How it Works
Xylem
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IM157
User Manual [en, es, fr]
36 pgs927.97 Kb0

Xylem IM157 User Manual [en, es, fr]

INSTRUCTION MANUAL
IM157
Model MPVN
COVERS PUMP SIZES: 40.2, 40.3, 65.1, 65.2, 100.1, 100.2, 125.1, 125.2
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
TABLE OF CONTENTS
SUBJECTS PAGE
1. General ......................................................................3
1.1 Foreword ..................................................................3
1.2 Guarantee ................................................................3
1.3 Safety Regulations ....................................................3
1.4 Safety instructions ....................................................3
2. DESCRIPTION .........................................................4
2.1 Model ......................................................................4
2.2 Shaft Sealing .............................................................4
2.3 Bearings and Lubrication .........................................4
3. TRANSPORT, HANDLING, STORAGE ...................5
3.1 Transport, handling ..................................................5
3.2 Storage .....................................................................5
4. INSTALLATION, OPERATION ...............................5
4.1 Assembly and connection of pump ...........................5
4.2 Installation and Alignment of Coupling ...................5
4.3 Connecting the Pipes to the Pump ............................6
4.4 Electrical Connection ...............................................6
4.5 Starting Up ...............................................................7
Putting into operation again (after longer standstill;
4.6 Operation and Monitoring .......................................7
4.7 Shutting Down .........................................................7
4.8 Dismantling ..............................................................8
5. MAINTENANCE, SERVICING ................................8
6. LONGER PERIODS OF NON-OPERATION ............8
6.1 Drained pumps .........................................................8
6.2 Filled pumps .............................................................8
7. FAULTS – CAUSES AND SOLUTIONS ....................9
8. REPAIRS ..................................................................10
9. SPARE PARTS, SPARE PUMPS ................................10
9.1 Spare Parts .............................................................10
9.2 Stand-by pumps .....................................................10
10. PLANT MANAGER LIST .....................................11
11. LOG BOOK ...........................................................11
2
1. GENERAL
1.1 Foreword
The staff employed on installation, operation, inspection and maintenance must be able to prove that they know about the relevant
accident prevention regulations and that they are suitably qualified for this work. If staff do not have the relevant knowledge, they should be provided with suitable instruction.
The operating safety of the pumps or units (i.e. pump plus motor) supplied is only guaranteed if these are used in accordance with the provisions in “Installation and Operation”.
The operator is responsible for following the instructions and complying with the safety requirements given in these Operating Instructions.
Smooth operation of the pump or pump unit can only be achieved if installation and maintenance are carried out carefully in accordance with the rules generally applied in the fields of engineering and electrical engineering.
If not all the information can be found in these Operating Instructions, please contact us.
The manufacturer takes no responsibility for the pump or pump unit if the Operating Instructions are not followed.
These Operating Instructions should be kept in a safe place for future use.
If this pump or pump unit is handed on to any third party, it is essential that these Operating Instructions and the operating conditions and working limits given in the Confirmation of Order are also passed on in full.
These Operating Instructions do not take into account all design details and variants nor all the possible chance occurrences and events which might happen during installation, operation and maintenance.
Alterations or changes to the machine are only permitted by agreement with the manufacturer. Original spare parts and accessories authorized by the manufacturer should be used for greater safety. We bear no responsibility for the consequences of using other parts.
We retain all copyright in these Operating Instructions; they are intended only for personal use by the owner of the pump or the pump unit. The Operating Instructions contain technical instructions and drawings which may not, as a whole or in part, be reproduced, distributed or used in any unauthorized way for competitive purposes or passed on to others.
1.2 Guarantee
The guarantee is given in accordance with our Conditions of Delivery and/or the confirmation of order. Repair work during the guarantee period may only be carried out by our authorized distributor. Otherwise the guarantee ceases to apply.
The guarantee shall not cover natural wear and tear and all parts subject to wear, such as impellers, shaft sealings, shafts, shaft sleeves, bearings, wear rings etc., or damage caused by transport or improper handling. In order for the guarantee to apply, it is essential that the pump or pump unit is used in accordance with the operating conditions given on the type plate, confirmation of order and in the Data Sheet. This applies particularly for the endurance of the materials and smooth running of the pump and shaft sealing.
If one or more aspects of the actual operating conditions are different, we should be asked to confirm in writing that the pump is suitable.
1.3 Safety Regulations
These Operating Instructions contain important instructions which must be followed when the pump is assembled and commissioned and during operating and maintenance. For this reason, these Operating Instructions must be read by the skilled staff responsible and/or by the operator of the plant before it is installed and commissioned, and they must be left permanently ready to hand at the place where the pump or pump unit is in use. The operator must ensure that the contents of the Operating Instructions are fully understood by the staff. The operator must confirm this by signing the “Plant Manager List” (see Point 10). These Operating Instructions do not refer to the General Regulations on Accident Prevention or local safety and/or operating regulations. The operator is responsible for complying with these (if necessary by calling in additional installation staff).
The safety instructions contained in these Operating Instructions have the following special safety markings.
Warning against personal accidents which could occur if the safety instructions given in this part of the Operating Instructions are not followed.
WARNING
Hazardous voltage
ATTENTION: WARNING AGAINST POSSIBLE DAMAGE TO PROPERTY OR THE ENVIRONMENT.
It is absolutely essential that safety information affixed directly to the pump ot pump unit is followed and maintained so that it is always easily legible.
1.4 Safety Instructions Dangers of not following safety instructions
Failure to follow the safety instructions can result in the following, for example:
• People being at risk because of electrical, mechanical
and chemical factors.
• Important functions of the pump or pump unit failing.
• Dangers to the environment.
Safety instruction for the operator
• Depending on the operating conditions, wear and
tear, corrosion or age will limit the working life of the pump/pump unit, and its specified characteristics. The operator must ensure that regular inspection and maintenance are carried out so that all parts are replaced in good time which would otherwise endanger the safe operation of the system. If abnormal operation or any damage are observed, the pump must cease operation immediately.
• If the breakdown or failure of any system or unit could
lead to people being hurt or property being damaged, such system or unit must be provided with alarm devices and/or spare modules, and they should be tested regularly to ensure that they function properly.
Warning against dangerous electrical voltage.
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• If there is any risk of injury from hot or cold machine
parts, these parts must be protected against contact by the user, or suitable warning signs must be affixed.
• Contact protection on moving parts (e.g. Coupling
guards) must not be removed from systems that are in operation.
• If dangerous media (e.g. explosive, toxic, hot) leak out
(e.g. from shaft seals), these must be directed away so that there is no danger to people or the environment. The provisions of the law must be observed.
• Measures should be taken to exclude any danger from
electricity (e.g. by complying with the local regulations on electrical equipment). If work is carried out on live electrical components, they should be unplugged from the mains or the main switch turned off and fuse unscrewed. A motor protection switch is to be provided.
• Basically, all work on the pump or pump unit should
only be carried out when the pump is stationary and not under pressure. All parts must be allowed to return to ambient temperature. Make sure that no one can start the motor during such work. It is essential that the procedure for stopping the system described in the Operating Instructions is observed. Pumps or pump systems that carry media that are dangerous to health must be decontaminated before being taken apart. See Safety Data Sheets for the various liquids handled. After the work has been completed, all safety and protective devices must be replaced or restarted.
Speed, Pressure, Temperature
Suitable safety measures must be taken at the plant to ensure that the speed, pressure and temperature of the pump and the shaft sealing do not exceed the limit values given in the Data Sheet. The given suction pressures must also be sufficiently high. In addition, the pump must be protected against pressure surges such as can be caused by switching off the plant quickly (e.g. by non-return valve on the pressure side, flywheel, air vessel).
Permitted Forces on Flanges
Basically, the suction and pressure lines should be such that the forces on the pump are kept to a minimum. If this is not feasible, contact your distributor for limits.
NPSH
When entering the impeller, the liquid being handled must have a minimum pressure NPSH to prevent cavitation or breaking off of flow. This requirement is met if the unit NPSH value (NPSHA) is well above the pump NPSH value (NPSHR) under all operating conditions.
Attention must be paid to the NPSH value in particular when liquids close to boiling point are being handled. If the value falls below the pump NPSHR value, this can lead to damage resulting from cavitation or serious damage from overheating.
The NPSHR for each pump type is given in the sheets of characteristic curves. We can supply leaflets for calculation of NPSH values on request.
Sealing, Flushing, Cooling
Suitable facilities for the regulation and monitoring of sealing, flushing or cooling are to be provided. When handling dangerous liquids or if temperatures are high, care should be taken to ensure that the pump ceases operating if the sealing, flushing or cooling system fails.
Sealing, flushing and cooling systems must always be operational before the pump is started up. They should not be taken out of operation until the pump has stopped, provided that he nature of the operation allows this at all.
Minimum Flows
If the pump is started against a closed pressure line valve, it should be noted that the power taken up by the pump is transmitted to the liquid handled in the form of heat. This can cause the liquid to heat up excessively within a relatively short time, which will then cause damage to the pump’s internal fittings. After the pump has reached operating speed, the discharge valve should therefore be opened as quickly as possible. If operating conditions mean that Q = 0 is unavoidable, or if hot water is circulating, a free flow non-return valve, or, on smaller systems, a by-pass pipe, should be provided. Your distributor can help in determining the minimum flow or designing the by-pass line.
Protection against Running Dry
The pumps must not run dry under any circumstances, since overheating can damage pump components (e.g. mechanical seals).
Back Flow
In systems where pumps are operating in closed circuits under pressure (gas cushions, steam pressure), the pressure of the gas cushion must not be reduced via the pump, since the back flow speed may be much higher than the operating speed, which would destroy the unit.
2. DESCRIPTION
2.1 Model Design MPVN
Design Features:
• Vertical conguration with separate thrust bearing,
grease lubrication with grease nipples.
• Motors according NEMA-Standard MG 1-4.07.
• Flexible coupling between pump and motor.
• Medium lubricated sleeve bearing in suction casing.
• Maintenance friendly design. Shaft sealing maintainable
without pump disassembly.
Installation Position
Shaft vertical. Other installation positions only by agreement.
2.2 Shaft Sealing
Basic design with mechanical seal. Seal code SA with unbalanced seal; seal code SB with balanced seal.
ATTENTION: YOU WILL FIND MORE INFORMATION ABOUT MECHANICAL SEALS, AND THE RISKS OF ACCIDENTS THAT THESE MAY INVOLVE, UNDER POINT 4.6 “OPERATION AND MONITORING” AND IN POINT 5 “MAINTENANCE AND REPAIRS’.
2.3 Bearings and Lubrication Drive Side: re-lubricatable roller bearings (thrust
bearing). Pump Side: medium-lubricated sleeve bearing in the
suction casing.
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Lubrication of Roller Bearings
Standard: grease lubrication with grease nipples. Grease lubricants to be of Lithium Base Grade 2. The bearings are already filled with grease and are thus
ready for use.
Bearing Types (roller bearings)
Bearing
MPVN 40.2 / MPVN 40.3 B306-C3 MPVN 65.2 / MPVN 65.2 B307-C3 MPVN 100.1 / MPVN 100.2 2 x 7308 (X-arrangement) MPVN 125.1 / MPVN 125.2 2 x 7310 (X-arrangement)
Pump Size
Grease Lubricated
Interval of re-lubrication / grease quantity
Grease Interval of re-lubrication in operating hrs Pump Size Qty. [oz.]
MPVN 40.2 / MPVN 40.3 0.41 3800 4300 5500 6000 6500 MPVN 65.1 / MPVN 65.2 0.53 3500 4000 5000 5500 6000 MPVN 100.1 / MPVN 100.2 0.78 3300 3800 4500 5000 5500 MPVN 125.1 / MPVN 125.2 1.12 2500 3300 4300 4800 5000
3550 2950 2200 1750 1450
3. TRANSPORT, HANDLING, STORAGE
3.1 Transport, Handling
• Check the pump/pump unit immediately
upon delivery/receipt of shipment for damage or missing parts.
• The pump/pump unit must be transported
carefully and by competent personnel. Avoid serious impacts.
• Keep the pump/pump unit in the same
position in which it was supplied from the factory. Take note of the instructions on the packaging.
• The intake and discharge side of the pump
must be closed with plugs during transport and storage.
ATTENTION: DISPOSE OF ALL PACKING MATERIALS IN ACCORDANCE WITH LOCAL REGULATIONS.
• Lifting devices (e.g. fork-lift truck, crane, crane device,
pulleys, sling ropes, etc.) must be sufficiently strong.
• The pump/pump unit may only be lifted by solid
points such as the casing, flanges or frame. The illustration above shows the correct method of carrying by crane.
Do not stand underneath suspended loads; take
note of the general regulations on prevention of
accidents. The pump/pump unit must be secured against tipping
over and slipping until it has been fixed in its final location.
3.2 Storage
Pump or pump units that are stored for a long time before use must be protected against moisture, vibrations and dirt (e.g. by wrapping in oil paper or plastic sheeting). Pumps must basically be stored in a place where they are protected from the weather, e.g. under cover. During this time, all suction and discharge branches and all other intakes and outlets must be closed with dummy flanges or plugs.
Preservation
On storing the pump longer than 3 months (depends on order): Special preservation has been used for shipment prep. The product used for that must be removed from the unit before the first normal operation.
4. INSTALLATION, OPERATION
4.1 Assembly and Connection of Pump
MPVN type pumps must be bolted to a xed subframe
(e.g. concrete foundation, steel plate, steel beam, etc.). The subframe must withstand all loads that arise during operation. The size of the subframe and the location and size of the recesses for the foundation anchors are given in the dimension drawing, which is binding.
ATTENTION: SUFFICIENT SPACE MUST BE PROVIDED FOR MAINTENANCE AND REPAIR WORK, ESPECIALLY FOR REPLACING THE DRIVE MOTOR OR THE COMPLETE PUMP UNIT. THE MOTOR FAN
MUST BE ABLE TO TAKE IN
ENOUGH COOL AIR, AND THE
INTAKE GRILLE MUST THEREFORE
BE AT LEAST 10 CM AWAY FROM ANY WALL, ETC.
To prevent vibrations being transmitted to adjoining components, the foundation should be laid on a suitable insulating base (panels providing insulation against structure-borne sound or vibration panels).
ATTENTION: THE SIZE OF THESE INSULATING PANELS WILL VARY, DEPENDING ON CIRCUMSTANCES, AND SHOULD THEREFORE BE DETERMINED BY AN EXPERIENCED SPECIALIST.
Concrete foundations must be completely set and the surfaces must be smooth before the pump unit is mounted. Put pump unit onto the foundation and, if necessary, level vertically with the help of thin sheet-metal panels (with spirit level). Tighten foundation anchor evenly and firmly.
The alignment must be carried out with the utmost care and attention, so that the unit will operate without failure. If you do not pay attention to this hint you will lose your warranty!
4.2 Installation and Alignment of Coupling
Make sure that nobody can start the motor when work is being carried out on the coupling. In accordance with the Accident Prevention Regulations, the pump unit may
only be operated when the coupling guard is mounted.
• Before starting installation, carefully clean shaft ends
and coupling components.
• Pull coupling hub onto motor shaft end. The coupling
may be heated beforehand in an oil bath to approx. 100°C. The motor hub will need to be mounted flush to the motor shaft.
• The motor coupling hub will have an interference t
and the pump coupling hub will have a clearance fit. The clearance allows the pump hub to be adjusted on
the pump shaft. Keep pump hub loose for adjusting the
elastomer element.
• Place half of the coupling elastomer element around
the hubs and secure with self-locking capscrews.
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• The elastomer element will space the pump hub. Now
secure the pump hub to the shaft.
• Mount other half of the elastomer element. Tighten all
capscrews to recommended torques.
• Mount coupling guard.
Capscrew Torques
Recommended Capscrew Torques Coupling Torque – Dry Size In. lbs. Ft. lbs.
2 3 4 204 17 5 10
20 30 360 30 40
Capscrews can be further used
50 60
70 900 75 80
100 3240 270 120
140 7080 590
IMPORTANT
Capscrews have self-locking
patches which should not
be reused more than twice.
with applications of a thread-
locking adhesive.
Do Not Lubricate Capscrew
Threads.
Equipment Alignment
(coupling alignment is directly related to equipment and coupling life.)
Although Omega couplings can withstand gross misalignment, care should be taken for best possible alignment to assure optimum performance. The caliper/straightedge alignment procedure is described below. If greater alignment accuracy is desired, a dial indicator method is recommended. There are occasions when equipment manufacturers require more specific alignment tolerances, in which case, the manufacturer’s recommendations should be followed.
• To correct for angular misalignment, use calipers to
check the gap between hubs. Adjust or shim equipment until the gap is the same at all points around the hubs.
• To correct parallel offset, place a straightedge across
the hub flanges in two places at 90° to each other. Adjust or shim equipment until the straightedge lays flat on both sides.
• Tighten down connected equipment and recheck
alignment.
• Install elastomer element, tightening all capscrews to
the values shown in table.
• If practical, recheck and tighten capscrews after several
hours of operation.
PARALLEL OFFSET
ADJUST FOR ANGULAR MISALIGNMENT ADJUST FOR PARALLEL OFFSET
4.3 Connecting the Pipes to the Pump Suction and Discharge Pipe
• The pipes must be of a size and design that liquid can
flow freely into the pump and that the pump functions without problems. Particular attention is to be paid to ensuring that suction pipes are airtight and that the NPSH values are observed. Lay the suction pipe in the horizontal section towards the pump so that it is slightly inclined upwards so that no air pockets occur. In most cases, it is recommended that a non-return valve is installed in the discharge pipe shortly after the pump.
• When laying the pipes, make sure that the pump is
accessible for maintenance and installation.
• Please note 1.4: “Permitted Forces on Flanges”.
• Before connecting up to pump: remove protective
coverings from suction and discharge branches.
• To protect the shaft sealing (especially mechanical seals)
against foreign bodies, it is recommended that a sieve, 800 micron, is installed in the suction/intake pipe when the motor is being started up.
• Before starting up, the pipe system, ttings and
equipment must be cleaned to remove weld spatter, scale etc. Any pollutants are to be completely removed from pump units that are directly or indirectly connected to drinking water systems before being installed and taken into use.
• If the pipe system is tested with the pump installed, do
not exceed the maximum permitted casing pressure of the pump and/or shaft sealing (see Data Sheet).
• When emptying the pipe after the pressure test, make
sure that the pump is treated properly (danger of rust and problems when starting up).
• In the case of pumps with stufng boxes, replace
packing after pressure test (packing may be over­compressed and thus no longer suitable for use).
Auxiliary Pipes
Any sealing, flushing or cooling pipe connections that are necessary must be installed. Please consult the Data Sheet to see which pipes, pressures and quantities are necessary.
The relevant detail drawing of the shaft sealing contains a diagrammatic proposal for the pipework and fittings. This proposal does not take into account the safety requirements for each specific pump unit.
ATTENTION: POINT 1.4, “SEALING, COOLING” MUST BE OBSERVED AS REGARDS REGULATION AND MONITORING.
It is recommended that a pipeline is installed to take off any leakage from the shaft seal. For connection, see the Dimension Sheet.
4.4 Electrical Connection
WARNING
Hazardous voltage
Electrical connection work may only be carried out by an authorized professional. The rules and regulations valid for electrical technology, especially those concerned with safety measures, must be observed. The regulations of the power supply companies operating in that area must also be observed.
Before starting work, check that the information on the motor rating plate is the same as the local mains network. The power supply cable of the coupled drive motor must be connected up in accordance with the wiring diagram produced by the motor manufacturer. A protective motor switch is to be provided.
ATTENTION: THE DIRECTION OF ROTATION SHOULD ONLY BE CHECKED WHEN THE PUMP IS FULL. DRY RUNNING WILL CAUSE DAMAGE TO THE PUMP.
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4.5 Starting Up
The plant may only be started up by people who are familiar with the local safety regulations and with these Operating Instructions (especially with the safety regulations and safety instruction
given here). In order to be able to observe and monitor the shaft sealing,
no protective covering is provided in this area. If the pump is running, particular care should therefore be taken (watch out for long hair, loose pieces of clothing etc.).
Hints for the Use as Boiler Feed Pump
Limits for cast iron when used in boiler feed or condensate applications: pH-value 9,0 (optimum 9,3), short term: pH-value 8,5.
The above stated values must be guaranteed at the suction side of the pump in any case.
The water treatment must be in accordance with the specifications for water treatment of boiler feed water in steam plants up to 64 bar.
Air traps in the system must be avoided in any case.
Starting up for the First Time
• With MPV type pumps, no further lubrication is needed
before initial start-up.
• Pump and suction pipe must be completely exhausted
from air and filled with handling liquid before each start up of the pump unit. When filling the pump open screwed plug “PM2”. Close it when water is flowing out.
• Open slide valve in suction/intake pipe.
• Turn pump unit once again by hand and check that it
moves smoothly and evenly.
• Check that coupling guard is installed and that all safety
devices are operational.
• Switch on any sealing, ushing or cooling devices that are
provided. See Data Sheet for hydraulic requirements.
• Set discharge side slide valve to approx. 25% of rated
flow quantity. With pumps with a discharge branch rated width less than 200 GPM, the slide valve can remain closed when starting up (see also Point 1.4 “Minimum Quantities”.
• Check direction of rotation by switching on and off
briefly. It must be the same as the directional arrow on the bearing frame.
• Start drive device.
• As soon as it reaches normal operating speed, open
discharge valve immediately and adjust the required operating point (see Data Sheet).
• Mechanical seals don’t need to be maintained and are
almost free of leakage.
Putting into Operation Again (after longer standstill; 1 month)
Each time you put the pump into operation again you have to do the same things you do when starting the pump for the first time. The control of the rotation direction of the unit can be dropped. You are only allowed to put the pump into operation again automatically when the pump remained filled with liquid during standstill and the required test drives have been made, see point 4.7.
4.6 Operation and Monitoring
Be particularly careful not to touch hot machine
parts and when working in the unprotected
shaft seal area. Remember that automatically
controlled systems may switch themselves on
suddenly at any time. Suitable warning signs should be affixed.
ATTENTION: REGULAR MONITORING AND MAINTENANCE WILL EXTEND THE LIFE OF YOUR PUMP OR PUMP SYSTEM.
• You must observe the area of application given on the
Data Sheet.
• Do not exceed the output given on the motor rating
plate.
• Avoid dry running, running against closed discharge
valves or operation while the liquid handled is in the vapor phase.
• Avoid sudden changes in temperature (temperature
shocks).
• The pump and motor should run evenly and without
vibrations; check at least once a week.
• Check the regulating and monitoring facilities of any
sealing, flushing or cooling systems once a week to ensure that they function properly. Outgoing cooling water should be body temperature.
• Pumps which are exposed to corrosive chemicals or to
wear through abrasion must be inspected periodically for corrosion or wear and tear. The first inspection should be carried out after six months. All further inspection intervals should be determined on the basis of the state of the pump.
Permitted Number of Starts
Do not exceed the pump’s permitted number of starts – see diagram. With electric motors, the permitted number of starts is given in the motor operating instructions. If two different figures are given, the lower figure is valid.
4.7 Shutting Down
• Close slide valve in discharge pipe. This is not necessary
if there is a spring-loaded non-return valve.
• Switch off motor (make sure it runs down quietly.
• Close slide valve on suction side.
• Close auxiliary systems. Do not shut down cooling
system until pump has cooled down.
• If there is any risk of freezing, empty pump, cooling
system and pipes completely.
• If the pump also remains under operating conditions
(pressure and temperature) when stationary: leave all sealing, flushing and cooling systems switched on.
• If the pump remains under operating conditions when
stationary, test drives have to be made in regular intervals with a duration of at least 5 minutes. The intervals
7
between the test drives depend on the unit, but they should be made at least once a week.
4.8 Dismantling
The operator’s or manufacturer’s fitters
should be informed as to the nature of the
liquid handled. In the case of pumps handling
dangerous liquids, the liquid handled should be disposed of by environmentally acceptable means before the pump is dismantled.
• Before starting to disassemble the pump unit make sure
that it cannot be switched on again.
• The pump casing must be depressurized and empty.
• All valves in the suction, intake and discharge pipes
must be closed.
• All components must have cooled down to ambient
temperature.
• To avoid corrosion it is recommended to ush the
pump and fill it with a water-repellant preservative,
e.g. KLÜBERTOP K01.601 or equal.
• To spread the preservative turn the pump several times
with the hand. Then drain the pump and lock the nozzles.
5. MAINTENANCE, SERVICING
Work should only be carried out on the pump or pump unit when it is not in operation. You must observe Point 1.4 “Safety Instructions”.
ATTENTION: MAINTENANCE AND SERVICING WORK MUST ONLY BE CARRIED OUT BY TRAINED, EXPERIENCED STAFF WHO ARE FAMILIAR WITH THE CONTENTS OF THESE OPERATING INSTRUCTIONS, OR BY THE DISTRIBUTOR’S OWN SERVICE STAFF. THE WORK CARRIED OUT MUST BE DULY ENTERED IN THE “LOG BOOK” (SEE POINT 11) AND CONFIRMED BY BEING SIGNED.
Mechanical Seals
Before opening the pump, it is essential that you note Point 1.4 “Safety Instructions”, Point
4.8 “Dismantling” and Point 8 “Repairs”.
Mechanical seals do not need to be maintained and are completely free of leakage. Pumps with mechanical seals must only be operated when completely filled and without air locks (or air pockets). The seal casing where the mechanical seal is located must always be filled with the sealing liquid. If the liquid being handled drips out at the mechanical seal, it is damaged and must be replaced.
When installing the mechanical seal, make sure that the seal cavity is absolutely clean, particular care has to be paid to the surface of the seal rings. To facilitate the slip-on of the rotating components of the seal onto the shaft, lubricate all moving components and sliding areas by means of water, soapy water or soft soap. Use mineral oils only in case all elastomers are oil resistant. Do not lubricate the surface of the seal rings. Do not force elastomeric elements over sharp edges, if necessary use assembling aiding sleeves.
Lubrication of Bearing
• Intervals of re-lubrication/grease quantities (see point
2.3 “bearing and lubrication”).
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• If the pump is left non-operational for any length of
time, the grease in the bearings should be changed after 2 years.
Coupling
When inspecting the element, look for fatigue cracks (over ½") originating near the stress relief grooves (approximately ¼" – ½" above the metal shoe), discoloration (a darker faded orange color signals possible material degradation) or surface cracking if used in adverse conditions such as cooling towers or severe environments (pH < 4 or pH > 10).
In critical applications, the probability of unexpected downtime can be greatly diminished by scheduling flexible element replacement at regular intervals. The frequency of replacement will depend upon the severity of the application and environmental conditions. A properly sized element which is stored and operated
under normal conditions (i.e. under 85% humidity and
85°F) should obtain a minimum of 6 to 8 years of service life after the date of manufacture. A production date sticker is applied to all elements for ease of inspection (I.E. 3Q93 indicates Third Quarter 1993 production).
After the coupling has been in operation for some time, a “torsional set” may develop in the flex element (up to
1
⁄4" on a size E40, even more on larger sizes). This does not affect the performance of the coupling, as it is simply the material creeping under the applied stress. A very large torsional set may suggest a sizing problem and will warrant a close review of the application and coupling selection parameters. For ease of assembly/disassembly, elements should be re-installed in the same “position of rotation” in which they were removed.
INSPECT
HERE
Cleaning the Pump
Dirt on the outside of the pump has an adverse effect on transmission of heat. The pump should therefore be cleaned with water at regular intervals (depending on the degree of dirt).
ATTENTION: THE PUMP SHOULD NOT BE CLEANED WITH PRESSURIZED WATER – WATER WILL GET INTO THE BEARINGS AND INTO THE MOTOR.
6. LONGER PERIODS OF NON-OPERATION
6.1 Drained Pumps
• Turn by hand at least 1 x week (do not switch on because
of dry running).
• If necessary, unblock by tapping gently on the coupling in
axial direction.
• Change the grease in the bearings after 2 years.
• Replace bearings after 5 years.
6.2 Filled Pumps
• Switch stand-by pumps on and immediately off again
once a week.
• If the stand-by pump is at operating pressure and
temperature:
• Change the grease in the bearings after 2 years.
• Replace bearings after 5 years.
7. FAULTS – CAUSES AND SOLUTIONS
The following notes on causes of faults and how to repair them are intended as an aid to recognizing the problem. The distributor’s Customer Service Department is available to help repair faults that the operator cannot or does not want to repair. If the operator repairs or changes the pump, the design data on the Data Sheet and Points 1.2 – 1.4 of these Operating Instructions should be particularly taken into account. If necessary, the written agreement of the distributor must be obtained.
FAULTS
DISCHARGE TOO LOW Code no. 1, 4, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15
DISCHARGE STOPS AFTER A TIME Code no. 8, 10, 11, 12, 30 HEAD TOO LOW Code no. 2, 4, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 30, 34
HEAD TOO HIGH Code no. 3, 5, 34
DRIVE MECHANISM OVERLOADED
Code no. 2, 3, 5, 15, 25, 27 PUMP NOT RUNNING QUIETLY
Code no. 7, 10, 14, 22, 23, 24, 25, 29, 30, 33 TEMPERATURE IN THE PUMP TOO HIGH
Code no. 7, 10, 30 TEMPERATURE IN THE SHAFT SEALING TOO
HIGH Code no. 18, 19, 21 TEMPERATURE AT THE BEARING TOO HIGH
Code no. 2, 14, 23, 24, 25, 26, 29, 31, 32
PUMP LEAKING
Code no. 25, 28
LEAKAGE RATE AT SHAFT SEALING TOO HIGH
Code no. 19, 21, 22, 25
MEANING OF CODE NUMBER FOR CAUSE AND METHOD OF REPAIR
1. Back-pressure too high
• open discharge valve further
• reduce resistance in discharge pipe (e.g. clean lter if
necessary)
• Use larger impeller (note available motor power)
2. Back-pressure too low, discharge too low
• throttle discharge valve
3. Speed too high
• reduce speed
• compare speed of motor with specied pump speed
(rating plate)
• when adjusting speed (frequency transformer) check
reference value setting
4. Speed too low
• increase speed (check available motor power)
•compare speed of motor with specied pump speed
(rating plate)
• when adjusting speed (frequency transformer) check
reference value settings
5. Impeller diameter too large
• use smaller impeller
6. Impeller diameter too small
• use larger impeller (check available motor power)
7. Pump and/or pipes not completely filled with liquid
• ll
• vent
8. Pump or suction/intake pipe blocked
• clean
9. Air pocket in pipeline
• vent
• improve course of pipe
10. NPSH of system too small
• increase liquid level
• increase admission pressure
• reduce resistance in the intake/suction pipe (change
course and rated width, open shutoff valves, clean filters)
11. Air being sucked in
• increase liquid level
• check suction pipe is vacuum-tight
• provide straightening vanes in suction pipe ttings with
water seal
12. Air being sucked in through shaft sealing
• clean sealing pipe
• increase sealing pressure
• replace shaft sealing
13. Direction of rotation is wrong
• swap over two phases of power supply (to be done by
a specialist electrician)
14. Inner components suffering from wear
• replace worn parts
15. Density and/or viscosity of liquid handled is too high
• seek assistance
16. Shaft sealing worn
• check sealing, ushing and cooling pipes (pressure)
• avoid dry running
17. Lines and roughness on shaft or shaft sleeve
• replace parts
18. Deposits on mechanical seal
• clean
• replace mechanical seal if necessary
• if necessary provide additional rinsing or quench
19. Impeller out of balance
• remove blocks/deposits
• replace if broken or unevenly worn
• check shafts to ensure that they are running true
20. Coupling not aligned
• align pump unit better
21. Coupling distance too small
• change
22. Forces in pipeline too high (pump unit under strain)
• change (support pipes, use copensators, etc.)
• is foundation plate/frame properly cast in place?
23. Too much, too little or the wrong type of lubricant
• change
24. Electricity supply not right
• check voltage of all phases (2-phase running)
• check cable connections
• check fuses
25. Sealing insufficient
• tighten screws
• replace sealing
26. Bearing damaged
• replace
• check lubricant and bearing cavity for pollutants (clean
grease cavity if needed)
27. Discharge too small
• increase min. amount carried (open slide valves, bypass)
28. Discharge too high
• reduce amount carried (throttle slide valve)
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29. Relief fittings insufficient
• clean balance in impeller
• replace worn parts (impeller, split rings)
• adjust in line with the system pressure/intake
pressure given on ordering
30. System-related vibrations (resonance)
• seek assistance
31. Flow indicator wrong
• check owmeter
• get rid of blockages
• put owmeter in suitable place (no ow distortion
or burbling)
8. REPAIRS
Repairs to the pump or pump system may only be carried out by authorized skilled personnel or by the distributor’s specialist staff.
Trained Customer Service engineers are available to assist with installation and repair work on request. When removing the pump, you must comply with Point 1.4 “Safety Instructions”, Point 3.1 “Transport, Handling” and Point 4.8 “Dismantling”.
9. SPARE PARTS, SPARE PUMPS
9.1 Spare Parts
Spare parts should be selected to last for two-years continuous operation. If no other guidelines are applicable, we recommend that you stock the number of parts listed below.
ATTENTION: TO ENSURE OPTIMUM AVAILABILITY, WE RECOMMEND THAT SUITABLE QUANTITIES OF SPARE PARTS ARE HELD IN STOCK, ESPECIALLY IF THESE ARE MADE FROM SPECIAL MATERIALS AND IN THE CASE OF MECHANICAL SEALS, BECAUSE OF THE LONGER DELIVERY TIMES.
Ordering Spare Parts
When ordering spare parts, please supply the following information:
Pump Type: Pump Order No. Part Designation in sectional drawing All the information is given in the Data Sheet and the
relevant sectional drawing.
9.2 Stand-By Pumps
It is essential that a sufficient number of stand­by pumps are kept ready for use in plants where failure of a pump could endanger human life or
cause damage to property or high costs. Regular checks should be carried out to ensure that such pumps are always ready for use (see Point 6.2).
Number of Pumps (including stand-by pumps) 2 3 4 5 6/7 8/9 10+
Spare Part Number of Spare Parts
Impeller i i i 2i 2i 3i 30% Diffuser i/2 i/2 i/2 i i 3i/2 15% Shaft with key and shaft screws/nuts 1 1 2 2 2 3 30% Bearing (roller bearing) 1 1 2 2 2 3 30% Shaft sleeve 2 2 2 3 3 4 50% Joints for Pump Casing – sets 4 6 8 8 9 12 150% Other joints†– sets 4 6 8 8 9 10 100% Mechanical seal 2 3 4 5 6 7 90% i = no. of stages
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10. PLANT MANAGER LIST
Each plant manager should sign below to confirm that he has received, read and understood these Operating Instructions. He undertakes to follow the instructions conscientiously. If these instructions are not followed, the manufacturer’s guarantee and liability shall cease to apply.
Name: Date: Signature:
11. LOG BOOK
Each plant operator shall duly enter all maintenance and service work that has been carried out, and shall see that the person responsible confirms such work by signing below.
Plant Operator Person Responsible
Maintenance Work Date
Signature Confirmed By
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