended application

Page 1 of 3

2. Application

2.3

The pump is to be used only for the operating

Chapter 2

Construction and mode of

operation

conditions stated by the customer and confirmed

ULN pumps are horizontal, self-priming single

by the supplier. Guarantee is assumed within the

scope of the Sterling Fluid Systems conditions

stage volume casing pumps with dimensions and

of sale.

Their back pull out construction allows the

Appropriate application and operating conditions

disassembly of the complete bearing unit towards

are contained in the attached data sheets.

the drive side without removing the pump casing

nominal outputs acc. to EN 733 / DIN 24255.

out of the pipe system.

The side channel suction stage is arranged at the

2.1

Warning of misuse

drive side of the volute casing. It is connected in

parallel to the liquid pumping stage and works
according to the sucking through principle.
ULN pumps are preferably used when it is
necessary to suck in and to handle without
problems and automatically, pure resp. turbid not

The pump may only be used for the

aggressive liquids which do not contain any

application(s) stated. Otherwise hazards for

solids.

people and environment may arise.

ATTENTION

Do not exceed fluid density stated.

Otherwise, there is a the danger of motor
overload.

The pump must not be operated beyond its

characteristic curve otherwise there is a
danger of cavitation and motor damage.

2.2

Accessories

The accessories included in the scope of supply

are indicated in the delivery note or in the order
confirmation. The corresponding operating and
installation instructions are also indicated in the
Annex relating to accessories.
If it is intended to mount other accessories on the
pump or on the pump set, please inform the
manufacturer in advance in order that appropriate
technical advice can be given.

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Intended application

Page 2 of 3

Chapter 2

2.4 Description
Type
size

Hydraulic + Bearing
A speed = 1450 rpm
B speed = 2900 rpm

Shaft seal
AAE: Unbalanced standard mechanical seal. Orings: Perbunam

ULN
32125
to
125250

B Two greased
antifriction bearings

AA1: Unbalanced standard mechanical seal. Orings: Viton

Casing gasket

Material design
0A: Cast iron GG25
0C: Cast iron GG25,
Bronze G-CuSn10 impeller

2: flat gasket
without asbestos

3B: Bronze G-CuSn10

Alternatively

Alternatively

A, B

AAE, AA1

Alternatively

0A, 0C, 3B
B

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Intended application

Page 3 of 3

2.5

Example of a pump designation:

Chapter 2

Shaft sealing

Depending on the application, different shaft

1-3 4

sealing executions are offered (see 2.4)

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

ULNC 100 200 A B AAE OA 2

Casing gasket
Construction

utilised in the following cases:

if the pump draws from a suction line,

if the pump is fed by a feed line with a

pressure of less than 0.5 bar or

Shaft sealing
Bearings:B
Hydraulic: A/B

mechanical seals according to DIN 24960 are

if the pumped liquid is at or near its boiling

point.

Impeller size
Nominal discharge

Pump series

ATTENTION
Section 2.4 does not contain the codes for all
variations of mechanical seals. Where the code is
not included or replaced by QQQ, consult the
relevant data sheet of the mechanical seal
supplier (e.g. special execution of the mechanical
sealing in a back to back position).

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Planning the installation

Page 1 of 2

3. Planning the installation

Chapter 3

3.1.1 Suction line / inflow line

See the sketches below for the optimum layout of

3.1

Piping system

pump installation for flow and suction lift

operation.

ATTENTION

Note the arrows on the pump branches

indicating the direction of flow.

Choose nominal widths of the pipelines

according to the nominal widths of the pump
branches or larger ones with the
corresponding reductions.

Flange sealing must not protrude on the

inside.

Ensure that the pipework is clean before

installing of the pump.

positive suction head operation

suction lift operation

The suction line has to be laid acc. to fig. 1. The

lift of the suction line by the dimension "H" is
necessary to secure sufficient service liquid during
the priming phase of the pump.
H > nominal width suction side L > 400 mm

Support the pipework in order to avoid

distortions at the pump components (risk of
damage to pump components)

Avoid abrupt changes of cross section and

direction.

Where different diameter pipework is to be

used, connection should be by eccentric
fig. 1

transition pieces. This will avoid the formation

of air pockets in the pipework.

For difficult pumping on the suction side, to

stabilise the flow, a pipe length 15 times the
diameter of the suction branch should be

It is recommended that a filter is installed in front

of the pump with a filter surface of at least 3 times
the pipe cross section (approx. 100 meshes/cm).

installed before the suction branch.

When handling fuel the manometric suction

head must not exceed 3 m.

The flow rate in the suction line or inflow line,

must not exceed 2 - 3 m/s.

The suction opening of the suction line should be

well below the liquid level, and a strainer should
be used.
The strainer must be far enough from the bottom
to avoid excessive inlet losses, which could impair
pumping performance. It is advisable to check that
there is no leakage.
A shut-off valve should be installed in the feed
line. It must be closed for maintenance work.
It should be installed in order to avoid air pockets
forming in the spindle cap, i.e. with the spindle in
a horizontal position or pointing vertically
downward.

For local contact details:

www.sterlingfluidsystems.com

5
In the search to improve continuously its products,
Sterling Fluid Systems reserves the right to modify its
products at any time without prior notice.

(Sterling Fluid Systems BV) 2001

Planning the installation

Page 2 of 2

Chapter 3

3.1.2 Discharge line

For flow regulation, a valve must be installed
behind the pump. If non-return valves are used,
they should close smoothly. Pressure shocks
must be avoided.

3.1.3 Inlet and outlet connections

The various connecting points are shown in the
drawings. (See Annex, Chapter 10, point 10.1).
The air venting tube has to be connected above
the shut-off gate at discharge side or at the non-

fig. 3

return trap (fig. 2).

3.1.4 Pressure control

For consistent control of pressure, it is advisable
to install in the pipework a measuring point in front
of, and behind the pump.

3.2 Electrical connections

For the drive motor a mains connection is required
which complies with the European Regulations
and Directives for the Standards in Industry and
with the instructions of the local power supply
utilities of the country concerned.

fig. 2
The air, sucked in by the venting stage, is ejected
on starting-up through the discharge line without
counter pressure or at a counter pressure up to
0,5 bar
In case of priming conditions with higher counter
pressures the air venting tube has to be returned
into the suction tank (fig. 3).

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Unpacking, storage, transport

Page 1 of 2

4. Unpacking, storage, handling

4.4

Chapter 4

Handling

The pump or pump set must be lifted and handled

4.1

Safety measures

as shown in the following sketches.

Never stay below the suspended load.

Keep a safe distance while the load is being

transported.

Use only approved lifting appliances, which

are in good condition.

Adjust the length of the lifting appliances in

such a way that the pump and/ or the pump
set, is suspended horizontally.

Do not use the eyebolts on the pump

components for lifting the assembled pump or
the complete set.

Do not remove documents, which are

Pump without motor

attached to the pump.

Do not remove the protection covers from the

pump suction/discharge. Otherwise, there
may be a risk of contamination.

4.2

Unpacking

Before unpacking, a visual check of the packing is

recommended. If transport damage is visible, the
extent should be noted on the receipt or on the
delivery note. Potential claims must be lodged
immediately with the carriers or the insurance
company.
Pump set

4.3

Interim storage

If the pump or the pump unit is not installed

4.5

immediately after delivery, it must be stored free

In general, a protective coating is only applied to

from vibration in a dry room.

the following executions: OA, OC.

For local contact details:

www.sterlingfluidsystems.com

Protection against corrosion

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Unpacking, storage, transport

Page 2 of 2

Chapter 4

4.5.1 Removal of protective coating

To remove the protective coating, the pump
should be filled and drained several times using
appropriate agents, e.g. solvent naphtha, diesel
oil or alkaline detergent. Flush with water, if
necessary.
The pump must be installed and started up
immediately afterwards.

4.5.2 Renewing corrosion protection

If the pump has been supplied with a protective
coating and has to be stored, a new protective
coating should be applied after six months.
For suitable protective coatings, contact Sterling
Fluid Systems.

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Installing the pump

Page 1 of 3

Chapter 5

5. Installing the pump

5.1

Requirements

5.4.3 Base, foundation

The pump and the pump set, must have been

The pump must be installed on a flat floor or

unpacked and handled as described in Chapter 4.

foundation free from vibration. In case of doubt

use vibration dampening feet.

5.2

Use of trained staff

The pump set must be correctly mounted on the

Only appropriately trained staff must undertake

foundations. To avoid distortion of the pump set

the work described in this chapter.

and/or the foundation, parallel shims must be

used between the base plate and foundation.

5.3

Safety measures

Prior to installing, checks should be made with

regard to:
- possible damage to the pump or the
pump set that may occur in transit
- ease of running ( check that the shaft is
free to rotate by hand )

Connect the pipework carefully to prevent the

- the foundation dimensions.

pumped liquid escaping during operation and

The following preparatory work must be carried

endangering operating personnel.

out before to placing the pump:

Ensure that the suction or inflow line, and the

- roughen and clean foundation surface

discharge line are closed by valves.

- remove shuttering/cores from the anchor

Ensure that all electrical connections are

holes

dead. Otherwise, there is a risk of electric

- blow the anchor holes clean

shock.

- check the position and dimensions of

Pay attention to relevant internal plant

the anchor holes against the arrangement

regulations.

drawing.

Avoid accidental contacts with hot

5.4.4 Installation of the set

components.
ATTENTION

Remove the protective coating by following

The complete set mounted on the base plate must

the instructions of Chapter 4. Otherwise there

be placed on the foundation with its foundation

is a danger of contamination .

(rag) bolts hanging below the baseplate.

5.4.5 Space required

5.4

General information

The space required for the pump set is set out in

the foundation plan or installation drawing.

5.4.1 Assembly tools

Ensure easy access to the shut-off and regulation

Special tools are not required for assembly and

valves as well as to any measuring instruments.

installation.

5.4.2 Permissible ambient conditions

The ambient temperature can be from -20 C to
+60 C. The atmospheric humidity should be as
low as possible in order to avoid corrosion.
For local contact details:
www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Installing the pump

Page 2 of 3

Chapter 5

5.4.6 Position
In principle the ULN pumps are installed

half of the N-EUPEX B ( FLENDER ) coupling

horizontally.

must be 2 - 3 mm (see fig.).

If other manufacturers couplings are used, follow
the manufacturers instructions. After installation
on the foundation and connecting the pipework,
the coupling alignment must be checked and realigned, if necessary. Moreover, after reaching the
operating temperature the alignment of the
coupling must be checked again.
The coupling requires a guard that meets DIN
31001 in order to avoid accidental contact during
operation.

5.5

Motor

In any event, the operating instructions of the

Before assembly check the direction of rotation of

the motor (indicated by an arrow on the pump

coupling manufacturer must be followed, since the

coupling is a component incorporated by Sterling

casing). If this is not possible the direction of

Fluid Systems.

rotation of the complete unit can only be checked

ruler

only if the pump is filled.

In any event, the operating instructions of the
motor manufacturer must be followed, since the
motor is generally incorporated by STERLING
FLUID SYSTEMS into the pump set.

5.6

Alignment of the set

Place shims under the base plate on both sides of

The following is required a = a1 and b = b1

the foundation bolts, 10 mm from the base plate

edge. Use a spirit level to align the set.
If necessary, place shims between the foundation
bolts to prevent the base plate from sagging. Care
should be taken to minimize distortion of the base
plate during installation. The location of the driver
must not be higher than that of the pump. The
max. deviation from the shaft centre line is 0.1
mm.
The foundation bolts should be embedded in
concrete using quick-setting grout.

5.7

5.8

Checking before installation

Before installing the pump on the plant, the

following points must be checked:
1. is the electrical current to the drive motor
switched off?
2. are suction and discharge lines emptied and
closed by valves?
3. Is it possible to rotate the pump easily by
hand (for this purpose turn the fan of the
motor or the coupling)?
4. Have the latest internal/plant instructions been

Coupling

Instal the coupling avoiding hard blows, if

observed?.

necessary in warm condition. Arrange the pump

and motor on a level base. The shaft ends must
be aligned exactly. The distance between each
For local contact details:
www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Installing the pump

5.9

Page 3 of 3

Chapter 5

Mounting the pump and

installation into pipework

The following instructions must be carried out:

1. remove the protective covers from the pump
flanges and the auxiliary pipework
connections.
2. correctly insert the flange seals.
3. connect the suction or feed line.
4. connect the discharge line
The pump must be aligned with the pipework. The
pipework must be supported so that distortion
cannot occur when connecting the pump.

5.10 Final work

The following final steps must be undertaken:
1. check the tightness of the connecting flanges.
2. check for easy running of the pump (for that
purpose turn the motor fan or the coupling).
3. check the coupling alignment.
4. instal the coupling guard.

5.11 Hydrostatic pressure test

When subjecting the piping system to a
hydrostatic pressure test, exclude the pump from
the pressure test.
If it is not possible to test the pipework without the
pump, ensure that foreign material cannot enter
the pump.

The max. permmisible pressure for a

pressure test is 1.3 times the nominal
pump pressure.

The nominal pump pressure is indicated

in the tecnical data sheet.

Water should be used for testing

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Starp-up and shut-down

Page 1 of 3

6. Start-up and shut-down

operations

Chapter 6

If there is no bypass line, do not run the

pump with the control valve closed for any

6.1

Requirements

length of time.

The pump or the pump set, must be installed acc.

to the instructions of Chapter 5.

Safety measures should be taken by the

end user to ensure (for example by
means of a relief valve) that the

6.2

Use of trained staff

permissible pump casing pressure is not

Only appropriately trained staff must carry out the

exceeded during operation

work described in this chapter.

Repeat the alignment of the coupling at

operating temperature. Re-align the pump

6.3

Safety measures

or the motor, if necessary.

6.4

Electrical connection

The motor must be connected at set out in the

circuit diagram in the terminal box.

Electrical connections must be made

according to the European Regulations and

6.5

Directives for the Standards in Industry and in

Before switching on the pump unit, the following

compliance with the instructions of the local

points should be checked:

power supply utilities of the country

1. is all pipework connected and are the unions

concerned.

Checks before switching-on

tight?

Only appropriately authorized personnel may

carry out this work.

2. is the pump including the pipework filled

properly?
3. is the air ejector line connected properly?

ATTENTION

4. is the shut-off valve in the discharge line

closed?

Fill the pump correctly; otherwise the shaft

seal could be destroyed.

5. is the shut-off valve in the suction line

completely opened?

Fill the supply lines correctly.

6. is the motor ready for operation?

Check the direction of rotation only when the

7. is the direction of rotation of the motor

pump is filled.

correct?

Fill the pump slowly if hot media are being

(check by running the motor for a short time)

pumped in order to avoid distortions or heat

8. is the coupling aligned exactly?

shock.

9. has the shaft seal been installed?

When handling explosive, toxic, hot,

10. are the supply lines, if any, to the shaft seal

crystalline or corrosive media, ensure that

there is no risk to people or the environment.

Control the output at constant speed at the

open?
11. in the case of oil lubrication - has the bearing
housing been correctly filled with oil?

discharge side only. The valve at the suction

side must always be completely open during
operation to avoid the risk of cavitation.

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems) 2001

Starp-up and shut-down

6.6

Page 2 of 3

Chapter 6

Start-up operation
ATTENTION

For starting proceed as follows:

1. Before the first start-up the pump has to be
filled with pumping liquid

Priming periods of more than 5 minutes are not

admissible, because of warming-up of the suction

2. open fully the valve on the suction side

stage.

3. close the valve on the discharge side

4. switch on the motor
5. check the pressure gauges at the pressure
measuring points
When pumping petrol or liquids with similar
If the pumping pressure does not increase

physical properties priming periods must be

consistently with increasing speed, switch off the

shorter than 3 minutes because of warming-up of

motor again and vent the pump one more.

the suction stage.

6. After reaching operating speed, regulate the

operating point of the pump by adjusting the

The alignment of the coupling should be repeated

valve in the discharge line (see technical data

at operational temperature. If necessary the pump

for permissible range of operation).

or the drive motor, respectively, is to be realigned.

Pumping against a closed valve in the discharge

line is permitted only if a minimum output via a
bypass line is guaranteed.

6.7

Switching frequency

Size

By means of safety measures at the plant (e.g.

overflow valve) it must be ensured that the
admissible casing pressure of the pump is not
exceeded by malfunction during operation.

Permissible number of
starts equally spaced
per hour

32-125, 32-160, 32-200, 32-250,

40-125, 40-315, 50-125, 50-160,
50-200, 50-250, 50-315,
65-125, 65-160, 65-200, 65-250,
65-315, 80-160, 80-200, 80-250,
80-315, 100-200, 100-250, 100-315
125-250

The suction stages of the ULN pumps are

constructed in such a way that the suction line is

6.8

Special instructions

evacuated and then the centrifugal stage gets

During operation the following points must be

liquid and will be able to pump. If penetration of

observed:

gas happens during pumping, the pumping flow

breaks down and the priming phase must begin

- control the speed and the delivery head

again and that partly under more unfavourable

- ensure that the pump runs without vibration

conditions than initially because the suction stage

- control the liquid level in the suction line and/or

is filled with liquid and must pump "free" itself.

inflow tank
- control the bearing temperature (max.

The capability of ULN pumps to handle gas is the

temperature 100 C)

same as of centrifugal pumps, i.e. max. 8 %

- shaft seal: As a rule leakage of some cm/h at

(referring to the output) can be handled during

mechanical seals occur as vapour or fog.

normal duty.

Additionally slight drop leakage may occur.

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems) 2001

Starp-up and shut-down

Page 3 of 3

Chapter 6

ATTENTION
If the initial leakage does not disappear within 5
minutes of operation, stop the pump, dismantle
the seal and check for damage of the seal faces
and auxiliary sealing.

6.9

Shutting-down

Before shutting down close the valve on the

discharge side.
After shutting down, all valves may be closed.
If there is a risk of very low ambient temperatures,
remove the pump and then drain it using the
threaded plug 90.30.

When handling explosive, toxic, hot, crystalline or

corrosive media, ensure that people and the
environment are not endangered. Even if the
pump has been drained using the threaded plug
90.30, residues can remain in the pump. For
transport, the pump must be free from any
dangerous material. In case of extended periods
out of service, protect the pump against corrosion.

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems) 2001

Maintenance, dismantling, assembly

Page 1 of 4

Chapter 7

7. Maintenance, dismantling,
assembly
7.1

lubricating nipple

Requirements

The pump or the pump set must have been shut

down in the manner described in Chapter 6.

7.2

Use of trained staff

Only appropriately trained and skilled staff should

undertake the work described in this chapter.
Only authorised personnel must undertake
electrical work associated with maintenance of the
pump/pump set.

7.3

Grease lubrication:
The roller bearings receive their first grease filling
in the factory.
Lubrication intervals:
-

Safety measures

at 2900 rpm approx. every 2500 operating

hours

at 1450 rpm approx. every 5000 operating

hours

Quantities:
Bearing support 25:

For explosive, toxic, hot, crystalline as well as

different pumping media ensure that people

(shaft diameter at drive journal 24 mm)

9 gr

and the environment are not endangered.

Flush the pump with clean liquid before

dismantling.

The working place for disassembly or

Bearing support 35:

(shaft diameter at drive journal 32 mm)
15 gr

assembly must be clean.

Before reinstallation, the pump must be free of

any dangerous material.

7.4

Maintenance and inspection

The pump needs only minimum maintenance after

the running-in phase.

The roller bearing on the pump side must be

removed, washed and filled with a new filling of
grease after approx. 10.000 operating hours, at
the latest after 2 years. The roller bearing on the

7.4.1 Bearing with grease lubrication

The pump is fitted with a roller bearing with
lifetime lubrication on the drive side, and a roller
bearing with a lubricating nipple (DIN 71412 Form
A) on the pump side.

Bearing support 45:

(shaft diameter at drive journal 42 mm)
22 gr

drive side (suffix 2RS) must be replaced.

In extreme operating conditions (wet and dusty
operation or high ambient temperatures), the
lubricating intervals must be shortened.
Only high grade lithium-based roller bearing
grease may be used for replacement or topping
up (e.g. Mobilux 2, Shell Aero Grease 16, Esso
Unirex N3).

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Maintenance, dismantling, assembly

7.4.2 Drive motor

Page 2 of 4

Chapter 7

7.5.3 Dismantling the pump

The drive motor is to be maintained according to

the manufacturer's instructions

7.4.3 Mechanical seal

The mechanical seal should have little or no
visible leakage. Where there is considerable
leakage, check the mechanical seal. To do this, it
is necessary to dismantle the rotating part(s).

7.5

Fig. 1

Dismantling

7.5.1 Preparation for the dismantling

Proceed as follows:

1.

The respective positions of the parts are to be

marked with a coloured pen or scribing iron.

2.

Unscrew vent pipe 71.10 complete with union

drain the plant, at least within the pump area,

3.

Unscrew hex. screws 90.10.

i.e. between the valves on the suction- and

4.

Lift module out of pump housing 10.20.

disconnect power to the motor

73.10, stop plug 75.70 and sleeve 73.11.

discharge side

if necessary, disconnect any measuring

probes or control devices and remove them

drain liquid from the pump by means of the

drain plug

Take precautions to support the complete module

the pump casing must not be detached from

and possibly to catch any leaking pumping

the pipe union

medium.

remove motor mounting bolts and move the

motor so that there is sufficient space to
remove the back pull out unit. When using a
spacer coupling repositioning of the motor is
not necessary.

dismantle guard coupling, pump feet and

coupling.
Fig. 2

7.5.2 Replacement parts

The item numbers necessary for ordering spare

5.

Unscrew shaft nut 92.20. Remove lock

parts are provided in the component parts list in

washer 93.10, impeller 23.00 and feather key

the Annex.

94.01.
6.

Unscrew hex. nut 92.02 and dismantle cover

16.10, spacer 10.90, impeller 23.50 and
feather key 94.02 and spacer 11.40 .

7.

Mark position of set collar 48.50 on shaft.

8.

Unscrew set collar 48.50, carefully remove

axial seal 43.30 and shaft seal housing 47.10.

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Maintenance, dismantling, assembly

Page 3 of 4

Chapter 7

7.6.2 Points to be checked

The
ATTENTION

following

pump

components

must

be

checked:

The mating surfaces of the axial seal are

1. Check the axial seal for damage and wear. If

particularly vulnerable to damage and scratches.

the mating surfaces are damaged or worn, the

It is advisable to place these parts on a felt

surface.

axial seal must be replaced.

2. Check the split ring surfaces for damage and
wear. The difference in diameter between split
ring on impeller and the housing components
should be between 0.3 mm and 0.5 mm. If the
split rings are too

worn, they must be

replaced.
3. Check the suction stage and impeller for wear
and replace if necessary.
4. Bearing bushing 54.50 is to be replaced when
worn. It must be glued in with a special glue
(e.g.. Loctite 648).

Fig. 3
9.

Loosen bearing cover 36.00 by unscrewing

hex. screws 90.11.

10. Pull the shaft completely out of bearing

7.7
Assembly
7.7.1 Tightening torque
When tightening the bolts the following torques
must be used:

support 33.00.
11. Dismantle support foot 18.30 by unscrewing
hex. screw 90.12 and hex. nut 92.01.

Thread
Torque

M8

M10

M12

M16

M20

12Nm 25Nm 40Nm 90Nm 175Nm

7.7.2 Pump assembly

Proceed as follows:
1. as per fig. 4, assembly of shaft unit
Fig. 4

ATTENTION
12. Remove bearing 32.00 and 32.10 and spacer
tube 52.50 from shaft 21.00.

In roller bearing 32.00, the refill groove of the balls

must point in the direction of the impeller which is
still to be assembled.

7.6

Post dismantling activities

7.6.1 Hints for cleaning.

2. Slide pre-assembled shaft unit in bearing

Clean all parts.

support 33.00 and mount bearing cover 26.00

Clean the clearances and sealing surfaces

as per fig. 3. Screw on support foot 18.30.

with an appropriate liquid.

3.

Slide shaft sealing housing 47.10 complete

with axial seal counter ring over the shaft as
per fig. 2. Ensure that the connection for vent

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Maintenance, dismantling, assembly

tube 71.10 is flush with the corresponding

4.

Page 4 of 4

9.

Chapter 7

Insert seal 40.00 in spiral housing 10.20 and

bore in the bearing support.

slide the complete module in spiral housing

Slide axial seal 43.30 carefully onto the shaft

10.20. Insert hex. screws 90.10 and screw

using the assembly tool and then fix set collar

tight.

48.50 in the previously marked position.

ATTENTION
The sealing surfaces of the suction stage (i.e.
sealing surfaces between items 16.10, 10.90,
11.40, 47.10) are to be coated with liquid
sealant (e.g. Epple 33) before assembly.
The spacers are to be aligned on the basis of
the marks (fig. 5).
Rub Molykote Paste G into the mating surfaces
of spacer 10.90 and spacer 11.40.

Take into
account the
groove
position

Take into
account the
groove
position

Fig. 5
5.

Mount spacer 11.40, insert feather key 94.02,

mount impeller 23.50 and spacer 10.90.

6.

Screw set screws 90.21 in cover 16.10. Fit

cover and fasten to shaft seal housing 47.10
using nuts 92.02 and washers 55.02.

7.

Insert feather key 94.01, mount impeller

23.00 and hold in position with lock washer
93.10 and nut 92.20.

8.

Screw vent tube 71.10 complete with union

73.10, stop plug 75.70 and sleeve 73.11 in
the shaft seal housing.

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Troubleshooting

Page 1 of 1

Chapter 8

8. Help in case of trouble

8.1

Use of trained staff

Trouble shooting must be undertaken only by appropriately trained personnel.

8.2

Symptoms, causes and remedies

Symptom

Cause

Output too low

- Counter pressure too high.

- Pump or pipeline, resp., not completely
filled.
- Suction lift too high or positive suction
head too low.
- Sealing gap too large beause of wear.
- Wrong sense of rotation.
- Casing or suction line leaky.

Pump loses its prime or does

not prime

- Pump casing, shaft seal, foot valve or

suction line leaky..
- Suction lift too high or positive suction
head too low.
- Loose or jammed particles in the
pump.
- Lliquid quantity in the pump not sufficient
- Air venting tube clogged
- Counter pressure too high for air ejection
- Casing screws not correctly
tightened.

Leakage of the pump

- Mechanical seal leaky

- Joints defective

Temperature rise in the pump

- Pump or pipeline not completely filled.

- Suction lift too high or positive suction
head too low.
- Pump is running against closed gate.

Pump runs unquiet or noisy

- Pump or pipeline not completely filled.

- Suction lift too high or positive suction
head too low..
- Pump is not properly leveled on the floor
or is
distorted
- Foreign matters in the pump.

Motor protection switch

switches off.

For local contact details:

www.sterlingfluidsystems.com

Remedy
Check the plant for contamination. Re-set
the operating point.
Vent and fill the pump as well as the
suction or inflow line, resp.
Check the liquid levels, open the shut-off
elements at suction side.
Clean the filters and dirt traps installed at
suction side.
Replace the worn out parts.
Modify the motor connection.
Replace the casing seal.
Check the flange connections
Replace the casing seal.
Check the shaft seal.
Check the flange connections..
Check the liquid levels, open the shut-off
elements at suction side.
Clean the filters and dirt traps installed at
suction side.
Open and clean the pump.
Fill the pump properly
Clean the air venting tube
Check the operating conditions of the
installation
Check the tightening torque of the casing
screws.
Check the condition of the mechanical
seal. If necessary, replace it.
Replace the joints.
Vent and fill the pump as well as the
suction line or inflow line, resp.
Check the liquid levels, open the shut-off
elements at suction side.
Clean the filters and dirt traps installed at
suction side.
Open the shut-off element at discharge
side.
Vent and fill the pump as well as the
suction line or inflow line, resp.
Check the liquid levels, open the shut-off
elements at suction side.
Clean the filters and dirt traps installed at
suction side.
Check the pump installation
Disassemble and clean the pump.

- Pump is not properly leveled or is

distorted.

Check the pump installation.

- The admissible operating conditions were

not complied with.
- Loose or jammed parts in the pump.

Observe the operating conditions stated in

the data sheet.
Open and clean the pump.

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV 2001)

Technical data

Page 1 of 4

Chapter 9

9. Technical Data
For technical information about the pump or pump

Direction of rotation:

set, which is not described in this chapter, see the

Clockwise seen from the drive end of the pump.

specific data sheet. Note that data relating to a

specific order may conflict with information

Materials of construction, and of shaft seals:

provided here. In any such case, the order

See Chapter 2.4.

specific information will override data provided in

the general technical documentation.
Vibrations:
Pressure component operating limits:

ULN range pumps comply with VDI 2056 and ISO

5199 Class K for pumps with a driving power of up

Material

Temperature

OA/OC/3B

-40C to 120C

Pressure
16 bar
10 bar

Sizes
32125 to 80315
100200 to 125250

to 15 kW and Class M with a driving power of

more than 15 kW
Noise levels:

Shaft sealing operating limits:

The noise levels of the pump comply with the

Shaft sealing execution
AAE
AA1

Temperature range
-40C to + 120C
-40C to + 140C

Directive 001/30 - 1992 of the EUROPUMP

Commission.
The following table provides approximate values:

LWA (dB)

ATTENTION

All indicated operating limits are not valid

for all liquids which can be pumped. See
technical data or delivery note.

Flange locations:
Axial suction flange, discharge flange radially

P (kW)

upwards.

pump without motor

Flanges:

Note that additional noise can be generated by:

Material design 0A, 0C, 3B : DIN 2533 PN16 /

2532 PN10

1)

Flanges drilled according to ANSI 150 can be

supplied.
1)

the driver.

a possible misalignment of the coupling.

pipework (note: the larger the pipe diameter,

the lower the pipe noise).

100200 to125250

For local contact details:

www. sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Techical Data

Page 2 of 4

Chapter 9

Permissible branch forces and moments:

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

Material execution 0A / 0C / 3B:

End branch x-Axis

Top branch z-Axis

DN

Fy

Fz

Fx

My

Mz

Mx

flanges

(N)

(N)

(N)

(N)

(Nm)

(Nm)

(Nm)

(Nm)

32

500

625

550

975

450

525

650

950

40

500

625

550

975

450

525

650

950

50

675

825

750

1300

500

575

700

1025

65

1025

1250

1125

1975

575

650

800

1175

80

1025

1250

1125

1975

575

650

800

1175

100

1350

1675

1500

2625

625

725

875

1300

125

2025

2500

2250

3925

875

1025

1250

1825

50

750

675

825

1300

500

575

700

1025

65

1125

1025

1250

1975

575

650

800

1175

80

1125

1025

1250

1975

575

650

800

1175

100

1500

1350

1675

2625

625

725

875

1300

125

2250

2025

2500

3925

875

1025

1250

1825

150

2250

2025

2500

3925

875

1025

1250

1825

For local contact details:

www. sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Techical Data

Page 3 of 4

Chapter 9

Maximum permissible speeds at 50 Hz:

Size

Characteristic Nominal speed

Maximum permissible speed

rpm

design

rpm

2900

2900

1450

1450

2900

2900

40250

1450

1800

40250

2900

2900

40315

1450

1800

2900

2900

50250

1450

1800

50250

2900

2900

50315

1450

1800

2900

2900

1450

1800

2900

2900

80200

1450

1800

80250

2900

2900

1450

1800

100200

2900

2900

100200

1450

1800

100250

2900

2900

1450

1800

0A, 0C, 3B

32125
32160
32200
32250
32250
40125
40160
40200

50125
50160
50200

65125
65160
65250
65250
65315
80160
80200

80250
80315

100250
100315
125250

For local contact details:

www. sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Techical Data

Page 4 of 4

Chapter 9

Operating range:
(Continuous operation)

0,3 Qopt < Q < 1,1 Qopt

0,5 Qopt < Q < 1,1 Qopt

Sizes
32125 to 80315
100315
100200 to 100250
125250

This operating range is applicable if waterlike liquids are pumped. If liquids having distinctly different physical
properties are handled, it may be necessary to narrow the permissible operating range.
See the specific performance curve for more details.

For local contact details:

www. sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Annex

Page 1 of 5

Chapter 10

10. Annex
10.1

Connections

III : air vent pipe connection

UAL : leakage connection

Size
32125
32160
32200
32250
40125
40160
40200
40250
40315
50125
50160
50200
50250
50315
65125
65160
65200
65250
65315

III

Ue

Ue : drainage

UAL

G1/4

G3/8

G1/4

80160
80200
80250
80315

G3/8

100200
100250
100315
125250

Drawings are indicative only.

10.2

Table of Dimensions

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Annex

Page 2 of 5

Chapter 10

All dimensions in mm

Size

DNA

DNE

32125

50

32160
32200

50
50

80

50

50

100

65

32

32250

15
80

40160
40

360

50

100

40250

65

40315

65

125

50125

18

470

32,5

50

50160
50200

25

40125

40200

100

50

15

360

125

140

132
160

160
180

180

225

112

140

132

160

160

180

180

225

225

250

132

160

65

18

80

100

65250

15
80

470

225

225

280

160

180
200

180

225

200

250

225

280

360
40
470

65315

18

80160

360
65
80

100

m2

100

70

125

95

100

87

73

125

100

100

180

125

50

80

125

18

470
62,5
75

150

87
125

70

95

n1

n2

190

140

240

190

320

250

210

160

240

190

265

212

320

250

345

280

240

190

265

212

320

250

345

280

280

212

320

250

15

d1

267

80

24

50

27

342

100

32

80

35

10

267

80

24

50

27

340

100

32

80

35

10

267

80

24

50

27

340

100

32

80

35

10

24

50

27

32

80

35

10

24

50

27

32

80

35

10

70

200
250
200
225
250

95

73

87

225

15

140
125

m1

73

180

180
65

65125
65160

80250
80315
100200
100250
100315
125250

112

h3

200

50315

80200

h2

160

50250

65200

h1

160

120

125

95

160

120

73

250

360

280

400

315

320

250

345

280

400

315

267

19

15

80

340
267

100

280
315
87

280

19

340
120

315
355

Flange connections acc. to DIN 2501 PN 16 and PN 10

DNA/DNE

32

40

50

65

80

100

125

150

D
k
d2 x number

140
100
18x4

150
110
18x4

165
125
18x4

185
145
18x4

200
160
18x8

220
180
18x8

250
210
18x8

285
240
22x8

10.3 Parts list

For local contact details:
www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Annex

Page 3 of 5

Chapter 10

When ordering spare parts give the following information: position number, the complete pump designation
and the serial number, which can be found on the nameplate fixed to the pump.
Pos. Nr.
10.20
10.90*
11.40*
16.10
18.30
21.00*
23.00*
23.50*
32.00*
32.10*
33.00
36.00
40.00*
42.10*
43.30*
47.10
48.50
52.50*
54.50*
55.00
55.01
55.02
63.60
71.10
73.10
73.11
75.70
90.10
90.11
90.12
90.21
90.40
90.42
90.30
90.31
92.01
92.02
92.20*
93.10*
94.00*
94.01*
94.02*

Description

Volute casing
Intermediate piece
Intermediate piece
Cover
Support foot
Shaft
Impeller
Vane wheel impeller
Inclined ball bearing
Grooved ball bearing
Bearing bracket
Bearing cover
Joint
Radial shaft seal ring
Mechanical seal
Shaft seal casing
Locating ring
Spacer
Bearing bush
Disc
Disc
Disc
Grease nipple
Pipe
Pipe union
Socket
Orifice plate
Hexagon screw
Hexagon screw
Hexagon screw
Stud
Grub screw
Orifice plate
Screwed plug
Screwed plug
Hexagon nut
Hexagon nut
Hexagon nut
Lock washer
Key
Key
Key

*Recommended spare parts

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Annex

Page 4 of 5

Chapter 10

ULN 32125 to 125250

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

Annex

Page 5 of 5

Chapter 10

COPYRIGHT WARNING
Please read this notice
The material you are viewing in this document is protected
by Copyright and may only be used in accordance with
Copyright, Designs and Patent legislation.
You are not permitted to copy - either in full or in
part - nor substantially extract, reproduce or re-use any
of the contents of this document in any material form or in
any medium without permission from the Copyright
holders or their assignees. Any unlawful use of the
material in this document may result in claims for civil
remedies, including an injunction to restrain further use
and a claim for damages; or may result in criminal penalties.

For local contact details:

www.sterlingfluidsystems.com

In the search to improve continuously its products,

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

(Sterling Fluid Systems BV) 2001

SIHI SuperNova Program

Supplementary operating instructions in accordance to EC directive
94/9/EC (ATEX) for the intended use in potentially explosive
atmospheres of the following pumps types, manufactured by
Sterling Fluid Systems (Spain), S.A.:
ZLN, ZLK and ZLI (Industrial Pumps)
ULN (Self Priming Pumps)
ZTN, ZTK and ZTI (Thermal Oil Pumps)
ZHN, ZDN, ZEN and ZLI (Hot Water Pumps)

These supplementary operating instructions give only general instructions for the
use of pumps in conditions that need explosion protection. The operating
instructions of the specific pump must be taken into consideration as well.
Contents

Page

General objective

2
2.1
2.2
2.3
2.4

Safety issues
Identification of safety symbols in the supplementary operating instructions
Compliance with regulations
Qualification and training of personnel
Safety instructions for maintenance, inspection and installation work

2
2
2
2
3

3
3.1
3.2
3.2
3.4

Instructions referring to design of pump and accessories

General
Pump pressure containment components
Coupling, coupling guard
Belt drive

3
3
3
3
3

4
4.1
4.2
4.3
4.4

Instructions referring to installation and start-up of pump sets

Coupling
Connection to power supply
Earthing
Belt drive

3
3
3
3
3

5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9

Instructions concerning operation and servicing

Unauthorised modes of operation
Explosion protection
Pump filled and vented
Marking
Fluid pumped
Checking of direction of rotation (see also pump-specific operating manual)
Pump operating mode
Temperature limits
Maintenance

3
3
3
4
4
4
4

5
5
6

General Objective

Pumping systems can be operated in hazardous areas. It is the obligation of the operator to define the zone and to
select the pump with the correct category for this zone.
The pump installation and operation must take the Operating Instructions into accounts that are described in these
supplementary operating instructions. They contain important information for safe and reliable pump operation in
hazardous areas. This information plus all information given for all components of the system (e.g. the operating
instructions for the pump) are of vital importance to avoid risks.
These supplementary operating instructions do not take into account national nor local regulations; the operator must
ensure that such regulations are strictly observed by all, including the personnel in charge of the installation.
For any further information or instructions exceeding the scope of this manual or in case of damage please contact
Sterling Fluid Systems nearest customers service.

Safety issues

These supplementary operating instructions contain fundamental information concerning all actions with pumping
systems, when operated in hazardous areas like: installation, inspection, operation, monitoring and maintenance.
Therefore these and all other instructions with related to safety must be known and available with easy access to all
personnel, which is involved in the above stated actions.
Not only must the general safety instructions established in this chapter on Safety issues be complied with, but also
the safety instructions outlined under specific headings as well as the safety instructions contained in the specific
operating manual of the specific pump.
2.1 Identification of safety symbols in the supplementary operating instructions
In these supplementary operating instructions the safety instructions related to explosion protection are marked with:

The sign

is used to highlight safety instructions where non-compliance may pose a damage to the pump and its functions.
2.2 Compliance with regulations
It is imperative to comply with the safety instructions contained in these supplementary operating instructions, the
operating instructions of the pump type concerned, the relevant national and international explosion protection
regulations, health and safety regulations and the operators own internal work, operation and safety regulations.
Ex symbol relates to additional requirements, which must be complied with when the pump is operated in
hazardous areas.
In addition the following must be observed:
If the pumps / units are located in hazardous areas, it is imperative to make sure that the correct category of
pump and equipment is selected and that unauthorised modes of operation are prevented. Non-compliance may
result in first: increased risk of explosion and second: the specified temperature limits might be exceeded.

Non-compliance with these safety instructions may also result in the loss of any rights to claim damages.
In addition to the hazards indicated in the operating manual of the relevant pump type,

Non-compliance may also result in hazards to persons by explosion.

2.3 Qualification and training of personnel
The personnel responsible for or involved in the installation, the operation, maintenance and inspection of the pump
and the unit must be adequately qualified to carry out these works in hazardous areas.
The scope of responsibility and supervision of the personnel must be exactly defined by plant management. If the
staff does not have the necessary knowledge, they must be trained and instructed. The pump manufacturer or
supplier on behalf of the plant management may perform this task. Moreover, plant management must ensure that
the contents of the operation instructions are fully understood by plant operators and other relevant personnel such
as maintenance staff.

Page 2

2.4 Safety instructions for installation work, inspection operation and maintenance
The operator is responsible to assure that all installation work, inspection, operation and maintenance must be
carried out by authorised and qualified specialist personnel, which is thoroughly familiarised with the pump operating
instructions and these supplementary operating instructions.
If necessary, additional explosion protection regulations must be considered.

Instructions concerning design of pump and accessories

3.1 General
The pumps and the accessories for installations in hazardous areas must comply with the relevant category of
mechanical and electrical equipment.
Some details are pointed out below:
3.2 Pump pressure containment components

For handling inflammable fluids, the pump pressure containment components must be made of ductile
material.
3.3 Coupling, coupling guard
The accident prevention regulations require, that pump drives must not be operated without a coupling guard. If a
customer specifically decides, not to include a coupling guard in our delivery, then the operator must provide such
coupling guard himself. The coupling must be selected and sized in accordance with the instructions of the coupling
manufacturer. It is important to make sure that the materials selected for coupling and coupling guard are nonsparking in the event of mechanical contact. Sterling Fluid Systems scope of supply meets this requirement.
In hazardous areas coupling guards must be of non-sparking material, whereby the coupling material must be
considered.
3.4 Belt drives
Belts must include some electrically conductive material.

Instructions concerning installation and start-up of pump sets

In addition to the normal installation instructions, the specific criteria for explosion proof are listed below:
4.1 Coupling
The coupling must be installed, started-up and operated in accordance with the operating instructions of the
coupling manufacturer. Misalignment of the coupling may result in inadmissible temperatures at the coupling and
pump and motor bearings. It has to be ensured, that the half couplings are correctly aligned at all times.
4.2 Connection to power supply
Only a properly trained electrician must effect connection to the power supply. The available main voltage
must be checked against the data on the motor rating plate and an appropriate start-up method must be selected.
It is strongly recommend to use a motor protection device (motor protection switch).
In hazardous areas, compliance with national and local regulations form an additional requirement for
electrical connections.
4.3 Earthing
To eliminate risks due to electrostatic charging, the pump set must be earthed directly or through an earthing
line.
4.4 Belt drive
Belt-driven pump sets must always be earthed. The condition of the belts must be checked regularly.

Page 3

Instructions concerning operation and maintenance

5.1 Unauthorised modes of operation

The warranty relating to the operating reliability and safety of the unit supplied is only valid if the equipment is used in
accordance with its designated use as described in the following sections of this supplementary operating manual
and the pump-specific operating manual. The limits stated in the data sheet must not be exceeded under any
circumstances.
Any operation of the pump outside the permissible operating range and any unauthorised modes of operation
may result in the specified temperature limits being exceeded (see section 5.8).
5.2 Explosion protection
If the pumps / units are installed in hazardous areas where compliance with EC directive 94/9/EC is required,
the measures and instructions given in the following sections 5.3 to 5.9 must be carried out with no excuse, to ensure
explosion protection.
5.3 Pump filled and vented
Especially dry running of a pump results in friction and non-allowed temperature rise. Therefore precautions have to
be taken to prevent dry running.

It is necessary that the system of suction and discharge lines and thus the wetted pump internals including
seal chamber and auxiliary systems are completely filled with the fluid to be handled at all times during pump
operation, so that an explosive atmosphere is prevented.
If the operator cannot warrant this condition, appropriate monitoring devices must be used.
Improper installation (e.g. vertical installation) may impair the self-venting properties of the seal chamber, so that gas
bubbles may be collected in the pump and cause the mechanical seal to run dry.
High negative pressure on the suction side (e.g. due to clogged suction-side strainers or low system pressure)
may result in air intake at the shaft seal forming gas bubbles in the pump. This may also cause the mechanical seal
to run dry. Suitable monitoring facilities shall be installed, if necessary.
For design-inherent reasons, however, it is not always possible to exclude the existence of a certain residual
volume not filled with liquid after the pump has been filled prior to start of operation. However, once the motor is
started up the pumping effect will immediately fill this volume with pumped fluid.

It is imperative to make sure that the seal chambers and auxiliary seal systems are properly vented from air and filled
with liquid.

5.4 Marking
The Ex marking on the pump only refers to the pump part, i.e. the coupling and motor must be considered
separately. The coupling must have an EC Declaration of Manufacturer and the EC marking. The driver must be
treated separately.
Example of marking on the pump part:
CE Ex II 2 G c T1 - T5
The safety instructions published in section 5.8 must be complied with.
5.5 Fluid handled
Abrasive particles in the fluid handled may erode the casing walls to such an extent that fluid may escape.
When handling inflammable media, it has to be ensured that the fluid does not contain any abrasive particles, or that
the pump is regularly checked with respect to erosion.
5.6 Checking the direction of rotation (see also pump-specific operating manual)
If the explosion hazard also exists during the installation phase, the direction of rotation must never be
checked by starting up the unfilled pump unit, even for a short period, to prevent temperature increases resulting from
contact between rotating and stationary components. If it is not possible to fill the pump, the direction of rotation must
be checked with the pump / motor coupling removed.

Page 4

5.7 Pump operating mode

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

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

Specific heat of liquid [J / kg K]

2
Acceleration due to gravity [m /s]
Pump head [m]
Temperature of fluid handled [ C]
Temperature of casing surface [ C]
Pump efficiency [-]
Temperature difference [ C]

5.8 Temperature limits

In normal pump operation, the highest temperatures are to be expected on the surface of the pump casing, at
the shaft seal, at the bearing areas and at the pump shaft end in close coupled executions.
Unless the pump is equipped with an additional heating facility, the surface temperature at the pump casing will
correspond to the temperature of the fluid handled, assuming that the pump surface is freely exposed to the
atmosphere.
In any case, responsibility for compliance with the specified fluid temperature (operating temperature) lies with the
plant operator. The maximum permissible fluid temperature depends on the temperature class to be complied with.
The following limits for the maximum permissible fluid temperature must be observed for the individual temperature
classes as per EN13463-1 given below (temperature increase in the shaft seal area, if any, has been taken into
consideration):
Temperature classes
as per EN 13463-1:

Permissible
surface
temperature

Max. permissible fluid

temperature for compliance
with temperature class

T5
T4
T3
T2
T1

100 C
135 C
200 C
300 C
450 C

80 C
115 C
180 C
280 C
Temperature limit of pump

Safety note:

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

Page 5

Because of the very close contact between pumps and motors in close coupled design (ZLK and ZLI,
Industrial Pumps; ZTK and ZTI, Thermal Oil Pumps; and ZLI, Hot Water Pumps), there is a thermal influence
between pump and motor.
Especially for motors with protection type EExe (increased safety) the possibility exists that the declaration of
conformity looses its validity, as for the EC type examination an ambient temperature of 40C is taken as a basis.
This admissible ambient temperature could be exceeded in the area of the motor flange when pumping hot liquids.
In the event of fluid temperature above 80C, the temperature category of the unit / set is determined by the pump not
by the motor.
The motor is usually rated for continuous operation at the data indicated in the technical data. Frequent motor
start-ups may result in increased surface temperatures at the motor. Contact the motor manufacturer, if necessary.
Based on ambient temperatures of max. 40 C and assuming that the pump unit is properly serviced and operated
and that the surfaces in the bearing area are freely exposed to the atmosphere, compliance with temperature class
T4 is warranted for surfaces in the area of the rolling element bearings.
If temperature classes T5 (100C) and T6 (85C) have to be complied with, special measures may have to taken with
regard to bearing temperature. In such cases, and if ambient temperatures are higher, contact the manufacturer.
Operators errors or malfunctions may result in substantially higher temperatures. Please refer to section 5.1 in this
context.
Mechanical seals may exceed the specified temperature limits if run dry. Dry running may not only result from
an inadequately filled seal chamber, but also from excessive gas content in the fluid pumped.
Pump operation outside the specified operating range may also result in dry running.
Shaft seals shall be regularly checked for leakage.
The above stated and also stated in other paragraphs related to the mechanical seal, is also applicable for
any shaft sealing execution (i.e. packing rings, lip seal rings, etc.)
In any case the operator has the responsibility to check the real compatibility between the normal leakage of the fluid
and the atmosphere in the case of shaft sealing made by packing rings.
It has to be verified, that V-rings are properly fitted to the shaft. Only proper contact should be exist between
the sealing lip and the shaft.

5.9 Maintenance

Only a pump set, which is properly operated and maintained in perfect technical condition, will give safe and
reliable operation.
This also applies to the reliable function of the rolling element bearings whose actual lifetime largely depends on the
operating mode and operating conditions.
Regular checks of the lubricant and the running noises will prevent the risk of excessive temperatures as a result of
bearings running hot or defective bearing seals.
The correct function of the shaft seal must be checked regularly.
Any auxiliary systems installed must be monitored, if necessary, to make sure they function correctly.
Static sealing elements shall be regularly checked for leakage.
The coupling guard and any other guards of fast rotating components must be regularly checked for deformation and
sufficient distance from rotating elements.
Regularly verify the correct position and the status of plastic components exposed to the atmosphere.
It is strongly recommended to draw up a maintenance schedule, which includes the above-mentioned points.

In case of repair only original Sterling Fluid Systems spare parts must be used, which comply with the
corresponding EC Directives.

Sterling Fluid Systems

In the search to improve continuously its products, Sterling Fluid Systems
reserves the right to modify its products at any time without prior notice
For local contact details: www. sterlingfluidsystems.com

Page 6

Sterling Fluid Systems (Spain), S.A.

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

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

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

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

EN 733

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

In the actual version.

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

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

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

J. A. Cobo
June 10, 2003