HS
Horizontal split case pump
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
Installation and operating instructions
http://net.grundfos.com/qr/i/99296580
English (GB) Installation and operating instructions
English (GB)
Original installation and operating instructions
These installation and operating instructions
describe HS.
Sections 1-5 give the information necessary to be
able to unpack, install and start up the product in a
safe way.
Sections 6-12 give important information about the
product, as well as information on service, fault
finding and disposal of the product.
CONTENTS
1. General information
1.1 Symbols used in this document
2. Receiving the product
2.1 Inspecting the product
3. Installing the product
3.1 Mechanical installation
3.2 Electrical connection
3.3 Pipes
3.4 Inlet pipe guidelines
4. Starting up the product
4.1 Prestart checks
4.2 Priming
4.3 Startup
4.4 Final alignment
4.5 Greasing the grid coupling
5. Storing and handling the product
5.1 Handling the product
5.2 Temporary storage
6. Product introduction
6.1 Applications
6.2 Pumped liquids
6.3 Identification
7. Operating the product
7.1 Operating checks
7.2 Frequency of starts and stops
7.3 Operating at reduced flow and/or head
8. Servicing the product
8.1 Maintaining the product
9. Taking the product out of operation
9.1 Short-time shutdown
9.2 Long-term shutdown
10. Fault finding the product
11. Technical data
11.1 Operating conditions
11.2 Flange forces and torques
12. Disposing of the product
Page
1. General information
Grundfos HS horizontal split case pumps are
supplied either as a complete pump with motor, base
frame and approved coupling guard or as a bare
shaft pump.
These instructions apply to both types.
2
The HS pump can be driven by an electric motor or
2
another type of driver. In the following we assume
3
that the pump is driven by an electric motor.
3
1.1 Symbols used in this document
3
3
1.1.1 Warnings against hazards involving risk of
6
7
9
11
11
11
12
13
14
15
15
15
16
16
16
16
The text accompanying the three hazard symbols
19
DANGER, WARNING and CAUTION is structured in
19
the following way:
19
19
19
19
21
21
21
22
25
25
27
27
Prior to installation, read this document
and the online version of the installation
and operating instructions. Installation and
operation must comply with local
regulations and accepted codes of good
practice.
death or personal injury
DANGER
Indicates a hazardous situation which, if
not avoided, will result in death or serious
personal injury.
WARNING
Indicates a hazardous situation which, if
not avoided, could result in death or
serious personal injury.
CAUTION
Indicates a hazardous situation which, if
not avoided, could result in minor or
moderate personal injury.
SIGNAL WORD
Description of hazard
Consequence of ignoring the warning.
- Action to avoid the hazard.
2
1.1.2 Other important notes
A blue or grey circle with a white graphical
symbol indicates that an action must be
taken.
A red or grey circle with a diagonal bar,
possibly with a black graphical symbol,
indicates that an action must not be taken
or must be stopped.
If these instructions are not observed, it
may result in malfunction or damage to the
equipment.
Tips and advice that make the work easier.
2. Receiving the product
2.1 Inspecting the product
The pump is delivered from factory in a crate or
wooden box specially designed for transport by a
forklift truck or a similar vehicle.
Upon receipt, check the pump visually to determine
whether any damage has happened to it during
transport or handling.
Check especially for these points:
1. broken or cracked equipment, including base
frame, motor or pump feet and flanges
2. broken motor fan cover, bent eyebolts or
damaged terminal box
3. missing parts.
Parts or accessories are sometimes wrapped
individually or fastened to the equipment.
If any damage or losses have occurred, promptly
notify Grundfos' representative and the carrier's
agent at once.
Bolts for HS bare shaft pumps have US
threads for which inch tools are required.
Bolts for coupling guard and for mounting
of pump and motor on the base frame
have metric threads.
3. Installing the product
3.1 Mechanical installation
WARNING
Crushing hazard
Death or serious personal injury
- Make sure that all installations are
performed by persons experienced in
the placement, alignment and
connection of pumping equipment.
3.1.1 Location
Install the pump with accessibility for inspection and
maintenance. Allow ample space and headroom for
the use of an overhead crane or hoist sufficiently
strong to lift the unit.
Fig. 1 HS pump with accessibility for
Install the pump as close as possible to the supply of
pumped liquid, so that the inlet pipe is as short and
direct as possible.
3.1.2 Foundation
We recommend that you install the pump on a
concrete foundation which is heavy enough to
provide permanent and rigid support for the entire
pump. The foundation must be capable of absorbing
any vibration, normal strain or shock. We
recommend that the weight of the concrete
foundation is 3 times the weight of the complete
pump unit. For specific requirements, consult the
contractor, engineer, or established industry
standards.
In installations where silent operation is particularly
important, we recommend a foundation that is up to
5 times as heavy as the complete pump unit.
inspection and headroom for the use of
an overhead crane
English (GB)
TM04 0382 1016
3
3.1.3 Vibration dampers
5-10 mm
Bolt length
above base
frame
Thickness of
base frame
19 to 32 mm
allowance
for grout
Base frame
Top of
foundation
left rough
Pipe sleeveLugWasher
Wedges and
shims left in
place
English (GB)
Vibration dampers may be required to prevent pump
vibrations from being transmitted to the building or
the pipes. In order to select the right type of vibration
damper, you need this information:
• Forces transmitted through the damper.
• Motor speed. Take the motor speed into account
in the case of speed control.
• Desired dampening in %. The recommended
value is 70 %.
The choice of vibration dampers differs from
installation to installation. In certain cases a wrong
damper may increase the vibration level. Vibration
dampers must therefore be sized by the supplier of
the vibration dampers.
3.1.4 Expansion joints
Expansion joints provide these advantages:
• absorption of thermal expansion and contraction
of pipes caused by variations in liquid
temperature
• reduction of mechanical influences in connection
with pressure surges in the pipes
• isolation of structure-borne noise in the pipes
(only rubber bellows expansion joints).
Do not fit expansion joints to make up for
inaccuracies in the pipes, such as centre
displacement or misalignment of flanges.
Fit the expansion joints at a minimum distance of 2
pipe diameters (DN) away from the pump flange on
the inlet side. This prevents turbulence in the joints,
thus ensuring optimum inlet conditions and minimum
pressure drop on the outlet side.
At flow velocities greater than 2.4 m/s, we
recommend that you fit larger expansion joints
matching the pipes.
3.1.5 Foundation and preliminary alignment
procedure
The foundation and preliminary alignment procedure
has four steps:
1. pouring of foundation
2. shimming of base frame
3. preliminary alignment
4. grouting.
Pouring of foundation
We recommend the following procedure to ensure a
good foundation:
1. Pour the foundation without interruptions to
within 19-32 mm of the final level. Use vibrators
to ensure that the concrete is evenly distributed.
The top surface must be well scored and grooved
before the concrete sets. This provides a bonding
surface for the grout.
2. Embed anchor bolts in the concrete as shown in
fig. 2. Allow enough bolt length to reach through
grout, shims, lower base frame, nuts and
washers.
Fig. 2 Typical anchor bolt design
Let the foundation cure for several days before the
base frame is shimmed and grouted.
Shimming of base frame
TM04 0383 0608TM04 0381 0608
4
Fig. 3 Shimming of base frame and levelling of
pump
1. Lift/jack up the base frame to the final level 19-32
Vertical Horizontal
Vertical Horizontal
mm above the concrete foundation, and support
the base frame by means of blocks and shims,
both at the anchor bolts and midway between
bolts. See fig. 3.
2. Level the base frame by adding or removing
shims under the base frame. See fig. 3.
3. Tighten the anchor bolt nuts against the base
frame. Make sure the pipes can be aligned to the
pump flanges without putting strain on the pipes
or flanges.
Preliminary alignment
DANGER
Electric shock
Death or serious personal injury
- Before starting work on the pump, make
sure that the power supply has been
switched off and that it cannot be
accidentally switched on.
The pump and motor are pre-aligned on the base
frame from the factory. Some deformation of the
base frame may occur during transport and it is
therefore essential to check alignment at the
installation site prior to final grouting.
Inaccurate alignment results in vibration and
excessive wear on the bearings, shaft and wear
rings.
2. Checking soft foot on pump and motor
A pump or a motor having a soft foot can be
compared to sitting down at a table and finding that
the table rocks when someone leans on it.
Technically, it is a condition where the feet of a motor
or a pump are not at the same level as the base
plate.
To check for soft foot, set the pump or motor on its
base plate and bolt it down. Set up a dial gauge on
one foot, loosen the hold-down bolt, and watch the
dial gauge. If the dial gauge indicator moves while
loosening the bolt, the pump or motor has soft foot.
The movement measured by the dial gauge indicates
how many shims you need to level the pump or
motor. Repeat this procedure at all four corners.
If the pump was installed a long time ago, the
stresses induced in the pump casing by soft foot can
cause permanent deformation of the casing.
3. Checking parallel alignment
Place a straight edge across both coupling rims at
the top, the bottom and both sides. See fig. 4. After
each adjustment, recheck all features of alignment.
Parallel alignment is correct when the measurements
show that all points of the coupling faces are within ±
0.2 mm of each other.
English (GB)
Carry out alignment of the motor only, as
pipe strain will occur if the pump is shifted.
Carry out alignment of the motor by placing shims of
different thickness under the motor. If possible,
replace several thin shims with one thick shim.
The preliminary alignment procedure has four steps:
1. Checking coupling clearance
Make sure that the gap between the coupling halves
is equal to the values in the table and that the
keyways are 180 ° displaced.
For a coupling with
an outside diameter
of ∅ [mm]
∅90-213 3.2 0/-1
∅251-270 4.8 0/-1
∅306-757 6.4 0/-1
Coupling clearance
[mm]
Nominal Tolerance
Fig. 4 Checking parallel alignment
4. Checking angular alignment
Insert a pair of inside callipers or a taper gauge at
four points at 90 ° intervals around the coupling. See
fig. 5. The angular alignment is correct when the
measurements show that all points of the coupling
faces are within ± 0.2 mm of each other.
Fig. 5 Checking angular alignment
Recheck the coupling clearance and tighten the set
screws on the couplings.
TM03 0209 4504TM03 0213 4504
5
Grouting
5-10 mm
Base frame
Grout
Levelling
wedges or
shims left
in place
Top of
foundation
(rough)
19 to 32
mm grout
Formwork
English (GB)
Grouting compensates for uneven foundation,
distributes the weight of the unit, dampens vibrations
and prevents shifting. Use an approved,
non-shrinking grout. If you have questions or doubts
about the grouting, consult an expert on grouting.
Proceed as follows:
1. Build a strong formwork around the foundation to
contain the grout.
2. Soak the top of the concrete foundation
thoroughly, then remove surface water.
3. Fill the formwork with grout up to the top edge of
the base frame. See fig. 6. Allow the grout to dry
thoroughly before attaching the pipe to the pump.
24 hours is sufficient time with approved grouting
procedure.
4. When the grout has thoroughly hardened, check
the anchor bolt nuts and tighten them if
necessary.
5. Approximately two weeks after the grout has
been poured, or when the grout has thoroughly
dried, apply an oil-based paint to the exposed
edges of the grout to prevent air and moisture
from getting in contact with the grout.
3.2 Electrical connection
The electrical connections must be carried out by an
authorised electrician in accordance with local
regulations.
DANGER
Electric shock
Death or serious personal injury
- Before you remove the terminal box
cover and before you remove or
dismantle the pump, make sure that the
power supply has been switched off and
that it cannot be accidentally switched
on.
The operating voltage and frequency are marked on
the motor nameplate.
Make sure that the motor is suitable for the power
supply of the installation site.
Carry out the electrical connections as shown on the
motor nameplate or in the wiring diagram on the
back of the terminal box cover.
For further information, contact the motor supplier.
DANGER
Electric shock
Death or serious personal injury
- Whenever you use powered equipment
in explosive surroundings, observe the
rules and regulations generally or
specifically imposed by the relevant
responsible authorities or trade
organisations.
Fig. 6 Sectional view of foundation with anchor
6
bolt, grouting and base frame
TM04 0384 0608
3.2.1 Frequency converter operation
You can connect all three-phase motors to a
frequency converter.
However, frequency converter operation often
exposes the motor insulation system to a heavier
load and causes the motor to be more noisy than
usual due to eddy currents caused by voltage peaks.
If in doubt whether the supplied motor can
handle frequency converter operation,
contact the motor supplier.
In addition, large motors driven via a frequency
converter will be loaded by bearing currents.
When the pump is operated via a frequency
converter, check the following operating conditions:
Operating
conditions
2-, 4- and 6-pole
motors of 45 kW
and up
Noise-critical
applications
Particularly
noise-critical
applications
Cable length Fit a cable that meets the
Supply voltage
up to 500 V
Supply voltage
between 500 V
and 690 V
Supply voltage
of 690 V and
upwards
Action
Check that one of the motor
bearings is electrically isolated.
Contact Grundfos.
Fit a dU/dt filter between the
motor and the frequency
converter. It reduces the voltage
peaks and thus the noise.
Fit a sinusoidal filter.
specifications laid down by the
frequency converter supplier.
The length of the cable between
the motor and frequency
converter affects the motor
load.
Make sure that the motor is
suitable for frequency converter
operation.
• Fit a dU/dt filter. It reduces
the voltage peaks and thus
the noise.
• Or make sure that the motor
has reinforced insulation.
• Fit a dU/dt filter.
• Make sure that the motor
has reinforced insulation.
3.3 Pipes
Protective covers are fitted to the inlet and
outlet ports to prevent foreign bodies from
entering the pump during transportation
and installation. Remove these covers
from the pump before connecting any
pipes.
Inlet and outlet pipe
In order to minimise friction losses and hydraulic
noise in the pipes, choose a pipe that is one or two
sizes larger than the pump inlet and outlet ports.
Typically, flow velocities must not exceed 2 m/s (6
ft/sec) for the inlet pipe (port) and 3 m/s (9 ft/sec) for
the outlet pipe (port).
Make sure that the NPSH available (NPSHA) is
higher than the NPSH required (NPSHR). NPSH =
Net Positive Suction Head.
3.3.1 General precautions
When installing the pipes, observe these
precautions:
1. Always run the pipes directly to the pump.
2. Do not move the pump to the pipes. This could
make the final alignment impossible and cause
stress to the pump flanges and pipes.
Make sure that both the inlet and outlet
pipes are independently supported near
the pump so that no strain is transmitted to
the pump when you tighten the flange
bolts. Use pipe hangers or other supports
with necessary spacing to provide support.
3. When you use expansion joints in the pipe
system, fit the joints at a minimum distance of 2
pipe diameters away from the pump on the inlet
side. This prevents turbulence in the joints, thus
ensuring optimum inlet conditions.
4. Install the pipes as straight as possible and avoid
unnecessary bends. Where necessary, use 45 °
or long-sweep 90 ° fittings to reduce friction loss.
5. Make sure that all pipe joints are tight.
6. Where you use flanged joints, ensure that the
inside diameters match properly.
7. Remove burrs and sharp edges when making up
joints.
8. Make sure that the pipes do not cause stress or
strain in the pump.
9. Provide for expansion of pipe material by means
of expansion joints on both sides of the pump.
10. Always allow sufficient space and accessibility for
maintenance and inspection.
English (GB)
7
3.3.2 Inlet pipes
English (GB)
Place the pump below system level whenever
possible. This will facilitate priming, assure a steady
liquid flow and provide a positive suction head.
The sizing and installation of the inlet pipe
is extremely important.
You can avoid many NPSH problems if you install the
inlet pipe properly. See section 3.3.1 General
precautions.
In section 12. Disposing of the product, common
inlet pipe installations are illustrated for two
situations:
• flooded systems
Closed systems and open systems where the
liquid level is above the pump inlet.
• suction lift systems
Closed systems and open systems where the
liquid level is below the pump inlet.
3.3.3 Valves in the inlet pipe
If the pump is operating under permanent suction lift
conditions, install a non-return valve in the inlet pipe
to avoid having to prime the pump each time it is
started. The non-return valve must be of the flap type
or a foot-valve with a minimum of pressure loss.
3.3.4 Outlet pipe
The outlet pipe is usually preceded by a non-return
valve and an isolating or throttle valve. The
non-return valve protects the pump against
excessive counterpressure and reverse rotation of
the pump and prevents backflow through the pump in
case of operational stop or failure of the motor.
In order to minimise friction losses and hydraulic
noise in the pipes, flow velocities must not exceed 3
m/s (9 ft/sec) in the outlet pipe (port).
On long horizontal runs, keep the pipe as level as
possible.
Avoid high spots, such as loops as they will collect
air and throttle the system or lead to uneven
pumping.
3.3.5 Auxiliary pipes
Drains
Install the drain pipes from the pump casing and
stuffing boxes to a convenient disposal point.
Flushing pipes
• Pumps fitted with stuffing boxes
When the inlet pressure is below the ambient
pressure, supply the stuffing boxes with liquid to
provide lubrication and prevent the ingress of air.
This is normally achieved via a flushing pipe from the
outlet side to the stuffing box. You can fit a control
valve or orifice plate in the flushing pipe to control
the pressure to the stuffing box.
If the pumped liquid is dirty and cannot be used for
flushing the packing rings, we recommend a
separate clean, compatible liquid supply to the
stuffing box at 1 bar (15 psi) above the inlet
pressure.
• Pumps fitted with mechanical seals
Seals requiring re-circulation will normally be
provided with a flushing pipe from the pump casing.
3.3.6 Measuring instruments
To ensure continuous monitoring of operation, we
recommend that you install pressure gauges on the
pump inlet and outlet flanges. The pressure gauge
on the inlet side must be capable of measuring
vacuum. The pressure tappings must only be opened
for test purposes. The measuring range of the outlet
side pressure gauge must be minimum 20 % above
the maximum pump outlet pressure.
When measuring with pressure gauges on the pump
flanges, note that a pressure gauge does not register
dynamic pressure (velocity pressure). The diameters
of the inlet and outlet flanges are different, and this
results in different flow velocities in the two flanges.
Consequently, the pressure gauge on the outlet
flange will not show the pressure stated in the
technical documentation, but a value which may be
lower.
8
3.4 Inlet pipe guidelines
Eccentric reducer
Turbulent flow
Airlock
Concentric reducer
Eccentric reducer
Pipe sloping down
towards pump
Eccentric reducer
Pipe sloping
up towards
pump
Eccentric reducer
Airlock
Pipe sloping
down towards
pump
3.4.1 Common guidelines
Avoid airlocks or turbulence in the inlet pipe
Never use reducers in a horizontal inlet pipe as shown in fig. 8. Instead, use an eccentric reducer as illustrated
in fig. 7.
Correct Wrong
English (GB)
TM04 0093 4907
Fig. 7 Correctly mounted reducer Fig. 8 Reducers resulting in airlocks and
turbulence
3.4.2 Flooded systems
Closed systems and open systems where the liquid level is above the pump inlet.
Correct
TM04 0148 4907
Fig. 9 Correctly mounted inlet pipe
3.4.3 Suction lift systems
Closed systems and open systems where the liquid level is below the pump inlet.
Install the inlet pipe sloping upwards towards the inlet port. Any high point in the pipe will be filled with air and
thus prevent proper operation of the pump. When reducing the pipe to the inlet port diameter, use an eccentric
reducer with the eccentric side down to avoid airlocks.
Correct Wrong
TM04 0098 4907
Fig. 10 Correctly mounted inlet pipe Fig. 11 Inlet pipe resulting in airlocks
TM04 0092 4907
TM04 0097 4907
9
3.4.4 Inlet pipe if the feed line comes in different horizontal planes
Eccentric reducer
Eccentric reducer
Airlock
DN
10 x DN
10 X DN plus
expansion joint
Uneven flow
Water pressure
increases here
causing a
greater flow to
one side of the
impeller than to
the other
English (GB)
Avoid high spots, such as loops, as they will collect
air and throttle the system or lead to uneven
pumping.
Correct Wrong
TM04 0095 4907
Fig. 12 Correctly mounted inlet pipe Fig. 13 Inlet pipe resulting in airlocks
3.4.5 Inlet pipe with a horizontal elbow in the feed line
Make sure that the liquid flow is evenly distributed to
both sides of the double-suction impeller.
There is always an uneven, turbulent flow through an
elbow. See below. If you install an elbow in the inlet
pipe near the pump in a position other than vertical,
more liquid will enter one side of the impeller than
the other. This will result in heavy, unbalanced thrust
loads overheating the bearings, causing rapid wear
and reducing the hydraulic performance.
Correct Wrong
TM04 0150 4907
Fig. 14 Recommended inlet pipe installation
with a length of straight pipe between
horizontal elbow and pump
Fig. 15 Unbalanced loading of a double-suction
impeller due to uneven flow through a
horizontal elbow close to the pump
3.4.6 Installations with vertical inlet pipe in confined space
TM04 0094 4907
TM04 0149 4907
Fig. 16 Inlet diffuser (1) in the inlet pipe
10
TM04 0096 4907
4. Starting up the product
The startup procedure for the pumps has four steps:
1. Prestart checks. See section 4.1 Prestart checks.
2. Priming. See section 4.2 Priming.
3. Starting. See section 4.3 Startup.
4. Final alignment. See section 4.4 Final alignment.
Only start the pump when you have gone
through all the prestart checks.
4.1 Prestart checks
Prestart checks have four steps:
1. Bearings
2. Stuffing boxes
3. Pressure gauge
4. Direction of rotation.
4.1.1 Bearings
Make sure that all bearings are properly lubricated.
See section 8.1.3 Lubrication.
4.1.2 Stuffing boxes
Make sure that the stuffing box packing rings have
been properly tightened.
4.2 Priming
If not primed properly, the pump will not
deliver liquid.
Closed systems or open systems where the
liquid level is above the pump inlet (flooded
systems)
Fill the inlet pipe and pump with liquid and vent them
before the pump is started. Proceed as follows:
1. Close the outlet isolating or throttle valve.
2. Loosen the vent screw (17) and the plug for shaft
seal flushing (20d).
English (GB)
This does not apply to pumps with
mechanical shaft seals.
4.1.3 Pressure gauges
Make sure that the pressure gauge connections are
closed.
4.1.4 Direction of rotation
Check the direction of rotation in the following way:
1. Disconnect the two coupling halves between
pump and motor.
2. Make sure that the motor shaft can turn freely.
3. Start the motor briefly to check the direction of
rotation. The correct direction of rotation is
indicated by the arrows on the pump casing.
The direction of rotation of the pump is not
always the same as the flow direction.
4. If the direction of rotation is wrong, correct it by
interchanging two phases on the motor.
DANGER
Electric shock
Death or serious personal injury
- Before interchanging two phases, make
sure that the power supply has been
switched off and that it cannot be
accidentally switched on.
5. Check the direction of rotation again.
6. Reassemble the coupling and the guards.
Fig. 17 Position of the vent valve and plug for
shaft seal flushing
WARNING
Hot or cold surface
Death or serious personal injury
- Pay attention to the direction of the vent
hole, and ensure that the escaping
water does not cause injury to persons
or damage to the motor or other
components.
- In hot-water installations, pay special
attention to the risk of injury caused by
scalding hot water and hot surfaces.
- In cold-liquid installations, pay special
attention to the risk of injury caused by
cold liquids and cold surfaces.
3. Slowly open the isolating valve in the inlet pipe
until a steady flow of liquid runs out of the vent
hole.
4. Rotate the shaft by hand, if possible, while
priming and venting to free entrapped air from
the impeller channels.
5. Tighten the vent screw and completely open the
isolating or throttle valve(s).
TM04 2592 2708
11
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