Type Series: DSC

Single Stage Horizontal Centrifugal Pump

Operating Manual
Manual No. DSC003 (2020)

These operating instructions contain fundamental information

and precautionary notes. Please read the manual thoroughly prior to
installation of unit, electrical connection and commissioning. It is
imperative to comply with all other operating instructions referring to
components of individual units.

It is imperative to keep the operating instructions close to the

unit or on the unit itself!

DBR Pumpen Limited

Office 4, 219 Kensington High Street, Kensington, London, England W8 6BD
Website: www.dbrpumpen.com Email: [email protected]
 Installation

1. Safety
These oper ating i nstructions c ontain f undamental In particular, non -compliance c an, f or e xample, r esult
information which m ust be c omplied w ith dur ing in:
installation, o peration and m aintenance. T herefore t his - failure of important machine / unit functions
operating manual must be read and understood both by - failure of pr escribed m aintenance and s ervicing
the installing per sonnel and the r esponsible trained practices
personnel / oper ators pr ior t o i nstallation and - hazard t o pe rsons by el ectrical, m echanical and
commissioning, and it must always be k ept c lose to t he chemical effects
location of o peration of the m achine / uni t for eas y - hazard to the environment due to leakage of
access. hazardous substances.
Not only must the general safety instructions laid down in
this c hapter on “ Safety” b e c omplied w ith, but al so t he 1.4 Safety Awareness
safety instructions outlined under specific headings. It is i mperative t o c omply w ith t he s afety i nstructions
contained i n t his m anual, the r elevant national heal th
1.1 Marking of Instructions in the Manual and safety regulations and the operator’s own internal
The s afety instructions c ontained i n this m anual w hose work, operation and safety regulations.
non-observance m ight c ause haz ards t o per sons ar e
specially marked with the general hazard sign, namely
1.5 Safety Instructions for the Operator / User
- Any hot or c old c omponents t hat c ould pos e a
safety sign in accordance with DIN 4844 - W9. hazard m ust be equi pped w ith a gua rd by t he
operator.
- Guards which are fitted to prevent accidental
The electrical danger warning sign is Safety sign contact with moving parts (e.g. coupling) must not
in accordance with DIN 4844 - W8. be removed whilst the machine is operating.
- Leakages ( e.g. at t he s haft s eal) of haz ardous
media handled (e.g. explosive, toxic, hot) must be
The w ord is us ed t o i ntroduce s afety contained s o as t o a void any danger t o per sons
instructions whose non-observance may lead to damage and t he env ironment. P ertinent legal provisions
to the machine and its functions. must be adhered to.
Instructions attached directly to the machine, e.g. the - Electrical haz ards m ust be el iminated. ( In t his
manual. respect r efer t o t he r elevant s afety r egulations
- arrow indicating the direction of rotation applicable t o di fferent c ountries and/ or t he l ocal
- marking for f luid c onnections m ust al ways be energy supply companies.)
complied w ith and be k ept i n per fectly l egible
have been drained. 1.6 Safety Instructions for Maintenance, Inspection
and Installation Work
1.2 Personnel Qualification and Training The operator is responsible for ensuring that all
All per sonnel i nvolved in t he oper ation, m aintenance, maintenance, inspection and installation work be
inspection an d i nstallation of t he m achine m ust be fully performed by authorized, qualified specialist personnel
qualified to carry out the work involved. who are thoroughly familiar with the manual.
Personnel r esponsibilities, c ompetence and s upervision The pump must have cooled down to ambient
must be clearly defined by the operator. If the personnel temperature. Pump pressure must have been released
in ques tion i s not al ready i n pos session of t he r equisite and the pump must condition at all times.
know-how, a ppropriate t raining and i nstruction m ust be Work on t he m achine m ust be c arried o ut onl y dur ing
provided. I f r equired, t he operator m ay c ommission t he standstill. T he s hutdown procedure des cribed i n the
manufacturer / s upplier t o t ake c are of s uch t raining. I n manual f or t aking t he m achine out of s ervice m ust be
addition, the operator is responsible for ensuring that the adhered to without fail.
contents of the oper ating i nstructions ar e f ully s trictly Pumps or p ump uni ts h andling m edia injurious to
observed by al l, including t he per sonnel c alled i n f or health must be decontaminated.
installation.
Immediately following completion of the work, all
1.3 Non-compliance with Safety Instructions safety-relevant and pr otective de vices m ust be r e-
installed and/or re-activated.
Non-compliance w ith s afety i nstructions c an j eopardize
the safety of personnel, the environment and the Please observe all instructions set out in the chapter on
machine i tself. N on-compliance w ith t hese s afety “Commissioning” before returning the machine to
instructions will also lead to forfeiture of any and all rights service.
to claims for damages.

Page 1
 Installation

1.7 Unauthorized Modification and Manufacture of

Spare Parts
Modifications or alterations of the machine ar e only
permitted after consultation with the manufacturer. Original
spare par ts and ac cessories aut horized by t he
manufacturer ensure safety.
The us e of ot her par ts c an i nvalidate any l iability o f t he
manufacturer for consequential damage.

1.8 Unauthorized Modes of Operation

The w arranty r elating to the oper ational r eliability and
safety o f t he pum p / uni t s upplied i s only valid i f the
machine is used in accordance with its designated use as
described i n t he f ollowing s ections of these oper ating
instructions. The limits stated in the datasheet must not be
exceeded under any circumstances.

2 Transport and Interim Storage

2.1 Transport
Transport of t he uni t r equires pr oper pr eparation and
handling. A lways m ake sure t hat t he pum p or t he uni t
remains in position during transport and cannot slip out of
the t ransport suspension a rrangement. Do not us e l ifting
slings on t he f ree s haft end of t he pum p or on t he motor
eyebolt.
If t he pum p / uni t s lips out of t he s uspension
arrangement, it may cause personal injury and damage to
property.
2.2 Interim Storage / Preservation
When t he uni t is t emporarily put i nto storage, onl y t he
wetted low alloy components (e.g. nodular cast iron GG25,
etc.) m ust be pr eserved. C ommercially av ailable
preservatives can be used for this purpose. Please
observe t he m anufacturer’s instructions f or
application/removal.
The unit / pump should be stored in a dry room where the
atmospheric humidity is as constant as possible.
If stored outdoors, the unit and crates must be covered by
waterproof material to avoid any contact with humidity.

Protect al l s tored good s agai nst hum idity, di rt,

vermin and unauthorized access!
All openings of the assembled unit components are closed
and m ust onl y be op ened w hen r equired dur ing
installation.
All bl ank par ts and s urfaces of t he p ump ar e oi led or
greased ( silicone-free oi l and gr ease) t o pr otect them
against corrosion.

Page 2
 Installation

3 Installation at Site
3.1 Safety Regulations

Electrical equipment operated in hazardous

locations must comply with the explosion protection
regulations. This is indicated on the motor rating
plate.
If the equipment is installed in hazardous locations,
the applicable local explosion protection regulations
and the regulations of the test certificate supplied with
the equipment and issued by the responsible approval
authorities must be observed and complied with. The Fig. 3.1: Aligning a flexible coupling without spacer
test certificate must be kept close to the location of sleeve
operation for easy access (e.g. foreman’s office).
The radial and axial deviation between the two coupling
halves shall not exceed 0.1 mm.
3.2 Checks to be Carried out Prior to Installation
All structural work required must have been prepared Improper al ignment of t he uni t c an c ause
in accordance with the dimensions stated in the damage to both the coupling and the unit itself!
dimension table / installation plan. The foundations
shall have sufficient strength (min. B 15) to DIN 1045. 3.4 Connecting the Piping
Make sure that the foundation has set firmly before placing
the unit on it. Its surface shall be truly horizontal and even. Never us e t he pum p i tself as an anc horage
point for the piping.
3.3 Installing the Pump/Unit The i nlet l ine m ust be l aid w ith a d ownward s lope
towards the pump to avoid the formation of air pockets.
After pl acing the uni t on t he f oundation, al ign i t w ith t he
help of a spirit level placed on the shaft/discharge nozzle. The pipelines must be anchored in close proximity to the
The c orrect di stance bet ween t he c oupling hal ves as pump and c onnected w ithout t ransmitting any s tresses
specified in the installation plan must be observed. Shims or s trains. T he pum p m ust not bear t he w eight of t he
shall be f itted bet ween t he bas eplate/ f oundation f rame pipelines.
and the foundation itself; they shall always be i nserted to The nom inal di ameters of s hort pi pelines s hall be at
the l eft and right of t he foundation bol ts and i n c lose least equal t o t he nom inal di ameters of t he pu mp
proximity to these bolts. nozzles. For long pipelines the most economical nominal
Tighten the foundation bolts evenly and firmly. diameter has to be determined from case to case.
Baseplates up t o 400 m m w ide m ade of c hannel s ection Adapters t o l arger di ameters s hould h ave a di ffuser
steel ar e t orsion-resistant i n t heir ow n r ight and need not angle of appr ox. 8 i n or der t o av oid any i ncrease i n
be grouted. After fastening, baseplates more than 400 mm pressure losses.
wide made of folded steel plate must be grouted up to the It is recommended to install check and shut-off elements
upper edge v ia t he hol es Ø 120 m m) i n t he f olded plate, in the system, depending on the type of plant and pump.
using low-shrinkage concrete.
Thermal ex pansions of t he pi pelines m ust be
compensated by appr opriate m easures s o a s not t o
3.3.1 Aligning the Pump/Drive impose any extra loads on the pump.
After fastening the baseplate on the foundation, An ex cessive, i mpermissible i ncrease i n t he
the c oupling must be t horoughly c hecked and t he p ump pipeline forces may cause leaks on the pump where the
set be r ealigned ( at t he m otor), i f r equired. P rior t o medium handled can escape into the atmosphere.
checking the alignment/realignment, loosen coupling bolts Danger of life when hot media are handled!
and re-tighten without transmitting any stresses or strains.
The f lange c overs on t he pum p s uction and di scharge
Coupling check and r ealignment must be effected even if nozzles m ust be r emoved pr ior t o i nstallation i n the
pump and m otor ar e s upplied c ompletely as sembled and piping. Before commissioning new installations,
aligned. thoroughly c lean, f lush a nd bl ow t hrough al l vessels,
The pump set is correctly aligned, if a straight-edge placed pipelines and connections.
axially on both coupling halves is the same distance from Often w elding beads , s cale and ot her i mpurities onl y
each s haft at al l poi nts ar ound t he c ircumference. M ake come off after a certain period of operation. Fit a strainer
sure t o t urn t he m easuring poi nt by han d al l t he time. I n in t he s uction l ine t o pr event t hem from ent ering t he
addition, the di stance bet ween t he t wo c oupling hal ves pump. The total cross section of the holes in the strainer
must remain the same all around the circumference. Use a shall be three times the cross section of the pipe line in
gauge to verify, for example (see Figures 3.1). order t o av oid excessive pressure loss ac ross the
strainer due t o c logging. Conical s trainers w ith l aid-in
wire mesh having a mesh width of 1.25 mm and a wire
diameter of 0.4 mm, of corrosion-resistant material, shall
be used.

Page 3
 Installation

For voltage 380/695V 50Hz (440/830V 60Hz) with power

from 2.2kW and higher:

Fig. 3.4 Direct on line – Delta connection

Fig. 3.2 Conical strainer for the suction line
If r equired, connect the P TC r esistors as per D IN
44081/44082 w ith t he t ripping uni t i n ac cordance with
3.4.1 Auxiliary Connections fig. 3.5.
The di mensions and l ocations of t he aux iliary c onnection
required f or t he pum p ( leakage c onnection) ar e i ndicated
on the installation plan or piping layout.

This c onnection i s r equired f or pr oper

functioning of t he pum p and i s t herefore of v ital
importance! Fig. 3.5 Connecting the PTC resistors
3.5 Final Check 3.6.2 Setting the Time Relay
Re-check t he al ignment a s des cribed i n s ection 3 .3.1. I t Make s ure t hat i n t he c ase of three-phase m otors w ith
must be easy to rotate the coupling/shaft by hand. star-delta starting method, s witching ov er f rom s tar t o
delta w ill be effected at very s hort i ntervals. P rolonged
The alignment check must be repeated at switch-over intervals will result in pump damage.
operating t emperature. C heck t he i ntegrity and p roper
functioning of all connections. Setting of the time relay for star-delta starting:
3.6 Connection to Power Supply Motor rating Y time to be set
≤ 30kW < 3 sec.
Connection to the power supply must be effected by
a trained electrician only. > 30kW < 5 sec.
Check av ailable m ains v oltage agai nst t he dat a on t he
motor rating plate and select appropriate start-up method. 3.6.3 Checking the Direction of Rotation
Make sure to observe the technical regulations The direction of rotation of the motor must correspond to
stipulated by the local energy supply company when the direction indicated by the arrow on the volute casing
connecting the pump to the power supply. We of the pum p ( clockwise, when v iewed f rom t he m otor
strongly recommend to use a motor protection switch. end). This can be verified by switching the pump on and
DIN V DE 0170/0171 s tipulates t hat ex plosion-proof then off again immediately.
motors, t ype of pr otection IP 54, ” increased s afety” E x If the pum p r uns i n t he w rong di rection of r otation,
EEx, temperature class T3, must always be connected via interchange any t wo pha ses L1, L2or L3 of t he p ower
a motor protection switch. cable in the motor terminal box.
3.6.1 Connecting the Motor
In c ompliance w ith D IN VDE 0530 - Part 8, t he t hree-
phase m otors ar e al ways w ired f or clockwise rotation
(looking at the motor s haft s tub). The pump’s direction of
rotation is anticlockwise (looking at the suction flange).
For t he m otor’s di rection o f r otation to match t he pum p’s
direction of r otation, t he motor m ust be c onnected as
shown in fig. 3.3 or 3.4, as applicable.
For voltage 230/415V 50Hz (277/480V 60Hz) with power
up to and include 1.5kW, use star connection as below:

Fig. 3.3 Direct on line – Star connection

Page 4
 Commissioning, Startup / Shutdown

4 Commissioning, Start-up/ Shutdown

4.1 Commissioning In the event of frost and/or prolonged shutdowns, the
pump (if handling water) must be drained or otherwise
Before starting up the pump make sure that the protected against freezing.
following requirements have been checked and fulfilled. 4.2 Operating Limits
- Make sure that the unit has been properly 4.2.1 Temperature of the Medium Handled
connected to the electric power supply and is
equipped with all protection devices. Do not operate the pump at temperatures
- Make sure that the pump has been primed with exceeding those specified on the data sheet or the
the liquid to be pumped. name plate.
- Verify the correct direction of rotation.
- Make sure all auxiliary lines are connected and 4.2.2 Switching Frequency
functioning. To prevent high temperature increases in the motor
4.1.1 Shaft Seal and excessive loads on the pump, coupling, motor,
seals and bearings, the switching frequency must not
See sections 5.4.3 and 5.5.2. exceed 15 start-ups per hour (h).
4.1.2 Priming the Pump and Checks to Be Carried 4.2.3 Minimum Flow
out
If the plant configuration is such that the pump might
Before start-up, the casing and the inlet line must be be operated against a closed discharge side valve, a
vented and primed with the liquid to be pumped. minimum flow of 25 % of Qopt. has to be ensured
The pump can be primed with clean liquid from the during this interval.
system through the inlet line. Vent the pump casing by 4.2.4 Density of the Medium Handled
opening the air vent plug. Rotate the shaft several times
by hand during priming to ensure that the pump casing is The power input of the pump will increase in proportion
completely vented (fluid escapes). After priming, screw to the density of the medium handled. To avoid over
the plug back into the vent hole. loading of the motor, pump and coupling, the density of
the medium must comply with the data specified on the
Protect electric components from escaping purchase order.
liquid! 4.3 Shutdown / Storage / Preservation
Each of our pumps leaves the factory carefully
Dry-running will result in increased wear and assembled. If commissioning is to take place sometime
must be avoided! after delivery, we recommend that the following
4.1.3 Start-up measures be taken for pump storage.
Always make sure that the shut-off element in the 4.3.1 Storage of New Pumps
discharge line is closed before the pump is started up. - New pumps are supplied by our factory duly
Only after the pump has reached full rotational speed prepared for storage. Maximum protection for up
shall the shut-off element be opened slowly and adjusted to 12 months, if the pump is properly stored
to comply with the duty point. indoors.
If the system is completely primed, start-up can take - Store the pump in a dry location.
place with the shut-off valve on the discharge side open 4.3.2 Measures to Be Taken for Prolonged
even when commissioning a new pump. Shutdown
During operation, the pump inlet pressure must not fall 1.The pump remains installed; periodic check of
below the atmospheric pressure. operation
4.1.4 Shutdown In order to make sure that the pump is always ready for
Close the shut-off element in the discharge line. If the instant start-up and to prevent the formation of deposits
discharge line is equipped with a non-return or check within the pump and the pump intake area, start up the
valve, the shut-off element may remain open, provided pump set regularly once a month or once every 3
there is back pressure in the line. months for a short time (approx. 5minutes) during
prolonged shutdown periods. Prior to an operation
Make sure the shut-off element in the inlet line is check run ensure that there is sufficient liquid available
open when switching off the pump. Switch off the drive, for operating the pump.
making sure that the unit runs smoothly down to a
standstill.
Depending on the type of installation, the pump should
have a sufficient run-down period - with the heat source
shut off until the medium handled has cooled down
sufficiently to avoid a heat build-up in the pump.
In the case of a prolonged shutdown, the shut-off valve in
the inlet line must be closed. Close the auxiliary lines.

Page 5
 Commissioning, Startup / Shutdown

2.The pump is removed from the pipe and stored

Before putting the pump into storage carry out all checks
specified in section 5.4. Then apply appropriate
preservatives:
- Spray-coat the inside wall of the pump casing,
and in particular the impeller clearance areas,
with a preservative. Spray the preservative
through the suction and discharge nozzles. It
is advisable to close the nozzles (for ex. with
plastic caps or similar).

4.4 Returning to Service after Storage

Before returning the pump to service carry out all checks
and maintenance work specified in sections 5.1 and 5.2.
In addition, the instructions laid down in the sections
on “Commissioning” (4.1) and “Operating Limits” (4.2)
must be observed.
Upon completion of the work, all safety-related and
protective equipment must be properly refitted and/or
reactivate before starting the pump set.

Page 6
 Maintenance

5 Maintenance
5.1 General Instructions 5.3 Drainage / Disposal
The operator is responsible for ensuring that all
If the pump was used for handling liquids posing
maintenance, inspection and installation work is carried
out by authorized, duly qualified staff who are thoroughly health hazards, see to it that there is no risk to persons
familiar with these operating instructions. or the environment when draining the medium. All
relevant laws must be heeded. If required, wear safety
A regular maintenance schedule will help avoid expensive clothing and a protective mask.
repairs and contribute to trouble-free, reliable operation of
the pump with a minimum of maintenance expenditure The flushing liquid used and any liquid residues in the
and work. pump must be properly collected and disposed of
without posing any risk to persons or the environment.
Work on the unit must only be carried out with 5.4 Dismantling
the electrical connections disconnected. Make sure Before dismantling, secure the pump so as to make sure
that the pump set cannot be switched on accidentally. it cannot be switched on accidentally. The shut-off
elements in the suction and discharge lines must be
Pumps handling liquids posing health hazards
closed and absolutely tight. The operator is responsible
must be decontaminated. When draining the medium,
for the perfect functioning of the shut-off valves. Special
see to it that there is no risk to persons or the care must be taken when repairing pumps installed in an
environment. All relevant laws must be adhered to. on-duty system. The pump must have cooled down to
ambient temperature. Pump pressure must have been
5.2 Maintenance released and the pump must have been drained.
5.2.1 Supervision of Operation Dismantling and reassembly must always be carried out
in accordance with the general drawing/exploded view.
The pump must run quietly and free from 5.4.1 Fundamental Instructions and
vibrations at all times. The pump must never be allowed to Recommendations
run dry. Repair and maintenance work to the pump must only be
Max. permissible ambient temperature: 40 deg C. carried out by specially trained personnel, using original
The bearing temperature may exceed ambient spare parts.
temperature by up to 50 deg C but must never rise above Observe the safety regulations laid down in section
+90 deg C (measured on the outside of the bearing Any work on the motor shall be governed by the
bracket). specifications and regulations of the respective
Prolonged operation against a closed shut-off motor supplier.
element is not permitted, in order to avoid a heat build-up
in the liquid handled.
Minimum flow required see 4.2.3.
The shut-off element in the suction line must not be
closed during operation.
Monitor the suction strainer and clean it whenever it shows
signs of clogging, to prevent the development of vacuum
in the pump’s bearing bracket and thus the risk of dry-
running of the bearing and mechanical seal.
Any stand-by pumps installed must be switched on and
then immediately off again once a week to keep them
operational.
Attention shall be paid to the correct functioning of the
auxiliary connections.

Page 7
 Maintenance

5.4.2 Preparations for Dismantling The pump shall be dismantled in the sequence given
1 Interrupt power supply. in the exploded views shown on page 9.
We recommend to place a drip pan under the whole
2 Disconnect all auxiliary supply lines.
length of the pump, which collects the medium
3 Disconnect the motor from the mains supply. flowing out during dismantling.
4 Remove the coupling guard.
5 Remove the coupling bolts. 5.4.3 Mechanical seal
In order to replace the mechanical seal, the pump
6 Shift the motor to decouple it from the pump.
must be dismantled.
7 Remove the pump cover together with bearing
housing from the pump casing. 5.5 Reassembly
8 Unscrew the impeller nut. 5.5.1 Pump
9 Remove the impeller from the pump shaft. The pump must be reassembled in accordance with
10 Put in position the seal positioning screw. the rules of sound engineering practice.
Loosen the bolts to the mechanical seal. Reassembly shall be effected in the reverse order of
dismantling. Make sure to reassemble the pump in the
correct sequence.
11 Remove the pump cover from the bearing
housing. Shift the motor to decouple it from the Additional instructions:
pump. Check the condition of the parts and replaced it
12 Carefully removed the mechanical seal accordingly if needed.
rotating part from the shaft.
13 Carefully removed the mechanical seal Clearance between wear ring and impeller -
stationary part from it seat. Diameter of the Renewal
wearing surface required
14 Wear rings in the pump casing and cover are 50 0.7 0.8
sectioned by chisel if replacement is required.
100 1.0 1.1
15 Remove the bearing cover from the bearing 150 1.1 1.2
housing. 200 1.5 1.6
16 Remove the pump shaft from the bearing 300 1.8 2.0
housing. Dimension in mm
17 Extract out the ball bearing from the pump 5.5.2 Mechanical seal
shaft.
Reassembly is done in reverse order to dismantling.
The following rules shall be observed when mounting
the mechanical seal:
- Extreme care and cleanliness.
- The protective wrapping of the contact faces
must only be removed immediately before
assembly takes place.
- Take care not to damage the seal faces and
the O-rings.
- Clean the shaft and the seat ring holder and
carefully remove any deposits

Page 8
 Maintenance

Exploded view and list of components

Mechanical Seal

Page 9
Water Piping Diagram

Cooling Water OUTLET

Outlet 3 4"
Yard Piping

INLET Aflex

3
Cooling Water Inlet 4"
45 LPM @ 1.5bar
Max Temp: 35degC
Yard Piping
 Troubleshooting

Troubleshooting

Excessive rise of temperature inside the

Excessive pump discharge pressure

Excessive leakage at the shaft seal

Pump delivers insufficient flow rate

Vibrations during pump operation

Increase in bearing temperature
Leakages at the pump
Motor is overloaded

pump

Cause Remedy
* Pump delivers against an excessively high Re-adjust duty point.
discharge
* Excessively high back pressure. Check plant for impurities.
2)
Fit a larger impeller.
Increase the speed (turbine, I.C. engine)
* * * Pump of piping are not completely vented or Vent and or Prime. Clean vent hole.
primed.
* Supply line or impeller clogged. Remove deposits in the pump and / or piping.
* Formation of air pockets in the piping. After piping layout. Fit a vent valve.
* * * NPSH available (positive suction head) is too low. Check/ after liquid level.
Install pump at a lower level.
Fully open shut-off valve in the suction line are to high.
Check any strainers installed.
Observe permissible rate of pressure fall.
* Reverse rotation. Interchange two of the phases of the power supply
cable.
2)
* Speed is too low. Increase speed.
* * Wear of internal pump parts. Replace worn components by new ones.

* * * Pump back pressure is lower than specified in the Adjust duty point accurately.
purchase order. In case of persistent overloading, turn down impeller, if
2)
necessary
* Density or viscosity of the fluid pumped is higher 2)
than stated in the purchased order.
2)
* * Speed is too high. Reduce speed.
* Defective gasket. Replace the gasket between the volute casing and the
discharge cover.
* Worn shaft seal. Fit new shaft seal.
* * * The unit is misaligned. Re-align
* * * Pump is warped of sympathetic vibrations in piping. Check pipeline connections and secure fixing of pump;
if required, reduce the distances between the pipe
clamps. Fix the pipelines using anti-vibration material.
2)
* Increased axial thrust Clean the balancing holes in the impeller.
Replace the casing wear rings.
* * Insufficient or excessive quantity of lubricant or Top up, reduce of change lubricant.
unsuitable lubricants.
* No-compliance with specified coupling distance. Correct distance according to the installation plan.
* * Motor is running on two phases only. Replace the defective fuse.
Check the electric cable connections.
* Rotor is out of balance. Clean the impeller. / Re-balance the impeller.
* Defective bearings. Fit new bearing.
* * Insufficient rate of flow. Increase the minimum rate of flow.
1)
The pump pressure must be released before attempting remedy faults on parts which are subject to pressure.
2)
Contact the supplier.

Page 10
 Operating Spares

Recommended Spare Parts

P/N Description One Year Operation Two Years Operation

201 Ball Bearing Three Six
GSM-2415 Mechanical Seal Repair Kit One Two
020 Wear Ring One Two
021 Back Wear Ring 1)see below One Two
1)
Back wear ring only used on the following model:
- DSC40-320
- DSC50-320
- DSC65-260, DSC65-320
- DSC80-200, DSC80-260, DSC80-320, DSC80-400
- DSC100-200, DSC100-260, DSC100-320, DSC100-400
- DSC125-200, DSC125-260, DSC125-320, DSC125-400
- DSC150-200, DSC150-260, DSC150-320, DSC150-400

Page 11
 Spare Part List

Pos. No. Description Quantity Material

001 Pump Casing 1 Bronze Cast Iron Stainless Steel
002 Pump Cover 1 Bronze Cast Iron Stainless Steel
003 Impeller 1 Bronze
020 Wear Ring 1 Bronze Cast Iron
021 Back Wear Ring 1 Bronze Cast Iron
050 Casing O Ring 1 NBR
080 Drain Plug & Washer (Pump Casing) 1 Carbon Steel / Copper
081 Gauge Plug & Washer (Pump Casing) 2 Carbon Steel / Copper
082 Studs & Nuts (Pump Cover) 12 HTS
101 Pump Shaft 1 Stainless Steel
103 Impeller Key 1 Stainless Steel
104 Coupling Key 1 Stainless Steel
107 Flinger 1 NBR
120 Impeller Nut 1 Bronze | Stainless Steel 316
124 Impeller Lock Washer 1 Bronze
201 Ball Bearing 3 Bearing Steel
205 Bearing Housing 1 Cast Iron
206 Bolts (Bearing Cover) 6 HTS
209 Bearing Cover 2 Carbon Steel
207 Gasket (Bearing Cover) 2 Paper
530 Oil Seal 2 NBR
540 Studs & Nuts (Seal Cover) 2 HTS
406 Support Foot 1 Carbon Steel
407 Bolt (Support Foot) 1 HTS
GSM-24 Cartridge Mechanical Seal 1 SIC/SIC/316/Kalrez6375
FXR6222 Cooler 1 SS316 / SS304

Cartridge mechanical seal, Type F02-24mm

GSM-2401 Seal cover 1 SS316

GSM-2402 Rotating Part 1 SIC
GSM-2403 Stationary Part 1 SIC
GSM-2404 Pressure Cap 1 SS316
GSM-2405 Spring 8 SS316
GSM-2406 Inner Locking ring 1 SS316
GSM-2407 Outer Locking ring 1 SS304
GSM-2408 Circlip 1 SS316
GSM-2409 O Ring 1 Kalrez6375
GSM-2410 O Ring 1 Kalrez6375
GSM-2411 O Ring 1 Kalrez6375
GSM-2412 Seal packing 1 PTFE
GSM-2413 Stud 3 SS316
GSM-2414 Stud 3 SS316
GSM-2415 Mechanical Seal Repair Kit 1

Page 12
 Electrical Motor

OPERATION & MAINTENANCE

MANUAL

FOR INDUCTION MOTOR

Page 13
 Electrical Motor

Customer Safety and Installation Instruction

Safety warning For Delta Connection:
- All operation, installation and services must be
carried out by appropriated trained personnel. We
cannot be held responsible for damage as a
result of installation or service by unqualified
personnel.
- Maximum hand lift is 20kg below shoulder, but
above ground level. Please use all lifting facilities
provided.
For Star Connection:

- Check for any damage, corrosion or loose

fasteners.
- Do not lift other equipment with motor lifting
- Check the direction of rotation when it is
points only. Make sure the eye bolts are fully
specified.
screwed before hoisted.
- Check insulation resistance between phase and
earth, and between phase with 500 volt or 1000
volt megger for 60 sec. If the reading is less than
10MΩ, it is recommended that motors are died
out or run on no load at approximately 20% of
rated volts to ensure that any internal moisture is
dried out.
- Please make sure the shaft can move freely.

- Please be careful while open the end shield for

Storage
motor with heater, because the heater may still
be alive. Heater should be cut off before open the When motors are not in operation, the following
end shield. precautionary measures should be undertaken to
- Please do not do meager ohm test for any motor ensure best performance:
with PTC Thermister. - Please store motors in the place which is high
- Please contact with our office if there are any and dry, well-ventilated without direct sun, dust or
safety concerns regarding these motor. corrosive gas.
- Please rotate the shafts with hand to make sure - Do not locate motors near to a boiler or freezer.
the shafts are free to rotate before doing any
testing on motor. - Entirely free from vibration and easy for
- For safety concern, the motor must be grounded movements.
by a proper connection to the electrical system - Motors should place on pallets to prevent
ground. Grounding pad or bolts are provided moisture.
along with motors. - Motors should be well shielded from dust, but
Inspection under well-ventilated circumstances.
- Please check the description on the delivery note - Motors temperatures should be maintained about
with your specification. 3°C above the dew point temperature by
- Please check the name plate detail. Please providing either external or internal heat. For
mention that it is important to check whether the motor equipped with space heater, please do
motors connection are tally to the connection energized the heater followed the voltage showed
diagram, check the connection with the below in the heater nameplates.
information: - Insulation resistance test should be performed
Power Delta Connection Star Connection
once every three months. Make sure the readings
Motor < 3kW 220V-240V (50hz / 380V-415V (50Hz)
are acceptable. For detail of insulation test,
60Hz) 440V-480V (60Hz)
please refer to Part B. INSPECTION, condition
Motor ≥ 3kW 380V-415V (50Hz) 660V – 720V No.5.
440V-480V (60Hz)

Page 14
 Electrical Motor

Pre-commissioning Fitting Coupling and Alignment

- The ambient temperature range in which a - Extreme care must be exercised in lining up
standard motor will operate without any problems coupling as miss-alignment can be detrimental to
is -15°C to +40°C. If motor are required to the shaft and bearings.
operate outside this temperature range, and were - For direct drives, we recommend that flexible
not specifically ordered and supplied for such coupling are used. Please ensure that the
conditions, please contact ATT office for advice alignment instruction given by the coupling
before proceeding. manufacturer is followed.
- When a motor is operated for the first time it is - Do not any time use force in the fitting of
recommended that it is run at no load to ensure couplings, pulleys etc.
that the direction of rotation is correct and that
there is no undue noise or vibration. - A bolt should be used in the thread hole, which is
provided in the drive end shaft, and a nut with a
- To reverse the direction or rotation, interchange large washer used to press the coupling or pulley
any 2 of 3 supply lead. against the shoulder of the shaft.
- Please ensure that the motor is installed in a - Care must be taken to ensure that the motor
suitably ventilated area. Ensure that there is a bearings are not subjected to end-thrust caused
free area in front of the air intake of at least a by the two halves of the coupling being squeezed
quarter of the shaft height. The exhausted air too tightly together.
must not be re-circulated back over the motor.
- Please ensure that all couplings, belts, pulleys etc
- If the air contains a high concentration of dust, it are properly and permanently guarded against
may result in the motor overheating. accidental contact while the motor is running.
- Ensure that the motor is certified for use in the - Field application of a coupling to the motor shaft
area of operation. Hazardous area required should follow the procedures recommended by
specially certified motors. the coupling manufacturer. The motor shaft
extension must not be subjected to either
Installation Of Motor extreme heat or cold during coupling installation.
- Ensure that the motor is installed on a solid floor, - Basically, the coupling should be heated and
foundation, or rigid base, free from any external pushed onto the shaft extension with slight axial
vibration. force. Do not hammer coupling to prevent bearing
damage.
- Please use appropriate fastener torques during
mounting. - Motors with anti-friction bearings are suitable for
connection to the driven load through a flexible
- Ensure that the gaskets or sealants are fitted coupling. Coupling solidly to the load is not
correctly. acceptable.
- All motors are available in B3, B35 and V1
- In aligning the motor (and rotor) axially with the
configuration. They can also be mount B5, but for driven equipment, consideration should be given
315 and 355 frame motors, it is recommend to be not only to the end-play indicator position but also
mounting only B3, B35 or V1. Please be mention
to axial shaft expansion and increase in shaft
that motors to be mounted with the shaft vertically centerline height due to thermal effects. In
must be provided with a suitable cover to ensure general, the axial shaft growth for motors can be
foreign bodies are prevented from entering motor.
disregarded since neither bearing is fixed nor any
- Please ensure these fixing bolts are correctly shaft growth due to temperature increase will
tightened. It is recommended that a flat washer produce an elongation away from the coupling.
and a spring washer are used to prevent too
much stress on the foot or flange of a motor, and
to prevent fixing bolts from becoming loose. Shaft height growth (change in shaft centerline
elevation) for machines can be calculated as follows
- Standard environment and site conditions for the
installation of motors are usually set as follows:
- Ambient temperature :-10~40°C = (0.0005”) x (shaft dimension, Foot mounted)
- Humidity: Relative humidity below 90% RH for
totally-enclosed types, and below 80% RH for - It is desirable, in normal operation, which the
semi-enclosed types. motor operate on its magnetic center, so that no
- Elevation: below 1000 meters. axial force is exerted on the coupling.
- Harmful gases, liquids, dusts, high moisture
should be absent.
- Foundation should be strong and free of vibration.
- If there are any special environment conditions,
please inform us upon ordering.
- Installation area should be well-ventilated.
- The installation space should be large enough to
facilitate heat dissipation and maintenance.

Page 15
 Electrical Motor

-
The motor shaft and the driven shaft should be aligned
within the following tolerances in both angular and parallel
alignment:

TIR Range of rotating Solid Flexible coupling

speed coupling

C 2500rpm and above 0.03mm 0.03mm

Below 2500rpm 0.04mm 0.05mm

A 2500rpm and above 0.03mm 0.03mm

Below 2500rpm 0.03mm 0.04mm

Maintenance
We recommended that if a motor is used continuously
that it is removed for inspection and dismantled every 5
years. The following items should be checked and
recorded:
- Insulation resistance and temperature at which it
is measured.
- Inspection of the bearing and check for
discoloration of the grease.
- Tightness of “V-Belts” and alignment of coupling.
- Ensure that the holding down bolts is tight and
the base plate or foundations are rigid.
- Cleanliness inside and outside the motor.

Page 16
 Electrical Motor

Page 17
 Type Series: DSC

Single Stage Horizontal Centrifugal Pump

Cartridge Seal
Assembly & Disassembly
Manual No. DSC Annex 1

DBR Pumpen Limited

Office 4, 219 Kensington High Street, Kensington, London, England W8 6BD
Website: www.dbrpumpen.com Email: [email protected]
 Maintenance

ILLUSTRATION PROCEDURES

DISASSEMBLY PROCEDURE

Step 1:
Retaining
clip, Pos Removed the SPACER CLIP (4 in nos) Pos. 8
10 using allen key

Removed the RETAINING CLIP (1 pce) Pos. 10

Spacer
clip, Pos 8 Removed the LOCK SCREW (4 pcs) Pos. 16
using allen key

Removed the PLACING RING, Pos. 9 by sliding

Fig 1 out of the SLEEVE.
Lock
screw, Pos
16

At this stage, the parts removed will be

• 4 pcs SPACER CLIP,

• 4 pcs LOCK SCREW,
• 1 pce RETAINING CLIP
• 1 pce PLACING RING
Placing
Ring, Pos 9

Fig 2

Step 2:
Seal Cover,
Slide the SLEEVE out of the SEAL COVER
Pos 5

Sleeve, Pos 1

Fig 3

1
 Maintenance

Step 3:

Slide out the SEAL FACES (Pos 3, 4), O RING

(Pos 11, 12 & 14) and PRIMARY RING (Pos 2)
from the SLEEVE

Primary
Ring, Pos 2

Fig 4
Step 4:

Remove the SECONDARY RING, Pos 7 (2 pcs)

using the allen key.

Carefully retrieve the SPRING HOLDER, Pos 6

from the SEAL COVER as in fig 8

Fig 5
Secondary
Ring, Pos 7

Fig 6
Spring Holder, Pos 6

INSPECTION:
Inspect all component for any damages or
wears.

Replace the components or parts accordingly.

Clean all components thoroughly.

DSC Mechanical Seal Repair Kits consists of:

1) SEAL FACE with O RING - Stationary
and Rotating (1 set)
2) O RING for SLEEVE (1 pce)
3) SEAL COVER GASKET (1 pce)
4) SPACER CLIP (4 pcs)

2
 Maintenance

ASSEMBLY PROCEDURE

Step 1:

Installed the SPRING HOLDER and

SECONDARY RING into the SEAL COVER.
Make sure all the springs are in place.

Lock the SECONDARY RING in place. Due to

the spring action, assert some forces to push
the SECONDARY RING to the SEAL COVER.
Tighten the lock screw with allen key.
Fig 7
Check that the SECONDARY RING is flushed
with the SEAL COVER, using a parallel bar.

Fig 8

Fig 9

Step 2:

Installed the STATIONARY SEAL FACE with O

RING to the SEAL COVER. Make sure the seal
is position into the slot of the SPRING
HOLDER.

Apply some light oil to the O ring before

installing.

Fig 10

3
 Maintenance

Step 3:

Apply some light oil to the o Ring.

Insert the O RING for SLEEVE into the

SLEEVE.

Fig 11
Step 4:

Insert the PRIMARY RING into the SLEEVE,

ensure that the PRIMARY SLEEVE seated into
the slot.

Push the ROTATING SEAL FACE with O RING

into the SLEEVE.

Ensure the seal seated into the slot.

Fig 12
Step 5:

Insert the SLEEVE with the seal face into the

SEAL COVER.

Make sure both seal faces are clean (without oil

or dirt)

Fig 13

Step 6:

Insert the SPACER CLIP into PLACING RING.

Do not tighten.

Fig 14

4
 Maintenance

Step 7:

Insert the LOCK SCREW to the PLACING

RING, do not tighten.

Insert the PLACING RING to the SLEEVE.

Push down the PLACING RING, screw in the

LOCK SCREW to the SLEEVE (make sure the
holes inside is aligned)

Tighten the SPACER CLIP screws

Fig 15
Step 8:

Insert the RETAINING CLIP to the SLEEVE

groove.

Assembly process completed.

Fig 16

Warning!
Reminder: after installed into the pump, please
removed the retaining clip (4pcs) before
operation. Failure to do so will damage the
mechanical seal and pump.

Fig 17

5
 Maintenance

Exploded view and list of components

Pos Item Description Qty MATERIAL

1 SLEEVE 1 SUS 316
2 PRIMARY RING 1 SUS 316
3 ROTATING FACE 1 SIC
4 STATIONARY FACE 1 SIC
5 SEAL COVER 1 SUS 316
6 SPRING HOLDER 1 SUS 316
7 SECONDARY RING 1 SUS 316
8 SPACER CLIP 4 SUS 304
9 PLACING RING 1 SUS 316
10 RETAINING CLIP 1 SUS 316
11 O RING FOR SLEEVE 1 AFLAS
12 O RING (ROTATING FACE) 1 AFLAS
13 GASKET 1 COMPRESSED FIBRE
14 O RING (STATIONARY FACE) 1 AFLAS
15 SPRING 8 SUS 316
16 LOCK SCREW 4 SUS 316

6
 Cooler for Boiler Water
Installation, Operation & Maintenance
Manual

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Authorised DBR Pumpen Distributor:

Singapore
Aflex Ships Equipment Pte Ltd
35 Tannery Road, #04-06/ #05-06 Tannery Block, Ruby Industrial Complex, Singapore 347740
Tel: +65 6293 8680 Fax: +65 6293 8396 Website: www.aflex.com.sg Email: [email protected]

Shanghai
Aflex Ships Equipment (Shanghai) Co., Ltd
10/F Central Plaza,381 Huai Hai Zhong Lu, Room 1031, Shanghai 200020
Tel: +86 21 6391 5997 Fax: +86 21 6373 0129 Website: www.aflex.net.cn Email: [email protected]

Dubai
Aflex Ships Equipment LLC
P.O. Box 171456, Suite 701, Al Attar Tower, Sheik Zayed Road, Dubai, UAE
Tel: +971 4 3108006 Fax: +971 4 3257200 Website: www.aflex.ae Email: [email protected]