SF RANGE OF CENTRIFUGAL PUMPS FOR VACUUM ASSISTED SELF PRIMING APPLICATIONS

Transcription

1 SF RANGE OF CENTRIFUGAL PUMPS FOR VACUUM ASSISTED SELF PRIMING APPLICATIONS Types SF200, SF250, SF300 and SF400 ACME Dynamics, Inc. P.O. Box 1780 Plant City Florida Telephone: Fax: Document No. W77-005E/3 USA Revision No. 3 Revision Note No. R26413 Date Issued. Sept Produced at ACME Dynamics, Inc. Plant City, Florida 33564

2 CONTENTS Section... Page 1 General Information & Safety Instructions Transport Handling and Storage General Description Assembly and Installation Commissioning and Operation Maintenance and Service Faults and Remedial Action Supplementary Documents Spare Parts Additional Information...20 After Sales Service... Back Cover Manufacturer Information: (Where applicable) Priming Equipment...Appendix I Coupling...Appendix II Driver...Appendix III Introduction This manual gives the safety, installation, operation and maintenance instructions for pumps in the ACME Dynamics DYNAPRIME SF range of horizontal, end suction, centrifugal pumps for vacuum assisted self priming applications. The ACME Dynamics, Inc. code may identify pumps typically in the form 'SF200DV306'. This manual applies to the following pump types. SF200, SF250, SF300 & SF400 Section 1 General Information and Safety Instructions The products supplied by ACME Dynamics, Inc. have been designed with safety in mind. Where hazards cannot be eliminated, the risk has been minimized by the use of guards and other design features. Some hazards cannot be guarded against and the instructions below MUST BE COMPLIED WITH for safe operation. These instructions cannot cover all circumstances; YOU are responsible for using safe-working practices at all times. 1.1 ACME Dynamics, Inc. products are designed for use in appropriate locations which are to be kept free of obstructions that may restrict safe access to the controls and maintenance access points. A pump nameplate is fitted to each unit and must not be removed. Loss of this plate could make identification impossible. This in turn could affect safety and cause difficulty in obtaining spare parts. Should accidental loss or damage occur, contact ACME Dynamics, Inc. immediately. 1.2 Access to the equipment should be restricted to the personnel responsible for installation, operation and maintenance and they must be trained, adequately qualified and supplied with the appropriate tools for their respective tasks. 1.3 ACME Dynamics, Inc. requires that all personnel that are responsible for installation, operation or maintenance of the equipment, have access to and study the product instruction manual BEFORE any work is done and that they will comply with all local and industry based safety instructions and regulations. 1.4 Ear defenders should be worn where the specified equipment noise level exceeds locally defined safe

3 levels. Safety glasses or goggles should be worn where working with pressurized systems and hazardous substances. Other personal protection equipment must be worn where local rules apply. 1.5 Do NOT wear loose or frayed clothing or jewelry, which could catch on the controls or become trapped in the equipment. 1.6 Check and confirm that the manual is the relevant copy by comparing the serial number on the identification plate with that on the manual. 1.7 Note any limits to the pump application specified in the contract documentation. Operation of the equipment outside these limits will increase the risk from hazards noted below and may lead to premature and hazardous pump failure. 1.8 Clear and easy access to all controls, gauges and dials etc. MUST be maintained at all times. 1.9 IMPROPER INSTALLATION, OPERATION OR MAINTENANCE OF THIS ACME Dynamics, Inc. PRODUCT COULD RESULT IN INJURY OR DEATH Within the manual, safety instructions are marked with safety symbols. Hazard This symbol refers to general mechanical aspects of safety. Hazard This symbol refers to electrical safety. ATTENTION This symbol gives warning of a hazard to the pump itself, which in turn could cause a risk to personal safety. Section 2 Transport Handling and Storage Instructions 2.1 Transport DYNAPRIME SF pumps are dispatched fully assembled and lubricated except for overseas orders for the SF300 & SF400 pumps, the lubricating oil in the drive end bearing housing is drained. Pumps are protected against corrosion and packed for transport by normal road, rail and sea carriers. 2.2 Handling Crushing Hazard When lifting the pump, use lifting equipment having a safe working load rating suitable for the weight specified. Use suitable slings for lifting any pump not provided with lifting points. The use of suitable forklift truck and four-chain crane sling equipment is recommended but locally approved equipment of suitable rating maybe used. Pumps supplied on pallets may be lifted by forklift truck, to lift from the pallet the pump should be slung as shown. Pump weight is shown in Section Storage Temporary Storage for up to Six Weeks FALIFT1

4 If the pump unit is not to be used immediately it should be stored carefully in a horizontal position, in a sheltered, dry location. Additional rust preventative should be applied to all unpainted carbon steel or cast iron parts, and should not be removed until final installation Long Term Storage Shearing Hazard Do NOT place fingers or hands etc. into the suction or discharge pipe outlets and do NOT touch the impeller, if rotated this may cause severe injury. To prevent ingress of any objects, retain the protection covers or packaging in place until removal is necessary for installation. If the packaging or suction and discharge covers are removed for inspection purposes, replace afterwards to protect the pump and maintain safety. For SF300 & SF400 pumps, fill the drive end bearing housing with recommended oil to ensure that the shaft and bearings remain rust free. The pump shaft should be rotated by hand at least five turns every six weeks. For special protection of the coupling, diesel engine and electric motors, where applicable, refer to the manufacturers' instructions in the relevant appendix Exposed or Extreme Conditions Storage For exposed storage or extreme variants in atmospheric or environmental conditions, please refer to ACME Dynamics, Inc. for special storage instructions to suit the conditions applicable. Section 3 General Description ACME Dynamics DYNAPRIME SUPRAFLOW pumps are a range of horizontal centrifugal pumps. The two or three vane open impeller design will handle dirty water, industrial effluents, and sludge etc, including solids. The mechanical assembly comprises a rigid shaft, supported by grease lubricated pump end bearings and either grease or oil lubricated drive end bearings with an open vane type impeller mounted in a removable bearing housing assembly. This is attached to an end suction volute casing fitted with a front wear plate. The bearing housing, shaft and impeller assembly can be withdrawn from the volute for maintenance without disconnection of pipework or the driver provided that a spacer coupling has been fitted. The discharge branch is positioned at 45 above the center of the pump volute. This allows the fitting of a ball or flap type non-return valve to give a horizontal discharge. The pump is centerline mounted and the volute is provided with an access point for examination of the impeller. The pump has been designed for use with an automatic priming system typically one using a vacuum pump with a priming tank. As several varieties of priming systems may be fitted, the details and operation instructions for the particular priming system used are fully described in a separate priming system manual. References to priming functions in this manual apply to all priming systems in general. The complete assembly is of a rigid construction, being intended for mounting on suitable baseplate with electric motor or diesel engine driver. A suitable coupling is required to transmit the rotational drive between pump and driver. The shaft is sealed with a vacuum pressure seal. Alternative seals can be supplied by arrangement to suit special customer requirements and the liquid being pumped. The materials of construction are: Component Impeller Volute Casing Material Stainless Steel or Cast iron (Note - SF400 Cast iron only) Cast Iron

5 Suction Cover Backplate Bearing Housing Shaft SG Cast Iron Stainless Steel or Cast iron Cast Iron Stainless Steel Nameplate details are shown on the back cover of this manual. Full pump specification can be supplied on a data sheet, if requested. Section 4 Assembly and Installation Shearing Hazard Do NOT place fingers or hands etc. into the suction or discharge pipe outlets and do NOT touch the impeller, if rotated this may cause severe injury. To prevent ingress of any objects, retain the protection covers or packaging in place until removal is necessary for installation. 4.1 Initial Inspection for Damage During transport and storage, accidental damage to the pump may have occurred. When the pump is to be installed, or in the event of a handling accident, carefully check that no damage has been sustained by the pump before installation and commissioning. 4.2 Preparation for Mounting Before installation, check that the pump mounting location is suitable for accepting the pump unit. Refer to Section 8, for details of pump installation dimensions or to a certified General Arrangement Drawing, when available. 4.3 Pump Preparation Abrasion and Entrapment Hazard Do NOT touch any moving or rotating parts. Guards are provided to prevent access to these parts, where they have been removed for maintenance they MUST be replaced before operating the equipment. Remove packaging but leave the flange covers in place, check that the impeller rotates freely by hand by turning the shaft. 4.4 Pump Installation It is recommended that the pump unit be fitted to the baseplate before fitting the motor and coupling. The distance between shaft ends should be established to suit the coupling by reference to the manufacturer's instructions. 4.5 Shaft Alignment To minimize the side load on the bearings and to achieve full coupling and bearing life, it is recommended that the shafts be aligned as accurately as possible i.e. well below the allowable misalignment of the coupling. Refer to the coupling manufacturer's instructions or proceed generally thus: a) Lateral Alignment Mount a dial gauge on the motor shaft or coupling with the gauge running on the outer machined diameter of the pump coupling. Turn the motor shaft and note the total indicator reading. b) Angular Alignment Mount a dial gauge on the motor shaft or coupling to run on a face of the pump coupling as near the outside diameter as possible. Turn the motor shaft and note the total indicator reading. c) Confirm Lateral Alignment Mount the dial gauge on the pump shaft or coupling with the gauge running on

6 the outer machined diameter of the motor coupling. Turn the pump shaft and note the total indicator reading. d) Adjustment The motor must be shimmed and re-positioned to align the shafts within the coupling manufacturer's specifications. e) Alternative Method If a dial gauge is not available, calipers or taper gauge may be used to measure the distance between the coupling flanges at four points around the circumference and a straight edge used to check the lateral alignment of the outer flange diameters. ATTENTION Shaft alignment must be checked again after the final positioning of the pump unit and connection to pipework as this may have disturbed the pump or motor mounting positions. 4.6 Suction Pipework It is recommended that the pump be installed as near to the liquid source as possible Any rigid pipework should be supported independently and close to the pump so that no strain is transmitted to the pump when the flange bolts are tightened. Use pipe supports at intervals necessary to provide support. When expansion joints are used in the piping system, they must be installed beyond the piping supports closest to the pump. ATTENTION Collapsible hoses must not be used on the suction side of the pump. Install piping as straight as possible, avoiding unnecessary bends. Where necessary use long sweep 90 bends or fittings to decrease friction losses. Make sure that all suction piping joints are airtight. Provide pipe expansions when hot fluids are to be pumped. Where reducers are used, eccentric reducers (tapered side down) are to be fitted in horizontal suction lines and straight taper reducers in vertical discharge lines. Undulations in the pipe runs or misuse of reducers may cause the formation of air pockets in the pipe and thus prevent the efficient operation of the pump. The suction (and discharge) pipes can be one or two sizes larger than the pump flange connections. A horizontal suction line should have a gradual rise to the pump. A correctly sized filter or strainer must be fitted to hold back larger items. The suction pipe work should be flushed clean to ensure that site debris is not drawn into the pump when it is commissioned. 4.7 Discharge Pipework Pipework should be as short and straight as possible to reduce friction head loss. A non-return valve is usually fitted to prevent the pump from excessive back pressure and reverse rotation and a discharge valve must be fitted to regulate the flow and allow for inspection and maintenance on the pump. The suction and discharge pipework must be independently supported and positioned such that no excessive forces and moments are exerted on the pump flanges. Typical Pipework

7 XFPIPE1.CDR ATTENTION Failure to support suction and delivery pipework may result in distortion of the pump casing, with the possibility of early pump failure. 4.8 Baseplate and Foundations The pump is designed to be secured to a substantial baseplate to maintain the shaft alignment between the driver and the pump. The baseplate should be securely located on level ground or mounted on foundations. The shaft alignment should be checked again before commissioning and putting the pump into operation. Section 5 Commissioning and Operation Abrasion and Entrapment Hazard Do NOT touch any moving or rotating parts. Guards are provided to prevent access to these parts, where they have been removed for maintenance they MUST be replaced before operating the equipment. 5.1 Commissioning Checks These checks must be done after first installation and after pump maintenance, which required removal of the rotating assembly. ATTENTION On SF300 and SF400 pumps check the level of oil in the bearing housing is at the level mark on the sight glass on the side of the bearing housing. Refer to Section Bearing Lubrication. ATTENTION Failure to supply the bearings with specified lubrication may result in damage and premature failure of the pump. Check that the rotating assembly is free to rotate by hand before connecting the power supply. Also check that the piping system has been properly connected with all joints tightened and instrumentation is in position. When using an electric motor, connect the electrical supply to the pump unit. Momentarily switch on motor and check direction of rotation. This should be such that the pump assembly turns clockwise when viewed on the driven end. For three phase electric motors, if direction of rotation is incorrect, disconnect the supply and change over two of three supply wires. When using a diesel engine verify that the direction of rotation of the engine is correct for the pump by reference to the engine manual.

8 5.2 Starting Procedure Open any valves in the discharge pipes to prevent hydraulic lock from occurring. Start the engine or switch on the motor and allow it to build up to full operating speed. Check that the motor is not overloading, unit is not vibrating or excessively noisy, bearings are not overheating, and that the pump is developing the correct flow and head requirements. If the pump is operating at its normal speed, the pump should be shut down at once if any of the following defects are found: a) Excessive vibration. b) Motor runs hot. c) Excessive noise from cavitation d) Pump bearing overheating. Recommended corrective action for these faults is given in Section 7 Faults and Remedial Action. 5.3 During Operation Hot Surfaces Hazard Do NOT touch surfaces, which during normal running will be sufficiently hot to cause injury. Note that these surfaces will remain hot after the pump has stopped, allow sufficient time for cooling before maintenance. Be cautious and note that other parts of the pump may become hot if a fault is developing. Cold Conditions Hazard Beware of operating water pumps in temperatures below freezing point, without first checking that the pumped fluid is not frozen and the pump is free to turn. Remember to drain down the pump after stopping. Hazardous Noise In addition to local or site regulations for noise protection, ACME Dynamics, Inc. recommends the use of Personal Ear Protection equipment in all enclosed pump rooms and particularly those containing diesel engines. Hazardous Gases, Mists, Sprays and Leaks Be aware of the hazards relating to the pumped fluid, especially the danger from inhalation of noxious and toxic gases, skin and eye contact or penetration. Obtain and understand the hazardous substance data sheets relating to the pumped fluid and note the recommended emergency and first aid procedures. Periodic Checks: a) Vacuum Pressure Seal: A small amount of leakage may occur but significant leakage indicates seal failure and that replacement is necessary. b) Bearings: Check the bearing temperatures do not exceed the maximum levels in the table below. If these temperatures are exceeded, the pump should be shut down for investigation, as an increase in bearing temperature may indicate the early stages of bearing trouble. Pump Maximum Bearing Temperature Type Non Drive End Drive End SF200 SF C 100 C SF300 SF C 130 C c) Noise: Listen for any unusual noise or an increase in normal sound level.

9 This may result from: i) Loose fasteners for guards and other equipment. ii) Worn coupling. iii) Cavitation caused by air in the liquid from leaks in the suction pipework. SERIES PUMP d) Alignment: Alignment should be checked after the first run and after any maintenance requiring removal or disconnection of the coupling. For detailed instructions, refer to Section Shaft Alignment 5.4 Stopping Procedure Refer to the diesel engine instruction manual for the engine stopping procedure. Reduce the engine speed and stop the engine then close any valves in the discharge pipes, or switch off the electric motor and the speed will reduce quickly, when stopped close the discharge valve. Section 6 Maintenance and Service 6.1 General Introduction ACME Dynamics DYNAPRIME pumps will provide many years of trouble free service when maintained in accordance with these instructions. In the event of failure of the pump it is recommended that ACME Dynamics, Inc. Service Department be called to investigate and carry out repairs. The following instructions are given to cover the main elements of strip and rebuild but do NOT include instructions for work that MUST be done by an ACME Dynamics, Inc. Service Engineer. The following hazards may arise during maintenance work: Fluid Pressure Jet Hazards Check and ensure that the pump operates at below the Maximum Working Pressure specified in the manual or on the pump nameplate and before maintenance, ensure that the pump is drained down. Hazardous Materials Wear a suitable mask or respirator when working with Packing and Gasket components, which contain fibrous material, as these can be hazardous when the fibrous dust is inhaled. Be cautious, if other supplier's components have been substituted for genuine ACME Dynamics parts, these may then contain hazardous materials. Hazardous Gases, Mists, Sprays and Leaks Be aware of the hazards relating to the pumped fluid, especially the danger from inhalation of noxious and toxic gases, skin and eye contact or penetration. Obtain and understand the hazardous substance data sheets relating to the pumped fluid and note the recommended emergency and first aid procedures. BEFORE ATTEMPTING ANY MAINTENANCE ON A PUMP, PARTICULARLY IF IT HAS BEEN HANDLING ANY FORM OF HAZARDOUS LIQUID, ENSURE THAT THE UNIT IS SAFE TO WORK ON. THE PUMP MUST BE FLUSHED THOROUGHLY WITH A SUITABLE CLEANSER TO PURGE AWAY ANY OF THE PRODUCT LEFT IN THE PUMP COMPONENTS. THIS SHOULD BE CARRIED OUT BY THE PLANT OPERATOR AND A CERTIFICATE OF CLEANLINESS OBTAINED BEFORE STARTING WORK. TO AVOID ANY RISK TO HEALTH IT IS ALSO ADVISABLE TO WEAR PROTECTIVE CLOTHING AS RECOMMENDED BY THE SITE SAFETY OFFICER, ESPECIALLY WHEN REMOVING OLD PACKING WHICH MAY BE CONTAMINATED. Recommended Maintenance Schedule For motor or engine maintenance and maintenance of the priming system (when fitted) refer to the separate operators handbooks included within the pump documentation pack. PERIOD Daily TASK For SF300 & SF400 pumps, check the lubricating oil level in

10 PERIOD Weekly or 170 hours Monthly or 700 hours 6 monthly or 4000 hours Annually or 8000 hours TASK bearing housing sight glass and top up if needed. Check the bearing temperatures. Check visually for leaks. Check for vibration. Check security of all fasteners and hose fittings. Apply grease as shown in the schedule in Section 6.4. For SF300 & SF400 pumps, replace the oil in the drive end bearing housing. Renew packing in the vacuum pressure seal. Check condition of impeller and wear plate. Check pump bearings. The above schedule is given for guidance but site-operating conditions may override the suggested maintenance intervals. Adjustments to time scales will also have to be made if the pump is idle for long periods. 6.2 Preparation for Maintenance Electric Shock & Accidental Starting Hazard ISOLATE the equipment before any maintenance work is done. Switch off the main supply, remove fuses, apply lockouts where applicable and affix suitable isolation warning signs to prevent inadvertent reconnection. For diesel driven pumps disconnect the negative battery lead to prevent inadvertent starting. In order to avoid the possibility of maintenance personnel inhaling dangerous fumes or vapors. It is recommended that maintenance work be carried out away from the pump location by removal of the bearing housing and shaft assembly to a suitable maintenance area. It is important to ensure the suitable lifting equipment is available and that the work is carried out in a clean area. 6.3 Maintenance of the Vacuum Pressure Seal The seal is product lubricated and requires only regular inspections for signs of leakage, which when significant indicates the need to replace the packing. To replace the seal packing: Ensure the volute is drained. A plug in the bottom of the volute is provided for this purpose. Remove guard from around pump shaft. Release screws and nuts holding the spring carrier to the rear cover plate and slide the spring carrier along the pump shaft. This will automatically withdraw the packing holder. Remove old packing from packing holder. Examine the spring for signs of corrosion. Replace if necessary.

11 Cut a length of packing to match the original packing ensuring the ends are square. The packing material is four ply graphite impregnated braided P.T.F.E. Place the packing into the holder, butting the two ends first then pressing the remainder of the packing into the holder. (NB the length of the packing is greater than the circumference of the holder and some difficulty may therefore be experienced) The packing will protrude slightly from the face of the holder on completion. Slide the seal assembly back along the shaft to locate on backplate. Tighten securing nuts and screws evenly. Refit the shaft guard. 6.4 Bearing Lubrication Schedule Frequency of re-lubrication is dependent on a number of factors, which can vary with the application. These include operating conditions, frequency and duration of service, environment (humidity, dust & other contaminants) and operating temperature. The frequency of re-lubrication listed below is therefore for guidance only and should be modified to suit operating conditions. PUMP TYPE SF200 SF250 SF300 SF400 RADIAL BEARING Non-drive end (NDE) GREASE LUBRICATED 4 weeks hours 2.03 oz. grease GREASE LUBRICATED 4 weeks hours 3.38 oz grease RADIAL & THRUSTBEARING Drive end (DE) GREASE LUBRICATED 4 weeks hours 6.09 oz. grease OIL LUBRICATED DAILY - Check level and top up as required. Change oil every 6 months or 4000hours Recommended Lubricants Grease: Oil: Mobile 1 Synthetic HP Bearing Lubrication & Care a) Bearing Description: The smaller pumps, SF200 and SF250 incorporate a combination of cylindrical roller and angular contact ball bearings which even at relatively high speed, only require grease lubrication. The larger pumps, SF300 & SF400 due to high axial thrust, use a high capacity taper roller bearing pair at the drive end which must be oil lubricated at speeds over 1,500rpm, with a grease lubricated pump end bearing. Oil lubrication limits the pump to horizontal (or near horizontal) applications. b) Initial Lubrication:

12 Greased bearings are pre-packed with lubricant during pump manufacture or re-assembly. The grease is thoroughly worked into all parts of the bearing, and the space in the housing is lightly packed to a maximum of two-thirds full. Oil chambers on the larger pumps are emptied for transport and must be filled with the specified synthetic oil to the BOTTOM of the sight glass prior to running. b) Lubrication of Grease Lubricated Bearings: Because of shrinkage and normal loss of grease, re-greasing should be carried out at regular intervals. Clean the bearing housing nipples and the grease gun nozzle before use. Check the output from the grease gun beforehand and calculate the correct number of strokes to supply the specified quantity of grease and apply to each bearing position as specified in the lubrication schedule in Section 6.4. Overfilling can be as harmful to bearings as under-lubrication. If the housing becomes compacted, the grease is churned by the bearing rolling action leading to overheating and breakdown of the lubricant with subsequent damage to the bearing. Immediately after re-lubrication of greased bearings it is normal for the temperature of the housing to rise during service. This should soon drop to normal under continuous running. If the temperature remains elevated above normal or continues to rise, temporarily remove the grease nipples and allow the escape of excess grease. c) Lubrication of Oil Lubricated Bearings: Oil should be topped up when not visible in the pump sight glass. It is IMPORTANT to use the specified oil only. Oil lubrication is complicated by the probability that these pumps may not be operated on a totally horizontal platform. Sight glasses are provided on both sides of the pump and the oil level should be checked in both to ensure that the oil level is visible at the bottom of the higher sight glass. 6.6 Impeller Inspection The pump-casing volute is fitted with a removable cover to allow limited visual inspection only of the pump internals. Ensure that the pump prevented from starting and that the volute has been drained before removing the inspection cover. 6.7 Disassembly of the Pump Refer to Section 8 - Pump cross-section Drawing. The pump is designed to allow removal of the bearing housing, shaft and impeller assembly without disconnecting the pipework. If the pump is fitted with a spacer coupling, the driver need not be removed. a) Removal of the Rotating Assembly Disconnect the drive coupling as per the coupling manufacturer s instructions, and either remove the pump complete from the baseplate or move the driver or spacer coupling to allow withdrawal of the rotating assembly without de-mounting the pump volute casing. Remove any bolts connecting the drive end of the bearing housing (62) to a support from the baseplate and remove the support. On SF300 & SF400 pumps, drain the oil from the bearing housing by removal of the drain plug (1L). Support the bearing housing assembly and ensure that suitable lifting facilities are available. Remove all the screws (1B) from the volute casing (1). Insert two of these screws into the jacking screw positions and gently tighten to separate the bearing housing (62) from the volute casing.

13 Remove the bearing housing complete with shaft and impeller from the volute casing and move this rotating assembly to a clean area for further disassembly. b) Removal of the Impeller Support the rotating assembly securely and ensure that suitable lifting facilities are available. Remove the plastic cap (21X) from the center of the impeller to give access to the impeller retaining screw (21A). Use the drive shaft keyway to prevent the impeller from turning and loosen the impeller retaining screw. Using a soft faced mallet, gently tap the impeller to free it from the tapered shaft. When free remove the screw and using suitable lifting equipment, withdraw the impeller. Extract the impeller key (116) from the shaft and retain for re-assembly. Do not remove the balance weights (if fitted) from the impeller. c) Removal of the Backplate and Seal Housing Remove the screws (36A) securing the backplate (36) to the bearing housing (62). Carefully withdraw the backplate from the shaft (71) ensuring that the seal components are not damaged on the shaft. The seal spring carrier (41) may be removed from the backplate at this stage. d) Removal of the Shaft and Bearings Remove the pump half coupling from the shaft as per the coupling manufacturer s instructions. On SF200 & SF250 pumps: Remove the shaft sealing rings (63R & 64R) from both ends of the bearing housing. Remove the drive end bearing cap (64) from the bearing housing. On SF300 & SF400 pumps: Remove the inner shaft sealing ring (63R) Remove the screws (A62A) to allow the rear bearing housing (B62) to be removed with the shaft. Using a suitable press, apply pressure to the tapered end of the shaft and push the shaft out from the bearing housing, complete with the drive end bearings and the inner race of the non drive end bearing. Do NOT drive the shaft from the bearing housing using hammer blows as this will damage the bearings and prevent their re-use. On SF300 & SF400 pumps: Remove the drive end bearing cap (64) from the rear bearing housing (b62). Using a suitable press, apply pressure to the tapered end of the shaft and push the shaft out from the rear bearing housing, complete with the drive end bearings. Drive end bearings may be cleaned and examined whilst on the shaft. e) To remove the bearings from the shaft: Unlock the tabwasher (75F) and using a suitable C spanner, remove the locknut (75). Using a collar of suitable diameter, press the drive end bearings (67) off the shaft by applying force to the inner race only. To remove the inner race of the non-drive end bearing (66), heat may be needed before applying force

14 using a suitable drift and hammer blows. The outer race and roller cage of the non drive end bearing (66) may be removed after withdrawal of screws (63A) and removal of the non drive end bearing cap (63). Bearing Specifications: For SF200 & SF2500 Pumps: Drive End Bearings SKF 7319 Pump End Bearing SKF nu217 For SF300 & SF400 Pumps: Drive End Bearings Timken Assy 904A3 Pump End Bearing SKF nu2222 Drive end bearings are fitted in matched pairs and must be replaced in pairs. Inspect the bearings for wear, fractures, cracks, corrosion or other damage, which may necessitate bearing replacement. If the bearings are to be re-used, ensure they are thoroughly flushed with white spirit or similar cleaning fluid, dried and protected to prevent any abrasive media from coming into contact with the races and balls. Bearings should be lightly oiled and wrapped for storage. Check the shaft (71) for straightness by mounting between centers and measuring the runout with a dial gauge at the coupling, bearings, center, seal and impeller positions. The run-out should not exceed 0.05 mm in any of the positions measured. All parts should be cleaned, inspected for damage and replaced. If pump efficiency has reduced, the suction cover (2) wear plate and impeller (21) may be replaced, contact the ACME Dynamics, Inc. Parts and Service Departments for supply of new parts. 6.8 Re-assembly of the Pump The pump unit may be re-assembled in the reverse manner to disassembling. To ensure correct and trouble free operation, care should be taken on re-assembly and the following precautions taken: a) Precautions Cleanliness is important ensure that all pump components together with the working areas, are completely free of foreign matter, dirt and dust. All O ring grooves, V ring housings and mating surfaces for shims are to be properly cleaned and new O rings, V rings and shims fitted. O rings and V rings should be lubricated lightly to ease assembly. Check the locking washer (75F) for wear or damage and replace if necessary. It is recommended that only spare parts manufactured by and obtained from ACME Dynamics, Inc. are used during maintenance re-assembly of any DYNAPRIME SF range pump. The company cannot be held responsible for any failure, which may cause danger to property or health, arising from the use of spare parts manufactured and supplied by others, these will also invalidate the pump warranty. When ordering spare parts it is essential to quote the pump serial number from the identification plate and the required part number(s) as shown in the parts list in Section 8. If new proprietary parts such as bearings O rings and V ring seals are to be fitted, ensure they are the correct size, grade and quality. b) Bearing Assembly

15 When fitting new bearings they should be pre-heated on an induction heater bar to 80 0 C for a short time. This will enable the bearing to be easily slid on the shaft seating and when cool will give a positive shrink fit. Always ensure bearings abut correctly against shaft shoulder and that angular contact ball bearings have been fitted back to back as shown on the section drawing. After the shaft, bearings and bearing covers (63 & 64) etc. have been reassembled in the bearing housings (62 and B62) with all the V ring seals (B62T and 63S) and circlips (A/B74) etc., the end float of the rotor should be within the following dimensions. Rotor End Float 0.13 to 0.18 mm If the lock nut is used to push-home the bearing then a special hook spanner must be used to turn it. Do not use a drift and hammer blows. The tab washer should NOT be in place during this procedure since there is a risk of shearing off the inner tab. The nut should be removed when the bearing is fully pushed home then the tab washer and nut placed in position and tightened to Nm and the tab washer locked. c) Initial Lubrication Grease lubricated bearings: Bearings should be cleaned, dried and packed with new grease, on both sides to about two thirds of their circumference and then rotated several times to spread the grease before installation in the bearing housing. The drive end bearing cap should also be loaded with new grease to about two thirds full before refitting. Oil lubricated bearings: d) Refitting the Backplate and Seal Assembly Locate the seal spring carrier (41) complete with seal assembly with packing in position on the shaft (71). Place the backplate assembly in position over the shaft and align all the fixing holes. Secure the backplate in position with three fasteners, but do not tighten fully at this stage. Install the impeller on its taper and ensure that it is fully seated in position. Measure the gap between the back of the impeller and the backplate. Disassemble the impeller and backplate and insert the required thickness of shims (36U) to give a clearance between the backplate and impeller of between 0.5mm and 1.0mm (0.020 and )

16 Refit the backplate and tighten the retaining screws uniformly. Refit the impeller and check the clearance with feeler gauges and adjust the shims again if necessary. Locate the seal spring carrier assembly on the backplate and secure in position with screws (41B/C) e) Refitting the Impeller Fit the key (116) to the shaft (71) and slide the impeller (21) on to the shaft. Ensure that it sits fully and squarely on the taper on the shaft. Fit the impeller retaining capscrew (21A) and washers (21F & 12G), lock the shaft using the drive end keyway and tighten the impeller retaining capscrew to 350 Nm. Rotate the impeller and visually confirm that it runs true, if not remove, clean all parts and reassemble. Fit the plastic cap (21X) in the impeller recess. f) Refitting the Rotating Assembly Replace any casing plugs removed during dismantling. Lubricate and install the O ring (36R) in its groove on the backplate (36). If the suction cover (2) has been removed, ensure that it has been fitted the correct way round for clockwise impeller rotation (looking on the pump drive end). Fit 3mm (6 x 0.5mm) shims (A62U) between the volute casing (1) and the bearing housing (62) and fit the rotating assembly in the volute casing, secure with screws (1B) lightly tightened. Taking care to prevent pump rotation, reach in through the suction port and using feeler gauges, measure the average clearance between the impeller vanes and the suction cover (2). Calculate the amount of shims to be removed to give a final average clearance of between 0.38mm and 0.50mm (0.015 and ). Disassemble and reduce the shim pack to give this clearance, reassemble and fully tighten all screws uniformly. Measure the clearance again and if necessary repeat the procedure to ensure the required clearance is achieved. 6.9 Hydrostatic Testing After maintenance or repair involving strip down of the pump, a hydrostatic test to a maximum of 1.3 times the nominal pump working pressure is recommended.

17 7.1 Priming System Faults Pump Fails to Prime Check pump drain valve is closed. Check vacuum pump is operating, if not rectify or replace the pump. Disconnect vacuum hose and take a vacuum reading, refit the hose and fit vacuum gauge to the pump inlet and take another vacuum reading. YES Are vacuum gauge readings the same? NO Check the suction hose for internal collapse. Replace any faulty hose. Check suction intake for blockage. Clear blockage, using back flush where provided. Check that the static suction lift does not exceed the pump capabilities, if so - Reposition pump closer to the liquid level. Stop pump and listen for air leaks. Stop any air leaks found. Remove vacuum hose and check for collapsed internal hose lining. Replace hose if faulty. Check air filter for blockage. Clean housing or replace filter. Check non return valve is seating. Remove any debris found. Check the mechanical seals. Replace if leaking or faulty. Pump runs with low flow Check that the static suction lift does not exceed the pump capabilities, if so- Reposition pump closer to the liquid level. Check that the delivery head is not higher than the pump capability, if so - Raise the pump if possible or install a pump with higher head rating. Check suction intake or pipes for blockage, also check impeller for blockage. Clear blockage, using back flush where provided. Check non return valve is n ot blocked. Remove any debris found. Check that pump speed is correct. Adjust driver to give correct speed. Check the impeller for wear or damage, Replace impeller if worn. Check liquid viscosity and density, if greater than water, the pumped head will be reduced. Pump surges with intermittent flow Check that the impeller is not blocked. Clear any impeller blockage. Check non return valve is not blocked. Remove any debris found. Check for a suction air leak. Cure air leaks as required. If further faults are evident, refer to the following pump faultfinding tables 7.2 Pump Fault Finding

18 POTENTIAL FAULT OR DEFECT: Insufficient liquid delivered. Liquid delivered at low pressure (Fails to achieve the required delivery head) Loss of liquid after starting. Excessive vibration. Pump bearings run hotter than normal. PROBABLE CAUSES Speed too low. Speed too high. Blockage or Internal collapse of suction or delivery hose Air leaking into pump casing or priming system. Lubricating oil dirty or contaminated. Foundation not rigid or pump mountings loose or worn. Misalignment of pump and driver. Impeller worn or increased clearances Bearing worn. Rotor out of balance due to blockage or damage. Shaft bent. CAUSE Speed too low. Speed too high. Blockage or Internal collapse of suction or delivery hose Air leaking into pump casing or priming system. Bearing lubricating oil dirty or contaminated. Foundation not rigid or pump mountings loose or worn. Misalignment of pump and driver. Bearings worn. Rotor out of balance. Shaft bent. REMEDIAL ACTION Check that the driver is functioning correctly and running at the required speed. Check that the driver is functioning correctly and running at the required speed. Check hoses. Replace damaged hoses or clear blockage. Check all hose joints, plugs and pipes. Check that the vacuum pressure seal is not leaking. Drain the oil, check type of contaminant, if no metal pieces are present, flush the bearing housing and refill with new oil. Run the pump and monitor bearing noise and temperature. If metal pieces are present check for shaft movement and if excessive dismantle the pump and replace the pump bearings. Ensure that the pump driver mounting bolts are tight and the pump foundations are secure. Check and realign the pump and driver as specified. Remove the bearings, clean and inspect for damage and wear, replace as necessary. Check the impeller for damage. Replace as necessary. Check shaft run-out and replace if needed.

19 Section 8 Supplementary Documents 8.1 Pump Dimensions For details of pump installation dimensions, please refer to the following General Arrangement drawings: Pump Size SF200 SF250 SF300 SF400 General Arrangement DN DN DN DN Approx. Weight Note - Pump Only 1764 lbs lbs lbs lbs. 8.2 SF Pump Technical Data Casing Pressure The maximum casing pressure is 145 PSI Direction of Rotation The direction of rotation is clockwise when viewed on the drive end Maximum Speed The maximum operating speed of SF pumps is 2000rpm, except SF400, which is 1800rpm. 8.4 Spare Parts SF200& SF250

20 2 1A 1F 2U R SERIES PUMP 305A 305F U 62U 21B A 63F A 64F XF XS1 64R 75 75F 21A 21F 21G 21X 2R 1 1L 21Y 21Z 1B 21C 1G 36 36A 36F 36R 63R 63 63S B, 41F 41X 41R A 47 47R A ENLARGED VIEW OF VACUUM PRESSURE SEAL Pumps NOTE 41C, 41F 41S * The angular contact ball bearing pair are fitted back to back as shown.

21 Parts List for SF200 & SF250 Pumps ITEM DESCRIPTION PART No. QTY 1 Casing A Screw: M16 x B Screw: M16 x F Washer: spring M G Washer: spring M L Plug: 1"BSP Cover: suction R O ring: 379.3mm ID U Shim Impeller Stainless Impeller Cast Iron A Screw: M16 x B Screw: M8 x C Screw: M8 x F Washer: copper M G Washer: brass M X Cap: plastic Y Balance weight Wear ring Backplate Stainless Backplate Cast Iron A Screw: M10 x F Washer: spring M R O ring: 379.3mm ID U Shim Spring carrier A Dowel: 8 Dia. x B Screw: M10 x C Screw: M10 x F Washer: spring M R Seal: 94.3mm ID S O ring: 160mm ID ITEM DESCRIPTION PART No. QTY 41X Spring Shaft sleeve A Screw: M6 x R O ring: 59.5mm ID Packing holder Packing: 12.5 sq mm 62 Bearing housing U Shim Bearing cap A Screw: M12 x F Washer: spring M R Oil seal: V ring S Oil seal: 85 x Bearing cap A Screw: M12 x F Washer: spring M R Oil seal: V ring Brg: cyl roller 85 dia * Brg: a/con ball 95 dia Shaft Locknut: M95 x F Washer: locking Grease nipple: 1/8 BSP x 90E SY Key: 14 x 9 x Key: 14 x 9 x Plate: anti rotation Inspection cover A Screw: M12 x F Washer: spring M R Gasket

22 8.4.2 SF300 & SF400 Pumps 1A 1F 2U R 305A 305F SERIES PUMP 305 A62U 36U 21B A 63F A62 A62A A62F A74 B62T B62 64A 64F 64S 64 64L B74 64R XF XS F 21A 21F 21G 21X 2R L 21Y 21C 41C, 41F 21Z 1B 1G 36 36A 36F 36R 63R 63S B62R B62L B62M 67 41X 41R B62S A 47 47R A 115 B62S 2 41S ENLARGED VIEW OF VACUUM PRESSURE SEAL 41B, 41F VIEW ON DRIVE SHAFT END

23 Parts List for SF300 and SF400 Pumps ITEM DESCRIPTION PART No. QTY 1 Volute Casing SF Volute Casing SF A Screw: M16 x B Screw: M16 x F Washer: spring M G Washer: spring M L Plug: 1"BSP Cover: suction R O ring: 459.3mm ID U Shim Impeller Stainless SF Impeller Cast Iron SF Impeller Cast Iron SF A Screw: M20 x B Screw: M10 x C Screw: M10 x F Washer: copper M G Washer: brass M X Cap: plastic Y Balance weight Wear ring Backplate Stainless SF Backplate Cast Iron SF Backplate Cast Iron SF A Screw: M10 x F Washer: spring M R O ring: 459.3mm ID U Shim Spring carrier A Dowel: 8 dia x B Screw: M10 x C Screw: M10 x F Washer: spring M R O ring: 124.3mm ID S O ring: 190mm ID X Spring Shaft sleeve A Screw: M6 x R O ring: 89.5mm ID Packing holder Packing: 12.5 sq mm A62 Brg housing: main A62A Screw: M12 x ITEM DESCRIPTION PART No. QTY A62F Washer: spring M A62U Shim B62 Brg housing: rear B62L Plug: 1/2"BSP mag B62M Plug: 1/2"BSP B62R Seal B62S Seal B62T Oil seal:125 x Bearing cap A Screw: M12 x F Washer: spring M R Oil seal: V ring S Oil seal:110 x Bearing cap A Screw: M12 x F Washer: spring M L Plug: 1/8"BSP R Oil seal: 65 x S O ring: 164.3mm ID Bearing: cyl roller Brg: 2 row tpr roller Shaft A74 Circlip: internal B74 Circlip: internal Locknut: M75 x F Washer: locking Cap: filler/breather 3/4"BSP 105 Grease nipple: 1/8"BSP x 90Ε SY Window nut Key: 18 x 11 x Key: 18 x Plate: anti rotation Inspection cover A Screw: M12 x F Washer: spring M! R Gasket The following part is not illustrated but is fitted to the side of the main bearing housing (A62) Plug: 1 1/2"BSP

24 Section 9 Additional Information 9.1 Standard Metric Nut and Bolt Torque Recommendations This information is for reference only. The user must check that the torque figures listed here are applicable to the fasteners used. Nuts and bolts should be neither under nor over tightened. Grade of Approximate Torque (Nm) for Bolt Diameters: Bolt M5 M6 M8 M10 M12 M16 M20 M24 M30 M Note: These torque figures are approximate, and for unplated fasteners only. No allowance has been made for special finishes or lubricants, washers or mating surfaces. Bolt and Nut Grade Combinations Grade of BOLT Note: It is permissible to fit higher Grade of NUT grade nuts than recommended. Grade Identification BOLTS & NUTS - Grade 4.6 BS4190 (ISO272, 885, 888 & 4759/1). Grade marking is optional. Normally there will be no mark other than the 'M' thus: BOLTS - Grade 8.8 BS 3692 (ISO272, 4759/1). Grade marking is mandatory, may also have trademarks. NUTS - Grade 8 Indented marks as a clock face, dot at 12.00, bar at 8.00, indicates grade 8 nut. High Strength Friction Grip Bolts & Nuts BOLT NUT BOLT Grade 10.9 NUT Grade 12

25 Maintenance Record Date Summary of maintenance & repairs done - replacement parts fitted etc: Installed & Commissioned SERIES PUMP ACME Dynamics, Inc. operates a comprehensive Spares and Service support network throughout the world, and can be