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Homa GRP Installation, Operation And Maintenance Manual

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Installation, Operation, and Maintenance Manual
GRP Series
Version 05/2019- No. 00507610.02
60
Page 2
Content
2. Safety .................................................................................................................................03
3. General description .......................................................................................................... 06
4. Package, Transport, Storage ...........................................................................................09
5. Installation and initial commissioning ...........................................................................10
6. Maintenance .....................................................................................................................16
7. Repairs ............................................................................................................................... 18
8. Shutdown ..........................................................................................................................19
9. Troubleshooting ...............................................................................................................19
10. Connection of pumps and mixers ................................................................................. 22
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1.2. Preface
Dear Customer, Thank you for choosing HOMA Pump Technology. You have purchased a product which has been manufactured to the latest technical standards. Read this operating and maintenance manual carefully before first use, in order to ensure the product is used safely. 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
In the event of improper use, there is a danger to life for the user as well as for third parties. Additionally, the prod­uct and/or attachments may be damaged or destroyed. It is important to ensure that the product is only operat­ed in good condition and as intended. To do so, follow the operating instructions. The pumps can be used in the range specified by the manufacturer in accordance with the current HOP.SEL version. Please note that the offered pumps may only be used in the defined field of applica­tion. Operating the pump outside the application range can lead to operational problems or significant damage to the unit.
Please note that the surfaces of the product become very hot!
“transportable” installation type
With this installation type the product is equipped with a pedestal. It can be installed and operated at any location. Please observe the values for the maximum submersion depth and the minimum water coverage, and remember that the surfaces of the product become very hot.
“S1” operating mode (continuous operation)
At the rated load, a constant temperature is reached that does not increase even in prolonged operation. The oper­ating equipment can operate uninterruptedly at the rated load without exceeding the maximum permissible tem­perature.
Operating mode “S3“ (intermittent operation):
For this operating mode, after the abbreviation, the per­cent duty cycle is displayed, as well as the cycle duration if it is greater than 10 minutes. For example: S3 40% 60 minutes means the pump can operate continuously for 40% (24 minutes) of one hour, and must then pause for 36 minutes.
Low Level Lockout
The low level lockout is designed to automatically shut down the product if the water level falls below the mini­mum water coverage value of the product. This is made possible by installing a float switch.
Level control
The level control is designed to switch the product on or off depending on the water level. This is made possible by installing a float switch.
1.4. Copyright
This operation and maintenance manual has been copy­righted by the manufacturer. This operation and mainte­nance handbook is intended for 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. Technical terms
Various technical terms are used in this operating and maintenance manual.
Dry run
The product is running at full speed, however, there is no liquid to be pumped. A dry run is to be strictly avoided. If necessary, a safety device must be installed.
“wet” installation type
This installation type requires the product to be immersed in the pumped fluid. It is completely surrounded by the pumped fluid. Please observe the values for the maximum submersion depth and the minimum water coverage.
“dry” installation type
In this installation type, the product is installed dry, i.e. the pumped fluid is delivered to and discharged via a pipeline system. The product is not immersed in the pumped fluid.
2. Safety
This chapter lists all the generally applicable safety in­structions and technical information. Additionally, other chapters contain 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, including irreparable damage!
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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. 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 the electrical 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:
• Failure of the safety and/or control devices
• Damage to critical parts
• Damage to electric installations, cables and
insulation.
• 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.
These instructions must be strictly observed. Non-observance can result in injury or serious damage to property. This product may contain chem­icals known to the State of California to cause cancer and birth defects or other reproductive harm. www.p65warnings.ca.gov
2.3. Operating personnel
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.
2.4. Electrical work
Our electrical products are operated with alter­nating or industrial high-voltage current. The lo­cal regulations (e.g. 2017 NEC) must be adhered to. 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 Moisture! Moisture penetrating into cables can damage them and render them useless. Furthermore, water can penetrate into the terminal compartment or motor and cause damage to the terminals or the winding. Never immerse cable ends in the pumped fluid or other liquids.
2.4.1. 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 equipment meets NEC 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.
2.4.2. 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.
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2.5. 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 impeller 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!
2.9. 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. Different materials and impeller shapes are required for different pumped fluids. The more exact your specifications on your order, the more exactly we can modify our product to meet your requirements.
If the area of application and/or the pumped fluid change, we will be happy to offer supportive advice. When switching the product into another pumped fluid, observe the following points:
2.6. Safety and control devices
Our products are equipped with various safety and control devices. These include, for example moisture sensors and temperature sensors. These devices must never be dis­mantled or disabled. Equipment such as thermo sensors, float switches, etc. must be checked by an electrician for proper functioning before start-up. Please remember equipment such as PT100 temperature monitors or float switches require the use of a HOMA GO switch for con­nection. Please contact your HOMA distributor for infor­mation.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.
2.7. Operation in an explosive atmosphere
Products marked as FM approved for suitable operation in explosive atmosphere, are designed for Class I, Division 1, Groups C and D and Temperature class T4. The per­mitted ambient temperature is between -4°F and 104°F. The enclosures protection class is IP68. 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-proof rated by FM. In addition, an “FM” symbol must be included on the name plate!
2.8. Sound Safety
Depending on the size and capacity (kW), the products produce a sound pressure of up to110 dB. The actual sound pressure, however, depends on several factors. These include, for example, the installation type (wet, dry, transportable), fastening of accessories (e.g. suspension unit) and pipeline, operating site, immersion depth, etc. Once the product has been installed, we recommend that the operator make additional measurements under all op­erating conditions.
• 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!
2.10. Danger due to spark generation
Mechanically generated sparks can ignite flammable gas­es and condensates. According to EN1127-1 Para.6.4.4, sparks must also be excluded for category 2 in normal operation. In normal operation no spark generation is pos­sible due to fluid covering (medium covering of the pump hydraulic).The ingress or suction of foreign bodies (stones, pieces of metal, etc.) through the suction nozzles into the pump hydraulic is not possible in an expected case of mal­function in which the enclosure fails as the pump cannot suck up pumping medium nor its containing solids.
In the ventilated shaft, the explosion-protected submers­ible motor pumps are drained via a drain system with two guide tubes of galvanized steel, between their guide claws of grey cast iron that guide into the automatic cou­pling arrangement.
The guide velocity, with max 0.1 m/s (10cm/s) is so low that no sparks can be generated even in the most dis­advantaged conditions. In the first installation, the guide claws of the drain arrangement should be lubricated with ball bearing grease in order to supredd heat and spark generation in the most disadvantaged case.
Caution: Wear ear protectors! In accordance with the laws in effect, guidelines, standards and regula­tions, ear protection must be worn if the sound pres­sure is greater than 85 dB (A)! The operator is re­sponsible for ensuring that this is observed!
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3. General description
3.1. Application
Waste water disposal with small pipework cross-sections, good delivery heads at relatively low flow rates and pres­sure drainage systems in areas with difficult topography. GRP pumps shred solids in the pumped medium in next to no time, so plastic pipework with a cross-section as small as 2” can be used.
This significantly reduces the cost of materials and laying the waste water systems. If the pumped medium con­tains corrosive substances, the corrosion resistance of the materials used must be observed. For such applica­tions, versions made partly or entirely of highly resistant materials (stainless steel) are also available
3.3. Construction
The major pump components consist of the motor hous­ing, volute, and impeller.
According to the type of installation and motor cool­ing, the machine must be submerged in pumped liq­uid at least up to the top edge of the pump or motor housing.
For continuous operation (S1) without a cooling jack­et, the motor housing must be completely submerged.
The temperature of the pumped medium may be up to 104°F or up to 140°F for a short period. The maximum density of the medium is 0.03757 lbs/in³ and the pH may be from 6 – 11.
Stainless steel variants can be used at a pH of 4 - 14. However, the pH alone only serves as a guideline. Consult factory for assistance with chemically aggressive liquids. Depending on the composition, it may be necessary to use special sealing materials.
3.2. Types of use
The motors are designed for continuous operation (S1), maximum 15 starts per hour. The hydraulic is designed for permanent operation, e.g. supply of industrial water.
No. Description
1 Lifting handle 2 Name plate 3 Motor housing 4 Cable inlet 5 Discharge 6 Suction piece with cutting system 7 Volute
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No. Description
1 Lifting handle 2 Motor housing 3 Cable inlet 4 Discharge 5 Name plate 6 Volute 7 Suction cover with feet
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
No. Description
1 Lifting handle 2 Motor housing 3 Name plate 4 Discharge 5 Cable inlet 6 Volute 7 Suction cover with feet
3.3.1. Type label
Pump: Cont. Duty: 40° C amb.
Hmax:
Motor: U: V
Hz
a

Cl.I,DIV.1,GR.CD
Hmin:
ft
P:
~
Flow max.:
I
:
HP Nema code:
Wiring Diagram:
Operating Mode:
APPROVED
21
Thermally protected! See manual for cord replacement! Do not remove covers while circuits are alive!
Sn:
Date:
cos
Ins. cl.:
φ:
IP 68
gpm lbs
A
ft
rpm
No. Description
a b c d e f g h i j k l m
m a
n o p q r s t
21
3.3.2. Motor
The pump motor consists of the stator and shaft with impeller assembly. The cable for the power supply is de­signed for maximum mechanical performance in accor­dance with the characteristic or pump name plate. Both the cable entries and the cable are water-pressure tight to the depth provided on the name plate. The shaft bearing assembly is supported via robust, maintenance-free and permanently lubricated roller bearings. All motors can also be delivered in an explosion-proof version in accordance with FM Class I, Division 1, Groups C & D.
General motor data
Service factor 1.15
Operating mode S1
Operating mode at 208V only if a 208Vmotor was ordered S3 42% 60min
Max. liquid temperature 35°C / 95°F
Insulation class H (180°C / 356°F)
Degree of protection IP68
Cable length 32 ft
Rotor shaft seal Silicon-carbide / Silicon-carbide
Rotor shaft seal GRP10-21 Silicon-carbide / Buna N
Mechanical shaft seal Silicon-carbide / Silicon-carbide
Bearing One grooved ball bearing (above),
Pump name Serial number Flow max Hmax (Head max)
Hmin (Head min) Submersion depth Weight Motor name Date of manufacture Voltage Motor Power Nominal current Frequency Phase Motor speed Cos phi Temperature class Nema Code Letter
Wiring diagram Insulation class Operating mode Comments
double-row type angular ball bearing (below)
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3.3.3. Monitoring Equipment
The unit is equipped with various types of monitoring-safe­ty equipment. The following table shows an overview of the options available. The options may vary depending on the size of the pressure outlet
Motortype Motorversion
…/C Temperature monitoring in the winding, Oil chamber
seal conditions sensor
...FM Temperature monitoring in the winding, Explosion
proof
.../C FM Temperature monitoring in the winding, Oil chamber
seal conditions sensor and motor connecting chamber, Explosion proof
ET... Jacket cooled motor, thermal monitoring of winding,
monitoring of oil chamber seal
ET... FM Jacket cooled motor, thermal monitoring of winding,
monitoring of oil chamber seal, explosion-proof
Temperature Sensor
All pumps are equipped with a temperature sensor in each motor winding. In standard pumps, the connections for the temperature sensor are fed via the power cable to the outside and are to be connected in the electric con­trol box using the T1 and T3 power cable endings in such a way that the motor automatically restarts after it has cooled down.
Instead of the standard sensor, the explosion-proof ver­sions are equipped with a temperature sensor assembly that has a higher activation temperature. This is to be con­nected via the power cable endings T1 and T2 in such a way that after activation, a manual reset is necessary to restart the pump. The temperature sensor assembly must be connected in the control panel so that it switches off when it overheats.
Switch-off temperature of the sensors:
Motor Frame
T 140°C / 284°F 140°C / 284°F 80°C /
Stator Winding T1+T3 Regulator
Stator Winding FM T1+T2 Limiter
Lower Bearing
Upper Bearing
n/a
176°F
ET 125°C / 257°F 125°C / 257°F n/a n/a
Seal monitoring: In case of a leak in the lower shaft seal, water enters the oil chamber and changes the resistance of the oil. The conductivity of the oil is monitored via one sensor to ground. In the motor housing, another sensor monitors for the resisitance to ground in case of water intrusion. The sensors are to be connected via 2 cables (consult wiring diagram) from the pump connection cables in the control panel to a monitor galvanically separated from the probe circuit. The response sensitivity should be adjustable from 0-100 kΩ, the standard setting being 50 kΩ. For external seal probes an electrode relay with an intrinsically safe circuit is to be chosen. FM pumps: The sensors are connected via 2 cables (labelled S1 and S2) of the pump connector cable in the switching system to an evaluation device with an electri­cally isolated special circuit.
3.3.4. Sealing / Seal Housing
Sealing is accomplished in GRP24 and larger models by two silicon carbide mechanical seals in a tandem arrange­ment, acting independently from each other. In smaller models, sealing is accomplished by a silicon carbide lower mechanical seal, and a nitrile rubber (Buna N) upper lip seal. The seal housing is situated between the motor and the pump housing. It consists of the bearing housing and the pressure cover, which together form the sealing cav­ity with containing white mineral oil. Monitoring possibili­ties are available using the inspection plug on the bearing housing and optional electronic monitoring.
3.3.5. Jacketed Pump Option
The cooling jacket has been supplied based upon the specified operating conditions of this application. It is im­portant this jacket is functioning properly, or the internal motor components could become damaged. Several cool­ing configurations are available depending upon customer preference and system requirements. You must know what configuration of cooling system is to be used with the pump prior to installation. In some cases, field test results may indicate a change of cooling method is required. Consult factory for necessary chang­es to the pump.
COOLING REQUIREMENTS Standard Media Cooled –
This construction does not require any external piping and it is completely self-contained. This design is suitable for the routine collection system application. No pump modi­fications are required.
3.3.7. Volute
The volute depending on the model, will have one of sev­eral discharge connections. Please consult an available drawing or your local HOMA distributor if you need help identifying the discharge connection on your pump.
3.3.8. Impeller
The impeller is fastened directly to the motor shaft and driven by it. GRP pumps are only available with an open multi-channel impeller.
3.3.9. Cutter system
The cutter system includes a fixed cutting ring and a cut­ter head which is mounted on the motor shaft. Thereby the cutter head turns with motor rotation speed and cut all solids in the sewage. Both parts consist of stainless steel hardened to HRC55.
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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.
Beware of electrical current! Damaged power supply cables can cause fatal inju­ry! Defective cables must be replaced by a qualified electrician immediately.
Beware of moisture! 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 impellers, rotors and coatings.
• The impeller must be turned at monthly 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 impellers. There is a risk of injuries. Wear protective gloves.
Never lift the pump by its power cable! Jacketed pump should not be lifted or supported by the jacket. Damage to sealing O Rings may result.
4.3. Storage
Newly supplied products are prepared that they can be stored for 1 year. The product should be cleaned thor­oughly before interim storage. The following should be taken into consideration 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.
Falling Hazard! Never leave the pump unsecured!
• The product has to be stored in a place free from vibrations and agitation to avoid damage to the ball bearings.
• The device should be stored in a dry place without temperature fluctuation.
• 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 coatings.
• Be careful to not remove or damage the corrosion resistant coatings.
• 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.
• The cable will wick water into the pump if it is not pro­tected properly. Power cable lead should be covered with shrink tubing or suitable sealing material during storage.
• If the product has been stored for longer than six months it should be cleaned of impurities such as dust and oil deposits before start-up. Rotors and im­pellers should be checked for smooth running, hous­ing coating and damage.
• After remaining in storage for longer than one year, it is necessary to change the oil in the seal chamber. This is necessary even if the pump has never been run, due to natural deterioration of mineral oil.
Before start-up, the filling levels (oil, cooling fluid etc.) of the individual products should be checked and topped up if required. Please refer to the machine data sheet for specifications on filling. Damaged coatings should be repaired immediately. Only a coating that is completely intact fulfills the criteria for intended usage!
If these rules are observed, your product can be stored for a longer period. Please remember that elastomer parts and coatings become brittle naturally. If the product is to be stored for longer than 6 months, we recommend checking these parts and replacing them as necessary. Please consult the manufacturer.
4.4. Returning to the supplier
Products which are delivered to the factory must be clean and correctly packaged. In this context, clean means that impurities have been removed and decontaminat­ed if it has been used with materials which are hazard­ous to health. The packaging must protect the product against damage. Please contact the manufacturer before returning!
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5. Installation and initial commissioning
5.1. General
To avoid damage to the lifting unit during installation and operation, the following points must be observed:
• The installation work must be performed by qualified personnel, in compliance with safety regulations.
• The pump must be inspected for damage prior to in­stallation.
• For level controls, pay attention to the minimum wa­ter coverage.
• Air bubbles in the volute and pipework must be avoid­ed (by suitable ventilation devices or a slight incline of the pump).
• Protect the pump from frost.
• The lifting device must have a maximum load capaci-
ty which is greater than the weight of the pump with attachments and cable.
• The power lines of the pump must be laid in such a way, that a safe operation and easy assembly/disas­sembly is ensured.
• The power lines must be fixed properly in the operat­ing room to prevent the cable from hanging loosely. Depending on the cable length and weight, a cable holder must be attached every 2-3 m.
• The foundation/structure must have sufficient strength for secure and functionally correct fastening of the pump. The operator is responsible for this.
• Verify low level lockout is functioning.
• Use baffles for the inlet. This prevents air entry into
the pumping medium, which can lead to unfavorable operating conditions and result in increased wear.
• Do not install more than one check valve into any pip­ing system or problems will occur.
No. Description
1 Pipe
2 Coupling system
3 Wet well
4 Inlet
5 Baffle plate
6 min. liquid level
7 Pump
External Seal Probe Installation Procedure
Mechanical Seal Leak Detection probe has been shipped loose to protect from shipping damage. Please follow this procedure to install the probe.
1. Lay pump on its side with the plug on the seal cham­ber facing upwards as indicated.
2. Unscrew the plug with the proper wrench, taking care not to damage the sealing surface.
3. Verify that seal chamber oil level is within ¼” of the indicated value. Measurement is from oil level to the top of hole. See IOM Manual for seal chamber oil vol­ume, if required.
4. Remove the new sealing gasket from package and install it onto the seal probe plug.
5. Install the seal probe with gasket into the opening, taking care not to damage the cable. Then tighten the seal probe with the proper wrench until snug. Do not overtighten. Once tight, verify the seal gasket is prop­erly seated and the cable is not pinched or twisted. NOTE: At installation of the seal probe be careful not to bind the seal probe cord as it is being installed into the pump.
6. Lift pump into a vertical position and inspect for any leaks.
7. Secure seal probe cable to pump body and power ca­ble with tyraps before installing pump.
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5.2. Installation
Risk of falling! When installing the pump and accessories, work is carried out directly on the water‘s edge! Careless­ness or wearing the wrong shoes can lead to falling. This is life threatening! Take all safety precautions to prevent this.
Torque Values
PUMP Installation
Bolts Anchors
SIZE TORQUE
Autocoupling 8 M16X60mm 146 Nm / 108 ft lb
4 M16 100 Nm / 74 ft lb
Ring stand 4 M16x25mm 146 Nm / 108 ft lb
Notes:
1. Flange bolts must be tightened in cross pattern to avoid damage to the raised face flanges.
2. Standard flange bolts are 316SS
3. Standard anchors are plated steel.
4. Autocoupling systems include qty. 4 M12 anchors for the upper bracket. Torque to 51 Nm / 38 ft lb.
5. Anchor bolt holes should be drilled to the actual di­ameter of the anchor (M12 anchor requires 12mm diameter hole).
Submerged installation on ring stand
Attach the ring stand (available as an accessory) with screws to the pump suction nozzle. 90° connection-el­bow or connection loop to the pressure port of the pump, mount pressure line. Gate valves and check valves may need to be installed in accordance with local regulations. The pressure line must be fitted free of tension, when using a hose, ensure it is laid kink-free. Secure the pump by the handle with a cable or chain, and lower it into the pumping medium. Properly position power cable and chain so they stay above the pump and cannot enter the pump suction.
guide tubes, using a plumb bob where necessary.
• Check the correct installation dimensions of the pump(s) (see dimensional drawings in the appendix).
• Drill mounting holes for the guide rail bracket on the inside edge of the shaft opening. If this is not possi­ble due to the space available, the guide rail bracket can also be mounted in an offset position with a 90° folded plate on the underside of the shaft cover. Pro­visionally fasten the guide rail bracket with 2 screws.
• Align the base elbow to the shaft floor, use a plumb bob from the pipe bracket - the guide tubes must be exactly perpendicular! Fasten the base elbow to the wet well floor using anchor bolts. Ensure that the base elbow is exactly horizontal! If the wet well floor is uneven, support the bearing surface accordingly.
• Mount the pressure pipes with fittings free of tension according to the usual mounting principles.
• Insert both guide rails into the eyelets on the base elbow and cut to size according to the position of the guise rail bracket. Partially unscrew the guide rails bracket, insert them into the guide rails and fasten the bracket. The guide rails must be positioned with no play at all, otherwise vibration will occur during op­eration of the pump.
• Clean the wet well of any solid material (debris, stones, etc.) before commissioning.
• Mount the guide claw on the pump discharge. For threaded discharge connections, apply pipe sealant to the threads for installation and DO NOT OVER TIGHTEN. DISCHARGE THREADS ARE NOT NPT. Ensure that the rubber profile seal is correctly seated in position in the guide claw (as a seal against the coupling base), so that it will not fall out when lower­ing the pump. See graphic below
• Attach the chain to the pump handle or lifting lugs. For model GRP 10-50 series pumps, attach tether through the large opening of the lifting handle. DO NOT attach to the small, rear tab. Insert the pump with the guide rails in the guide claw ears. Lower the pump into the wet well. If the pump is seated on the base elbow, it automatically seals itself off to the pressure line and is ready for operation.
• Hang the end of the retrieval chain from a hook at the wet well opening.
• Hang the motor connection cable of the pump in the shaft at an appropriate length, with strain relief. Make sure that the cables can not be bent or damaged.
Correct
Rubber Ring
Incorrect
Rubber Ring
Wet well installation with automatic coupling system
The following instructions apply to the installation of the original HOMA Autocoupling system:
• Determine the approximate position of the position of the base elbow and the upper pipe bracket for the
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Dry Installation Foundation and Piping Requirements:
General
The following recommendations are basic guidelines which are intended to outline basic requirements in the design of the dry pit station. It is essential that a licensed professional engineer be retained by the owner to design the station and all support structures.
Foundations
Foundations may consist of any structure heavy enough to provide permanent rigid support for the pump and inlet elbow stand. Concrete foundations built up from the solid ground are the most commonly used. The concrete floor shall be level. The space required by the inlet stand and the location of the foundation anchor bolts are shown on the outline dimension drawing. Foundation bolts are to be embedded in the concrete.
Suction Piping
Suction piping should be at least as large as the pump inlet elbow suction. If reducers are utilized they should be of the conical type. If the liquid source level is below the volute horizontal centerline, the reducer must be eccentric and installed with the level side up. If the liquid level is above the pump volute horizontal centerline, either eccentric or concentric reducers may be used. Suction piping should be run as straight as possible. All pipe flange joints should be gasketed to prevent air from entering the pipe. High points that may collect vapor are to be avoided. Isolation valves such as gate valves can be installed in or­der to facilitate the removal of the pump for maintenance. Any valve installed in the suction line should be installed with the stems horizontal.
• Attach the other end to the lifting device.
• Ensure tension on the chain, and then lift the pump in
a slow and controlled manner.
• Gently lower the pump into operating space.
• Lower the pump to the operating point and make
sure that the pump has a secure footing or the cou­pling system is engaged correctly.
• Remove the chain from the lifting device and secure it to the safety chain, which is located at the top of the operating room. This ensures that the chain can not fall into the operating area and constitute a dan­ger to anyone.
Please note the following diagrams during installation.
Discharge Piping
A check valve and isolation valve shall be installed in the discharge line. The check valve should be installed be­tween the pump discharge flange and the isolation valve. If pipe increasers are used on the discharge line, they should be placed between the check valve and the pump. The inlet elbow stand allows the pump to be installed in a stationary position in a dry pit. Place the inlet stand in position and tighten the anchor nuts.
Lower the pump on to the top flange of the inlet stand. DO NOT ALLOW SLACK ON THE LIFTING CABLE UNTIL THE PUMP IS BOLTED DOWN. Make sure the flange bolt holes align with the mounting holes on the underside of the volute. Secure the pump to the mounting flange with the fasteners that are specified in the accessory fastener selection table below.
5.3. Use of chains
Chains are used to lower a pump in the operating space or to pull it out. They are not intended to secure a floating pump. Intended use is as follows:
• Fasten one end of the chain on the handle of the pump provided for this purpose. If your pump has two ring bolts as an attachment point, you must use a double-strand chain. When doing so, the angle of inclination of the chain strands must be between 0° and 45°.
No. Description
1 Chain guard 2 Chain 3 Handle 4 Pump
5.4. Initial operation
This chapter contains all the important instructions for op­erating personnel for the safe commissioning and opera­tion of the machine. The following information must be strictly adhered to and checked:
• Type of installation
• Operating mode
• Minimum submergence
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Page 13
After a long downtime, these specifications are also to be checked and any defects are to be rectified! The operation and maintenance manual must always be kept with the machine, or be kept in a designated place where it is always accessible for all of the operating personnel.
To avoid injury to persons or damage during operation of the machine, the following points must be observed:
• The initial operation may only be carried out by qual­ified and trained personnel accompanied by an au­thorized HOMA representative following the safety instructions.
• All staff working on the machine must receive, read, and understand the instructions.
• Activate all safety devices and emergency stop switches before initial operation.
• Electrical and mechanical adjustments may only be performed by professionals.
• This machine is only suitable for use at the specified operating conditions.
Make sure that all temperature sensors and monitoring devices, seal chamber probe, are connected and tested for function.
Risk of electrocution! Improper use of electricity can be fatal! All pumps with exposed cable ends must be connected by a qualified electrician.
All electrical work shall be carried out under the super­vision of an authorized, licensed electrician. The present state adopted edition of the National Electrical Code as well as all local codes and regulations shall be complied with.
5.6.1 Verification of power supply
Prior to making any electrical connections or applying power to the pump, compare the power supply available at the pump station to the data on the unit‘s nameplate. Confirm that both voltage and phase match between pump and control panel.
5.5. Preparatory work
This pump has been designed so that it will operate re­liably and for long periods under normal operating con­ditions. This requires, however, that you comply with all advice and instructions.
Please check the following points:
• Cable routing - no loops, slightly taut
• Liquid temperature and immersion depth check - see
machine data sheet
• If a hose is used on the discharge side, it should be flushed before use with fresh water so that no depos­its cause blockages
• For wet installation, the wet well must be cleaned
• The pressure and suction side pipe systems are to be
clean and all valves are to be opened.
• If the pump is jacketed with media cooling, the jacket must be completely bled of air, i.e. it must be com­pletely filled with the medium and there may be no more air in it. The venting can be done by suitable ventilation devices in the system, or, if available, by venting screws at the outlet nozzle.
• Check the accessories, pipe system and suspension unit for firm and correct fit
• Review the present level control.
• An isolation test and a level control must be carried
out before commissioning.
5.6.2 Power lead wiring
HOMA pumps may be provided with 1 or more cables, depending on motor horsepower and operating voltage. Power leads L1, L2, & L3 may be provided as single con­ductor, or as multiple conductors. Multiple conductor configurations may use leads from separate cables, or may use two conductors within one cable. Please refer to wiring diagram in the appendix for specific connection details. The pump must be connected electrically through a motor starter with proper circuit breaker protection in order to validate warranty. Do not splice cables.
5.6.3 Thermal switch wiring
Pumps are equipped with thermal switches embedded in the stator windings which are normally closed, automat­ically resetting switches. Switches will open when the internal temperature rises above the design temperature, and will close when the temperature returns to normal. Thermal switches must be wired to a current regulated control circuit in accordance with the NEC.
Identify thermal switch leads marked T1 and T2 in the power or control cable.
The resistance across the leads will be 0.5 Ohms. Ther­mal leads must be connected to the thermal overload relay located in the control panel. Thermal switch leads must be connected to validate warranty.
5.6. Electrical
When installing and selecting electrical lines and when connecting the motor, the relevant local and NEC regula­tions must be observed. The motor must be protected by a motor protection circuit breaker. Connect the motor per the wiring diagram. Pay attention to the direction of rota­tion! If rotation is in the wrong direction, the machine will not perform to specifications. And can be damaged under adverse circumstances.
Check the operating voltage, and ensure there is uniform power consumption by all phases in accordance with the machine data sheet.
Note: All sizes of Class 1, Div. 1 pumps for hazardous service must have thermal switch leads connected to a current regulated control circuit in accordance with NEC.
5.6.4 Seal probe wiring
The mechanical seal leak detector probe utilized in the pump is a conductive probe which is normally open. The intrusion of water into the seal chamber completes the electrical circuit. Control panel provisions will sense this circuit closure, and will provide indication or alarm func­tions depending on the panel design.
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Page 14
Either single or dual wire systems may be provided. Sin-
START
REACTION
ROTOR
REACTION
ATTENTION
The direction of rotation
is correct if the
impeller/propeller rotates
in a clockwise manner
when viewing down from
top of the placed unit
ATTENTION
The start reaction is
counter clockwise
gle wire systems utilize one energizing conductor, and the pump casing and neutral lead as the ground or return portion of the circuit. The dual wire systems utilize two separate conductors for each leg of the circuit.
( ) The standard capacitor kit provided includes:
____________ µf start capacitor
____________ µf run capacitor.
With either system, the seal probe leads must be wired into a control circuit provided in the control panel. This control circuit must energize the probe with a regulated power source, and sense the closed circuit in event of water intrusion Indication and alarm functions must also be provided in the control circuit. Please see control panel wiring diagram for seal probe connection points.
For Hazardous Area Classification Pumps, leak de­tector circuit must be in conformance with applica­ble NEC codes and regulations.
5.6.5 Start / Run Capacitors and Relays
All single phase motors require start and run capacitors along with a start relay to operate. Capacitors and relays must be sized for the specific motor. Capacitors are sized based on ideal conditions. The run capacitor may need to be resized to match the available field voltage. Each cap kit shipped is supplied with a wiring diagram and start up procedure.
5.6.6 Single Phase Pump Start-Up Procedure
Run Capacitor sizing can vary depending on the incoming supply voltage provided. HOMA Single Phase pumps are provided with Start and Run Capacitor(s) sized for 220­230V under load. Frequently, the available line voltage is considerable different than indicated, and the Run capac­itor(s) may need to be resized to match the available field voltage. The following procedure will allow you to verify proper operation of your single phase pump, and/or make necessary changes to you capacitors to correct for your power supply.
After verifying wiring is in accordance with your pump re­quirements, start pump and record the following readings from each of the (3) pump cable leads.
( ) Additional run capacitors have been included for use in tuning the pump to match available line voltages for optimum performance.
____________ µf run capacitor
____________ µf run capacitor
____________ µf run capacitor
This form is provided for your use in optimizing the perfor­mance and service life of your single phase pumps, and is applicable to most Capacitor Start/Capacitor Run motors. Please contact our customer service with any questions or if you require any additional information or assistance.
5.7. Direction of rotation
Rotation Direction Check
All pumps have the proper rotation direction when con­nected to a clockwise field of rotation (U, V, W -> L1, L2, L3). If the pump rotation is backwards, swap two lead and reconnect. For smaller pumps, the check can be done by observing the pump’s movement while starting.
To do this, set the pump lightly on the ground in a perpen­dicular fashion and switch it on briefly. When observing from above, the pump itself moves slightly in a count­er-clockwise direction when rotating in the right direction.
The correct direction of rotation of the pump is achieved once the pump moves counter-clockwise, since when viewed from above, the motor starts in a clockwise di­rection.
Current under load:
U1________Amps,>U2________Amps,>Z2________Amps
U1: (Should be) highest reading U2: middle reading Z2: lowest reading
Lead U1 (common) should have the highest current read­ing. Lead Z2 (start) should have the lowest reading.
If Z2 current draw is greater than the current draw of ei­ther U1 or U2, a smaller size Run capacitor (lower micro­farad rating) is required to correct the condition. Example: If a 60 µf Run capacitor was supplied, change to a 50 µf Run capacitor and check current readings. Typically, only one step down in capacitor size is required, but in certain instances 2 steps may be required.
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For large pumps, the direction can also be determined by looking through the pump discharge into the volute. Brief­ly run the motor in order to verify it is running clockwise.
Caution – Rotating Impeller! Do not touch the rotating impeller or reach into the volute through the pressure outlets! Never reach into the volute or touch any rotating parts during operation. Switch the machine off and wait until all rotating parts have come to a stop prior to carrying out maintenance and repair work!
Page 15
It is also possible to check the direction of rotation with a “motor and phase rotation indicator”. This measurement device is held from the outside up to the motor housing of the switched-on pump and displays the direction of ro­tation via an LED.
The switch breaks specified in the technical data must be adhered to before turning on again. If there is a new fault, the machine must again be shut down immediately. The machine may only be started up again after troubleshoot­ing.
5.8. Motor protection
The minimum requirement is a thermal relay/motor pro­tection circuit breaker with temperature compensation, differential triggering, and reclosing lock in accordance with VDE 0660 or similar national regulations. If the equip­ment is connected to power grids where problems often occur, we recommend the additional use of protective devices (e.g. overvoltage protection or under voltage pro­tection or phase failure relays, lightning protection, etc.). When connecting the machine, the local and legal require­ments must be adhered to.
5.9. Variable Frequency Drives
Special considerations must be taken when operating pumps with variable frequency drives (inverters).The in­verter circuit design, horsepower required by pump, mo­tor cooling system, power cable length, operating voltage, and anticipated turndown ratio must be fully evaluated during the design stage of the installation.
As a minimum, properly sized load reactors and filters must be installed between the inverter and the pump to protect the pump motor from damaging voltage spikes.
Warranty coverage will not be provided on any pump mo­tor that is operated with a variable frequency drive, unless the load side of the inverter is properly isolated from the pump.
The following items should be checked:
• Current consumption (permissible deviation between phases max. 5%)
• Voltage difference between the individual phases (max. 1%)
• Switching frequency and pauses (see Technical Data)
• Air entry at the inlet - if necessary, a baffle plate must
be attached
• Minimum water coverage, level control, dry run pro­tection
• Smooth running
• Check for leaks: if necessary, take the necessary
steps according to the chapter “Maintenance”
5.10. Types of startups
Types of startup using with cables with exposed ends
Direct start up
At full load, the motor protection circuit breaker should be set to the rated current. In partial load operation it is recommended to set the motor protection circuit breaker 5% above the measured current at the operating point.
Soft start
At full load, the motor protection should be set to the rat­ed current. In partial load operation, it is recommended to set the motor protection 5% above the measured current at the operating point. The starting time must be max. 5s. The starting voltage is to be set at 40% of the rated voltage according to the rating plate.
Start up with HOMA GO switch
Plug the connector into the socket provided and press the on/off switch on the GO switch.
5.10.1. After start up
The nominal current is briefly exceeded on start-up. Af­ter completion of this operation, the operating current should not exceed the nominal current. If the motor does not start immediately after switching on, it must be shut down immediately.
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6. Maintenance
6.1. General
The machine and the entire system must be inspected and maintained at regular intervals. The time limit for maintenance is set by the manufacturer and applies to the general conditions of use. The manufacturer should be consulted if the system is to be used with corrosive and/or abrasive pumped liquids, as the time limit between inspections may need to be reduced.
Note the following information:
• The operating and maintenance manual must be available to the maintenance personnel and its in­structions followed. Only the repair and maintenance measures listed here may be performed.
• All maintenance, inspection and cleaning work on the machine and the system may only be carried out by trained specialists exercising extreme care in a safe workplace. Proper protective clothing is to be worn. The machine must be disconnected from the electric­ity supply before any work is carried out. There must be no way that it can be inadvertently switched on.
• Above a weight of 50kg / 110 pounds, only hoisting gear which has been officially approved and which is in a technically perfect condition should be used for lowering and raising the machine.
Make sure that all fastening devices, ropes and safe­ty devices are in a technically perfect condition. Work may only commence if the auxiliary hoisting gear has been checked and found to be in perfect working order. If it is not inspected, danger to personnel may result!
Oil type: white mineral oil. Used oil is to be disposed ac-
cordingly.
When using white mineral oil, note the following:
• Machines which have previously been operated us­ing other lubricants must first be thoroughly cleaned before they can be operated using white mineral oil.
Screw (fill with oil)
Screw (drain oil)
• Wiring work on the machine and system must be carried out by an electrician. For machines approved for work in areas subject to explosion danger, please refer to the “Explosion protection in accordance with the regulation” chapter.
• When working with inflammable solvents and clean­ing agents, fires, unshielded lighting and smoking are prohibited.
• Machines which circulate fluids hazardous to health, or which come into contact with them, must be de­contaminated. It must be ensured that no dangerous gases can form or are present.
• Ensure that all necessary tools and materials are available. Tidiness and cleanliness guarantee safe and problem-free operation of the machine. After work­ing on the machine all cleaning materials and tools should be removed from it. All materials and tools should be stored in an appropriate place.
• Operating supplies such as oil and lubricants must be collected in appropriate vessels and properly dis­posed. Appropriate protective clothing is to be worn for cleaning and maintenance jobs. Only lubricants expressly recommended by the manufacturer may be used. Oils and lubricants should not be mixed. Only use genuine parts made by the manufacturer.
A trial run or functional test of the machine must be performed as instructed in the general operating con­ditions.
6.2 Maintenance intervals
Before initial start-up or after a longer period of storage:
• Check insulation resistance
• Check oil level in seal chamber
• Check that impeller rotates freely by hand
Monthly:
• Monitor the amperage and voltage
• Check the used relays for proper operation
Every six months:
• Visual inspection of the power supply cable
• Visual inspection of the cable holder and the cable
bracing
• Visual inspection of accessories, e.g. the suspension device and hoisting gears
8,000 operating hours or after two years, whichever is earlier:
• Check the insulation resistance
• Check the lubricant in the seal chamber
• Functional inspection of all safety and control devices
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Page 17
15,000 operating hours or after five years, whichever is earlier:
• General overhaul
If it is used in highly abrasive or corrosive material, the maintenance intervals should be reduced!
6.3. Maintenance tasks
Monitoring the current consumption and voltage
The current consumption and voltage is to be monitored periodically for all winding phases. This remains constant during normal operation. Slight fluctuations are a result of the composition of the pumped fluid. The current con­sumption can assist in early detection and correction of damage and/ or faulty operation in the impeller/propeller, bearings and/or the motor. More extensive resulting dam­age can thus be largely prevented and the risk of a total failure can be reduced.
Checking the used relays for posistors, oil chamber monitors, etc.
Check the relays used are functioning fault-free. Defective devices must be immediately replaced, because these cannot ensure safe operation of the machine. The test procedure details should be followed closely (in the oper­ating instructions for each relay).
Checking the insulation resistance
To check the insulation resistance, the power supply ca­ble must be disconnected. The resistance can then be measured with an insulation tester (measuring voltage = 1000V DC).
The following values may not be exceeded:
• The insulation resistance may not be below 20 MΩ during initial operation. For all further measurements the value must be greater than 2 MΩ.
• Insulation resistance too low: Moisture may have penetrated the cable and/or the motor.
Do not connect the machine, consult manufacturer!
Visual inspection of power supply cables
The power supply line must be examined for bubbles, cracks, scratches, chafed areas and/or crushed sections. If damage is found, the power cable must be exchanged immediately.
The cables may only be changed by the manufacturer or an authorized/certified service workshop. The ma­chine may not be used again until the damage has been adequately rectified.
Visual examination of the cable holders (carabiners) and the cable bracing
When the machine is used in basins or pits, the lifting cables/cable holders (carabiners) and the cable bracing are subject to constant wear. Regular inspections are nec­essary in order to prevent the lifting cables/cable holders (carabiners) and/or cable bracing from wearing out and to prevent the electricity cable from being damaged. The lifting cables/cable holders (carabiners) and the ca­ble bracing are to be immediately replaced if any signs of wear appear.
Visual inspection of accessories
Inspect accessories such as suspension units and hoist­ing gear to check whether they are secured in a stable manner. Loose and/or defective accessories should be repaired immediately or replaced.
Oil Level check in Seal Chamber
Visual Inspection of Oil Chamber:
Oil Level
Please take the precise filling quantity from the spare parts list or contact the manufacturer with the pump serial number.
Oil Condition
The condition of the mechanical seals can be visually in­spected as follows: Put the pump in horizontal position, so that the oil chamber drain plug is on top (for larger pumps: one of both oil chamber screws). Remove the drain plug and take out a small quantity of oil. The oil becomes grey­ish white like milk if it contains water. This may be the result of defective shaft seals. In this case the condition of the shaft seals should be checked by a HOMA Service shop. Oil type: Mineral Oil Used oil has to be disposed according to the existing en­vironmental rules and regulations.
Functional inspection of safety and control devices
Monitoring devices are temperature sensors in the motor, oil chamber monitors, motor protection relays, overvolt­age relays, etc.
Motor protection and overvoltage relays and other trip elements can generally be triggered manually for test purposes. To inspect the oil chamber monitor or the tem­perature sensor, the machine must be cooled to ambient temperature and the electrical supply cable of the moni­toring device in the switch cabinet must be disconnected. The monitoring device is then tested with an ohmmeter. The following values should be measured:
Bi-metal sensor: Value = “0” - throughput PTC sensor: A PTC sensor has a cold resistance of be-
tween 20 and 100 Ω. For 3 sensors in series this would result in a value of between 60 and 300 Ω. PT 100 sensor: PT 100 sensors have a value of 100ohms at 0°C. Between 0°C and 100°C this value increases by
0.385 Ω per 1°C. PT 20 sensors have a value of 107.7 Ω at 20°C. Moisture sensor: This value must approach infinity. If there is a low value, there may be water in the oil. Also observe the instructions of the optionally available evaluation relay.
In the case of larger deviations, please consult the manufacturer.
Please consult the appropriate operating manual for de­tails on inspecting the safety and monitoring devices on the auxiliary lifting gear.
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Page 18
General overhaul
During this the bearings, shaft seals, O rings and power supply cables are inspected and replaced as required in addition to normal maintenance work. This work may only be conducted by the manufacturer or an authorized ser­vice workshop.
7. Repairs
7.1. General
When carrying out repair work, the following information should always be noted:
Changing the oil
The drained oil must be checked for dirt and water con­tent. If the oil is very dirty and shows water intrusion, it must be changed again after four weeks. If there is again water in the oil then, it seems likely that a seal is defec­tive. In this case, please consult the manufacturer. If a oil chamber or leakage monitoring system is being used, the display will light up again within four weeks of changing the oil if a seal is defective.
The general procedure for changing oil is as follows: Switch off the machine, let it cool down, disconnect it from the power supply (have this done by an electri­cian), lock out tag out the control panel, clean it and place it vertically on a solid base. Warm or hot oil may be pressurized. The leaking oil may cause burns. For that reason, let the machine cool down to ambient temperature before you touch it.
6.4. Seal chamber
As there are several versions and designs of these mo­tors, the exact location of the drain plugs varies depending on the model used.
• Slowly and carefully remove the drain plug.
Caution: The oil may be pressurized!
• Remove the drain plug. Drain the oil and collect it in a suitable reservoir. Clean the drain plug, fit with a new sealing ring and screw it in again. For complete drainage, the machine must be slightly tipped on to its side.
Make sure that the pump is on its side and secure!
• Fill lubricant by means of the opening in the filling plug. Comply with the specified lubricants and filling quantities.
• Clean the filling plug, fit with a new sealing ring and screw it in again.
• Round sealing rings as well as existing seals should always be replaced.
• Screw fixings such as spring washers should always be replaced.
• The correct torques must be observed.
In general, the following applies to repairs: Switch off the machine, disconnect it from the power supply (have this done by an electrician), clean it and place it on a solid base in a horizontal position. Secure it from falling over and/or slipping.
If not otherwise stated, the torque values of the below tables should be used. Values stated are for clean, lubri­cated screws. Fixing torque [ft lbs] for screws A2/A4 (Co­efficient of friction = 0.2)
A2/A4, Hardeness class 70
DIN912/DIN933 DIN912/DIN933
M6 5 ft lbs 9 ft lbs
M8 12.5 ft lbs 21 ft lbs
M10 24 ft lbs 43 ft lbs
M12 42 ft lbs 73.5 ft lbs
M16 103 ft lbs 180.5 ft lbs
M20 201.5 ft lbs 364.5 ft lbs
7.2. Changing the impeller
Abstract
This document will provide the proper procedure for the replacement of an impeller on a GRP pump. CAUTION: the cutters used on the GRP are sharp and can cause in­jury if handled improperly. Take care when handling and removing them.
Procedure
• Position and support pump upside down with the suction connection facing up.
• Mark the location of the suction cover to the volute to ease reassembly.
• Remove socket head cap screws that retain suction cover. Do not disturb the set screws for suction cover adjustment.
• Remove suction cover, taking care to protect the O Ring.
• Holding cutter head with suitable device loosen the impeller retaining bolt and remove.
• Remove cutter head from impeller. Carefully pull im­peller off of shaft. Important: The impeller holds low­er mechanical seal in place. Take care not to disturb mechanical seal.
• Verify impeller key is still properly positioned on shaft.
• Install new impeller onto shaft, and reinstall cutter
head. Note: Take care to properly position dowel pin into locating hole in impeller.
A2/A4, Hardeness class 80
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Page 19
• While holding the cutter head with suitable device, reinstall impeller bolt. Torque to 18 ft. lbs. ( Use of Loctite 242 on impeller bolt is desirable)
• Reinstall suction cover, taking care to lubricate the O-ring before installation.
• Replace the retaining bolts for the suction cover. Torque to 12 ft. lbs.
• Rotate the cutter head and verify that no contact oc­curs between cutter and ring.
• Unit should now be ready for test operation. Return unit to normal orientation, connect power, and start pump. Some slight rubbing may be heard, and is ac­ceptable. However, if severe grinding or rubbing is evident, adjust suction cover (with unit disconnected from power supply) until components move freely. This may require more than one adjustment to obtain proper clearance.
Notes: If oil is found leaking from the impeller/volute/ seal area, the mechanical seal was not compressed properly during the impeller installation. Disassem­ble unit, and reinstall impeller properly, taking care to keep mechanical seal compressed until impeller bolt is secured.
Only OEM Parts may be used for replacement.
Inspecting and replacing these parts is performed by the manufacturer during the general overhaul or by specially trained personnel.
7.3 Spare Parts
In order to obtain spare parts identify the required parts, and contact authorized HOMA customer service with your order. Authentic HOMA parts shall be used to maintain warranty.
Explosion Proof pumps must be identified as such, and the pump serial number must be referenced for proper parts identification.
Note the following information concerning storage:
Beware of hot parts! When removing the machine, be careful of the tem­perature of the housing components. These can heat up to well above 104°F. Let the machine cool down to ambient temperature before you touch it.
• Clean the machine.
• Store it in a clean, dry place, protect the machine
against frost.
• Place it down vertically onto a firm foundation and secure it against falling.
• Support the cable at the cable entry assembly to help avoid a permanent deformation.
• Protect the ends of the electric power cable from moisture.
• Protect the machine from direct sunshine as a pre­ventive measure against brittleness in elastomer parts and the impeller and casing coating.
• When storing the machine in a shop please remem­ber: Radiation and gases which occur during electric welding destroy the elastomers of the seals.
• During lengthy periods of storage, regularly (for ex­ample every six months) turn the impeller or propeller by hand. This prevents indentations in the bearings and stops the rotor from rusting up.
8.3. Restarting after an extended period of storage
Before restarting the pump, it should be completely re­commissioned. Clean it of dust and oil deposits, then car­ry out the necessary maintenance actions (see “Mainte­nance”). Check that the mechanical shaft seal is in good order and working properly. Once this work has been completed, the machine can be installed (see “Installa­tion”) and connected to the electricity supply by a special­ist. See “Start-up” for instructions on restarting.
Only restart the machine if it is in perfect condition and ready for operation.
8. Shutdown
8.1. Temporary shutdown
For this type of shutdown, the machine remains installed and is not cut off from the electricity supply. For tempo­rary shutdown, the machine must remain completely sub­merged so that it is protected from frost and ice. Make sure the operating room and the pumped fluid cannot be covered by ice. This ensures that the machine is always ready for operation. Carry out a monthly start-up and run the pump in operating conditions for 5 minutes.
Caution! Only test the pump under the proper conditions of op­eration and use. Never run the machine dry. This can result in irreparable damage!
8.2. Final shutdown / storage
Switch off the system, disconnect the machine from the electricity supply and dismantle and store it.
9. Troubleshooting
In order to prevent damage or serious injury while rec­tifying machine faults, the following points must be observed:
• Only attempt to rectify a fault if you have qualified personnel. This means each job must be carried out by trained specialist personnel, for example electrical work must be performed by a trained electrician.
• Always secure the machine against an accidental restart by disconnecting it from the electric system. Take appropriate safety precautions.
• Always have a second person make sure the ma­chine is switched off in an emergency.
• Secure moving parts to prevent injury.
• Independent work on the machine is at one‘s own
risk and releases the manufacturer from any warranty obligation.
English | 19
Page 20
The machine will not start
Cause Remedy
Electricity supply interrupted – short circuit or ground connection in the cable or motor windings
Fuses, the motor protection switch and/or monitoring devices are triggered
Have the motor and wires checked by a specialist and replaced if necessary
Have a specialist inspect the connection and correct them as necessary Have the motor protection switch adjusted according to the technical specifications, and reset monitoring equipment. Check that the impeller/propeller runs smoothly. Clean it or free it as necessary
The moisture sensor has interrupted the power circuit (operator-related) See fault below: “Mechanical shaft seal leaks, seal chamber monitor
reports fault and switches the machine off“
Machine runs but does not pump
Cause Remedy
No pumped fluid Open the container intake or valves
Intake blocked Clean the intake, valve, suction port or intake strainer
Impeller/propeller blocked or obstructed Switch off the machine, secure it against being switched on again and
free the impeller/ propeller
Defective hose or piping Replace defective parts
Intermittent operation Check the control panel
The motor starts, but the motor protection switch triggers shortly after start-up
Cause Remedy
The thermal trigger on the motor protection switch is incorrectly set Have a specialist compare the setting of the trigger with the technical
specifications and adjust it if necessary
Increased power consumption due to major voltage drop Have an electrician check the voltage on each phase and rewire if
necessary
Excessive voltage differences on the three phases Have a specialist inspect the connection and the switching system and
correct it as necessary
Incorrect direction of rotation Swap the U and V power leads
Impeller/propeller impeded by adhesive material, blockages and/or solid matter, increased current consumption
Switch off the machine, secure it against being switched on again and free the impeller/ propeller or clean the suction port
The pumped fluid is too dense Contact the manufacturer
The machine runs, but not at the stated operating levels
Cause Remedy
Intake blocked Clean the intake, valve, suction port or intake strainer
Valve in the discharge line closed Fully open the valve
Impeller/propeller blocked or obstructed Switch off the machine, secure it against being switched on again and
free the impeller/ propeller
Incorrect direction of rotation Swap the U and V power leads
Air in the system Check the pipes, pressure shroud and/or pump unit, and bleed if
necessary
Machine pumping against excessive pressure Check the valve in the discharge line, if necessary open it completely
Signs of wear Replace worn parts
Defective hose or piping Replace defective parts
Inadmissible levels of gas in the pumped liquid Contact the factory
Two-phase operation Have a specialist inspect the connection and correct it as necessary
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Page 21
The machine does not run smoothly and is noisy
Cause Remedy
Machine is running in an impermissible operation range Check the operational data of the machine and correct if necessary and/
or adjust the operating conditions
The suction port, strainer and/or impeller/propeller is blocked Clean the suction port, strainer and/or impeller/ Propeller
The impeller is blocked Switch off the machine, secure it against being switched on again and
free the impeller
Inadmissible levels of gas in the pumped liquid Contact the factory
Two-phase operation Have a specialist inspect the connection and correct it as necessary
Incorrect direction of rotation Incorrect direction of rotation
Signs of wear Replace worn parts
Defective motor bearing Contact the factory
The machine is installed with mechanical strain Check the installation, use rubber spacers if necessary
Mechanical shaft seal leaks, sealing chamber monitor reports fault and switches the machine off
Cause Remedy
Increased leakage when operating with new mechanical shaft seals Change the oil
Defective seal chamber probe Replace the moisture sensors
Mechanical shaft seal is defective Replace the mechanical shaft seal after contacting the factory
Further steps for troubleshooting
If the items listed here do not help you rectify the fault, contact our customer service. They can help you as fol­lows:
• Telephone or written help from customer service
• On-site support from customer service
• Checking and repairing the machine at the factory
Note that you may be charged for some services provided by our customer support. Customer service will provide you with details on this.
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Page 22
10. Connection of pumps and mixers
Danger from electric current! Incorrect working with electric current brings danger to life! All pumps with bare cable ends must be connected by a skilled electrician.
10.1 Power cables
Pumps in Star 3-phase version
Cable identification Motor Terminal in control cabinet
U1 U1
V1 V1
W1 W1
U2 U2
V2 V2
W2 W2
Pumps in Direct start version
Cable identification Motor Terminal in control cabinet
U U1
V V1
W W1
10.2 Control cables
Depending on the design of the pump/agitator, it may be that no separate control cable is used. In this case monitoring devices are run from the power cable.
Cable identification Motor Monitoring system
Monitoring in winding
T1 / T2 Temperature limiter (2 switches in series)
T1 / T4 Temperature controller (2 switches in series)
T1 / T2 / T3 Temperature limiter and controller
K1 / K2 PTC – Thermistor (3 thermistors in series)
PT1 / PT2
PT3 / PT4
PT6 / PT6
Bearings monitoring
P1 / P2 PT100 upper bearing
P3 / P4 PT100 lower bearing
Seal monitoring
S1 / S2 Seal monitoring in oil chamber
S3 / S4 Seal monitoring in connection compartment
S5 / S6 Seal monitoring in Motor compartment with 2 Electrodes
S7 / S8 Seal monitoring in Motor compartment with float switch
S9 / S10 Seal monitoring in Gearbox (Agitator)
S11 / S12 Seal monitoring in Leakage compartment (internal cooling)
Heating
H1 / H2 Heating system
3 x PT100 individually installed
22 | English
Page 23
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Page 24
HOMA Pump Technology
390 Birmingham Blvd Ansonia, CT 06401
Phone: 203-736-8890 Fax: 203-736-8899
e-Mail: info@homapump.com Internet: www.homapump.com
Version 05 / 2019
Page 25
Name Tag Voltage ________V
All Pumps Off
All Pumps On
Actual Supply Voltage:
__________ V
__________ V
Capacitor Values:
Run: __________ µf
Start: __________ µf
Capacitor Voltage Rating
Actual Capacitor Voltage:
Run: __________ V
Start: __________ V
Full Load Amp Rating:
__________ A
Actual Amp Readings:
U1 __________ A
U2 __________ A
Z2 __________ A
Name Tag Voltage ________V
All Pumps Off
All Pumps On
Actual Supply Voltage:
__________ V
__________ V
Capacitor Values:
Run: __________ µf
Start: __________ µf
Capacitor Voltage Rating
Actual Capacitor Voltage:
Run: __________ V
Start: __________ V
Full Load Amp Rating:
__________ A
Actual Amp Readings:
U1 __________ A
U2 __________ A
Z2 __________ A
Single Phase Start-Up
and Check List
Technical Pages
ABSTRACT
Troubleshooting a single-phase pump is easier if there has been data recorded at start-up. This is useful to see if there have been any changes to the pump, start components or supply voltage. It is also important at start-up to verify that the ampere­draw and supply voltages are within tolerance. Please refer to the HOMA Pump Selection software (HOPSEL) for specific pump data. You will find the Full Load Amp value and the standard capacitors listed in the pump data pack.
PROCEDURE
Log in all data at commissioning in the Start-Up Check List. If troubleshooting is necessary at a later date, complete the same readings in the section below, Troubleshooting Check List.
Please refer to the Single Phase Pump Start-Up Procedure, Publication 88LM2015C to assure proper capacitor selection. This affects amp draw on each power lead and should be verified for all single phase applications.
Start-Up Check List
Troubleshooting Check List
88LM2010C Published: May-19 Page 1 of 1
Page 26
GRP 10/1 – 21/1
25µf @ 370V Run Capacitor
50µf @ 330V Start Capacitor
PN#: 8857005
GRP 26/1
40µf @ 370V Run Capacitor
80µf @ 330V Start Capacitor
PN#: 8857010
GRP 28/1 – 41/1
50µf @ 370V Run Capacitor
150µf @ 330V Start Capacitor
PN#: 8857015
GRP 44/1
70µf @ 370V Run Capacitor
320µf @ 330V Start Capacitor
PN#: 8857084
GRP 58/1
120µf @ 370V Run Capacitor
200µf @ 330V Start Capacitor
PN#: 8857025
GRP 78/1
120µf @ 370V Run Capacitor
300µf @ 330V Start Capacitor
PN#: 8857030
GRP 59/1
100µf @ 370V Run Capacitor
350µf @ 330V Start Capacitor
PN#: 8857085
GRP 79/1
120µf @ 370V Run Capacitor
350µf @ 330V Start Capacitor
PN#: 8857090
Single Phase Pump
Start-Up Procedure
Technical Pages
7.5 HP and larger motors require multiple run and start capacitors to achieve the necessary capacitance value. Refer to the capacitor wiring diagram supplied with each capacitor kit.
Run Capacitor sizing can vary depending on the incoming supply voltage provided. HOMA Single Phase
pumps are provided with a Start and a Run Capacitor sized for 220-230V under load. Frequently, the available line voltage is considerably different than indicated, and the start or run capacitors may need to be resized to match the available field voltage. The following procedure will allow you to verify proper operation of your single phase pump, and/or make necessary changes to your capacitors to correct for your power supply.
After verifying wiring is in accordance with your pump requirements, start pump and record the following
readings from each of the (3) pump cable leads.
Current under load:
U1 _________Amps > U2 __________Amps > Z2 __________Amps
Should be: (highest reading) (middle reading) (lowest reading)
Lead U1 (common) should have the highest current reading. Lead Z2 (start) should have the lowest reading. If Z2 current draw is greater than the current draw of either U1 or U2, a smaller size Run capacitor (lower
microfarad rating) is required to correct the condition. Example: If a 60 µf Run capacitor was supplied, change to a 50 µf Run capacitor and check current readings. Typically, only one step down in capacitor size is required, but in certain instances 2 steps may be required.
The standard capacitor kit provided includes: __________ µf start capacitor
__________ µf run capacitor
Additional run capacitors have been included for use in tuning the pump to match available line voltages for optimum performance: __________ µf run capacitor
__________ µf run capacitor __________ µf run capacitor
Capacitor Sizing Chart
88LM2015C Published: May-19 Page 1 of 1
Page 27
START-UP REPORT
This report is designed to ensure the customer that customer service and a quality product are the number one priority with HOMA Pump Technology. Please answer the following questions completely and as accurately as possible. Mail this form to:
HOMA PUMP TECHNOLOGY
390 BIRMINGHAM BOULEVARD
ANSONIA, CT 06401
ATTN: SERVICE MANAGER
Receipt of completed report will initiate operational warranty. Reports that are not returned can delay or void warranty.
1.) Pump User's Name: _____________________________________________________________
Site Location: __________________________________________________________________
Site Contact: ___________________________________________________________________
Distributor: _______________________________ Phone Number: ________________________
Contractor: _______________________________ Phone Number: ________________________
Engineer: ________________________________ Phone Number: ________________________
Owner: __________________________________ Phone Number: ________________________
2.) HOMA Pumps Model __________________________________ Serial No._____________________ Voltage____________ Phase_________________ Hertz________________ Horsepower_________ Method Used to Check Rotation (viewed from bottom) __________________________________ Does Impeller Turn Freely By Hand: YES________ NO _________
3.) Condition of Equipment: EXCELLENT____________ GOOD____________ AVERAGE____________ Condition of Cable Jacket: EXCELLENT____________ GOOD ___________ AVERAGE____________ Resistance of Cable and Pump Motor (measured at pump control)
1 Phase: U1 – U2 _________ Ohms; U1 - Z2 ________ Ohms; U2 – Z2 _________Ohms; T1 – T2 ________Ohms 3 Phase: U - V____________ Ohms; V - W __________Ohms; U -W ___________Ohms, T1 – T2 ________Ohms
Single Phase Capacitor Sizes Installed: _________________ Start Capacitor; __________________ Run Capacitor Resistance of Ground Circuit Between Control Panel and Outside of Pump __________ Ohms MEG Ohm Check of Insulation: U to Ground _______________ V to Ground _______________ W to Ground____________ Hour Meter installed in panel? ______ Chains/Cables for retrieval? ________ Date Code: __________
4.) Condition of Equipment at Start-Up: Dry __________ W et _____________ Muddy_________
Was Equipment Stored: _______________ Length of Storage ________________________ Describe Station Layout ___________________________________________________________
Wet Well Diameter ________ ft Volume per Inch __________ Gal
5.) Liquid Level Controls: Model _____________________________ Type ______________________
Is Control Installed Away From Turbulence? ___________________________________________ Operation Check: (IF FLOAT SWITCHES SUPPLIED). Tip lowest float (stop float), all pumps should remain off. Tip second float (and stop float), one pump comes on. Tip third float (and stop float), both pumps on (alarm on simplex). Tip fourth float (and stop float), high level alarm on (omit on simplex).
Control Voltage: _________ VFD Manufacturer: _____________ Soft Start Manufacturer: ____________ Running Hz: __________ Phase Monitor Number: __________
Pump Technology,Inc 390 Birmingham Blvd. Ansonia, CT 06401 (203) 736-8890 Fax:(203) 736-8899
Page 28
6.) Electrical Readings:
Single Phase: Voltage Supply at Panel Line Connection, Pump Off, U1-U2 _______ U1-Ground ________ U2-Ground ________ Voltage Supply at Panel Line Connection, Pump On, U1-U2 _______ U1-Ground ________ U2-Ground ________ Amperage: Load Connection, Pump On, U1 ___________ U2 ___________ Z2 ___________ Voltage across Run Capacitor Terminals ________ volts (note: value will be over 300V) Resistance across Thermal Switch leads T1-T2 _______ ohms (switches are NC 0.4 ohm is normal) No Load Voltage: AB_______ AC_______ BC_______ AN_______BN_______ CN_______ Full Load Amps: __________ Service Factor: ___________
Three Phase:
Voltage Supply at Panel Line Connection, Pump Off, U-V _________ V-W _______ U-W ______ Voltage Supply at Panel Line Connection, Pump On, U-V _________ V-W _______ U-W ______ Amperage Load Connection, Pump On, U_____________ V_____________ W______________ Resistance Across Thermal Switch leads T1-T2 _______ ohms (switches are NC 0.4 ohm is normal) Overloads: U________ V________ W________ No Load Voltage: AB_______ AC_______ BC_______ AN_______BN_______ CN_______ Full Load Amps: __________ Service Factor: ___________
7.) Final Check:
Are Thermal Switches properly wired? _______ What Overtemperature Relay is being used? ____________ Is Pump Seated On Discharge Properly? ______________ Check For Leaks? __________________ Does Check Valves Operate Properly? _________________________________________________ Flow: Does Station Appear To Operate At Proper Rate ____________________________________ Vibration Level: Measured _____________________ Observed_____________________________ Design Point: Flow ___________ Head ___________ Draw Down _________ inch Flow:_________ gpm Discharge:_________ psi Discharge:_________ ft Static:_________ ft Friction loss:_________ ft Total Head:_________ft
COMMENTS: _____________________________________________________________________
8.) Equipment Difficulties During Start-Up: _________________________________________________
_________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________
9.) I Certify this Report to be accurate.
Authorized Homa Service Representative:
___________________________________________________________ Phone #____________________ (Signature)
DATE_______________________
Pump Station Owner/ Operator
___________________________________________________________ Phone # ____________________ (Signature) DATE _______________________
Pump Technology,Inc 390 Birmingham Blvd. Ansonia, CT 06401 (203) 736-8890 Fax:(203) 736-8899
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