Godwin HS80, HS100, HS100NC, HS150NC, HS150 Operator's Handbook Manual
...
OPERATOR HANDBOOK
Heidra Pumps
HS80
HS100
HS100NC
HS100-SG
HS103
HS150
HS150NC
HS150-SG
HS150V
HS150V-SG
HS150HH
HS200
HS200-SG
HS250
HS300
READ BEFORE INSTALLING OR OPERATING THIS EQUIPMENT
Xylem Dewatering Solutions UK
Ltd
Quenington
Cirencester
Gloucestershire
GL7 5BX,
England
Tel: *44 (0)1285 750271
Fax: *44 (0)1285 750352
E-mail: sales@godwinpumps.co.uk
Website: www.godwinpumps.co.uk
Pump Serial Number
Xylem Dewatering Solutions
One Floodgate Road
Bridgeport
New Jersey 08014
U.S.A.
Tel: 856 467 3636
Fax: 856 467 4841
E-mail: sales@godwinpumps.com
Website: www.godwinpumps.com
Book No
95-0014-0000/A
Issue
6
Date
September 2012
OPERATOR Book No.: 95-0014-0000/A
HANDBOOK Issue: 06
Page 2 of 30
CONTENTS
1 INTRODUCTION ........................................................................................................... 3
2 HOW TO USE THIS HANDBOOK ................................................................................. 3
3 SAFETY PRECAUTIONS .............................................................................................. 4
4 IDENTIFICATION .......................................................................................................... 4
5 INSTALLATION ............................................................................................................. 5
5.1 General Notes ....................................................................................................................................................... 5
5.2 Hydraulic motor ..................................................................................................................................................... 5
5.2.1 Determining motor inlet and outlet ports ....................................................................................................... 5
5.2.2 Front seal removal ........................................................................................................................................ 6
5.3 Hoses .................................................................................................................................................................... 7
6 OPERATION .................................................................................................................. 7
6.1 Starting ................................................................................................................................................................. 7
6.2 Draining ................................................................................................................................................................ 7
6.3 Storage Procedure ................................................................................................................................................ 7
7 MAINTENANCE ............................................................................................................ 8
7.1 HS80 pumps ......................................................................................................................................................... 8
7.1.1 Dismantling ................................................................................................................................................... 8
7.1.2 Reassembly .................................................................................................................................................. 9
7.2 HS100, HS100-SG, HS103, HS150, HS150-SG, HS150V & HS150V-SG pumps ............................................. 10
7.2.1 Dismantling ................................................................................................................................................. 10
7.2.2 Reassembly ................................................................................................................................................ 12
7.3 HS150HH, HS200-SG, HS200 & HS250 pumps................................................................................................. 13
7.3.1 Dismantling ................................................................................................................................................. 13
7.3.2 Reassembly ................................................................................................................................................ 14
7.4 HS300 pumps ..................................................................................................................................................... 16
7.4.1 Dismantling ................................................................................................................................................. 16
7.4.2 Reassembly ................................................................................................................................................ 18
7.5 HS100NC & HS150NC Pumps ........................................................................................................................... 19
7.5.1 Dismantling ................................................................................................................................................. 19
7.5.2 Reassembly ................................................................................................................................................ 21
7.5.2.1 Guide Pin Fitting ..................................................................................................................................... 21
7.5.2.2 Impeller Fit t ing ........................................................................................................................................ 23
7.5.2.3 Adjusting Impeller Front Clearance ......................................................................................................... 24
8 WARRANTY ................................................................................................................ 25
9 FAULT FINDING ......................................................................................................... 25
10 TECHNICAL DATA ..................................................................................................... 26
10.1 HS80, HS100, HS100-SG, HS103, HS150, HS150V & HS150V-SG Pumps ..................................................... 26
10.2 HS150HH, HS200, HS200-SG, HS250 & HS300 Pumps ................................................................................... 27
10.3 HS100NC & HS150NC Pumps ........................................................................................................................... 28
10.4 Fastener Torques ................................................................................................................................................ 29
Book No.: 95-0014-0000/A OPERATOR
Issue: 06 HANDBOOK
Page 3 of 30
1 INTRODUCTION
The purpose of this Installation, Operating and Maintenance Handbook is to provide the owner or user of the equipment
with sufficient information to carry out those tasks on the Heidra hydraulically driven range of vertical suct io n
Submersible Pumps.
Pump models covered: HS80 HS103 HS150V-SG HS250
HS100 HS150 HS150HH HS300
HS100NC HS150NC HS200
HS100-SG HS150V HS200-SG
Because this handbook covers so many variants the user must ensure that they are reading the correct diagrams and
instructions for the unit they are working on.
Installation and maintenance is designed to be carried out using simple hand and service tools. A range of special tools
designed to ease dismantling and reassembly is available from Xylem Dewatering Solutions. When the user has
insufficient tools, experience or ability, this work should not be attempted. Under no circum stances should makeshift
tools or equipment be used, as this may adversely affect safe working practices and pump operation.
Ensure that suitably qualified personnel carry out the installation. The variety of conditions and environments in which
this equipment can be used means that the operator and those responsible must satisfy themselves as to the safety
and acceptability of each application and operating condition of this equipment. Under no circumstances will Xylem
Dewatering Solutions be responsible or liable for indirect or consequential damages arising from the use or application
of this equipment.
The pump may be supplied with or without a hydraulic motor fitted. This handbook covers the pump end only. For
packaged pump sets, information on equipment other than the pump end is contained in separate documentation.
Parts that have not been approved by Xylem Dewatering Solutions cannot be relied upon for correct material,
dimensions or finish. Xylem Dewatering Solutions cannot therefore be held responsible for any damage arising from the
use of such parts. This and failure to observe any instruction or procedure in this handbook will invalidate the warranty.
The information contained in this handbook was correct at the time of publication. It is subject to amendment at any
time. Should any doubt exist about the veracity of the information, contact Xylem Dewatering Solutions for clarification
before proceeding.
Associated Publications: - 95-0014-0000/B Operator handbook – Heidra Power Packs.
2 HOW TO USE THIS HANDBOOK
Read this section before installing, opera ting or carrying out any maintenance on the unit.
When the pump is being installed operated or maintained there are a number of practices that may lead to personal
injury or product damage. Your attention is drawn to the following symbols used throughout this handbook.
CAUTION. This caution symbol draws attention to special instructions or procedures which, if not correctly
followed, may result in damage to, or destruction of equipment.
WARNING. This warning symbol draws attention to special instructions or procedures which, if not strictly
observed, may result in personal injury.
WARNING. A WARNING SYMBOL WITH THIS TYPE OF TEXT DRAWS ATTENTION TO SPECIAL
INSTRUCTIONS OR PROCEDURES WHICH, IF NOT STRICTLY OBSERVED MAY RESULT IN SEVERE
PERSONAL INJURY, OR LOSS OF LIFE.
NOTE: A note is used to draw your attention to additional important information.
OPERATOR Book No.: 95-0014-0000/A
HANDBOOK Issue: 06
Page 4 of 30
3 SAFETY PRECAUTIONS
WARNING. ALL ITEMS IN THIS SECTION, IF NOT STRICTLY OBSERVED, COULD RESULT IN SEVERE
PERSONAL INJURY OR LOSS OF LIFE.
Only use lifting equipment of suitable capacity for the size and weight of the equipment being lifted. The pump units are
designed for lifting by wire rope in use or slings around the workshop.
The equipment must always be lifted using safe working practices and in accordance with any local and national
guidelines or statutes. If in doubt, consult Xy lem Dew ater in g Soluti ons or a local lifting expert.
Whilst lifting the unit keep personnel well away and never allow people underneath.
Personnel working on the pump must always wear clean, correctly fitting clothing and safety footwear. Clothing
impregnated with oil or fuel can constitute a health hazard through prolonged contact with the skin and may also
constitute a fire hazard.
Check the type of liquid the pump has been used for before working on them. Residues could be hazardous to your
health. If in doubt, flush thoroughly with clean water before commencing work.
Rotating equipment presents a hazard in itself. Alert surrounding personnel before starting and post notifications whilst
in operation.
Moving parts are guarded to protect you. Guards removed for maintenance must be replaced before starting the pump.
Never insert anything into the pump body whilst the pump is running and the delivery hoses are disconnected.
Where connections are flanged, use all flange bolt holes and ensure the correct bolt size and quality is utilised when
connecting suction and delivery hoses.
Where connections are threaded, ensure the threads are sound before use and protected from damage if left
unconnected during storage or transpor ta tio n.
Although the pump can handle solids up to the size indicated in the Technical Data section of this manual, larger or
irregular solids may cause blockage with consequent damage to pump components.
Always allow adequate ventilation for the pump driver. Diesel engines require air for both combustion and cooling.
Electric motors require air for cooling purposes. This air must never be allowed to recirculate.
Be aware of burn and fire risks from items such as diesel engine exhaust pipes and silencers. Never place flammable
items around the unit.
Diesel engines exhaust and some of its constituents are known in the State of California to cause cancer, birth defects
and other reproductive harm.
Liquid pressure may still be present even after shutdown of the pump. Particular attention should be paid to delivery
lines that are long, or rise through any height, as these can contain large volumes of liquid. These lines must be
isolated and drained down before commencing work. Sudden release of this liquid can cause serious injury to an
operator either directly or indirectly through the rotational motion it can induce.
Never run the pump above its maximum speed.
Wear protective gloves when handling the equipment. There may be sharp metal edges.
4 IDENTIFICATION
Every pump unit has a nameplate similar to one of those shown below. This nameplate lists the serial number and type
of the pump. These numbers must be quoted in any enquiry for spares or service.
Book No.: 95-0014-0000/A OPERATOR
Issue: 06 HANDBOOK
Page 5 of 30
5 INSTALLATION
5.1 General Notes
Xylem Dewatering Solutions may refute warranty liability if the installation does not meet the requirements of the pump.
Consult Xylem Dewatering Solutions should any doubt exist over the suitability of an installation .
Only suitably qualified personnel (both mechanical and electrical) should carry out the installation. All local and national
regulations in force must be observed.
The delivery pipe work s houl d be kept as short as possible with a minimum number of large radii bends to minimise
pipe friction losses. Fitting larger diamet er pipe work than the pump outlet will maximise flow rates. Size increases in
the horizontal plane should be achieved using eccentric reducers to minimise the risks of air locks.
Lay out above ground piping runs before connecting to the pump to ensure that tight bends and other flow restrictions
are not included.
5.2 Hydraulic motor
CAUTION. Hydraulic motors on submersible pumps can suffer serious damage, including catastroph ic fail ure, if
they are operated in the wrong rotation.
This occurs when either the hydraulic pipe connections are made incorrectly; i.e. inlet line to the outlet side of the motor
and vice versa or, a wrong rotation motor is fitted on replacement. Failures result in unnecessary down time and
possible pollution from escaped hydraulic fluid. Correctly specifying a replacement motor and identifying the inlet and
outlet motor ports on new or existing motors before connection and start up is critical.
Figure 1 Hydraulic system schematic
A Xylem Dewatering Solutions supplied system is fitted with male and female quick release couplings at all terminal
points to prevent incorrect connection. A typical system illustrating this is shown in Figure 1.
5.2.1 Determining motor inlet and outlet ports
Many older motors have their bolted on connecting ports stamped with ‘IN’ or ‘HIGH PRESSURE’. These stampings
should be treated with a degree of caution as the ports could have previously been removed from the motor and
replaced incorrectly. Later motors will have their rotation and ‘IN’ stamped on the body (see Figure 3). These may be
taken as much more reliable, but even so caution must be exercised and the user must be satisfied that they are
correct before proceeding.
The Xylem Dewatering Solutions serial number of the pump is vitally important in any request for spares. It will be found
on a serial plate located on the main body of the pump. If the serial number cannot be found then the following
procedure should be employed to determine the requirement.
It is important to understand that when specifying any directional rotation it must be qualified by stating the direction in
which that rotation is viewed. This is illustrated in Figure 2 where, when viewed from above the submersible pump, the
direction of rotation is clockwise, but the Xylem Dewatering Solutions method of specification is the direction of rotation
looking from the underside (i.e. the inlet side) of the pump and is anti-clockwise. Figure 2 shows a Heidra 10022
submersible pump but the principles are equally applicable to any submersible pump.
1. Identify the submersib le pump rot ati on – clockwise or anti-clockwise? (Refer to Figure 2).
2. The hydraulic motor rotation notation is the same as the pump; i.e. an anti-clockwise pump requires an anticlockwise motor and vice versa.
OPERATOR Book No.: 95-0014-0000/A
HANDBOOK Issue: 06
Page 6 of 30
3. The output shaft from the motor is offset one way from the port centres in the body (see Figure 3). Ensure the
motor is in the correct orientation to Figure 3 and identify the motor ports accordingly. Mark appropriately. Note
that the hydraulic fluid passes around the outside of the gear wheels and not through the middle.
4. Connect the high pressure feed to the ‘IN’ inlet port and the low pressure return to the outlet port.
Figure 2 Pump rotation
Figure 3 Hydraulic motor ports
5.2.2 Front seal removal
The bearings (and mechanical seal for HS80 units) of HS80, HS100, HS150, HS100-SG,
HS150V, HS150V-SG, HS100NC and HS150NC pumps are designed to be lubricated
and cooled by the hydraulic motor system oil. The oil is bled from the motor by removing
the seal from the front cover. A typical motor front cover arrangement is shown in Figure
4. Removing the circlip allows the seal and O-ring to be withdrawn. On some pumps the
seal is fitted from the inside of the front cover. In these cases the front cover will need to
be removed prior to removing the seal.
Note that this oil is returned to the hydraulic reservoir by a separate leakage line (see
Figure 1).
On all other pumps the bearings and mechanical seal are enclosed in their own
separately sealed housings and the motor seal must not be removed.
Figure 4 Typical motor front seal
arrangement
Book No.: 95-0014-0000/A OPERATOR
Issue: 06 HANDBOOK
Page 7 of 30
5.3 Hoses
Maximum recommended hose lengths are: -
Pump
Flow Rate
GPM(Imperial)/ litres per min
Hose length
Metres/feet
HS80
2.6 / 12
35 / 115
2.4 / 11
45 / 148
2.2 / 10
50 / 164
2.0 / 9.2
65 / 213
The lengths are for ½”nominal bore hose with SAE 10 oil at 15°C. They may be increased by 50% if
¾”nominal bore hoses are used.
HS100
9.6 / 36.4
15 / 49.2
9.0 / 34.0
20 / 65.5
8.5 / 32.0
30 / 98.5
8.1 / 29.5
35 / 115
6.8 / 25.5
40 / 131
The lengths are for 5/8”nominal bore hose with SAE 10 oil at 15°C. They may be increased by 50% if
¾”nominal bore hoses are used.
HS150
14.7 / 55.8
20 / 65.5
(3)
14.5 / 55.0
30 / 98.5
(3)
13.7 / 52.0
35 / 115
(3)
13.0 / 49.0
40 / 131
(3)
The lengths are for 3/4” nominal bore hose with SAE 10 oil at 15°C. They may be increased by 50% if 1”
nominal bore hoses are used.
Long hose lengths result in high back pressure in the return line
Table 1 Recommended hose length table
6 OPERATION
6.1 Starting
1. Before starting a system, the three-way valve (see Figure 1) is turned to direct the flow back into the reservoir.
2. Start the prime mover. This immediately starts the hydraulic pump. The flow should be allowed to continue back
into the reservoir for a few minutes to allow the system to warm and enables visual checking for leaks or faults.
3. Operate the three-way valve to direct the flow to the hydraulic motor and product pump.
4. Vary the speed of the prime mover to regulate the product pump.
CAUTION. The three way valve should never be used to control the speed of the hydraulic motor and product
pump. This will lead to overheating of the hydraulic fluid and consequential failure.
6.2 Draining
A pump situated in a position where it could be exposed to frost must be drained when that possibility exists unless
steps have been taken to alleviate the condition.
CAUTION. Failure to drain the pump and non-return valve in these conditions could result in the pumped
product residue freezing and cracking the casing.
It should also be drained if it is to be stopped for an extended period.
6.3 Storage Procedure
Disconnect the pump from the pipelines.
Allow air to circulate and try to ensure that the body is completely dry internally.
A proprietary flushing/protective fluid may be used if required. Ensure that this is compatible with any pump residue
before using it.
Place the pump to a cool dry storage area.
OPERATOR Book No.: 95-0014-0000/A
HANDBOOK Issue: 06
Page 8 of 30
7 MAINTENANCE
In this section it is assumed that the pump: -
has been removed from its operating position
has been drained of pumped product
has been drained of hydraulic oil
all hoses have been disconnected
7.1 HS80 pumps
7.1.1 Dismantling
1. Undo set screws (75) holding lifting
bracket (25) to both the pump body (1)
and outlet pipe (2). Remove lifting
bracket.
2. Undo set screws (75) holding the strainer
(24) to the pump body (1). Remove
strainer.
3. Release the screws (72) holding the
bearing bracket, wear plate and impeller
assembly to the pump body (1). (NOTE.
These are the screws on the larger PCD.
The screws on the smaller PCD retain the
wear plate to the bearing bracket).
4. Extract the bearing bracket assembly
from the pump body (1). The extension
pipe (2) and front wear plate (6) can be
removed from the pump body (1) if
required by removing the respective
screws (71) or (79).
5. Place a bar through the vanes of the
impeller (3) to lock it in position and
prevent rotation. Unscrew (RH thread)
and remove the impeller retaining screw
(68) and washer (19). Note that the screw
has a nylon plug through it that provides a
self-locking function. The screw will
therefore remain stiff to turn until this
nylon plug is clear of the shaft.
6. Remove the impeller (3) and the wearing
sleeve (4). Remove the impeller shims (if
any were fitted) noting the number and
thickness for comparison on rebuild.
Remove the key (36).
7. Release the screws (72) holding the rear wear plate
(5) to the bearing bracket assembly. Remove the
wear plate to expose the mechanical seal housing (8).
8. Extract the mechanical seal housing (8) complete with O-ring (46) from the bearing bracket (12). The stationary
seat of the mechanical seal will probably stay in the seal housing and can be removed by pressing out.
9. Carefully extract the mechanical seal (52) from the bearing bracket.
10. Release the screws (74) holding the hydraulic motor (55) to the bearing cover (11) and remove the motor.
11. Undo the screws (67) and remove the bearing cover (11) from the bearing bracket.
12. Press the shaft assembly out of the bearing bracket from the pump end.
13. Flatten the tags on the locking washer (42), prevent the shaft from rotating, and unscrew the bearing locknut (41).
14. Pull the ball bearing (39) off the shaft and remove the bearing outer (17) and inner (16) spacers.
15. Pull the roller bearing inner race (40) off the shaft.
Dismantling is now complete. Inspect all parts for damage or wear.
Figure 5 Typical HS80 pump
Book No.: 95-0014-0000/A OPERATOR
Issue: 06 HANDBOOK
Page 9 of 30
7.1.2 Reassembly
New seals and O-rings must be fitted when reassembling. It is also prudent to fit a new impeller retaining screw.
1. Heat both bearings (39 & 40) with a temperature controlled bearing heater until they are a consistent 110°C. Do
not overheat or allow the bearings to remain at this temperature for longer than their fitting time.
CAUTION. Bearing races must be pressed into position and not hammered either directly or by drift. Direct
hammering will damage the bearing or rollers. Drift hammering will introduce swarf into the assembly. Either will
result in early bearing failure.
2. Once up to temperature, slide the roller bearing inner race (40) up hard against the shaft shoulder, fit the bearing
inner (16) and outer (17) spacers and slide the ball bearing (39) up hard onto the spacers. Hold them in position for
a minimum of 30 seconds. The locknut (41) fitted without the tab washer is suitable for this purpose. This allows
the races to grip the shaft and prevent them from creeping away from the shoulder during cooling. Let the
assembly cool completely.
3. Once cool, remove the lock nut (41), fit the locking washer (42) and refit the lock nut. Knock up at least two tags on
the locking washer to secure.
4. Press the shaft assembly into the bearing bracket (12) from the motor end until the back of the ball bearing race is
6-7 mm below the surface. Use the bearing cover (11) without an O-ring (46) to press the assembly to its final
position.
5. Remove the bearing cover (11), fit an O–ring (46), refit the cover and secure with screws (67).
6. Fit the hydraulic motor (55) to the bearing cover (11) and secure with screws (74). Note that the oil seal in the front
of the motor must be removed beforehand (see section 5.2.2 for details).
CAUTION. Failure to remove the hydraulic motor oil seal will block the oil feed to both the bearings and
mechanical seal. Immediate failure of the seal and damage to the bearings will result.
7. Clean the shaft thoroughly and lubricate with clean water or a diluted soft soap solution. Do not use heavy grease,
silicone or PTFE based lubricants, as these would prevent the seal from gripping the shaft.
CAUTION. Mechanical Seals are precision engineered devices. Extreme care must be taken to ensure that no
damage occurs to the lapped faces. These faces must be kept absolutely clean throughout the entire
installation. Do not touch them or allow any contaminant to come into contact with them. Soiled faces will have
to be cleaned with appropriate degreasing cleaner and soft tissue. Failure to observe these precautions will
lead to premature seal failure.
8. Carefully slide the rotating parts of the mechanical seal (52) over the shaft until they abut the shaft shoulder.
9. Press the stationary seat of the mechanical seal (52) into the seal housing (8). Fit an O-ring (46) to the outside
diameter and carefully press the assembly into the bearing bracket from the pump end.
10. Fit the rear wear plate (5) to the bearing bracket assembly using screws (72).
11. Fit the key (36), wearing sleeve (4) and impeller (3) to the shaft. Secure with the impeller retaining screw (68) and
washer (19).
12. Measure the clearance between rear of impeller and rear wear plate. Remove the impeller and add shims as
necessary to obtain the clearance given in the Technical Data section.
13. Refit the impeller, lock the assembly with a bar through the vanes of the impeller and torque the retaining screw to
the value given in the Technical Data section.
14. Fit the front wear plate (6) to the pump body (1) using screws (79), spring (97) and plain (89) washers.
15. Fit the pump body (1) to the bearing bracket, wear plate and impeller assembly with screws (75), spring (94) and
plain (87) washers. Measure the clearance between the front of the impeller and front wear plate and check that it
corresponds to the value given in the Technical Data section. If it is not correct then the build is incorrect and the
cause must be investigated before proceedin g fur ther.
16. Place a gasket (30) on the pump body (1), fit the extension pipe (2) and attach with screws (71) and washers (87).
17. Attach the strainer (24) to the pump body with screws (75), spring (94) and plain (87) washers.
18. Attach the lifting bracket (25) to both the pump body (1) and outlet pipe (2) using set screws (75), spring (94) and
plain (87) washers.
Assembly is now complete, but before attaching the hydraulic lines, the unit must be filled with hydraulic oil to prevent
dry running on start up. Ensure the unit is completely filled with no air lock s before pr oc eed i ng.
Loading...