GRUNDFOS INSTRUCTIONS
HS
Horizontal split case pump Installation and operating instructions
Declaration of Conformity 1: HS pump complete with motor and base frame: We Grundfos declare under our sole responsibility that the products HS, to which this declaration relates, are in conformity with the Council Directives on the approximation of the laws of the EC Member States relating to — Machinery (98/37/EC). Standard used: EN ISO 12100. — Electromagnetic compatibility (89/336/EEC). Standards used: EN 61000-6-2, EN 61000-6-4, EN55011 Gr. 1 Class A and EN61000-4 chapter 2, 3 & 8. — Electrical equipment designed for use within certain voltage limits (73/23/EEC). Standard used: EN 60204-1.
2: HS bare shaft pump: We Grundfos declare under our sole responsibility that the products HS, to which this declaration relates, are in conformity with the Council Directive on the approximation of the laws of the EC Member States relating to — Machinery (98/37/EC) and fulfils Annex II B. Standard used: EN ISO 12100. An HS bare shaft pump must not be put into service until the machinery into which it is incorporated has been declared in conformity with the Directive. Bjerringbro, 1 July 2006
Svend Aage Kaae Technical Director
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2. Delivery and handling Page
1.
General description
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2. 2.1 2.2 2.3
Delivery and handling Delivery Handling Temporary storage
3 3 3 4
3. 3.1
Applications Pumped liquids
4 4
4. 4.1
Identification Type key
4 5
5. 5.1 5.2 5.3 5.4 5.5 5.6 5.7
Operating conditions Ambient temperature Liquid temperature Maximum pressure Minimum inlet pressure Maximum inlet pressure Minimum flow rate Maximum flow rate
5 5 5 5 5 5 5 5
6. 6.1 6.2 6.3 6.4 6.5
Mechanical installation Location Foundation Vibration dampers Expansion joints Foundation and alignment procedure
5 5 5 5 6 6
7. 7.1 7.2 7.3 7.4 7.5
Piping System types General information Suction piping Valves in suction piping Discharge piping
8 8 8 9 10 10
8. 8.1
Electrical connection Frequency converter operation
10 10
9. 9.1 9.2 9.3 9.4 9.5
Start-up Pre-start checks Starting Operating checks Operating at reduced flow and/or head Frequency of starts and stops
11 11 11 11 11 12
10. 10.1 10.2 10.3
Maintenance General information Frequency of inspections Lubrication
12 12 12 12
11.
Frost protection
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12.
Service
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13.
Fault finding
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14.
Disposal
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2.1 Delivery The pump is delivered from factory in a crate or wooden box specially designed for transport by fork-lift truck or a similar vehicle. Upon receipt, check the pump visually to determine whether any damage has happened during transport or handling. Check especially for 1. broken or cracked equipment, including base frame, motor or pump feet and flanges 2. broken motor fan cover, bent eye bolts or damaged terminal box 3. missing parts. Parts or accessories are sometimes wrapped individually or fastened to the equipment. If any damage or losses have occurred, promptly notify Grundfos’ representative and the carrier’s agent.
2.2 Handling
TM03 2692 4805
CONTENTS
Fig. 1
How to lift and handle HS pumps. Note: Use shackles at all four corners.
Fig. 2
How to lift and handle HS bare shaft pumps.
Prior to installation, read these installation and operating instructions. Installation and operation must comply with local regulations and accepted codes of good practice.
Grundfos type HS horizontal split case pumps are supplied either as complete pump with motor, base frame, approved coupling guard and CE mark or as bare shaft pump without CE-mark.
TM03 4290 1906
1. General description
These instructions apply to both types. The HS pump can be driven by an electric motor or other type of driver. In the following we assume that the pump is driven by an electric motor.
When unloading the pump, lift equally at four or more points on the base frame. Do not lift by the motor or pump. Do not lift by the flanges or by the eyebolts on the motor.
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2.3 Temporary storage
4. Identification
If the pump is not to be installed and operated soon after arrival, store it in a clean, dry place with slow, moderate changes in ambient temperature. Protect the pump from moisture, dust, dirt and foreign bodies. Prior to and during storage we recommend these precautions:
The type designation and rating information of Grundfos horizontal split case pumps are stated on the nameplate, see fig. 3. The type designation includes serial number, model number, size and type. Permanent records for this pump are kept under its year-week code and serial number (pos. 5 and 6) and this number must therefore be stated in all correspondence and spare parts orders.
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2. Ensure that suction and discharge ports of the pump and all other openings are covered with cardboard, wood or masking tape to prevent foreign objects from entering the pump.
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3. Cover the unit with a tarpaulin or other suitable covering if it is to be stored where there is no protective covering.
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circulation in heating, ventilating, air-conditioning and cooling systems
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liquid transfer and pressure boosting in various industrial systems
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liquid transfer in irrigation systems.
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MADE IN SINGAPORE
11 9 Fig. 3
containing additives to prevent system corrosion, calcareous deposits, etc. (this may be the case in heating and ventilating systems).
When pumping water mixed with glycol, it may be necessary to use another shaft seal. For further information, please contact Grundfos.
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5
6
HS 80-65-240 / 220 1/1 F A BBQV 1
A 96XXXXXX P2
8
180
01 27 0001
57
10
2900
16/80
7
MADE IN SINGAPORE
11 9
Fig. 4 Pos. 1
4
Nameplate CE-marked HS pump 2
Special stuffing box packing rings/shaft seal O-rings may be required if the pump is used for pumping treated water •
10
2900
16/80
When pumping liquids with a density and/or viscosity higher than that of water, use motors with correspondingly higher outputs.
at temperatures above 80°C (176°F)
57
180
Thin, clean and non-aggressive liquids, not containing solid particles or fibres. Do not pump liquids that will attack the pump materials chemically.
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01 27 0001
A 96XXXXXX P2
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3.1 Pumped liquids
The stuffing box packing rings/mechanical shaft seal O-rings chosen must be suitable for the liquid to be pumped.
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HS 80-65-240 / 220 1/1 F A BBQV 1
3. Applications Grundfos HS horizontal split case pumps are typically used for
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TM03 2104 3705
4. Rotate the shaft 2 turns every 2 weeks to prevent corrosion of the bearing surfaces and the stuffing box/shaft seal faces due to moisture.
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Nameplate HS bare shaft pump without CE-mark Description Type designation
2
Model
3
Product number
4
Place of production
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Production year and week
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Serial number
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Maximum pressure and temperature
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Rated flow rate
9
Head at rated flow rate
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Speed
11
Country of production
TM03 4291 1906
1. Ensure that the bearings are filled with the recommended grease to prevent moisture from entering around the shaft, see 10.3 Lubrication.
4.1 Type key
5.6 Minimum flow rate
The type key is an explanation of the product type designation, see fig. 3, pos. 1.
A minimum flow rate equal to 30% of the flow rate at maximum efficiency is needed at all times. Flow rate and head at maximum efficiency are stated on the nameplate.
HS
85
x65
x240
/220
1/1 F
A BBQV
1
Type range
5.7 Maximum flow rate
Nominal diameter of suction port
The maximum flow rate must not exceed 120% of the value stated on the nameplate. If the maximum flow rate is exceeded, cavitation and overload may occur.
Nominal diameter of discharge port
6. Mechanical installation
Nominal impeller diameter Actual impeller diameter
6.1 Location
Pump version: 1 = Standard 2 = Extended 3 = Two-stage, through-bore 4 = Two-stage, non-through-bore /1 = With standard coupling /2 = With spacer coupling /3 = Bare shaft pump
Install the pump as close as possible to the supply of pumped liquid, with the shortest and most direct suction pipe practical.
Code for pipework connection: F = DIN flange G = ANSI flange
6.2 Foundation
Code for materials (pump housing and impeller): A = Cast iron pump housing with cast iron impeller B = Cast iron pump housing with bronze impeller E = Spheroidal graphite iron (GGG40) pump housing with bronze impeller S = Cast iron pump housing with stainless steel impeller N = Stainless steel pump housing with stainless steel impeller Z = All bronze
Install the pump with sufficient accessibility for inspection and maintenance. Allow ample space and headroom for the use of an overhead crane or hoist sufficiently strong to lift the unit. Make sure there is a suitable electricity supply available for the motor.
We recommend that you install the pump on a concrete foundation which is heavy enough to provide permanent and rigid support for the entire pump. The foundation must be capable of absorbing any vibration, normal strain or shock. As a rule of thumb, the weight of the concrete foundation should be 1.5 times the weight of the pump or unit. For further information on the building of the foundation, see section 6.5 Foundation and alignment procedure.
Code for shaft seal or stuffing box TM03 2500 4405
Directon of rotation: 1 = Clockwise 2 = Counter-clockwise
5. Operating conditions Fig. 5
5.1 Ambient temperature Maximum +40°C.
5.2 Liquid temperature The maximum liquid temperature marked on the pump nameplate depends on the mechanical shaft seal used. Max. temperature for NBR: +80°C Max. temperature for Viton: +90°C.
5.3 Maximum pressure The maximum pressure is stated on the nameplate, see fig. 3.
5.4 Minimum inlet pressure The minimum inlet pressure must correspond to the NPSH curve for the pump + a safety margin of minimum 0.5 metres head. NPSH appears from the data booklet and WebCAPS.
HS pump with base frame mounted on a concrete foundation (B) with expansion joints (A) and vibration dampers (C)
6.3 Vibration dampers To prevent vibrations from being transmitted to the building or the pipework, we recommend you to isolate the pump foundation from buildings by means of vibration dampers. In order to select the right vibration damper, you need this information: •
Forces transferred through the damper.
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Motor speed. In the case of speed control, this must also be taken into account.
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Desired dampening in % (recommended value: 70%).
The selection of vibration damper differs from installation to installation. In certain cases a wrong damper may increase the vibration level. Vibration dampers should therefore be sized by the supplier of the vibration dampers.
5.5 Maximum inlet pressure Inlet pressure + pressure when the pump is running against closed valve must never be higher than the maximum pressure stated on the nameplate.
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6.4 Expansion joints
6.5.2 Shimming of base frame
Expansion joints provide these advantages: •
Absorption of thermal expansion and contraction of pipework caused by variations in liquid temperature.
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Reduction of mechanical influences in connection with pressure surges in the pipework.
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Isolation of structure-borne noise in the pipework (only rubber bellows expansion joints).
Note: Do not fit expansion joints to make up for inaccuracies in the pipework, e.g. centre displacement or misalignment of flanges. The expansion joints should be fitted at a minimum distance of 1-1.5 flange diameters away from the pump, both on the suction and the discharge sides. This prevents turbulence in the joints, thus ensuring optimum suction conditions and minimum pressure drop on the discharge side.
If the pump is installed on a foundation with vibration dampers, fit expansion joints on both sides of the pump. The pump must have these flexible connections both at the discharge side and the suction side to allow the pump to move up and down.
The foundation and alignment procedure has five steps: 1. Pouring of foundation 2. Shimming of base frame
Shimming of base frame and levelling of pump
2. Level the base frame by adding or removing shims under the base frame, see fig. 7.
3. Preliminary alignment
3. Tighten the foundation bolt nuts against the base frame. Make sure the piping can be aligned to the pump flanges without putting strain on pipes or flanges.
4. Grouting 5. Final alignment 6.5.1 Pouring of foundation
6.5.3 Preliminary alignment
We recommend the following procedure to ensure a good foundation. 1. Pour the foundation without interruptions to within 15 - 30 mm of the final level. Use compactors to ensure that the concrete is evenly distributed. The top surface should be well scored and grooved before the concrete sets. This provides a bonding surface for the grout. 2. Embed foundation bolts in the concrete as shown in fig. 6. Allow enough bolt length to reach through grout, shims, lower base frame, nuts and washers.
Base frame
5-10 mm
Bolt length above base frame
15 to 30 mm allowance for grout
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The pump and motor are correctly aligned on the base frame from the factory. Some deformation of the base frame may occur during transport and it is therefore essential to check alignment at the installation site prior to final grouting. A flexible coupling will only compensate for minor misalignments and should not be used to compensate for excessive misalignment of the pump and motor shafts. Inaccurate alignment results in vibration and excessive wear on the bearings, shaft or wear rings.
The preliminary alignment procedure has three steps:
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Before starting work on the pump, make sure that the electricity supply has been switched off and that it cannot be accidentally switched on.
Carry out alignment of motor and pump by placing shims of different thickness under motor and pump, respectively. If possible, replace several thin shims with one thick shim.
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Washer
Lug
Pipe sleeve
TM03 0190 4504
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Typical foundation bolt design
Let the foundation cure for several days before the base frame is shimmed and grouted
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Fig. 7
1. Lift/jack up the base frame to the final level, 15 - 30 mm above the concrete foundation, and support the base frame by means of blocks and shims both at the foundation bolts and midway between bolts, see fig. 7.
6.5 Foundation and alignment procedure
Fig. 6
TM03 2804 4805
At high water velocities (> 2.4 m/s), we recommend you to fit larger expansion joints matching the pipework.
1. Checking coupling clearance 2. Checking parallel alignment 3. Checking angular alignment. 1. Checking coupling clearance Check that the gap between the coupling halves is equal to the values in the table and that the keyways are 180° displaced. the coupling clearance [mm] must be:
For a coupling with an outside diameter of ø [mm]...
Nominal
Tolerance
ø90 to ø180
3
0/–1
ø200 to ø315
4
0/–1
ø355 to ø630
5
0/–1
2. Checking parallel alignment
6.5.5 Final alignment
Place a straight edge across both coupling rims at the top, the bottom and both sides, see fig. 8. After each adjustment, recheck all features of alignment. Parallel alignment is correct when the measurements show that all points of the coupling faces are within ±0.2 mm of each other.
Make final alignment after the base frame has been properly fastened and the grout has dried thoroughly according to instructions.
TM03 0209 4504
Make final alignment by shimming the motor only.
Fig. 8
Checking parallel alignment
Proceed like this: 1. Check direction of rotation, see 9.1.5 Direction of rotation. 2. Let the pump run until it has reached its operating temperature under normal operating conditions (approx. 1 hour). 3. Check alignment on the coupling by means of a dial gauges, see below.
3. Checking angular alignment Insert a pair of inside calipers or a taper gauge at four points at 90° intervals around the coupling, see fig. 9. Angular alignment is correct when the measurements show that all points of the coupling faces are within ±0.2 mm of each other.
Checking coupling alignment by means of dial gauges Start the procedure by removing coupling pins and checking that the motor shaft and pump shaft can turn freely.
TM03 0213 4504
Dial gauge (2) for parallel alignment
270°
90°
Checking angular alignment
Recheck coupling clearance and tighten the set screws on the couplings
180°
6.5.4 Grouting Grouting compensates for uneven foundation, distributes weight of unit and prevents shifting. Use an approved, non-shrinking grout and proceed as follows: 1. Build a strong formwork around the foundation to contain the grout. 2. Soak top of concrete foundation thoroughly, then remove surface water.
Dial gauge (1) for angular alignment Fig. 11 Dial gauge arrangements; the end view of the coupling is seen from the motor The coupling alignment procedure has four steps: 1. Parallel alignment - vertically
3. Fill the formwork with grout up to a thickness of 15 - 30 mm. Allow grout to dry thoroughly before attaching piping to pump (24 hours is sufficient time with approved grouting procedure). 4. When the grout has thoroughly hardened, check the foundation bolt nuts and tighten if necessary.
2. Parallel alignment - horizontally 3. Angular alignment- horizontally 4. Angular alignment - vertically. 1. Parallel alignment - vertically
5-10 mm
Base frame
1. Mount dial gauge (2) in position 0° (12 o’clock), see fig. 11.
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Grout
2. Make index lines on the two coupling halves, see fig. 11.
Levelling wedges or shims
3. Set the dial gauge pointer to zero, turn motor and pump shaft simultaneously until dial gauge is in position 180° (6 o’clock) and check that the index lines are still in line.
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Fig. 10 Sectional view of foundation with foundation bolt, grouting and base frame
TM03 2946 4905
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TM03 2939 4905
5. Approximately two weeks after the grout has been poured, or when the grout has thoroughly dried, apply an oil base paint to the exposed edges of the grout to prevent air and moisture from getting in contact with the grout.
15 to 30 mm grout
TM03 0210 4504
Fig. 9
0°
Index line
4. Read dial gauge (2). If dial gauge shows a deflection exceeding ±0.2 mm, add or remove shims under the motor until the reading of the dial gauge is within the allowable tolerance of ±0.2 mm.
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TM03 2941 4905
2. Parallel alignment - horizontally
Note: Coupling tolerances may differ from coupling make to coupling make. For the standard mounted pin and bush coupling the allowable tolerance is ±0.2 mm. For other coupling types, please see the coupling data supplied with the pump. Finish the alignment procedure by refitting and tightening the coupling pins. Do not operate unit without ensuring that all guards are in place.
1. Turn motor and pump shaft 90°. 2. Set the dial gauge pointer to zero, turn motor and pump shaft 180° and check that the index lines are still in line. 3. Read dial gauge. If dial gauge shows a deflection exceeding ±0.2 mm, move the motor sideways until the reading of the dial gauge is within the allowable tolerance of ±0.2 mm.
7. Piping
4. Remove dial gauge (2).
The Grundfos HS horizontal split case pumps can be installed in two types of system:
7.1 System types
TM03 2942 4905
3. Angular alignment - horizontally
1. Mount dial gauge (1) in position 90° (3 o’clock), see fig. 11.
1. Closed systems or open systems where the liquid level is above the pump inlet, meaning that a certain suction head will be available. 2. Open systems where the liquid level is below the pump inlet, meaning that the pump will be operating with a suction lift.
7.2 General information When installing the piping, observe these precautions:
2. Make index lines on the two coupling halves, see fig. 11. 3. Set the dial gauge pointer to zero, turn motor and pump shaft simultaneously until dial gauge is in position 270° (9 o’clock) and check that the index lines are still in line. 4. Read dial gauge (1). If the dial gauge shows a deflection exceeding ±0.2 mm, move the motor sideways until the deflection is halved. 5. Set the dial gauge pointer to zero, turn motor and pump shaft simultaneously until dial gauge is in position 90° (3 o’clock) and read dial gauge (1) again.
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Always run the piping to the pump.
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Do not move pump to the piping. This could make final alignment impossible.
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Make sure that both suction and discharge piping are independently supported near the pump so that no strain is transmitted to the pump when the flange bolts are tightened. Use pipe hangers or other supports with necessary spacing to provide support.
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When expansion joints are used in the piping system, fit the joints at a minimum distance of 1-1.5 flange diameters away from the pump, both on the suction and the discharge sides. This prevents turbulence in the joints, thus ensuring optimum suction conditions and minimum pressure drop on the discharge side.
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Install piping as straight as possible and avoid unnecessary bends. Where necessary, use 45° or long sweep 90° fittings to reduce friction loss, see fig. 19.
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Make sure that all piping joints are tight.
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Where flanged joints are used, ensure that inside diameters match properly.
6. Now the reading should be within the allowable tolerance of ±0.2 mm. If not - repeat the procedure.
TM03 2940 4905
4. Angular alignment - vertically
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Remove burrs and sharp edges when making up joints.
1. Turn motor and pump shaft until dial gauge (1) in position 0° (12 o’clock).
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Make sure that the piping does not cause stress or strain in the pump.
2. Set the dial gauge pointer to zero, turn motor and pump shaft simultaneously until dial gauge is in position 180° (6 o’clock) and check that the index lines are still in line.
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Provide for expansion of pipe material when hot liquids are to be pumped.
3. Read dial gauge (1). If dial gauge shows a deflection exceeding ±0.2 mm, add or remove shims under the motor until the deflection is halved. 4. Set the dial gauge pointer to zero, turn motor and pump shaft until dial gauge is in position 0° (12 o’clock) and read dial gauge (1) again. 5. Now the reading should be within the allowable tolerance of ±0.2 mm. If not - repeat the procedure. 6. Remove dial gauge (1).
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7.3 Suction piping The sizing and installation of the suction piping is extremely important. The following procedure applies to •
closed systems and open systems where the liquid level is above the pump inlet
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open systems where the liquid level is below the pump inlet.
Make sure that the liquid flow is evenly distributed to both sides of the double suction impellers. There is always an uneven, turbulent flow through an elbow. So if an elbow is installed in the suction pipe near the pump in a position other than vertical, more liquid will enter one side of the impeller than the other, see fig. 15. This will result in heavy, unbalanced thrust loads overheating the bearings, causing rapid wear and reducing the hydraulic performance. Water pressure increases here causing a greater flow to one side of the impeller than to the other
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Ensure that pressure losses are minimized and sufficient liquid will flow into the pump.
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Make the suction piping is as short in length and as direct as possible, and never smaller in diameter than the pump suction port.
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Avoid air pockets or turbulence in the suction pipe, see fig. 12.
TM03 0212 4504
Many NPSH (Net Positive Suction Head) problems can be avoided if the suction piping is properly installed.
Fig. 15 Unbalanced loading of a double suction impeller due to uneven flow through an elbow close to the pump.
TM03 2542 4505
TM03 2518 4505
Air pocket
Turbulent flow
TM03 2541 4505
Uneven flow
The problems of uneven suction flow to the pump may be solved in two different ways: •
Fig. 12 NOT recommended suction pipe installations
Install a length of straight pipe of at least 10 times the diameter of the suction pipe, see fig. 17.
TM03 2519 4505
DN
Fig. 13 Upward sloping suction pipe
Air pocket
Fig. 17 Recommended suction pipe installation with a length of straight pipe •
or install a suction diffuser direct on the suction port of the pump, see fig. 18.
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Fig. 14 A concentric reducer will cause an air pocket to be formed at the top of the reducer.
TM03 2590 1109
Never use a straight, concentric reducer in a horizontal suction pipe, as it tends to cause the formation of air pockets at the top of the reducer and the pipe, see fig. 14.
TM03 2540 4505
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TM03 2539 4505
Install the suction pipe sloping upwards towards the suction port. Any high point in the pipe will be filled with air and thus prevent proper operation of the pump. When reducing the piping to the suction port diameter, use an eccentric reducer with the eccentric side down to avoid air pockets, see fig. 13. 10 x DN
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Fig. 16 NOT recommended suction pipe installation
Fig. 18 Pump installation with suction diffuser (1)
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8. Electrical connection
Generally recommended suction pipe installations
TM03 2537 4505
The electrical connections should be carried out by an authorised electrician in accordance with local regulations. Before removing the terminal box cover and before any removal/dismantling of the pump, make sure that the electricity supply has been switched off and that it cannot be accidentally switched on.
Eccentric reducer
TM03 2538 4505
Concentric reducer
TM03 2536 4505
The operating voltage and frequency are marked on the nameplate.
Fig. 19 Generally recommended suction pipe installations
7.4 Valves in suction piping If the pump is operating under static suction lift conditions, a nonreturn valve may be installed in the suction pipe to avoid having to prime the pump each time it is started. The non-return valve should be of the flap type or a foot-valve.
7.5 Discharge piping The discharge pipe is usually preceded by a non-return valve and a discharge isolating valve. The non-return valve protects the pump against excessive back pressure and reverse rotation of the pump and prevents back flow through the pump in case of stoppage or failure of the motor. If the discharge piping is short, the pipe diameter can be the same as the discharge port. If the piping is long, the pipe diameter should be one or two sizes larger than that of the discharge port. On long horizontal runs, it is desirable to keep the piping as level as possible. Avoid high spots, such as loops, as they will collect air and throttle the system or lead to uneven pumping.
Make sure that the motor is suitable for the electricity supply of the installation site. The electrical connections should be carried out as shown on the motor nameplate or in the wiring diagram on the back of the terminal box cover. Whenever powered equipment is being used in explosive surroundings, the rules and regulations generally or specifically imposed by the relevant responsible authorities or trade organisations must be observed.
8.1 Frequency converter operation All three-phase motors can be connected to a frequency converter. Frequency converter operation will often expose the motor insulation system to a heavier load and cause the motor to be more noisy than usual due to eddy currents caused by voltage peaks. In addition, large motors driven via a frequency converter will be loaded by bearing currents. When your pump is operated via a frequency converter, check the following operating conditions: Operating conditions
Action
2- and 4-pole motors of 110 kW and up and 6-pole motors of 75 kW and up
Check that one of the motor bearings is electrically isolated. Contact Grundfos.
Noise critical applications
Fit a dU/dt filter between the motor and the frequency converter (reduces the voltage peaks and thus the noise).
Particularly noise critical applications
Fit a sinusoidal filter.
Cable length
Fit a cable that meets the specifications laid down by the frequency converter supplier. (The length of the cable between motor and frequency converter affects the motor load).
Supply voltage up to 500 V
Check that the motor is suitable for frequency converter operation.
Supply voltage between 500 V and 690 V
•
Fit a dU/dt filter (reduces the voltage peaks and thus the noise) or
•
check that the motor has reinforced insulation.
Supply voltage of • 690 V and upwards •
10
Fit a dU/dt filter and check that the motor has reinforced insulation.
9. Start-up
9.1.5 Direction of rotation
The start-up procedure for HS pumps has three steps:
Direction of rotation is checked in the following way:
1. Pre-start checks, see 9.1 Pre-start checks
1. Remove coupling pins and check that the motor shaft can turn freely.
2. Starting, see 9.2 Starting 3. Operating checks, see 9.3 Operating checks. Do not start the pump until you have gone through all the pre-start checks.
9.1 Pre-start checks Pre-start checks has six steps:
2. Start motor briefly to check direction of rotation.The correct direction of rotation is indicated by arrows on the pump housing. Note: The direction of rotation of the pump is not always the same as the flow direction. 3. If direction of rotation is wrong, correct it by interchanging two phases on the motor. Check direction of rotation again. 4. Reassemble coupling with pins and guards.
1. Bearings
9.1.6 Opening of valves
2. Stuffing boxes
Completely open the isolating valve on the suction side of the pump and leave the discharge isolating valve closed or almost closed.
3. Pressure gauge 4. Priming 5. Direction of rotation
9.2 Starting
6. Opening of valves.
1. Start the pump.
9.1.1 Bearings
2. Vent the pump during starting by loosening the air vent screw until a steady stream of liquid runs out of the vent hole.
Check that all bearings are properly lubricated, see 10.3 Lubrication. 9.1.2 Stuffing boxes Check that the stuffing boxes have been properly tightened. Note: Does not apply to pumps with mechnical shaft seal. 9.1.3 Pressure gauge Check that the pressure gauge connection is closed. 9.1.4 Priming Closed systems or open systems where the liquid level is above the pump inlet: The suction pipe and the pump must be filled with liquid and vented before the pump is started. Proceed as follows: 1. Close the discharge isolating valve and loosen the air vent screw. Pay attention to the direction of the vent hole and ensure that the escaping water does not cause injury to persons or damage to the motor or other components. In hot-water installations, pay special attention to the risk of injury caused by scalding hot water. 2. Slowly open the isolating valve in the suction pipe until a steady flow of liquid runs out of the vent hole. 3. Tighten the air vent screw and completely open the isolating valve(s). Open systems where the liquid level is below the pump inlet: The suction pipe and the pump must be filled with liquid and vented before the pump is started. Proceed as follows: 1. Close the discharge isolating valve and open the isolating valve in the suction pipe.
Pay attention to the direction of the vent hole and ensure that the escaping water does not cause injury to persons or damage to the motor or other components. In hot-water installations, pay special attention to the risk of injury caused by scalding hot water. 3. When the piping system has been filled with liquid, slowly open the discharge isolating valve until it is completely open.
9.3 Operating checks 1. Check pump and piping for leaks. 2. Check and record pressure gauge readings for future reference. 3. Check the differential pressure. If the differential pressure is lower than anticipated, the motor may be overloaded. 4. Measure motor current consumption and compare the result with the rated current stated on the motor nameplate. In the event of motor overload, throttle the discharge isolating valve until the motor is no longer overloaded. 5. Check bearings for lubrication and temperature. Normal temperature is 80°C (176°F). Maximum temperature depends on the type of lubrication, see the lubrication nameplate on the pump. Stop the pump immediately if any defects are noticed. Do not start the pump unless defects have been remedied, see 13. Fault finding. Report immediately to the supplier if it is not possible to remedy the defects. Note: The operating checks apply not only to the start-up procedure, but should be used when checking the pump during normal operation.
2. Remove the air vent screw.
9.4 Operating at reduced flow and/or head
3. Pour liquid through the vent hole until the suction pipe and the pump are completely filled with liquid.
Do not operate the pump at a flow below 30% of flow at best efficiency point or with the discharge isolating valve closed. Operating the pump in such condition may involve the risk of the pump being overheated. To prevent possible damage, use protective devices such as liquid temperature relay, bearing temperature relay, low suction pressure control, etc.
4. Refit the air vent screw and tighten securely. The suction pipe can to some extent be filled with liquid and vented before it is connected to the pump. A priming device can also be installed before the pump.
If a pump is operated at reduced head, the flow will increase and the motor will consume more current than normal; this will result in overheating of the motor. In such situations, throttle the valve on the discharge side either manually or automatically.
11
10. Maintenance
9.5 Frequency of starts and stops The recommended maximum number of starts and stops per hour appearing from this table apply to complete pumps with motor supplied by Grundfos: P2 [kW]
Before starting work on the pump, make sure that the electricity supply has been switched off and that it cannot be accidentally switched on.
Max. starts/stops per hour 2-pole
1.5
4-pole
6-pole
5
2.2
10.1 General information Routine maintenance is essential to maintain the pump in a good condition.
3
A high degree of cleanliness should be maintained during all maintenance procedures.
4
10.2 Frequency of inspections
5.5
Inspections should be carried out in accordance with the routine maintenance chart below.
15
7.5
Depending on operation and environmental conditions together with a comparison of previous inspections, the frequency of inspections may be altered to maintain satisfactory operation of the pump.
11 15 18.5 22
10 10
30
Every week
a. Visually check for leaks. b. Check for vibrations. c. Hand test bearing housing for any sign of temperature rise.
Every month
Check bearing temperature.
37 45
5
55 75
Every 3 months Check whether the grease in the bearings has hardened.
5
90 110
5
132 160 200
15
Every 6 months a. b. c. d: Every year
Between regular maintenance inspections, be aware of signs of motor or pump trouble.
355 355
2
375 400
shaft for scoring. alignment of pump and motor. fixing bolts and tighten, if necessary coupling for wear.
a. Check rotating assembly for wear. b. Check wear ring clearances.
250 315
Check Check Check Check
2
450 525 600 The grey squares indicate non-existing pump models.
Common symptoms are listed in the fault finding chart, see 13. Fault finding Correct any trouble immediately and avoid costly repairs and shutdowns.
10.3 Lubrication Pump bearings Pump bearings are lubricated during manufacture and prior to delivery. To refill the bearings with fresh grease, use a grease gun and press grease through the two lubricating nipples provided. Note:
HS pump complete: We recommend to apply grease while pump is running. HS bare shaft pump combined with motor not supplied by Grundfos: Do not apply grease while pump is running, unless a CE-approved coupling guard is fitted.
Fig. 20 Lubricating plate
12
TM03 3766 0906
96616407
The relubricating intervals and information on quantity and type of grease are stated on the lubricating plate on the pump, see fig. 20.
For every 10,000 operating hours or every two years, •
remove bearing housings from pump
•
remove old grease
•
thoroughly clean bearing housings
•
refill bearings with fresh grease
•
refit bearing housings in accordance with assembly instructions.
Grease specifications: See Ball bearing grease below. Motor bearings Lubricate the motor in accordance with the indications on the motor nameplate. Grease specifications: See Ball bearing grease below. Ball bearing grease Use Lithium-based grease according to the following specifications: •
NLGI class 2 or 3.
•
Viscosity of basic oil: 70 to 150 cSt at +40°C.
•
Temperature range: –30°C to +140°C during continuous operation.
11. Frost protection Pumps which are not being used during periods of frost should be drained to avoid damage. Drain the pump by loosening the air vent screw at the top of the pump housing and by removing the drain plugs from the bottom of the pump housing, see fig. 21.
Drain plug, pump housing and discharge port
Drain plug, suction port
TM03 2948 4905
Ensure that the escaping water does not cause injury to persons or damage to the motor or other components. In hot-water installations, pay special attention to the risk of injury caused by scalding hot water.
Fig. 21 Position of drain plugs Do not tighten the air vent screw and refit the drain plug until the pump is to be used again.
12. Service If a pump has been used for a liquid injurious to health or toxic, the pump will be classified as contaminated. If Grundfos is requested to service the pump, Grundfos must be contacted with details about the pumped liquid, etc. before the pump is returned for service. Otherwise Grundfos can refuse to accept the pump for service.
13
13. Fault finding Before removing the terminal box cover and before any removal/dismantling of the pump, make sure that the electricity supply has been switched off and that it cannot be accidentally switched on.
X
X
X X
X
Pump not primed, lack of priming liquid, incomplete priming.
1.
Loss of priming liquid.
2.
Suction lift/static lift too high.
3.
Discharge pressure too high (measured at discharge port).
4.
Speed too low.
5.
X
X
X
X
X
X
X
X
Wrong direction of rotation.
6.
X
X
Impeller completely clogged.
7.
Suction pipe partially blocked.
8.
X
X X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Air leak in suction pipe or flange.
9.
X
Air leak in stuffing box (flushing channel may be blocked).
10.
Cavitation; insufficient NPSH (depending on installation).
11.
Impeller or wear rings worn.
12.
Defective packing rings.
13.
Non-return valve too small or partially obstructed (cross section of non-return valve port should be at least as large as cross section of suction pipe).
14.
Suction pipe not immersed deeply enough.
15.
X
Impeller diameter too small (probable cause if none of above causes can be established).
16.
X
Obstruction in pump housing.
17.
X X
X
X
X
X
X
X
X
X
Air or gases in liquid.
18.
The actual duty point of the pump lies to the right of the specified duty point on the pump curve. The result is lower head, higher flow and higher power consumption.
19.
Viscosity or specific gravity of pumped liquid is higher than that of water.
20. 21.
X
X
X
X
X
X
Shaft bent due to damage.
X
X
X
X
Mechanical failure of bearing.
22.
X
X
Misalignment.
23.
X X
X
X
X
X X X
14
Reference number to remedies
Pump operates for a short time and then stops
Pump bearings overheated
Cavitation noise
Causes
Vibration
Motor overloaded
The pump consumes too much power
Pump loses liquid after running for a short time
The pump does not create enough pressure
The pump does not deliver enough liquid
The pump delivers no liquid
Faults
Electrical defects.
24.
Speed to high.
25.
Foundation not rigid enough.
26.
Lubricating oil/grease dirty or contaminated.
27.
No.
Cause
Remedy
1.
Pump not primed, lack of priming liquid, incomplete priming.
Fill pump and suction pipe completely with pumped liquid.
2.
Loss of priming liquid.
Mend possible leaks in suction pipe, joints and fittings; vent pump housing to remove accumulated air.
3.
Suction lift/static lift too high.
Reduce the difference in height between the water reservoir/water supply and the pump.
4.
Discharge pressure too high.
Make sure that valves in discharge pipe are fully open.
5.
Speed too low.
1. Make sure the motor receives full voltage. 2. Make sure the frequency is correct. 3. Make sure all phases are connected.
6.
Wrong direction of rotation.
Compare direction of rotation with directional arrow on pump housing. If required, change direction of rotation by interchanging two phases in the motor.
7.
Impeller completely clogged.
Dismantle pump and clean impeller.
8.
Suction pipe partially blocked.
Remove any obstructions in the suction pipe.
9.
Air leak in suction pipe or flange.
Replace or repair defective pipe section or flange.
10.
Air leak in stuffing box.
Clean flushing channel. Replace stuffing box packing rings, if necessary.
11.
Cavitation; insufficient NPSH (depending on installation).
1. Increase net positive suction head by placing the pump in a lower position. 2. Pressurise suction vessel.
12.
Impeller or wear rings worn.
Replace impeller and/or wear rings. If necessary, also replace bearings and shaft.
13.
Defective packing rings.
Replace packing rings.
14.
Non-return valve too small or partially obstructed.
Replace or clean non-return valve.
15.
Suction pipe not immersed deeply enough.
Extend the suction pipe so that the risk of sucking air is eliminated.
16.
Impeller diameter too small
Check with factory if a larger impeller can be used; if not, reduce discharge pipe friction losses. But be careful not to seriously overload motor.
17.
Obstruction in pump housing.
Dismantle pump and remove obstruction.
18.
Air or gases in liquid.
Remove gas or air from pumped liquid. Possibly, see 11) above.
19.
The actual duty point of the pump lies to the right of the specified duty point on the pump curve. The result is lower head, higher flow and higher power consumption.
Install an orifice plate immediately after the discharge flange. The orifice plate will raise the system characteristic/increase the counter pressure thus increasing the head and lowering the flow. The size of the orifice plate must be adapted so that the pressure corresponds to the required duty point.
20.
Viscosity or specific gravity of pumped liquid is higher than that of water.
Use larger motor. Consult factory for recommended size.
21.
Shaft bent due to damage.
Check deflection of shaft by turning on bearing journals. Total indicator runout should not exceed 0.05 mm on shaft and 0.1 mm on impeller wearing surface. Possibly replace shaft.
22.
Mechanical failure of bearing and/or impeller.
Check bearings and impeller for damage. Possibly replace bearings or impeller.
Test liquid for viscosity and specific gravity.
23.
Misalignment.
Realign pump and motor.
24.
Electrical defects.
Check that voltage and frequency of the electricity supply are correct. Check for possible defects in the motor. Check that the motor is properly ventilated.
25.
Speed too high.
Check that frequency of electricity supply corresponds to frequency stated on motor nameplate.
26.
Foundation not rigid enough.
Retighten foundation bolt nuts. Check that foundation was made according to installation and operating instructions.
27.
Lubricating oil/grease dirty or contaminated.
1. Clean bearings and bearing housings according to instructions and relubricate bearings. 2. Check that the V-ring (extended and two-stage, through-bore versions) is working properly.
15
14. Disposal This product or parts of it must be disposed of in an environmentally sound way: 1. Use the public or private waste collection service. 2. If this is not possible, contact the nearest Grundfos company or service workshop.
Subject to alterations.
16
17
18
Denmark
France
Mexico
Thailand
GRUNDFOS DK A/S Martin Bachs Vej 3 DK-8850 Bjerringbro Tlf.: +45-87 50 50 50 Telefax: +45-87 50 51 51 E-mail:
[email protected] www.grundfos.com/DK
Pompes GRUNDFOS Distribution S.A. Parc d’Activités de Chesnes 57, rue de Malacombe F-38290 St. Quentin Fallavier (Lyon) Tél.: +33-4 74 82 15 15 Télécopie: +33-4 74 94 10 51
GRUNDFOS (Thailand) Ltd. 947/168 Moo 12, Bangna-Trad Rd., K.M. 3, Bangna, Phrakanong Bangkok 10260 Phone: +66-2-744 1785 ... 91 Telefax: +66-2-744 1775 ... 6
Argentina
GRUNDFOS GMBH Schlüterstr. 33 40699 Erkrath Tel.: +49-(0) 211 929 69-0 Telefax: +49-(0) 211 929 69-3799 e-mail:
[email protected] Service in Deutschland: e-mail:
[email protected]
Bombas GRUNDFOS de Mexico S.A. de C.V. Boulevard TLC No. 15 Parque Industrial Stiva Aeropuerto Apodaca, N.L. 66600 Mexico Phone: +52-81-8144 4000 Telefax: +52-81-8144 4010
Netherlands
GRUNDFOS POMPA San. ve Tic. Ltd. Sti. Gebze Organize Sanayi Bölgesi Ihsan dede Caddesi, 2. yol 200. Sokak No. 204 41490 Gebze/ Kocaeli Phone: +90 - 262-679 7979 Telefax: +90 - 262-679 7905 E-mail:
[email protected]
Bombas GRUNDFOS de Argentina S.A. Ruta Panamericana km. 37.500 Lote 34A 1619 - Garin Pcia. de Buenos Aires Phone: +54-3327 414 444 Telefax: +54-3327 411 111
Australia GRUNDFOS Pumps Pty. Ltd. P.O. Box 2040 Regency Park South Australia 5942 Phone: +61-8-8461-4611 Telefax: +61-8-8340 0155
Austria GRUNDFOS Pumpen Vertrieb Ges.m.b.H. Grundfosstraße 2 A-5082 Grödig/Salzburg Tel.: +43-6246-883-0 Telefax: +43-6246-883-30
Belgium N.V. GRUNDFOS Bellux S.A. Boomsesteenweg 81-83 B-2630 Aartselaar Tél.: +32-3-870 7300 Télécopie: +32-3-870 7301
Belorussia Представительство ГРУНДФОС в Минске 220090 Минск ул.Олешева 14 Телефон: (8632) 62-40-49 Факс: (8632) 62-40-49
Bosnia/Herzegovina GRUNDFOS Sarajevo Paromlinska br. 16, BiH-71000 Sarajevo Phone: +387 33 713290 Telefax: +387 33 231795
Brazil GRUNDFOS do Brasil Ltda. Rua Tomazina 106 CEP 83325 - 040 Pinhais - PR Phone: +55-41 668 3555 Telefax: +55-41 668 3554
Bulgaria GRUNDFOS Pumpen Vertrieb Representative Office - Bulgaria Bulgaria, 1421 Sofia Lozenetz District 105-107 Arsenalski blvd. Phone: +359 2963 3820, 2963 5653 Telefax: +359 2963 1305
Canada GRUNDFOS Canada Inc. 2941 Brighton Road Oakville, Ontario L6H 6C9 Phone: +1-905 829 9533 Telefax: +1-905 829 9512
China GRUNDFOS Pumps (Shanghai) Co. Ltd. 22 Floor, Xin Hua Lian Building 755-775 Huai Hai Rd, (M) Shanghai 200020 PRC Phone: +86-512-67 61 11 80 Telefax: +86-512-67 61 81 67
Croatia GRUNDFOS predstavništvo Zagreb Cebini 37, Buzin HR-10000 Zagreb Phone: +385 1 6595 400 Telefax: +385 1 6595 499
Czech Republic GRUNDFOS s.r.o. Čajkovského 21 779 00 Olomouc Phone: +420-585-716 111 Telefax: +420-585-438 906
Estonia GRUNDFOS Pumps Eesti OÜ Peterburi tee 44 11415 Tallinn Tel: + 372 606 1690 Fax: + 372 606 1691
Finland OY GRUNDFOS Pumput AB Mestarintie 11 Piispankylä FIN-01730 Vantaa (Helsinki) Phone: +358-9 878 9150 Telefax: +358-9 878 91550
Germany
Greece GRUNDFOS Hellas A.E.B.E. 20th km. Athinon-Markopoulou Av. P.O. Box 71 GR-19002 Peania Phone: +0030-210-66 83 400 Telefax: +0030-210-66 46 273
Hong Kong GRUNDFOS Pumps (Hong Kong) Ltd. Unit 1, Ground floor Siu Wai Industrial Centre 29-33 Wing Hong Street & 68 King Lam Street, Cheung Sha Wan Kowloon Phone: +852-27861706/27861741 Telefax: +852-27858664
Hungary GRUNDFOS Hungária Kft. Park u. 8 H-2045 Törökbálint, Phone: +36-23 511 110 Telefax: +36-23 511 111
India GRUNDFOS Pumps India Private Limited 118 Old Mahabalipuram Road Thoraipakkam Chamiers Road Chennai 600 096 Phone: +91-44 2496 6800
Indonesia PT GRUNDFOS Pompa Jl. Rawa Sumur III, Blok III / CC-1 Kawasan Industri, Pulogadung Jakarta 13930 Phone: +62-21-460 6909 Telefax: +62-21-460 6910/460 6901
Ireland GRUNDFOS (Ireland) Ltd. Unit A, Merrywell Business Park Ballymount Road Lower Dublin 12 Phone: +353-1-4089 800 Telefax: +353-1-4089 830
Italy GRUNDFOS Pompe Italia S.r.l. Via Gran Sasso 4 I-20060 Truccazzano (Milano) Tel.: +39-02-95838112 Telefax: +39-02-95309290/95838461
Japan GRUNDFOS Pumps K.K. 1-2-3, Shin Miyakoda Hamamatsu City Shizuoka pref. 431-21 Phone: +81-53-428 4760 Telefax: +81-53-484 1014
Korea GRUNDFOS Pumps Korea Ltd. 6th Floor, Aju Building 679-5 Yeoksam-dong, Kangnam-ku, 135-916 Seoul, Korea Phone: +82-2-5317 600 Telefax: +82-2-5633 725
Latvia SIA GRUNDFOS Pumps Latvia Deglava biznesa centrs Augusta Deglava ielā 60, LV-1035, Rīga, Tālr.: + 371 714 9640, 7 149 641 Fakss: + 371 914 9646
Lithuania GRUNDFOS Pumps UAB Smolensko g. 6 LT-03201 Vilnius Tel: + 370 52 395 430 Fax: + 370 52 395 431
Malaysia GRUNDFOS Pumps Sdn. Bhd. 7 Jalan Peguam U1/25 Glenmarie Industrial Park 40150 Shah Alam Selangor Phone: +60-3-5569 2922 Telefax: +60-3-5569 2866
GRUNDFOS Nederland B.V. Postbus 104 NL-1380 AC Weesp Tel.: +31-294-492 211 Telefax: +31-294-492244/492299
New Zealand GRUNDFOS Pumps NZ Ltd. 17 Beatrice Tinsley Crescent North Harbour Industrial Estate Albany, Auckland Phone: +64-9-415 3240 Telefax: +64-9-415 3250
Norway GRUNDFOS Pumper A/S Strømsveien 344 Postboks 235, Leirdal N-1011 Oslo Tlf.: +47-22 90 47 00 Telefax: +47-22 32 21 50
Poland
Turkey
Ukraine ТОВ ГРУНДФОС Украина ул. Владимирская, 71, оф. 45 г. Киев, 01033, Украина, Тел. +380 44 289 4050 Факс +380 44 289 4139
United Arab Emirates GRUNDFOS Gulf Distribution P.O. Box 16768 Jebel Ali Free Zone Dubai Phone: +971-4- 8815 166 Telefax: +971-4-8815 136
GRUNDFOS Pompy Sp. z o.o. ul. Klonowa 23 Baranowo k. Poznania PL-62-081 Przeźmierowo Phone: (+48-61) 650 13 00 Telefax: (+48-61) 650 13 50
United Kingdom
Portugal
U.S.A.
Bombas GRUNDFOS Portugal, S.A. Rua Calvet de Magalhães, 241 Apartado 1079 P-2770-153 Paço de Arcos Tel.: +351-21-440 76 00 Telefax: +351-21-440 76 90
GRUNDFOS Pumps Corporation 17100 West 118th Terrace Olathe, Kansas 66061 Phone: +1-913-227-3400 Telefax: +1-913-227-3500
România
Представительство ГРУНДФОС в Ташкенте 700000 Ташкент ул.Усмана Носира 1-й тупик 5 Телефон: (3712) 55-68-15 Факс: (3712) 53-36-35
GRUNDFOS Pompe România SRL Bd. Biruintei, nr 103 Pantelimon county Ilfov Phone: +40 21 200 4100 Telefax: +40 21 200 4101 E-mail:
[email protected]
GRUNDFOS Pumps Ltd. Grovebury Road Leighton Buzzard/Beds. LU7 8TL Phone: +44-1525-850000 Telefax: +44-1525-850011
Usbekistan
Russia ООО Грундфос Россия, 109544 Москва, Школьная 39 Тел. (+7) 095 737 30 00, 564 88 00 Факс (+7) 095 737 75 36, 564 88 11 E-mail
[email protected]
Serbia and Montenegro GRUNDFOS Predstavništvo Beograd Dr. Milutina Ivkovića 2a/29 YU-11000 Beograd Phone: +381 11 26 47 877, 11 26 47 496 Telefax: +381 11 26 48 340
Singapore GRUNDFOS (Singapore) Pte. Ltd. 24 Tuas West Road Jurong Town Singapore 638381 Phone: +65-6865 1222 Telefax: +65-6861 8402
Slovenia GRUNDFOS PUMPEN VERTRIEB Ges.m.b.H., Podružnica Ljubljana Blatnica 1, SI-1236 Trzin Phone: +386 1 563 5338 Telefax: +386 1 563 2098 E-mail:
[email protected]
Spain Bombas GRUNDFOS España S.A. Camino de la Fuentecilla, s/n E-28110 Algete (Madrid) Tel.: +34-91-848 8800 Telefax: +34-91-628 0465
Sweden GRUNDFOS AB Lunnagårdsgatan 6 431 90 Mölndal Tel.: +46-0771-32 23 00 Telefax: +46-31 331 94 60
Switzerland GRUNDFOS Pumpen AG Bruggacherstrasse 10 CH-8117 Fällanden/ZH Tel.: +41-1-806 8111 Telefax: +41-1-806 8115
Taiwan GRUNDFOS Pumps (Taiwan) Ltd. 7 Floor, 219 Min-Chuan Road Taichung, Taiwan, R.O.C. Phone: +886-4-2305 0868 Telefax: +886-4-2305 0878
Addresses revised 29.05.2006
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96624468 0706
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