TOWER CLEAN (TC) & SIDE STREAM CLEAN (TB) SYSTEM I&O MANUAL

Transcription

1 INSTALLATION OPERATIONS MAINTENANCE TOWER CLEAN (TC) & SIDE STREAM CLEAN (TB) SYSTEM I&O MANUAL 1365 N. Clovis Avenue Fresno, California (559) LS-591B (Rev. 4/18)

2 Tower Clean (TC) & Side Stream Clean (TB) System I&O Manual I. INTRODUCTION The LAKOS Tower Clean and Side Stream Clean are compact filtration packages for the removal of grit, airborne particles and scale from cooling tower water in order to avoid system fouling. Featuring the centrifugal-action performance of a LAKOS Separator, the packages combine quality, reliability and engineered efficiency to control the accumulation of troublesome solids in a heat transfer system. This control leads to a reduction in tower cleaning, system shutdown, maintenance & servicing costs, blowdown and water/chemical loss. You will enjoy the energy/operating savings of reduced solids fouling. The Tower Clean System continuously recirculates the tower basin water, where appropriate using LAKOS HydroBoosters to provide the necessary directed turbulence and to prevent not only solids accumulation in the basin, but also help protect the entire system from solids fouling. The Side Stream Series is installed as a side stream system off of a pump discharge in a main water line. II. Warranty All products manufactured and marketed by this corporation are warranted to be free of defects in material and workmanship for a period of at least one-year from the date of delivery. Extended warranty or no coverage applies as follows: **All LAKOS separators---five year warranty **Pump seals are not covered under warranty All other components and coatings: 12 months from the date of installation; if installed 6 month or more after ship date, warranty shall be a maximum of 18 months from ship date. If a fault develops, notify us or your local representative, giving a complete description of the alleged malfunction. Include the model numbers(s), date of delivery and operating conditions of subject products(s). We will subsequently review this information and, at our option, supply you with either servicing data or 2

3 shipping instructions with returned materials authorization number. Upon prepaid receipt of subject product(s) at the instructed destination, we will perform such necessary product repairs or replace such product(s) at our expense. This limited warranty does not cover any products, damages or injuries resulting from misuse, misapplication, neglect, normal expected wear, chemically-caused corrosion, improper installation or operation contrary to factory recommendation. Nor does it cover equipment that has been modified, tampered with or altered without authorization. No other extended liabilities are stated or implied and this warranty in no event covers incidental or consequential damages, injuries or cost resulting from any such defective product s(s). This warranty supersedes any and all previous warranties provided by LAKOS Claude Laval Corporation. Ill. PRE-ASSEMBLY/PRE-START-UP CHECK LIST 1. A licensed and/or trained/experienced plant electrician and millwright - pipe fitter should install this packaged system. 2. Ensure that the concrete pad is level and structurally sound to accommodate the weight of the system, including liquid. 3. To firmly position this unit, appropriate size anchor bolts are necessary. 4. To minimize pipe strain to the separator, suction and discharge pipes should be supported independently. 5. Tower clean (TCX/TCI) systems must be located within 25 ft of the tower basin. Contact factory if distance is greater than 25 ft. 6. Side-stream (TBX/TBI) systems must have a minimum of 3 ft. distance between side-stream suction and return on main system piping. Refer to typical installation diagram. 7. The pump suction line should be sized for about 5 ft/sec. regardless of the actual pump suction size. Minimize suction lengths (no more than 30') and restrictions such as elbows. These practices will minimize friction losses and help extend pump seal life. Exceptions may apply if a qualified individual calculates NPSHA and NPSHR for the pump. 8. The threads of the pipe fittings screwed into the pump must be sealed with pipe sealants, sealant tape, R.T.V. or other sealing materials approved for pipe threads. In case of flanged connections, rubber gaskets should be used. 3

4 9. Tighten pump and pipe fittings only as much as required to avoid leaks and air intrusion. Air entrapment into the pump may affect its efficiency and result in cavitation. DO NOT OVER-TIGHTEN. 10. The control panel must be wired for the proper voltage and rotation of the pump (see wiring diagram in control box door). All wiring should be done by a licensed electrician in accordance with local codes. Motor nameplates indicate voltage, amperage draw, cycles, phase, speed and other motor information. 11. Allow water to enter the pump, jog-start the pump to verify correct rotation as indicated in the pump's housing. Reverse terminal leads as necessary. IV. TYPICAL INSTALLATIONS 1. TCX/TCI 4

5 2. TBX/TBI V. START-UP AND OPERATION 1. FOR FLOODED SUCTION The pump suction strainer needs to be filled with water before starting the Pump (Tower Clean Systems only). Partially close (approximately 25%) the discharge valve and make sure that the suction valve is fully open. Start the pump and observe the pressure gauge which reads the discharge pressure of the pump at the inlet of the separator. The needle of the gauges might flicker for a few seconds and will then settle, indicating that any air in the system is being bled off naturally. If it continuously flickers and if the pump cavitates for more than a minute, bleed-off air from the system. Once pressure has reached 20 psi or more (Tower Clean System) or 15 psi (Side Stream System), slowly open the discharge valve to ensure proper pump operation. If the valve cannot be fully opened without the pump cavitating, be sure there are the correct number of Hydro-Boosters installed downstream of the Tower Clean System. In a Side Stream System application the valve may need to be adjusted to ensure proper backpressure on the pump. This is normal. NOTE: Make sure that all suction valves (from the source of water to the pump intake) are fully opened when the pump is running. Operating the system with a partially closed suction valve can damage the pump and/or affect 5

6 the system's performance. Each model requires a minimum liquid submergence level (above the pump intake) to meet the pump's Net Positive Suction Head Required (NPSHR) to avoid air intrusion or cavitation (vortexing at point of source). See appropriate pump curve included with this manual. This is also very important when LAKOS Hydroboosters are in use.entrapped air will always seek the highest elevation in the system. A valve in the system outlet will be at the highest elevation. When partially opened during start-up, it will relieve air from the system. The Solids Recovery System, if installed with your system, must also be primed and vented at the solids collection vessel (SRV). Please see SRV operating procedure. DO NOT DRY-RUN THE PUMP. All pumps require a wet/primed suction before starting, using water as a lubricant for their seals. John Crane-type seals (e.g., Silicon Carbide Seals) can wear out in 20 seconds of dry operation. It only takes a small amount of water to lubricate the seal, and it vaporizes during pump operation. Also, when replacing the seals, avoid touching the Silicon Carbide faces; oils, moisture and dirt from your fingers escalate seal wear. 2. FOR NEGATIVE SUCTION (LIFT) If the water level of the sump is lower than the centerline of the pump inlet, the use of a self-priming pump might be necessary. Follow priming procedures every time the pump is started. Consult the factory for systems requiring suction lift. 3. WINTERIZING In areas subject to freezing winter temperatures, protect the pump when not in use by removing both drain plugs (from the pump volute and from the suction strainer). Use a compressed air hose to remove any water trapped in the pump casing or flush the system with antifreeze. Do not replace the plugs. Store them in the strainer basket for the winter. Alternatively, remove the pump and motor from the plumbing entirely. Store them indoors in a warm and dry place. The separator and the purge line should also be drained of liquid to prevent damage from freezing. To remove trapped water from the separator, use a compressed air hose, directed into the acceptance chamber. Alternatively, flush system with antifreeze. Heat tracing or pipe insulation may be used. Please contact your local supplier of these products to ensure proper usage. 6

7 VI. MAINTENANCE 1. A TC/TB System START-UP FORM is included in this manual. Record all readings (inlet and outlet pressures, motor amperage draw and liquid flow rate) during start-up as reference point (see note 3). Please complete the required information and return this form to your local representative as soon as possible. You may want to keep a copy for your records. 2. Record and compare these readings whenever periodic check-up and maintenance is required. These records would be helpful in troubleshooting the system when a problem occurs during the operational life of the system. A. SUCTION STRAINER BASKET: The suction strainer basket is sized to allow a maximum pressure drop of 2 psi at the specified flow rate. It will protect the pump, separator, flow control valves and other equipment from becoming plugged by dirt and debris 1/4" in size and greater. The strainer basket is easy to clean. Isolate the strainer by closing the isolation valves installed before the pump and after the separator outlet. These are not provided as a standard option by Lakos, but are available if a valve kit is ordered. Loosen the nuts or threaded stud and remove the lid. Remove the basket and clean. Inspect the 'O' ring or gasket and, if damaged, replace. Replace the lid and tighten the nuts. B. PUMP AND MOTOR Make sure that there are no leaks in the pump housing. If leaks occur at the back of the volute casing, you may have a damaged the seal (pump seals are not covered under warranty) and/or loose bolts. Replace and/or tighten as necessary. Whenever maintenance or repair is needed for the pump, SHUT-OFF and LOCK-OUT power into the panel feeding the pump; close the suction and discharge valves, open drain plug/valve, making sure no air or hydraulic pressure is in the system before unhooking the pump. Refer to Pump Manual. Outside air is very important to cool the motor. The TEFC motor has a fan in the back. Ensure that the fan is rotating when motor is energized. Zerk fittings were installed in the front and back of the pump shaft/bearing housing. A small amount of grease might be needed periodically to replenish the old grease in the housing. Whenever new grease is injected, the old grease will ooze out on the 7

8 NOTE: Each System is provided with either a SRV Solids Recovery System (see E below), Compact Motorized Ball Valve (see F below) or ABV (see G below) for evacuating separated solids from the system. Follow the appropriate instructions for your system componentry. 8

9 EQUIPMENT CHECK & ASSEMBLY The basic SRV System includes a bag-like housing. Standard systems include an auto air vent assembly and either 2 solids collection bags (single bag units) or 6 solids collection bags (triple bag units), typically inserted in the SRV vessel for shipping. Open the vessel and remove all extra items (except for one bag per basket assembly, properly seated in the internal basket). Be sure the stainless steel basket is seated properly with the o-ring under the upper lip. START-UP PROCEDURES Do not attempt to start-up the SRV System until the LAKOS Separator is in full operation. Then, follow these steps: 1. Close the manual valve going to the pump suction. 2. Fully open the manual valve on the purge line coming from the separator. 3. The Auto Vent on the top of the SRV lid will vent air (this will be audible) until the SRV is filled with water. 4. Fully open the valve going to the pump suction. If the Indicator Package is installed, check the sightglasses for proper flow to and from the SRV vessel. System is now in operation. MAINTENANCE PROCEDURES Separated solids collected in the SRV vessel must be periodically removed. The collector bag may be cleaned and re-used (up to three times) or discarded and replaced. This operation can be performed without interrupting system flow or the LAKOS Separator's operation (see instructions below). Recommended maximum solids load per bag is 25 lbs. (11 kg) or until 18psid is reached indicated by the "red" zone on the differential gauge attached to the SRV. The Indicator Package uses a pressure-differential sensor to identify when the bag should be serviced. The standard gauge will point to a red zone, indicating service is needed. The optional dry electric contact will engage whatever indicator is connected (a light, buzzer, horn, etc. which is not provided as a standard option). Follow these steps: 1. Close the manual valve on the purge line off the separator. 2. Close the manual valve on the line going to the pump suction. IMPORTANT: Wait until all pressure has been released before proceeding. Open the lid to the SRV vessel. Grasp the handle and remove the entire assembly from the SRV vessel. Remove the bag(s) and clean/replace in the basket. 9

10 3. Check o-rings on the basket lip and SRV vessel lid; replace if damaged. Replace the basket/bag assembly in the SRV vessel. Close lid and secure properly. 4. Fully open the manual valve on the purge line. 5. The Auto Vent will vent all air from the SRV vessel. 6. Fully open the valve going to the pump suction. If the Indicator Package is installed, check the sight-glasses for proper flow to and from the SRV vessel. System is now back in operation. F. COMPACT MOTORIZED BALL VALVE: COMPONENT FUNCTION The LAKOS Compact Motorized Ball Valve provides for periodic and automatic flushing of separated solids at timed intervals selected by the system operator. PROGRAMMING FUNCTIONS The controls for programming this valve are located within the cover on the valve's actuator. CAUTION: Before removing the valve cover to program the valve, disconnect power to the TC System's control box in order to avoid electrical shock. Loosen the valve cover's screws and remove the cover to reveal a bank of eight (8) switches. Each must be programmed in order to set the Purge Duration (how long the valve will stay open each time) and the Purge Frequency (how often the valve will open). To set these times, the switches must be set ON (marked below as an "O") or OFF (marked below as an "X") in the exact pattern as shown. (see charts on next page) 10

11 PURGE DURATION PURGE FREQUENCY 10

12 G. ABV (Automatic Ball Valve w/ controller) COMPONENT FUNCTION The LAKOS Automatic Ball Valve provides for periodic and automatic flushing of separated solids at timed intervals selected by the system operator. PROGRAMMING FUNCTIONS The controls for programming this valve are located in the main motor starter control panel. Timer should be factor preset to the settings below. If settings need to be changed based on field conditions please consult the programming instruction on the next page. CAUTION: Before changing time settings, be sure the main power is off. TC Package Factory Setting (20 second purge every 12 hours) TB Package Factory Setting (25 second purge every 24 hours) 12

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14 VII. TROUBLE SHOOTING PROCEDURES A. PUMP WILL NOT PRIME (if pump is not self-priming). Possible causes and solutions: 1. Make sure the strainer basket is not clogged (if applicable). 2. Make sure the strainer basket is positioned correctly (if applicable). 3. Tighten the strainer lid down completely (if applicable). 4. Make sure the strainer is full of water (if applicable). 5. Tighten all the fittings and seal all the joints on the suction side. 6. Open all the valves on the return and suction lines. 7. Remove and replace the pump seal if needed. 8. Check the compatibility of the pump and motor. 9. Check pump rotation. Reverse motor wire terminals if necessary. B. MOTOR RUNS HOT Possible causes and solutions: 1. Motors will run warm to the touch. The motor starter thermal and overload module will function to turn off the motor if there is an overload current problem. 2. Factors which will increase the operating temperature: a. The pump is installed in the direct sun. b. Poor ventilation in the area the pump is located. c. Low voltage is available to the pump. d. The wiring is the incorrect size for the load. e. The solids loading requires more than the pump's motor horsepower rating. f. The pump is operated above the full load Amp rating of the motor. g. Motor is experiencing imbalance load (in case of 3 phase; it is doing a single phase.) h. Fan is broken/missing. C. THE MOTOR WILL NOT TURN The following procedure advises a warning and caution: There is a safety/shock hazard. Have a qualified electrician perform the testing. Opening the motor starter box does not shut off power into the box; it only disconnects the starter module and control transformer. Follow electro-mechanical safety lock-out procedure. 1. If the system does not start, open the motor control box and check for power and/or blown control transformer fuses. If the motor overload trips, check the overload amp setting. Adjust the overload module to the motor's full load amp rating. Replace the overload with the correct 14

15 overload module going from 460 to 230 system and re-wire the control transformer and motor terminals inside the motor junction box. Do not set or adjust to above full load amp rating. 2. If deadhead pressure cannot be met: a. First determine if the pump motor is rotating in the correct direction. Jog-start the motor control box hand switch off and on while observing the motor shaft/fan rotation. b. If the pump is not rotating correctly, shut off the power and switch two of the motor lead wires. c. If the pump is rotating correctly, check for shut valves on the suction line, a clogged suction line at inlet, a clogged strainer basket, or a clogged pump. Adjust the separator outlet valve to the required pressure drop across the separator for the desired flow. If the flow rate cannot be obtained, check for closed valves downstream of the separator, or restricted outlet piping. Systems with LAKOS HydroBoosters can use the HydroBoosters to act as a control valve. D. NO SOLIDS IN THE SOLIDS RECOVERY VESSEL (Filter Bag Housing) 1. Purge valve to the inlet of the SRV is closed. 2. Air-locked in the system, bleed SRV of trapped air. Follow SRV maintenance procedure. 3. Purge line is blocked. Isolate the system from pressure by closing the purge line and liquid recovery line valves. Remove piping and clean out the blockage or replace the appropriate components. 15

16 VII. STANDARD PUMP CURVES & PARTS LIST Models: TCX & TCI (0030) Flow-rate: 30gpm Impeller Trim: 4.88 Motor HP: 1 Pump part number: Pump Repair Kit number:

17 17

18 18

19 19

20 19

21 Models: TCX & TCI (0200) Flow-rate: 200gpm Impeller Trim: 5.25 Motor HP: 7 1/2 Pump part number: Pump Repair Kit number: Models: TCX & TCI (0280) Flow-rate: 280gpm Impeller Trim: 5.37 Motor HP: 10 Pump part number: Pump Repair Kit number:

22 Models: TCX & TCI (0400) Flow-rate: 400gpm Impeller Trim: 5.50 Motor HP: 15 Pump part number: Pump Repair Kit number:

23 Models: TCX & TCI (0525) Flow-rate: 525gpm Impeller Trim: 5.68 Motor HP: 20 Pump part number: Pump Repair Kit number: Models: TCX & TCI (0600) Flow-rate: 600gpm Impeller Trim: 5.75 Motor HP: 25 Pump part number: Pump Repair Kit number:

24 Models: TCX & TCI (0825) Flow-rate: 825gpm Impeller Trim: 5.75 Motor HP: 30 Pump part number: Pump Repair Kit number: Models: TCX & TCI (1100) Flow-rate: 1100gpm Impeller Trim: 6.00 Motor HP: 40 Pump part number: Pump Repair Kit number:

25 24

26 25

27 26

28 Models: TBX & TBI (0145) Flow-rate: 145gpm Impeller Trim: 7.25 Motor HP: 3hp Pump part number: Pump Repair Kit number: Models: TBX & TBI (0200) Flow-rate: 200gpm Impeller Trim: 7.63 Motor HP: 5hp Pump part number: Pump Repair Kit number:

29 28

30 29

31 30

32 31

33 Models: TBX & TBI (0825) Flow-rate: 825gpm Impeller Trim: 8.50 Motor HP: 20hp Pump part number: Pump Repair Kit number: Models: TBX & TBI (1100) Flow-rate: 1100gpm Impeller Trim: 8.63 Motor HP: 20hp Pump part number: Pump Repair Kit number:

34 VIII. STANDARD PUMP CONTROL PANEL WIRING DIAGRAMS A. The following control panel wiring schematics represent our LAKOS standard control panels for the TC and TB system packages. All control panels supplied by LAKOS are provided with NEMA-4X enclosures and are UL Listed. If the system you purchased has a different voltage or phase than those shown on the drawings, please request the correct control panel wiring schematic for your model from LAKOS. B. There are three sizes of control panels sized on the horsepower of the pump for each system. Please refer to the title block on the drawings and select the panel which represents your package. Pump horsepower ratings can be found on each page of the pump curve data supplied in this manual. 33

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36

37

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40 IX. SPARE PARTS FOR TC & TB SYSTEMS SRV replacement bags (set of 10): - CBX (25 micron) - CBX (50 micron) LAKOS P/N LAKOS P/N TC/TB Pump Repair Kits**: - Pump repair kits to be selected based on TC/TB package pump model. Please refer to the pump curve and parts breakdown pages in this manual for the pump repair kit based on your system. TC packages are equipped with VITON / Silicon Carbide seal faces. TB packages are equipped with BUNA N / Ceramic seal faces. SRV Parts: **ALL KITS INCLUDE (1) SHAFT SLEEVE, (1) IMPELLER RETAINER, (1) IMPELLER KEY, (1) SHAFT O-RING, (1) FLINGER, (1) CASE GASKET, (1) MECHANICAL SEAL ASSEMBLY - AUTOVENT - GASKET FOR LID (NITRILE) - STAINLESS STEEL BASKET - O-RING FOR BASKET (BUNA-N) LAKOS P/N LAKOS P/N LAKOS P/N LAKOS P/N SRI Parts: - DIFFERENTIAL PRESSURE INDICATOR - SIGHT GLASS - FLOW CONTROL ORIFICE (10 GPM) - MANUAL ISOLATION BALL VALVE (3/4") LAKOS P/N LAKOS P/N LAKOS P/N LAKOS P/N

41 X. STANDARD PUMP 1&0 MANUAL, MECHANICAL SEAL 1&0 MANUAL A. LAKOS supplies Scot Pumps on all of our standard TC and TB system packages. The following manuals are for reference when servicing or repairing a Scot Pump. Please review these manuals before attempting any disassembly of the pump. LAKOS would highly recommend that any pump repairs by done by a certified pump repair service technician. A pump identification guide page is included (prior to manuals) to help you identify the Scot Pump supplied with your system. LAKOS recommends that the SPECIFICATION NUMBER, SALES ORDER NUMBER, and DATE CODE be documented and kept with the records for the system. These codes will be requested by LAKOS for any type of warranty issues that may arise with the pump and motor. B. If you pump is other than a Scot pump, please contact LAKOS and request the supplied pump manufacturer's l&o manuals. C. There are multiple Scot Pump l&o manuals based on the size of the pumps. The manuals are arranged in the following order: - l&o Manual for C56 & JM Frames o Scot Pump models #16, #17, #19, #54, #55, #56F, #57, #59 - l&o Manual for TCZ & JP Frames o Scot Pump models #96, #102, #103, #104 - l&o Manual for Mechanical Seal (Type 21) o Supplied in all Scot Pump models listed above 40

42 PUMP IDENTIFICATION GUIDE Below is a representative nameplate from one of our standard pumps: SPECIFICATJON NUMBER SALES ORDER NUMBER DATE.--CODE CONSTRUCTION PUMP SfZE SEAL PUMP TYPE- Designates pump driver. Example: Motor pump, Frame pump, Engine pump. PUMP NUMBER - Number designating a specific pump. SPECIFICATION NUMBER- Refers to a specific bill of material for a pump and driver combination that identifies all of the components of the pump. SALES ORDER NUMBER- Refers to a specific order that the pump was ordered on. CONSTRUCTION- Identifies metallurgy of major pump components. PUMP SIZE- Size of suction x discharge connections. Cases include wear rings and cad steel pipe plugs. The "X'' suffix indicates a bronze wear ring (where applicable) for standard fitted, bronze fitted and all bronze construction. The "X1 suffix indicates a steel wear ring (where applicable) for all iron construction. Example: X - lron Case, Includes Bronze Wear Ring X1 - Iron Case, Includes Steel Wear Ring SEAL - Identifies major components of mechanical seal. DATE CODE - Month and year the pump was manufactured. Scot recommends stocking a spare mechanical seal or repair kit to eliminate down time. PM

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44 INSTALLATION, CONT. 3. Install check and gate valves in discharge line; check valve (if used) between pump and gate valve. OPERATION Pre-Start - Before initial start of the pump, check as follows: 1. The rotation must be checked upon installation. Close, then break the contacts quickly and observe the rotation of the exposed portion of the rotating parts. Rotation must agree with the rotation arrow on the motor. For all pumps, the standard rotation is counterclockwise when viewed from the suction end. Motor wiring is easily changed in the field. Observe the wiring diagram on the inside of the terminal box cover, or on the motor nameplate. 2. Check voltage, phase and frequency of line circuit with motor nameplate. 3. Check suction and discharge piping and pressure gauges for proper operation. 4. Assure that pump is full of liquid (primed). Priming - If pump is installed with a positive head on the suction, prime by opening suction valve and allowing liquid to enter the casing, at the same time venting all air out of the top of the casing. If pump is installed with a suction lift, priming must be done by other methods, such as foot valves, ejectors, or by manually filling casing and suction line. CAUTION - DO NOT RUN PUMP DRY HOPING IT WILL SELF-PRIME. Serious damage may result if started dry. Starting - Proceed as follows to start pump: 1. Close drain valves and valve in discharge line. 2. Open fully all valves in the suction line. 3. Prime the pump. If pump does not prime properly, or loses prime during start-up, shut down and correct condition before repeating procedure. 4. For pumps moving high temperature liquids, open warm-up valve to circulate liquid for preheating. Close valve after pump has warmed up. 5. Start the motor (pump). 6. When pump is operating at full speed, open discharge valve slowly. Running - Periodically inspect pump while running, but especially after first start and following repair. 1. Check pump and piping for leaks. Repair immediately. 2. Record pressure gauge readings for future reference. 3. Record voltage, amperage per phase, and kw (if an indicating wattmeter is available). 4. Adjust pump output capacity with discharge valve. DO NOT throttle suction line. Freezing Protection - Protect pumps shut down during freezing conditions by one of the following methods: 1. Drain pump; remove all liquid from the casing. 2. Keep fluid moving in pump and insulate or heat the pump to prevent freezing. If heated, do not let temperature go above 100 to 150 degrees F. 3. Fill pump completely with antifreeze solution. MAINTENANCE Cleaning - Remove oil, dust, dirt, water, chemicals from exterior or motor and pump. Keep motor air inlet and outlet open. Blow out interior of open motors with clean compressed air at low pressure. Regularly drain moisture from TEFC motors. Temperature - Total temperature, not the rise, is the measure of safe operation for a motor. If temperature by thermometer exceeds limits for insulation class, investigate and change operating conditions. Labeled Motors - It is imperative for repair of a motor with Underwriters' Laboratories label that original clearances be held; that all plugs, screws, other hardware be fastened securely, and that parts replacements be exact duplicates or approved equals. Violation of any of the above invalidates Underwriters' label. Lubrication - Pumps should require no maintenance, other than the motor bearings, according to the following instructions: DOUBLE SHIELDED. When double shielded prelubricated bearings are furnished, no lubrication is required for the life of the bearings. Inspect bearings periodically to determine the condition of the grease and replace the bearings if necessary. SINGLE SHIELDED W/GREASE FITTING PROVISIONS. When single shielded bearings are furnished, periodic inspection, cleaning and relubrication is required. See motor manufacturer's specific instructions for lubrication. MECHANICAL SEAL REPLACEMENT JM FRAME MOTOR A.) Disassembly: 1. Turn off power. 2. Close suction and discharge valves. 3. Drain pump. 4. Remove bolts holding base to foundation 5. Remove casing bolts. 6. Remove motor and rotating element from casing, leaving casing and piping undisturbed. 7. Insert a screwdriver in one of the impeller waterway passages and back off the impeller retaining assembly with a socket wrench, as shown in Figure 1. Figure 1 43

45 B.) 8. Remove impeller from shaft, being careful not to lose the impeller key, spring and seal retainer. If impeller is difficult to remove, it may be necessary to use a bearing puller to pull off impeller. 9. Pry off rotating member of mechanical seal from sleeve by using two (2) screwdrivers. (Figure 2) Figure Remove bolts holding adapter to motor and take off adapter. 11. Place adapter on a flat surface with case rabbet facing down, and push out stationary part of mechanical seal. 12. Inspect the shaft sleeve, shaft 0-ring and flinger. If damaged or worn, remove and replace with a new one. Reassembly: CAUTION: The mechanical seal is a precision product and should be handled accordingly. Use care when handling the lapped running surfaces of the mechanical seal to ensure they remain clean and free of chips or scratches. 1. Clean gasket and flange faces, seal seat cavity, shaft sleeve, and motor shaft. 2. Lubricate the seal seat cavity of the adapter and the rubber cup or 0-ring of seal seat with the lubricating fluid that comes with the mechanical seal or repair kit. Press the stationary seat in seal seat cavity of the adapter squarely and evenly using a arbor press (if possible) and the cardboard disc supplied with the seal. Be certain that the lapped face (shiny side) is facing you. 3. Install the flinger on the motor shaft until it bottoms on the motor shaft. 4. Slide the shaft 0-ring on the motor shaft until it is tight against the flinger. Make sure that the shaft 0-ring does not get damaged during this procedure. 5. Position shaft sleeve chamfer towards motor and slide on motor shaft. 6. With motor preferably in vertical position, remount the adapter on motor, making sure the motor shaft does not dislocate or chip the stationery seat of the seal. 7. Apply the lubricating fluid that comes with the mechanical seal or repair kit to the shaft sleeve and the rubber bellows of the rotary seal. Slide the seal head on the sleeve; press the rubber drive band on the rotary head until the lapped face on the head seats firmly against the lapped face of the stationary seat. Do not chip or scratch faces during installation. Take extra care to make sure the lapped faces are clean. Install seal spring on seal head and retainer on spring. 8. Place key in key seat. Line up keyway in impeller with key on motor shaft, and slide impeller on motor shaft. Be certain that the key is positioned in the keyway of the motor and impeller. Slightly compress seal spring with impeller and hold impeller while installing impeller retaining assembly in motor shaft. 9. Insert a screwdriver in a waterway passage of the impeller holding it against rotation and tighten the retaining assembly as discussed in paragraph 7 of disassembly instructions. The impeller will compress the seal spring to the proper length assuring the correct pressure on the lapped surfaces. 1O. Remove any burrs caused by screwdriver on the vane of impeller in waterway passage. 11. Slide motor and rotating element in casing. Be sure that any damaged 0-ring or gasket is replaced. 12. Tighten casing bolts alternately and evenly. 13. Replace hold-down bolts. 14. Check for free rotation after assembly is completed. 15. Seal all drain openings using pipe sealant on threads. 16. Reprime before starting. Do not start until pump is completely filled with water. MECHANICAL SEAL REPLACEMENT C56 FRAME MOTOR A.) Disassembly: 1. Refer to "JM FRAME" Disassembly, Notes Inspect the stub shaft. If damaged or worn, replace with a new one; removal: A.) Drive pin from stub shaft and remove pin. B.) Loosen set screws C.) Remove stub shaft from motor shaft. Assembly: For motors with drilled hole: A.) Slide stub shaft on motor shaft. Line up set screws in stub shaft with motor keyway, and drilled hole in stub shaft with drilled hole in motor shaft. B.) Tighten set screws C.) Insert #12 drill in pilot hole of stub and motor shaft. Drill out opposite side of stub shaft. D.) Install pin For motors without a drilled hole in the motor shaft: A.) Slide stub shaft on motor shaft. Line up set screws in stub shaft with keyway in motor shaft. B.) Position stub 3 3/32" from Motor C face. See Figure 1. C.) Tighten set screws D.) Insert #12 drill in stub shaft pilot hole and drill completely through motor shaft and opposite side of stub shaft. See Figure 2. E.) Install pin 44

46 B.) I 3 3/32" Figure 1 Figure 2 Reassembly: CAUTION: The mechanical seal is a precision product and should be handled accordingly. Use care when handling the lapped running surfaces of the mechanical seal to ensure they remain clean and free of chips or scratches. 1. Clean gasket and flange faces, seal seat cavity, and stub shaft. 2. Lubricate the seal seat cavity of the adapter and the rubber cup or O-ring of seal seat with the lubricating fluid that comes with the mechanical seal or repair kit. Press the stationary seat in seal seat cavity of the adapter squarely and evenly using a arbor press (if possible) and the cardboard disc supplied with the seal. Be certain that the lapped face (shiny side) is facing you. 3. With motor preferably in vertical position, remount the adapter on motor, making sure the stub shaft does not dislocate or chip the stationery seat of the seal. 4. Apply the lubricating fluid that comes with the mechanical seal or repair kit to the stub shaft and the rubber bellows of the rotary seal. Slide the seal head on the stub; press the rubber drive band on the rotary head until the lapped face on the head seats firmly against the lapped face of the stationary seat. Do not chip or scratch faces during installation. Take extra care to make sure the lapped faces are clean. Install seal spring on seal head and retainer on spring. 5. Place key in key seat. Line up keyway in impeller with key on stub shaft, and slide impeller on stub shaft. Be certain that the key is positioned in the keyway of the stub and impeller. Slightly compress seal spring with impeller and hold impeller while installing impeller retaining assembly in stub shaft. 6. Insert a screwdriver in a waterway passage of the impeller holding it against rotation and tighten the retaining assembly as discussed in paragraph 7 of disassembly instructions for JM shaft. The impeller will compress the seal spring to the proper length assuring the correct pressure on the lapped surfaces. 7. Remove any burrs caused by screwdriver on the vane of impeller in waterway passage. 8. Slide motor and rotating element in casing. Be sure that any damaged O-ring or gasket is replaced. 9. Tighten casing bolts alternately and evenly. 10. Replace hold-down bolts. 11. Check for free rotation after assembly is completed. 12. Seal all drain openings using pipe sealant on threads. 13. Reprime before starting. Do not start until pump is completely filled with water. The approved lubricating fluid for seal installation is included with the mechanical seal or repair kit. DO NOT USE OTHER LUBRICATING LIQUIDS! WE RECOMMEND STOCKING A SPARE MECHANICAL SEAL OR REPAIR KIT TO ELIMINATE DOWN TIME. PRESSURE AND TEMPERATURE LIMITATION STANDARD FITTED PUMPS PUMP PRESSURE TEMPERATURE NO. STANDARD OPTIONAL STANDARD OPTIONAL 68, 69 51, 61, 74 71, 72, 77, 78, 79, 82 11, 13, ALL OTHERS N/A-NOT AVAILABLE 75 PSI N/A 220 F 275 F 75 PSI 150 PSI 220 F 275 F 75 PSI N/A 220 F 275 F 75 PSI 150 PSI 220 F 275 F 165 PSI 165 PSI 220 F 275 F 175 PSI 175 PSI 220 F 275 F CAUTION DO NOT ALLOW EITHER THE DISCHARGE PRESSURE OR THE TEMPERATURE OF THE LIQUID TO EXCEED THE LIMITATIONS LISTED ABOVE. 45

47

48 INSTALLATION, CONT. 1. Short discharge lines may be the same size as the discharge port. Long runs require a pipe larger than the discharge port. 2. Long horizontal runs require a grade as even as possible. Avoid high spots and loops. Trapped air will throttle flow and may result in erratic pumping. 3. Install check and gate valves in discharge line; check valve (if used) between pump and gate valve. OPERATION Pre-Start - Before initial start of the pump, check as follows: 1. The rotation must be checked upon installation. Close, then break the contacts quickly and observe the rotation of the exposed portion of the rotating parts. Rotation must agree with the rotation arrow on the motor. For all pumps, the standard rotation is counterclockwise when viewed from the suction end. Motor wiring is easily changed in the field. Observe the wiring diagram on the inside of the terminal box cover, or on the motor nameplate. 2. Check voltage, phase and frequency of line circuit with motor nameplate. Priming - Pumps installed with a flooded suction can be primed by opening suction valve and allowing liquid to enter the casing. At the same time vent air out the top of the casing. 3. Fill pump completely with antifreeze solution. MAINTENANCE Cleaning - Remove oil, dust, dirt, water, chemicals from exterior or motor and pump. Keep motor air inlet and outlet open. Blow out interior of open motors with clean compressed air at low pressure. Regularly drain moisture from TEFC motors. Temperature - Total temperature, not the rise, is the measure of safe operation for a motor. If temperature by thermometer exceeds limits for insulation class, investigate and change operating conditions. Labeled Motors - It is imperative for repair of a motor with Underwriters' Laboratories label that original clearances be held; that all plugs, screws, other hardware be fastened securely, and that parts replacements be exact duplicates or approved equals. Violation of any of the above invalidates Underwriters ' label. Lubrication Pumps should require no maintenance, other than the motor bearings, according to the following instructions: DOUBLE SHIELDED AND DOUBLE SEALLED. When prelubricated bearings are furnished, no lubrication is required for the life of the bearings. Inspect bearings periodically to determine the condition of the grease and replace the bearings if necessary. If pump is installed with a suction lift, priming must be done by other methods, such as foot valves, ejectors, or by manually filling casing and suction line. SINGLE SHIELDED W/GREASE FITTING PROVISIONS. When single shield bearings are furnished, periodic inspection, cleaning and relubrication is required. See motor manufacturer's specific instructions for lubrication. CAUTION - DO NOT RUN PUMP DRY. Serious damage may result if started dry. Starting - Proceed as follows to start pump: PUMP IDENTIFICATION The pumps are manufactured with a one piece adapter or 1. Close drain valves and valve in discharge line. a two piece adapter. Identify design from photos shown 2. Open fully all valves in the suction line. below. 3. Prime the pump. If pump does not prime properly, or loses prime during start-up, shut down and One Piece Two Piece correct condition before repeating procedure. 4. For pumps moving high temperature liquids, /Adapter /Adapter open warm-up valve to circulate liquid for preheating. Close valve after pump has warmed up. 5. Start the motor (pump). 6. When pump is operating at full speed, open discharge valve slowly. Running - Periodically inspect pump while running, but especially after first start and following repair. 1. Check pump and piping for leaks. MECHANICAL SEAL REPLACEMENT Repair immediately. ONE PIECE ADAPTER 2. Record pressure gauge readings for future reference. A.) Disassembly : 3. Record voltage, amperage per phase, and kw 1. Turn off power. (if an indicating wattmeter is available). 2. Close suction and discharge valves. 4. Adjust pump output capacity with discharge valve. 3. Drain pump. DO NOT throttle suction line. 4. Remove bolts holding base to foundation Freezing Protection - Protect pumps shut down 5. Remove casing bolts. 6. Remove motor and rotating element during freezing conditions by one of the following from casing, leaving casing and piping methods: undisturbed. 1. Drain pump; remove all liquid from the casing. 7. Insert a screwdriver in one of the impeller 2. Keep fluid moving in pump and insulate or heat the waterway passages and back off the impeller pump to prevent freezing. If heated, do not let retaining nut with a socket wrench temperature go above 100 to 150 degrees F. as shown in Figure 1. 47

49 Figure 2 B.) Figure 1 8. Remove impeller from shaft, being careful not to lose the impeller key, spring and seal retainer. If impeller is difficult to remove, it may be necessary to use a bearing puller to pull of impeller. 9. Pry off rotating member of mechanical seal from sleeve by using two (2) screwdrivers. (Figure 2) 10. Remove bolts holding adapter to motor and take off adapter. 11. Place adapter on a flat surface with case rabbet facing down, and push out stationary part of mechanical seal. 12. Inspect shaft sleeve, shaft O-ring and flinger. If damaged or worn, replace with a new one. Reassembly: CAUTION: The mechanical seal is a precision product and should be handled accordingly. Use care when handling lapped running surfaces of the mechanical seal to ensure they remain clean and are free of chips or scratches. 1. Clean gasket and flange faces, seal seat cavity, shaft sleeve and motor shaft. 2. Lubricate the seal seat cavity of the adapter and the rubber cup or O-ring of seal seat with the lubricating fluid that comes with the mechanical seal or repair kit. Press the stationary seat in seal seat cavity or the adapter squarely and evenly using a arbor press (if possible) and the cardboard disc supplied with the seal. Be certain that the lapped face (shiny side) is facing you. 3. Install the flinger on the motor shaft until it bottoms on the motor shaft. 4. Slide the shaft O-ring on the motor shaft until it is tight against the flinger. Make sure that the shaft O-ring does not get damaged during this procedure. 5. Position shaft sleeve chamfer towards motor and slide on motor shaft. A.) 6. Remount the adapter on motor, making sure the motor shaft does not dislocate or chip the stationary seat of the seal. 7. Apply the lubricating fluid that comes with the mechanical seal or repair kit to the shaft sleeve and the rubber bellows of the rotary seal. Slide the seal head on the sleeve; press the rubber drive band on the rotary head until the lapped face on the head seats firmly against the lapped face of the stationary seat. Install seal spring on head and seal spring retainer on spring. Do not chip or scratch faces during installation. Take extra care to make sure the lapped faces are clean. 8. Place key in key seat. Line up keyway in impeller with key on motor shaft, and slide impeller on motor shaft. Be certain that the key is positioned in the keyway of the motor and impeller. Slightly compress seal spring with impeller and hold impeller while installing impeller retaining assembly in motor shaft. 9. Insert a screwdriver in a waterway passage of the impeller holding it against rotation as described in paragraph 7 of disassembly instructions, and tighten impeller retaining assembly. The impeller will compress the seal spring to the proper length assuring the correct pressure on the lapped surfaces. 1O. Remove any burrs caused by screwdriver on the vane of impeller in waterway passage. 11. Slide motor and impeller into the pump case. Replace any damaged gasket. 12. Tighten casing bolts alternately and evenly. 13. Replace hold-down bolts. 14. Check for free rotation after assembly is completed. 15. Seal all drain openings, using pipe sealant on threads. 16. Reprime before starting. Do not start unit until pump is completely filled with water. The approved lubricating fluid for seal installation is included with the mechanical seal or repair kit. DO NOT USE OTHER LUBRICATING LIQUIDS! MECHANICAL SEAL REPLACEMENT TWO PIECE ADAPTER Disassembly: 1. Refer to "One Piece Adapter" Disassembly, Notes Remove bolts holding cover to pump adapter. Pry cover from pump adapter. This process will remove mechanical seal head and shaft sleeve from motor shaft. Use caution when removing cover to eliminate the possibility of marring shaft sleeve. See Figure Remove (4) bolts that hold seal plate to cover. Place seal plate on flat surface and push out stationary part of mechanical seal. 11. It is not necessary to remove adapter from motor. 48

50 SCOT INSTALLATION INSTRUCTIONS TYPE 21 SHAFT SEAL The seal assembly consists of these components: A SPRING B ROTARY SEAL HEAD C STATIONARY SEAT - May have an O-ring groove in seat (C) or a rubber cup seat (CC). CAUTION: This seal is a precision product and should be handled accordingly. Be especically careful of the lapped sealing surface of the rotary washer and stationary seat. THE SEAL IS SUPPLIED WITH A PACKET OF LUBRICANT. LAPPED RUNNING FACES The lapped running surfaces of the rotary seal head and stationary seat must be treated with care. KEEP CLEAN. DO NOT SCRATCH. Use a clean, soft cloth during installation. Protect the faces. Install both the seat and rotary square to the shaft. Check the stationary seat installation from behind the seal cavity for squareness. STATIONARY SEAT INSTALLATION (C) Clean the seal seat cavity of the adapter and lubricate. Lubricate the seat O-ring or cup and press the stationary seat in seal cavity of the adapter squarely and evenly using an arbor press and the cardboard disc supplied with the seal. Be careful not to scratch or touch the lapped surface of stationary seat. Inspect the face of the stationary seat to be certain there is no dirt on face. If there is any dirt or fingerprints on the face, wipe it off carefully with a soft cloth. ROTARY SEAL HEAD INSTALLATION (B) Clean, polish and lubricate the shaft (or shaft sleeve). Check lapped faces on the stationary seat and rotary seal head. Be certain no dirt is on either face. Lubricate lightly. Slide the rotary seal head on the shaft with the carbon rotating ring facing the stationary seat. Press the drive band until the head seats firmly against the seat. Install spring (and spring retainer washer if used). Install impeller which will compress the spring to proper length assuring correct pressure on the lapped faces. CAUTION: Never operate the lapped running faces dry. The liquid being handled ensures proper lubrication. In some cases a short period of operation is required to clear up slight leakage. NOTE: The lubricant supplied with the seal is the only approved lubricant. DO NOT USE OTHER LUBRICATING LIQUIDS! HOME OFFICE Cedarburg, WI P.O. Box FAX FACTORY BRANCHES Irvine, CA Kettering FAX Ft. Lauderdale, FL SW 20th Street FAX SCOT Replaces March 1990 DIVISION OF ARDOX CORP B JANUARY 2000

51 SUCCESSFUL SEAL INSTALLATION 1. Read entire installation procedure before beginning installation. 2. Handle components carefully. Careless handling of the critical seal components may result in chipping, cracking or breakage. 3. Do not touch sealing areas. The sealing faces, O-rings, wedges, and bellows must kept perfectly clean. Even a fingerprint can cause a seal to leak. Primary and secondary sealing areas must be kept clean and undamaged to ensure a proper seal. Rubber gaskets tear easily when handled carelessly. 4. Make sure that the shaft or sleeve is free of burrs, nicks, grooves, and sharp edges. 5. Bleed all trapped gases from the seal cavity before start-up, otherwise the seal cavity may vapor lock and burn the seal. 6. All valves must be open on the suction side of the pump so that the seal is assured of a positive flow of liquid at all times. Failure to do so will also cause the seal to burn. 51

52 (Please include titles) (Please include titles) Prior to start-up, please record this data: Prior to start-up, please record this data: For start-up, please record this data: For start-up, please record this data: Please complete this form and send a copy to LAKOS; keep a copy for your records. Please complete this form and send a copy to LAKOS; keep a copy for your records. 52