Im CB GB
Im CB GB
Im CB GB
CombiBloc
Horizontal centrifugal
monobloc pump
Manufacturer
Johnson Pump Water B.V.
Dr. A.F. Philipsweg 51
P.O. Box 9
9400 AA Assen
Netherlands
hereby declares that the pump, in case it is delivered as an assembly with drive (last position
of serial number = A), is in conformity with the provisions of Directive 98/37/EC (as altered
most recently) and the following directives and standards:
• EC directive 73/23/EEC, "Electric equipment for use within certain voltage limits"
• standards EN 292 part 1 & 2, EN 809
The pump to which this declaration refers may only be put into operation after it has been
installed in the way prescribed by the manufacturer, and, as the case may be, after the
complete system of which this pump forms part, has been made to fulfil the requirements of
Directive 98/37/EC (as altered most recently).
Manufacturer’s declaration
(Directive 98/37/EC, appendix II-B)
Manufacturer
Johnson Pump Water B.V.
Dr. A.F. Philipsweg 51
P.O. Box 9
9400 AA Assen
Netherlands
hereby declares that the pump, in case it is delivered without drive (last position of serial
number = B), is in conformity with the following standards:
• EN 292 parts 1 & 2, EN 809
and that this pump is meant to be incorporated in or combined with another machine (electric
motor, combustion engine) and may only be put into use after the complete machine of
which the pump under consideration forms part has been made and declared to comply with
that directive.
G.A. Schaafsma,
Managing Director
Instruction manual
CombiBloc
(CB/EN #E)
Table of contents
1 Introduction 7
1.1 Preface 7
1.2 Safety 7
1.3 Guarantee 8
1.4 Service and support 8
1.4.1 Ordering spare parts 8
1.4.2 Pump number 8
1.5 Inspection of delivered items 8
1.6 Forwarding instructions 9
1.6.1 Dimensions and weight 9
1.6.2 Use of pallets 9
1.6.3 Lifting 9
1.7 Storage 9
2 General 11
3 Installation 15
(CB/EN #E)
Table of contents 3
3.1 Safety 15
3.2 Preservation 15
3.3 Environment 15
3.4 Installation of the set 15
3.5 Piping 15
3.6 Mounting accessories 16
3.7 Connection of the electric motor 16
4 Commissioning 17
5 Maintenance 19
6 Cause of failures 21
(CB/EN #E)
4 Table of contents
CombiBloc
9 Parts 41
10 Technical data 45
Index 53
(CB/EN #E)
Table of contents 5
(CB/EN #E)
6 Table of contents
CombiBloc
1 Introduction
1.1 Preface
This manual contains important and useful information for the proper functioning
and maintenance of this pump. It also contains important instructions to prevent
possible accidents and serious damage and to ensure the safe and smooth
functioning of this pump.
1.2 Safety
The manual contains instructions for the safe operation of the pump. Operators and
maintenance staff shall be familiarized with these instructions.
A list of the symbols used in the aforementioned instructions as well as their
meaning is stated below:
Personal danger for the user. Strict and prompt observance of the
corresponding instruction is imperative!
This manual has been compiled by Johnson Pump with the utmost care.
Nevertheless Johnson Pump cannot guarantee the completeness of this
information and therefore assumes no liability for possible deficiencies in this
manual. The buyer/user shall at all times be responsible for testing the information
and for taking possible additional and/or deviating safety measures.
Johnson Pump reserves the right to change the safety instructions at any time.
(CB/EN #E)
Introduction 7
1.3 Guarantee
Johnson Pump shall not be bound to any guarantee other than the guarantee
accepted by Johnson Pump. In particular, Johnson Pump will not assume any
liability for explicit and/or implicit guarantees such as but not limited to the
marketability and/or suitability of the articles supplied.
The guarantee shall forthwith and legally defunct in case:
• Service and/or maintenance has not been carried out strictly in accordance with
the instructions.
• Necessary repairs have not been carried out by our personnel or have been
carried out without our prior written consent.
• The articles supplied have been changed without our prior written consent.
• The spare parts used are not original Johnson Pump parts.
• Additives or lubricants used are other than those prescribed.
• The articles supplied are not used according to their nature and/or destination.
• The articles supplied are used amateurishly, carelessly, improperly and/or
negligently.
• The articles supplied become defective due to outside circumstances beyond
our control.
All wearing parts shall be excluded from guarantee.
Furthermore, all deliveries are subject to our "General conditions of delivery and
payment", which will be forwarded to you free of charge on request.
(CB/EN #E)
8 Introduction
CombiBloc
! When using a forklift: Always place the shovels of the forklift as far apart as
possible and lift the box with both levels to prevent it from toppling over.
1.6.3 Lifting
If a pump or a complete pump unit has to be lifted, the slings should be fixed as
shown in figure 1.
1.7 Storage
In case the pump is not immediately being used, the pump shaft has to be rotated
manually twice a week.
(CB/EN #E)
Introduction 9
(CB/EN #E)
10 Introduction
CombiBloc
2 General
(CB/EN #E)
General 11
2.3 Applications
• In general, the CombiBloc pumps can be used for thin, clean or slightly polluted
liquids. These liquids should not affect the pump materials.
• Further details about the application possibilities of your specific pump are
mentioned in the order confirmation and/or in the data sheet enclosed with the
delivery.
• Please do not use the pump for purposes other than those for which it is
delivered without prior consultation with your supplier.
2.4 Construction
2.4.1 Design
The design is characterized by a compact construction. The pump is combined, by
means of a lantern and stub shaft, with a standard IEC electric motor. type B5 for
electric motors upto and including size 112M, type B3/B5 for bigger types, in
vertical position type V1 for all types. The pump cover is clamped between the
pump casing and the lantern piece.
2.4.2 Materials
This concerns the parts that are exposed to the pumped liquid. For each individual
pump type there is only one construction of pump casing and impeller. These parts
are available in 3 different types of material: cast iron, bronze and stainless steel.
The stub shaft is made of stainless steel.
2.4.3 Shaft sealing
The CombiBloc is provided with a mechanical shaft seal with mounting dimensions
according to DIN 24960 (L1K).
Only 3 diameters are used for the whole CombiBloc range: d1 = 30 mm, 40 mm or
50 mm.
2.4.4 Bearing construction
The bearing of the CombiBloc is provided by the motor bearings. The choice of the
motor-pump is such that the bearings of the applied electric motors can absorb the
axial and radial forces without the bearing life being affected.
The electric motors must be provided with a fixed bearing.
(CB/EN #E)
12 General
CombiBloc
Maximum value
Capacity 850 m3/h
Delivery head 105 m
System pressure 10 bar
Temperature 110°C
2.6 Re-use
The pump may only be used for other applications after prior consultation with
Johnson Pump or your supplier. Since the lastly pumped medium is not always
known, the following instructions should be observed:
• Flush the pump properly
• Make sure the flushing liquid is discharged safely (environment!)
2.7 Scrapping
If it has been decided to scrap a pump, the same procedure as for Re-use (2.6)
should be followed.
(CB/EN #E)
General 13
(CB/EN #E)
14 General
CombiBloc
3 Installation
3.1 Safety
² Read this manual carefully before installing and commissioning the pump.
Non-observance of these instructions may cause serious damage to the pump that
is not covered by our guarantee terms. Follow the instructions step by step.
• Make sure the motor cannot be started when work is done to the pump- motor
combination and running parts are insufficiently shielded.
• The pumps are suitable for liquids with a temperature up to 110°C. As from 70°C
the user, when installing the pump unit, should take appropriate protection and
warning measures to prevent contact with hot pump parts.
• If danger arises in case of static electricity, the entire pump unit should be
earthed properly.
• If there is a danger that the pumped liquid might be harmful to men or the
environment, the user should take appropriate measures for safe drainage. Also
possible leakage fluid from the shaft seal should be safely discharged.
3.2 Preservation
To prevent corrosion, the pump is flushed with a preserving agent before leaving
the works. Before putting the pump into operation, drain off any preservative agent
and flush the pump thoroughly with hot water.
3.3 Environment
• The foundation must be hard, level and flat.
• The area in which the pump unit is to be placed should be adequately ventilated.
A too high ambient temperature and air humidity, as well as a dusty environment
may have a negative effect on the functioning of the motor.
• Around the pump unit there should be enough space to operate and if necessary
repair the pump.
• Behind the cooling air inlet of the motor there should be a free area of at least
1/4 of the electric motor diameter, to ensure unobstructed air supply.
(CB/EN #E)
Installation 15
3.5 Piping
• The piping to the suction and delivery connections must fit exactly and must not
be subject to stress during operation.
• The passage of the suction pipe must be amply dimensioned. This pipe should
be as short as possible and run towards the pump in such a way that no air
pockets can arise. If this is not possible, a venting facility should be provided at
the highest point of the pipe. If the inside diameter of the suction pipe is larger
than the suction connection of the pump, an excentric reducer should be applied
to prevent air pockets and whirls. See figure 2.
• The maximum allowable system pressure is stated in 2.5. If there is a risk that
this pressure might be exceeded, for instance because of an excessive inlet
pressure, appropriate measures should be taken by mounting a safety valve in
the piping.
• Sudden changes in the rate of flow can lead to high pressure impulses in the
pump and the piping (water shock). Therefore, don’t use quick-acting closing
devices, valves etc.
(CB/EN #E)
16 Installation
CombiBloc
4 Commissioning
Make sure that when a pump is running, rotating parts are always properly
screened off by the protective cap!
(CB/EN #E)
Commissioning 17
4.6 Control
If a pump is in operation pay attention to the following:
• The pump should never run dry.
• Never use a stop valve in the suction pipe to control pump capacity. The stop
valve should always be fully opened during operation
• Check whether the absolute inlet pressure is sufficient, so that no vapour can be
formed.
• Check whether the pressure difference between suction and delivery pressure
corresponds with the specifications for the duty point of the pump.
• The mechanical seal may never show visible leakage.
4.7 Noise
The noise production of a CombiBloc pump depends to a great extent on the
operating conditions. The values stated in chapter 10 are based on normal
operation of the pump, driven by an electric motor. In case the pump is used
outside the normal operation area, as well as in case of cavitation, the noise level
may exceed 85 dB(A). In that case precautions should be taken, like building a
noise-barrier around the unit or wearing hearing protection.
(CB/EN #E)
18 Commissioning
CombiBloc
5 Maintenance
No water should get into the terminal box of the electric motor when the
pump room is sprayed clean!
Never spray water on hot pump parts! The sudden cooling down may cause
them to burst and hot water may flow out!
5.5 Noise
If, after some time, the pump starts making noise this may indicate that something
is wrong with the pump unit. For instance, a crackling noise can indicate cavitation
or an excessively noise motor can indicate deterioration of the bearings.
(CB/EN #E)
Maintenance 19
5.6 Faults
The pump, of which you want to determine the fault, may be hot or under
pressure. Take the appropriate precautions first and protect yourself with the
proper safety devices (safety goggles, gloves, protective clothing)! To
determine the source of the malfunctioning of the pump, proceed as follows:
1 Switch off the current supply to the pump unit. Block the working switch with a
lock or remove the fuse.
2 Close the stop valves.
3 Determine the nature of the fault.
4 Try to determine the cause of the fault (see chapter 6) and take the appropriate
measures,
or:
Contact your installer!
(CB/EN #E)
20 Maintenance
CombiBloc
6 Cause of failures
(CB/EN #E)
Cause of failures 21
Possible causes
1 Pump or suction pipe not sufficiently filled or de-aerated
2 Gas or air coming from the liquid
3 Air lock in the suction pipe
4 Suction pipe leaks air
8 The manometric suction head is too high.
9 Suction pipe or suction strainer is blocked.
10 Insuffiecient immersion of foot valve or suction pipe during operation of the pump.
11 NPSH available too low.
12 Speed too high.
13 Speed too low.
14 Wrong sense of rotation.
15 Pump doesn’t work at the right duty point.
16 Liquid density differs from the calculated liquid density.
17 Liquid viscosity differs from the calculated liquid viscosity.
18 Pump works when the liquid flow is too low.
19 Wrong pump selection.
20 Obstruction in impeller or pump housing.
21 Obstruction in the piping.
22 Wrong installation of the pump unit.
23 Pump and motor not well aligned.
24 Rotating part running out of true.
25 Imbalance in rotating parts (for instance impeller, stub shaft)
26 Pump shaft is running out of true.
27 Bearings faulty or worn out.
28 Sealing ring faulty or worn out.
29 Damaged impeller.
30 Running surfaces of the mechanical seal are worn out or damaged.
32 Bad mounting of the mechanical seal.
33 Mechanical seal not suitable for the operation liquid or operation circumstances.
36 The flushing liquid to the mechanical seal is polluted.
37 Axial retaining of impeller or pump shaft is defective.
38 The bearings have been mounted wrongly.
39 Too much or too little bearing lubrication.
40 Wrong or polluted lubricant.
42 Too high axial force because of worn dorsal blades or excessive inlet pressure.
(CB/EN #E)
22 Cause of failures
CombiBloc
Take adequate measures to avoid that the motor is started while you are
working on the pump. This is especially important for electric motors with
remote control:
• Switch the operating switch near the pump (if available) to "off".
• Switch off the pump switch on the switchboard.
• If necessary remove the fuses.
• Hang a danger board near the switchboard cabinet.
7.2 Tools
For assembly and disassembly no special tools are required. However: special
tools can make certain jobs easier, like replacing a mechanical seal. When this is
the case it will be stated in the instructions.
(CB/EN #E)
(CB/EN #E)
(CB/EN #E)
4043
b d
A B
C D
After removing the Back Pull Out unit the casing wear ring can be removed. In
most cases this ring is fixed so tightly that it cannot be removed undamaged.
1 Measure the thickness (d) and the width (b) of the ring, see figure 5A.
2 Make a centre hole in the middle of the edge of the ring at two opposite points,
see figure 5B.
3 Use a drill with a diameter just a little bit smaller than the thickness (d) of the
ring and drill two holes in the ring, see figure 5C. Don’t drill deeper than the
width (d) of the ring. Take care not to damage the fitting edge of the pump
casing.
4 Use a chisel to cut the remaining part of the ring thickness. Now you can
remove the ring in two parts from the pump casing, see figure 5D.
5 Clean the pump casing and carefully remove all bore dust and metal splinters.
7.5.4 Assembly of the casing wear ring
1 Clean and degrease the fitting edge of the pump casing where the casing wear
ring is to be mounted.
2 Degrease the outer edge of the casing wear ring and put a few drops of Loctite
641 on it.
3 Mount the casing wear ring in the pump casing. Take care it is not pushed out
of alignment!
(CB/EN #E)
(CB/EN #E)
(CB/EN #E)
(CB/EN #E)
(CB/EN #E)
6 Push the impeller over the motor shaft until the back blades lie against the
pump cover.
7 Secure the stub shaft on the motor shaft with the set screws (2280).
8 Slightly loosen the fastening bolts (0850) of the electric motor and remove the
shims.
9 Tighten the fastening bolts (0850) of the electric motor crossways with the
prescribed tightening moment, see chapter 10.2.
10 Mount the pump casing and the protective caps (0270).
(CB/EN #E)
figure 10 Dimensions.
(CB/EN #E)
(CB/EN #E)
ta
32-125 453 467 487 566 601
32-160 453 467 487 566 601 658
32-200 453 467 487 566 601 658 769
32-250 473 487 507 586 621 678 789 839
40-125 453 467 487 566 601 658
40-160 453 467 487 566 601 658 769
40-200 473 487 507 586 621 678 789
40-250 473 487 507 586 621 678 789 839 865
50-125 473 487 507 586 621 678 789
50-160 473 487 507 586 621 678 789
50-200 473 487 507 586 621 678 789 839 865 999
50-250 473 487 507 586 621 678 789 839 865 1019
65-125 473 487 507 586 621 678 789
65-160 473 487 507 586 621 678 789 839 865 999
65-200 473 487 507 586 621 678 789 839 865 999
65-250 502 522 601 636 693 731 804 854 880 900 1034 1045
80-160 512 532 611 646 703 814 864 890 1024
80-200 528 548 627 662 719 757 830 880 906 1040 1071 1118 1136
80-250 527 547 626 661 718 756 829 879 1059 1070 1137 1155
100-125 498 512 532 611 703 814
100-160 548 627 662 719 830 880 906 1040
100-200 627 662 719 757 830 880 906 1040 1071 1118 1136
100-250 641 676 733 771 844 894 920 1074 1085 1152 1170 1255
125-125 547 626 661 718 829
125-250 641 676 733 771 844 894 920 940 1074
125-315 726 726 861 861 943 981 1049
150-125 646 681 738
150-160 662 697 754 792 941 1075 1106 1153
150-200 697 754 792 865 915
150-250 732 732 867 867 949 987
200-160 794 832 905
200-200 793 831 904 954 980 1000 1134
250-200 772 772 907 907 989 1027
(CB/EN #E)
vt
32-125
32-160 229
32-200 229 278
32-250 217 266 266
40-125 229 278
40-160 229 278
40-200 229 278
40-250 217 266 266 279
50-125 229 278
50-160 229 278
50-200 229 278 278 291 303
50-250 217 266 266 279 311
65-125 217 266
65-160 217 266 266 279 291
65-200 217 266 266 279 291
65-250 219 219 268 268 281 281 313 339
80-160 217 266 266 279 291
80-200 232 232 281 281 294 306 352 371 393
80-250 219 219 268 268 313 339 378 400
100-125 217 266 266
100-160 220 269 269 282 294
100-200 220 220 269 269 282 294 340 359 381
100-250 219 219 268 268 281 313 339 378 400 400
125-125 217 266
125-250 216 216 265 265 278 278 310
125-315 225 225 275 275 288 288 300
150-125 204
150-160 220 220 282 294 340 359
150-200 220 220 269 269
150-250 212 212 261 261 274 274
200-160 205 205 254
200-200 204 204 253 253 266 266 298
250-200 212 212 261 261 274 274
(CB/EN #E)
65-250 100 65 200 140 160 280 360 18 120 14 80 125 250
80-250 125 80 225 140 160 315 400 18 120 18 80 125 280
100-200 125 100 200 140 160 280 360 18 120 15 80 125 280
100-250 125 100 225 140 160 315 400 18 120 16 80 140 280
125-250 150 125 250 140 160 315 400 18 120 28 80 140 355
(CB/EN #E)
ta
32-125 453 467 487 566 601
32-160 453 467 487 566 601 658
32-200 453 467 487 566 601 658 769
32-250 473 487 507 586 621 789 839 865 1019
40-125 453 467 487 566 601 658
40-160 453 467 487 566 601 658 769
40-200 473 487 507 586 621 678 789
40-250 473 487 507 586 621 678 789 839 865 1019
50-125 473 487 507 586 621 678 789
50-160 473 487 507 586 621 678 789
50-200 473 487 507 586 621 678 789 839 865 999
50-250 498 512 532 611 646 703 814 864 890 1044 1055
65-125 473 487 507 586 621 678
65-160 483 497 517 596 631 688 799 849 875 1009
65-200 483 497 517 596 631 688 799 849 875 1009
65-250 527 547 626 661 718 756 829 879 905 925 1059 1070
80-160 522 542 621 656 713 824 874 900 1034
80-200 528 548 627 662 719 757 830 880 906 926 1040 1071 1071 1118 1136 1221
80-250 527 547 626 661 718 756 829 879 905 925 1059 1070 1070 1137 1155 1240
100-200 642 677 734 772 845 895 921 1055 1086 1133 1151
100-250 641 676 733 771 844 894 920 1074 1085 1152 1170 1255
125-250 641 676 733 771 844 894 920 940 1074
(CB/EN #E)
vt
32-125
32-160 229
32-200 229 278
32-250 266 266 279 311
40-125 229
40-160 229 278
40-200 229 278
40-250 217 266 266 279 311
50-125 229 278
50-160 229 278
50-200 229 278 278 291 303
50-250 217 266 266 279 311 337
65-125 217
65-160 227 276 276 289 301
65-200 227 276 276 289 301
65-250 219 219 268 268 281 281 313 339
80-160 227 276 276 289 301
80-200 232 232 281 281 294 294 306 352 371 393 393
80-250 219 219 268 268 281 281 313 339 378 400 400
100-200 220 220 269 269 282 294 340 359 381
100-250 219 219 268 268 281 313 339 378 400 400
125-250 202 202 251 251 264 264 296
(CB/EN #E)
(CB/EN #E)
9 Parts
(CB/EN #E)
Parts 41
9.2 Sectional drawing
(CB/EN #E)
42 Parts
CombiBloc
(CB/EN #E)
Parts 43
9.4 Sectional drawing shaft sealing CB 200-160
(CB/EN #E)
44 Parts
CombiBloc
10 Technical data
(CB/EN #E)
Technical data 45
10.3 Maximum allowable speed
Max. speed [min-1]
CB G1 G2 B2 R6
(cast iron/bronze pump) (stainless steel pump)
32-125 3600 3600
32-160 3600 3600
32-200 3600 3600
32-250 3000 3000
40-125 3600 3600
40-160 3600 3600
40-200 3600 3600
40-250 3000 3000
50-125 3600 3600
50-160 3600 3600
50-200 3600 3600
50-250 3000 3000
65-125 3600 3600
65-160 3600 3600
65-200 3600 3600
65-250 3000 3000
80-160 3600 3600
80-200 3600 3600
80-250 3000 3000
100-125 3600 -
100-160 3600 -
100-200 3000 1800
100-250 3000 1800
125-125 1800 -
125-250 1800 1800
125-315 1800 -
150-125 1800 -
150-160 1800 -
150-200 1800 -
150-250 1800 -
200-160 1800 -
200-200 1800 -
250-200 1800 -
(CB/EN #E)
46 Technical data
CombiBloc
(CB/EN #E)
Technical data 47
figure 15 Survey curve 3600 min-1 (G1, G2, B2).
(CB/EN #E)
48 Technical data
CombiBloc
(CB/EN #E)
Technical data 49
figure 19 Survey curve 3600 min-1 (R6).
(CB/EN #E)
50 Technical data
CombiBloc
(CB/EN #E)
Technical data 51
10.5.2 Noise level
L [dB]
4102
|L1 - L2| [dB]
To determine the noise level of the entire set the noise level of the motor must be
added to the noise level of the pump. This can simply be done by means of the
graph printed above.
1 Determine the noise level of the pump (L1, see graph) and the motor (L2).
2 Calculate the absolute difference between both levels |L1 - L2|.
3 Find this value on the X-axis.
4 Go straight up to the curve.
5 Go left to the Y-axis.
6 Read the value on this Y-axis.
7 Add this value to the highest noise level (L1 or L2).
Example:
1. Pump 75 dB; motor 78 dB
2. |75 - 78| = 3 dB
3. 3 dB on X-axis = 1,75 dB on Y-axis
4. Highest noise level + 1,75 dB = 78 + 1,75 = 79,75 dB
(CB/EN #E)
52 Technical data
CombiBloc
Index
A F
Application area 13 Failures
Applications 12 causes 21, 22
Assembly Faults 20
casing wear ring 26
impeller 25
G
Guarantee 8
B
Back Pull Out system 24
Back Pull Out unit
I
assembly 24 Impeller
disassembly 24 replacement 25
Inspection
delivered items 8
C Installation 15, 16
Casing wear ring pump set 15
replacement 25
Commissioning 17, 18
Construction
L
Bearing 12 Lifting 9
Design 12 Liquid
Materials 12 draining 23
Shaft sealing 12
Control 18 M
electric motor 17
pump 17 Mechanical seal 27
assembly 29
disassembly 28
D instructions for mounting 27
Dimensions 9 Motor
cast iron or bronze pump 34 assembly 30
foot 33 disassembly 30
stainless steel pump 37 Mounting
Disassembly accessories 16
casing wear ring 26
impeller 25 N
Noise 18, 19
E as a function of pump power 51
Electric motor Noise data 51
connection 16 Noise level 52
(CB/EN #E)
Index 53
P
pallets 9
Preservation 15
Pump description 11
R
Re-use 13
Recommended locking liquids 45
Replacing
motor 30
S
Safety 15
Scrapping 13
Sense of rotation 17
Special tools 27
Starting the pump 17
Storage 9
Stub shaft
assembly 30
disassembly 30
replacing 30
Survey curves 47
T
Tightening moments
for bolts and nuts 45
for impeller nut 45
Tools 23
Type code 11
W
weight 9
Weights 40
Working switch 16
(CB/EN #E)
54 Index
Order form for spare parts
FAX:
ADDRESS:
Your order will only be dealt with if this order form has been correctly completed and signed.
Order date:
Pumptype:
Execution:
BESTFORM/004-EN
55
BESTFORM/004-EN
56
Johnson Pump Group
www.johnson-pump.com
Dr. A.F. Philipsweg 51, P.O. Box 9, 9400 AA Assen, The Netherlands. Tel. +31 (0)592-37 67 67. Fax +31 (0)592-37 67 60
E-mail: [email protected]