1 BTA Pump 250M V1.2.1 002-EN
1 BTA Pump 250M V1.2.1 002-EN
1 BTA Pump 250M V1.2.1 002-EN
V 1.2.1 EN
Table of contents
1 General ............................................................................................... 5
1.1 Information about these operating instructions ................................................... 5
1.2 Manufacturer ............................................................................................................. 5
1.3 Service ....................................................................................................................... 5
1.4 Operating instructions – formalities ....................................................................... 6
1.5 Conventions used in this document....................................................................... 6
1.5.1 Instructions and system reactions .............................................................................. 6
1.5.2 Operating steps .......................................................................................................... 6
1.5.3 Bulleted lists ................................................................................................................ 6
1.6 Abbreviations and definitions ................................................................................. 7
2 Safety .................................................................................................. 8
2.1 Notes on operation ................................................................................................... 8
2.2 Presentation of safety instruction .......................................................................... 8
2.2.1 Warnings ..................................................................................................................... 8
2.3 Personnel qualifications .......................................................................................... 9
2.3.1 Operating personnel requirements ............................................................................. 9
2.3.2 Maintenance personnel requirements ...................................................................... 10
2.3.3 Requirements for trained specialists ........................................................................ 10
2.4 Intended use ............................................................................................................ 10
2.5 Foreseeable misuse ............................................................................................... 11
2.6 Pictograms .............................................................................................................. 11
2.7 Spare and wear parts ............................................................................................. 11
7 Commissioning ................................................................................ 34
7.1 Safety instructions ................................................................................................. 34
7.2 Putting into service for the first time .................................................................... 34
8 Operation .......................................................................................... 37
8.1 Safety instructions ................................................................................................. 37
8.2 Operational requirements ...................................................................................... 39
8.3 Starting operation ................................................................................................... 39
8.3.1 Checking the oil pressure (if oil pump is present) .................................................... 39
8.3.2 Checking the operating pressure.............................................................................. 40
12 Disassembly ..................................................................................... 59
12.1 Safety instructions ................................................................................................. 59
12.2 Preparation for dismantling ................................................................................... 59
12.3 Perform dismantling ............................................................................................... 59
13 Disposal ............................................................................................ 60
13.1 Instructions on disposal ........................................................................................ 60
14 Lists .................................................................................................. 61
14.1 List of figures .......................................................................................................... 61
14.2 List of tables ............................................................................................................ 62
15 Appendix .......................................................................................... 63
15.1 Water quality guideline .......................................................................................... 63
15.2 Consumables .......................................................................................................... 64
15.3 Dimension sheet ..................................................................................................... 65
15.3.1 Pump 150M (with centrifugal lubrication) ................................................................. 65
15.3.2 Pump 150M (with pressure oil lubrication) ............................................................... 66
15.3.3 Pump 190M / 250M .................................................................................................. 67
15.4 EC Declaration of Conformity ............................................................................... 68
1 General
1.1 Information about these operating instructions
These operating instructions have been compiled in accordance with
the Directive 2006/42/EC. They are provided so that you can use the
complete 150M / 190M / 250M High-pressure Plunger Pump safely
and efficiently (referred to simply as the “pump” below).
These operating instructions are a part of the pump and must be kept
in the immediate vicinity of the pump and accessible to operating
personnel at all times.
The original operating instructions were written in German.
1.2 Manufacturer
WOMA GmbH
Werthauser Straße 77-79
47226 Duisburg
Germany
Tel.: + 49 2065-304-0
Fax: + 49 2065-304-200
E-Mail: [email protected]
www.woma-group.com
1.3 Service
Our Worldwide Service is available to you for all technical information
about WOMA products and their applications in systems.
If you encounter difficulties with our products at any time, please
contact WOMA Service, the responsible representative or the
manufacturing plant, where help is readily available.
WOMA GmbH
Werthauser Straße 77-79
47226 Duisburg
Germany
Tel.: + 49 2065-304-0
Fax: + 49 2065-304-200
E-Mail: [email protected]
www.woma-group.com
2 Safety
The pump complies with the Machinery Directory 2006/42/EC and
has been designed, manufactured and safety-tested according to the
currently valid safety regulations and laws and state-of-the-art
technology.
The pump is in a technically flawless condition.
However, there may be hazards at the pump if it:
is not operated by trained personnel.
is used improperly or not used for the intended purpose.
is not in a flawless safety condition.
Source of danger
Possible consequences when not observed
Actions / prohibitions
Danger signs
The danger sign is used to mark warnings about personal injury.
Source of danger
The source of the danger states the cause of the danger.
8 / 68 BTA 150M 190M 250M V1.2.1 002-EN.docx
2 Safety
2.3 Personnel qualifications
Actions / prohibitions
All activities that need to be carried out to avoid a danger
(e.g. stopping a drive) or that are prohibited to avoid a danger are
listed at measures / prohibitions.
2.6 Pictograms
Pictograms on the product which are no longer legible must be
replaced with new ones.
Table 2: Pictograms
Pictogram Description
The manual must be read and fully understood prior
to operation of the product
3 Technical data
3.1 Labelling
Table 3: Labelling
Name Size
Machine name High-pressure Plunger Pump
Serial number The serial number is entered on the
nameplate and on the gearbox
housing.
Name Size
Ambient temperature min. +5 °C
max. +45 °C
3.3 Dimensions
Table 5: Dimensions
3.4 Rating
Table 6: Rating
Name Size
Power requirement max. 195 kW (150M)
(depending on interchangeable 124 kW (190M)
conversion set)
147 kW (250M)
Operating pressure max. 3,000 bar
Flow rate max. 34 l/min (150M / 190M)
(depending on interchangeable 40 l/min (250M)
conversion set)
Available ratios 2.96 / 3.69 / 4.57 (150M)
4.25 (190M)
3.04 / 3.57 (250M)
Crankshaft speed max. 507 rpm (150M)
424 rpm (190M)
504 rpm (250M)
min. Depending on the operating
parameters, this value can be defined
by WOMA GmbH.
The speed can be controlled
continuously in the range between
the operating and pump-dependent
maximum and minimum speeds.
Torque max. 603 Nm (150M)
(on the drive shaft) 656 Nm (190M)
917 Nm (250M)
Emission sound pressure level > 80 dB(A)
according to DIN EN ISO 11203
3.5 Media
Table 7: Media
Name Size
Delivery medium inlet pressure Relative pressure:
min. 1.5 bar
max. 5.0 bar
Table 7: Media
Name Size
Pumping medium supply
requirement min. 2 times the nominal flow rate of the
pump, depending on interchangeable
conversion set
(1.5- times the nominal flow rate of
the pump, depending on inter-
changeable conversion set, if the
internal gearbox cooling is installed)
Pumping medium quality See the Water quality guideline in
Appendix 15.1
Oil filling quantity approx. 9 l (150M)
8 l (190M / 250M)
2
Oil viscosity ISO VG 320 mm /s
according to DIN 51517-2 or -3
Oil pressure of forced lubrication 1.5 - 5.0 bar
(if present)
Oil pressure of overflow valve 5.0 bar
(set, if present)
Oil filter fineness (if present) 0.025 mm
Oil temperature max. 80 °C
Setpoint 60 - 70 °C
Heat exchanger min. 2.0 l/min (150M)
Required cooling water 2.5 l/min (190M / 250M)
Heat exchanger min. +5 °C
Cooling water temperature max. +45 °C
Heat exchanger min. 1.5 bar
Cooling water pressure max. 10.0 bar
3.6 Weights
Table 8: Weights
Name Weight
Total weight approx. 320 kg (150M)
370 kg (190M / 250M)
Gearbox approx. 219 kg (150M)
269 kg (190M / 250M)
Interchangeable conversion set
approx. 39 kg
Pump head approx. 62 kg
The weight can vary according to the equipment. The weights are
with oil and without optional accessories.
3.7 Connections
Table 9: Connections
Connection Size
Inlet pressure G 1 1/2"A
High pressure 9/16" UNF-LH with flange
Cooling water G 1" A
Sealing water outlet G 1/2"
Drive shaft Diameter 50 mm k6,
Permissible pressure amplitude 1,
A14 x 9 x 72
4 Functional description
The pump is a horizontal plunger pump with screw-on pump head
and easy-to-swap plunger interchangeable conversion sets. It can be
installed in a high-pressure water-jet machine.
The pump is used in combination with a drive unit and a water tool or
other flow restricting device to generate water under high pressure that
can be used for cleaning, removing, cutting etc. of, for example,
concrete and steel.
The pump is driven directly by a highly elastic coupling via a slip-on or
intermediate gear unit or via a balanced joint shaft.
Using a V-belt to drive the pump is permitted in principle. For the
exact design, please contact WOMA GmbH.
1 Gearbox
2 Interchangeable conversion set
3 Pump head
4.2.1 Gearbox
Pressure oil lubrication consisting of oil pump, oil filter and oil
pressure gauge is recommended for a rating of 90 kW or more and is
mandatory for a rating of 110 kW or more.
Figure 3: Gearbox with pressure oil lubrication (for illustration purposes only)
1 Plunger
2 Cylinder unit (with seals and plunger)
3 Sealing water system
4 Plunger screw connection (union nut)
5 Guide pistons
There are 3 holes that are closed with plugs (Figure 6: item 3).
The inlet pressure gauge is inserted in one of these holes and can be
used to read the current inlet pressure.
The valve system is installed in the pump head and contains guided
suction and pressure valves (Figure 6: item 7).
The pump head is connected by stud bolts (Figure 6: item 4) and nuts
(Figure 6: item 9) directly to the gearbox.
Check valve
The check valve is a pneumatically actuated regulator that prevents
water from escaping from open consumers when the pump is
depressurised.
– for operating pressure ≤ 2,500:
3/2-way, 2x M18x1.5-LH (9.893-685.0)
– for operating pressure > 2,500 to 3,000 bar:
3/2-way, 2x 9/16 UNF (9.871-300.0)
Bypass valve
The bypass valve is a pneumatically operated switching valve that
switches high pressure on and off. When high pressure is switched
off, the volume flow is diverted via a bypass.
- 2/2-way, up to 3,000 bar operating pressure (9.871-118.0)
Figure 11: Flange for valve connection (for illustration purposes only)
Figure 12: Flange for high-pressure connection (for illustration purposes only)
Intermediate flange
Firstly, the intermediate flange is used to attach wide valve bodies to
narrow pressure bars on the pump head. Secondly, the intermediate
flange is a device that is installed between the pump head and the
pressure flange to rotate these components by 90°.
– for pressure flange (9.872-464.0)
– for overflow valve / check valve (9.913-847.0)
– for check valve (9.915-523.0)
Pressure switch
The pressure switch outputs a signal to the controller when the inlet
pressure falls below the limit value.
– 10 bar, pressure switch XML-A (6.025-133.0)
When medium is returned to the break tank from the overflow valves,
make sure that the temperature of the incoming medium does not
exceed the permissible values. A certain amount of cool medium may
have to be added.
The piping system should be designed with as few connections and
bends as possible. Connections must be connected with 45°
Y-branch pipes. If the manufacturer has not provided specifications,
the bending radius must not be less than 2.5xD.
Only lift the pump at the lifting points intended for transport
(Figure 18).
5.3 Storage
The pump may only be stored under the following conditions:
All openings must be closed
Do not store outdoors
Store in a dry and dust-free location
Do not expose to aggressive media (e.g. salt-laden air)
The storage temperature must be between +5 °C and +45 °C
Maximum relative air humidity of 60%
With a suitable protective agent (see chapter 11.3 - Antifreeze /
preservation)
In the case of pumps that are stored for more than 6 months, we
recommend rotating the drive shafts at regular intervals so that the
condition of the teeth can be checked from all sides.
Replace soft parts installed in the pump (e.g. seals etc.) following
storage for more than 18 months prior to commissioning
Do not store soft parts (e.g. seals etc.) for longer than 36 months
6 Assembly / Installation
6.1 Safety instructions
Medium under pressure
When pressure-bearing components fail, there is a danger that the
medium under pressure will spray onto people.
Ensure that only components approved for this pressure load are
used at all connections.
Hose lines
If hose lines are inadequately attached, there is a risk of people being
struck by them.
Visually inspect the connections before tightening the joints.
Tighten the hose lines in accordance with the manufacturer’s
information.
Hose lines
The instructions of the hose manufacturer must be observed.
Use hose retainers. These must be attached securely.
The inlet pressure lines of the pump must be completely leak-tight
at the allowed inlet pressure.
The supply lines must be laid so that they do not pose a tripping
hazard.
The pump must be connected using hoses to avoid transfer of
mechanical vibrations.
Pump
The pump may only be installed by expert, trained personnel.
The pump may only be installed on a flat surface.
The pump may only be installed on an incline of max. 8° in all
directions.
The base frame for the pump to be installed must be stable and
torsionally rigid.
The pump must be carefully aligned to the drive unit.
The permitted alignment error depends on the specifications of the
coupling manufacturer.
6.2 Assembly
Electrostatic charge / current
Risk of electric shock on contact with the housing.
To prevent electrostatic charges building up, a potential
equalisation for the relevant equipment is to be provided,
if necessary, by use of an earthing cable.
6.3 Interfaces
The following figure shows the interfaces of the pump:
1a Cooling water intake connection (the cooling water system can also
be installed on the other side)
1b Cooling water outlet connection
2 Drive shaft (drive on right as standard; after technical review, drive
can be connected on left or second pump can be connected)
3 High-pressure connection (optionally right or left, normally valve
block / regulator, see chapter 6.3.1)
4 Inlet pressure connection (optionally on right or left)
5 Sealing water outlet connection (normally connected with a plug
connector on the cooling water inlet).
7 Commissioning
7.1 Safety instructions
Medium under pressure
When pressure-bearing components fail, there is a danger that the
medium under pressure will spray onto people.
Ensure that only components approved for this pressure load are
used at all connections.
Never connect the ventilating valves to the pressure side.
The pump may only be put into service by expert, trained
personnel.
A safety device must be used to prevent the system exceeding the
maximum operating pressure.
The pump must never be switched on without an adequate water
supply.
Noise
Hearing damage can occur depending on the intended purpose and
type of drive.
Wear hearing protection.
Soft parts which have been installed in the pump (e.g. seals etc.)
must be replaced prior to commissioning following storage for over
18 months. Operation after exceeding this storage period can lead to
severe pump damage.
The pump must be level when you check the oil sight glass.
The oil level should be in the middle of the oil sight glass.
Figure 22: Putting into operation for the first time (for illustration purposes only)
When first putting into service and when installing the motor again or
its supply lines, check that it is driving in the correct direction of
rotation (see Figure 24).
Figure 24: Default direction of drive rotation (right) (for illustration purposes only)
8 Operation
8.1 Safety instructions
Driven components
When drives are in motion, there is a risk of crushing due to moving
parts, and there is a risk of being drawn in by rotating parts at the
interface to the drive.
Drive movements may only be performed with covers installed.
High-pressure jet
Depending on the application of the pump, there is a risk that fluid will
come out and cause injury to a third party.
The work area must be cordoned off. Entry must be restricted.
The adjacent area must be protected against spray water.
Never direct the water jet at people, animals, machines or
electrical components.
Hot oil
Risk of severe scalding from contact with hot oil.
Do no open the oil drain or the gearbox cover in operation.
The pump must not be operated without gearbox cover.
Hot surfaces
Risk of minor burns from contact with the surfaces of the pump.
Do not operate the pump without any or only with inadequate
cooling.
Do not perform any maintenance work while the unit is in
operation.
Do not touch the surface in operation.
The pumps can be set up for other ratings and operating points by
changing the interchangeable conversion set. When changing the
interchangeable conversion set, the safeguard against excess
pressure must also be adapted to the new conditions or, if
necessary, changed!
We recommend speaking to your WOMA service centre or the
manufacturer's factory before making a change.
You will find assistance with rectifying malfunctions in the table below.
Unless otherwise noted, qualified personnel are responsible for
rectifying the fault. Qualified personnel are operating, maintenance
and trained specialists (see chapter 2.3 - Personnel qualifications).
Table 11: Malfunction table
Hot oil
Risk of severe scalding from contact with hot oil.
Allow the oil to cool until lukewarm before changing oil.
Do an oil change only when the unit is at a standstill.
Wear protective goggles and oil-proof gloves when carrying out
maintenance work involving oil.
Hot surfaces
Risk of minor burns from contact with the surfaces of the pump.
Do not operate the pump without any or only with inadequate
cooling.
Let the pump components cool down before maintenance.
Wear suitable protective gloves.
Do not perform any maintenance work while the unit is in
operation.
Do not touch the surface in operation.
Replace
Check
Clean
Daily or every 10 h
Replace
Check
Clean
Weekly or every 50 h
Replace
Check
Clean
After 50 h for the first time / always 50 h after repair
and at every maintenance interval (see chapter 10.4.2)
Replace
Check
Clean
for pump operated at operating pressure >2,500 bar
Every 12 months or every 750 h (whichever occurs first)
for pump operated at operating pressure ≤2,500 bar
Interchangeable conversion set: Check wearing parts (plunger, compression rings,
compression springs)
Interchangeable conversion set: Replace maintenance parts (seals, guide rings etc.)
Interchangeable conversion set P12H Maintenance package (9.919-006.0) - Wear package (9.919-007.0)
Interchangeable conversion set P14H Maintenance package (9.919-009.0) - Wear package (9.919-010.0)
Interchangeable conversion set P16H Maintenance package (9.919-015.0) - Wear package (9.919-016.0)
Interchangeable conversion set P18H Maintenance package (9.919-018.0) - Wear package (9.919-019.0)
Replace
Check
Clean
Additionally
Every 12 months or every 1,500 h (whichever occurs first)
Replace
Check
Clean
machines without pressure oil lubrication
Additionally every 24 months or every 3,000 h (whichever occurs first) for
machines with pressure oil lubrication
Clean gearbox and check for leaks
Check guide pistons, crankshaft and drive shaft for damage / corrosion
Check connecting rod bearing shells
Gearbox cover: Replace seal
GE 150
Maintenance package for seals (9.918-558.0) - Wear package for bearing shells (9.918-571.0)
Clean magnet plug
Change oil (filling quantity: 9 litres)
Oil (9.892-356.0 [5 litres])
Replace
Check
Clean
Additionally
Every 24 months or every 3,000 h (whichever occurs first)
Replace
Check
Clean
machines without pressure oil lubrication
Additionally every 36 months or every 4,500 h (whichever occurs first) for
machines with pressure oil lubrication
Replace crankshaft roller bearings
GE 150
Maintenance package for crankshaft bearings (9.918-562.0)
Replace
Check
Clean
Additionally
Every 48 months or every 6,000 h (whichever occurs first)
Replace
Check
Clean
Additionally
Every 60 months or every 12,000 h (whichever occurs first)
Replace
Check
Clean
Additionally
Every 72 months or every 15,000 h (whichever occurs first)
Replace
Check
Clean
Additionally
Every 12 months or every 1,500 h (whichever occurs first)
Replace
Check
Clean
Additionally
Every 24 months or every 3,000 h (whichever occurs first)
Replace
Check
Clean
Additionally
Every 24 months or every 3,000 h (whichever occurs first)
Replace
Check
Clean
Additionally
Every 48 months or every 6,000 h (whichever occurs first)
Additionally
Every 60 months or every 12,000 h (whichever occurs first)
Figure 25: Oil change - Pump 190M / 250M (left), pump 150M (right)
The pump must be level when you check the oil sight glass.
The oil level should be in the middle of the oil sight glass.
16. Screw the oil filling plug (Figure 25: item 1) back into the housing.
Use this step to check the sealing water pipe and clean it if
necessary.
6. Carefully mount the top sealing water lines (Figure 5: item 3).
7. Mount the cover plate above the interchangeable conversion set.
Falling objects
Risk of crushing or pinching from objects that can fall off the pump.
Before undoing the last screw in the gearbox cover, replace two
screws with grub screws.
12 Disassembly
12.1 Safety instructions
Oil
Risk of irritation to skin and eyes due to contact with oil.
Wear protective goggles and oil-proof gloves when carrying out
work involving oil.
13 Disposal
13.1 Instructions on disposal
The following points are to be noted when disposing of the pump, as
well as of operating and auxiliary materials:
Observe national regulations for the site.
Observe company-specific regulations.
Dispose of operating and auxiliary materials in compliance with the
applicable safety data sheets in each case.
14 Lists
14.1 List of figures
Figure 1: Position of nameplate (for illustration purposes only) ...................................................................... 12
Figure 2: Main modules of the pump (for illustration purposes only) .............................................................. 17
Figure 3: Gearbox with pressure oil lubrication (for illustration purposes only)............................................... 18
Figure 4: Gearbox with centrifugal lubrication (for illustration purposes only)................................................. 19
Figure 5: Interchangeable conversion set ....................................................................................................... 20
Figure 6: Pump head, rear (left), front (right) ................................................................................................... 21
Figure 7: Safety device (image is for illustration purposes only) ..................................................................... 22
Figure 8: Overflow valve (for illustration purposes only) ................................................................................. 22
Figure 9: Check valve (for illustration purposes only) ..................................................................................... 22
Figure 10: Bypass valve (for illustration purposes only) .................................................................................. 22
Figure 11: Flange for valve connection (for illustration purposes only) ........................................................... 23
Figure 12: Flange for high-pressure connection (for illustration purposes only) ............................................. 23
Figure 13: Intermediate flange (for illustration purposes only) ........................................................................ 23
Figure 14: Pressure gauge for inlet pressure monitoring ................................................................................ 23
Figure 15: Pressure switch .............................................................................................................................. 24
Figure 16: Pressure gauge for high-pressure monitoring ................................................................................ 24
Figure 17: Cooling water connection ............................................................................................................... 24
Figure 18: Lifting eyes (for illustration purposes only) ..................................................................................... 27
Figure 19: Earthing connection (for illustration purposes only) ....................................................................... 31
Figure 20: Fixings (for illustration purposes only) ............................................................................................ 31
Figure 21: Pump interfaces (for illustration purposes only) ............................................................................. 32
Figure 22: Putting into operation for the first time (for illustration purposes only) ........................................... 35
Figure 23: Inlet pressure gauge ....................................................................................................................... 36
Figure 24: Default direction of drive rotation (right) (for illustration purposes only) ........................................ 36
Figure 25: Oil change - Pump 190M / 250M (left), pump 150M (right) ............................................................ 51
Figure 26: Components to be checked (for illustration purposes only) ........................................................... 53
Figure 27: Tightening sequence for lantern fixing ........................................................................................... 54
Figure 28: Tightening sequence for pump head mounting .............................................................................. 54
Figure 29: Tightening sequence for clamping flange mounting....................................................................... 55
Figure 30: Draining the pump (for illustration purposes only).......................................................................... 57
Figure 31: Dimension sheet of pump 150M (with centrifugal lubrication) ....................................................... 65
Figure 32: Dimension sheet of pump 150M (with pressure oil lubrication) ..................................................... 66
Figure 33: Dimension sheet of pump 190M / 250M ........................................................................................ 67
15 Appendix
15.1 Water quality guideline
Filtration – standard ≤ 1 µm
Solids content max. 20 mg/l
Total water hardness 3 - 10°H
CaO 30 - 100 mg/l
CaCO3 54 - 178 mg/l
Calcium hardness 0.89 - 1.78 mmol/l
pH value 6.5 - 9.5
Degree of alkalinity (pH 8.2) 0 - 0.25 mmol/l
Proportion of all dissolved substances 10 - 75 mg/l
Conductivity 100 - 450 µS/cm
Chlorides (e.g. NaCl) < 100 mg/l
Iron (Fe) < 0.2 mg/l
Fluoride (F) < 1.5 mg/l
Free chlorine (Cl) < 1 mg/l
Copper (Cu) < 2 mg/l
Manganese (Mn) < 0.05 mg/l
Phosphate (H3PO4) < 50 mg/l
Silicates (SixOy) < 5 mg/l
Sulphate (SO4) < 100 mg/l
15.2 Consumables
Table 13: Consumables
Figure 32: Dimension sheet of pump 150M (with pressure oil lubrication)