Xylem LCP User Manual
VOGEL-Volute Casing Pumps
Installation, Operation and Maintenance Instruction
en
Model: LS, LC, LCP
Translation of the Original Operation Manual
Keep for further use !
en
Pay attention to this operating instruction before the delivery, installation, start-up a.s.o.!
Artikel Nr. 25-4265105 Rev. 02 01/2010
Xylem Water Solutions Austria GmbH
Ernst Vogel-Straße 2
A-2000 Stockerau
Telefon: +43 (0) 2266 / 604
Fax: +43 (0) 2266 / 65311
E-Mail:
Internet: www.xylemaustria.com
info.austria@xyleminc.com
Installation, Operating and Maintenance Instruction
TABLE of CONTENTS
Pump Name Plate ..................................................... 2
ATEX-Label (only for pumps in compliance with
EC directive 94/9/EG) ................................................ 2
1. General................................................................... 3
1.1 Guarantee ......................................................... 3
2. Safety Regulations ............................................... 3
2.1 Marking of References in the Operating
Instructions .............................................................. 3
2.2 Dangers of non-observance of the Safety
Instructions .............................................................. 4
2.3 Safety Instructions for the Operator / Worker ... 4
2.4 Safety Instructions for Maintenance, Inspections
and Mounting Work ................................................. 4
2.5 Unauthorized Alteration and Spare Parts
Production ............................................................... 4
2.6 Undue Operation ............................................... 4
2.7 Explosion Protection.......................................... 4
2.8 Use acc. to Regulations .................................... 6
3. Description ............................................................ 6
3.1 Design ............................................................... 6
3.2 Shaft Sealing ..................................................... 7
3.3 Bearings ............................................................ 7
3.4 Approximate Value for Sound Pressure Level .. 8
3.5 Permitted Nozzle Loads and Torques at the
Pump Nozzles ... ..................................................... 8
4. Transport, Handling, Storage .............................. 9
4.1 Transport, Handling ........................................... 9
4.2 Storage / Conservation.................................... 10
5. Mounting / Installation ....................................... 10
5.1 Mounting of Pump / Unit .................................. 10
5.2 Connection of Pipings to the Pump ................. 10
Model LS, LC, LCP
5.3 Coupling ........................................................... 11
5.4 Drive ................................................................ 12
5.5 Electric Connection .......................................... 13
5.6 Final Control .................................................... 13
6. Start-up, Operation, Shut down ......................... 13
6.1 Initial start-up ................................................... 13
6.2 Switch on drive ................................................ 13
6.3 Restarting ........................................................ 13
6.4 Limits of Operation .......................................... 14
6.5 Lubrication of Bearings .................................... 14
6.6 Monitoring ........................................................ 15
6.7 Shutting down .................................................. 15
6.8 Storage / longer periods of non-operation ....... 15
7. Servicing, Maintenance ...................................... 15
7.1 General remarks .............................................. 15
7.2 Mechanical seals ............................................. 16
7.3 Stuffing boxes .................................................. 16
7.4 Lubrication and Change of Lubricant ............... 16
7.5 Coupling ........................................................... 16
7.6 Cleaning of pump ............................................ 17
8. Dismantling and repair of pump ........................ 17
8.1 General remarks .............................................. 17
8.2 General ............................................................ 17
8.3 Disassembly of Back Pull Out Assembly ......... 17
8.4 Removal of Impeller ......................................... 18
8.5 Removal of Shaft Sealing ................................ 18
8.6 Removal of Bearing ......................................... 18
8.7 Reconditioning ................................................. 18
8.8 Mounting .......................................................... 19
9. Recommended Spare Parts, Spare Pumps ...... 20
9.1 Spare Parts ...................................................... 20
9.2 Stand-by pumps ............................................... 20
10. Faults - Causes and Solutions ......................... 20
LS 100-english page 1
Artikel No. 771073402
Revision 02
Issue 01/2010
Installation, Operating and Maintenance Instruction
Pump Name Plate
Model LS, LC, LCP
Type *) Type of pump
S/N *) Serial number
Year Year of construction
Q Rated capacity at the operating point
P Rated power at the operating point
H Head (Energy head) at the operating point
n Speed
p
all w C
t
max op
Item No Customer related order number
Max permitted casing-operation-pressure
(=highest discharge pressure at the rated
operating temperature to which the pump
casing can be used).
Maximum permitted operating temperature of
pumped liquid
*) All details of design and materials are defined with
this information. They must be stated on all inquiries to
the manufacturer resp. orders of spare.
Imp∅ Outer diameter of the impeller
ATEX-Label (only for pumps in compliance with EC directive 94/9/EG)
CE Marking of compliance with the EC directive
94/9/EG
Ex specific marking for explosion protection
II Symbol for the appliance group
2G Symbol for the category (2), explosive
atmosphere due to gases, vapours or mist (G)
c Symbol for used ignition protection
(constructive safety "c")
T1-T. Symbol for classification of the theoretically
available range of the temperature classes -
data for temperature class refer to chapter
2.7.5; Data for maximum permitted
temperature of pumped liquid refer to pump
name plate, data sheet and / or order
confirmation.
LS 100-english page 2
Artikel No. 771073402
The conformity with the EC directive 94/9/EG
"Appliances and Protection Systems for designated
use in areas endangered to explosion" is declared by
the issue of the EC-Declaration of Conformity and the
attachment of the ATEX-label at the pump (bearing
bracket). The ATEX-label is attached additionally to
the pump name plate.
Revision 02
Issue 01/2010
Installation, Operating and Maintenance Instruction
The staff employed on installation, operation,
inspection and maintenance must be able to
evant
dent prevention regulations and that they
are suitably qualified for this work. If the staffs
do not have the relevant knowledge, they
observance can impair the pump and its
Products intended for use in explosive
1. General
Model LS, LC, LCP
This product corresponds with the requirements of the
Machine directive 2006/42/EG.
prove that they know about the rel
acci
should be provided with suitable instruction.
The operation safety of the delivered pump resp. unit
(= pump with motor) can only be guaranteed on
designated use according to the attached data sheet
and / or order confirmation resp. chapter 6 "Start-up,
Operation, Shut down".
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 field 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.
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 unauthorised
way for competitive purposes or passed on to others.
1.1 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 us, or subject to our written approval.
Otherwise the guarantee ceases to apply.
Longer-term guarantees basically only cover correct
handling and use of the specified material. The
guarantee shall not cover natural wear and tear and all
parts subject to wear, such as impellers, shaft sealing,
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 name 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.
2. 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 available at the place where the pump or
pump unit is in use.
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).
Equally, instructions and safety devices regarding
handling and disposal of the pumped media and/or
auxiliary media for flushing, lubrication a.s.o.,
especially if they are explosive, toxically, hot a.s.o., are
not part of this operating instruction.
For the competent and prescribed handling only the
operator is responsible.
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Artikel No. 771073402
2.1 Marking of References in the
Operating Instructions
The safety regulations contained in these Operating
Instructions are specially marked with safety signs
acc. to DIN 4844:
Safety reference!
Nonfunction.
EC-Ex Marking
atmospheres must be marked.
General Symbol for Danger!
Persons can be endangered.
Warning of electric voltage!
Safety instructions attached directly to the pump resp.
unit must be followed under any circumstances.
Further they must be kept in good readable condition.
Revision 02
Issue 01/2010
Installation, Operating and Maintenance Instruction
On application of the unit in areas endangered
to explosion special attention must be paid to
During operation of the pump the system of the
suction and pressure pipe and the pump itself
must permanently be filled with the pumped
liquid. Thus, no explosive atmosphere can
If the operator can´t guarantee that, according
In the same way, as these Operating Instructions
of the pump, all possibly attached Operating
Instructions of accessories (e.g. motor) must be
noticed and kept available.
2.2 Dangers of non-observance of the
Safety Instructions
Non-observance of the Safety Instructions can
lead to loss of any claim for damages.
Further, non-observance can lead to following risks:
Failure of important functions of the machine or
facility.
Failure of electronic appliances and measuring
instruments by magnetic fields.
Endangering of persons and their personal
property by magnetic fields.
Endangering of persons by electric, mechanic and
chemical influences.
Endangering of environment through leakage of
dangerous substances.
sections marked with Ex.
2.3 Safety Instructions for the Operator /
Worker
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 is 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.
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 the sound level of a pump or pump unit is above
85 dB(A) an ear protection has to be used when
staying near the pump for some time.
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
LS 100-english page 4
Artikel No. 771073402
Model LS, LC, LCP
should be unplugged from the mains or the main
switch turned off and fuse unscrewed. A motor
protection switch is to be provided.
2.4 Safety Instructions for Maintenance,
Inspections and Mounting Work
The operator is responsible that any maintenance,
inspections and mounting work is made by
authorized competent personnel, which must be
informed by having read the Operating
Instructions.
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.
Safety Data Sheets for the various liquids handled.
Immediately after finishing work, all safety and
protective devices must be replaced or restarted.
2.5 Unauthorized Alteration and Spare
Parts Production
Alteration or changes of the machine are permitted
after agreement with the manufacturer.
Original spare parts and accessory authorized by the
manufacturer are serving the safety.
The use of other parts can lead to loss of liability for
there from resulting consequences.
2.6 Undue Operation
The operating safety of the delivered machine can
only be guaranteed by designated use acc. to the
following chapters of the Operating Instructions. The
limits stated in the data sheet and / or order
confirmation must not be exceeded under any
circumstances.
2.7 Explosion Protection
On application of units in areas endangered to
explosion measures and references in the chapters
2.7.1 to 2.7.6 must be observed, so that explosion
protection is guaranteed.
2.7.1 Filling of unit
develop and the danger of dry-run is avoided.
monitoring measures must be provided.
Issue 01/2010
Revision 02
Installation, Operating and Maintenance Instruction
Equally all seal casings, auxiliary systems of the
shaft sealing, as well as heating and cooling
The marking of the pump refers to the pump
itself. For coupling and motor resp. further
tions a separate Declaration of Conformity,
as well as a corresponding marking must be
Carry out rotation control with separated
pling halves only! Refer to chapter 5.5 and
If danger of explosion is also existing during
tion control must not be
up of the empty pump,
to avoid undue temperature increase in case of
There’s a danger, that high surface
tures are developing at the pump
casing after relatively short time, through fast
side the pump can
On pumps with mech. seals the permitted
run. Dry run not only can occur on insufficiently
but also because of too much
Operation of the pump out of the permitted
Under normal operating conditions the highest
e
of the pump casing and in the area of the
If the pump is heated (e. g. heating jacket), care
s,
During operation of the pump it must be
cured that an overabundant sedimentation of
g), to prevent
heating of pump surface over the permitted
The particular allowed operating temperature of
the pump is shown in the data sheet and / or the
order confirmation resp. the type plate at the
For a secure and reliable operation it must be
secured by regular inspections, which the unit is
and is kept in good
systems must be filled carefully.
2.7.2 Marking
addi
available.
Example of of marking at pump:
CE Ex II 2 G c T... .
The marking shows the theoretically applicable range
of temperature classes. The different temperatures,
permitted acc. to pump design, result as shown in
chapter 2.7.5. The same is valid for the drive.
For a whole unit (pump, coupling, motor) with different
temperature classes the lowest is valid.
2.7.3 Rotation Control
cou
6.1 as well.
installation, the rota
carried out by short start-
contact of rotating and stationary parts.
2.7.4 Operation of pump
The pump must only be started up with fully opened
suction side and slightly opened pressure side valve.
The start-up against closed non-return valve, however,
is possible. Immediately after the start-up the
discharge side valve must be adjusted to the operating
point.
Refer to chapter 6.2, as well.
Operation with closed valve in suction and / or
discharge pipe is not permitted!
tempera
Model LS, LC, LCP
temperature limits can be exceeded due to dry-
filled seal casing,
gas in the medium.
operating range can lead to dry-run, as well.
2.7.5 Temperature Limits
temperatures must be expected at the surfac
bearings.
The surface temperature occurring at pump casing
corresponds with the temperature of the pumped
liquid.
must be taken, that the temperature classe
prescribed for the plant are observed.
In the area of the bearing bracket free contact from
surface to surrounding must be given.
se
dust is avoided (regular cleanin
temperature.
The operator of the plant must secure that the
defined operating temperature is observed. The
max. allowed temperature of the pumped liquid at
suction depends on the particular temperature
class.
The following table shows the theoretical temperature
limits of the pumped liquid in consideration of the
temperature classes acc. to EN 13463-1.
Temperature class acc.
EN 13463-1
T4 (135°C) 135°C
T3 (200°C) 180°C
T2 (300°C) 180°C
T1 (450°C) 180°C
Temperature limit of
pumped liquid
heating of the liquid inside the pump.
Fast pressure increase in
lead to overload and, thus, the pump can burst.
In chapter 6.4.1 the minimum flow is stated. Longer
operating phases with these flows and the named
liquids don’t cause additional increase of surface
temperature at the pump.
Furthermore the references in chapter 6 of these
operating Instructions must be taken into
consideration.
LS 100-english page 5
Artikel No. 771073402
pump.
In the area of the bearings the temperature class T4 is
guaranteed, provided that the ambient temperature is
40°C and the appliance is duly operated and
maintained.
2.7.6 Maintenance
maintained competently
technical condition.
Revision 02
Issue 01/2010
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