INSTRUCTION MANUAL
FLEXIBLE-DIRECT-COUPLED PUMPS, STUFFING BOX
Dat:
30.06.00
No: 94-BA 4943E/ 1b
File:
Q_FLES_E
TABLE OF CONTENTS
Part II
2.0
Type code explanation
2.1
Flushing water connection
2.2
Direction of rotation
2.3
Level control system
2.3.1
Level switches
2.3.2
Level control
2.4
Start-up
2.5
Operating troubles
2.6
Maintenance and service
2.6.1
General
2.6.2
Visual checks of pump unit
2.6.3
Service connections
2.6.4
Sealing systems for soft packed pumps
2.7
Periodic maintenance of stuffing box
2.7.1
Regulation of stuffing box
2.7.2
Replacement of packing
2.7.3
Dimensions
2.8
Greasing instructions
2.8.1
Bearing lubrication chart
2.8.2
Conversion table
2.9
Instructions for fitting motors to flexible-direct-coupled pumps
INSTRUCTION MANUAL
FLEXIBLE-DIRECT-COUPLED PUMPS, STUFFING BOX
Dat:
30.06.00
14.02.06
2.0
No: 94-BA 4943E/ 2g
File:
Q_FLES_E
TYPE CODE EXPLANATION
Hydraulic size
Bearing frame size
Sealing type
Material execution
Bearing frame type
Basis
Seal specification (pumpside)
Execution information
Executionspecification
DDZ 1X - TT3K
EDS 1X - C132S
EFM 5X - L225
S
=
Special construction/execution
K
F
0,2,5
=
=
=
for K-Hydraulic
for F-Hydraulic
Standard Q-Hydraulic, part of Motor size
0,1,2,3
=
Part of Motor size
1,2 etc
T
C
=
=
=
Standard (C,G,M,X-seal and stuffing box)
Special construction/execution (for T-seal)
stuffing box bearing frame with cartridge seal
0
=
Without mech. seal (Pos. 515) / without packing
(seal / packing specified by customer)
C
G
M
X
T
Pump side mechanical seal specification
(bearing frame with mechanical seal)
L
=
Packing standard (bearing frame with stuffing box)
X
=
Bearing frame with flexible coupled motor
1
5
=
=
Normal, for hydraulic material 1,2 and 3
Wetted parts stainless steel, for hydr. mat. 5
S
Z
M
=
=
=
Bearing frame with stuffing box
Bearing frame with stuffing box without sleeve
Bearing frame with mechanical seal
C
D
F
G
etc.
=
=
=
=
for Motor
for Motor
for Motor
for Motor
100/112
132/160/180
160/180/200/225
250/280
See type code explanation Hydraulic code
INSTRUCTION MANUAL
FLEXIBLE-DIRECT-COUPLED PUMPS, STUFFING BOX
Dat:
30.06.00
14.02.06
2.1
No: 94-BA 4943E/ 3c
File:
Q_FLES_E
FLUSHING WATER CONNECTION
Pumps are supplied with a flushing water connection (service
connection "F", Fig. 1).
For normal sewage application this connection is not used.
However, in special cases when pumping high concentrations of
sludge or mud, it should be connected. It will conduct cleaning
water between impeller and stuffing box seal, providing periodic
removal of accumulated solids.
Flushing water must be pressure-regulated between 0,5 to 1
bar (7 to 14 psi) above pump discharge pressure. Water is
controlled by a solenoid valve on a time clock. Adequate duration
of each flushing is 60 seconds; frequently of flushing must be
established for each different installation.
F
The quantity of flushing water varies according to pumpsize and
application: in most cases, flowrates of 6-8 litres per minute will
be sufficient.
Fig. 1
2.2
DIRECTION OF ROTATION
Before start up the pump, power connections must be made as indicated in section 2.4. Check that the
direction of rotation is correct by giving the unit a starting impulse for one second and noting impeller
rotation.
Rotation must be counter-clockwise viewed from
suction end, and clockwise viewed from driving
side.
WARNING:
If rotation is not correct on multi-speed or multipump installations, only change the cable leads
of the pump or speed with wrong rotation at
its starter in the control panel. DO NOT change
the primary power leads coming into the control
panel: This would change the rotation of all
pumps or speeds.
counter clockwise viewed
from suction end
direction
of fan
Fig. 2
2.3
direction of
impeller rotation
LEVEL CONTROL SYSTEM
Prior to any work on the pump, the power supply must be disconnected either by means of a locked isolator
or by removing the fuses from the panel. It is not safe enough to switch off the control switch. A wiring
mistake or a control system malfuction could put the motor back into operation.
INSTRUCTION MANUAL
FLEXIBLE-DIRECT-COUPLED PUMPS, STUFFING BOX
Dat:
30.06.00
14.02.06
2.3.1
No: 94-BA 4943E/ 4c
File:
Q_FLES_E
LEVEL SWITCHES
-
For the on and off levels, use control systems that are appropriate for the pumped liquid.
Use a floating-ball type switch for the high-level alarm, even when there is another type used for the pump
control (this has proven to be the most fail-safe type).
- The floating ball for the alarm should be placed at a reasonable distance above the highest pump start
level to avoid false alarms.
2.3.2
LEVEL CONTROL
"ON" and "OFF" levels must be set in such a way as to provide sufficient sump capacity between "ON" and
"OFF" so that the pump cannot be switched on more than 10 times per hour. Higher starting frequency may
damage the motor control devices in the panel and will cause excessive power consumption. The following
formula will calculate the required minimum sump capacity:
V
2.4
=
0.9 x Qp
Z
V
= sump capacity or volume, between on and off levels (in cubic
meters)
Qp = pump flow for one pump, in litres/second
Z = number of starts per hour (Z = 10, maximum)
START - UP
Prior to starting, check that: -
Electrical connections of the motor are according to name plate
Level controls are correctly set
Off-level is sufficiently high to prevent air entrance to the pump suction
Suction and discharge gate valves are completely open
Flood pump sump
STARTING OF PUMP
Never start pump against closed valves (except non-return valves).
Start the pump using manual operation. Measure the amperage drawn on each phase leg. Record and
verify these readings with the nameplate ratings. If amperage is more than 5 % higher, stop unit and
check probable causes according to "Operating Troubles" chart, Section 2.5.
Once preliminary checks are complete, place the pump into automatic operation. Cycle the system through
several wetwell pumpdowns to observe that level controls are properly set and functioning correctly.
Observe that the alarm system and change over switch (if included in control panel) are working
properly.
Log date and hours meter reading, and set pump for automatic operation. Perform maintenance according
to Section 2.6.
GENERAL OPERATING CONDITIONS
The pump should not be allowed to operate continuous-duty outside of performance curve: high discharge
pressures with low flow or low discharge pressure with high flow. Bearing life is shortened and abrasive wear
is accelerated in these operating conditions.
INSTRUCTION MANUAL
FLEXIBLE-DIRECT-COUPLED PUMPS, STUFFING BOX
30.06.00
14.02.06
File:
Q_FLES_E
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Pump not sufficient submerged, not vented
RPM too low
RPM too high
Air entrance into suction line
Discharge line clogged / valve closed
Air or gas in pumped liquid
TDH too high (higher than calculated)
Suction head too high
Insufficient suction head on hot liquids
Insufficient submergence of suction
Sludge concentration higher than assumed
Specific weight of medium higher than assumed
Impeller or suction line clogged
Wrong direction of rotation
Impeller clearance too high
Damaged impeller
Motor damage
Unsuitable lubrication
Attachments loose
Bearings worn out
Impeller out of balance
Impeller too small
Impeller dragging against suction cover
Thick sludge and tight impeller clearance
Air or gas on impeller backside
X
X
X
X
X
X
X
X
Bearing temperature > 90° C
X
X
X
X
X
X
X
X
X
Noise
Head not sufficient
Flow not sufficient
POSSIBLE REASONS
No flow
TROUBLE
Motor overloaded
OPERATING TROUBLES
Vibrations
2.5
No: 94-BA 4943E/ 5c
Reduction of flow or head
after start up
Dat:
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
INSTRUCTION MANUAL
FLEXIBLE-DIRECT-COUPLED PUMPS, STUFFING BOX
Dat:
30.06.00
14.02.06
No: 94-BA 4943E/ 6c
2.6
MAINTENANCE AND SERVICE
2.6.1
GENERAL
File:
Q_FLES_E
Before doing any work on the pump unit, switch off main isolator switch and remove fuses from panel.
The following checks can be done in the field. When a repair is indicated, send the pump unit to the nearest
authorized Hidrostal service station.
2.6.2
-
VISUAL CHECKS OF PUMP UNIT
Check pump and motor for possible mechanical damage.
If pump volume or pressure are not acceptable, check impeller clearance (see manual for hydraulic).
Check overload relay, fuses and time relays (if any) for correct setting.
Check correct function of level control.
2.6.3
SERVICE CONNECTIONS
The service connections that are built into all pumps as standard are listed below. Please refer to Fig. 3
and sectional drawings.
552
Flushing Connection "F"
Alternatively or even in addition to the function described in section 2.1, this connection may be used to
manually bleed the air from the casing prior to start-up, if there is no other place for air to escape through
the discharge piping. In most cases the connection 552 will be closed and flushing water mixes with
product pumped. In cases where the solids accumulate, could form lumps, or be fibrous flushing out via
552 would be the preferred solution. Connection 552 also permits complete draining of product from
horizontal bearing frames if required.
131
Greasing point "G2"
Greasing instructions see Section 2.8.
134
Plug "G.O."
Possibility to remove old, excessive grease.
222
Packing flushing connection "Q"
See Section 2.6.4.
INSTRUCTION MANUAL
FLEXIBLE-DIRECT-COUPLED PUMPS, STUFFING BOX
Dat:
30.06.00
07.07.98
No: 94-BA 4943E/ 7b
Fig. 3
File:
Q_FLES_E
INSTRUCTION MANUAL
FLEXIBLE-DIRECT-COUPLED PUMPS, STUFFING BOX
Dat:
30.06.00
21.10.05
2.6.4
No: 94-BA 4943E/ 8e
File:
Q_FLES_E
SEALING SYSTEMS FOR SOFT PACKED PUMPS
GENERAL
All pumps factory supplied with a soft packed stuffing box are packed in accordance with Fig. 3.
Four flushing/packing lubrication systems are available and may be specified to best suit the pumping
application. See Fig. 4 - 7 and Section 2.1 Flushing connection. Flushing liquids should be at a pressure
of approximately 0.5 - 1 bar (7 - 14 psi) above that of the pumps working pressure. It is recommended
that a flow restrictor be fitted to the flushing line to prevent excessive flow of sealing liquid, generally,
approximately 6-8 litres per hour will be adequate for most applications.
SYSTEM 1 (Fig. 4)
This is recommended when pumping biological
sludges where due to the consistency and
nature of the sludge no flushing is necessary.
Fig. 4
SYSTEM 2 (Fig. 5)
Recommended for general dirty liquids, mud
and raw or digested sludge applications. The
flushing liquid is piped through connection No. 1
on the pump back cover to the lantern ring
thereby inhibiting the entrance of abrasive
material into the packing chamber so reducing
wear.
This connection can also be used to install a
vacuum pump.
Fig. 5
SYSTEM 3 (Fig. 6)
Recommended when pumping raw sewage. A
water repellent grease is supplied by a grease
lubricator at the packing chamber through
connection No. 1 so both preventing the
penetration of solids and helping to lubricate the
packing so reducing wear.
Note: NEVER use spring - or other type of
automatic greaser.
Fig. 6
Fig. 7
SYSTEM 4 (Fig. 7)
This plan is used to flush the cavity between the
impeller and the back cover free from any
accumulating solids. Especially recommended
when pumping highly concentrated paper pulp,
sludge or mud where due to the degree of
concentration there may be a tendency to
dehydrate or sedimentate.
If the pump is used in a vertical position on
materials having a natural tendency to gasify
connection No. 2 may also be used to bleed the
pump on plant start-up.
INSTRUCTION MANUAL
FLEXIBLE-DIRECT-COUPLED PUMPS, STUFFING BOX
Dat:
30.06.00
14.02.06
No: 94-BA 4943E/ 9c
2.7
PERIODIC MAINTENANCE OF STUFFING BOX
2.7.1
REGULATION OF STUFFING BOX
File:
Q_FLES_E
The stuffing box should be adjusted to permit a constant dripping, to insure continuous lubrication and
cooling to the stuffing box assembly. Excessive adjustment will cause the packing (215) and shaft sleeve
(208) to wear. When adjusting the stuffing box gland bolts (220), insure that left and right bolts are uniformly tightened. Once the stuffing box gland (202) has reached maximum adjustment, do not add packing rings to the gland. Replace the packing rings (215) in accordance with following section.
2.7.2
REPLACEMENT OF PACKING
Once the stuffing box gland (202) has reached maximum adjustment, it is required to revise all packing
rings (215). By replacing only one packing ring to the stuffing box, the lantern ring will be pushed towards
the pump housing causing higher flow of sealing liquid to the pump, reducing the sealing effect of the front
packing rings. In most cases the packing rings nearest the impeller will be worn out. First proceed as
follows by referring to Fig. 8 to 12.
1. Disconnect power to the driver, close suction and discharge valves, isolate external service connection to stuffing box casing (200) and drain pump.
2. Remove stuffing box gland bolts (220) with washer, slide stuffing box gland (202) towards bearing
frame and using an extractor (Fig. 9) to remove the upper packing rings. Slide lantern ring (204)
towards the bearing frame. Using an extractor (Fig. 9) to remove the lower packing rings. Inspect the
shaft sleeve (208) or shaft (110) and stuffing box casing (200). Excessive wear of shaft sleeve or shaft
can cause higher leakage of the stuffing box. Replacement of the shaft sleeve: pull-off by heating,
mounting of the new sleeve by shrinking on. Should the packing be worn out, replace according to
paragraphs 3 to 4. Clean the shaft sleeve (208) or shaft (110), lantern ring (204), neck bushes (203),
stuffing box gland (202) and coat with water repellent grease.
3. Prepare the packing rings by quantity and size (see Section 2.7.3 Dimensions). If packing rings are
cut from a coil or long length, wrap the packing around a sleeve of the diameter of the shaft sleeve
(208) and cut tangentially as shown in Fig. 10. An overlapping split of the packing rings provides better
sealing, refer to Fig. 11. Do not cut ends straight on a flat strip, as the packing rings would never seal
(Fig. 12).
4. Place the neck bush (203b). Using the lantern ring (204), tamp in the lower packing rings (215) towards
the impeller and alternate joints 90° apart. Align lantern ring (204) with the seal water admission port.
Using the stuffing box gland (202), tamp in the upper packing rings alternating joints 90° apart. Install
stuffing box gland bolts (220) with washers and adjust to finger tight. Place into operation according to
these instructions. Adjust every 10 minutes until normal operation has been reestablished.
INSTRUCTION MANUAL
FLEXIBLE-DIRECT-COUPLED PUMPS, STUFFING BOX
Dat:
30.06.00
07.07.98
2.7.3
No: 94-BA 4943E/ 10a
File:
Q_FLES_E
DIMENSIONS
Fig. 8
Bearing frame
type
BCZ.X-.112
BDZ.X-.132
CCZ.X-.112
CDZ.X-.132
DCZ.X-.112
DDZ.X-.132
DDS.X-.132
DFS.X-.160
180
200
EDS.X-.132
EFS.X-.160
180
Cone size
A
B
C
D
E
F
Number of rings x
length of the
stuffing-box packing
1 1/8"
56
1
10
8
46
30
5 x 130
1 1/2"
72.5
1
12
10
68.9
49.8
5 x 198
Fig. 10
Fig. 9
Fig. 11
Fig. 12
INSTRUCTION MANUAL
FLEXIBLE-DIRECT-COUPLED PUMPS, STUFFING BOX
Dat:
30.06.00
28.03.06
2.8
No: 94-BA 4943E/ 11g
File:
Q_FLES_E
GREASING INSTRUCTIONS
For greasing intervals and amounts see bearing lubrication chart (Section 2.8.1). For regreasing bearing
frames, we recommend grease according to following specifications (from KLÜBER LUBRICATION):
FOR BEARING FRAME TYPE:
. CZ . X - . IS . X
. LS . X + . MS . X
BEARING GREASE:
STABURAGS
ISOFLEX TOPAS
Typical characteristics:
Colour:
Apparent dynamic viscosity (approx.):
Operating temperature range:
Consistency class (NLGI)
Penetration DIN ISO 2137 (0.1 mm):
Dropping point DIN ISO 2176:
Corrosion protection DIN 51802:
RPM - parameter (n x dm):
NBU 8 EP
NB 52
Mineral-oil based,
Barium-complex
as thickener.
Synthetic oil based,
Barium - complex
as thickener.
beige
6000
mPas
-30 . . +150 °C
2
280
> 220
°C
0
500 000
beige
5000
mPas
-60 . . +160 °C
2
280
> 240
°C
0/1
1 000 000
Greasing amount: Overgreasing can cause excessive operating temperature and premature bearing
failure.
Greasing intervals can be used for Horizontal Installation. They should be halved for Vertical Installation or if the following conditions apply: High humidity or contamination, ambient temperature of more
than 40°C or with increased loads which could influence the Bearings. With greasing intervals of more
than 12 months (1 year) pump must be regreased at that time.
Regreasing (whole operation can be done whilst pump is running;
see Fig. G.O.): Remove plug 134 to drain old grease. Remove plug
131 (if available; see section 2.6.3; Service connections). Put fresh
grease (with suitable device) into greasing connection 131, take care
to avoid contamination. When regreasing is finished, greasing
connection 131 and grease relief connection 134 to be closed again
with plug.
Example to read bearing lubrication chart 2.8.1 (the fields in the
table are marked grey): Bearing frame type DDS1X with a shaft speed
of 1500 rpm has a greasing interval of 8500 hours and needs a grease
amount of 28 grams. Converting the greasing interval from hours to
months see table 2.8.2. It means for our example: For an assumed
running time of the pump of 18 hrs. / day, it gives an equivalent greasing
interval of 12 months.
Fig. G.O.
HIDROSTAL AG recommends continious regreasing with an automatic, electronic grease dispenser
and offers such a product for sale. These can be connected to the potential free contact within the starter
contactor by extending the included contact wire. With this it is guaranteed that pump is greased only
during running time (if needed). Overgreasing is not possible. Grease dispensers are factory refillable. If
lubricators are ordered from the factory, please indicate correct bearing frame type
Parts identification
Content approx.
Running time
:
:
:
8SB - 125STABU
120
gramms
2
weeks
or
8SB - 125ISOFLEX
to
18
months
For description, installation and operation of this grease dispenser see seperate instruction manual.
INSTRUCTION MANUAL
FLEXIBLE-DIRECT-COUPLED PUMPS, STUFFING BOX
BCZ . X
CCZ . X
DCZ . X
BDZ . X
CDZ . X
DDZ . X
DDS . X
EDS . X
2.8.2
3000
3500
5000
5500
8500
9500
10500
11000
12000
13000
2200
3000
3500
5000
7500
8500
9500
10500
11000
12000
12
File:
Q_FLES_E
DFS . X
EFS . X
FFS . X
HFS . X
3500
3000
1800
1500
1200
1000
900
750
2000
3000
5500
6500
8000
9000
9500
10000
Amount of
grease grams
Interval
hours
CONNECTION 131
Shaft speed
rpm
Interval
hours
4800
4200
3600
3000
1800
1500
1200
1000
900
750
4800
4200
3600
3000
1800
1500
1200
1000
900
750
Amount of
grease grams
BEARING LUBRICATION CHART
Shaft speed
rpm
2.8.1
No: 94-BA 4943E/12c
Bearing
frame size
30.06.00
14.02.06
Bearing
frame size
Dat:
48
28
CONVERSION TABLE
With conversion table below, greasing intervall from table 2.8.1 can be converted from hours to months.
Greasing
interval
hours
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
7000
7500
8000
8500
9000
10000
11000
12000
13000
0
-
2
Running time in hours per day
2 - 6
6 - 12 12 - 18 18
Equivalent greasing interval in months
11
6
4
12
7
5
8
6
10
6.5
11
7
12
8
9
10
11
12
More than 12 months (1 year)
- 24
3
3.5
4
5
5.5
6.5
7
7.5
8
9
9.5
10
11
12
INSTRUCTION MANUAL
FLEXIBLE-DIRECT-COUPLED PUMPS, STUFFING BOX
Dat:
30.06.00
14.02.06
2.9
No: 94-BA 4943E/ 13a
File:
Q_FLES_E
INSTRUCTIONS FOR FITTING MOTORS TO FLEXIBLE-DIRECT-COUPLED PUMPS
Prior to commencing fitting of motor rotate impeller by hand to ascertain the degree of drag due to bearing
and mechanical seals. This will assist in checking no increase in drag has occurred due to a badly fitted
motor.
The motor can be assembled to the pump with the shaft vertical or horizontal.
-
-
Prior to commencing assembly carefully degrease and deburr motor shaft and key way, and change
the key of motor to the new (shorter) key delivered with coupling side for motor shaft. Assembly
coupling to motor shaft (dimensions see drawing and table).
Fix coupling with set screws (605).
The motor should be lowered slowly into the pump until the coupling parts engages, ensure that the
two parts slide freely together, that no undue force is necessary.
Continue to lower the motor until the spigot on motor flange engages, then fix motor to pump (621).
ATTENTION:
NEVER PUSH OR FORCE MOTOR COUPLING INTO PUMP COUPLING!
CHECK DIMENSION i2 FOR CORRECT LENGTH!
Fig. 13
DC-Bearing frame
Motor size
d
i2
X
.CS.X
100/112
28
60
8
.DS.X
132
38
80
20
.FS.X
160
42
110
180
48
110
200
55
110
40
23