HYDRAFLOW
Limited Coleford England
HYDRAULIC SUBMERSIBLE PUMPS
OPERATORS INSTRUCTIONS
HYDRAFLOW
SUBMERSIBLE PUMP
S2TC-2
SPP Pumps Limited
Theale Cross
Reading
Berkshire
ENGLAND
RG31 7SP
Pump Weight 7.7 Kg Aluminium or 11 Kg Cast iron
Telephone:
++44(0)1594 832 701
Fax:
++44(0)1594 836 300
Document No: W79-006E
Revision No: 4
Revision Note Windchill
Date Issued:
Produced at SPP Pumps
Aug 2012
We
Of
SPP Pumps Limited
Crucible Close
Mushet Industrial Park
Coleford
Gloucestershire
GL16 8PS
Declare that:
Equipment:
Model/Type:
Serial Number:
In accordance with the following Directive:
HYDRAULIC DRIVE SUBMERSIBLE PUMP
S2TC-2
As shown on the Pump Nameplate
DECLARATION OF CONFORMITY
2006/42/EC Machinery Directive
have been designed and manufactured to the following specifications:
EN 809:1998+A1:2009 Pumps and Pump Units for Liquids - Safety Requirements
EN 12100:2003 Parts 1 and 2 - Safety of Machinery
We hereby declare that the equipment named above has been designed to comply with the
relevant sections of the above referenced specifications. The units comply with all essential
requirements of the Directive.
Signed:
Name: John Hollins
Position: Engineering Manager - Authorised to sign on behalf of SPP Pumps Limited
Mushet Industrial Park, Coleford, Gloucestershire, England, GL16 8PS
Date: 19 February 2010
W79-006E
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 2 of 12
Operators Instructions for
HYDRAFLOW S2TC-2 Hydraulic Submersible Pump
Manual No/Rev
W79-006E / 4
CONTENTS
1. INTRODUCTION 4
1.1 Power Unit 4
1.2 Hydraulic Hoses 5
1.3 Submersible Pumps 5
2. SAFETY PRECAUTIONS 5
2.1 Safety Symbols 5
2.2 Submersible Pump Safety Precautions 5
3. TRANSPORT & STORAGE 6
3.1 Transport 6
3.2 Storage 6
4. SERIAL NUMBER 6
5. OPERATING INSTRUCTIONS 6
5.1 Pump Installation 6
5.2 Operation 6
6. PUMP MAINTENANCE 6
6.1 Oil Specifications: 6
6.1.1 Hydraulic Oil: 6
6.1.2 Lubricating Oil: 7
6.2 Maintenance Chart 7
6.3 Pump Disassembly: 7
6.4 Pump Reassembly: 7
6.5 Pump Hose Connection: 8
7. TROUBLESHOOTING 8
7.1 Preliminary Check List 8
7.2 Troubleshooting Guide 8
8. PUMP SECTION DRAWING AND PARTS LIST 9
8.1 Pump Section Drawing 9
8.2 Parts List 10
9. SPARES & SERVICE 12
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 3 of 12
Manual No/Rev
Return Filter with
Fixed Displacement
Pilot Controlled
Pressure
Diesel
Suction
Strainer
Vent
Valve
(On/Off)
SCHEMATIC FOR HYDRAULIC
W79-006E / 4
HYDRAFLOW S6TC Hydraulic Submersible Pump
1. INTRODUCTION
The purpose of this handbook is to lay down
operating guidelines and routine
maintenance for the HYDRAFLOW S2TC-2
hydraulic drive submersible pump.
Instructions and statements contained
within this handbook are given with our best
intentions and are correct at the time of
compilation. They are subject to alteration
at any time
The S2TC-2 pump is designed to operate
with hydraulic input flows to 19 l/m (1.14
m3/h) and a maximum pressure of 170bar
(2500psi).
Operating this unit at pressures or flows in
excess of those listed above or connecting
this unit to a closed centre or reversing
Return Filter
Wear Indicator
Operators Instructions for
1.1 Power Unit
By-Pass Valve
circuit will cause damage to the unit and will
void the warranty!
The pump Is capable of a wide range of
applications as it is not subject to normal
suction lift limitations.
The power unit should be selected to meet
the power requirements of the pump for the
pump duty.
Hydraulic circuits must be open centre,
single direction and have an unrestricted
return flow from the hydraulic motor to the
oil reservoir. Please review the hydraulic
schematic.
Pressure
System Relief
Gauge
Valve
Hydraulic
Oli Cooler
Oil Reservoir
Valved Quick
Release Hose
Connectors
Compensated
Hydraulic Pump
Engine
Oil Reservoir
TYPICAL HYDRAULIC
SUBMERSIBLE PUMPS
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Hydraulic Motor
Page 4 of 12
Operators Instructions for
HYDRAFLOW S2TC-2 Hydraulic Submersible Pump
If you are not sure if the hydraulic power
source being used to drive this pump is
properly sized or connected, call SPP
Pumps Limited.
The power unit should be located as near to
the pump location as possible. The
maximum length of hydraulic hose that may
be used without a significant reduction in
pump performance is 40m. However, by
increasing the hose diameter, performance
can be restored. Consult SPP Pumps for
more details.
The power unit is usually driven by a diesel
engine that may be mounted inside a noisereducing canopy for use in noise sensitive
areas to comply with local noise regulations.
The fuel tank should be sized to give
extended running time. The running time
will depend upon the pumping load.
The power unit should be provided with
automatic shutdown to prevent damage in
the event of low levels of engine or
hydraulic oil and high engine or hydraulic oil
temperature.
The speed of the engine should be
adjustable to suit the load on the pump,
reducing the speed for reduced demand will
increase fuel efficiency and reduce wear.
To minimise the potential harmful effects on
the environment in the event of an oil leak
or spillage, SPP Pumps recommend the
use of Biodegradable Hydraulic 46 Oil.
However, the pump will run satisfactorily on
good quality hydraulic oils of viscosity below
150SSU @ 38°C (100°F) or equivalent
specification.
NOTE – DO NOT MIX OILS
Note: When using vegetable (Rape Seed) based
biodegradable oil it is important to check
the condition of the oil frequently as it tends
to breakdown more quickly than the more
expensive mineral or synthetic
biodegradable oils.
To minimise wear and maintain pump
performance, the hydraulic oil must be
replaced regularly and the hydraulic circuit
must be fitted with a 10micron filter.
1.2 Hydraulic Hoses
The hydraulic hoses supplied for use with
this equipment are designed to prevent
incorrect connection, but if non-approved
hoses are fitted incorrectly, damage or
danger may result.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 5 of 12
Manual No/Rev
W79-006E / 4
The hoses are supplied with quick release
couplings that must be correctly fitted
before starting the pump. Due to these selfsealing couplings, the hoses will remain
filled with oil when not in use.
Damaged hoses should not be used, due to
the high pressure of the oil, a burst or leak
is hazardous, any damaged hose must be
replaced and returned to the supplier for
testing and repair before reuse.
1.3 Submersible Pumps
The S2TC-2 has a channel impeller with 2”
discharge. This pump is from a wide range
of submersible pumps to suit a variety of
pump applications.
For borehole applications use slim-line
pumps, for compact high volume
requirements use axial flow pumps, for
open water pumping use a conventional
pump with a vertical side discharge port.
To pump sewage or similar liquids with
solids or sludge content use pumps with
vortex impeller and for maximum
performance with clean water use pumps
with a channel impeller.
All pumps are driven by simple and reliable,
compact hydraulic motors and are fitted with
mechanical seals.
2. SAFETY PRECAUTIONS
2.1 Safety Symbols
Safety instructions within this manual are
marked with the following symbols:
This symbol refers to general
mechanical aspects of safety.
This symbol refers to electrical
safety.
ATTENTION
2.2 Submersible Pump Safety Precautions
2.3.1
This symbol gives warning of a
hazard to the pump itself, which in
turn could cause a risk to personal
safety.
Ensure that the hydraulic power supply is
turned OFF and disconnect the hydraulic
hoses from the pump before working on the
pump.
Manual No/Rev
Max. Oil Flow
Max. Oil Press.
Kg
W79-006E / 4
HYDRAFLOW S6TC Hydraulic Submersible Pump
Operators Instructions for
2.3.2
Check the type of liquid being pumped
before working on the pump. Residues
could be hazardous to your health. If in
doubt flush out with clean water before work
commences.
2.3.3
Personnel working on the pump unit must
always wear clean correctly fitting clothing
and safety footwear. Clothing impregnated
with oil or fuel can constitute a health
hazard through prolonged contact with the
skin and may also constitute a fire hazard.
3. TRANSPORT & STORAGE
3.1 Transport
The pump is suitable for all normal forms of
transport. When lifting use the lifting point
provided. Ensure that the unit is strapped
down securely for vehicle transport.
3.2 Storage
The pump should be stored upright in a well
ventilated, dry location. For extended
storage refer to SPP Pumps for guidance
on additional protection.
4. SERIAL NUMBER
A serial number plate is attached to the
pump unit on the top plate over the volute
casing.
This serial number must be quoted in any
enquiry for spares or service.
Serial No.
Model
L/m
Bar
Weight
5. OPERATING INSTRUCTIONS
5.1 Pump Installation
5.1.1
BEFORE attempting to operate this pump,
read the safety and operating instructions
on the power unit and in its’ handbook and
this handbook carefully.
5.1.2
Check that the power unit has been
installed correctly by reference to the
operating instructions.
5.1.3
Check the hydraulic hoses visually for
damage that may have occurred since the
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
5.1.4
NOTE – Due to the pressure of the oil retained in
5.1.5
5.1.6
5.1.7
5.1.8
5.1.9
NOTE – Do not lower or raise the pump using the
5.2 Operation
6. PUMP MAINTENANCE
6.1 Oil Specifications:
6.1.1 Hydraulic Oil:
Page 6 of 12
pump was last run, any damage noted
should be reported and the hoses replaced
before the pump is run.
Ensure that the hydraulic couplings are
clean and free from grit or dust that may
prevent a leak-proof connection or
contaminate the oil. Connect the hydraulic
suction and delivery hoses making sure that
the hydraulic couplings are properly and
securely connected.
the hoses when disconnected, it is easier to
connect hoses to the RETURN circuit first.
This will allow the pressure to decay before
connecting to the pressure circuit. Always
connect the ‘Male’ hose end connection
first.
Lay out the hoses to the pump, ensuring
that each hose is fully uncoiled and is free
from kinks. The minimum bend radius of
the hose is 300mm.
If these hoses pass over roadways, ensure
that they are protected by suitable means to
prevent damage by crushing.
Connect the hydraulic hoses to the pump
unit, ensuring that the hydraulic couplings
are properly and securely connected.
Connect a suitable pump delivery hose to
the pump outlet connection and direct the
hose to the required discharge point.
Lower the pump unit into the liquid to be
pumped, ensuring that the pump remains
upright for best performance.
hydraulic hoses, a lifting point is provided on
the pump for attachment of a shackle and
lifting chain or rope.
Refer to the operating instructions for the
power unit for starting and stopping the
pump.
SPP Pumps recommend the use of Biodegradable Hydraulic 46 Oil. However, the
pump will run satisfactorily on good quality
Operators Instructions for
new oil.
Cleaning Solvent
HYDRAFLOW S2TC-2 Hydraulic Submersible Pump
hydraulic oils of viscosity below 150SSU @
38°C (100°F) or equivalent specification.
Note: When using vegetable (Rape Seed) based
bio-degradable oil it is important to check
the condition of the oil frequently as it tends
to breakdown more quickly than the more
expensive mineral or synthetic biodegradable oils.
NOTE – DO NOT MIX OILS
6.2 Maintenance Chart
Period Maintenance Items Required
Daily Check hydraulic hoses for damage and replace as required. Spare hydraulic hoses
Check Diesel fuel level, top-up as required. Diesel Fuel
Check Hydraulic oil level, top-up as required. Hydraulic Oil
500 hours Replace hydraulic oil filter element. (10 micron filter) Oil Filter Element.
1000 hours Drain hydraulic oil, clean the reservoir tank and replace with
6.3 Pump Disassembly:
6.3.1
Remove hydraulic hoses from pump.
6.3.2
Remove four 5/16" bolts (#11) from top
cover (#10).
6.3.3
Remove top cover and motor assembly
from volute (#13).
6.3.4
Check for debris and wear in volute and
clean or replace if wear is excessive.
6.3.5
Inspect 'O' ring (#12) and replace if worn.
6.3.6
Hold impeller (#14) secure and remove lock
nut (#17) and washer (#16) from motor
shaft (Right hand threads).
6.3.7
Evenly pry impeller off of motor shaft. (This
may require use of a puller) and remove
shaft key (#15).
6.3.8
Check impeller for wear and replace if
necessary.
6.3.9
Remove 2 handle bolts (#6) and remove
handle (#2).
6.3.10
Remove 4 motor flange bolts (#6)
6.3.11
Pry motor (#8) from top cover (#10). This
will allow shaft seal to slide off.
6.3.12
Inspect shaft seal assembly (#9). Seal
should be replaced whenever maintenance
is performed.
Manual No/Rev
Look especially for a darkening in colour as
an indicator of reduced lubrication
performance or contamination and arrange
to drain the system, clean the tank and
replace with new oil.
6.1.2 Lubricating Oil:
Use clean Bio-degradable Hydraulic 46 Oil
or 20W Hydraulic Oil or Mobil 10W30
Synthetic Oil.
Hydraulic Oil (100 l)
6.3.13
Check top cover for wear and replace if
wear is extreme.
6.3.14
Do not disassemble hydraulic motor (#8). If
the hydraulic motor needs service, it should
be performed by a qualified SPP Pumps
Service Engineer or replaced.
6.4 Pump Reassembly:
6.4.1.
To re-assemble pump, attach top cover to
motor (Use light coating of silicone sealant
on motor mounting flange) install new seal;
hold shaft with screwdriver while installing
impeller; install retaining washer and screw;
6.4.2.
Install handle onto top cover.
6.4.3.
Lightly lubricate mechanical shaft seal and
install stationary seat into top cover and
rotating assembly onto motor shaft. (Be
sure to keep seal parts extremely clean and
install correctly).
6.4.4.
Install shaft key (#15) and impeller.
6.4.5.
Install retaining washer (#16) and locknut
(#17).
6.4.6.
Install 'O' ring (#12) onto top cover.
6.4.7.
Install completed drive assembly into volute
using (4) bolts (#11) and lockwashers (#7).
6.4.8.
Connect hydraulic hoses to pump (Inlet port
on motor is marked 'A'). Test run and check
for oil leakage before putting pump into
operation.
W79-006E / 4
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 7 of 12
Manual No/Rev
Clear debris from
Inlet or Strainer
Replace Layflat
Be sure Pump is
submerged initially to
Replace Motor
Replace Worn Parts
Check Vent Screw
(on some models) to
be sure it is not plugged
Lower Pump into liquid
Lay Pump on it’s side with
the discharge in 12 o’clock
Remove Layflat discharge
W79-006E / 4
HYDRAFLOW S2TC-2 Hydraulic Submersible Pump
Operators Instructions for
6.5 Pump Hose Connection:
NOTE – When the pump hose connections have
been disconnected from the hydraulic motor
it is IMPORTANT to ensure that they are
refitted correctly. The inlet port on the
motor is marked with an ‘A’ and is
normally fitted with the Female quick
release hose coupling.
7. TROUBLESHOOTING
7.1 Preliminary Check List
7.1.1.
Check the hydraulic power source to be
sure the oil flow volume and available
pressure is within the range of the
submersible pump. If the power source is
capable of supplying oil in excess of the
required flow, damage will result to the
hydraulic motor and/or pump components
due to over speeding.
7.1.2.
Be sure the submersible pump is connected
to a single direction open centre power
source. The submersible pump is not bidirectional and operating in reverse rotation
can cause seal failure in the hydraulic
motor. The system must be open centre
at all times (return flow from the
submersible pump motor must be allowed
to flow freely to the system oil reservoir).
Do not use hydraulic directional valves that
block the return flow when in the centre
position of the valve. This type of valve is
for hydraulic cylinder operation only and will
cause the submersible pump to stop
abruptly when moved to the centre position
of the valve. This will cause excessive
pressure on the return side of the motor
causing seal failure and possible shaft
damage.
7.1.3.
Be sure that the hydraulic hose connections
are clean and properly connected. When
using quick released hose couplers, you
muse be sure that they are completely
connected. A partly connected coupler will
result in seal damage to the hydraulic motor
and pump seal.
7.1.4.
Be sure that the pump is submerged
adequately. This is especially important for
vortex impeller pumps since the impeller is
recessed up into the top of the volute.
7.2 Troubleshooting Guide
Hydraulic Pressure High
(above 70 BAR - 1000PSI)
Submersible Pump
NOT Spinning
Hydraulic Motor or
Pump Bearings Seized
Replace Hydraulic Motor
or Pump Bearings
Impeller
Jammed
Remove Top Cover
and free Impeller
PUMP NOT PUMPING
Submersible Pump
Spins
Discharge Head Too
High for Pump
Discharge Hose
Kinked or Plugged
Clear Hose of obstruction
Discharge Hose with
Rigid Hose or Pipe
Hydraulic Pressure Low
(below 70 BAR - 1000PSI)
Check Hydraulic Power
Unit with Submersible
Pump disconnected to be
sure it is functioning
properly
Lack of Water in Pump
Pump Inlet Obstructed
Pump not Properly
Submerged
Oil Filler Plug on
Bearing Housing
Air Trapped in Volute
while operating
position to allow air
to escape
hose that may trap air
Hydraulic Motor Worn
Excessive Wear
on Impeller
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 8 of 12
Operators Instructions for
HYDRAFLOW S2TC-2 Hydraulic Submersible Pump
8. PUMP SECTION DRAWING AND PARTS LIST
8.1 Pump Section Drawing
1
2
Manual No/Rev
W79-006E / 4
3
4
5
6
7
9
10
12
14
15
16
17
4
5
8
6
11
7
13
19
18
20
Water Strainer
S2TC-2 Pump (Parts)
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 9 of 12
(Optional)
Manual No/Rev
7. HT0002011
Lockwasher SS (6 req.)
8. HT3802000
Hydraulic Motor
12. HT3802001
'O' Ring, Top Cover
17. HT3802007
Impeller Locking Nut SS
18. HT0000109
Socket Head Bolt (4 req.)
HT3802013
Motor Seal and Bearing Kit
W79-006E / 4
HYDRAFLOW S2TC-2 Hydraulic Submersible Pump
8.2 Parts List
Always mention serial # when ordering parts
Item Part # Description
1
2. HT3802002 Handle
3. HT0807378 Female Quick Disconnect Coupler
4. HT0209571 Hex Nipple (2 req.)
5. HT0209323 Elbow (2 req.)
6. HT0002009 Hex Bolt SS (6 req.)
9. HT3809311 Mechanical Seal Assembly
10. HT3802005
11. HT0002010 Hex Bolt SS (4 req.)
HT0807320 Male Quick Disconnect Coupler
Top Cover (Ductile Iron)
HT3802004
Top Cover (Aluminum)
Operators Instructions for
13. HT3800132
HT3800133
Volute (Ductile Iron)
Volute (Aluminum)
14. HT3802012 Channel Impeller
15. HT3802008 Shaft Key
16. HT3802006 Retaining Washer SS
19. HT3800129 Strainer (Trash Type)
20. HT3800116 Strainer (Water Type)
Accessories Not Illustrated (Optional)
HT0900117 Hydraulic hose assy. 30' x 3/8" (Pair)
HT0900118 Hydraulic hose assy. 50' x 3/8" (Pair)
HT0800119 Quick disconnect coupling set for above hoses
HT3802013 Motor Seal and Bearing Kit
HT3802014 Motor Seal Kit
HT3802015 Motor Shaft
HT3802016 4 GPM Flow Control
HT3809207 3/8" In-Line Check Valve
HT0900117 Hydraulic hose assy. 30' x 3/8" (Pair)
HT0900118 Hydraulic hose assy. 50' x 3/8" (Pair)
HT0800119 Quick disconnect coupling set for above hoses
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 10 of 12
Operators Instructions for
HYDRAFLOW S2TC-2 Hydraulic Submersible Pump
Manual No/Rev
W79-006E / 4
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 11 of 12
Manual No/Rev
W79-006E / 4
HYDRAFLOW S2TC-2 Hydraulic Submersible Pump
Operators Instructions for
9. SPARES & SERVICE
SPP Pumps operate a comprehensive Spares and Service support network throughout the world, and can be
contacted as follows:
SPARES & SERVICE Telephone: +44 (0)118 932 3123
For spare parts, supply only. ask for - Spares Dept.
For breakdowns, spare parts and on-site fitting, pump installation and
commissioning, and service contracts. ask for - Service Dept.
For breakdowns outside office hours. Telephone : + 44 (0)118 930 3259
Spares & Service Office
SPP Pumps Limited General Fax line: + 44 (0)118 930 3259
1420 Lakeview
Arlington Business Park
Reading, Berkshire, RG7 4SA Direct Fax line: +44 (0)118 932 3123
Copies of this manual are available from the SPP Pumps Spares & Service Department by quoting reference
number W79-006E and the relevant issue number.
Our policy is one of continuous improvement and we reserve the right to alter specifications at any time
Page 12 of 12
Loading...