UNIPUMP. Operating Instructions. Close Coupled Sewage pump Series K, HK, QSH. Internet

Transcription

1 UNIPUMP Close Coupled Sewage pump Series K, HK, QSH Operating Instructions Also on the Internet! Herborner Pumpenfabrik J.H. Hoffmann GmbH & Co. House address: Littau 3-5 D HERBORN Phone ++49 (27 72) Telefax ++49 (27 72) Internet info@herborner-pumpen.de We reserve the right to make technical modifications in line with technological advancements! A - BA20 GB

2 1. General information Intended application Model designation Technical specifications rating plate Noise level Safety Marking of safety instructions in the operating manual Qualifications and training of personnel Dangers caused in negligence of safety instructions Safety awareness Safety instructions for the operator/user Safety instructions for maintenance, inspection and installation work Unauthorised modifications and use of non-genuine spare parts Unapproved usage Transportation Transport equipment Description Shaft seal Checking the seal on the tandem arrangement Drive Motor specifications Erection and installation Erecting the pump Sectional drawing Spare parts Laying the pipelines Intake line Discharge line Frost protection Electrical connection Checking the direction of rotation Altering the direction of rotation Start-up mode Commissioning Maintenance General maintenance instructions Maintenance instructions following a prolonged shutdown Greasing the bearings Greasing interval table Cleaning Removing the pump Filling and changing the oil - tandem arrangement Official acceptance

3 1. General information 1.1 Intended application General information UNIPUMP close coupled sewage pumps with non-clogging-system of Herborner Pumpenfabrik are suitable for pumping Contaminated fluids with grain sizes up to 80 mm diameter. They MUST NOT be used to pump the following: Combustible or explosive media! Media containing aggressive chemicals which could damage the pump material! Bronze or stainless steel pump materials are available for pumping aggressive and abrasive media. The use of explosion-proof motors is permissible. 1.2 Model designation Example: 10 / QSH Impeller diameter Number of paddles Size Series Motor output P, e.g. 10 = 10 horsepower 1.3 Technical specifications rating plate Technical specifications regarding the type of pump used can be taken from either the brochure, these operating instructions or the rating plate. We recommend that you make a note of the specifications for the supplied pump, as shown on the original rating plate, in the following diagram, so that this information is accessible whenever you need it. In case of queries and when ordering spare parts, you will be required to state the pump type and order no. 3

4 General information Key to rating plate Typ Pump type Nr. Serial number Bj. Year of construction A-Nr. Order no. Q Rated delivery rate [m³/h] H Rated discharge head [m] n Rotary speed [rpm] mp Power output [kw] Key to the rating plate on the motor (not shown) Typ Motor type Nr. Motor number U Operating voltage [V] I Rated current [A] 50Hz/60Hz Frequency [Hz] P 1 Power input [kw] P 2 Power output [kw] n Rotary speed [rpm] cos ϕ Power factor 3~ Three-phase a.c. motor IP 55 Protection category Kl.F Insulation category F Y Type of circuit The information on the rating plates may vary depending on the motor manufacturer! 1.4 Noise level The maximum noise level is generally determined by the drive motors via air, magnet and bearing noises. The system does not exceed the permissible limit curves for electric motors as specified by VDE 0530 part 9/ Lowest noise generation during operation is close to Q OPT. 4

5 2. Safety - Information Safety - Information (Based on VDMA- Instruction sheet 24292) The Operating Manual contains fundamental instructions to be observed during installation, operation and maintenance. Therefore, it is essential that these instructions are read carefully by both the fitter and the person responsible/user before installing and starting the unit. The Operating Instruction should always be available at the location of the unit. Not only the general instructions listed in this chapter Safety-Information should be followed carefully, but also the specific safety instructions stated in the other chapters of the manual. As soon as the pump as a single machine is part of an entirety of machines, the superior operating manual should be observed for a total safety inspection. 2.1 Marking of safety instructions in the Operating Manual All safety instructions stated in this Operating Manual, which may cause hazards if neglected, are highlighted with a common danger symbol (specifications DIN 4844-W9). Warning against dangerous voltage is indicated by this danger symbol (specifications DIN 4844-W8). refers to safety instructions which may cause damages to the equipment or affect its functions if neglected. Instructions written directly on the equipment, i.e.: direction of rotation arrow name plates must be absolutely followed and kept in a legible condition. 2.2 Qualifications and training of personnel Operating, maintenance, inspection and installation personnel must prove qualifications for the respective duties. Areas of responsibility, competence and personnel supervision should be clearly defined by the user. If the personnel is not sufficiently qualified, it should be trained and instructed accordingly. Such a training can be carried out on behalf of the manufacturer/supplier at the request of the user. Further, the user should ensure that the contents of the Operating Manual is fully understood by the personnel. 2.3 Dangers caused in negligence of safety instructions Disregarding safety instructions can cause danger to persons as well as to the equipment and to the environment. Disregarding safety instructions can invalidate the right to any damage claims. In particular, disregard for safety instructions may result in the following hazards: Failure of important functions of the plant. Danger to persons by electrical, mechanical or chemical impact. Danger to the environment by leakage of dangerous substances. 5

6 Safety - Information 2.4 Safety awareness The Safety Instructions listed in this Operating Manual, the existing national safety regulations, as well as any internal operating and safety instructions which apply in the users own premises should be respected. 2. Safety 2.5 Safety instructions for the user/ operator Safety guards for moving parts (e.g. ventilator hoods) may not be removed while the unit is in operation. Dangers due to electrical energy must be excluded (for details, please refer to the regulations of the VDE and of the local Power Supply Company). Leakage (for example of the mechanical seal) of dangerous liquids (explosiv, toxic, hot) have to be drained off without dangers for persons and country. Legal rules must be followed. 2.6 Safety instructions for maintenance, inspection and installation work The user must ensure that all maintenance, inspection and installation work is carried out by authorized and qualified personnel, that has familiarized itself thoroughly with the Operating Manual. As a rule, all work on the unit should only be carried out when it is switched off. The procedures described in the Operating Manual for stopping the unit should be strictly followed. Pumps or agregates used for pumping harmful substances should be decontaminated. Immediately after completion of work, all safety and protective devices should be refitted and fully functional. Before re-starting the plant, the instructions for electrical wiring and installation should be followed again. 2.7 Unauthorized modifications and use of non-genuine spare parts Modifications or changes to the unit are only authorized upon approval of the manufacturer. Only genuine spare parts and original accessories will ensure the safety of the unit. The use of non-genuine spare parts and accessories can result in the annulments of the liability for damages caused thereby. 2.8 Unapproved usage The operating safety of the unit is only guaranteed, provided that the unit is used in accordance with the Safety and Operating Instructions. Any other usage is not in conformity with the regulations. Consequently, the manufacturer is not liable for any resulting damages. Unauthorized usage is at the user s risk. The correct usage of the unit also implies a strict observation of the operating, maintenance and serving instructions issued by the manufacturer. The Installation and Operating Manual does not invalidate general regulations and standards not refered to. General technical rules should be observed. 6

7 Transportation 3. Transportation Brace the pump to protect it against falls and impact! Secure the pump to prevent it from tilting! 3.1 Transport equipment The pump should be transported using slings, taking care to ensure a secure grip. The lifting gear and slings must be adequately dimensioned for the weight of the pump! The pump should be deposited on a sufficiently firm surface which is completely level. 2. Safety Special care should be taken to ensure that the unit is not top-heavy, otherwise it could topple over. The accident prevention regulations and generally recognised technical rules must be observed. 7

8 Description 4. Description 4.1 Shaft seal On the intake side, all models are sealed with maintenance-free mechanical seals of wear-resistant materials which have been adapted to suit the respective operating conditions. The pump can optionally be fitted with a mechanical seal in a tandem arrangement. On the discharge side, all motors are equipped with a special seal to protect against splashes. If the pump is allowed to run dry, the mechanical seal will be destroyed! Checking the seal on the tandem arrangement In pumps with a tandem seal, the shaft seal consists of two mechanical seals arranged one in front of the other. The oil chamber is filled with lubrication oil for lubrication and cooling. Circuit example: The seal can be checked via an electrode. - Connect the electrode to an electrical level monitor. - Change the oil after 4000 hours. - Oil grade in accordance with ISO VG 46 (e.g. Shell Tellus 46). Function: - When the electrode is immersed in an electrically conductive liquid, a control voltage of approximately 3 ma will flow. - By means of a measuring amplifier, the control current can actuate a control current relay with a potential-free twoway contact. 4.2 Drive The pump is equipped with a three-phase squirrel-cage motor - Voltages to IEC 38 - Circuit: 380V 400V 50Hz 60Hz / V / V < 3kW V V > 3kW 230/400V 265/460V < 3kW 400/690V 460V > 3kW - Protection category IP 55 - Insulation category F The precise motor specifications can be taken from the rating plate. The motor is cooled via heat dissipation from the cooling fins to the ambient air. Observe the coolant temperature as specified on the rating plate! 8

9 Description Motor specifications 50Hz 60Hz 1500 rpm 1800 rpm Type Rated Rated current Rated Rated current Circuit Weight output [380V] [400V] output [440V] [460V] [kw] [A] [kw] [A] [kg] 0,75 /K 25 0,55 1,7 1,55 0,66 1,65 1,53 Y 26 1 /K 50 0,75 2,2 2,0 0,9 2,2 2,0 Y 34 1,5 /K 50 1,1 2,85 2,6 1,3 2,8 2,55 Y 38 2 /K 50 1,5 3,8 3,55 1,8 3,7 3,55 Y 41 3 /K 50 2,2 5,4 4,9 2,6 5,3 4,85 Y 49 3 /K 80 2,2 5,4 4,9 2,6 5,3 4,85 Y 70 4 /QSH 101 3,0 7,3 6,7 3,6 7,3 6,7 82 5,5 /QSH 101 4,0 9,4 8,6 4,8 9,3 8,7 89 7,5 /QSH 101 5,5 12,0 11,3 6,6 11,9 11, /QSH 101 7,5 15,6 14,8 9,0 15,8 15, Hz 60Hz 3000 rpm 3600 rpm Type Rated Rated current Rated Rated current Circuit Weight output [380V] [400V] output [440V] [460V] [kw] [A] [kw] [A] [kg] 1 /HK 25 0,75 1,93 1,75 0,9 1,9 1,73 Y 26 1,5 /HK 25 1,1 2,7 2,45 1,32 2,7 2,4 Y 27 3 /HK 50 2,2 4,9 4,6 2,6 4,9 4,55 Y 41 4 /HK 50 3,0 6,3 6,3 3,6 6,4 6,2 50 5,5 /HK 50 4,0 8,6 8,0 4,8 8,4 8, /HK 80 3,0 6,3 6,3 3,6 6,4 6,2 72 5,5 /HK 80 4,0 8,6 8,0 4,8 8,4 8,0 78 7,5 /HK 80 5,5 11,9 10,7 6,6 11,3 10, /HK 80 7,5 16,2 14,1 9,0 15,1 14, /HK 80 11,0 21,0 20,5 13,2 21,5 21, /HK 80 15,0 31,0 27,5 18,0 30,0 28,0 164 Rated output and rated current at a permissible temperature-rise limit of 80K and cooling temperature of 40 C to VDE. 9

10 Erection and installation 5. Erection and installation 5.1 Erecting the pump For operational safety reasons, the vertical type motor should not be positioned pointing downwards! Provide sufficient space for maintenance and repair work! When installing the pump, care should be taken to ensure an adequate supply of cooling air during operation. The lifting gear (load hook, crane) required for installation and removal must be adequately dimensioned for the overall weight of the pump and must comply with the valid safety regulations. 5.2 Sectional drawing K HK 25 Type F Type GF

11 K HK 50 Erection and installation K HK

12 Erection and installation QSH Detail "X" Detail "Y" 1 Casing 2 Impeller 3 Rear wall 5 Vent plug 7 Motor 11 Casing joint 12 Drain plug 13 Impeller nut 17 Mechanical seal 18 Bush 19 Cover 20 Impeller cap 27 Ball bearing 28 Ball bearing 29 Disc 44 Shaft with rotor 48 Labyrinth disc 63 Disc 64 Seal cover 66 O-ring 67 Mechanical seal 68 O-ring 69 Vent plug 70 Monitoring electrode 71 Vent plug 72 Oil drain plug 73 Oil 74 O-ring 75 Joint ring 81 Casing wear ring 12

13 Erection and installation No specific foundation is required for erecting the pump. A flat surface is adequate. Anchoring with four fastening bolts. Only use removable screws to facilitate subsequent removal without having to loosen the flange connections. Under no circumstances should studs or foundation anchors be used! When erecting outside, a protective roof should be erected to shield against the elements Spare parts The specifications for further selection of spare parts are related to the initial need for a two year operation based on DIN Spare parts (generally existing) Number of pumps (including reserve pump) Number of replacement parts Impeller % Cover % Mechanical seal % Ball bearing set % Shaft seal ring % Split ring % Seal set % Shaft + accessories % 5.3 Laying the pipelines Attach the intake and discharge line without tension Intake line To avoid air pocket formation: Lay the intake line with a continuous rise. The supply line should have a slight gradient towards the pump. If local conditions do not permit a continuous rise in the intake line, provision should be made for complete venting. Installation of a... gate valve to close the lines immediately in front of the pump, to allow the pump to be removed without first draining the lines. 13

14 Erection and installation Discharge line The locally valid regulations should be observed when laying the discharge line. When laying the discharge line, provisions should be made for complete venting. The discharge line should be installed in a frost-proof area. Installation of a... gate valve to close the lines immediately in front of the pump, to allow the pump to be removed without first draining the lines. non-return device between the discharge connection and gate valve, prevents return flow of the pumping medium after shutting off the pump. 5.4 Frost protection During long periods of shutdown, the pump should be drained if there is a risk of frost. Open the drain plug in the casing. Take care to ensure that the escaping medium does not cause injury or damage the motor or other components. In systems with hot media, beware particularly of the risk of scalding. Before commissioning the pump Close the drain plug in the pump casing. 14

15 5.5 Electrical connection Erection and installation Before commissioning, have the system checked by an expert to verify that the required electrical safety measures have been implemented. The earthing, TN system and residual current operated system etc. must satisfy local regulations and must be inspected by a qualified electrician to verify proper functioning. The cross-section and voltage drop of the mains supply line must comply with the relevant regulations (e.g. VDE, ÖVE or local equivalent). The voltage specified on the pump s rating plate must match the available mains voltage. Motors with built-in thermistor temperature sensors: - Test voltage of PTC thermistor max. 1,5 V! - Only are able to work in conjunction with a tripping unit! The pump should be protected by an appropriate back-up fuse (corresponding to the rated output of the motor). The size of the motor protective circuit breaker should be 1,05-fold of the current consumption. 5.6 Checking the direction of rotation For rotary current pumps, the direction of rotation should be conscientiously checked when commissioning for the first time and at every new location. An incorrect direction of rotation will impair performance and may damage the pump. In the case of control systems comprising several pumps, each pump should be checked individually. Looking at the motor fan, it should rotate in a clockwise direction. The direction of rotation should match the arrow. Switch the pump off immediately after starting. If the pump is allowed to run dry, the mechanical shaft seal will be destroyed. When checking the direction of rotation, the pump should be secured in such a way as to eliminate the possibility of injuries caused by the rotating impeller. Never put your hand into the discharge connection or the intake opening of the pump casing Altering the direction of rotation If the direction of rotation is incorrect, it can be reversed by swapping over two phases of the supply cable in the control unit. 5.7 Start-up mode The following motor circuit-breaker settings are required: For direct starting: set to rated motor current For Y starting: set to rated motor current x

16 Erection and installation Motor connection diagrams: Operating voltage (mains) Motor voltage (motor rating plate) Direct starting or Star/delta starting The incorrect electrical circuit type will cause failure of the electric motor! 16

17 6. Commissioning Commissioning Before commissioning, the pump should be inspected and a functional check carried out. In particular, the following points should be checked: Have the pump and pipelines been connected in accordance with regulations? Does the electrical connection satisfy the valid provisions? Is the motor circuit-breaker correctly set? Are the valves required for operation open? Have the connection cables been installed in accordance with regulations? Is the pump correctly seated in the anchor? Have the covers of the suction- and delivery side been removed before mounting (only with water supply)? When commissioning, the pump and intake line should be vented and primed with pumping liquid before starting up! The shut-off valve in the intake and discharge lines must be fully open. If the pump is allowed to run dry, the mechanical shaft seal will be destroyed. Do not touch pumps which are used for pumping hot water risk of burns! If the density or flowrate exceeds the designed capacity, care should be taken to ensure that the motor is not overloaded and that the available feed height is reached (cavitation!). 17

18 Maintenance 7. Maintenance Before starting maintenance work, all poles of the pump should be disconnected from the mains and secured against re-activation. When carrying out maintenance and repair work, the safety regulations governing work in enclosed spaces and the generally recognised technical rules must be observed. The maintenance tips given here are not intended as a guide for carrying out your own repairs specialised experience is required for this purpose. By entering into a maintenance contract with our customer service department, you can be assured of top quality, expert service at all times. 7.1 General maintenance instructions Pumps manufactured by Herborner Pumpenfabrik are established quality products and are subject to stringent final inspections. Should you experience a malfunction despite this, under no circumstances should you attempt to improvise consult our customer service department. This applies in particular in the case of repeated shutdowns by the overcurrent trip in the control unit, or in the event of alarms. To ensure a long service life, the checks and maintenance work outlined below should be carried out at regular intervals. Our sales force will be pleased to advise you on special applications and help solve your pumping problems. 6. Commissioning 7. Maintenance Within the context of supply agreements, Herborner Pumpenfabrik will only guarantee its products provided repairs are carried out by authorised agents and proof is furnished that original spare parts for Herborn pumps have been used. 18

19 Maintenance 7.2 Maintenance instructions following a prolonged shutdown Before switching on the pump and during a prolonged shutdown, rotate the motor shaft several times by hand on the fan. 7.3 Greasing the bearings Bearing of the common shaft for the pump and motor Anti-friction bearings have been greased in the factory Refer to the greasing interval table for lubrication periods The grade of lubrication grease which should be used is STABURAGS NBU 8 EP Avoid over-greasing the bearings. Grease presses with hydraulic head H to DIN The quantity of grease dispensed is approximately g per stroke with a high-pressure plungertype grease gun approximately 1.2 g per stroke with a hand-lever grease gun The quantity of grease required is shown in the greasing interval table Greasing interval table Motor Ball bearing (drive side) Ball bearing (fan side) [kw] Greasing interval [h] Quantity of grease [g] Greasing interval [h] Quantity of grease [g] 1, , , , , , , Re-greasing device Re-greasing device for 4-pole drives from 1.1 kw Motors with kw and 0.75 kw rpm - Ship classification are not suitable for re-greasing. 19

20 Maintenance 7.4 Cleaning When removing or dismantling the pump, it should be cleaned to remove deposits, if appropriate by mechanical means, in order to ensure perfect operation. 7.5 Removing the pump Before removing the pump, the motor connection cables should be disconnected from the terminal box by a qualified electrician. All shut-off valves in the intake and discharge lines must be closed. With hot pumping media, the pump casing must have cooled down to the ambient temperature. The pump unit must be pressureless and empty. For this purpose, open the drain plug. Care must be taken to ensure that escaping medium does not cause injury or damage to the motor or other components. In case of systems with hot media, beware particularly of the risk of scalding! The lifting gear must be adequately dimensioned for the overall weight of the pump. Observe accident prevention regulations and general technical regulations. Deposit the pump on a firm surface and secure to prevent it from tipping over. Caution - tilting danger with the loosening of the pump from the piping network - squeezing danger below the motor! 7.6 Filling and changing the oil - tandem arrangement The oil chamber between the motor and pump unit is filled with lubrication oil in the factory. The quantity of oil necessary will be indicated by oil escaping from the vent opening. Only genuine spare parts must be used for repair purposes. Approx. 1,5 Litres of oil, Change the oil after 4,000 hours of operation, Oil grade in accordance with ISO VG 46 (e.g. Shell Tellus 46). Do not mix different oils. Used oil should be disposed of properly in accordance with the local regulations! 7.7 Official acceptance The delivered goods may be officially accepted by: All classification companies The German Armed Forces quality inspection service or National technical inspectorates 20