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Homa GRP Installation, Operation And Maintenance Manual

Hz
Installation, Operation, and Maintenance Manual
GRP Series
Version 05/2019- No. 00507610.02
60
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
02 | English
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!
English | 03
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.
04 | English
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!
English | 05
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
06 | English
No. Description
1 Lifting handle 2 Motor housing 3 Cable inlet 4 Discharge 5 Name plate 6 Volute 7 Suction cover with feet

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)
English | 07
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.
08 | English
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!
English | 09
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