Sulzer Flow Booster Type ABS SB / XSB Operating instructions

Brand: Sulzer

Model: Flow Booster Type ABS SB / XSB

Type: Operating instructions

www.sulzer.com

SB 900 - 2500

XSB 900 - 2750

SB 900 - 2500

XSB 900 - 2750

SB 900 - 2750

0580-0002

Flow Booster Type ABS

SB 900 to 2500 / XSB 900 to 2750

6006572-01 (09.2023)

Maintenance Instructions

Sulzer reserves the right to alter specications due to technical developments!

26006572-01

Maintenance Instructions (Translation from original instruction)

for ow booster type ABS SB:

SB 931 SB 1221 SB 1621 SB 1821 SB 2021 SB 2221 SB 2521

SB 932 SB 1222 SB 1622 SB 1822 SB 2022 SB 2222 SB 2522

SB 933 SB 1223 SB 1623 SB 1823 SB 2023 SB 2223 SB 2523

SB 934 SB 1624 SB 1824 SB 2024 SB 2224 SB 2524

SB 1625 SB 1825 SB 2025 SB 2225 SB 2525

SB 2026 SB 2226

For ow booster type ABS XSB:

XSB 931 M XSB 1621 M XSB 1821 M XSB 2021 M XSB 2221 M XSB 2521 M

XSB 932 M XSB 1622 M XSB 1822 M XSB 2022 M XSB 2222 M XSB 2522 M

XSB 933 M XSB 1623 M XSB 1823 M XSB 2023 M XSB 2223 M XSB 2523 M

XSB 934 M XSB 1624 M XSB 1824 M XSB 2024 M XSB 2224 M XSB 2524 M

XSB 1625 M XSB 1825 M XSB 2025 M XSB 2525 M

XSB 1431 LX XSB 2231 LX XSB 2531 LX XSB 2731 LX

XSB 2232 LX XSB 2532 LX XSB 2732 LX

XSB 2233 LX XSB 2533 LX XSB 2733 LX

6006572-01

Table of contents

1 General ................................................................................................................................................... 4

1.1 Introduction ............................................................................................................................................. 4

2 Safety ..................................................................................................................................................... 5

3 Maintenance .......................................................................................................................................... 5

3.1 Removal .................................................................................................................................................. 5

3.1.1 Removal(owboosterwithlockablecouplingsystem) ........................................................................... 5

3.1.2 Removal(owboosterwithselfadjustingcouplingsystem) ................................................................... 5

4 Operating proplems .............................................................................................................................. 7

5 Checking the coupling system ............................................................................................................ 7

6 Inspection intervals ow booster SB / XSB ........................................................................................ 8

7 Inspections .......................................................................................................................................... 10

7.1 Initialinspection ..................................................................................................................................... 10

7.2 Check .................................................................................................................................................... 11

7.3 Annualinpection .................................................................................................................................... 12

7.4 Generaloverhaul ................................................................................................................................... 13

8 Maintenance ........................................................................................................................................ 14

8.1 Checking/changingofthegearboxoil(Allmodels) ............................................................................... 14

8.2 Propellerremoval/assembly .................................................................................................................. 15

8.2.1 Propellerremoval/assemblySB900-2500 .......................................................................................... 15

8.2.2 Propellerremoval/assemblyXSB900,XSB2500 ................................................................................ 16

8.2.3 Propellerremoval/assemblyXSB2750 ................................................................................................. 17

8.3 Mechanicalsealremoval/assembly ...................................................................................................... 18

8.3.1 Mechanicalsealremoval/assemblySB900-2500,XSB900-XSB2500 ............................................ 18

8.3.2 Mechanicalsealremoval/assemblyXSB2750 ..................................................................................... 19

8.4 Oilllingandoilchange(OldSBversions) ........................................................................................... 22

8.5 Oilllingandoilchange ........................................................................................................................ 23

8.5.1 OilllingandoilchangeSB(Model2006withlargeroilchamber) ....................................................... 23

8.5.2 OilllingandoilchangeXSB ................................................................................................................ 23

8.6 SD-ring(Solids-deection-ring)removal/assembly ............................................................................... 24

46006572-01

1 General

1.1 Introduction

Inspectionscarriedthroughatregularintervalsandpreventivemaintenanceensuretrouble-freeoperation.

Forthisreasonthecompleteunitshouldbecleanedthoroughlyonaregularbasis,maintainedandinspected.

Whendoingthis,onehastotakespecialcarethatallpartsoftheunitareinagoodconditionandthatthe

operationalsecurityisguaranteed.The inspection period is determined by the usage of the units!

Sulzer Pump Solutions Ireland Ltd. (inthefollowingcalledSulzer)ServiceOrganisationwouldbepleasedto

adviseyouonanyspecialapplicationsyoumayhave.

Theuseroftheunitmustensurethatallmaintenance,inspectionorinstallationworkiscarriedoutby

authorisedandqualiedskilledpersonnel.Theusermustalsomakesurethatthesepersonnelhavecarefully

studiedtheInstallationandOperatingInstructions.

Asamatterofprincipleallworkontheunitshouldonlybecarriedoutwhileitisswitchedo.Themethod

describedintheMaintenanceInstructionstoshutdowntheunitmustbecompliedwith.

Unitsusedforpumpingormixingofliquids,whichcouldendangerhealth,mustbedecontaminated.

Immediatelyaftercompletionoftheworkallsafetyandprotectivedevicesmustberettedandreactivated.

Beforerecommencingoperationallpointslistedunderthesection“Commissioning”intheInstallationand

OperatingInstructionsmustbecompliedwith.

TheseMaintenanceInstructionscontainbasicinformationontheinstallation,operationandmaintenanceand

shouldbefollowedcarefully.Forthisreasonitisessentialthattheseinstructionsarereadcarefullybefore

installationorcommissioningnotonlybytheinstallationcrew,butalsobythosewhoareresponsiblefor

operationormaintenance.TheMaintenancInstructionsshouldalwaysbereadilyavailableatthelocationofthe

unit.

SafetyInstructionswhichmightcausedangertolifeincaseofnon-observancehavebeenspecically

highlightedwiththegeneraldangersymbol.

Thepresenceofadangerousvoltageisidentiedwiththissafetysymbol.

Thissymbolindicatesthedangerofanexplosionoccurring.

ATTENTION Appears at safety hints, the non-observance of which could damage the unit or aect

its functioning.

NOTE Used for important pieces of information.

Illustrationscode,e.g.(3/2).Therstdigitreferstothegureno.andtheseconddigittotheposition

inthatgure.

6006572-01

2 Safety

ThegeneralandspecichealthandsafetyhintsaredescribedindetailintheseparatebookletSafety

Instructions for Sulzer Products Type ABS.Ifanythingisnotclearoryouhaveanyquestionsastosafety

makecertaintocontactthemanufacturerSulzer.

3 Maintenance

NOTE The Sulzer warranty conditions are only valid provided that any repair work has been

carried out in Sulzer approved workshops and where original Sulzer spare parts have

been used.

3.1 Removal

TakenoteoftheentireweightoftheunitThehoistandchainmustbeadequatelydimensionedforthe

weightoftheunitandmustcomplywiththecurrentvalidsafetyregulations,aswellasgoodtechnical

practicebeingobserved.

Donotstayorworkintheswivelareaofasuspendedload!

Theliftinghookheightmusttakeintoconsiderationtheentireheightoftheunitaswellasthelengthof

theliftingchain.

ATTENTION When using a mechanical lifting tool (e.g. truck crane) or a tool with higher nominal

load, special attention is required! Ensure that lifting power doesn‘t exceed 3000 N

when ow booster gets stuck on guide tube!

3.1.1 Removal (ow booster with lockable coupling system)

Incaseofowboosterunitswiththelockable couplingsystem(see Figure 2)thecouplingsystemmustbe

unlockedbeforeremoval.(See Figure 3 and 4).Lifttheowbooster(afterunlockingthecouplingsystem)with

theaidofahoistoutofthetankandplaceitontoanevenrmatsurface.

3.1.2 Removal (ow booster with self-adjusting coupling system)

Lifttheowboosterunitswithself-adjustingcouplingsystem(see Figure 1)withtheaidofahoistoutofthe

tankandplaceitontoanevenrmatsurface.

66006572-01

0579-0001

0579-0002

Figure 1 SB with self-adjusting coupling system

(old System)

Figure 2 SB/XSB with lockable coupling system

0579-0003

0579-0004

Figure 3 Locking/Unlocking of coupling system with xed

installation (Variant A)

Figure 4 Locking/Unlocking of coupling system with

freestanding installation (Variant B)

6006572-01

4 Operating proplems

Thesafetyhintsintheprevioussectionsmustbeobserved!

Inadditiontotheprescribedmaintenanceandinspectionperiodsaninspectionoftheunitmustbecarriedout

urgentlyifanyunusualsymptomsareobservedsuchasheavyvibrationsorunevenowformation.

Possible fault causes:

• Coverageofwateroverpropellerisinadequate.

• Aerationinthepropellerarea.

• Wrongdirectionofrotationofthepropeller.

• Ropingorentanglementofmaterialatthepropelleroronthecable.

• Propellerisdamaged.

• Flowboosterisnotcorrectlycoupledorlockedinposition.

• Partsoftheinstallationsuchasbracketsorcouplingpartsaredefectiveorhavebecomeloose.

Inthesecasestheunitshouldbeswitchedoimmediatelyandinspected.Ifnofaultcauseisfoundorifthe

problempersistsaftercorrectionoftheapparentfaultthentheunitshouldbeswitchedo.Thesameapplies

ifthecurrentoverloadinthecontrolpanelrepeatedlytrips,ifthemoisturesensor(DI)orthermalsensorsare

activated.PleasecontactyourSulzerservicecentreforassistance.

5 Checking the coupling system

Thesafetyhintsintheprevioussectionsmustbeobserved!

Undernormaloperatingconditionsthecouplingandclampingmechanismoftheowboostercannotopen,as

itisaspeciallyshapedclampeddevice.Forsafetyreasonshowever,thecouplingsystemmustbecheckedfor

properfunctioningeverytimeitiscoupledintoposition.Ashorttestrunshouldthenbemade.

• Switchounitandensureitcannotbeinadvertentlyswitchedbackon.

• Turnthetubeholdingscrewfullycounterclockwisefor“VariantA”orfullyclockwisefor“VariantB”(see

gures3and4respectively).

• Raisetheowboosteroutofthetankwiththehoist.

ATTENTION The lifting rope should be tensioned exactly vertically!

• Cleanowboosterandpowercable(seemaintenanceinstructionbelow).

• Lowertheowboosteruntilitconnectsintothecouplingpiece.Raisetheowboosteroncemoreabout

20cmandcoupleitagain.

Variant “A“

• Turnthetubeholdingscrewclockwise(see gure 3)sofaruntiltheindicationpinisinsidethegreenmarking

ofthespringloadindicationdeviceofthetubeholder.Iftheindicationpinisnotinsidethegreenmarkingthe

unithasnotcoupledinapropermanner!

Variant “B“

• Turnthetubeholdingscrewcounterclockwise(see gure 4)andtightenitwithatighteningtorqueof80Nm.

Tosecuretheholdingscrew,screwinthesocketheadscrew.Ifthetighteningtorqueof80Nmofthetube

hodingscrewwillnotbereachedtheunithasnotcoupledinapropermanner!

86006572-01

Variant “A and B”

Possible causes:

• Thehoistisnotsetupcorrectly.Ropeisnotexactlyvertical.

Measure: Adjusttheboompositionofthehoistorcrane.

• Otherunitspresentarecausingunevenowandpreventingtheunitfromcouplingcorrectly.

Measure: Switchotheotherunits.

• Thecouplingpieceiscloggedwithdirtorropedmaterial.Thiscanhappenafterlongerperiodsofnon-usage.

Measure: Cleanwithastrongjetofwater.

• Repeatthecouplingprocedureuntiltheunithascoupledinapropermanner.

Variant “A”

• Turnthetubeholdingscrewclockwisesofaruntiltheindicationpinisinsidethegreenmarkingofthespring

loadindicationdeviceofthetubeholder.

Variant “B”

• Tensionthetubeholderscrewto80 Nmandlockit.

Variant “A and B”

• Carryouttestrunasdescribedinchapter 6. “Commissioning”oftheInstallationandOperatingInstructions.

ATTENTION The ow booster should not be operated if symptoms such as uctuating ampere

readings, uneven ow formation, air ute formation or vibration occur!

PleasecontactyourresponsibleSulzerServiceOrganisation.

6 Inspection intervals ow booster SB / XSB

Thesafetyhintsintheprevioussectionsmustbeobserved!

Theinspectionintervalsneededdependontheoperationconditionsonsite.Theclassicationisdividedinto

operating classes 1 to 4.

Theevaluationoftheoperatingconditionsandtheoperatingclassshouldbemadeinadvance,duringthe

projectengineeringwithreferencetotheknownregulatoryenvironmentandparameters.Afterthatthe

preliminaryoperatingclasscanbeselected.

Duringcommissioningtherealoperationconditionsshouldbeestablished.Theseshouldbecheckedagain

duringtheinitialinspection(after500or100operatinghours).Thenalevaluationregardingtheoperatingclass

shouldthenbemade.

Dicult operating conditions

• Ahighproportionofbrousmatterinthemedium.

• Turbulentowscausedbysimultaneousoperationofaerators,deeptanks,unfavourabletankgeometryor

structuresinthetankwhichaecttheow.

• Aggressiveorcorrosiveliquids.

Afterassessmentoftheoperatingconditionspresent,theoperatingclassisassigned.If one or more of the

conditions mentioned above are causing difficult operating conditions, then the assessment of the

operating classes should be class 3 or 4.Theinspectionsshouldbecarriedoutasrequired.Ifyouhaveany

doubtsorquestionspleasecontacttheSulzerServiceOrganisation.

6006572-01

Operating class Evaluation

1Good conditions

2Normalconditions

3Heavydutyconditions

4Critical conditions

Prescribed inspection and maintenance intervals SB / XSB

Operating class 1 and 2 Operating class 3 and 4

After 500 operating hours

“1. Initial Inspection”

X-1 to X-8

“Check of operating conditions”

X-9

After 100 operating hours

“1. Initial Inspection”

X-1 to X-8

“Check of operating conditions”

X-9

After3months

“Check”

X-3 to X-8

After6months

“Check”

X-3 to X-8

After9months

“Check”

X-3 to X-8

After 12 months

“Annual inspection”

X-1 to X-8; Y-1 to Y-5

After 12 months

“General overhaul”

X-1 to X-8; Y-1 to Y-5; Z-1 to Z-3

After15month

“Check”

X-3 to X-8

After18month

“Check”

X-3 to X-8

After21month

“Check”

X-3 to X-8

After 24 months

“Annual inspection”

X-1 to X-8; Y-1 to Y-5

After 24 months

“General overhaul”

X-1 to X-8; Y-1 to Y-5; Z-1 to Z-3

After27month

“Check”

X-3 to X-8

After30month

“Check”

X-3 to X-8

After33month

“Check”

X-3 to X-8

After 36 months

“General overhaul”

X-1 to X-8; Y-1 to Y-5; Z-1 to Z-3

After 36 months

“General overhaul”

X-1 to X-8; Y-1 to Y-5; Z-1 to Z-3

10 6006572-01

7 Inspections

Thesafetyhintsintheprevioussectionsmustbeobserved!

7.1 Initial inspection

After500or100operatinghours,dependingontheoperatingclass,theowboostershouldundergoa

thoroughinitialinspection(X).Thedetailedinspectiontaskslistedbelowshouldbecarefullycarriedout.

X-1 Checkingthecurrentconsumptionviatheamperemeter.

X-2 Functionaltestingofthemonitoringdevices.

X-3 Decoupletheunitandraiseit.Thencleanit.

X-4 Visualinspectionoftheshacklesandallelementsoftheliftingequipment.

X-5 CheckingpropellerandSD-ring.

X-6 Checkingthetensionofthestrainreliefofthepowercable.

X-7 Checkthatthemotorandmonitoringcablesarenotdamaged.

X-8 Checkingthefunctioningofthecouplingsystem(Variant “B” tighten tube holding screw with

80 Nm!).

X-9 Assessment of the operating conditions.

Duringnormaloperationthecurrentconsumptionshouldbeconstant;occasionalcurrentuctuationsare

causedbytheconstitutionofthematerialbeingmixed.

X-1 Checkingthecurrentconsumptionviatheamperemeter

Measure: Ifthecurrentconsumptionistoohighforalongerperiodduringnormaloperationplease

contactyourresponsibleSulzerServiceOrganisation.

X-2 Functionaltestingofthemonitoringdevices

Partoftheinitialcheckingshouldincludeafunctionaltestofallmonitoringdevices.Forthesefunctionaltests

theunitmusthavecooleddowntotheambienttemperature.Theelectricalconnectionsofthemonitoringdevice

mustbedisconnectedatthecontrolbox.Thesemeasurementsarecarriedoutbymeansofanohmmeteratthe

respectivecableends.

Measure: Incaseofanyfunctionalproblemsonthemonitoringdevicespleasecontactyourresponsi-

bleSulzerServiceOrganisation.

X-3 Decoupletheunitandraiseit.Thencleanit

Disconnecttheunitfromthemainsandensureitcannotbeinadvertentlyswitchedbackon(turnthetubexing

screwanticlockwiseuntilitreachesthestopposition).Raisetheowboosteroutofthetankandcleanit.

Measure: Defectiveorwornpartsshouldbereplaced.IfnecessarycontactyourresponsibleSulzer

ServiceOrganisation.

X-4 Visualinspectionoftheshacklesandallelementsoftheliftingequipment

Liftingequipmentsuchashoists,shacklesandallelementsoftheliftingequipmentmustundergoavisual

examinationatregularintervalsforwearandcorrosion.

Measure: Defectiveorwornpartsshouldbereplaced.IfnecessarycontactyourresponsibleSulzer

ServiceOrganisation.

6006572-01

X-5 CheckingpropellerandSD-ring

ThepropellerandSD-ringshouldbecarefullyinspected.Thepropellermayshowspotsofruptureandwear

duetostronglyabrasiveoraggressivemixingmaterial.Ineithercasetheowformationisreducedconsiderably

andthepropellermustbereplaced.TheSDeection-ringmustalsobecheckedforexcessivewearand,if

necessaryitmustbeexchanged.

Measure: Defectiveorwornpartsshouldbereplaced.IfnecessarycontactyourresponsibleSulzer

ServiceOrganisation.

X-6 Checkingthetensionofthestrainreliefofthepowercable

Theplasticropeforthestrainreliefofthemotorconnectioncableshouldalsobechecked.Itshouldbe

underlighttension.Ifthetensionhasbecomelost,itcouldallowthemotorcabletoswinglooseandbecome

damaged.

Measure: Iftheplasticropeforthestrainreliefofthemotorcablehasbecomeloose,itmustbereten-

sioned. (see Installation and Operating Instructions Chapter 5, Figure 15).Dothisbyope-

ningtheupperropeclamp,formanewloopandretightentheclamp.Theropeissuspended

fromthecablehooksoitisunderlighttension.

X-7 Checkthatthemotorandmonitoringcablesarenotdamaged

Inspecialapplicationcases(forexampleifthemediumisheavilypollutedwithbrousorsolidmaterial)the

motorcablesshouldbecleanedofanybrousmaterial(depositsorropedmaterial).Inadditionthecables

shouldbecheckedforanydamagetotheinsulationsuchasscratches,ssures,bubblesorcrushing.

ATTENTION Damaged motor or control circuit cables must be replaced in all cases.

Measure: PleasecontactyourresponsibleSulzerServiceOrganisation.

X-8 Checkingthefunctioningofthecouplingsystem

Thetighttofthebracketandtheproperfunctionofthecouplingsystemhavetobechecked.Incaseof

Variant “A”itmustbeensuredthattheindicationpinofthespringloadindicationdeviceisinsidethegreen

marking.IncaseofVariant “B”especiallytheprescribedtighteningtorqueofthetubeholdingscrew(80Nm)

hastobechecked.(For detailed hints see chapter 5 “Checking the coupling system”).

Measure: Ifanypartshavebecomelooseorarenotlongertightlyfastenedorifthefunctionisaected

inanywaypleasecontacttheSulzerServiceOrganisation.

7.2 Check

For units with operating classes 3 or 4 a check must be carried out every 3 months.

X-3 Decoupletheunitandraiseit.Thencleanit.

X-4 Visualinspectionoftheshacklesandallelementsoftheliftingequipment.

X-5 CheckingpropellerandSD-ring.

X-6 Checkingthetensionofthestrainreliefofthepowercable.

X-7 Checkthatthemotorandmonitoringcablesarenotdamaged.

X-8 Checkingthefunctioningofthecouplingsystem (Variant “B” tighten tube holding screw with

80 Nm!).

12 6006572-01

7.3 Annual inspection

X-1 CheckingthecurrentconsumptionviatheAmperemeter.

X-2 Functionaltestingofthemonitoringdevices.

X-3 Decoupletheunitandraiseit.Thencleanit.

X-4 Visualinspectionoftheshacklesandallelementsoftheliftingequipment.

X-5 CheckingpropellerandSD-ring.

X-6 Checkingthetensionofthestrainreliefofthepowercable.

X-7 Checkthatthemotorandmonitoringcablesarenotdamaged.

X-8 Checkingthefunctioningofthecouplingsystem(Variant “B” tighten tube holding screw with 80 Nm!).

Duringtheannualinspectionthefollowingchecksshouldalsobecarriedout.

Y-1 Insulationresistancecheck.

Y-2 Checkthegearboxoil.

Y-3 Checkthelubricatingoilas per section 8.5 (onlyformodel2006).

Y- 4 Checkthatallboltsandnutsaretightenedwiththecorrecttorque.

Y-5 Repairanypaintdamage.

Y-1 Insulationresistancecheck

Theinsulationresistanceofthemotorwindingshouldbemeasuredonceayear.Iftheinsulationresistanceis

notatthecorrectlevel,moisturemighthaveenteredthemotor.

Measure: PleasecontactyourresponsibleSulzerServiceOrganisation.Theunitmustbetakenoutof

operationandshouldnotbestartedagain!

Y-2 Checkthegearboxoil

Onceayearthegearboxoilshouldbechecked(seechapter8.1Checking/changingofthegearboxoil).Check

ifthereisanemulsionofoilandwaterpresent.

ATTENTION After the oil inll and oil drain screws on the gearbox have been closed o they and

the surrounding area must be degreased and then carefully repainted.

Measure: Ifwaterisfoundinthegearboxthentheoilmustalwaysbereplaced.Inthiscaseitisessen-

tialthatyoucontactyourresponsibleSulzerServiceOrganisationastheprobablecauseis

leakageinthegearbox.Theunitshouldnotbeswitchedbackon.

Y-3 Checkthelubricatingoilas per section 8.5 (onlyformodel2006)

Onceayeartheunitsofthenewgeneration(from01.2006)shouldundergoacheckonthelubricatingoillevels.

(See Section 8.5)Checkalsoifthereisanemulsionofoilandwaterpresent.

ATTENTION For all SB 900 -2500 , the locking screw at position 6/2 must be replaced by a

magnetic locking screw (art.no.: 1156 0082) after changing the gear oil. After the

oil inll and oil drain screws on the gearbox have been closed o they and the

surrounding area must be degreased and then carefully repainted.

Measure: Ifwaterisfoundintheoilthemechanicalsealmustalwaysbereplaced.(see Section 8.3) In

thiscaseitisessentialthatyoucontactyourresponsibleSulzerServiceOrganisation.The

unitshouldnotbeswitchedbackon.

Y- 4 Checkingofthetighteningtorquesofthescrewsandnuts

Forsafetyreasonswerecommendcheckingonceayear(orafter8000operatinghours)thatthescrewsofthe

couplingbracketandthepropellerxingarecorrectlytightened.

6006572-01

ATTENTION Ensure that the tting position and tightening torque of the Nord-Lock® securing

washers is correct as in Figure 5 and table for tightening torque!

Outer side of the 2 securing washers

Inner side of the 2 securing washers

0562-0009

Figure 5 Correct tting position of the Nord-Lock® securing washers

Tightening torque in Nm for:

Sulzerstainlesssteelscrews

M6 M8 M10 M12 M16 M20 M24

6.9 17 33 56 136 267 460

Tubeholderscrew:80NmincaseofVariant“B”

Measure: Openthescrewsandthenretightenusingthecorrecttorques.

Y-5 Repairanypaintdamage

Onceayear,thoroughlycleantheunitandcheckforanypaintdamage.Anydefectsshouldberepaired.

7.4 General overhaul

X-1 Checkingthecurrentconsumptionviatheamperemeter.

X-2 Functionaltestingofthemonitoringdevices.

X-3 Decoupletheunitandraiseit.Thencleanit

X-4 Visualinspectionoftheshacklesandallelementsoftheliftingequipment.

X-5 CheckingpropellerandSD-ring.

X-6 Checkingthetensionofthestrainreliefofthepowercable.

X-7 Checkthatthemotorandmonitoringcablesarenotdamaged.

X-8 Checkingthefunctioningofthecouplingsystem (Variant “B” tighten tube holding screw with 80 Nm!).

Y-1 Insulationresistancecheck.

Y-2 Checkthegearboxoil.

Y-3 Checkthelubricatingoilas per section 8.5 (onlyformodel2006).

Y- 4 Checkthatallboltandnutsaretightenedwiththecorrecttorque.

Y-5 Repairanypaintdamage.

In addition to the annual inspection the following maintenance work should be carried out:

Z-1 Changingthegearboxoil.

Z-2 Changingthepowercables.

Z-3 Changingthemechanicalsealandthelubricatingoil.

Z-1 Changingofthegearboxoil

Changingthegearboxoilisdescribedinchapter 8.1 Checking/changing of the gearbox oil.

Measure: Duetothedesignoftheunitspecialtechnicalknowledgeisrequiredinordertobeableto

changethegearboxoil.Ifindoubt,pleasecontactyourSulzerServiceOrganisation.

14 6006572-01

Z-2 Changingthepowercable

Westronglyrecommendthatthepowercableandthesealsatthecableinletarereplaced.

Measure: Duetothedesignoftheunitspecialtechnicalknowledgeisrequiredinordertobeableto

changethepowercable.Ifindoubts,pleasecontactyourSulzerServiceOrganisation.

Z-3 Changingthemechanicalsealandthelubricatingoil

Westronglyrecommendthatthemechanicalsealandthelubricatingoilarereplaced.

Measure: Duetothedesignoftheunitspecialtechnicalknowledgeisrequiredinordertobeableto

changethemechanicalseal.Ifindoubts,pleasecontactyourSulzerServiceOrganisation.

8 Maintenance

m Thesafetyhintsintheprevioussectionsmustbeobserved!

8.1 Checking/changing of the gearbox oil (all models)

OIL

0579-0005

Filling quantity of the gearbox oil /

SB 900 - 2500

2.4 l+/-0.1l

Approved gearbox oils:

KlüberKlübersynthGH6-220

CastrolOptigearSynthetic800/220

ShellOmalaS4WE220

MobilGlygoyle220

FuchsRenolinPG220

Total Carter SY 220

OIL

0584-0006

Filling quantity of the gearbox oil /

XSB:900-2750

3.4 l+/-0.1l

Approved gearbox oils:

KlüberKlübersynthGH6-220

MobilGlygoyle220

FuchsRenolinPG220

Total Carter SY 220

Figure 6 Checking/changing of gearbox oil

Draining of the gearbox oil:

Whencarryingouttheoilchangetheregulationsforoilusagemustbeobserved.Wasteoilmustbe

disposedofinapropermanner.

6006572-01

Astheremaybeapressurebuild-upinthegearboxcareshouldbetakenwhenremovingtheoildrain-

orll-screw.Forthisreasonthescrewsshouldbecoveredwithaclothwhileremoving.

• Openoilllscrew(6/1)carefullyandreleasepressureifnecessary.

• Screwouttheoildrainscrew(6/2)andreleasetheoil.

Relling the gearbox oil:

ATTENTION The listed lling quantity should be strictly observed. Otherwise the gearbox might

be damaged!

Aftertheoilinllandoildrainscrewsonthegearboxhavebeenclosedotheyandthesurroundingareamust

becarefullydegreasedandthenrepainted.

8.2 Propeller removal/assembly

8.2.1 Propeller removal/assembly SB 900 - 2500

141108

107 106 110

101

99 100

140

0579-0006

Figure 7 Propeller removal/assembly SB

Propeller dismantling:

NOTE The xing strap (7/99) for the SD-ring (7/101) and the SD-ring itself does not have to

be dismantled when removing or changing the propeller!

• Removepropellerxingscrew(7/107)andwithdrawthepropeller(7/108).

NOTE Wear grooves may be visible at the circumference of the propeller hub in the area

where it overlaps with the SD-ring. These are normal signs of usage and have no

negative eect on the operation. This means that it is not necessary to change the

hub when changing the SD-ring.

ATTENTION Observe the storage instructions (for the propeller) Section 3.3 of the Installation and

Operating Instructions!

Propeller assembly:

16 6006572-01

• Lightlygreasethepropellerbossandshaftend.Checkkey(7/19)forwearordamageandreplaceif

necessary.

• Placeanewseal(7/141)onthepropellershaftandplaceintothegrooveofthexingring(7/140).

• Ifnecessary,tanewSD-ring(7/101)asper section 8.6andxinpositionwithanewclampingring(7/99)

andnewclamp(7/100).

• Carefullypressonthepropeller(7/108)andtanewseal(7/110).

• Pressonthesecuringrings(7/106)inthecorrectinstallationlocation(see Figure 5).

• Tightenthepropellerxingscrew(7/107)withatorque of 56 Nm.

8.2.2 Propeller removal/assembly XSB 900, XSB 2500

508

507

509

508

507

509

XSB 900 M

XSB 2500 M

0584-0008

Figure 8 Mechanical seal removal/assembly XSB 900, XSB 2500

Propeller dismantling:

NOTE The xing strap (8/508) for the SD-ring (8/507) and the SD-ring itself does not have to

be dismantled when removing or changing the propeller!

• Removepropellerxingscrew(8/1)andwithdrawthepropeller(8/6).

6006572-01

NOTE Wear grooves may be visible at the circumference of the propeller hub in the area

where it overlaps with the SD-ring. These are normal signs of usage and have no

negative eect on the operation. This means that it is not necessary to change the

hub when changing the SD-ring.

ATTENTION Observe the storage instructions (for the propeller) Section 3.3 of the Installation and

Operating Instructions!

Propeller assembly:

• Lightlygreasethepropellerbossandshaftend.Checkkey(8/9)forwearordamageandreplaceif

necessary.

• Placeanewseal(8/7)onthepropellershaftandplaceintothegrooveofthexingring(8/8).

• Ifnecessary,tanewSD-ring(8/507)asper section 8.6andxinpositionwithanewclampingring(8/508)

andnewclamp(8/509).

• Carefullypressonthepropeller(8/6)andtanewseal(7/110).

• Pressonthesecuringrings(8/2)inthecorrectinstallationlocation(see Figure 5).

• Tightenthepropellerxingscrew(8/1)withatorque of 56 Nm.

8.2.3 Propeller removal/assembly XSB 2750

0584-0009

Figure 9 Propellermontage/-demontage XSB 2750

Propeller dismantling:

NOTE The xing strap (12/508) for the SD-ring (12/507) and the SD-ring itself does not have

to be dismantled when removing or changing the propeller!

• Removepropellerxingscrew(9/1)andwithdrawthepropeller(9/2).

18 6006572-01

Propeller assembly:

NOTE Remove the edge guard on the propeller blade tip only shortly before the ow

booster is put into operation.

ATTENTION Observe the installation position of the propeller blades.

• Positionthepropellerblade(9/2).

• Tightenthecylinder-headscrews(9/1)nger-tight.

• Tightencylinder-headscrew(9/1)toatorque of 150 Nm

8.3 Mechanical seal removal/assembly

8.3.1 Mechanical seal removal/assembly SB 900 - 2500, XSB 900- XSB 2500

ATTENTION Due to the design of the unit, the lubricating oil in the older versions of the SB

can only be released after partial dismantling of the mechanical seal (rotating part

10+11/60.1)! See section 8.4.

141

140

142

60.1

60.2

0584-0010a

140

142

60.2

60.1

141

0584-0010b

Figure 10 Mechanical seal removal/assembly SB Figure 11 Mechanical seal removal/assembly

XSB 900 - 2500

Removal of the mechanical seal:

• Pressthekeyoutofthekeywayontheshaft(10+11/19).

• Withdrawthelipsealfromtheshaft(10+11/141).

• Openscrew(10+11/142)atthexingring(10+11/140)andwithdrawthexingringotheshaft.

NOTE The ow booster should be set up vertically (see Figure 16) so that the oil does not

gush out of the unit when the rotating part of the mechanical seal is removed.

• Placeowboostervertically(as shown in Figure 16)andensurethatitcannottoppleover.

• Haveacollectionvesselcorrectlypositioned(min.0.5l).

• Carefullywithdrawtherotatingpartofthemechanicalseal(10+11/60.1)fromtheshaftwithalightrotating

motion.Whendoingthis,coverorholdwithaclothtoallowthereleaseofanypressurewhichmaybeinthe

oilchamber.

ATTENTION Changing the oil where necessary is carried out in accordance with section 8.4/8.5.

6006572-01

NOTE If only the lubricating oil is being checked or changed, then the stationary part of the

mechanical seal (10+11/60.2) need not be removed from the seal holding plate!

Thexedstationaryring(10+11/60.2)isinsertedintothesealholdingplateofthegearboxwithaproleseal.

Thexedringcanberemovedifnecessarye.g.ifitneedstobereplaced,byproceedingcarefullyasfollows:

• Carefullypressoutthexedring(10+11/60.2)byexertingpressuresimultaneouslyusingtwosmallscrewdrivers.

ATTENTION After removal of the xed ring we recommend for security reasons (even if no

damage is visible) that the entire mechanical seal be replaced!

8.3.2 Mechanical seal removal/assembly XSB 2750

508

507

246

244

509

392

139

138

140

60.2

0 58 4 - 0 011

Figure 12 Mechanical seal removal/assembly XSB 2750

Removal of the mechanical seal:

• Withdrawcovercap(12/246)openclamp(12/66)atthexingringandwithdrawthepropellerhub(12/244)o

theshaft.

• Withdrawthelipsealfromtheshaft(12/392).

• Openscrew(12/140)atthexingring(12/139)andwithdrawthexingringotheshaft.

NOTE The ow booster should be set up vertically (see Figure 16) so that the oil does not

gush out of the unit when the rotating part of the mechanical seal is removed.

• Placeowboostervertically(as shown in Figure 16)andensurethatitcannottoppleover.

• Haveacollectionvesselcorrectlypositioned(min.0.5l).

• Carefullywithdrawtherotatingpartofthemechanicalseal(12/138)fromtheshaftwithalightrotatingmotion.

Whendoingthis,coverorholdwithaclothtoallowthereleaseofanypressurewhichmaybeintheoil

chamber.

ATTENTION Changing the oil where necessary is carried out in accordance with section 8.4/8.5.

20 6006572-01

NOTE If only the lubricating oil is being checked or changed, then the stationary part of the

mechanical seal (12/60.2) need not be removed from the seal holding plate!

Thexedstationaryring(12/60.2)isinsertedintothesealholdingplateofthegearboxwithaproleseal.The

xedringcanberemovedifnecessarye.g.ifitneedstobereplacedbyproceedingcarefullyasfollows:

• Carefullypressoutthexedring(12/60.2)byexertingpressuresimultaneouslyusingtwosmallscrewdrivers.

ATTENTION After removal of the xed ring we recommend for security reasons (even if no

damage is visible) that the entire mechanical seal be replaced!

Assembly of the mechanical seal:

ATTENTION When assembling the mechanical seal it is essential to proceed carefully and under

clean conditions. Otherwise damage during assembly or subsequent failure in

operation may result.

Inparticulartakespecialcarewhenttingandpressinghomethexedringthatitisnottilted.Whenpressingit

homeoverthesealsurfaceuseasuitablydimensionedplastictube(see Figure 13)withaperfectlyatsurface.

Theinnerdiametershouldbesuchthatitslidescloselyovertheshaftend.Thiswillpreventtiltinganddamage

totheslidingsurfaces!

D2 = d1 + 0,1 - 0,2 mm

0579-0008

Figure 13 Fitting of the xed ring

NOTE While the illustration Figure 13 shows the tting of the prole seal, in most cases it is

already tted to the xed ring.

• Lubricatesealandslidingsurfaceofthexedringlightlywithsomelubricatingoil.

• Pressxedringwithprolesealovertheshaftendandpressfullyhomeintotheseatinginthesealholding

plateusingasuitableplastictube.

D2 = D1 + 0.1 - 0.2 mm

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Sulzer Flow Booster Type ABS SB / XSB Operating instructions

Sulzer Flow Booster Type ABS SB / XSB Operating instructions

Sulzer Flow Booster Type ABS SB / XSB Operating instructions

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