Homa HRS, CHRS Original Instruction Manual

Original Betriebsanleitung Original Instruction Manual

HOMA Pumpenfabrik GmbH Industriestr. 1 D-53819 Neunkirchen-Seelscheid

Version 03/2015 - No. 00510601.01

60 Hz

Baureihe / Serie

CHRS

HRS

Contents

Page

1. General Information

1.1. Declaration of Conformity

1.2. Preface

1.3. Proper Use

1.4. Copyright

1.5. Warranty

2. Safety

2.1. Instructions and safety information

2.2. Guidelines used and CE-certification

2.3. General safety

2.4. Operating personal

2.5. Electrical work

2.6. Operating procedure

2.7. Safety and control devices

2.8. Operation in an explosive atmosphere

2.9. Pumped fluids

3. General description

3.1. Application

3.2. Types of use

3.3. Construction

4. Package, Transport and Storage

4.1. Delivery

4.2. Transport

4.3. Storage

4.4. Returning to the supplier

5. Installation and Start-Up

5.1. General

5.2. Installation

5.3. Start-Up

5.4. Electrical system

5.5. Motor protection

5.6. Operation with a static frequency converter

5.7. activation types

6. Maintenance

6.1. General

6.2. Maintenance

6.3. Change of oil

7. Additional for explosion-proofed submersible pumps

Attachement

8.1 Connection of pumps and mixers

8.2. Declaration of contamination

1. General Information

EC Machinery Directive

2006/42/EEC

EC Directive, electromagnetic compatibility

04/108/EEC

EC Low Voltage Directive

06/95/EEC

EC Directive, explosion-prooved operating material

94/ 9/EEC

EC Directive, construction products

11/305/EEC

EN 60335-2-41

EN 60335-1

EN 60204 Part 1

EN 61000-6-1

EN 60034-1

EN 61000-6-3

EN 61000-6-2

EN 55014-2

EN 61000-3-3

EN 50014/18/19/20

EN 12050-1-4

EN 61000-6-4

EN 55014-1

EN 61000-3-2

EN ISO 12100-1 and -2

ISO 9906

DIN 24250

1.1. Declaration of Conformity

EC Declaration of conformity in line with the EC Machinery Directive 2006/42/EEC, Appendix IIA

We, HOMA Pumpenfabrik GmbH, Industries trasse 1, D-53819 Neunkirchen-Seelscheid, hereby declare that in respect to their design and construction the following types, in the form in which they are marketed by us, conform to the relevant fundamental safety and health requirements of the EC Machine Directives...:

CHRS HRS

EC-Directives to which the types conform:

Relevant harmonized industrial standards:

Specially applied national standards and technical specifications (other applied standards for general mechanical engineering are deposited at the construction office):

Vassilios Petridis Technical Manager

Responsible for technical documents HOMA Pumpenfabrik GmbH Industriestr. 1 53819 Neunkirchen-Seelscheid (Germany)

This is an original instruction manual according to the EC Machinery Directive.

1.2. Preface

Dear Customer, Thank you for choosing one of our company’s products. You have purchased a product which has been manufactured to the latest technical standards. Read this operating and maintenance manual carefully before you first use it. This is the only way to ensure that the product is safely and economically used. The documentation contains all the necessary specifications for the product, allowing you to use it properly. In addition, you will also find information on how to recognize potential dangers, reduce repair costs and downtime, and increase the reliability and working life of the product.

All safety requirements and specific manufacturer’s requirements must be fulfilled before the product is put into operation. This operating and maintenance manual supplements any existing national regulations on industrial safety and accident prevention. This manual must also be accessible to personnel at all times and also be made available where the product is used.

1.3. Proper use

The HOMA products comply with the valid safety regulations and meet the demands of state-of-the-art technology. In the event of improper use, there is a danger to life for the user as well as for third parties. Moreover, the product and/or attachments may be damaged or destroyed. It is important to ensure that the product is only operated in technically perfect condition and as intended. To do so, follow the operating instructions.

1.4. Copyright

This operation and maintenance manual has been copyrighted by the manufacturer. This operation and maintenance handbook is intended for the use by assembly, operating and maintenance personnel. It contains technical specifications and diagrams which may not be reproduced or distributed, either completely or in part, or used for any other purpose without the expressed consent of the manufacturer.

1.5. Warranty

Costs for removal and installation of the complained product at the installation place, costs for the ride of the mechanicians to the location and from the installation place as well as costs for transport are not components of our warranty. Hereby arose costs, especially costs for checking and transport are bearing by the sender or operator of the pump. This is also valid for an asserted warranty claim if a check results that the unit works faultless and is free of defects. All products have a high quality standard. Each product is defeated by a strict technical end control before delivery. A warranty repair achieved by us does not extend the warranty period. Replaced spare parts give no reasons for a new warranty period. Extensive claims are excluded, especially such as diminution, change or compensation also for any kind of follow up damages.

To guarantee a quick transaction of a warranty claim, please return the product together with the warranty receipt, purchase receipt and declaration of defect carriage paid to the manufacturer (address 1.4.6.).

Claims caused by damages of transport could be only accepted, if the damage is established or confirmed by delivery in the presence of the forwarder, parcel service, train or post.

1.5.1. General information

This chapter contains the general information on the warranty. Contractual agreements have the highest priority and are not superseded by the information in this chapter!

The manufacturer is obliged to correct any defects found in the products it sells, provided that the following requirements have been fulfilled:

• The defects are caused by the materials used or the way the product was manufactured or designed.

• The defects were reported in writing to the manufacturer within the agreed warranty period.

• The product was used only as prescribed.

• All safety and control devices were connected and inspected by authorized personnel. If no other provisions have been made, the warranty period applies to the first 12 months after initial start-up or to

a max. of 24 months after the delivery date. Other agreements must be made in writing in the order confirmation. These agreements will remain valid at least until the agreed warranty period of the product has expired.

1.5.2. Spare parts, add-ons and conversions

Only original spare parts as supplied by the manufacturer may be used for repairs, replacements, add-ons and conversions. Only these parts guarantee a long working life and the highest level of safety. These parts have been specially designed for our products. Self-made add-ons and conversions or the use of non-original spare parts can seriously damage the product and/or injure personnel.

1.5.3. Maintenance

The prescribed maintenance and inspection work should be carried out regularly. This work may only be carried out by qualified, trained and authorized personnel. The maintenance and inspection log supplied must be properly updated. This enables you to monitor the status of inspections and maintenance work. Quick repairs not listed in this operation and maintenance manual and all types of repair work may only be performed by the manufacturer and its authorized servi ce centr es.

1.5.4. Damage to the product

Damage as well as malfunctions that endanger safety must be eliminated immediately by authorized personnel. The product should only be operated if it is in proper working order. During the agreed warranty period, the product may only be repaired by the manufacturer or an authorized service workshop! The manufacturer reserves the right to recall the damaged product to the factory for inspection!

1.5.5. Exclusion from liability

No liability will be assumed for product damage if one or more of the following points apply:

• Incorrect design and on our part due to faulty and/or incorrect information provided by the operator or customer

• Non-compliance with the safety instructions, the regulations and the requirements set forth by German law and this operating and maintenance manual

• Incorrect storage and transport

• Improper assembl y /dismantling

• Improper maintenance

• Unqualified repairs

• Faulty construction site and/or construction work

• Chemical, electrochemical and electrical influences

• Wear This means the manufacturer’s liability excludes all liability for personal, material or financial injury.

1.5.6. Manufacturer’s addres s

HOMA Pumpenfabrik GmbH Industriestrasse 1 D-53819 Neunkirchen-Seelscheid Phone: +49 2247 / 7020 Fax: +49 2247 / 70244 Email: info@homa-pumpen.de Homepage: www.homapumpen.de

2. Safety

This chapter lists all the generally applicable safety instructions and technical information. Furthermore, every other chapter contains specific safety instructions and technical information. All instructions and information must be observed and followed during the various phases of the product's lifecycle (installation, operation, maintenance, transport etc.). The operator is responsible for ensuring that personnel follow these instructions and guidelines.

2.1. Instructions and safety information

This manual uses instructions and safety information for preventing injury and damage to property. To make this clear for the personnel, the instructions and safety information are distinguished as follows:

Each safety instruction begins with one of the following signal words:

Danger: Serious or fatal injuries can occur! Warning: Serious injuries can occur! Caution: Injuries can occur! Caution (Instruction without symbol): Serious damage to property can occur, inc lud ing irreparable damage!

Safety instructions begin with a signal word and description of the hazard, followed by the hazard source and potential consequences, and end with information on preventing it.

2.2 Guidelines used and CE certification

Our products are subject to

- various EC directives

- various harmonized standards

- various national standards. Please consult the EU Declaration of Conformity for the precise information and the guidelines and norms in effect. The EU Declaration of Conformity is issued in accordance with EU Directive 2006/42/EEC, Appendix II A. Also, various national standards are also used as a basis for using, assembling and dismantling the product. These include the German accident prevention regulations, VDE regulations, German Equipment Safety Law etc. The CE symbol is found either on the type plate or next to the type plate. The type plate is attached to the motor casing.

2.3 General safety

• Never work alone when installing or removing the product.

• The machine must always be switched off before any work is performed on it (assembly,

dismantling, maintenance, installation). The machine must be disconnected from th e electrica l system and secured against being switched on again. All rotating parts must be at a standstill.

• The operator should inform his/her superior immediately should any defects or irregularities occur.

• It is of vital importance that the system is shut down immediately by the operator if any problems

arise which may endanger safety of personnel. Problems of this kind include:

• Tools and other objects should be kept in a place reserved for them so that they can be found quickly.

• Sufficient ventilation must be provided in enclosed rooms.

• When welding or working with electronic devices, ensure that there is no danger of explosion.

• Only use fastening devices which are legally defined as such and officially approved.

• The fastening devices should be suitable for the conditions of use (weather, hooking system, load,

etc). If these are separated from the machine after use, they should be expressly marked as fastening devices. Otherwise they should be carefully stored.

• Mobile working equipment for lifting loads should be used in a manner that ensures the stability of the working apparatus during operation.

• When using mobile working equipment for lifting non guided loads, measures should be taken to avoid tipping and sliding etc.

• Measures should be taken that no person is ever directly beneath a suspended load. Furthermore, it is also prohibited to move suspended loads over workplaces where people are present.

• If mobile working equipment is used for lifting loads, a second person should be present to coordinate the procedure if needed (for example if the operator's field of vision is blocked).

• The load to be lifted must be transported in such a manner that nobody can be injured in the case of a power cut. Additionally, when working outdoors, such procedures must be interrupted immediately if weather conditions worsen.

 Failure of the safety and/or control devices  Damage to critical parts  Damage to electric installations, cables and insulation.

These instructions must be strictly observed. Non-observance can result in injury or serious

damage to property.

2.4. Operating personal

All personnel who work on or with the product must be qualified for such work; electrical work, for example may only be carried out by a qualified electrician. The entire personnel must be of age. Operating and maintenance personnel must also work according to local accident prevention regulations. It must be ensured that personnel have read and understood the instructions in this operating and maintenance handbook; if necessary this manual must be ordered from the manufacturer in the required language.

2.5. Electrical work

Our electrical products are operated with alternating or industrial high-voltage current. The local regulations (e.g. VDE 0100) must be adhered to. The “Electrical connection” data sheet must be observed when connecting the product. The technical specifications must be strictly adhered to. If the machine has been switched off by a protective device, it must not be switched on again until the error has been corrected.

Beware of electrical current! Incorrectly performed electrical work can result in fatal injury! This work may only be carried out by a qualified electrician.

Beware of damp! Moisture penetrating cables can damage them and render them useless. Furthermore, water can penetrate into the motor and cause damage to the terminals or the winding. Never immerse cable ends in the pumped fluid or other liquids.

2.5.1. Electrical connection

When the machine is connected to the electrical control panel, especially when electronic devices such as soft startup control or frequency drives are used, the relay manufacturer's specifications must be followed in order to conform to EMC. Special separate shielding measures e.g. special cables may be necessary for the power supply and control cables.

The connections may only be made if the relays meet the harmonized EU standards. Mobile radio equipment may cause malfunctions.

Beware of electromagnetic radiation! Electromagnetic radiation can pose a fatal risk for people with pacemakers. Put up appropriate signs and make sure anyone affected is aware of the danger.

2.5.2. Ground connection

Our products (machine including protective devices and operating position, auxiliary hoisting gear) must always be grounded. If there is a possibility that people can come into contact with the machine and the pumped liquid (e.g. at construction sites), the grounded connection must be additionally equipped with a fault current protection device. The electrical motors conform to motor protection class IP 68 in accordance with the valid norms.

2.6. Operating procedure

When operating the product, always follow the locally applicable laws and regulations for work safety, accident prevention and handling electrical machinery. To help to ensure safe working practice, the responsibilities of employees should be clearly set out by the owner. All personnel are responsible for ensuring that regulations are observed. Certain parts such as the rotor and propeller rotate during operation in order to pump the fluid. Certain materials can cause very sharp edges on these parts.

Beware of rotating parts! The moving parts can crush and sever limbs. Never reach into the pump unit or the moving parts during operation. Switch off the machine and let the moving parts come to a rest before maintenance or repair work!

2.7. Safety and control devices

Our products are equipped with various safety and control devices. These include, for example suction strainers, thermo sensors, sealed room monitor etc. These devices must never be dismantled or disabled. Equipment such as thermo sensors, float switches, etc. must be checked by an electrician for proper functioni ng before start-up (see the “Electrical Connection” data sheet). Please remember that certain equipment requires a decoder device or relay to function properly, e.g. posistor and PT100 sensor. This decoder can be obtained from the manufacturer or a speciali st electr oni cs dea ler.

Personnel must be informed of the installations used and how they work.

Caution Never operate the machine if the safety and monitoring devices have been removed or damage, or if they do not work.

2.8. Operation in an explosive atmosphere

Products marked as explosion-proof are suitable for operation in an explosive atmosphere. The products must meet certain guidelines for this type of use. Certain rules of conduct and guidelines must be adhered to by the operator as well. Products that have been approved for operation in an explosive atmosphere are marked as explosion-protected “Ex”. In addition, an “Ex” symbol must be included on the type plate! When used in an explosive atmosphere, the additional chapter entitled “Explosion protection according to the …standard” must be observed!

2.9. Pumped fluids

Each pumped fluid differs in regard to composition, corrosiveness, abrasiveness, TS content and many other aspects. Generally, our products can be used for many applications. For more precise details, see chapter 3, the machine data sheet and the order confirmation. It should be remembered that if the density, viscosity or the general composition change, this can also alter many parameters of the product.

When switching the product into another pumped fluid, observe the following points:

• Products which have been operated in sewage or waste water must be thoroughly cleaned with pure water or drinking water before use.

• Products which have pumped fluids which are hazardous to health must always be decontaminated before changing to a new fluid. Also clarify whether the product may be used in a different pumped fluid.

• With products which have been operated with a lubricant or cooling fluid (such as oil), this can escape into the pumped fluid if the mechanical shaft seal is defective.

Danger - explosive fluids! It is absolutely prohibited to pump explosive liquids (e.g. gasoline, kerosene, etc.). The products are not designed for these liquids!

3. General description

3.1. Application

Submersible mixers are used for various applications such as mixing, homogenization and suspension of liquids with low to medium viscosity. Max. 6% liquids in the medium!

3.2. Types of Use

The motors are designed for continuous operation (S1), maximum 15 starts per hour.

3.3. Construction

The pump consists of the motor and the pump housing as well as the propeller which belongs to it. All important parts of the pump are characterized by generous dimensioning.

No.

3 Ph

3 Ph FM

Type description

Serial number

Impeller diameter

Immersion depth

Weight

Hmax (delivery head max)

Hmin (delivery head min)

Qmax (delivery volume max)

Standard

test lab

12a

Year type test

12b

Declaration of performance

Build year

Motor type

IE-Marking

Frequency

Nominal current 3-phase

Motor RPM

Voltage – Star connection

Voltage - Star connection

Nominal current Star connection

Insulation class

Power P1

Protection class

Power P2

Text field sales

Ex-certification number

29 Ex-test lab

31 Ex-i- power circuit details

32 Text field sales

3.3.1. Type label

3 Ph

3 Ph Ex

4 Temperature of medium Temperature of medium

11 Construction product regulations-

Construction product regulations-

17 Voltage – 3-phase Voltage – 3-phase

24 Cos phi Cos phi

27 Operating class Operating class

30 Ex-Designation

3.3.2. Motor

General motor data

Operating mode

Insulation class

H (180°C)

Degree of protection

IP68

Cable length

10 m / 15m

Shaft sealing HRS CHRS

NBR Viton

Bearing

one grooved ball bearing (suspension side) one double-row type angular ball bearing (propeller side)

The three-phase asynchronous motor is made from sheet metal with a double-varnished winding wire as well as the motor shaft with rotor package. The power supply cable is designed for the maximum mechanical load and is sealed against water pressure from the pumped liquid. The motor cable lead connections are sealed from the pumped liquid as well. The bearings used are permanently lubricated maintenance-free antifriction bearings. All models are available with explosion proof motors according to ATEX Ex II 2 G EExd.

3.3.3. Control devices

The pump is equipped with various safety and control devices:

Temperature Sensors

The mixers have a set of temperature sensors built in the stator windings. Standard models have the sensors connected to the motor power supply cable, the wire ends marked T1 and T3. They must be connected to the safety circuit of the control box in order to provide an automatic re-st art of the motor, when the motor cools. Explosion proof models with motors up to 15 kW have a set of temperature sensors built-in, with a higher switchoff temperature, connected to the motor cable, the wire ends marked T1 and T2. They must be connected t o a special relay in the starter box in order to provide manual pump re-start. All explosion proof models have both sets of sensors built-in, as described above, with wire ends marked T1, T2, T3. They have to be connected accordingly as described above. The temperature sensor set must be connected to the switchgear unit so that it switches off if it overheats.

Check of Direction of Rotation

After the electrical connection has been made, check that the agitator propeller is rotating in the correct direction. As seen from the motor, the propeller must rotate clockwise. If the direction of rotation of the agitator propeller is incorrect, transpose two of the three conductor phases (L1, L2, L3) coming directly from the mains.

Beware of rotating propeller! The moving propeller can crush and sever limbs. Switch off the machine and let the moving parts come to a rest before maintenance or repair work!

Seal condition sensors oil chamber

Agitator motors in the HRS…/C and CHRS…/C series are fitted as standard with monitoring of the sealing of the oil barrier chamber. Two sensors monitor the conductibility of the oil filling. The sensors are to be connected via the connecting cables with the cable-end designations S1 and S2 in the switchgear to an evaluation instrument with a galvanically isolated sensor circuit (electrode relay). If the shaft seal leaks, water enters the oil chamber and changes the resistance of the oil. Response sensitivity should be adjustable from 0-100 kÙ. The standard setting is 50 kÙ. If this is an antiexplosion design, select electrode relays with intrinsically safe circuits for sensors.

Motor cooling

They are cooled by the surrounding liquid.

3.3.4. Propeller

A self cleaning propeller from stainless steel is used.

4. Package, Transport, Storage

4.1. Delivery

On arrival, the delivered items must be inspected for damage and a check made that all parts are present. If any parts are damaged or missing, the transport company or the manufacturer must be informed on the day of delivery. Any claim made at a later date will be deemed invalid. Damage to parts must be noted on the delivery or freight documentation.

4.2. Transport

Only the appropriate and approved fastening devices, transportation means and lifting equipment may be used. These must have sufficient load bearing capacity to ensure that the product can be transported safety. If chains are used they must be secured against slipping. The personnel must be qualified for the tasks and must follow all applicable national safety regulations during the work. The product is delivered by the manufacturer/shipping agency in suitable packaging. This normally precludes the possibility of damage occurring during transport and storage. The packaging should be stored in a safe place if the location used is changed frequen tly .

4.3. Storage

Newly supplied products are prepared that they can be stored for 1 year. The product should be cleaned thoroughly before interim stora ge. The following should be taken into considerat ion for storage:

• Place the product on a firm surface and secure it against falling over. Submersible mixers and auxiliary lifting devices should be stored horizontally, submersible sewage pumps and submersible motor pumps should be stored horizontally or vertically. It should be ensured that they cannot bend if stored horizontally.

Danger from falling over!

Never put down the product unsecured. If the product falls over, injury can occur!

• The product has to be stored at a place free from vibrations and agitation to avoid damage from the ball bearings. We recommend a dry, frost-protected room with a temperature of between 5 °C and 25 °C for storage.

• The product may not be stored in rooms where welding work is conducted as the resulting gases and radiation can damage the elastomer parts and coat ing s.

• It is responsible to take care that the corrosion coating will not be spoiled

• Any suction or pressure connections on products should be closed tightly before storage to prevent

impurities.

• The power supply cables should be protected against kinking, damage and moisture.

Beware of electrical current!

Damaged power supply cables can cause fatal injury! Defective cables must be replaced by a qualified electrician immediately.

Beware of damp!

Moisture penetrating cables can damage them and render them useless. Therefore, never immerse cable ends in the pumped fluid or other liquids.

• The machine must be protected from direct sunlight, heat, dust, and frost. Heat and frost can cause considerable damage to propellers, rotors and coatings.

• The rotors or propellers must be turned at regular intervals. This prevents the bearing from locking and the film of lubricant on the mechanical shaft seal is renewed. This also prevents the gear pinions (if present on the product) from becoming fixed as they turn and also renews the lubricating film on the gear pinions (preventing rust film deposits).

Beware of sharp edges!

Sharp edges can form on rotors and propellers. There is a risk of injuries. Wear protective gloves.

• If the product has been stored for a long period of time it should be cleaned of impurities such as dust and oil deposits before start-up. Rotors and propellers should be checked for smooth running, housing coating and damage.

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Homa HRS, CHRS Original Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual