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  3. Flow Booster Type ABS SB / XSB

Sulzer Flow Booster Type ABS SB / XSB Operating instructions

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SB 900 - 2500
XSB 900 - 2750
SB 900 - 2500
XSB 900 - 2750
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
en
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
3
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.
5
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
XX
X
X
0579-0003
1
22
1
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)
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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.
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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
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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.
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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.
13
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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)
1
2
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
1
OIL
2
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.
15
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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
19
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
1
508
3
6
7
9
8
507
2
509
508
507
1
3
6
7
9
8
4
5
2
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).
17
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
2
1
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
19
60.2
0584-0010a
140
142
19
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.
19
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
66
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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