Sempomp ARS-D Series User Manual

ARS-D

Series

Motor Water Pump

ENGLISH INTRODUCTION AND USER MANUAL

TABLE OF CONTENTS

General Warnings About User Manual 1
Safety Instructions 2
Application Areas 3
Shipping Water Pumps 4
Transportation 4
Storage 5
Installation 6
Electrical Connections 12
First Operation 14
Lubrication 16
Dismounting of Pumps and Repair 17
Cross Section Drawings 19
Spare Parts 20
Failures and Troubleshooting 20
Tightening Moments 23
Noise Level 24
List Indicating Service Stations 25

GENERAL WARNINGS ABOUT USER MANUAL

Aim of this user manual is; ,

- to convey instructions about installation, maintenance and repair of pump, and to
explain start, operation and stop methods of pump.

-. Absolutely keep this manual in a secured place to be accessed easily

by official who is responsible for safe operation and maintenance of pump.

- Pump should not be operated under conditions which are not mentioned in
purchase order. Because, operational conditions which are given in purchase order
are considered at material selection and trial.

SEMPOMP , does not accept any warranty conditions for all kind of changes and
repair operations which are performed by user and unauthorized people.

- Instructions in this manual should carefully be examined and applied in every
installation and operation process of pump for preventing misuse.

- Responsible Personnel should be experienced and have knowledge about related
standards.

- If it is necessary to operate pump under conditions out of the ones those are
mentioned in purchase order, please contact with SEMPOMP authorized service.
SEMPOMP shall not be liable for damages which may occur because of operation
under conditions out of mentioned ones without written permission of service.

- If carried pumps shall not be installed immediately, it should be kept in an
environment where temperature and humidity does not change so frequently. If
appropriate precautions are not taken, very high temperatures and low temperatures
and humidity may severely damage pump.

- User is responsible for control and installation to be performed by authorized
personnel who have read and examined this user manual.

This user manual does not cover safety rules to be applied in usage area.
Usage tine for pumps which is determined and announced by Ministry is 5(five)

years.

1

SAFETY INSTRUCTIONS

- You should absolutely obey the following safety instructions.

- Never touch the pump and pipes having temperature more than 80 ºC. Necessary

precautions should be taken for warning users. (E.g Warning signs and signboards )

- Never operate pump in reverse direction.

- Do not walk over pump pr pipes which are connected to pump.

- Any operation which will be done in pump should be performed by at least two

staffs.

- No works should certainly be done over without stopping pump group.

- Power coming to pumps should be off and you should be sure that it will not operate

again before you make any work

- Absolutely install the safety guards which were dismounted before after work in
pump has finished.

- Tensions and cricks in pipe system absolutely should not reach to pump.

- Do not make any operation while pump and pipes which are connected to pump are

under pressure.

- Cloths of personnel who will work over should be suitable and/or they should use
safety equipments.

- Never do any operations when pump is still hot.

- Electrical connection related with pump and auxiliary equipments should be suitable

with local rules and made by authorized personnel.

- Operate pump with only specified conditions.

- Do not insert your hand and fingers into holes and spaces over pump body.

- Be always careful while working with pumps discharging hazardous liquids.

2

ARS-D SERİES PUMPS

ARS Series Pumps are centrifugal pumps having horizontal shaft, separable radial
body, are multi staged, has closed impellor, diffuser

Usage Areas of Motor Water Pump

Pumps are suitable for discharging liquids which are low viscose, whose flow
temperature is up to 120ºC and which are clean or a little dirty. (Max20mg/dm³) . In
addition to others; main application areas are:

- Heating and Cooling Systems

- Water Supply

- Fire Extinguishing Plants

- Water Supply and Circulation Systems in Industrial Plants

- Watering Systems

- Power Stations
Explanation of Pump Codes

ARS-D 32 / 06

Pump Type
Vertical Shaft
Rated Diameter of Discharge Flange (DN-mm)

Number of Stages(piece)

Technical information

Speed : Up to 3600 d/d rpm
Discharge Flange :DN32 …DN200
Suction Flange :TS ISO 7500-2/PN16,DIN2533/PN16
Discharge Flanges :TS ISO 7500-2/PN40,DIN2535/PN40
Operational Temperature :-10ºC…140ºC cooled soft gasket
Ambient Temperature (Maximum) :+40ºC
Body Pressure :30 bar-(50 Bar)
Isolation Class :F
Protection Class :IP55
Motor Connection :3 Phase-380 V-50 Hz
Motor Options(Optional) : Special Voltage Special Frequency

3

SHIPPING of PUMPS

- Check whether all materials in delivery list are sent. .

- If there is damage during shipping please notify SEMPOMP Shipping Department

and Transportation company.

- If there are missing materials, immediately inform SEMPOMP Shipping Department.

-. Check whether packaging is damaged during transportation.

- Please carefully take out packaged pump and accessories (if any). Check whether

they are damaged during transportation.

CARRYING
General warnings.

Absolutely obey the following rules during transportation.

-. Use proper wooden crane, forklift, or hoisting mechanisms For unloading or
loading wooden cases, packages, boxes and palettes depending on their weight and
volume.

- Wear gloves, hard tip shoes and helmet during carrying works.

4

Pump and Motor Group Loading/Unloading

Before lifting pump group please determined the following properties.

- Locations of lifting points

- Total weight and centre of gravity.

- Packaging external dimensions

- During loading/unloading make accelerating and braking operations as it shall not

cause any damage for working personnel.

- Load lifting capacity should be suitable with pump and pump group weight.

- You should never stay under or near lifted load.

- Pump should be hoisted as it is indicated in Figure 1-1 and Figure 1-2 for not

causing any damage in pumps. Motor hanging ring should absolutely not be used
while lifting complete group.

- Load should be kept in lifted position more than required time.

- Pump and pump group should always be lifted and carried in horizontal position

Figure 1-1 Single Pump Figure 1-2 Motopomp

STORAGE

- If pump group is not immediately installed, it should be stored in a place which is

clean dry and does not include freezing and explosion risk.

- If pump bearing are type which should be greased, they should be extra greased for
preventing entry of moisture to bearings around shaft

- Pump should be protected from moisture, dust, dirt and foreign objects by covering
with suitable material.

5

- Pump shaft should be rotated a few turns (e.g once a week) for preventing pitting
around pump bearing surfaces and jamming of shaft.

INSTALLATION

Installation of pump to its place and connection setup should only be done by expert
personnel. Failed installation and pump ground may cause failures.

This situations are not covered with warranty

- If pump is supplied without motor (without motor, proper motor should be selected
prior start to installation of group.

Following properties should be considered during motor selection.

- Maximum power of pump (in all operation ranges)

- Operational revolution of pump shaft

- Necessary power supply

- Motor Type

- Motor connection type ( footed, flanged, horizontal, vertical etc. )

- If pump is purchased as single pump (without motor and chassis); a proper frame
should be constructing for putting this group over it. Frame to be constructed should
have dimensions and strength which will not permit vibration and shape defects.
Starting the motor should be done with control cabinet which is prepared according
to power of motor and floater should absolutely be used for preventing to operate
without water. Also collector diameter should be suitable with pumps efficient
operational ranges not with installation.

Before start to pump installation

- Protecting parts in discharge and suction pumps should be removed and cleaned

well.

-. Pump should be installed in a places which does not have freezing or explosion
risk and have well air conditioning.

- There should be enough space around pump for accessing pump easily and for
maintenance operations and there should be sufficient height and space for lifting
pump if necessary.

- Pump suction pipe should be as short as possible.

- You should be carefully work at pump installation ground preparation and

installation of pump group into its place. Incorrect and careless installation causes
early wearing of pump parts and failures.

6

- Pump ground should be so heavy to absorb vibrations and sturdy to prevent bends
and adjustments defects. Ground concrete should completely be solidified,
completed its plug time and proper stud bolts are placed in pump frame fixing holes
and proper fixing lugs should be placed for using in making connections with welding.
Concrete and plate upper surface should be horizontal and very smooth.

Installation

Installation of pump group to ground by anchoring stud bolts:

- Pump group is placed to center the stud bolt slots which are opened in ground
concrete.

- Anchoring stud bolts are inserted through fixing holes over pump frame fixing holes
and places into their slots.

- Pump group is places over base concrete. Water balance is placed over pump
discharge flange and horizontality of pump is controlled. If there is a horizontal
imbalance in pumps position, steel wedges are put under frame and balance of pump
group is obtained.

- Nuts of anchoring stud bolts are installed.

- Anchoring stud bolt holes are filled with concrete grout.

- Anchoring stud bolts are reciprocally tightened.

- Coupling setup is controlled in this situation.

- Concrete is poured into pump frame. Joining of poured concrete and ground

concrete is cared.

- Complete binding of concrete is controlled and anchoring stud bolts are reciprocally
tightened.

- Coupling adjustment is again controlled with template. If there is maladjustment,
coupling adjustment is made again.

- Discharge and suction flange fixings of pump are controlled again. If there are
unnecessary strains and cricks they are eliminated.

- Coupling guards are placed after coupling adjustment.
:Installation of pump group with concrete fixing plug :

- Pump is placed into ground concrete or the ground to be installed carefully.
7

Pump group frame fixing holes are marked to concrete. Pump group lifted again.

- Marked places where fixing plugs will be placed are drilled carefully according to

standards.

- Fixing plugs are carefully placed into drilled places.

- Steps for installation with anchoring stud bold are made here with same order.

Installation of Pipe Equipment

- Nominal diameter of pump discharge and suction pumps are not an indicator for

correct diameters for discharge and suction pipes. Pipes and accessories having
diameter less than pump opening diameter should absolutely not be used. Especially
bottom backwater valve, dirt retainer, filter and check valves and similar elements
should be chosen to having a larger passing area. Never use pump as a supporting
point for pipe installation or a as a carrier.

-Cricks and stresses in pipe and pipe weight equipments should be controlled

whether they effect pump. For this reason, bolts of discharge and suction flanges
should be loosen and it should be controlled whether pipe system exerts a stress
over pump.

- Never use pumps as a support point or carrier for a pipe installation

- Flow rates generally should not exceed 2m/s in suction pipe and 3 m/s discharge

pipe. High speeds cause decrease in pressure which will cause cavitations
conditions and excess friction losses in discharge pipe.

- Pipe system should be supported from points which are close to pipe

- Pipe connections should be made by flanges. Flanges gaskets should be produced

from suitable material and should have suitable dimensions. Gaskets which will be
used between flanges should be centered for not preventing water flow.

- Proper expansion equipments should be used for preventing additional forces to

pump which may occur because of expansion in systems which operate in over
vibrant and hot liquids.

8

- Welding burrs, metal particles, which may occur during pipe equipment production

sand, and oakum and similar foreign objects may present inside pump. Suction and

discharge flanges should be closed with gasket without hole for preventing those

materials enter into pump during installation. At the end of installation, all pipe parts

should be dismounted, cleaned and dyed and installed again. If dirt retained is used

at pump suction line, it should be removed and cleaned after first few days of

operation and installed again.

Figure 2-1Suction from Height Figure 2-2 Suction from Height

Suction and Discharge Pipe Connections

- If pump is supplied from a tank which is higher than pump, there should be an

isolation valve in suction pipe whose axis will be in horizontal position. This valve
should be completely open while pump is in operation and should never be used as
flow rate adjustment valve. (Attention: Closing valve may cause pump operation with
cavitations. )

- Suction pipe should absolutely be impermeable and should not be arranged to

cause any air wall. In this case if a tank is supplied from a tank which is higher than
pump, (suction high installation) suction pipe should be slightly decreasing sloped
towards pump and supplied from a tank which is lower than pump, suction pipe
should be slightly increasing sloped towards pump.

9

Figure 3-1Suction from Height Figure 3-2 Suction from Height

- Sharp bends should not be used, sudden direction changes and cross section

narrowing should be avoided and suction pipe should be short as possible for
keeping pump friction losses as low as possible. If there is need of cross section
change in horizontal suction pipe, an intermediate eccentric conical part whose flat
type is at upper side should be used.

-. If pump discharging height is more than 10 m or discharging line is very long, a

check valve should be placed over discharging pipe between pump and isolation
valve for protecting pump against water impulses and reverse flows during stop.

- A control valve which is close to pump should be connected for flow rate and

discharge height adjustment.

- If pump discharging height is more than 10 m or discharging line is very long, a

check valve should be placed over discharging pipe between pump and isolation
valve for protecting pump against water impulses and reverse flows during stop.

10

Auxiliary Pipe Connections and Accessories

Depending on the practice auxiliary pipe connections (necessary seal, cooling, seal
washing, watering, drain, etc and/or) pressure gauge, temperature gauge
connections can be used for controlling operational conditions.

- Pressure or vacuum gauges should be installed sturdy in measurement points

which are over flanges or very close to flanges by means of estimated 8 mm pipes
which are bended in spiral form. Air taking valves should be used for devices to
operate safely and precisely.

- There are connection places in every pump for discharging pump and removing

leakages in seal bed. (Figure 6). Those connections can be connected to discharge
tank by means of pipes if requested. There should be isolation valve in pipe which is
used for pump discharging and this valve and pipe should be suitable with maximum
operational pressure of pump.

-Seal cooling, watering and washing pipes should be connected to correct places

over pump body which are specified for them.

By-Pass Valve Connection

-. A by-pass valve should be places over discharge pipe just after pump and before

adjustment valve or outlet flange of pump if there is a case that pump will operate in
conditions that pump discharge valve is completely closed(that is with zero flow rate)
or almost closed (that is with very small flow rate). If such valve is not used and
pumps operates with closed valve for a long time, power which is provided by motor
will completely transform into heat energy and pass into discharged liquid. This may
cause over heating and abnormal failures in pump.

- Those connections can be connected to discharge tank if requested with pipes.

There should be an isolation pump over the pipe which is used for discharging pump
and both valve and pipe should be suitable with maximum operational pressure of
valve.

-Seal cooling, washing and watering pipes should be connected to correct places

over body.

11

d1: Suction opening Pressure Meter Connection

d2: Discharge Opening Pressure Meter Connection

d3: Liquid Discharging Hole

d4: Seal Leakage Dİscharge

Figure4
ELECTRICAL CONNECTIONS

- Electrical connections should be done by authorized electricians

National instructions, regulations and instructions of motor manufacturers should be
obeyed.

- Power cables should absolutely be installed as not having contact with pipe

installation, pump and motor body.

- Motor shaft should be rotated by hand before making electrical conditions to control

whether it rotates easily.

- It is recommended to use PTC(Passive Thermal Control-Thermistor) in motors.

However usage of those depends on customer. If PTC is used ends of those should
be connected to motor terminal box and later should be connected to PTC control
device in motor control panel.

- Electrical motors should be protected against overloading by circuit breakers and/or

fuses. Circuit breakers and/or fuses should be selected with respect to full load
values those are written in nameplate on motor.

12

- Compare and control voltage, ampere and frequency values which are given in

motor nameplate with line values.

- Motor connection scheme can be found in motor terminal box or in handbook.

- Motor electrical connections should be done according to local Electrical

Regulations and earthing connection should absolutely be done.

- Protection class of motor body and control system cases in pump should be at least

EN 60029 IP 22. In addition to this, protection class of motor bodies and control
systems in pump group should be determined according to operational and
environmental conditions.

- Safety precautions which are determined in "Safety Instructions" should be applied.

All power connections should be disconnected before starting to any work.

- Motor connection type changes according to motor mains power and connection

type. Necessary connection types of jumpers in terminal box are displayed in Table 1
and Scheme 1a-1b and 1c

Start Type

Motor Power
PN<4kW

Motor Power
PN >4kW

Mains Power
3~400V

Mains Power
3~400V

Direct

Y-connection (1b)

Δ-connection (1a)

Y/ Δ Star Delta

Impossible

Remove Jumpers (1c)

Table 1

Scheme 1a Scheme 1b Scheme 1c

13

Attention! Transition time from star to delta should be short in star-delta connected
motors. In case that it is long damages may occur in pump and motors. (Table2 )

Motor Power

Y- Setup time

<30 kW
>30 kW

<3 seconds

<5 seconds

Table 2

- After all abovementioned operations are completed, pump rotor should be rotated a

few turns for being sure that it rotates easily.

- All safety guards should be installed into their places. Pump should absolutely be

not operated after this operation is made. This is a safety and occupational safety
rule which should absolutely be obeyed.

FIRST START
Controls Before Operation

- If there is bottom back flow water valve in pump with depth suction; they are filled

with water from filling hole in highest point and its air is taken.

- This case does not cause problem in force feed pumps. Suction valve is opened if

any. Air plugs are loosen and discharge of air and completely filling of pump is
provided.

- If system includes vacuum pump, rise of water in suction pump by means of

vacuum pump and filling pump is provided. When water reaches the highest level
pump is started.

- Pump bearings are shipped from the factory as being filled with grease which will be

enough for one year.

- Before first start of pump, bearings should be checked whether there dirt has

entered into it during shipment and installation. If bearings are dirt they should be
completely be cleaned and greased again.

- If pump has waited before installation for a long time (more than 6 months), new

grease should be inserted into bearings.

- Be sure that pump and suction pipe is completely filled with water.

ATTENTION! Never let pump run in dry conditions.

14

Determination of Rotation Direction

- ARS-D type pumps rotates in clockwise direction when you look from clutch

towards pump. This direction is shown with an arrow in pump body. Pump is
operated for a short while and checked whether it rotates in correct direction. If
protection guard is uninstalled during this operation, it should immediately be
installed after this operation.

Starting Pump

- Check that suction valve is open and discharge valve is closed.

- Close the circuit breaker and start the motor.

- Wait motor to reach full speed. (Wait motor to pass delta in motors operation with

star-delta)

- Observe the ammeter in panel and slowly open discharge valve. (If discharge pipe

is empty in first start, do not open discharge valve completely and open in controlled
way by controlling that value in ammeter is lower than motor rated values.)

Stopping the Pump

- Slowly close the discharge pump.

-. If there is water impulse prevention equipment in Discharge line and if the impulse

which may occur is not in dangerous levels, you can stop the pump without closing
the valve.

- Stop the motor. Watch that pump group has stopped calm and regular way.

- If there is external feed to seal, close this for decreasing the pressure in seal.

- If pump will be out of service for a long time close suction valve and auxiliary

circuits if any.

- If there is freezing danger and /or it will not be used for a long time, completely

discharge water inside pump by means of discharging plug over pump body. Take
necessary precautions against freezing risk.

Controls to be Made While Pump is Running

- Pump does not need any maintenance since it has mechanical seal. Very few

amounts of water may penetrate from mechanical seal but it can not ne noticed. If
water comes from mechanical seal this means that it surface is worn and needs to
be replaced. Lifetime of mechanical seal mainly depends on cleanness of discharged
water.

15

- Motor current should sometimes be controlled from ammeter over electrical panel

which controls the motor. If current values are more than motor nameplate values
there may be friction or squeezing in pump. Pump should immediately be stopped
and mechanical and electrical controls should be done.

- If there are spare pumps in system, this type of pumps should be run for a short

while at least once a week and controlled whether read for operation. Control with
auxiliary elements if any.

- Pump should absolutely be run in closed valve condition (zero flow rate) for a long

time.

- Pump should operate silent and without operation.

- Bearing temperatures should never exceed ambient temperature (more than 50ºC

). It should never exceed 80ºC

- Never operate pump without water.

LUBRICATION

-ARS-D series pump are bedded with liquid in pump shaft body and "lifetime grease

lubricated" in sliding bed and discharging body part. Entire bearings do not need
maintenance since motor bearings are lubricated with lifetime grease.

OIL CONTROL

- If pump has waited before installation for a long time (more than 3 months),

bearings should be greased. If liquid oil is used in bearings, old oil should be
removed and filled with new oil.

- Before running the pump, pump bearings should be checked whether dirt has

entered inside it. If there is dirt inside bearings they should completely be cleaned
and new liquid oil or grease should be filled.

-Oil filling or adding operations should be determined by enterprise according to

conditions in workplace and operation. This method is efficient.

-Pumps which are lubricated with liquid oil are shipped without oil. This type of

pumps should be filled with oil up to indicator level before starting to operation.

SAFETY CONDITIONS

- Works should be done by obeying workplace occupational safety rules.

- Inside of pumps should be cleaned after fluid has been discharged from pump.

- Reliability of explosive, poisonous, hot and substances in crystal structure with

respect to environment and human health should be assured.

16

- Considering that used cleaner and protector solvent wastes may give harm to

environment and human health; precautions should be taken for preventing
dissipation to environment and mixing to suction pool. Accumulation and putting the
used waste solvents in disposal area should be cared.

- Working area where dismounting and installation works are performed should be

clean.

- Pump should be free of all dangerous materials and be clean during return back.

- Lifting tools and equipments which are suitable with objective and occupational

safety should be used in dismounting and installation operations.

DISMOUNTING OF PUMP AND REPAIR

ATTENTION! - Before starting to any operation over pump always disconnect the
electrical connections and be sure that it will not run mistakenly. Certainly obey the
instructions which are given in "Safety Instructions".

Dismounting of Pump

- Close isolation valves in suction and discharge pipes.

- Open the fuses of electricity line fuses coming to motor as they will not carry current

and remove control cable coming to motor from motor terminal box.

- Open the discharge plug and discharge the water inside pump.

- If the liquid inside pump is special, discharge it after taking necessary safety

precautions.

-Uninstall the bolts of pump's suction, discharge flanges and foot.

-Disconnect pump from installation.

-Before starting to dismount pump mark the suction, discharge and stage bodies for

providing easiness during installation and mark the corresponding locations.

-Remove the clutch and other safety guards.

-Place the pump vertically from the motor carrier ground.

-Uninstall lower bearing feeding pipe.

- Uninstall pump foot from suction body.

-Uninstall lower bearing cover.

- Uninstall shaft safety nuts.

- Uninstall body stud bolts nuts and remove body stud bolts.

-Take the suction body

17

-Remove the lower bearing from suction body.

- Remove the shaft bearing and wedge.

-Take the impellor, diffuser and together with stage bodies, and last stage body

together.

-Uninstall the discharge body

-In mechanical seals first uninstall the mechanical seal cover from discharge body

and then separate discharge body from roller bearing bed.

-Lay down the pump for uninstalling the remaining parts.

-Uninstall the motor carrier.

-Separate the clutch from pump shaft by using puller and take the wedge.

-Uninstall the bearing cover with roller bearing.

-Uninstall the shaft safety nuts.

-Slightly hit the end of shaft and take the shaft and roller bearing from bed.

Take the roller bearing out of shaft.

-Uninstall the intermediate bushing and seal bushing.

-Take the two piece ring.

Installation of Pump

-. Pump installation operation is made by reverse order of pump dismounting

process. Pump cross section drawings will assist you for this subject.

-Clean all the parts, replace the damaged and worn onesç

- Before starting to installation operation, apply lubricious materials such as graphite,

silicone or similar slippery substances over contact surfaces or bolt surfaces. If you
can not find those substances use liquid oil. (drinking water pumps excluding

- Do not use gaskets which you had removed. Use new ones having same

dimensions. Be careful that new gaskets and O-rings are in same dimensions.

Pumps with Mechanical Seal

- Water leakage does not occur in a mechanical seal which properly operates.

Mechanical Seal does not need maintenance in cases that it does not have visible
water leakage. Besides this impermeability of mechanical seal should be regularly
controlled.

- Strictly obey the instructions of mechanical seal manufacturers instructions in

pumps where mechanical seals are used. Never run mechanical seal in dry
conditions.

18

PUMP CROSS SECTION DRAWING

1-Electrical Motor 9-Suction body
2-Coupling 10-Foot
3-Motor Shaft 11-Pump Shaft
4-Roller Bearing 12 Impellor wedge
5-Diffuser 13- Lower Bearing
6-Implellor 14- Lower bearing bushing
7-Mechanical Seal 15-Sliding Bearing

19

SPARE PARTS

- SEMPOMP warrants to provide the spare parts for ARS-D Series pumps for 5(five)

years beginning from production date. You can always easily obtain the spare parts
you need.

- In spare parts order, it will be sufficient for you to inform the following values which

are written in pump nameplate.
Pump Type : ARS -D50/04
Motor Power(P) and Revolution(n) : 22kW - 2900 d/d
Production Year and Serial No : 12/2011 - 201112-001
Flow rate(Q) and Manometric Height (Hm): 45 m³/h - 120mSS

REASONS FOR FAILURES AND TROUBLE SHOOTING

In this chapter failures which can be seen in ARS type pumps, possible reasons
(Table 3) and trouble shooting methods (Table 4) are given.

ATTENTION! Control the accuracy of all measurement gauges before starting to
eliminate the failure operation.

Table 3

20

FAILURES

POSSIBLE REASONS

Started pumps never discharges water

1-5-7-10-11-13

Flow rate decreases or no water is discharged

2-3-8-10-14

Motor is overloading

9-12-17-18-19-27-28

Bearings have over temperature

19-20-21-22-24

There is vibration in pump

15-16-19-23-25

Noise level is high

4-6-26

No

Possible Reasons

Trouble Shooting Methods

1

There may be air in pump
and/or suction line

Fill pump or suction pipe completely with liquid
and repeat the start process

2

Air is not absorbed from
seal, suction pipe, or
connections. Pump absorbs
liquid which is mixed with air

Control all connections in suction pipe. Check
seals. If necessary feed seals with pressurized
water. Check the submersion depth of suction
pipe pr deep back water valve and increase
submersion depth if necessary.

3

Air pocket in suction pipe

Control the slope of suction pipe and whether
there are suitable places for formation of air
pockets, if any make necessary corrections.

4

There is air in liquid

Swirls occur since depth of submersion pipe is
not enough and there fore air is not absorbed.
Control the liquid level in suction tank and
increase the depth of bottom/suction pipe back
water valve.

5

Suction depth is very much

If there is no obstacle which may cause clogging
control the friction losses of suction line. If
necessary use a suction pipe having larger
diameter. If static suction depth is too much you
should raise the height of water level in suction
tank or pump should be places in lower levels.

6

Pump operates with
cavitations

NPSH of plant is very low. Check the water level
in suction tank. Check whether there are over
friction losses in suction line. Check whether
isolation valve in suction line is completely open.
If necessary place the pump in low levels and
increase the load of pump at suction side

7

Pumps discharge height is
insufficient

Actual discharge height of plant is higher than given
values. Check the total static height and friction
losses of discharge pipe. Using pipes having
greater diameter may be solution. Check whether
valves are completely opened.

8

Increase in discharge height

Check whether valves are completely open. Check
whether there is an obstacle which may cause
clogging in discharge pipe.

9

Pump is operating at lower
discharge height

Discharge height of plant is lower than given
values. Lathe the impellor diameter according to
manufacturer suggestions

10

Pump rotates reverse

Check rotation direction of motor whether it is
same with the direction which is indicated in pump
body or nameplate

11

Speed very low

Check the voltage and frequency of line and check
whether phase is missing in motor.

12

Speed very much

Decrease the motor revolution if possible or Lathe
the impellor diameter according to manufacturer
suggestions

13

Impellor, check valve or filter
clogged

Clean Impellor, check valve or filter
14

Impellor, partially filter clogged

Clean Impellor, or filter

15

Impellor partially clogged

Clean the impellor

16

Worn or malfunctioned
impellor

Replace the impellor

17

Mechanical friction in pump

Check whether there are any obstacle or bend in
pump rotor

18

Soft seals are over tightened

Loosen the seal bushing

19

Clutch adjustment is broken

Check the clutch rubber and adjust again

20

Bearing covers are over
tightened.

Check the covers and make necessary corrections

21

Flow rate is less than pumps
necessary flow rate

Increase the flow rate, use by pass valve or line if
necessary

22

There is so much grease in
bearing

Remove the excess grease
23

Shaft is bend

Check the shaft and replace if necessary

24

Insufficient lubrication or
lubricant is dirty

Check the amount of lubricant, clean bearing bed
and capsules and grease again

25

Imbalanced rotating parts

Adjust the balance of rotating parts

26

Pump operates out of its
operation region

Check the operational region values

27

Density or viscosity of
discharged liquid is more than
given value

Use motor having greater power
28

Motor Failure

Check the motor,. Motor is not suitable for its air
conditioning position

Table 4

22

TIGHTENING MOMENT

SCREW DIAMETER

MAXIMUM TIGHTENING MOMENT(Nm)

CLASS PROPERTIES

8.8

10.9

M4 3 4,4

M5

5,9

6,7

M6

10

15

M8

25

36

M10

49

72

M12

85

125

M14

135

200

M16

210

310

M18

300

430

M20

425

610

M22

580

820

M24

730

1050

M27

1100

1550

M30

1450

2100

M33

1970

2770

M36

2530

3560

23

EXPECTED NOISE LEVELS

Motor Power
PN
(kW)

Sound Pressure Level (dB)

Pump and Motor

1450 rpm

2900 rpm

<0,55

63

64

0,75

63

67

1,1

65

67

1,5

66

70

2,2

66

71

3

70

74

4

71

75

5,5

72

83

7,5

73

83

11

74

84

15

75

85

18,5

76

85

22

77

85

30

80

93

37

80

93

45

80

93

55

82

95

75

83

95

90

85

95

110

86

95

132

86

95

160

86

96

* It is the value which is measured from 1 m distance from the pump in a free area

over the surface which reflects sound without having sound screen.

24

LIST DISPLAYING THE SERVICE STATIONS

MANUFACTURER COMOANY'S

Title : SEMPA ELK.MOT.SAT.POMPA İMLT.DEMİR
TİC.İTH.İHRC.SAN.TİC.LTD.ŞTİ.

Address : Büsan Özel Organize San.Bölgesi 4.Sk. İlerisi
No:43-45-47 Karatay / KONYA

Phone&Fax : [phone] & 345 32 95

Service Scope: Pumps (Waste, clean, water, oil, fuel oil, Lpg, Cng)

NO

TITLE

ADDRESS

NAME OF
OFFICIAL

TEL&FAX

1

SEMPA

LTD.ŞTİ.

Büsan
Org.San.Böl.

4.Sk. İlerisi

No:43-45-47
Karatay /
KONYA

SEYİT

MEHMET
FERAHKAYA

0 332 345 32
90
0 332 345 32
95

25

MANUFACTURER COMPANY

SEMPA ELK.MOT.SAT.POMPA İML.DEMİR TİC.İTH.İHRC.SAN.TİC.LTD.ŞTİ.

Factort :Büsan Org.San.Böl.4.Sk.İlerisi No:43-45-47 Karatay/KONYA/TÜRKİYE
Tel : [phone] (4Hat) Fax: + 90 (332) 345 32 95
Store:Horozluhan Mah.Çakırlı Cad.No:23 Selçuklu / KONYA
Tel : [phone] Fax: [phone]
Web :www.sempaltd.com
E-mail : [e-mail]

26

WARRANTY CONDITIONS
1-) Warranty period starts with delivery of goods and it is for 2(two) years.
2-) Complete of good including all parts under warranty of our company.
3-) In case that good had a failure within warranty period, duration which passes

through warranty is added to warranty period. Repair time for good can not exceed
20 days. In case that there is not service station related with failure of good, this
duration starts with the informing the seller, distributor, agency, importer, exporter or
producer. It is possible for consumer to make failure notification by telephone, fax, e­mail, certified mail and similar ways. However proof liability belongs to consumer in
dispute cases. If the failure of good can not be eliminated within 10 days;
manufacturer, produces or importer is liable to deliver a similar product until repair
has been completed.
4-) In case that product has failure because of labor or material failure, its repair will
be performed without charging any amount regardless with labor costs, or replaced
part prices.

5-) Although the repair right of product is used by consumer;

- Provided that remaining in defined warranty period after the date of delivery to

consumer;
, , in case that maximum four times in a year or more than six time in warranty period
defined by manufacturer-producer and/or importer it has a failure, and besides this if
those failure prevents usage,

- exceeding the maximum time which is determined for repair;

- Provided that there is not any service station, by means of a report issued by seller,

distributor, agency, representation, importer or manufacturer or produced indicating
that repair is impossible; consumer may request the replacement free od charge,
refunding or price deduction with same amount.
6-) Warranties which are caused by contrary usafe of product with user manual are
not covered by warranty.

7-) Consumer may apply to CUSTOMS AND COMMERCE MINISTRY
PROTECTION OF CONSUMER AND MARKET SUPERVISION GENERAL
DIRECTORATE for the problems which may be related with warranty certificate.

MANUFACTURER COMPANY

SEMPA ELK.MOT.SAT.POMPA İML.DEMİR TİC.İTH.İHRC.SAN.TİC.LTD.ŞTİ.

Factory :Büsan Org.San.Böl.4.Sk.İlerisi No:43-45-47 Karatay/KONYA/TÜRKİYE

Tel : [phone] (4Hat) Fax: + 90 (332) 345 32 95

e-mail:[e-mail] web:www.sempaltd.com

DISTRIBUTOR SEAL

In addition that this guarantee does not cover the failures which may be caused by
abnormal usage of pump also is not valid for following cases.

 Changes and repairs which are made by unauthorized service.
 Damages and failures which may be caused by using contrary with aspects

that are written in user manual

 Damages and failures which may be caused by faults in suction and discharge

lines of pump

 Damages and failures which may be caused by improper pump selection.
 Damages and failures caused by abrasives which may be found in water
 Especially the damages and faults which may be caused by liquids having

different properties which are mentioned in user manual.

 Damages and failures which occur after delivery of product to consumer in

loading, unloading, carrying, transportation and storage conditions.

 Low or high voltage, erroneous electrical installation and control cabinet,

wrong connection of cable ends, and usage of pump out of voltage values
which are written in pump nameplate.

 Damages and failures which may be caused by using cables with cross

sections which are not suitable with pump power.
 Damages and failures which may be caused by fire, lighting and freezing.
Failures which may occur because of abovementioned events are repaired in

return of charge.
Responsibility of filling warranty certificate and delivery to customer belongs to

seller, agency or distributor where product is purchased.
Warranty will be void in cases that alteration is made over warranty, original

series number over product is removed or altered.

WARRATY CERTIFICATE

MANUFACTURER OF IMPORTER COMPANY
Title: SEMPA LTD
Address: Büsan Özel Org. San. 4.Sk. İlerisi
Elit San Sir. No:43-45-47
Tel: : [phone] (4 lines)
Fax: [phone]
Invoice Date:
Invoice No:
Certificate nı:108981
Company Official Signature and Seal

Products'
Type:
Trademark:
Model:
Serial No:

Delivery Date and Place
Seller Company

Title:
Address
Phone:
Invoice Date
Invoice No:
Sales Date
Seal Signature

This certificate is issued according to permission of Customs and Commerce
Ministry Protection of Consumers and Market Supervision General Directorate

Customer
Name:
Address:
Phone
Fax:
Products'
Type:
Trademark:
Model:
Serial No:

Delivery Date and Place
Seller Company

Title:

Address
Phone:
Invoice Date
Invoice No:
Sales Date
Seal Signature

This part will be delivered to SEMPA LTD ŞTİ by agency, seller or

distributor.