OWNERS MANUAL

Industrial and General Purpose

end suction centri fugal pumps bare shaft models

THIS MANUAL CONTAINS THE NECESSARY INSTRUCTIONS FOR THE PROPER ASSEMBLY, INSTALLATION AND MAINTENANCE OF THE PUMPS

Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

GENERAL

This manual contains the installation, operation and maintenance instructions for the frame mounted pumps; when properly installed and when given reasonable care and maintenance, pumps should operate efficiently for a long period of time. The nameplate contains the serial number and pumps model; Keep this information at hand when consulting technical service.

! CAUTION
1.1 Transport

The installation and maintenance instructions must be followed to avoid serious damage on the pump.

The pump unit must be correctly packed in wooden boxes and well fixed to the box using screws in order to prevent serious damages. The pumps unit (pump and motor) alignment must be checked before installation, the unit must be lifted using the base plate, never use the motor or pump hooks to lift the unit. 1.2 Unpacking the Equipment Check the contents of each box for missing items and for damage that may have occurred during shipment. Report any missing parts or damage at once.

Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

PLANING THE INSTALLATION

The pumps should be installed as close as possible to the water tank, protected from rain and dust. They should be well ventilated. Make sure that the installation area provides sufficient height (If a pump shelter is used) and floor space, to permit proper inspection and maintenance of the pump and auxiliary equipment. Provide weather shelter, if necessary, and protect the pump against flooding. The water tank, pumping system and joints should be clean. Provide a strainer to prevent foreign substances from being drawn into the pump, the strainer in the foot valve must be at least four times the suction pipe area. It is highly recommended install a vacuum gauge to check the suction pumping condition. A coupling guard should be attached to the base plate to avoid accidents. Piping run and connection fittings should be properly aligned and independently supported to reduce strain on pump case or frame. The suction and discharge supports should be installed as close as possible to the pump. It is advisable to use flexible unions to avoid strain on the pump case or frame. Use Teflon tape or loctite in the piping joints; the piping joints should be hermetically sealed to avoid air pockets in the suction line or leakage in the discharge pipes. Undersized suction piping will create excess friction losses that may cause cavitation and will affect pump performance; so the suction and discharge piping should have the same or bigger diameter than the pump suction connection on the pump casing. If a bigger diameter is used an eccentric reducer should be installed in the suction line and a concentric reducer in the discharge line.

Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

INSTALLATION

3.1

Concrete Base (foundation) When the pump unit is installed over a concrete base (foundation), the concrete must be completely dry and leveled, also must havethe holes to place the anchor bolts. The anchor bolts will be used to fasten the pumps base plate to the concrete base.

Square washer welded to the hex cap stud

Hole to install the stud

Stud

Fig. 1
Pump

The base plate should be aligned using a bubble level; to correct any misalignment you can use metallic shims. After the base plate has been aligned, grout the cement in to the anchor holes of the concrete base and let it dry taking into consideration to the quality of the mortar used. Do not tighten the anchor bolt nuts until the concrete is completely dry. 3.2 Final Alignment. Although all pump units are aligned at he production line, it is highly recommended to check the alignment after the base plate has been fastened to the concrete base. Misalignment may be the cause of noisy pump operation, vibration, premature bearing failure or excessive coupling wear.

Concrete Base

Hole to Studs

Fig. 2

Two types of misalignment may exist: parallel misalignment and angular misalignment.

Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

Limits are indicated later, but should be limited to a minimum for maximum life expectancy on the pump unit. To check the coupling alignment, the following procedure should be followed: a) As an alternative method when checking coupling alignment you may use a dial indicator. Proceed as follow:
Concentricity Dial Coupling Pump Shaft

- Scribe index lines on coupling halves mark where the indicator points zero. - Set indicator dial to zero as well. - Slowly turn both coupling halves sothat the index lines match, or the indicator reference is always on the mark.

Motor Shaft

- Observe di reading to determine whether adjustment are needed.

Parallelism

b) Another alternative method for checking coupling alignment may be the use of a straight edge. Proceed as follow: - Check for parallel misalignment by placing a straight edge across both coupling halves at four different points each 90 apart. Correct alignment occurs when the straight edge is level across the coupling halves at all points.

Fig. 3

Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

.
Straight edge

Coupling

- Check angular misalignment with feeler gauge at four points 90 apart. Correct alignment occurs when the same gauge just enters between the halves at all four points. The maximum variation in the parallelism of the faces and concentricity of the plates should be:
? 0.1 mm on the dial indicator for rotation speeds of less than 1750 rpm.

Pump shaft

Motor Shaft

? 0.05 mm on the clock gauge for rotation speeds higher than 1750 rpm.

Straight edge

Straight edge

3.3

Pipes and accessories in the suction line. Never use the suction pipe sloping downward to pump inlet since it will trap air which will reduce performance and may cause pump to lose its priming.
The suction pipe should not be higher than the inlet connection of the pump because it may generate air pockets in the suction line and this decreases the pump performance. The elbows in the suction line should have large radii, Plan the piping so as to employ the minimum number of bends, elbows and fittings. Undersize Suction piping will create excess friction losses that may cause cavitation and reduction of pump performance.

Fig. 4

Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

Fig. 5

Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

The distance between the foot valve and the bottom and the sidewalls of tank, should be minimum two times the pumps inlet size; the foot valve should never be close to the water surface. A gate valve should be placed in the suction line if the pump is installed below water level. Excess fittings and bends in suction line results in trapped air, reduced performance, and high friction losses, which may cause cavitation. The Flow velocity should not exceed 6 ft/sec in the suction line. 3.4 Pipes and accessories in the discharge line. A connection must be installed in the discharge line in order to prime the pump; an elbow with a 1 plug is recommended. If the total dynamic head is higher than 32 ft, a check valve must be placed to avoid backflow or water hammer. After the check valve a gate valve must be placed, to regulate the flow. The Flow velocity should not exceed 8 ft/sec in the discharge line. 3.5 Other accessories A or 1 pipe must be placed to drain the soft packing leakage. This pipe should discharge the leakage water to the Water tank.

Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

PRIMING

The pump must be primed before starting, so that both the pump casing and suction line are filled with liquid. Suction lift with Foot Valve. (Pump above water level) ? Open the filling plug. ? Fill the pump and suction pipe with water completely to force all air out through filling plug. ? Rotate shaft slowly to allow any air trapped in the impeller to escape. ? When all air has been forced out of pump, replace the filling plug. Use pipe joint compound on plug threads and tighten as necessary to prevent leakage. Suction head. (Pump below water level) The suction pipe must be kept free of air leaks. It is advisable to keep the suction pipe short, setting the pump as near as possible to the liquid that will be pumped. ? Unscrew the filling plug located on the tee of the discharge line. ? Open the discharge and suction gate valves, allowing water to fill the pump completely and force all air out through vent. ? Rotate shaft slowly to allow any air trapped in the impeller to escape. ? When all air has been forced out of the pump, replace the pipe plug. Use pipe joint compound on plug threads and tighten as necessary to prevent leakage.

Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

BEFORE STARTING

Before starting the pump, check the direction of motor rotation. An arrow located on the pump casing indicates the correct rotation of the impeller. The motor should turn in the same direction. If the pump operates without liquid a serious damage could occur in the mechanical Seal or soft packing, because the temperature increases and causes breakings on the white surface (ceramic) and the Elastomeric of the mechanical seal.

STARTING

Any gate valve in the suction discharge should be close.

line must be open and the gate valve in the

Start the motor-pump unit to reach the maximum speed of the motor, gradually open the gate valve in the discharge line until, it reaches the working pressure. Check the soft packing leaks if this is too much tighten gradually the nuts of the packing gland, until it reaches the correct leakage.

!
9

The gate valve in the discharge line should not be fully opened

CAUTION without checking the motor amperage, because any excessive

flow in the discharge line can cause the motor overload.

Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

STOPPING

Close the gate valve in the discharge line.If the pump is stopped for a long period of time, drain the pumps casing to avoid rust.

INSPECTION

The wear ring clearances should be checked as they will increase with time and thus cause a decrease in efficiency. The frequency of inspection will depend upon the liquid handled. If the liquid contains gritty materials, inspection should be done on a monthly basis, but if clear water in pumped it may be sufficient to check them annually. A general rule is to replace the rings when the clearance has increased 100 per cent above the original. The packing should be replaced after it becomes hard and tends to scrape the shaft surface. When the packing is being replaced the finish of the shaft sleeve should be examine for smoothness. It is essential that the lantern ring be placed directly under the water inlet when putting in the new packing to insure a circulation of the water and a satisfactory seal. The packing should be gradually compressed with the pump running. It should not be compressed too much as local heating of the shaft and consequent misalignment will result. A slight leakage will insure proper lubrication and cooling. Frequently check the motor amperage; this should not be higher than the SFA (service factor amperage) located on the motors nameplate. The pump should not run with the discharges gate valve closed. This would cause damages due temperature increase.

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Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

8.1 Temperature The ball bearing temperature should be measurement on the external surface of the frame and this temperature should not be higher than 90C. 8.2 Packing leakage Most of the problems come from the fact that packing has too much cords unevenly tightened during the first running hours when the pump is running. Tighten the gland slightly and progressively and let it drip (about two liters per hour) this operation lubricates cools down and permits the running in of the packing. Avoid tightening too much, as this would mean immediate damage of the packing. 8.3 Mechanical Seal In all circumstances we recommend, to check the mechanical seal after 4000 running hours.

The contact surface on the shaft sleeve must be perfectly smooth. 8.4 Lubrication The frequency of lubrication depends on operating conditions and environment, therefore lubrication intervals must be determined by experience. Lubricants need replacing only because of contamination by dirt or dust, metal particles moisture or high temperature breakdown. A small quantity of grease may be added about every 400 hours of operation.

Proper lubrication is essential to the pump operation. Do not operate the pump if sufficient lubricant in not present in the bearing frame of if lubricant is contaminated with excessive dirt or moisture. Operation of the pump under this condition will lead to impaired pump performance and possible bearing failure. Dont operate the pump with excessive amount of lubricant. Such action will cause bearings to overheat.

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Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

Frame Model (reference) No. 2 No. 3 No. 4 No. 5

Bearing reference 6206 7306B 6307 7308B 6309 7310B 6312 7313B

Grease Quantity 15 gr 20 gr 30 gr 40 gr

It is recommended to change the grease after each 3000 running hours for a temperature rising up to 50C maximum above ambient temperature. It is preferable to use lithium grease. In the following table you will found the ball bearing reference and the grease quantity used by each bearing.

INSPECTION

If a stand-by pump is used, this pump must be turn on at least one time per week.

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Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

MAINTENANCE

10

The Frame mounted centrifugal series pumps are designed to operate efficiently for years, but like all other machinery, they require regular inspection and care. The purpose of maintenance is to prevent breakdowns and to obtain the longest service life possible. This pump does not need external lubrication, because the liquid being pumped (except the bearings) lubricates the internal parts. You should review periodically the whole installation to find any leaks, or other problems. You should clean the whole unit periodically. If you notice any internal noise, remove the casing to inspect the internal pump parts if you find any damage, you should consult immediately with the technical service. Always maintain proper water level. If the water level falls, the pump may lose its priming, run dry and may damage the seal or packing. Continued operation in this manner could cause a loss of pressure, and may damage to the pump case, impeller and seal. Protect motor against heat, dirt and moisture. Protect, the motor from the sun, provide ample cross ventilation. Keep motor, motor vents and surrounding area clean. Avoid sweeping or stirring up dust near the motor while it is running. Provide protection from rain, snow, lawn sprinklers etc. Avoid splashing water near the motor. Unscrew the drain plug to remove any dirt in the pumps casing.

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Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

10.1 Packing gland (Stuffing Box). The purpose of a stuffing box is to limit the leakage of the pump fluid and to prevent air from entering the suction spaces along the pump shaft. Normally the pumped liquid is used to lubricate the stuffing box seal. If the liquid is dirty, gritty or contains material that would gum or jam the seal, use a sealing liquid from an external source. Stuffing box glands should be adjusted after the pump is started. When the leakage is excessive, tighten gland nuts evenly and carefully. Never tighten gland to be leakproof, as this will cause overheating and undue wear on shaft sleeves.
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13 4

Take precautions to prevent the motor from being mistakenly started, while service is done. To change the packing follow the next steps. The suction and discharge gate valves should be fully closed. The casing must be completely drained and at ambient temperature. In order to change the soft packing all surfaces of the packing box (13) and shaft sleeve (2) must be completely clean, use packing cords with the appropriate dimensions according to the factory requirements indicated in the following table.

Fig. 6

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Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

Frame No.
Cylindrical Wood Shaft

Cord Section 7.9 mm (5/16) 9.5 mm (3/8) 15.8 mm (5/8)

Cord Length 60 mm 148 mm

Rings Quantity

No. 2 No. 3 No. 4

Fig. 7

4(*) 216 mm 205 mm

No. 5
Four cords Lantern Ring Joints Joint rotated 90

(*) On the 20x23 pump, the cord quantities are 5. To cut a cord, use a cylindrical wood shaft with the same diameter as the s shaft sleeve and cut as shown in the Figure 7. To install the cord (4) in the packing box, a small quantity of oil must be applied, over the cord surfaces. The cord rings (4) and lantern ring (5) should be installed as shown in the figure. Then place the packing gland (6) and nuts and tighten the nuts gradually.

Cords

Third cord Joint rotated 90 Second cord Joint rotated 90 First cord

Fig. 8

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Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

10.2 Mechanical Seal.

10

The mechanical seal does not need maintenance. Change it only if it leaks. To change the seal follow the next steps. Place the ceramic part of the mechanical seal (12a) on the packing gland (10) so that the white shiny surface is visible. To make this operation easier, put oil in the elastic ring of the seal. Do not hit or damage in any way the ceramic part of the seal. Insert the ceramic part of the mechanical sea (12) using finge pressure only.
23b

12

24

28

13

Then, place the gasket (24) and seal gland-ceramic assembly on the back plate (13) and then place the back plate on the frame. Clean the shaft sleeve surface (3). Place the rotating part of the mechanical seal (12b), on the shaft sleeve. To make this operation easier, put oil in the elastic ring of the mechanical seal. Then put the shaft gasket (28) on the shaft, and place the shaft sleeve-mechanical assembly on the pump shaft as was indicated on upon figure.
Frame Model (reference)

Fig. 9
Shaft Sleeve 15x40

35

mm

Mechanical Seal Diameter Type 1.1/4 1. 1.7/8 2. 21

No. 2 No. 3 No. 4 No. 5

Fig. 10

In the 15x40 the working distance of the mechanical seal is limited by a ring, which should be located 35mm from second shoulder of the shaft as shown in the following figure.

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Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

Key Gasket (7) Frame

(18a) Nut

(9) Back Bearing

(14) Shaft

(8) Front Bearing

(10) Seal Gland (24) Seal gasket gland (12) Mechanical Seal (3) SM Mechanical Sleeve (12a) (12b) (13) Back plate Impeller Gasket (20) Nut (19) Casing Gasket (1) Casing

(23) Nut (6) Parking Gland (4) Cord (5) Latern Ring (2) PE Shaft Sleeve (28) Shaft Gasket

(27) Spring Ring

Water Slinger (11) Front (15) Impeller Cover (22) Impeller key (21) Impeller washer

Drain Plug

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Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

11. Disassembly process The disassembly and assemble process, must be done following the drawing on this manual. Change the gaskets each time that you disassemble the pump. Check the internal part of the pump and change the worn parts if necessary. Unscrew the nuts (18a). Remove the casing (1) and the gasket (19). Unscrew the impeller nut (20) and impeller washer (21). Remove the impeller (15) and impeller key (22). Unscrew the nuts (23) of the packing gland or mechanical seal gland. Remove the packing gland. Unscrew the back plates nuts. Remove the back plate (13). Remove the shaft sleeve (2) or (3) depend of the pumps model. Remove the mechanical seal (12) from the shaft (14) or shaft sleeve (3), depend of the pumps model. k) Remove the seal gland (6) and gasket (24). l) Remove the water slinger (25). m) Unscrew the front covers screw (26). n) Remove the front cover (11). o) Remove the spring ring (27). p) Remove the shaft (14) along with the ball bearings (8) and (9). a) b) c) d) e) f) g) h) i) j)

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Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

PARTS INTERCHANGEABILITY PART NAME

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Owners Manual Industrial and General Purpose end Suction Centrifugal Pumps

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