Multi-stage Immersion Type

Transcription

1 Coolant Pump Instruction Manual Multi-stage Immersion Type VKA/VKC Series WARNING Do not hold the strainer (wire net) of the pump point at the handling of this product. Doing so may cause the strainer (wire net) to come off, resulting in injuries or damage. CAUTION This instruction manual describes important information related to handling the pump. Before using the pump, be sure to read this instruction manual thoroughly for correct handling. Be sure to provide this instruction manual to the operator who will actually install, operate, maintain, and inspect the pump. Be sure to keep this instruction manual in the place where the operator can read it any time. This product is subject to change without prior notice.

2 Safety Precautions Prior to use of the pump (transporting, installation, maintenance, etc.), be sure to read this instruction manual thoroughly for correct handling. All information related to the pump itself and safe use of it are described in this instruction manual, and should be clearly be understood before using the pump. Appropriate handling at the stage from the product arrival to the beginning of the actual operation is necessary, in addition to the maintenance and inspection after the operation starts, in order to fully achieve the performance of the Coolant Pump, prevent the accident beforehand, and to continue an excellent operation for a long term. Safety Notices used in this instruction manual are divided into two ranks: "Danger" and "Caution". WARNING Indicates a potential hazardous situation that, if not avoided, may result in death or serious injuries. CAUTION Indicates a potential hazardous situation that, if not avoided, may result in moderate injuries and/or damage to the equipment. Notices indicated by [ Caution] may lead to serious consequences in some situations. All of the following are important. Be sure to observe them: WARNING General Installation adjustment Piping Wiring Operation Transport, installation, piping, wiring, operation, and maintenance of the pump must be conducted by skilled personnel who thoroughly understand how to handle the pump. Failure to do so may result in electric shock, injuries, fire, etc. Be sure to turn off the power switch of the pump before conducting any operation. Failure to do so may result in electric shock or fire. Do not use the pump near flammable gas. Doing so may result in injuries or fire. Be sure to ground the grounding wire terminal. Failure to do so may result in electric shock or fire. Refer to the connection diagram inside the terminal box or this instruction manual for power cable connection. Incorrect wiring may result in electric shock or fire. Do not forcibly bend, pull, or crimp the power cable or wires connected to the pump. Doing so may result in electric shock or fire. Be sure to re-attach the cover of the terminal box correctly after wiring/piping is completed. Failure to do so may result in electric shock. Never access or touch moving parts (including external fan, impeller, etc.) during operation. You may be caught in any moving parts, resulting in injuries. If power failure occurs during operation, turn the power switch off. Failure to doing so may cause the pump to start suddenly when power is recovered, resulting in injuries. 1

3 CAUTION General Transport Carrying Unpacking Installation adjustment Be sure to comply with specifications on the nameplate or in this instruction manual. Failure to do so may result in electric shock, injuries, damages to the equipment, etc. Do not use this pump if damaged. Doing so may result in electric shock, injuries, fire, etc. Do not insert foreign objects or fingers etc. into openings (e.g.fan cover, discharge port, suction port, drain hole, etc.) of the pump. Doing so may result in electric shock, injuries, damage to equipment, etc. We are not liable for modifications to the pump made by the user. Be extremely careful not to drop or overturn the pump when carrying it. Dropping or overturning the pump may result in injuries. Before lifting the pump, check the exact mass of the pump, referring to the package box, catalog, nameplate, etc., and ensure that the lifting conditions satisfy the mass. Failure to do so may cause the pump to drop or overturn, resulting in injuries or damage. Place the package in the correct vertical direction to unpack it. Failure to do so may result in injuries. Be careful of nails in wooden frame packing. Failure to do so may result in injuries. Check that the correct product has been delivered. Using the incorrect product may result in injuries, damage, fire, etc. Do not hold the strainer when you take out the product. Doing so may result in injuries or damage. Never place flammable objects near the pump. Doing so may result in fire. Do not place objects around the pump that block ventilation. Doing so may affect the cooling effect, resulting in burns, fire, etc. due to excessive heating. Before connecting the pump to equipment, check the rotation direction. Incorrect rotation direction may result in injuries or damages. Do not touch the impellers of the pump. Do not touch the securing bolts and strainer with bare hands. Doing so may result in injuries. Never stand on the pump. Doing so may result in injuries. Install the pump in such a direction that the information on the nameplate is clearly visible. Do not place objects in front of the nameplate. Do not remove the nameplate. Do not operate the product exceeding the operating frequency 60Hz when driven with an inverter. Doing so may result in the pump burning out or fire. Do not use a fluid with a higher viscosity than the maximum limit of viscosity. Doing so may result in the pump burning out or fire. 2

4 CAUTION Piping Wiring Operation Maintenance Repair Disassembly Modification Disposal Conform to the Electric Facility Technical Standard authorized by the government and the Interior Wiring Code of the electric power company. Failure to do so may result in the pump burning out or fire. Do not touch terminals when measuring insulation resistance. Doing so may result in electric shock. A protective device is not equipped. An over-current protective device should be attached to the pump as required by the Electrical Facility Technical Standard. In order to prevent fire or damage due to the pump burning out, we recommend that you consult us and install other protective devices (e.g. Earth-leakage circuit breaker, etc.). If any problem occurs, stop operation immediately and turn the power switch off. Failure to do so may result in electric shock, injuries, or fire. Do not touch the pump during operation, as the temperature of it becomes considerably high. Doing so may result in burns. Do not operate the pump while the strainer removed. Doing so may result in injuries or damage. Do not insert foreign objects or fingers etc. into the openings of the pump. Doing so may result in electric shock, injuries, or fire. Do not operate the pump without fluid for 30 seconds or longer. This pump uses a mechanical seal and doing so may result in damage or fire. When the power is OFF, starting the next operation before the pump completely stops may apply excessive load to the shaft and may shorten the pump life. Be sure to start the pump always after ensuring the pump stops. Do not touch terminals when measuring insulation resistance. Doing so may result in electric shock. During operation, do not touch the frame of the pump, as the temperature of the frame becomes considerably high. Doing so may result in burns. Do not touch the screw when you remove the strainer. Doing so may result in injuries. Be careful when using solvent or similar to clean the pump. Inappropriate use of solvent may result in poisoning. In addition, the use of thinner and/or benzine may cause a change or abruption of painting color of the pump. The pump must be repaired, disassembled, or modified by skilled personnel. Failure to do so may result in electric shock, injures, or fire. Be sure to make an auxiliary pump readily available if the pump is used for key facilities in which disruption of water supply may cause a serious problem. Dispose of the pump as general industrial waste. 3

5 Acceptance checks Please check the following when the coolant pump is delivered. 1) Check the type, output, voltage, frequency, etc. of the delivered pump in reference with the nameplate to verify that the correct product has been delivered. 2) Check that the coolant pump has not been damaged during transport and that bolts are firmly tightened. If any problems are found, please consult the dealer where you purchased the coolant pump. Specifications Refer to the nameplate for the coolant pump's head, flow rate, frequency, voltage, current, etc. Other specifications are described below. 1) Type VKA(VKC) A Q Characteristic type : Q (Flow rate type) Series name (Multi-stage coolant pump) H (Pressure type) No. of impeller Phase No. of power supply : A (Three-phase) No. of casing stage Model 2) Fluid The Coolant Pump (standard product) is designed for use with coolant, including grinding oil and cutting oil. However, since the life of the pump, mechanical seal might decrease, when the fluid contains large quantities of hard sludge (e.g. abrasive powder, abrasive grain, diamond grain, etc.), install the filter (e.g. magnet filter, paper filter, etc.). In addition, the pump cannot be used with fresh water or special fluid, such as printing fluid, acids. When you want to use other special fluid (e.g. ceramic etc.), inquire of your dealer or our sales branches. 3) Fluid temperature -20 to 40 C (without freezing) 4) Fluid viscosity Using high viscosity fluids will shorten the life of the motor and may cause the motor to burn out. Be sure to use the fluids with the viscosity within the limit in the table below.note that the viscosity may greatly increase as the fluid temperature decreases. Check the viscosity when the temperature of the fluid in use is lowest. Limit of viscosity [mm 2 /s] Type At 50Hz At 60Hz VKA(C)1 AQ,VKA(C)2 AQ,VKA(C)3 AQ VKA5 AQ,VKA(C)1 AH,VKA(C)2 AH VKA(C)3 AH,VKA(C)5 AH,VKA(C)6 AH VKA8 AH,VKA9 AH VKA(C)4 AQ,VKA6 AQ,VKA4(C) AH VKA(C)7 AH Notes 1. The rated head and flow rate indicated on the nameplate is when the viscosity is 1 mm 2 /s. 5) Installation location Always use the pump indoors in a location free of flammable gas or vapor and at an altitude of 1,000 m or less. 6) Ambient temperature -20 to 40 C 4

6 Installation ) Select a well ventilated location with little dust and humidity. Do not install the pump where fluid splashes onto the motor. 2) Install the pump so that cooling air for the motor can be taken in. 3) Install the pump on a flat surface to prevent any clearance. 4) Select a location where servicing can be performed easily. (Secure sufficient space.) 5) The pump is resistant to externally applied vibration acceleration up to approximately 4.9 to 6.9m/s 2. 6) Because the pump section of the VKA and VKC type coolant pump is installed in a tank, an mounting hole larger than the outer diameter of the pump needs to be made. See the outline drawing. 7) Because the suction port is on the bottom of the pump in the pump section of the VKA and VKC type coolant pump, secure at least 5 mm between the bottom of the tank and the suction port. Secure the largest separation possible to prevent the strainer being clogged with cutting chips and dust. 8) The pump is painted. However, if you want to coat the pump with another color, lightly sandpaper the pump surface to improve paint sealability. 9) Handle the pump carefully not to give a shock or eccentric load to the pump during transportation or when lift the pump. Be careful the pump may tilt heavily due to the position of the center of gravity. 10) Do not put a protecting cover or a filter on the motor, or it may increase the temperature inside the motor and lead to unforeseen machine trouble. Piping ) Make the piping as short as possible with the minimum number of elbow bends, joints, valves. Use standard sized pipes. Thin pipes, or those with an excessive number of bends, may reduce the amount of discharge. 2) Support pipes to prevent the weight of the pipes being loaded directly onto the pump. 3) Do not forcibly screw the pipes into the pump. Doing so may damage the joints. 4) Use seal tape, fluid packing, etc. for threaded sections to prevent fluid and air leaks. Wind the seal tape correctly so that the port of the pipe is not blocked. 5) Use the largest fluid tank possible. * The recommended tank capacity is at least three times of discharge amount per minute. Using a tank with excessively small capacity may cause problems, such as the fluid temperature increasing, the strainer clogging with cutting chips faster than usual, reduction in the amount of discharge due to generation of bubbles, etc. * Put the fluid quietly so that air should not mix when you pour the fluid into the tank. 6) Prevent cutting chips and dust from entering the pump. * We recommend that you pass the cutting fluid through an overflow section and filter at least three times. Cutting chips entering the pump may damage the mechanical seal. Be extremely careful. 7) Take appropriate preventive measures to prevent water hammer (e.g. install an accumulator etc.). 8) Flange type pumps shall be shipped with a set of counter flanges. Use the counter flanges if needed. Be sure to fix the counter flanges with the O-rings packed in the same package of the counter flanges to the pump. (Reference data) - Pump discharge port (outlet) size: PS3/4 (for piping) - Pump mounting bolt: M6 (4 locatios) 5

7 Wiring ) Wiring must conform to the Electric Facility Technical Standard authorized by the government and the Interior Wiring Code of the electric power company. 2) For standard voltage products, see the drawing on the right and connect the motor terminals to the power supply terminals correctly. U V W Motor terminals U1 V1 W1 Power supply terminals * When the number of terminals is 4 or more, refer to the connection nameplate inside the terminal box. 3) Ground the wire in case of earth-leakage. Connect the ground cable to the ground terminal inside the motor terminal box. 4) We recommended that you use a thermal overload relay to protect the motor from overload and burn out. 5) You can change the position of the terminal box relative to the discharge port of the pump in 90-degree increments by shifting the motor frame. (excluding the right above the discharge port) Change the position of the terminal box depending on the installation location. 6) The position of power supply inlet of the terminal box on the motor can be modified by rotating the direction of the terminal box in steps of 90. However, do not modify to the up right position, or serious or fatal electrical shock may result from water comes into the terminal box. 7) When using connectors, glands, etc., take sufficient precautions to prevent cutting chips, coolant, etc. from entering the terminal box through the lead-in port. Do not remove the grommet from the lead-in ports that are not used. 8) Control the fluctuation of the power supply voltage within ±10% of the rated voltage and the frequency within +3 to -5% of the rated frequency. The pump can run while the power is controlled within this range, but DO NOT run it for a long period if the power is higher/lower than 5% of rated voltage or higher/lower than 2% of the rated frequency. And even if the supplied power falls within the allowable range, the pump characteristics, motor characteristics, and the temperature rise of the motor may differ from those shown at the power of rated voltage and frequency. Or else, the thermal overload relay may trip. 9) Cautions for inverter driven operation The operating frequency should be at least 20Hz. An inverter-driven motor can generate a magnetic sound and thus make a more unpleasant sound than those driven by commercial power supply. Although this magnetic sound does not cause an adverse effect on the quality of the motor, some inverters allow the user to adjust the tone by changing the carrier frequency. However, changing it may reduce the allowable output of the inverter. Pay particular attention when selecting the inverter. Operation Before starting operation Because a mechanical seal is used for the shaft seal of the pump section of the VKA and VKC type coolant pump, do not operate the pump without fluid. Doing so may damage the mechanical seal. Check that the fluid is above the specified level, and confirm that the discharge port is open. Turn the pump by hand, and check that it rotates easily. To turn the pump by hand from the motor fan cover, Insert a screwdriver into the groove on the end of the shaft, and turn it. ALWAYS turn off the main power supply before turning the pump by hand. 6

8 2. When starting operation (When conducting test run) 1) Check that the pump rotates counterclockwise (to the left) when viewed from the top. 2) If your pump is equipped with an air release valve, open the valve slightly and confirm water comes out of the valve. Close the valve securely after confirmation. 3) Check that there are no problems, such as overcurrent, vibration, or noise. If any problem is identified, see the "Troubleshooting" section for appropriate measures. 3. Operation 1) An involute pump is used for the Coolant Pump, meaning the flow rate can be adjusted by opening and closing the valve on the discharge side. Although the motor is not overloaded with the valve fully closed, the temperature of the fluid in the pump will rise, which may damage the mechanical seal. Do not operate the pump with the valve fully closed. If unavoidable, provide a bypass route to maintain a minimum flaw rate (0.1 L/min or more) or stop the motor when not operating the pump. When the temperature of the fluid rises excessively, the service life of the motor and pump parts may be shortened. 2) Depending on the viscosity of the fluid, air may be taken in if the fluid level is too low, lowering the amount of discharge or preventing the fluid being pumped. Make the fluid level higher than "Minimum fluid level". Note that the minimum fluid level differs depending on the viscosity of the fluid. For safety, keep the fluid level as high as possible. 3) The average starting frequency shall be recommended to keep less than 60 times per hour. 4) If power failure occurs during operation, turn the power switch off. 5) Start the pump again after confirming the pump has completely stopped. 6) Be careful not to apply drastic variation in pressure during pump operataion as possible. Maintenance Daily checks Check for abnormal vibration or sound when starting operation and during operation. 2. Periodic checks 1) Remove dust, oil, etc. on the external surface of the coolant pump. 2) Accumulation of cutting chips in the tank may cause pump failure. Clean the inside of the tank periodically. 3) Check that the pump's strainer is not clogged with cutting chips. Clean the strainer when it is clogged with cutting chips. 3. Maintenance of bearing Using shielded type grease-sealed bearings reduces the bulk of maintenance work including replenishing grease. Exchange the bearing when an abnormal sound or vibration occurs from the bearing. 4. Maintenance of mechanical seal 1) Mechanical seal is a precision parts for prevention of water leak. Handle it with care to operate without any trouble. 2) Mechanical seal is a consumable part. Its life depends on the quality of liquid, having foreign objects or no, pressure, etc. 3) If water leaks, replace it. During the initial period after the pump has been used, a small amount of leak may occur until the sliding surfaces on the mechanical seal completely settle (or fit) into place, but the leak should stop in several hours of operation. Since this initial leak does not mean the defect of the mechanical seal, you can use the pump without concerns. 4) If the pump is out of use for a long period, the pump may be difficult to start up due to binding of each contact surface of the seals. Periodical operation at shorter intervals shall be recommended. 7

9 5. Maintenance of oil seal Pumps with an external fan have an oil seal to prevent fluid entering in the bearing section. Replace the oil seal with a new one when replacing the bearing. Please request the component replacement, the resolution, the repair, and remodeling, etc. to the trader of the manufacturer specification. * Parts replacement The service life of parts is determined by the type, atmospheric conditions, and working conditions. We recommend that you replace parts referring to the table below: Replacement frequency of consumable parts Part name Model Replacement frequency (Note Not guaranteed) Bearing All Each 1 to 2 years Oil seal All Each 1 to 2 years Mechanical seal All Each 1 year For flow rate type of 6 stages Bearing ring Each 1 to 2 years or more casings Sleeve For pressure type of 7 stages Each 1 to 2 years or more casings Impeller All When worn out Rubber parts (mechanical/oil seal, etc.) All Each 2 to 3 years Gasket All Each time pump is disassembled Others (screw etc.) All When necessary 8

10 Configuration Cross sectional view of flow rate type, AQ Parts name Material 1 Pump leg FC150 Mechanical seal, Sliding stuff 2 SiC/SiC (fixed/rotational), Bellows,cup gasket Bayton 3 Washer SUS304 4 Collar SUS304 5 Packing PTFE 6 Casing (without guide vane) SUS304 7 Casing (with guide vane) SUS304 8 Imperrer SUS304 9 Suction chamber FC Screw SUS U-nut SUS Washer SUS Wide strainer SUS Tight bolt SUS Spring washer SUS Strainer guard SUS Plus machine screw SUS Bearing ring Ceramic 19 Sleeve WC 20 Oil seal NBR 21 Oil seal NBR 22 Air bleed valve Blass 23 Coupling flange FC O-ring seal 25 Hexagon socket head bolt Fluoride rubber SCM 26 Terminal box ADC 27 Terminal box covor SS Motor Note 1: The material shows the main materials of VKA type coolant pump. Stainless steel is used for the main part of a VKC type coolant pump. The material of pump leg and suction chamber is SCS14A. Note 2:The bearing ring and the sleeve are used for the product of the flow rate type of 6 stages or more casings and pressure type of 7 stages or more casings. Note 3: Only VKA5 AQ and VKA6 AQ series represents flange pump type and provided with a set of counter flange kit. No counter flange kit shall be provided for the other VKA series. VKC type coolant pump are all the model flange types. Note 4:The construction etc. may be modified without any preliminary notice

11 Exploded view of rate type, AQ

12 Cross sectional view of pressure type, AH Parts name Material 1 Pump leg FC150 Mechanical seal, Sliding stuff 2 SiC/SiC (fixed/rotational), Bellows,cup gasket Bayton 3 Washer SUS304 4 Collar SUS Packing PTFE 6 Casing (without guide vane) SUS304 7 Casing (with guide vane) SUS304 8 Imperrer SUS304 9 Suction chamber FC Screw SUS U-nut SUS Washer SUS Wide strainer SUS Tight bolt SUS Seal ring PTFE 16 Guard metal SUS Spring washer SUS Strainer guard SUS Plus machine screw SUS Bearing ring Ceramic 21 Oil seal NBR 22 Oil seal NBR 23 Air bleed valve Blass 24 Coupling flange FC O-ring seal 26 Hexagon socket head bolt Fluoride rubber SCM 27 Terminal box ADC 28 Terminal box covor SS Motor Note 1: The material shows the main materials of VKA type coolant pump. Stainless steel is used for the main part of a VKC type coolant pump. The material of pump leg and suction chamber is SCS14A. Note 2:The bearing ring and the sleeve are used for the product of the flow rate type of 6 stages or more casings and pressure type of 7 stages or more casings. Note 3: Only VKA8 AH and VKA9 AH series represents flange pump type and provided with a set of counter flange kit. No counter flange kit shall be provided for the other VKA series. VKC type coolant pump are all the model flange types. Note 4:The construction etc. may be modified without any preliminary notice. 11

13 Exploded view of pressure type, AH

14 Troubleshooting Troubleshooting If any problem is identified, see "Troubleshooting quick reference" below for appropriate measures. Troubleshooting quick reference Failure conditions Cause Solution Rotation disabled No sound Cables are disconnected or connected incorrectly. Check cables and connections. Rotation enabled Knocking sound Motor overheats /overcurrent Pumping fluid disabled Insufficient discharge Abnormal sound Excessive vibration Water hammer occurrence Fuse is blown or thermal overload relay is tripped. Stator coil is disconnected. Voltage is too low. Cables are disconnected or connected incorrectly. Fuse is blown or thermal overload relay is tripped. Stator coil is disconnected. Stator contacts rotor due to worn bearing. Foreign matter caught in impeller. Voltage is too high or too low. Voltage is unbalanced. Stator coil is disconnected, short-circuited, or grounded. Stator contacts rotor due to worn bearing. Viscosity of fluid is too high. Suction port is above fluid level. Large amount of bubbles in fluid. Rotation direction is incorrect. Piping loss is high. Fluid does not run smoothly. Impellers are worn out. Bearing is worn out. Pump is in single-phase operation. Water hammer occurs when a valve is closed suddenly. Replace fuse or check thermal overload relay. Contact authorized dealer for repairs. Adjust voltage. Check cables and connections. Replace fuse or check thermal overload relay. Contact authorized dealer for repairs. Replace bearing. Eliminate foreign matter. Adjust voltage. Check circuit. Contact authorized dealer for repairs. Replace bearing. Use fluid with lower viscosity. Adjust fluid level. Prevent bubble generation/suction. Connect terminals correctly. Review piping. Eliminate foreign matter. Check connections. Replace impellers. Replace bearing. Check circuit. Install an accumulator. 13

15 Scope and period of guarantees The guarantee period of the pump is one year after shipment to the place indicated in the purchase order. When failure occurs during the guarantee period, under normal use within the range of the product specifications according to this instruction manual, damaged parts will be replaced or the pump will be repaired for free, excluding failure due to any of the following: (1) Inappropriate handling or operation by the user (2) Any cause other than the pump (3) Incorrect repair or modification (4) Any occasion out of control of the supplier such as natural disaster or casualty This guarantee applies to delivered pumps only, and does not apply to other equipment damaged due to failure of the pump. This guarantee is effective in Japan only. Investigation and repair After the guarantee period elapses, all diagnosis and repair fees are charged. Even during the guarantee period, we also provide repairs or diagnosis of failures due to causes not included in the free services listed above at a charge. When you need repairs or replacement parts, contact your dealer or our sales branches. 14

16 Head Office 230, Moriwake, Miyuki-cho, Fukuyama-city, Hiroshima, , Japan Tel Fax