Related Manuals for OSNA LG 100
Summary of Contents for OSNA LG 100
- Page 1 Original Operating Manual LG Piston Pump OSNA-Pumpen GmbH Brückenstrasse 3 49090 Osnabrück, Germany Phone: +49 541 1211 - 0 Fax: +49 541 1211 - 220 Internet: http://www.osna.de E-mail: info@osna.de Ver.16-08...
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Page 3: Table Of Contents
Contents GENERAL ...........................5 About this operating manual....................5 Target groups ........................5 Other valid documents ......................5 Warning notices and symbols....................6 Copyright/changes ........................6 SAFETY ............................7 Correct and proper use ......................7 General safety instructions....................8 2.2.1 Product safety........................8 2.2.2 Duties of the system owner ....................8 2.2.3 Duties of personnel ......................9 Dangers of non-observance of the safety instructions............10... - Page 4 6.1.1 Checking the surrounding conditions................18 6.1.2 Preparing the installation location .................18 6.1.3 Preparing the base surface and foundations..............18 Installation ..........................18 6.2.1 Installing the pump.......................18 6.2.2 Electrical connection ....................19 6.2.3 Water connection ......................19 6.2.4 Assembling the piston pump with additional pressurized container .......20 Installation ..........................21 6.3.1 Installing the V-belt.......................21...
- Page 5 Table 11: Selection of SIOS valves ....................36 Table 12: Fault causes........................38 Table 13: Parts list for the LG 100-400 piston pump ................41 Table 14: Parts list for the LG 500-750 piston pump ................43 Table 15: Motor assembly parts list for LG 100-400................44 Table 16: Motor assembly parts list for LG 500-750................45...
- Page 6 Figure 29: Explosion diagram of the LG 100-400 piston pump............40 Figure 30: Explosion diagram of the LG 500-750 piston pump............42 Figure 31: Explosion diagram of the LG 100-400 motor assembly .............44 Figure 32: Explosion diagram of the LG 500-750................45 LG Piston Pump...
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Page 7: General
1 General This operating manual: 1 General • is part of the pump 1.1 About this operating manual is valid for all type series mentioned • This operating manual contains important in- • describes safe and proper use in all structions that must be observed during instal- phases of operation lation, operation and maintenance. -
Page 8: Warning Notices And Symbols
CAUTION Any violation is punishable and subject to compensation. Potentially Material dam- NOTICE dangerous OSNA GmbH reserves the right to change the situation contents of this documentation without notice. Table 3: Warning notices and consequences of non- observance Symbol Meaning Safety sign ►... -
Page 9: Safety
(→ Manufacturer information). proper use. OSNA shall bear no liability for any resulting damages. The owner bears full risk for improper use. Any other use must be agreed with the •... -
Page 10: General Safety Instructions
2 Safety 2.2.2 Duties of the system owner 2.2 General safety instructions Safety-conscious work Please observe the following specifications before performing any activities. Observe the safety specifications detailed in this operating manual, along with the occupa- tional safety regulations and all additional in- 2.2.1 Product safety ternal safety regulations. -
Page 11: Duties Of Personnel
2 Safety Guarantee Personnel qualification • Please consult the manufacturer be- The owner of the system must ensure that the fore carrying out any conversions, re- personnel tasked with working on the pump pairs or changes during the guarantee have read and understood this operating man- period. -
Page 12: Dangers Of Non-Observance Of The Safety Instructions
2 Safety 2.6 Special hazards 2.3 Dangers of non-observance of the safety instructions 2.6.1 Explosion area Non-observance of the safety instruc- • tions can lead to hazards to personnel, the machine and the environment. Do not use the pump in areas where •... -
Page 13: Layout And Function
3 Layout and function 3 Layout and function 3.1 Labeling This operating manual applies to pumps of the LG 100 to LG 750 series. Model code: LG 100 Size OSNA - piston pump with gear unit Figure 2: Scope of delivery for type LG... -
Page 14: Table 5: Starting Torques
3 Layout and function Motor power Starting torque ratio [kW] Ms/Mn Mn [Nm] 0.37 0.55 0.75 14.6 20.0 Table 5: Starting torques = Starting torque = Nominal torque = Kilowatt = Newton meter List applies only to three-phase motors. LG Piston Pump... -
Page 15: Transport And Intermediate Storage
4 Transport and intermediate storage 4.1.2 Lifting 4 Transport and intermediate storage 4.1 Transport DANGER Weight information (→ Other valid docu- ments) Risk of death or crushed limbs from falling transported goods! ► Choose lifting equipment that is suitable for the total weight to be transported. -
Page 16: Intermediate Storage
4 Transport and intermediate storage 4.3 Intermediate storage Ensure during intermediate storage that the NOTICE pump is not exposed to any weather conditions for a long period of time. If the pump is de- commissioned for a longer period of time (ap- proximately 2 to 3 months), ensure that it is ful- ly drained. -
Page 17: Layout And Mode Of Operation
The OSNA piston pump can be used together with a pressurized container for household wa- ter supply. Figure 4: Functional elements 2 Key: 5.2 Functional and operating ele-... -
Page 18: Layout Of The Piston Pump With Pressurized Container
5 Layout and mode of operation 5.3 Layout of the piston pump with pressurized container Figure 5: Layout with pressurized container Key: 1 Consumer 2 Shut-off valve with water outlet 3 Delivery pipe 4 Pressurized container 5 Leakage fluid outlet 6 Suction pipe 7 Foot valve 8 Suction head... -
Page 19: Technical Data
Figure 7: Dimensions in side view Please check the pump type on the type plate to determine the correct gap. Figure 6: Dimensions in front view Pump type LG 100 LG 200 LG 400 LG 500 LG 750 Flow rate... -
Page 20: Assembly And Installation
6 Assembly and installation protection against frost – 6 Assembly and installation 6.1.3 Preparing the base surface and foundations NOTICE ► Ensure that the base surface and founda- tions meet the following conditions: Material damage due to contamination! level – clean (no oils, dust or other contami- –... -
Page 21: Electrical Connection
6 Assembly and installation 6.2.2 Electrical connection CAUTION Electrical connection must be carried out by a specialist electrician, in line with the Figure 8: Installation area side view specifications of the local energy supplier or the VDE. Figure 9: Installation area front view Ensure a minimum clearance to aid mainte- nance work (→... -
Page 22: Assembling The Piston Pump With Additional Pressurized Container
6 Assembly and installation CAUTION Ensure compliance with all safety specifi- cations during installation and operation. Figure 11: Water connection 1 Suction pipe 2 Suction nozzle 3 Water container 4 Discharge nozzle 5 Delivery pipe 6 Non-return valve 7 To consumer Figure 12: Assembly with pressurized container We recommend installing shut-off valves (6) on the system side to make it easier to... -
Page 23: Installation
6 Assembly and installation 6.3 Installation Insert the lock screw (4). • Place the motor (2) on the rocker arms • Screw the pump horizontally to the (1) and tighten slightly. foundation. Position the V-belt and align the motor • on the rocker arm until the pulleys are Provide a noise-insulating base aligned. -
Page 24: Belt Guard
• Tighten the screws (7) on the rocker arms (1). 6 Crankcase • Insert the oil dipstick. Assembling the belt guard for LG 100 - 400 Push the clamp (3) onto the rocker • 6.3.2 Belt guard shaft (5). •... -
Page 25: Figure 16: Assembling The Belt Guard For Lg 500 And 750
6 Assembly and installation Removing the belt guard for LG 100 - 400 Loosen and remove the screw (4). • 1 Belt guard 2 V-belt • Pull off the belt guard. 3 V-role pulley key 4 Clamp 5 Rocker shaft... -
Page 26: Installing The Snifter Valve
6 Assembly and installation Removing the belt guard for LG 500 and 6.3.3 Installing the snifter valve Figure 17: Removing the belt guard for LG 500 and 750 Figure 18: Snifter valve Loosen the tapping screws (7). • 1 Snifter valve Remove the front section of the belt •... -
Page 27: Commissioning/ Decommissioning
7 Commissioning/decommissioning Oil quantity: 7 Commissioning/ decommissioning Series LG 100 - LG 400 min. 0.4 l Series LG 500 - LG 750 min. 0.8 l 7.1 Preparing for commissioning 7.1.1 Determining the pump configura- tion ► Determine the pump configuration... -
Page 28: Commissioning
7 Commissioning/decommissioning 7.2 Commissioning 7.2.1 Filling the pump WARNING If using long suction pipes, fill the entire pipe before initial commissioning. Risk of poisoning or injury due to hazard- ous pumping media! ► Collect any escaping pumping medium safely and dispose of in an environmentally friendly way. -
Page 29: Checking Direction Of Rotation
7 Commissioning/decommissioning 7.2.2 Checking direction of rotation DANGER CAUTION Risk of injury due to running pump! Incorrect direction of rotation ► Do not touch the running pump. ► Do not perform any work on the running pump. Insufficient lubrication The cast arrow (→ Figure 19: Drive casing, pg 25) on the casing (opposite the pump disc) in- dicates the required direction of rotation. -
Page 30: Figure 21: Starting The Piston Pump
7 Commissioning/decommissioning 0.1 MPa = 1 bar ≈ 10 m • Check before commissioning that all NOTICE pipe connections are fitted and pres- sure tight. Ensure that the snifter valve on the pump is closed. Open the suction-side fitting, and do not •... -
Page 31: Decommissioning
For optimal system operation, ensure a mini- ers. ► Apply pre- mum suction head of 2 m or -0.2 bar. servative to For other modes of operation, we recommend pump and con- contacting OSNA customer service. tainers. Remains fluid, – – non-corrosive Remains fluid, ►... -
Page 32: Recommissioning
7 Commissioning/decommissioning Draining the pump and protecting against (4) and the cylinder (2) until the re- frost maining water in the pump drains out on both sides. Re-tighten the loosened screws and • reattach the suction and discharge pipes. Reinsert the suction-side screwed plug •... -
Page 33: Table 9: Measures Following Longer Shut Down Time
7 Commissioning/decommissioning For operating interruptions > 1 year: Shut down Measure time > 1 year ► Check visually for leaks ► Replace elastomer seals > 2 years (gaskets, round seals, shaft seal rings and gland packings). ► Replace anti-friction bearings. Table 9: Measures following longer shut down time LG Piston Pump... -
Page 34: Maintenance And Repair
8.1 Maintenance Risk of injury due to running pump! ► Do not touch the running pump. OSNA piston pumps are virtually maintenance free as far as their main components are con- ► Do not perform any work on the running cerned. -
Page 35: V-Belt
8 Maintenance and repair Re-tension new V-belts after around 4-5 weeks of running time using the tensioning screw (2) (→ Figure 23) ). 1 Dipstick The V-belt and pulley must remain free of oil 2 Tensioning screw and grease, as the belt could otherwise slip and be destroyed. -
Page 36: Stuffing Box
Any worn or scored piston rods can lead to premature destruction of the packing. Assembly sequence: Have the pump inspected every 3 years by a specialist service provider or the OSNA Tallow ring customer service. Grooved ring Grooved ring... -
Page 37: Oil Change
Re-tighten the oil drain plug. 8.3 Safety valve Re-seal the oil drain plug! OSNA piston pumps are fitted with a TÜV- approved OSNA - SIOS safety valve (→ Figure 28: Safety valve), located in the pump's air Fill with oil as described in section •... -
Page 38: Table 11: Selection Of Sios Valves
Figure 28: Safety valve Pumping medium: Water Temperature range: 0-40°C If using a piston pump without OSNA-SIOS safety valve, the system should be protected against vacuums by means of a TÜV- appropriate safety valve. To ensure the installed OSNA-SIOS safety... -
Page 39: Faults And Troubleshooting
Suction head too high. No air cushion in pressurized Check for leaks with soap and remedy. Top up air container. cushion. OSNA-SIOS safety valve Insufficient air cushion in air Reduce switching pressure, add air by opening the responds. vessel, snifter valve not func- snifter valve. -
Page 40: Table 12: Fault Causes
9 Faults and troubleshooting Fault Cause Remedy Oil leak on pump or bear- Oil leak on pump or bearing. Consult specialist. ing. Drive knocks. Drive components defective. Have drive components replaced by specialist. Damage can be caused by: Change oil and improve ventilation of installation area. -
Page 41: Appendix
This can in turn jeopardize safety. Any Notes on ordering spare parts: liability and guarantee on the part of OSNA for damages resulting from the use of non-original spare parts and accessories is excluded. -
Page 42: Individual Parts Of The Lg Piston Pump
10 Appendix 10.2 Individual parts of the LG piston pump Figure 29: Explosion diagram of the LG 100-400 piston pump LG Piston Pump... -
Page 43: Table 13: Parts List For The Lg 100-400 Piston Pump
Pump cylinder cover Configuration A Snifter valve (incl. 43 rubber lip) Valve plate Rubber lip Valve body Stud Air vessel with SIOS valve Joint ring Gasket Domed nut Gasket Table 13: Parts list for the LG 100-400 piston pump LG Piston Pump... -
Page 44: Figure 30: Explosion Diagram Of The Lg 500-750 Piston Pump
10 Appendix Figure 30: Explosion diagram of the LG 500-750 piston pump LG Piston Pump... -
Page 45: Table 14: Parts List For The Lg 500-750 Piston Pump
10 Appendix Item Designation Item Designation Casing Liner Casing cover Plug with rim O-Ring Pump cylinder cover Oil level dipstick Gasket Hexagon head bolt Hexagon head bolt with nut Plug with rim Disc Rocker axis without hole Rubber lip (separate) Motor rocker Snifter valve (incl. -
Page 46: Motor Assembly
10 Appendix 10.3 Motor assembly Figure 31: Explosion diagram of the LG 100-400 motor assembly Item Designation Item Designation Motor (optional) Disc Belt guard Hexagon head bolt with nut Belt guard holder Disc Hexagon head bolt Table 15: Motor assembly parts list for LG 100-400... -
Page 47: Table 16: Motor Assembly Parts List For Lg 500-750
10 Appendix Figure 32: Explosion diagram of the LG 500-750 Item Designation Item Designation Belt guard complete Spring washer Cylinder tapping screw Disc Hexagon head bolt Hexagon head bolt with nut Disc Disc Hexagon head bolt Motor (optional) Hexagon nut Table 16: Motor assembly parts list for LG 500-750 LG Piston Pump... -
Page 48: Declaration Of Conformity As Per Ec Directive 2006/42/Ec, Annex Iia
We hereby declare under our sole responsibility as manufacturer that the following machine series of the type, as well as the configurations distributed by us, conform to the relevant specifications of the EC Machinery Directive 2006/42/EC. Piston pump LG 100, LG 200, LG 400, LG 500, LG 750 Designation: Pump no.:... -
Page 49: Clearance Certificate
10 Appendix 10.5 Clearance Certificate Please copy and send with the pump. Clearance Certificate Legal provisions oblige all businesses to protect their employees, other persons and the environment from damaging effects when handling hazardous substances. Products and their components may therefore only be repaired or inspected when the following declaration has been fully and correctly filled out and singed by an authorized and qualified specialist. - Page 50 10 Appendix Notes _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ LG Piston Pump...
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- Page 52 Phone: +49 541 1211 – 0 - Planning - Maintenance Fax: +49 541 1211 – 220 - Project management - Repair Internet: http://www.osna.de - Assembly E-mail: info@osna.de OSNA customer service Tel.: +49 541 1211 – 254 Emergency service Tel.: +49 171 4151 – 674...
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