Grundfos PACOpaQ Installation And Operating Instruction Manual

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PACOpaQ™

HVAC Packaged Systems

Installation and Operating Instructions

GRUNDFOS INSTRUCTIONS

Table of Contents

English (US) Installation and operating instructions

Original installation and operating instructions.

CONTENTS

Page

1. Symbols used in this document 3

2. Terms and Conditions 4

2.1 The contract 4

2.2 Price 4

2.3 Payment terms 4

2.4 Acceptance and inspection 4

2.5 Title and risk of loss 4

2.6 Patent or trademark information 4

2.7 Changes 4

2.8 Cancellation or termination 4

2.9 Delivery and delays 4

2.10 Warranty 5

2.11 Technical documents 5

2.12 Limitation of liability 5

2.13 This company is an equal opportunity 5 employer

2.14 Law and arbitration 5

3. PACOpaQ system installation 6

3.1 General instructions 6

3.2 Lifting and rigging instructions 6

3.3 Storage 6

3.4 Bolt check instruction 6

3.5 Field connection 6

3.6 Assembly of packaged sections (if applicable) 7

3.7 Other package system requirements 7

4. Pump Installation-Mechanical 8

4.1 Pump Identication 8

4.2 Receiving 8

4.3 Temporary storage 8

4.4 Location 8

4.5 Horizontal pump foundation 8

4.6 Securing base plate 9

4.7 Vertical mounting instructions 9

4.8 Piping-general 9

4.9 Suction (inlet) piping 9

4.10 Discharge (outlet) piping 10

4.11 Shaft, sealing-general comments 10

4.12 Packing gland adjustment 10

4.13 Mechanical seals 10

4.14 Coupling alignment (LF) 11

4.15 Coupling alignment (LCS) 11

5. Pump Installation-electrical 11

5.1 Motors general 11

5.2 Installation wiring 11

6. Pump operation 12

6.1 Priming 12

6.2 Pre-start checklist 12

6.3 Motor rotation 12

6.4 Starting the pump 12

6.5 Voltage regulation 13

6.6 Pump shutdown 13

6.7 Short duration shutdown 13

6.8 Extended period shutdown 13

7. Pump Maintenance 13

7.1 Motor lubrication 13

7.2 Pump lubrication 14

7.3 Disassembly of pumps 14

7.3.1 Disassembly of liquid end 14

7.3.2 Disassembly of bearing frame (LF) 14

7.4 Seal replacement (LCS) 14

7.5 Wear ring replacement 15

7.6 Reassembly of pumps 15

7.7 Ordering parts 16

7.8 Type LF, cross section and parts list 17

7.9 Type LC, cross section and parts list 18

7.10 Type LCV, cross section and parts list 19

7.11 Type LCS, cross section and parts list

8. Pump Troubleshooting 21

8.1 Symptom 21

8.2 Possible causes 21

9. Grundfos CUE Variable Frequency Drive 22

9.1 CUE introduction 22

9.2 General description 22

9.3 Applications 23

9.4 References 23

10. CUE safety and warnings 23

10.1 Warning 23

10.2 Safety regulations 23

10.3 Installation requirements 23

10.4 Reduced performance under certain conditions 23

11. Identication 23

11.1 Nameplate 23

11.2 Packaging label 23

12. CUE installation-mechanical 23

12.1 Reception and storage 23

12.2 Transportation and unpacking 23

12.3 Space requirements and air circulation 24

12.4 Mounting 24

13. Electrical connection 24

13.1 Electrical protection 24

13.2 Mains and motor connection 25

13.3 Connecting the signal terminals 30

13.4 Connecting the signal relays 32

13.5

13.6 EMC-correct installation 34

13.7 RFI lters 34

13.8 Output lters 34

14. CUE operating modes 35

15. CUE control modes 35

15.1 Uncontrolled operation (open loop) 35

15.2 Controlled operation (closed loop) 36

16. Menu overview 37

17. Setting by means of the cotnrol panel 40

17.1 Control panel 40

17.2 Back to factory setting 40

17.3 Start-up guide 41

17.4 Menu GENERAL 45

Connecting the MCB 114 sensor input module 33

17.5 Menu OPERATION 45

7. Trouble Shooting

7.1 Symptom

7.2 Possible Causes

Caution

Note

17.6 Menu STATUS 46

17.7 Menu INSTALLATION 48

18. Setting by means of PC Tools E-products 55

19. Priority of setttings 56

19.1 Control without bus signal, local operating 56 mode

19.2 Control with bus signal, remote-controlled 56 operating mode

20. External control signals 56

20.1 Digital inputs 57

20.2 External setpoint 57

20.3 GENibus signal 57

20.4 Other bus standards 57

21. CUE Maintenance and service 57

21.1 Cleaning the CUE 57

21.2 Service parts and servie kits 57

22. CUE Troubleshooting 58

22.1 Warning and alarm list 58

22.2 Resetting of alarms 58

22.3 Indicator lights 58

22.4 Signal relays 58

23. Technical data 59

23.1 Enclosure 59

23.2 Main dimensions and weight

23.3 Surroundings 60

23.4 Terminal tightening torques 60

23.5 Cable length 61

23.6 Fuses and cable gauge size 61

23.7 Inputs and putputs 63

23.8 Sound pressure level 63

24. Disposal 63

25. CU 352 product description 64

25.1 Indicator lights 64

25.2 Terminals 64

25.3 Potentially explosive environments

26. Identication

27. CU352 installation 65

27.1 Location 66

27.2 Enclosure class 66

27.3 Terminals 66

27.4 Cables 66

28. CU 352 Installation-Mechanical 66

29. EMC-correct installation 67

29.1 Internal GENibus connection 68

29.2 Fieldbus communication interface 68 modules

29.3 Fitting the CIM module 69

30. CU 352 Startup 70

31. Technical data 70

32. Electrical data 70

32.1 Supply voltage 70

32.2 Power consumption 70

32.3 Circuit breaker 70

32.4 Backup fuse 70

32.5 Short-circuit protection 70

32.6 Digital inputs

32.7 Analog inputs

70 70

32.8 Digital outputs (relay putputs) 70

32.9 Conductors 70

32.10 USB port 70

32.11 Battery backup (UPS) 71

32.12 Terminal groups 71

33. Overview of inputs and outputs 72

34. CU 352 Maintenance 73

35. CU 352 Service

36. Replacing the CU 352 73

36.1 Replacing the CIM module

37. CU 352 Dimensions 73

38. CU 352 Disposal 73

39. Suctiondiuser-IOM 74

39.1 Installation 74

39.2 Operation and maintenance 74

39.3 Sectional drawing and components 74

1. Symbols used in this document

The following symbols may be used in this document.

Warning

If these safety instructions are not observed, it may result in personal injury.

Warning

If these instructions are not observed, it may lead to electric shock with consequent risk of serious personal injury or death.

Warning

When pumping hazardous liquids, special attention must be paid to the risk of personal injury.

Warning

The surface of the product may be so hot that it may cause burns or personal injury.

Warning

The sound pressure level is so high that hearing protection must be used.

If these safety instructions are not observed, it may result in malfunction or damage to the equipment.

Notes or instructions that make the job easier and ensure safe operation.

Table of Contents

English (US)

Terms and Conditions

2. Terms and Conditions

2.1 The contract

The Contract shall be comprised of the following terms, together with such terms and conditions as are set forth in Seller's written proposal or quotation (the "Quotation"), including any documents, drawings or specifications incorporated t any additional or different terms proposed in Buyer's purchase order (the "Purchase Order") that are accepted by Seller in writing, which together shall constitute the entire agreement between the parties, provided, however, that preprinted terms on Buyer's purchase order or invoice shall not apply and Seller gives notice of objection to such terms. An offer by Seller in its Quotation that does not stipulate an acceptance date is not binding. This Contract shall be deemed to have been entered into upon written acknowledgment of the Purchase Order by an officer or authorized representative of Seller, which may not be modified, supplemented, or waived except in a writing executed by an authorized representative of the party to be bound.

2.2 Price

The price quoted in the Quotation shall be the Purchase Price unless otherwise agreed in the Purchase Order. The Purchase Price for equipment shall include packing for shipment. Field Services shall be provided at Seller's standard rates. All other costs, including packing for storage, freight, insurance, taxes, customs duties and import/export fees, or any other item not specified in the Contract, shall be paid by Buyer unless separately stated in the Quotation and included in the price quoted. Any sales, use, or other taxes and duties imposed on the transaction or the equipment supplied shall be paid or reimbursed by Buyer.

2.3 Payment terms

Payment shall be due within 30 days of the date of Seller's invoice in U.S. funds unless otherwise agreed. If Buyer does not observe the agreed dates of payment, Buyer shall pay interest to Seller on overdue amounts at a rate that is the higher of: 9 % per annum or a rate 5 % in excess of the rate borne from time to time by new issues of six-month United States Treasury bills. Seller shall be entitled to issue its invoice for the Purchase Price for equipment upon the earlier of shipment, or notice to Buyer that Seller is ready to ship, and for services, upon completion. If the Purchase Price exceeds $250,000 USD, Buyer shall pay the Purchase Price in Progress payments as follows: Fifteen percent (15 %) upon submittal of general arrangement drawings, thirty five percent (35 %) after receipt of first Bowl Casting, twenty percent (20 %) after first case/bowl hydro test or bowl machining and thirty percent (30 %) after notification of ready to ship.

2.4 Acceptance and inspection

All equipment shall be finally inspected and accepted by Buyer within 14 days after delivery or such other period of time as is agreed in the Purchase Order. Buyer shall make all claims (including claims for shortages), excepting only those provided for under the warranty clause contained herein, in writing within such 14 day period or they are waived. Services shall be accepted upon completion. Buyer shall not revoke its acceptance. Buyer may reject the equipment only for defects that substantially impair its value, and Buyer's remedy for lesser defects shall be in accordance with Section 10, Warranty. If tests are made by Buyer to demonstrate the ability of the equipment to operate under the contract conditions and to fulfill the warranties in Section 10, Buyer is to make all preparations and incur all expenses incidental to such tests. Seller will have the right of representation at such tests at its expense, and the right to technically direct the operation of the equipment during such tests, including requiring a preliminary run for adjustments.

herein by reference, and

2.5 Title and risk of loss

Full risk of loss (including transportation delays and losses) shall pass to Buyer upon delivery, regardless of whether title has passed to Buyer, transport is arranged or supervised by Seller, or start-up is carried out under the direction or supervision of Seller. Delivery shall be ex works, INCOTERMS 2000. Loss or destruction of the equipment or injury or damage to the equipment that occurs while the risk of such loss or damage is borne by Buyer does not relieve Buyer of its obligation to pay Seller for the equipment.

2.6 Patent or trademark information

If the equipment sold he manufactured according to Buyer's specifications, Buyer shall indemnify Seller and hold it harmless from any claims or liability

r patent or trademark infringement on account of the sale of

fo such goods.

reunder is to be prepared or

2.7 Changes

Buyer may request, in writing, changes in the design, drawings, specifications, shipping instructions, and shipment schedules of the equipment. As promptly as practicable after receipt of such request, Seller will advise Buyer what amendments to the Contract, if any, may be necessitated by such requested changes, including but not limited to amendment of the Purchase Price, specifications, shipment schedule, or date of delivery. Any changes agreed upon by the parties shall be evidenced by a Change Order signed by both parties.

2.8

Buyer shall have the right to cancel the Contract upon 15 day prior upo Buyer. If Buyer cancels the Contract, it shall pay: (a) the agreed unit price for equipment or components completed and delivered, (b) additional material and labor costs incurred, and for engineering services supplied by Seller with respect to the canceled items, which shall be charged to Buyer at Seller's rates

n effect at the time of cancellation, but which shall not exceed the

i contract price for such items, and (c) such other costs and expenses, including cancellation charges under subcontracts, as Seller may incur in connection with such cancellation or termination.

ellation or

Canc

en notice

writt

n the receipt of such notice except as otherwise agreed with

ermination

to Seller, and Seller shall stop its performance

2.9 Delivery and delays

Seller shall use its best efforts to meet quoted delivery dates, which are estimated based on conditions known at the time 16 A1d.1 606 supercedes 9/05 PACO PUMPS of quotation. Seller shall not be liable for any nonperformance, loss, damage, or delay due to war, riots, fire, flood, strikes or other labor difficulty, governmental actions, acts of God, acts of the Buyer or its customer, delays in transportation, inability to obtain necessary labor or materials from usual sources, or other causes beyond the reasonable control of Seller. In the event of delay in performance due to any such cause, the date of delivery or time for completion will be extended to reflect the length of time lost by reason of such delay. Seller shall not be liable for any loss or damage to Buyer resulting from any delay in delivery.

2.10 Warranty

English (US)

3.2 Receiving

• Check pumping unit for shortage and damage immediately upon arrival. Pump accessories when required are packaged in a separate container and shipped with the unit.

• If equipment is damaged in transit, promptly report this to the carrier's agent. Make complete notations on the freight bill to speed satisfactory adjustment by the carrier.

• Unload and handle the unit with a sling. Do not lift unit by eye bolts on the motor!

3.3 Temporary storage

• If pump is not to be installed and operated soon after arrival, store it in a clean, dry area of moderate ambient temperature.

English (US)

2.14 law and arbitration

The Contract shall be governed by the law of the State of Texas. Any disputes arising out of this Contract shall be resolved by informal mediation in any manner that the parties may agree within 45 days of written request for mediation by one party to the other. Any dispute that cannot be resolved through mediation shall be resolved by binding arbitration conducted in English in Portland, Oregon under the Commercial Rules of the American Arbitration Association except as otherwise provided in this Section. The arbitration shall be conducted by three arbitrators chosen in accordance with said Rules. The arbitrators are not entitled to award damages in excess of compensatory damages. Judgment upon the award may be entered in any court having jurisdiction.

3.2 Receiving

• Check pumping unit for shortage and damage immediately upon arrival. Pump accessories when required are packaged in a separate container and shipped with the unit.

• If equipment is damaged in transit, promptly report this to the carrier's agent. Make complete notations on the freight bill to speed satisfactory adjustment by the carrier.

• Unload and handle the unit with a sling. Do not lift unit by eye bolts on the motor!

3.3 Temporary storage

• If pump is not to be installed and operated soon after arrival, store it in a clean, dry area of moderate ambient temperature.

• Rotate the shaft by hand periodically to coat bearing with lubricant to retard oxidation and corrosion.

• Follow motor manufacturer's storage recommendations where applicable.

3.4 Location

• Locate the pump as close to the suction supply as possible. Use the shortest and most direct suction piping practical. Refer to 3.9 Suction (inlet) piping.

• Locate the pump below system level wherever possible. This will facilitate priming, assure a steady liquid flow, and provide a positive suction head.

• Make sure sufficient NPSH (Net Positive Suction Head) is provided at the suction end by considering the pump's location in relation to the entire system. Available NPSH must always equal or exceed required NPSH specified on the pump performance curve.

Seller warrants that the equipment or services supplied will be free from

24 months from the d 30 months from the date of shipment, whichever shall first

occur. In the case of spare or replacement parts manufactured by Seller, the warranty period shall be for a period of six months from shipment. Repairs shall be warranted for 24 months or, if the repair is performed under this warranty, for the remainder of the original warranty period, whichever is less. Buyer shall report any claimed defect in writing to Seller immediately upon discovery and in any event, within the warranty period. Seller shall, at its sole option, repair the equipment or furnish replacement equipment or parts thereof, at the original delivery point. Seller shall not be liable for costs of removal, reinstallation, or gaining access. If Buyer or others repair, replace, or adjust equipment or parts without Seller's prior written approv Buyer under this section with respect to such equipment or parts. The repair or replacement of the equipment or spare or replacement parts by Seller under this section shall constitute Seller's sole obligation and Buyer's sole and for all claims of defects. SELLER MAKES NO OTHER WARRANTY OR RESPECT TO THE EQUIPMENT OR SERVICES OTHER THAN AS SPECIFIED IN THIS SECTION 10. ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR

PURPOSE, ARE HEREBY DISCLAIMED. For purposes of this Section, the equipment warranted shall not include equipment, parts, and work not manufactured or performed by Seller. With respect to such equipment, parts, or work, Seller's only obligation shall be to assign to Buyer any warranty provided to Seller by the manufacturer or supplier providing such equipment, parts or work. No equipment furnished by Seller shall be deemed to be defective by reason of normal wear and tear, failure to resist erosive or corrosive action of any fluid or gas, Buyer's failure to properly store, install, operate or maintain the equipment in accordance with good industry practices or specific recommendations of Seller, or Buyer's failure to provide complete and accurate information to Seller concerning the operational

application of the equipment.

defects in material, and workmanship for a period of

ate of initial operation of the equipment, or

al, Seller is relieved of any further obligation to

exclusive remedy

REPRESENTATION OF ANY KIND WITH

Warning

Prior to installation, read these installation and

operating instructions. Installation and operation

must comply with local regulations and accepted

codes of good practice.

Warning

The use of this product requires experience with

and knowledge of the product. Persons with reduced physical, sensory or mental

capabilities must not use this product, unless

they are under supervision or have been

instructed in the use of the product by a person

responsible for their safety. Children must not use or play with this product.

2.11 Technical documents

Technical documents furnished by Seller to Buyer, such as drawings, descriptions, designs and the like, shall be deemed provided to Buyer on a confidential basis, shall remain Seller's exclusive property, shall not be provided in any way to third parties, and shall only be used by Buyer for purposes of installation, operation and maintenance. Technical documents submitted in connection with a Quotation that does not result in a Purchase Order shall be returned to Seller upon request.

2.12 Limitation of liability

Seller shall in no event be liable for any consequential, incidental, indirect, special or punitive damages arising out of the Contract, or out of any breach of any of its obligations hereunder, or out of any defect in, or failure of, or malfunction of the equipment, including but not limited to, claims based upon loss of use, lost profits or revenue, interest, lost goodwill, work stoppage, impairment of other equipment, environmental damage, nuclear incident, loss by reason of shutdown or nonoperation, increased expenses of operation, cost of purchase of replacement power or claims of Buyer or customers of Buyer for service interruption whether or not such loss or damage is based on contract, tort (including negligence and strict liability) or otherwise. Seller's maximum liability under this Contract shall not exceed the Purchase Order amount of the equipment or portion thereof upon which such liability is based. All such liability shall terminate upon the expiration of the warranty period, if not sooner terminated.

2.13 This company is an equal opportunity employer

This agreement incorporates by reference applicable provisions and requirements of Executive Order 11246 and FAR Section

52.222-26 (covering race, color, religion, sex and national origin); the Vietnam Era Veterans Readjustment Assistance Act of 1974 and FAR Section 52.222-35 (covering special disabled and Vietnam era veterans); and the Rehabilitation Act of 1973 and FAR Section 52.222-36 (covering handicapped individuals). By acceptance of this agreement Buyer certifies that it does not and will not maintain any facilities in a segregated manner, or permit its employees to perform their services at any location under its control where segregated facilities are maintained, and further that appropriate physical facilities are maintained for both sexes. Buyer agrees that it will obtain a similar certificate prior to award of any nonexempt lower-tier subcontracts.

2.14 law and arbitration

Terms and Conditions

PACOpaQ System Installation

Installation instructions

Assembly of packaged sections (if applicable):

1. Refer to specic installation documents or

drawings for the package system.

2. Familiarity with the parts requirements and any referenced documents or drawings will aid in the piping assembly. All hardware and gaskets required for re-assembly are supplied. Final package system connections hardware by others.

3. Check pipe/pump/ttings/valves end

connections. Any loose scale, paint or dirt must be removed.

4. Ensure alignment of end connections

between pump/pipe/ttings/valves

Connections must be square.

5. Package piping must be supported independent of the pump. If package pipe support is not part of the original package others should supply it. Package steel base is designed to provide a structural support beginning.

6. Use proper gasket (if required) and install

the individual pump suction & discharge pipe/

ttings/valves with the nuts & bolts provided (at & lock washers also provided). Install the required bolts for the tting connections (elbow, wye strainer,and buttery valve)-to-pipe connection and tighten bolts to a snug t.

7. Tighten and torque all pipe connection bolts as required.

8. Install and/or tighten loose pipe support brackets as required. Remove any temporary supports.

9. Refer to specic installation documents or

drawings for the package system.

10. Familiarity with the parts requirements and any referenced documents or drawings will aid in the piping assembly. All hardware and

gaskets required for re-assembly are supplied. Final package system connections hardware by others.

11. Ensure alignment of pipe end connections between sections. Connections must be square.

Install the required bolts for each of the tting connections- (elbow, separator, valve, etc.) -to pipe connections and tighten bolts to a snug t.

Gasket may be required.

12. Working from the middle of base sections to the outside. Snug all base connection bolts

making sure the base channel anges are ush

top, bottom and side. Torque base connection bolts to approx. 75 ft/lb

13. Ensure pipe connections are aligned. Tighten and torque all the pipe connection bolts as required.

14. Install and/or tighten loose pipe support brackets and bolts as required.

Other packaged system requirements:

1. Required electrical wiring can now be

connected. A qualied electrician should do

the electrical wiring. Power/control/sensing runs may be disconnected for package splits or remote/future use, and tagged with color-coded tape or with a numbering system.

2. Mount the gauge & switch wing panel. Required sensing lines can now be connected. Sensing lines may be disconnected for package splits or for remote/future use, and tagged with color-coded tape or with a numbering system.

3. Complete the package system installation per individual parts provider or manufacturer, customer, or maintenance instructions requirements.

Installation

3. PACOpaQ Installation

3.1 General instructions

Important notice:

Carefully inspect this equipment for damage, and missing pieces. If the shipment has been damaged or there are missing pieces, have the carrier note the condition on the receipt. Also, check as soon as possible for any concealed damage. It is the customer’s

responsibility to le a claim for damage or

missing pieces with the carrier. Failure to follow this procedure may result in refusal by the carrier to honor any claims with a consequent loss to the customer.

3.2 Lifting and rigging instructions:

Avoid twisting or uneven lifting of unit. Lifting lugs are provided on the sides, or as part of the internal structure of the system base. Lifting with a single hook will require cables. Cables are to be connected to the lugs by use of shackles. Required cable lengths may vary due to lifting lugs not being symmetrical to the center of gravity of system, or to avoid system internals.

Fig. 1 Side view of lifting points

Fig. 2 Plan view of lifting points

3.3 Storage:

Unit should be stored in a dry and dust free and temperature controlled environment. It is not recommended the unit be stored outside. If the unit must be stored outside it is required that the entire unit must be covered with a watertight seal. Electronic equipment is delicate and will not withstand variations in humidity and temperature.

3.4 Bolt check instructions:

System bolts may become loose during shipment due to vibration. Bolts must be checked for tightness and for required torque. This must be done before system is pressurized.

3.5 Field connections:

Piping isolation is recommended on all package

system eld connections. It is the installer’s responsibility to suppor

piping.

Request for assistance:

If there are questions concerning the installation of this package system contact:

Service Department Grundfos Commercial Building Services 902 Koomey Road Brookshire, TX. 77423

t and anchor eld

1-800-955-5847

3.6 Assembly of packaged sections

Installation

(if applicable):

gaskets required for re-assembly are supplied. Final package system connections hardware by others.

1. Refer to specic installation documents or

drawings for the package system.

3. Check pipe/pump/ttings/valves end

connections. Any loose scale, paint or dirt must be removed.

4. Ensure alignment of end connections

between pump/pipe/ttings/valves

Connections must be square.

6. Use proper gasket (if required) and install

the individual pump suction & discharge pipe/

7. Tighten and torque all pipe connection bolts as required.

8. Install and/or tighten loose pipe support brackets as required. Remove any temporary supports.

11. Ensure alignment of pipe end connections between sections. Connections must be square.

Install the required bolts for each of the tting connections- (elbow, separator, valve, etc.) -to pipe connections and tighten bolts to a snug t.

Gasket may be required.

12. Working from the middle of base sections to the outside. Snug all base connection bolts

making sure the base channel anges are ush

top, bottom and side. Torque base connection bolts to approx. 75 ft/lb

13. Ensure pipe connections are aligned. Tighten and torque all the pipe connection bolts as required.

14. Install and/or tighten loose pipe support brackets and bolts as required.

3.7 Other packaged system requirements:

1. Required electrical wiring can now be

connected. A qualied electrician should do

the electrical wiring. Power/control/sensing runs may be disconnected for package splits or remote/future use, and tagged with color-coded tape or with a numbering system.

3. Complete the package system installation per individual parts provider or manufacturer, customer, or maintenance instructions requirements.

PACOpaQ System Installation

9. Refer to specic installation documents or

drawings for the package system.

10. Familiarity with the parts requirements and any referenced documents or drawings will aid in the piping assembly. All hardware and

English (US)

2.14 law and arbitration

3.2 Receiving

• Check pumping unit for shortage and damage immediately upon arrival. Pump accessories when required are packaged in a separate container and shipped with the unit.

• If equipment is damaged in transit, promptly report this to the carrier's agent. Make complete notations on the freight bill to speed satisfactory adjustment by the carrier.

• Unload and handle the unit with a sling. Do not lift unit by eye bolts on the motor!

3.3 Temporary storage

• If pump is not to be installed and operated soon after arrival, store it in a clean, dry area of moderate ambient temperature.

• Rotate the shaft by hand periodically to coat bearing with lubricant to retard oxidation and corrosion.

• Follow motor manufacturer's storage recommendations where applicable.

3.4 Location

• Locate the pump as close to the suction supply as possible. Use the shortest and most direct suction piping practical. Refer to 3.9 Suction (inlet) piping.

• Locate the pump below system level wherever possible. This will facilitate priming, assure a steady liquid flow, and provide a positive suction head.

• Always allow sufficient accessibility for maintenance and inspection. Provide a clear space with ample head room for use of a hoist strong enough to lift the unit.

• Make sure a suitable power source is available for the pump motor. Electrical characteristics should match those specified on the motor data plate, within the limits covered in

4. Installation-electrical and 5. Operation.

• Avoid pump exposure to sub-zero temperatures to prevent pump liquid from freezing. If freezing conditions exist during shutdown periods, see Sections 5.6 Pump shutdownand

5.7 Short duration shutdown for specific recommendations.

3.5 Horizontal pump foundation

Horizontal pumps should be permanently installed on a firm, concrete foundation mounting pad of sufficient size to dampen any vibration and prevent any deflection or misalignment. The pad may float on springs or be a raised part of the equipment room floor. The foundation should be poured without interruption to 3/4 to 1 - 1/2 inches below the final pump elevation. The top surface should be well scored or grooved before the concrete sets to provide a suitable bonding surface for the grout. Anchor bolts should be set in pipe sleeves for positioning allowance, as shown in Fig. 2. Allow enough bolt length for grout, lower base plate flange, nuts and washers. Allow the foundation to cure several days before proceeding with pump installation.

Warning

Prior to installation, read these installation and

operating instructions. Installation and operation

must comply with local regulations and accepted

codes of good practice.

Warning

The use of this product requires experience with

and knowledge of the product. Persons with reduced physical, sensory or mental

capabilities must not use this product, unless

they are under supervision or have been

instructed in the use of the product by a person

responsible for their safety. Children must not use or play with this product.

PACO Pumps

Paco Pumps Installation and Opereating Procedures

3.4 Installation - Mechanical

Read these instructions thoroughly before installing and operating your PACO Type L Centrifugal Pump. Successful operation depends on careful attention to the procedures described in Sections 1, 2, 3 and 4 of this manual. Keep this instruction manual handy for future use.

4.1 Pump identification

All PACO Pumps are identified by Catalog and Serial Numbers. These numbers are stamped on the pump nameplate (Fig. 1) affixed to each pump volute casing, and should be referred to in all correspondence with the Company.

Fig. 1 Nameplate

4.2 Receiving

• Check pumping unit for shortage and damage immediately upon arrival. Pump accessories when required are packaged in a separate container and shipped with the unit.

• If equipment is damaged in transit, promptly report this to the carrier's agent. Make complete notations on the freight bill to speed satisfactory adjustment by the carrier.

• Unload and handle the unit with a sling. Do not lift unit by eye bolts on the motor!

4.3 Temporary storage

• If pump is not to be installed and operated soon after arrival, store it in a clean, dry area of moderate ambient temperature.

• Rotate the shaft by hand periodically to coat bearing with lubricant to retard oxidation and corrosion.

• Follow motor manufacturer's storage recommendations where applicable.

4.4 Location

• Locate the pump as close to the suction supply as possible.

TM 05 8912 3712

Use the shortest and most direct suction piping practical. Refer to 3.9 Suction (inlet) piping.

• Locate the pump below system level wherever possible. This will facilitate priming, assure a steady liquid flow, and provide a positive suction head.

• Always allow sufficient accessibility for maintenance and inspection. Provide a clear space with ample head room for use of a hoist strong enough to lift the unit.

• Make sure a suitable power source is available for the pump motor. Electrical characteristics should match those specified on the motor data plate, within the limits covered in

4. Installation-electrical and 5. Operation.

• Avoid pump exposure to sub-zero temperatures to prevent pump liquid from freezing. If freezing conditions exist during shutdown periods, see Sections 5.6 Pump shutdownand

5.7 Short duration shutdown for specific recommendations.

4.5 Horizontal pump foundation

Finished

Wedges or shims

grouting

.75 to 1.25

allowance for grout

Base plate

Grout

left in place

4.9 Suction (inlet) piping

The sizing and installation of suction piping is particularly important. It must be selected and installed in a manner that minimizes pressure loss and permits sufficient liquid flow into the pump during starting and operation. Many NPSH problems can be traced directly to improper design of suction piping systems. Observe the following precautions when installing suction piping:

PACO Pumps

Dam

Pipe sleeve

Washer

Fig. 2 Anchor bolt installation

ecuring base plate

4.6 S

• After the concrete pad has been poured and set, lower the pump base plate over the anchor bolts and rest it on loose adjustment wedges or shims placed near each anchor bolt and at intervals not to exceed 24" along each side. Shims or wedges must be placed to raise the bottom of the base 3/4" to 1 - 1/4" above the pad, allowing clearance for grout. Level the pump shaft, flanges, and base plate using a spirit level, adjusting the wedges or shims, as required.

• Check to make sure that the piping can be aligned to the pump flanges without placing any strain on either flange.

• After pump alignment has been established (LF), put nuts on foundation bolts and tighten them just enough to keep the unit base plate from moving. Construct a form or dam around the concrete pad and pour grout in and around the pump base, as shown in Fig. 2. Grout compensates for uneven foundation, distributes the weight of the unit, and prevents shifting. Use an approved, non shrinking grout (such as Embeco 636 by Master Builders, Cleveland, Ohio or equivalent). Allow at least 24 hours for this grout to set before proceeding with piping connections.

• After the grout has thoroughly hardened, check the foundation bolts and tighten if necessary. Recheck the pump alignment after the foundation bolts are secured.

• No alignment or grouting required for LCS pump.

4.7 Vertical mount

The PACO LCV Vertical Close Coupled pump need not be grouted to its foundation, but should be anchored with 4 anchor bolts set in concrete similar to the horizontal anchoring arrangement Fig. 2.

4.8 P

iping-general

• Do not use pump as a support for piping! Use pipe hangers or other supports at proper intervals to provide complete piping support near the pump.

• Both suction and discharge piping should be independently supported and properly aligned so that no strain is transmitted to the pump when flange bolts are tightened.

• Make sure piping is as straight as possible, avoiding unnecessary bends and fittings. Where necessary, use 45 ° or long-sweep 90 ° pipe fittings to decrease friction loss.

• Where flanged joints are used, make sure that inside diameters properly match and mounting holes are aligned.

• Do not spring or force piping when making any connections!

ing instructions

Top foundation

leave rough clean

& wet down

LUG

TM 05 4775 2512

TM05 4791 2613

Fig. 3 Inlet piping

• Suction piping should be as direct as possible, and ideally the length should be at least ten times the pipe diameter. Short suction piping can be the same diameter as the suction opening. Longer piping should be one or two sizes larger (depending on length), reducing to the diameter of the pump suction opening.

• Use an eccentric reducer, with the eccentric side down Fig. 3 when reducing the pipe diameter to the diameter of suction opening.

• At no point should suction piping be smaller in diameter than the pump suction opening.

• Horizontal suction lines should follow an even gradient, if possible. A gradual upward slope to the pump is recommended for suction lift conditions, and a gradual downward slope for positive suction head.

• Avoid any high points, such as pipe loops Fig. 4, that may create air pockets and throttle the system or produce erratic pumping.

• Install a valve in the suction line to isolate the pump during shutdown and maintenance, and facilitate pump removal. Where two or more pumps are connected to the same suction line, install duplicate gate valves to isolate each pump from the line.

• Gate valves should always be installed in positions that avoid air pockets. Globe valves should not be used, particularly when NPSH is critical.

• During pumping operation, valves on suction line must always be at FULL OPEN.

• Properly sized pressure gauges can be installed in gauge taps on pump suction and discharge nozzles. Gauges enable the operator to monitor pump performance and determine that the pump conforms to the parameters of the performance curve. If cavitation, vapor binding, or other unstable operation occurs, pressure gauges will indicate wide fluctuation in suction and discharge pressures.

English (US)

PACO Pumps

Fig. 4 Air pocket prevention

4.10 Discharge (outlet) piping

• Short discharge piping can be the same diameter as the pump discharge opening. Longer piping should be one or two sizes larger depending on length.

• An even gradient is best for long horizontal runs of discharge piping.

• Install a valve near the discharge opening to prime and start the pump. The discharge gate valve is also used to isolate the pump during shutdown, maintenance, and facilitate pump removal.

• Any high points in discharge piping may entrap air or gas and thus retard pump operation.

• If the possibility of liquid hammer exists, (i.e. check valves are used) close the discharge gate valve before pump shutdown.

4.11 Shaft sealing-general comments

• PACO offers both mechanical seals and packed stuffing boxes as a means to seal the shaft. Pumps with stuffing boxes are normally packed before shipment. If the pump is installed within 60 days after shipment, the packing material will be in good condition for operation with a sufficient supply of lubrication. If the pump is stored for a longer period, it may be necessary to repack the stuffing boxes.

• The stuffing box must be supplied at all times with a source of clean, clear liquid to flush and lubricate the packing. When pumps are equipped with mechanical seals, no maintenance or adjustment is required. Mechanical seals are preferred to packing on most applications because they require less maintenance.

4.13 Mechanical seals

All PACO Type L pumps that are equipped with mechanical seals are matched to conditions for which the pump was sold. Observe the following precautions to avoid seal damage and obtain maximum seal life:

• Do not exceed temperature or pressure limitations for the mechanical seal used.

• DO NOT RUN THE PUMP DRY OR AGAINST A CLOSED VALVE! Dry operation will cause seal failure within minutes.

• Clean and purge suction piping in new installations before installing and operating pump. Pipe scale, welding slag and

TM05 4792 2613

other abrasives can cause rapid seal failure.

Fig. 5 Checking parallel alignment

TM05 4795 2613TM05 4794 2613

4.12 Packing gland adjustment

With the pump running, the packing gland should be adjusted to permit 40 to 60 drops per minute leakage. This is required for shaft lubrication. After initial start up, additional packing and adjustment may be required. Pumps with mechanical seals require no adjustment.

Fig. 6 Checking alignment

4.14 Coupling alignment (LF)

• The following anchoring and alignment procedure is typical and, if performed with care, should result in a smooth running, trouble-free installation.

• If the pump and motor were shipped mounted on the pump base as an assembly, remove the coupling guard.

• The pump and motor were accurately aligned at the factory, but handling during shipment usually alters this pre-alignment. Using a small straight edge and feeler gauges or a dial indicator, check for horizontal, vertical, and angular misalignment of the coupling hubs Fig. 5 and Fig. 6.

• Coupling alignment is correct when the dial indicator reads no more than .005" run out in any direction (or when the straight edge contacts both hubs evenly in both horizontal and vertical positions). If misalignment is detected, loosen the motor and shift or shim as necessary to re-align, then re-tighten bolts. Always align the motor to the pump as piping strain will occur if the pump is shifted. Never reposition pump on base!

• After final piping connections to the pump have been made, motor wiring compared, correct rotation has been established, and piping filled with liquid, check shaft alignment once again.

• Leave the coupling guards off until the pump priming procedure is completed for a final shaft alignment check.

• To protect personnel from rotating machinery, Always install coupling guards after installation is complete; before starting pump!

4.15 Coupling alignment (LCS)

• No alignment of the pump and motor is required.

Installation-electrical

Warning

Use only qualified electricians for electrical installation and maintenance.

Refer to manuals provided with electrical accessory components and disconnect power supply as recommended for servicing.

Warning

Never do maintenance work when the unit is connected to power.

5.1 Motors general

the motor control circuit must have the following components in order to comply with the National Electrical Code.

• Motor Disconnecting Device: A motor disconnecting device must be installed that is capable of disconnecting both the controller (motor starter) and the motor from their source of power.

• The disconnecting device must be located so that the controller (motor starter) can be seen from the disconnecting means. In all cases, the distance from the disconnecting device to the controller must be less than 50'.

• In most installations the disconnecting device will be a circuit breaker or fusible disconnect switch.

Motor short circuit and ground fault protection:

• Short circuit and ground fault protection are usually provided by means of a circuit breaker or fusible disconnect switch.

• The selection of the size of the circuit breaker or fuse must be in accordance with Section 430-52 and Table 430-152 of the National Electrical Code.

Motor controller with running over current protection (magnetic starter):

• These components must be installed in accordance with applicable local and state electrical codes in addition to the National Electrical Code.

PACO Pumps

Warning

Whenever powered equipment is being used in explosive surroundings, the rules and regulations generally or specifically imposed by the relevant responsible authorities or trade organizations must be observed.

5.2 Installation wiring

• Mount the control panel or motor starter(s) in close proximity to the pump to provide convenient control and ease of installation.

• Wire panel or starter(s) to motor(s) and pilot device(s): Wires to each motor must be sized for at least 125 % of the motor nameplate full load amps. AWG #16 Type THW stranded wire is recommended for wiring of pilot devices (float switches).

• Check incoming power source to ensure that it is the same as the voltage and phase of the motors.

• Verify that the starters are suitable to operate the pump motors on voltage and phase that is available.

English (US)

Caution

PACO Pumps

Operation

5.1 Priming

• The PACO Type L pump is not self-priming, and must be completely primed (filled with liquid) before starting.

• If the pump will operate with a positive suction head, prime by opening the suction valve and allowing liquid to enter pump casing. Open air vents at this time, and make sure all air is forced from pump by liquid before closing.

• Rotate the shaft by hand to free entrapped air from impeller passageways.

• If pump has a suction lift, priming must be accomplished by other methods. The use of foot valves or ejectors, or manual filling of the pump casing and suction line with liquid are possible methods suggested for this purpose.

• CAUTION: Never run the pump dry in the hope that it will prime itself! Serious damage to the mechanical seal will result.

Never run the pump dry in the hope that it will prime itself! Serious damage to the shaft seals, pump wear rings and shaft sleeves will result.

6.2 Pre-start checklist

Warning

In the interest of operator safety, the unit must not be operated above the nameplate conditions. Such operation could result in unit failure causing injury to operating personnel. Consult instruction book for proper operation and maintenance of the pump and its supporting components.

Make the following inspections before starting your PACO Type L pump:

1. Make sure the suction and discharge piping has been cleaned

and flushed to remove dirt and debris before operating pump.

2. Double check rotation must be clockwise operating in reverse

will destroy the impeller and shaft.

3. Make sure all wiring connections to the motor (and starting

device) match the wiring diagram and produce clockwise rotation as viewed from the back of the motor.

4. If the motor has been in storage for an extended length of

time, either before or after installation, refer to motor instructions before starting.

5. Check the voltage, phase, and line circuit frequency with the

motor nameplate. Turn rotating element by hand to make sure it rotates freely.

6. Tighten plugs in gauge and drain taps. If the pump is fitted

with pressure gauges, keep gauge clocks closed when not in use.

7. Check suction and discharge piping for leaks, and make sure

all flange bolts are securely tightened.

6.3 Motor rotation

Never check driver rotation unless pump and driver couplings are disconnected and physically separated. Failure to follow this instruction can result in serious damage to pump and driver if rotation is wrong.

After the unit has been wired and checked to insure that all components in the system (disconnect device, magnetic starters, pilot devices and motors) are properly connected, check motor rotation as follows:

• For 3 phase units only—momentarily energize the motors to ensure that the rotation is correct as indicated by the arrow cast into the pump volute. If rotation is incorrect, interchange two wires at the motor starter terminals T1 and T2.

• IMPORTANT: The pumps must not be operated while dry. Use extreme caution that motors are energized only momentarily to determine proper rotation.

6.4 Starting the pump

Warning

The pump must not be operated without an approved coupling guard in place. Failure to observe this warning could result in injury to operating personnel.

1. Install coupling guard on coupled units.

2. Fully open gate valve (if any) in suction line, and close gate

valve in discharge line.

3. Fill suction line with liquid and completely prime pump.

4. Start the motor (pump).

5. Immediately make a visual check of pump and suction piping

for pressure leaks.

6. Immediately after pump reaches full operating speed, slowly

open the discharge gate valve until complete system flow is achieved.

7. Check discharge piping for pressure leaks.

8. If pump is fitted with pressure gauges, open gauge cocks and

record pressure reading for future reference. Verify that the pump is performing in accordance with parameters specified on performance curve.

9. Check and record voltage, amperage per phase, and

kilowatts, if a wattmeter is available.

6.5 Voltage regulation

The motor will operate satisfactorily under the following conditions for voltage and frequency variation, but not necessarily in accordance with the standards established for operation under rated conditions:

• The voltage variation may not exceed 10 % above or below rating specified on the motor data plate.

• The frequency variation may not exceed 5 % above or below motor rating.

• The sum of the voltage and frequency variations may not exceed 10 % above or below motor rating, provided the frequency variation does not exceed 5 %.

6.6 Pump shutdown

The following shutdown procedures will apply in most normal shutdowns for the PACO Type L pumps. If the pump will be inoperative for an extended length of time, follow storage procedures in Extended Period Shutdown.

• Always close the discharge valve before stopping the pump. Close the valve slowly to prevent hydraulic shock.

• Cut and lock off power to the motor.

6.7 Short duration shutdown

• For overnight or temporary shutdown periods under nonfreezing conditions, the pump may remain filled with liquid. Make sure the pump is fully primed before restarting.

• For short or frequent shutdown periods under freezing conditions, keep fluid moving within the pump casing and insulate or heat the pump exterior to pre vent freezing.

6.8 Extended period shutdown

• For long shutdown periods, or to isolate the pump for maintenance, close suction gate valve. If no suction valve is used and the pump has positive suction head, drain all liquid from suction line to terminate liquid flow into pump suction nozzle. Remove plugs in pump drain and vent taps, as required, and drain all liquid from the pump volute casing.

• If freezing conditions will exist during long shutdown periods, completely drain the pump and blow out all liquid passages and pockets with compressed air. Freezing of pump liquid can also be prevented by filling the pump with antifreeze solution.

7. Maintenance

Warning

Do not attempt any maintenance, inspection, repair or cleaning in the vicinity of rotating equipment. Such action could result in personal injury to operating personnel.

Before attempting any inspection or repair on the pump, the driver controls must be in the "OFF" position, locked and tagged to prevent injury to personnel performing service on the pump.

7.1 Motor lubrication

Always follow motor manufacturer's lubrication instructions if available, and periodically check grease fittings and drain plugs for leaks. If lubricating instructions do not accompany motor, refer to for recommended lubrication periods.

• To lubricate the motor while running or at rest, remove grease drain plug (if any) and filler plug on grease fitting. Grease with clean lubricant until grease appears at drain hole or along motor shaft.

Recommended Lubrication Periods

Motor RPM Motor HP Operating conditions

Standard Severe Extreme

0.33 - 7.50p 3 yrs 1 yr 6 mo

1750 and

below

above 1750 all hp 6 mo 3 mo 3 mo

Standard conditions:

8 Hours per day operation, normal or light loading, clean air, 100 °F, maximum ambient temperature.

Severe conditions:

Continuous 24-hour operation, shock loading or vibration, poor ventilation, 100-150 °F, ambient temperature.

Extreme conditions:

Continuous operation, heavy shock or vibration, dirt or dust in air, extreme ambient temperature.

• One-half to one cubic inch of grease is sufficient for motors 5 HP and under, with proportionately more grease for greater HP motors.

• Most fractional and some integral frame motors have "sealedfor-life" bearings, and do not require further lubrication throughout motor life.

• Always follow motor manufacturer's lubrication instructions, and periodically check grease fittings and drain plugs for leaks.

• If lubricating instructions do not accompany motor, refer to Table , “Recommended Lubrication Periods,” on page 10 for recommended lubrication periods.

• Table , “Approved lubricants,” on page 11 lists recommended types of grease for both pump and motor lubrication. These types have all been thoroughly tested and should be used whenever possible.

10-40 1-3 yrs 6 mo - 1 yr 3 mo

50-150 1 yr 6 mo 3 mo

200 and up 1 yr 6 mo 3 mo

PACO Pumps

English (US)

PACO Pumps

7.2 Pump lubrication

• PACO Type LF pumps on horizontal bearing frames have bearing that may be sealed for life (requiring no lubrication), regreasable or oil lubricated.

Approved lubricants

MANUFACTURER LUBRICANT

SHELL DOLIUM

EXXON POLYREX

CHEVRON

PHILIPS POLYTAC™

TEXACO POLYSTAR RB

• To lubricate regreasable bearings, remove grease drain plug (if any) and filler plug. Add clean ball bearing lubricant until grease appears at drain hole or along shaft. On units with drain hole, all old grease can be purged out ahead of new. In such cases, the drain should be left unplugged for several minutes during pump operation to allow excess grease to be forced out.

• Lubricate bearing frame bearings at intervals of one to three months, depending on severity of environment. Pumps in a clean, dry, moderate temperature (100 °F maximum) environment should be regreased at three month intervals. Too much grease can cause premature bearing failure-do not overgrease.

On those PACO Type LF Centrifugal End Suction pumps

• ordered with oil lubricated bearings, Fig. 7. A regular oil maintenance program must be enforced.

After the first 200 hours of operation the oil should be

• changed. To change the oil, remove the drain plug at the bottom of the bearing cover and the filler plug (that also acts as a vent plug) at the top of the housing. After draining oil, replace the fittings and refill with an acceptable oil selected from Table , “List of acceptable Lube oils,” on page 11. After the first oil change, the oil should be changed again at 2000 hours and then at intervals of 8000 hours or once yearly, thereafter.

SRI GREASE NLGI 2

BLACK PEARL - NLGI 2

List of acceptable Lube oils

Lubricant Manufacturer Bearing oil brand name

Aral Refining Co.

British Petroleum Co.

Calypsol Oil Co.

Standard Oil Co.

Esso Corp

Fina Oil Co.

Gulf Refining Co.

Socony Mobil Oil Co.

Shell Oil Co. Shell Tellus oil 29

Sundco Oil Co. Sunvis 821

The Texas Co.

Wisura Refining Co.

Aral Oil CMU

Aral Oil TU 518

BP Energol

TH 100-HB

Calypsol Bison Oil

SR 25 or SR 36

Chevron

Hydraulic Oil 11

Circulating oil 45

Esso-Mar 25

Teresso 47

Esstic 50

Fina hydran 34

Fina Cirkan 32

Gulf Harmony 47

Gulf Paramount 45

Vac hlp 25

Mobulix D.T.E. 25

Texaco ursa oil P 20

Dea viscobil sera 4

Wisura norma 25 (36)

Wisura tempo 25 (36)

7.3 Disassembly of pumps

Caution

Note

Caution

Warning

Depending on the product being pumped, the pump should be washed down before any work is done on it.

Warning

Observe extreme caution when venting and/or draining hazardous liquids. Wear protective clothing in the presence of caustic, corrosive, volatile, flammable, or hot liquids. DO NOT breathe toxic vapors. DO NOT allow sparking, flames, or hot surfaces in vicinity of the equipment.

1. Complete disassembly instructions are outlined below. Proceed only as far as required to perform the maintenance work needed.

2. Turn of power.

3. Drain System. Flush, if necessary.

4. Closed coupled units. Remove motor hold down bolts.

7.3.1 Disassembly of liquid end

1. Remove casing bolts (8B).

2. Remove back pull-out bearing frame assembly (20Y) from

casing (1A).

3. Unscrew impeller nut (8A).

Do not screwdriver between impeller vanes to prevent rotation. It may be necessary to use a strap wrench around the impeller or shaft to prevent rotation.

4. Use appropriate size gear puller aligned behind impeller

vanes to remove impeller (3A) from shaft (6A).

5. Remove impeller key (12A).

6. Remove back plate bolts (8D). Remove back plate (2K) and

seal housing (26P).

7. Place seal housing on flat surface and press out seal seat

(14A).

8. If shaft sleeve (5A) requires replacement, it must be evenly

heated to approximately 350 °F to loosen locktite. Twist sleeve off shaft (6A).

7.3.2 Disassembly of bearing frame (LF)

1. Remove slinger (13G).

2. Remove grease seal(s), (14S) if any.

3. Remove bearing house retaining ring (61K).

4. Press or tap on the pump end of the bearing-shaft assembly

until one bearing is out.

5. When one bearing is out, remove second retaining ring (61F),

then remove complete assembly from bearing housing.

6. Remove shaft retaining ring (61C) and press off bearings.

7. press on new bearings, remember to press only on inner race

of bearing while pressing them on.

8. Assemble frame in the reverse procedure used for

disassembly.

9. Observe the following when reassembling the bearing frame.

10. Replace lip seals (14S) if worn or damaged.

11. Replace bearings (18A), (18B) if loose, rough or noisy when

rotated.

12. Check shaft (6A) for runout at the sleeve (5A) area. Maximum

permissible is .002" T.I.R.

7.4 Seal replacement (LCS)

1. Complete preparations noted.

2. Remove coupling guard (34F).

3. Remove coupling bolts (8E). Pry apart the coupling halves (23D), remove keys (12B) and set aside.

Mark or measure the original position of the pump coupling on the motor side.

4. Unscrew tubing connector from pipe tee of air vent assembly. Pipe dope is applied to threads during factory assembly, and resulting bond may retard but will not prevent manual disassembly.

5. Remove seal cap bolts and slide seal cap (2N) up shaft to remove.

6. Remove seal head assembly manually from shaft (6A). Water-soluble lubricant may be applied to shaft to ease removal of shaft seal (14A). Pull seal head assembly manually from shaft, using slight twisting motion (as necessary) to loosen bellows from shaft.

7. Remove and discard seal spring and retainer.

8. remove and discard seal seat from seal cap (2N) and thoroughly clean the inside cavity of seal cap.

9. Interior surface of bellows on new seal head is coated with bonding agent that adheres to motor shaft. When old seal head is removed, bonding agent no longer exists and bellows may crack or split during removal. Installation of new mechanical seal is always recommended if it becomes necessary to remove existing seal from shaft.

10. Clean and lubricate shaft (6A) with water-soluble lubricant and make sure no sharp edges exist to cut or scratch bellows of new seal.

11. Press new seal seat firmly into seal cap. Avoid direct contact of seal face with metallic or abrasive objects and wipe clean after installation to ensure abrasive free sealing surface.

12. Slide new seal head assembly onto shaft by applying even pressure to base of assembly.

13. Install seal cap (2N) down shaft.

14. See reassembly instructions.

7.5 Wear ring replacement

1. Complete preparations.

2. Back-pull rotating assembly.

3. It may be necessary to remove volute (1A) from piping, to facilitate easy access to interior of volute. If necessary, remove flange bolts at piping.

4. To remove worn Case Wear Ring (4A), drill two holes slightly smaller than width of ring into exposed edge of ring. Once holes are drilled, a chisel may be used to completely sever ring at holes and break ring into two halves for easy removal.

5. Clean the ring cavity in the volute prior to installing wear ring to ensure a properly aligned fit.

6. To reassemble, press fit new wear ring squarely into volute casing cavity. Ring may be tapped into place to make sure it is completely impressed into cavity.

Do not use metal tooling against wear ring surfaces. Use only rubber, rawhide, wood or other soft material to prevent damage to ring.

PACO Pumps

English (US)

PACO Pumps

7.6 Reassembly of pumps

1. All parts should be cleaned before reassembly.

2. Refer to parts list to identify required replacement items Specify pump serial or catalog number when ordering parts.

3. Reassembly is the reverse of disassembly.

4. Observe the following when reassembling the liquid end:

• All mechanical seal components must be in good condition or

leakage may result. Replacement of complete seal assembly is recommended.

• New shaft sleeves are installed by bonding to shaft with

hydraulic setting locktite.

5. Re-install coupling guards on coupled pumps.

7.7 Ordering parts

Grundfos Pumps has over 90 years of experience in the design, manufacture, and application of centrifugal pumps and pumping systems. Grundfos's commitment to state-of-the-art pump design and quality manufacturing assures maximum user benefits with optimum equipment life at lower cost.

Grundfos's commitment to their customers continues through an extensive service organization. Highly trained technicians can assist customers with initial startup, troubleshooting, repair, and system analysis.

PACO maintains an extensive stock of replacement parts and parts kits for our most popular model pumps. Shipment of these parts is normally made within three days after receipt of an order. On larger pumps, where it is impractical for our factory to inventory low usage parts, replacement parts are normally manufactured and shipped within 15 working days of receipt of an order. In order to reduce pump repair time and shorten inconvenient pump service interruptions, it is suggested that the pump user stock spare parts. For suggested spare parts see Replacement Parts Guide A1b.2, attached, and contact your local PACO Sales Representative (see back cover for the number of your nearest PACO Sales office). Since spare parts requirements and quantities vary for specific pump constructions, allow your PACO Representative to help in defining your spare part requirements. To ensure that the proper replacement parts are ordered for your particular pump model, when you call:

• Identify all pertinent data from the pump name plate (see

Pump Identification ). This should always include the pump Catalog or Model Number, and the pump Serial Number.

• For replacement impellers, also include from the nameplate

the operating conditions (GPM and TDH) and the impeller diameter.

• Identify all parts by item number and description as indicated

by the appropriate assembly drawing in this manual, for your particular pump model.

Warning

Coupling guard must be reinstalled and in place prior to operation.

7.8 Type LF, cross section and parts list

PACO Pumps

ITEM NO PART NAME ITEM NO PART NAME ITEM NO PART NAME

1A Casing *10A Washer, Packing 16L Plug, Seal Chamber

2K Backplate 10A Washer, Impeller 18A Bearing, Inboard

3A Enclosed Impeller 11A Gasket, Casing 18B Bearing, Outboard

4A Case Wear Ring 11F Gasket, Backplate 20Y Bearing Frame

**4F Balance Ring 12A Key, Impeller *22A

5A Shaft Sleeve 12B Key, Coupling 26P Seal Housing

*5L Lantern Ring *13A Packing *26U Packing Box

6A Shaft 13G Slinger *35F Nut, Packing Gland

*7A Packing Gland 14A Shaft Seal 61C Snap Ring

8A Cap Screw, Impeller 14S Lip Seal *61J Snap Ring

8B Cap Screw, Casing 16A Plug, Drain

8D Cap Screw, Brg. Frame 16D Plug, Grease/Oil Filter

* Packed Pumps Only

** If Applicable

Stud, Packing

Gland

TM05 4796 3712

English (US)

PACO Pumps

7.9 Type LC, cross section and parts list

ITEM NO PART NAME ITEM NO PART NAME

*1A Casing 11F Gasket, backplate

2K Backplate 12A Key

3A Impeller *13A Packing

4A Front case wear ring 13G Slinger

4F Rear case wear ring 14A Mechanical seal

5A Shaft sleeve 16A Plug, drain

*5L Lantern ring 16J Plug, stuffing box

*7A Packing gland 21A Bracket

8A Impeller capscrew *22A Stud, packing gland

8B Capscrew, casing 34B Nameplate

8D Capscrew, bracket *35F Nut, packing gland

8N Capscrew, motor 61B Snap ring

10A Washer, impeller *61L Retaining ring

*10K Washer, packing 65A Motor

11A Gasket, casing 84R Set screws

* Packed pumps only

TM05 8911 2913

7.10 Type LCV, cross section and parts list

PACO Pumps

ITEM NO PART NAME ITEM NO PART NAME

1A Volute 10A Impeller washer 2H Hand hole cover (not shown) 12A Key 2K Backplate 13G Slinger 3A Impeller 14A Single mechanical seal assembly

4Q Suction cover wear ring 20H Stand

4S Impeller wear ring 21F Pedestal bracket 5A Sleeve 32C Elbow with clean out port 8A Impeller screw

TM05 8910 2913

English (US)

PACO Pumps

7.11 Type LCS, cross section and parts

ITEM NO PART NAME ITEM NO PART NAME

1A VOLUTE 17E SEAL CAP O-RING

2N SEAL CAP 20B BASE RAIL

3A IMPELLER 20C MOTOR DECK

4A CASE WEAR RING 20J CAST IRON STAND

4F BALANCE RING 20D PUMP SUPPORT

6A PUMP SHAFT 21A MOTOR BRACKET

8B VOLUTE SCREW 22A SEAL CAP STUDS

8C PUMP SHAFT SCREW 23D COUPLING HALVES

8E COUPLING SCREW 24H BUSHING

8F COUPLING GUARD SCREW 34B IMPELLER WASHER

8G LOCATING RING SCREW 34C PUMP SHAFT WASHER

8N MOTOR SCREW 34D COUPLING WASHER

11A VOLUTE GASKET 35E COUPLING NUT

12B COUPLING KEY 34F COUPLING GUARD

14A SEAL ASSEMBLY 35F SEAL CAP NUT

15A LOCATING RING 65A MOTOR

16A PIPE PLUG

TM06 1700 2614

Trouble Shooting

8.1 Symptom

Symptoms Cause Code

Pump does not deliver any liquid at start-up.

Pump stops delivering liquid after start-up.

Pump overheats and/or ceases to deliver liquid.

Shaft seal leaks appreciably, or the packing leaks excessively.

Shaft seal or packing fails prematurely.

Bearings overheat and/or fail prematurely.

Insufficient flow rate.

Excessive flow rate.

Discharge pressure is too high.

Pump uses too much power.

Pump runs rough and noisily.

8.2 Possible Causes

1*2*3*4*5*6*7*8*9*10*11*14*16*17*22*23*24*34

2*3*4*5*6*7*8*9*10*11*12*13*22*23*24*34

1*3*9*10*11*21*22*27*29*30*31*33*34*40*41

2*3*4*5*6*7*8*9*10*11*14*16*17*20*21*22*23*24*25*26*34

15*18*20*34

4*14*16*18*20*22*23*24*25*26*34

27*28*29*30*33*34*35*36*39*41

12*13*27*28*29*30*33*34*35*36*37*38*39*41

15*16*18*19*20*23*25*27*28*31*33*34*35*37*38*44

2*3*4*5*6*7*8*9*10*11*15*17*18*21*23*24*27*28*29*30*

31*32*33*34*40*41*42*45*46*

27*28*29*30*31*32*33*34*40*41*42*43*44*45*46

PACO Pumps

1. The pump has not been properly bled of air.

2. The pump suction line have not been completely primed.

3. The suction head (NPSHR) required by the pump is too high, or the net positive suction head available (NPSHA) at your facility is too low.

4. The fluid pumped contains too much entrained air or gas.

5. There are air pockets in the suction line.

6. An entry of air has suddenly occurred in thesuction line.

7. An entry of air past the shaft seal into the pump has occurred.

8. The inlet of the suction line is insufficiently submerged.

9. The suction valve is closed or only partially open.

10. The suction strainer is clogged with dirt or debris.

11. The foot valve is clogged or undersized.

12. Little or no cooling fluid supplied to the shaft seals.

13. The lantern ring is not positioned opposite the flushing inlet thereby restricting fluid flow.

14. Pump drive rotational speed too low.

15. Pump drive rotational speed too high.

16. Pump rotation wrong or impeller installed backwards.

17. Total head of installation (back Pressure) higher than rated total head of the pump.

18. Total head of installation (back Pressure) lower than rated total head of the pump.

19. Density of fluid pumped differs from that specified when the pump was purchased.

20. Viscosity of fluid pumped differs from that specified when the pump was purchased.

21. The pump is operating at too low a rate of flow (The discharge valve may be throttled too much).

22. If pumps are operating in parallel, the pump characteristics may not be suitable for parallel operation.

23. The impeller may be clogged with debris.

24. The impeller may be damaged.

25. The casing and impeller wear rings may be excessively worn.

26. There may be internal leakage from the discharge to the suction compartments as the result of internal gasket failure.

27. There may be a misalignment of the pump shaft.

28. The shaft may chatter because it is bent.

29. The pump may run rough due to improper balancing of the impeller.

30. The shaft may not be running due to worn bearings.

31. The impeller may be rubbing against the inside of the case.

32. The concrete pad might not be of sufficient size to provide pump stability.

33. The pump may have become misaligned during Installation.

34. The operating conditions of the installation do not agree with the data specified when the pump was purchased.

35. The shaft seal may be incorrectly installed, or the stuffing box has not been packed correctly.

36. The shaft sleeve may be scored or pitted in the region of the packing due to dirt or abrasive matter in the flushing fluid.

37. Excessive tightening of the packing gland may block the flushing port thereby diminishing the sealing fluid flow.

38. Packing material may have become wedged or extruded between the shaft and the bottom of the stuffing housing due to excessive clearance on the packing backup washer.

39. The mechanical seal may have been damaged by running dry.

40. There may be excessive axial thrust (side loading) due to improper impeller central alignment.

41. The bearings may be worn.

42. The bearings may have been damaged during installation and/ or dirt or other foreign matter may have entered the bearings during greasing or oiling.

43. Excessive greasing may cause the bearings to overheat.

44. Inadequate lubrication may be causing bearing failure.

45. Dirt may have entered the bearings past the O-Rings.

46. Moisture may have entered the bearing housing causing the bearings to rust.

16. Technical data 42

16.1 Enclosure 42

16.2 Main dimensions and w eig ht 43

16.3 Surroundings 43

16.4 Terminal tightening tor qu es 43

16.5 Cable length 44

16.6 Fuses and cable gauge size 44

16.7 Inputs and outputs 46

16.8 Sound pressure level 46

17. Disposal 46

Caution

Note

Grundfos CUE

9. Grundfos CUE

Variable Frequency Drive

Installation and Operating Instructions

Warning Prior to installation, read these installation and

operating instructions. Installation and operation must comply with local regulations and accepted codes of good practice.

Symbols used in this document

Warning If these safety inst ructi ons ar e not obser ved,

it may result in pe rsonal injury!

If these safety inst ructi ons ar e not obser ved, it may result in malfunction or damage to the equipment!

Notes or instructions that make the job easier and ensure safe operation.

Introduction

9.1

This manual introdu ce s all as pects of your Grundf os C UE variable frequency dri ve in the o utpu t curre nt ra nge of 1.8 to 177 A.

Always keep this manu al clos e to the CUE.

9.2 General description

The CUE is a series of ext erna l varia ble frequen cy drive s especially designe d for pumps.

Thanks to the start-up guide in the CU E, the install er can quick ly set central parameter s and put the CUE int o ope rati on.

Connected to a sen so r or an external control signa l, the CUE will quickly adapt th e pump speed to t he actu al dem and .

9.3 Applications

The CUE series an d Grundfos standard pumps are a supplement to the Grundfos E- pumps r ange w ith int egr ated variab le frequency drive .

A CUE solution offers t he same E-pu mp fu ncti onali ty

• in the su pply v oltage o r powe r ra nges not c overe d by the E-pump range.

• in applications where an integrated variable frequency drive is not desirable or permiss ible.

9.4 References

Techn ical do cum entation f or G rund fos C UE:

• The ma nu al contains all info rma tion r equir ed for put ting t he CUE into oper ation.

• The data boo klet contains a ll technic al infor mation abo ut the construction and applic atio ns of the C UE.

• Service in str uction s contain a ll requir ed ins truct ions fo r dismantling and r epairing the variable frequency d riv e.

Techn ical do cum entation is avail able on www.grundfos .com > International webs ite > WebCAP S.

If you have any ques tion s, pl ease c ontact th e ne arest Gr un dfos company or servic e work shop .

Safety and warnings

10.

10.1 Warning

Warning Any installation, maintenance and inspection

must be carried out by trained personnel.

Warning Touching the electrical p arts m ay be fatal, ev en

after the CUE has been switched off. Before making any work o n th e CUE , the m ains

supply and other input voltages must be switched off at least for as long as stated below.

Voltage Min. waiting time

4 minutes 15 minut es 20 m inutes 200-240 V 1 - 5 hp 7.5 - 60 hp 380-500 V 0.75 - 10 hp 15 - 125 hp 525-600 V 1 - 10 hp 525-690 V 15 - 125 hp

Wait only for shorter time if stated s o on the n amep late o f the CUE in question.

10.2 Safety regulations

• The On/Off button of the control panel does not disconnect the CUE from the p ower su ppl y a nd mu st t her ef or e n ot be us ed as a safety switch.

• The CUE mus t be gro unded c orre ctly an d protec ted aga inst indirect contact a ccor ding t o nat ional re gu lation s.

• The leak age c urre nt to gr ound ex ceed s 3. 5 mA.

• Enclos ure c lass N EMA 1 mus t no t be install ed freely accessible, but only in a panel.

• Enc losur e clas s NE MA 12 mu st n ot be in stalled outdoor s without additional pro tect ion agai nst wat er an d the sun .

• Alwa ys ob serv e nat ional an d local r egu lations as t o cable gauge size, short-circuit protection and overcurrent protection.

10.3 Installation requirements

The general safe ty ne cess itates s pe cial co nside rations as t o these aspects:

• fuses and sw itch es for o ve rcur rent and sh ort- circ uit p rotect ion

• selection of cables (mains current, motor, load distribution and relay)

• net configur atio n (IT, TN, grounding)

• safety on c onnec ting inputs a nd out puts (PELV).

10.3.1 IT mains

Warning Do not connect 380-500 V CUE variable frequency

drives to mains supplies with a voltage between phase and ground of more than 440 V.

In connection with IT mains and grounded delta mains, the supply voltage may exceed 440 V between phase and ground.

10.3.2 Aggressive environment

The CUE should not be installed in an

Caution

The CUE contains a l arge n umber of mec hanic al and el ec tronic components. They ar e all vuln erab le to en vi ronm ental effects.

environment where the air contains liquids, particles or gases wh ich may affec t and dama ge the electronic components.

10.4 Reduced performance under certain conditions

The CUE

• low air pre ssure ( at hig h altitu de)

• long mot or ca ble s.

The required measures are described in the next two sections.

10.4.1

PELV = Protective Extra Low Voltage. At low air pressure, the cooling capacity of air is reduced, and the

CUE automatic ally redu ce s the perfo rma nce t o prev ent overl oad . It may be necessa ry to se lect a CU E w ith a h igher perform anc e.

10.4.2 Reduction in connection with long motor cables

The maximum cable length for the CUE is 1000 ft for unscreened and 500 ft for screen ed c ables . In case of long er cables , co ntact Grundfos.

The CUE is designe d for a motor ca ble with a ma ximu m gaug e size as stated in se ctio n 16. 6 Fuses and cable gau ge s ize .

will reduce its performance under these conditions:

Reduction at low air pressure

Warning At altitudes above 6600 ft, PELV cannot be met.

Grundfos CUE

+ 53 hidden pages

Grundfos PACOpaQ Installation And Operating Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual