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Table of Contents
Table of Contents
Introduction and Safety...................................................................................................................................................3 Introduction.......................................................................................................................................................................3 Safety terminology and symbols.....................................................................................................................................3 Inspect the delivery...........................................................................................................................................................4 Inspect the package........................................................................................................................................................4 Inspect the unit...............................................................................................................................................................4 Product warranty...............................................................................................................................................................4 Spare parts.......................................................................................................................................................................5 Safety...................................................................................................................................................................................5 User safety..........................................................................................................................................................................5 Hazardous liquids...........................................................................................................................................................6 Wash the skin and eyes..................................................................................................................................................6 Ex-approved products......................................................................................................................................................6 Guidelines for compliance............................................................................................................................................7 Permitted liquid level for ATEX.................................................................................................................................7 Monitoring equipment..................................................................................................................................................7 MSHA requirements.........................................................................................................................................................7 Environmental safety........................................................................................................................................................8 Transportation and Storage............................................................................................................................................9 Transportation guidelines.................................................................................................................................................9 Precautions......................................................................................................................................................................9 Position and fastening...................................................................................................................................................9 Lifting...............................................................................................................................................................................9 Storage guidelines..............................................................................................................................................................9 Storage location..............................................................................................................................................................9 Freezing precautions....................................................................................................................................................10 Long-term storage.......................................................................................................................................................10 Product Description........................................................................................................................................................11 Products included............................................................................................................................................................11 Pump design.....................................................................................................................................................................11 Monitoring equipment....................................................................................................................................................12 The data plate...................................................................................................................................................................12 The MSHA approval plate..........................................................................................................................................13 Product denomination....................................................................................................................................................13 Installation.........................................................................................................................................................................14 Install the pump...............................................................................................................................................................14 Sedimentation prevention...........................................................................................................................................14 Discharge line requirements.......................................................................................................................................14 Fasteners........................................................................................................................................................................15 Install with S-installation.............................................................................................................................................15 Make the electrical connections....................................................................................................................................16 General precautions.....................................................................................................................................................16 Requirements................................................................................................................................................................16 Cables.............................................................................................................................................................................16 Earthing (Grounding).................................................................................................................................................17 Earth (ground) conductor length..............................................................................................................................17 Switch between higher and lower supply voltages..................................................................................................17 Connect the motor cable to the pump.....................................................................................................................17 Cable charts for connection with sealed terminal plate, standard version .........................................................18
Table of Contents
Cable charts for connection without sealed terminal plate, standard version ...................................................21 Cable charts, MSHA version .....................................................................................................................................23 Check the impeller rotation...........................................................................................................................................24 Operation...........................................................................................................................................................................25 Precautions.......................................................................................................................................................................25 Distance to wet areas......................................................................................................................................................25 Noise level........................................................................................................................................................................25 Start the pump.................................................................................................................................................................25 Clean the pump...............................................................................................................................................................26 Maintenance......................................................................................................................................................................27 Precautions.......................................................................................................................................................................27 Maintenance guidelines..................................................................................................................................................27 Torque values...................................................................................................................................................................27 Service...............................................................................................................................................................................28 Inspection......................................................................................................................................................................28 Major overhaul..............................................................................................................................................................29 Change the oil..................................................................................................................................................................29 Empty the oil................................................................................................................................................................30 Fill with oil....................................................................................................................................................................30 Replace the impeller........................................................................................................................................................31 Remove the impeller MT, HT ...................................................................................................................................31 Remove the impeller , sludge version ......................................................................................................................32 Install the impeller MT, HT ......................................................................................................................................34 Install the impeller , sludge version ..........................................................................................................................37 Troubleshooting...............................................................................................................................................................39 Introduction.....................................................................................................................................................................39 The pump does not start................................................................................................................................................39 The pump does not stop when a level sensor is used...............................................................................................40 The pump starts-stops-starts in rapid sequence.........................................................................................................40 The pump runs but the motor protection trips..........................................................................................................41 The pump delivers too little or no water.....................................................................................................................41 Technical Reference........................................................................................................................................................43 Application limits............................................................................................................................................................43 Motor data........................................................................................................................................................................43 Specific motor data, standard version .........................................................................................................................43 Specific motor data, MSHA version ...........................................................................................................................45 Dimensions and weights................................................................................................................................................46 Performance curves........................................................................................................................................................50
WARNING:
A hazardous situation which, if not avoided, could result in death or serious injury
CAUTION:
A hazardous situation which, if not avoided, could result in minor or moderate injury
NOTICE:
A potential situation which, if not avoided, could result in undesirable conditions A practice not related to personal injury
Hazard categories Hazard categories can either fall under hazard levels or let specific symbols replace the ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol: Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary hazard levels and may use complementing symbols: Crush hazard Cutting hazard Arc flash hazard
Product warranty
Coverage ITT undertakes to remedy faults in products from ITT under these conditions: The faults are due to defects in design, materials, or workmanship. The faults are reported to an ITT representative within the warranty period. The product is used only under the conditions described in this manual. The monitoring equipment incorporated in the product is correctly connected and in use. All service and repair work is done by ITT-authorized personnel. Genuine ITT parts are used. Only Ex-approved spare parts and accessories authorized by ITT are used in Ex-approved products. Limitations The warranty does not cover faults caused by these situations: Deficient maintenance Improper installation Modifications or changes to the product and installation made without consulting ITT Incorrectly executed repair work Normal wear and tear
ITT assumes no liability for these situations: Bodily injuries Material damages Economic losses Warranty claim ITT products are high-quality products with expected reliable operation and long life. However, should the need arise for a warranty claim, then contact your ITT representative. Spare parts ITT guarantees that spare parts will be available for 10 years after the manufacture of this product has been discontinued.
Safety
WARNING: The operator must be aware of safety precautions to prevent physical injury. Any pressure-containing device can explode, rupture, or discharge its contents if it is over-pressurized. Take all necessary measures to avoid over-pressurization. Operating, installing, or maintaining the unit in any way that is not covered in this manual could cause death, serious personal injury, or damage to the equipment. This includes any modification to the equipment or use of parts not provided by ITT. If there is a question regarding the intended use of the equipment, please contact an ITT representative before proceeding. This manual clearly identifies accepted methods for disassembling units. These methods must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never apply heat to impellers, propellers, or their retaining devices to aid in their removal. Do not change the service application without the approval of an authorized ITT representative. CAUTION: You must observe the instructions contained in this manual. Failure to do so could result in physical injury, damage, or delays.
User safety
General safety rules These safety rules apply: Always keep the work area clean. Pay attention to the risks presented by gas and vapors in the work area. Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash hazards. Always bear in mind the risk of drowning, electrical accidents, and burn injuries. Safety equipment Use safety equipment according to the company regulations. Use this safety equipment within the work area: Helmet Safety goggles, preferably with side shields Protective shoes Protective gloves Gas mask Hearing protection
First-aid kit Safety devices NOTICE: Never operate a unit unless safety devices are installed. Also see specific information about safety devices in other chapters of this manual. Electrical connections Electrical connections must be made by certified electricians in compliance with all international, national, state, and local regulations. For more information about requirements, see sections dealing specifically with electrical connections. Hazardous liquids The product is designed for use in liquids that can be hazardous to your health. Observe these rules when you work with the product: Make sure that all personnel who work with biologically hazardous liquids are vaccinated against diseases to which they may be exposed. Observe strict personal cleanliness. Wash the skin and eyes Follow these procedures for chemicals or hazardous fluids that have come into contact with your eyes or your skin: Condition Chemicals or hazardous fluids in eyes Chemicals or hazardous fluids on skin Action 1. Hold your eyelids apart forcibly with your fingers. 2. Rinse the eyes with eyewash or running water for at least 15 minutes. 3. Seek medical attention. 1. 2. 3. Remove contaminated clothing. Wash the skin with soap and water for at least 1 minute. Seek medical attention, if necessary.
Ex-approved products
Follow these special handling instructions if you have an Ex-approved unit. Personnel requirements These are the personnel requirements for Ex-approved products in potentially explosive atmospheres: All work on the product must be carried out by certified electricians and ITT-authorized mechanics. Special rules apply to installations in explosive atmospheres. All users must know about the risks of electric current and the chemical and physical characteristics of the gas, the vapor, or both present in hazardous areas. Any maintenance for Ex-approved products must conform to international and national standards (for example, IEC/EN 60079-17). ITT disclaims all responsibility for work done by untrained and unauthorized personnel. Product and product handling requirements These are the product and product handling requirements for Ex-approved products in potentially explosive atmospheres: Only use the product in accordance with the approved motor data. You must fully submerge the Ex-approved product during normal operation. Dry running during service and inspection is only permitted outside the classified area. Before you start work on the product, make sure that the product and the control panel are isolated from the power supply and the control circuit, so they cannot be energized. Do not open the product while it is energized or in an explosive gas atmosphere.
Make sure that thermal contacts are connected to a protection circuit according to the approval classification of the product, and that they are in use. Intrinsically safe circuits are normally required for the automatic level-control system by the level regulator if mounted in zone 0. The yield stress of fasteners must be in accordance with the approval drawing and the product specification. Do not modify the equipment without approval from an authorized ITT representative. Only use parts that are provided by an authorized ITT representative. Guidelines for compliance Compliance is fulfilled only when you operate the unit within its intended use. Do not change the conditions of the service without the approval of an ITT representative. When you install or maintain explosion proof products, always comply with the directive and applicable standards (for example, IEC/ EN 6007914). Permitted liquid level for ATEX ATEX-approved products must be fully submerged according to the ATEX approval. Level-sensing equipment must be installed if the product can be operated at less than the minimum submersion depth. Monitoring equipment For additional safety, use condition-monitoring devices. Condition-monitoring devices include but are not limited to the following: Level indicators Temperature detectors MSHA requirements According to the Code of Federal Regulations, the following requirements must be fulfilled to maintain permissibility of this equipment: Subject area Requirements General safety Frequent inspections must be made. All electrical parts, portable cable, and wiring must be kept in a safe condition. There must not be any openings into the casings of the electrical parts. The machine frame must be effectively earthed (grounded). Power wires must not be used for earthing (grounding). The operating voltage must match the voltage rating of the motor.
Requirements Inspections, service, and repairs are only allowed when the portable cable is disconnected from the power supply. Work must be performed by trained personnel (preferably the manufacturer or agent) to ensure that the pump is restored to its original state of safety in regards to all flame-arresting paths. Replacement parts must be exactly equal to those provided by the manufacturer. When cable entries are disturbed on pump or control, they must be reassembled in the approved manner. DANGER: Failure to restore the permissible equipment to its original state of safety will void the MSHA approval. The creation of a safety hazard will subject the owner / operator of a mine to citations and penalties under the law.
Fastenings Cables
All bolts, nuts, screws, and threaded covers must be properly tightened and secured. A flame-resistant portable cable must be used. It has to bear an MSHAassigned identification number and be adequately protected by an automatic circuit-interrupting device. Special care must be taken in handling the cable to avoid mechanical damage and wear. Poly-Life equipped products must not be operated dry in hazardous areas.
Operation
Environmental safety
The work area Always keep the station clean to avoid and/or discover emissions. Waste and emissions regulations Observe these safety regulations regarding waste and emissions: Appropriately dispose of all waste. Handle and dispose of the processed liquid in compliance with applicable environmental regulations. Clean up all spills in accordance with safety and environmental procedures. Report all environmental emissions to the appropriate authorities. Electrical installation For electrical installation recycling requirements, consult your local electric utility.
Lifting
WARNING: Crush hazard. The unit and the components can be heavy. Use proper lifting methods and wear steeltoed shoes at all times. Lift and handle the product carefully, using suitable lifting equipment. The product must be securely harnessed for lifting and handling. Use eyebolts or lifting lugs if available. Always lift the unit by its lifting handle. Never lift the unit by the motor cable or by the hose. Do not attach sling ropes to shaft ends. Mechanical lifting When lifting the unit mechanically, always use the lifting eyes.
Storage guidelines
Storage location The product must be stored in a covered and dry location free from heat, dirt, and vibrations.
NOTICE: Protect the product against humidity, heat sources, and mechanical damage. Do not place heavy weights on the packed product. Freezing precautions The unit is frost-proof while operating or immersed in liquid, but the impeller/propeller and the shaft seal may freeze if the unit is lifted out of the liquid into a surrounding temperature below freezing. Follow these guidelines to avoid freezing damage: When Guideline Before storage The unit must be allowed to run for a short time after raising it to discharge remaining pumped liquid. This does not apply to impeller/propeller units. The discharge opening must be covered in a suitable way, or placed facing down so that any still remaining pumped liquid runs out. If present, the cooling jacket must be drained manually by opening the air vent screws at the top of the cooling jacket. After storage If the impeller/propeller is frozen, it must be thawed by immersing the unit in liquid before operating the unit. NOTICE: Never use a naked flame to thaw the unit.
Long-term storage If the unit is stored more than 6 months, the following apply: Before operating the unit after storage, it must be inspected with special attention to the seals and the cable entry. The impeller/propeller must be rotated every other month to prevent the seals from sticking together.
10
Product Description
Product Description
Products included Pump model 2630.180 Approvals European Norm ATEX Directive EN 1127-1, EN 60079-0, EN 60079-15 2630.081 MSHA II 3G Ex nA/nC c IIC T1...T4
MSHA (Mine Safety and Health Administration, USA): 30CFR Part 7, Approval number 07JA060012-0 European Norm
2630.280
Pump design
The pump is submersible, and driven by an electric motor. Intended use The product is intended for moving waste water, sludge, raw and clean water. Always follow the limits given in Application limits (page 43). If there is a question regarding the intended use of the equipment, please contact an ITT representative before proceeding. Pumps with MSHA (Mine Safety and Health Administration, USA) certifications are designed to be used in explosive zones. WARNING: In explosive or flammable environments, only use Ex- or MSHA-approved pumps.
NOTICE: Do NOT use the pump in highly corrosive liquids. For information about pH, see Application limits (page 43). The warm media (liquid) version has certain operational limitations, which are stated on a plate on the pump. For applicability, see Application limits (page 43). Particle size Version code 280: The pump can handle liquid containing particles with the diameter of 80 mm ( 3.15 in.). Version code 081/180: The pump can handle liquid containing particles that correspond to the holes in the strainer. For more information about the strainer, see Dimensions and weights (page 46). Pressure class MT HT Medium head High head
11
Product Description
Impeller type Version code 081, 180: K Version code 280: D Clog resistant
Monitoring equipment
The following applies to the monitoring equipment of the pump: The stator incorporates thermal contacts connected in series that activate the alarm at overtemperature. The thermal contacts open at 140C (284F) and close at 105C (221F).
23 22 21 20
10
11
12 13 14 15 16
17
18
19
Curve code/Propeller code Serial number, see Product denomination (page 13) Product number Country of origin Additional information Phase; type of current; frequency Rated voltage Thermal protection Thermal class Rated shaft power International standard Degree of protection Rated current Rated speed Maximum submergence Direction of rotation: L=left, R=right Duty class Duty factor Product weight Locked rotor code letter Power factor Maximum ambient temperature Read installation manual Notified body/only for EN-approved Ex-products
12
Product Description
Product denomination
Sales denomination The sales denomination consists of the four-digit sales code and two letters that indicate the hydraulic end and type of installation. This is an example of a sales denomination, and an explanation of its parts.
NP 3085
1 2 3
1. 2. 3. Hydraulic part Installation type Sales code
Product code The product code consists of nine characters divided into two parts. This is an example of a product code, and an explanation of its parts.
NP 3085.183 1 2
1. 2.
Serial number The serial number is used for identification of an individual product, and is divided into four parts. This is an example of a serial number, and an explanation of its parts.
3 4
13
Installation
Installation
Install the pump
WARNING: Before installing the pump, check that the cable and cable entry have not been damaged during transportation. Make sure that the unit cannot roll or fall over and injure people or damage property. Do not install CSA-approved products in locations that are classified as hazardous in the national electric code, ANSI/NFPA 70-2005. NOTICE: Never force piping to make a connection with a pump. These requirements apply: Use the pump dimensional drawing in order to ensure proper installation. Provide a suitable barrier around the work area, for example, a guard rail. Check the explosion risk before you weld or use electric hand tools. Remove all debris from the inlet piping system before you install the pump. Always check the impeller rotation before lowering the pump into the pumped liquid. Sedimentation prevention In order to avoid sedimentation when the pumped liquid contains solid particles, the velocity of the liquid in the discharge line must exceed a certain value. Choose applicable minimum velocity from the table, and choose proper dimension of the discharge line accordingly. Mixture Water + coarse gravel Water + gravel Water + sand, particle size <0.6 mm (0.024 in) Water + sand, particle size <0.1 mm (0.004 in) Minimum velocity, meter per second (feet per second) 4 (13) 3.5 (11) 2.5 (8.2) 1.5 (4.9)
For more permanent installations with a heavily contaminated pumped liquid, a settling pump-sump is recommended.
Discharge line requirements The discharge line can be run vertically or horizontally, but must be without sharp bends.
14
Installation
Fasteners WARNING: Only use fasteners of the proper size and material. Replace all corroded fasteners. Make sure that all fasteners are properly tightened and that there are no missing fasteners.
15
Installation
Requirements These general requirements apply for electrical installation: The supply authority must be notified before installing the pump if it will be connected to the public mains. When the pump is connected to the public power supply, it may cause flickering of incandescent lamps when started. The mains voltage and frequency must agree with the specifications on the data plate. If the pump can be connected to different voltages, then the connected voltage is specified by a yellow sticker close to the cable entry. The fuses and circuit breakers must have the proper rating, and the pump overload protection (motor protection breaker) must be connected and set to the rated current according to the data plate and if applicable the cable chart. The starting current in direct-on-line start can be up to six times higher than the rated current. The fuse rating and the cables must be in accordance with the local rules and regulations. If intermittent operation is prescribed, then the pump must be provided with monitoring equipment supporting such operation. The thermal contacts/thermistors must be in use. Cables These are the requirements to follow when you install cables: The cables must be in good condition, not have any sharp bends, and not be pinched. The sheathing must not be damaged and must not have indentations or be embossed (with markings, etc.) at the cable entry. The cable entry seal sleeve and washers must conform to the outside diameter of the cable. The minimum bending radius must not be below the accepted value.
16
Installation
If using a cable which has been used before, a short piece must be peeled off when refitting it so that the cable entry seal sleeve does not close around the cable at the same point again. If the outer sheath of the cable is damaged, then replace the cable. Contact an ITT service shop. The voltage drop in long cables must be taken into account. The drive units rated voltage is the voltage measured at the cable connection point in the pump. Earthing (Grounding) Electrical Hazard: You must earth (ground) all electrical equipment. This applies to the pump equipment, the driver, and any monitoring equipment. Test the earth (ground) lead to verify that it is connected correctly. If the motor cable is jerked loose by mistake, the earth (ground) conductor should be the last conductor to come loose from its terminal. Make sure that the earth (ground) conductor is longer than the phase conductors. This applies to both ends of the motor cable. Risk of electrical shock or burn. You must connect an additional earth- (ground-) fault protection device to the earthed (grounded) connectors if persons are likely to come into physical contact with the pump or pumped liquids. Earth (ground) conductor length The earth (ground) conductor must be longer than the phase conductors in the junction box of the unit. The table shows how much longer, than the phase conductors, the earth (ground) conductor must be. Standard version MSHA version 200 mm (7.9 in.) 100 mm (4.0 in.)
17
Installation
WARNING: Do not install the starter equipment in an explosive zone unless it is explosion-proof rated.
Cable charts for connection with sealed terminal plate, standard version
Description This topic provides cable charts that show connection alternatives with sealed terminal plate, for use with different cables and power supply. Connection locations 1 2 3
T1 T2 T3 T4
13
L1 L2 L3
14
15 5 10 16
11 6 7
Earth (ground) Starter equipment and main leads (L1, L2, L3) Control leads (T1, T2, T3, T4) Phase shifter Motor cable, minimum 20 m (66 ft.) Pump Motor protector Coil Transformer Capacitor Softstarter Level regulator Contactor, start relay or thermal relay Thermal contact Terminal board, terminal plate Stator leads (U1, U2, U5, U6, V1, V2, V5, V6, W1, W2, W5, W6, Z1, Z5, Z6)
18
WS001021A
12
Installation
Color code standard Code BN BK WH OG GN GNYE RD BU YE Stator leads and thermal contacts connection to the terminal plate
W V U
Description Brown Black White Orange Green Green-Yellow Red Blue Yellow
RD GN BN BU YE BK WH/YE
762 54 00
3 - P H A S E (3~)
W V U T1 T2
3 leads Y W V U T1 T2
9 leads Y // W1 W5 V1 V5 U1 U5 T1 T2 W2 V2 U2
12 leads Y // W1 W5 V1 V5 U1 U5 T1 T2 W2 W6 V2 V6 U2 U6
12leads D serial W1 V6 V1 U6 U1 W6 T1 T2 W2 W5 V2 V5 U2 U5
12 leads D // W1 W5 V2 V6 V1 V5 U2 U6 U1 U5 W2 W6 T1 T2
1 - P H A S E (1~)
W V U T1 T2
Figure 3
WS001028B
19
Installation
COLOUR STANDARD
BN=Brown BK=Black WH=White OG=Orange GN=Green GNYE=Green-Yellow RD=Red GY=Grey BU=Blue YE=Yellow *SUBCAB AWG **GC= Ground check
762 54 00
SCREENED MOTOR CABLE Screen as ground conductor
Pump
3 - P H A S E (3~)
Motor cable
L3 L2 L1 T1 T2 T3 T4
GY BK BN WH WH WH WH
W V U T1 T2
5 3 1
Subcab (3+4+S)
5 3 1 FGB (3+S)
Terminal plate
W V U T1 T2
GC**
3 - P H A S E (3~)
Pump
5 - 6 3 - 4 1 - 2 A1 A2
Contactor
Terminal plate
W V U T1 T2
3 - P H A S E (3~)
Relay
H GC** A2 15 16
5 - 6 3 - 4 1 - 2 A1 A2
Contactor
Terminal plate
W V U T1 T2
3 - P H A S E (3~)
L3 GY L2 BK L1 BN GNYE
Motor cable
Pump
Softstarter
5 3 1 A2 A1
6 4 2 22 11 P2 P1 BU
Terminal plate
W V U T1 T2
1 - P H A S E (1~)
Pump
Contactor
GC**
BU
5 - 6 3 - 4 1 - 2 A1 A2
W V U T1 T2
Thermal contact
OR*
Figure 4
20
Installation
Cable charts for connection without sealed terminal plate, standard version
Description This topic provides cable charts that show connection alternatives without sealed terminal plate, for use with different cables and power supply. 6-leads, Y, D or Y/D connection, with terminal board
21
Installation
22
Installation
WS001018A
23
Installation
Check the direction of rotation each time the cable has been re-connected and after phase or total supply failure. 1. Start the motor. 2. Stop the motor. 3. Check that the impeller rotates in the correct direction. The correct direction of impeller rotation is clockwise when you look at the pump from above. When started, the pump will react in the opposite direction to the impeller rotation.
L2
L1 L1 L2
L3 L3
4.
If the impeller rotates in the wrong direction, then do the following: If the motor has a 3-phase connection, then transpose two phase conductors and repeat this procedure from step 1. For 3-phase pumps with external starters or without built-in motor protection, the phases must be shifted on the output terminal of the starter.
24
Operation
Operation
Precautions Never operate the pump without safety devices installed. Never operate the pump with the discharge valve closed. Make sure that all safety guards are in place and secure. Make sure you have a clear path of retreat. Never work alone. Beware of the risk of a sudden start if the product is used with an automatic level control and/or internal contactor.
Distance to wet areas Electrical Hazard: Risk of electrical shock. Make sure no one gets closer than 20 m (65 ft.) to the unit when being in contact with the pumped or mixed liquid. Electrical Hazard: Risk of electrical shock. This unit has not been investigated for use in swimming pools. If used in connection with swimming pools special safety regulations apply.
Noise level NOTICE: The noise level of the product is lower than 70 dB. However, the noise level of 70 dB may be exceeded in some installations and at certain operating points on the performance curve. Make sure that you understand the noise level requirements in the environment where the pump is installed. Failure to do so may result in hearing loss or violation of local laws.
25
Operation
NOTICE: Make sure that the rotation of the impeller is correct. For more information, see Check the impeller rotation. 1. 2. 3. 4. 5. Check the oil level in the oil housing. Remove the fuses or open the circuit breaker, and check that the impeller can be rotated freely. Check that the monitoring equipment (if any) works. Check that the impeller rotation is correct. Start the pump.
26
Maintenance
Maintenance
Precautions WARNING: Always follow safety guidelines when working on the pump. See Introduction and Safety (page 3). Disconnect and lock out electrical power before installing or servicing the pump. Make sure that the unit cannot roll or fall over and injure people or damage property. Rinse the pump thoroughly with clean water before working on the pump. Rinse the components in water after dismantling. Make sure that you follow these requirements: Check the explosion risk before you weld or use electrical hand tools. Allow all system and pump components to cool before you handle them. Make sure that the product and its components have been thoroughly cleaned. Do not open any vent or drain valves or remove any plugs while the system is pressurized. Make sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump, remove plugs, or disconnect piping. Maintenance guidelines During maintenance and before reassembly, always remember to perform these tasks: Clean all parts thoroughly, particularly O-ring grooves. Change all O-rings, gaskets, and seal washers. Lubricate all springs, screws, and O-rings with grease. During reassembly, always make sure that existing index markings are in line.
Torque values
Lubricate all screws and nuts to reach correct tightening torque. Screws that are screwed into stainless steel must have the threads coated with suitable lubricants to prevent seizing. If there is a question regarding the tightening torques, please contact a sales representative. Screws and nuts
Table 1: Stainless steel, A2 and A4, torque Nm (ft-lbs)
Property M4 class 50 1.0 (0.74) 70, 80 2.7 (2) Property M4 class 8.8 2.9 (2.1) 10.9 4.0 (2.9) 12.9 4.9 (3.6)
M5 2.0 (1.5) 5.4 (4) M5 5.7 (4.2) 8.1 (6) 9.7 (7.2)
M20
M24
M30
127 (94) 220 (162) 434 (320) 364 (268) 629 (464) 1240 (915) M20 M24 M30
385 (285) 665 (490) 1310 (966) 541 (399) 935 (689) 1840 (1357) 649 (480) 1120 (825) 2210 (1630)
Hexagon screws with countersunk heads For hexagon socket head screws with countersunk head, maximum torque for all property classes must be 80% of the values for property class 8.8 above.
27
Maintenance
Service
Regular inspection and service of the pump ensures more reliable operation. Type of service Inspection Purpose To prevent operational interruptions and machine breakdown. Measures to secure performance and pump efficiency are defined and decided for each individual application. It can include such things as impeller trimming, wear part control and replacement, control of zinc-anodes and control of the stator. To secure a long operating lifetime for the product. It includes replacement of key components and the measures taken during an inspection. Inspection interval 2,000 hours or 1 year, whichever comes first. Applies to normal applications and operating conditions at media (liquid) temperatures < 40C (104F).
Major overhaul
4,000 hours or 2 years, whichever comes first. These intervals apply to normal applications and operating conditions at media (liquid) temperatures < 40C (104F).
NOTICE: Shorter intervals may be required when the operating conditions are extreme, for example with very abrasive or corrosive applications or when the liquid temperatures exceed 40C (104F).
Inspection
Regular inspection and service of the pump ensures more reliable operation. Service item Action Visible parts on 1. Check that all screws, bolts, and nuts are properly tightened. the pump and 2. Check the condition of lifting handles, eye bolts, ropes, chains, and wires. installation 3. Check for worn or damaged parts. 4. Adjust and/or replace if necessary. Pipes, valves, 1. Check for worn or damaged parts. and other 2. Adjust and/or replace if necessary. peripheral equipment Pump casing 1. Check for worn or damaged parts. and impeller 2. Adjust and/or replace if necessary. Wear on the impeller or surrounding parts necessitates fine adjustments of the impeller or replacement of worn parts. See Replace the impeller (page 31). Oil Check the water and oil mixture as follows: 1. Insert a tube or hose into the oil hole. 2. Cover the top end of the tube. 3. Take up a little oil from the bottom. (Air/oil mixture can be confused with water/oil mixture.) 4. If the mixture contains too much water, in other words if it is heavily emulsified (creamlike) or if the water has settled out, then change the oil. See Change the oil (page 29). Check again one week after changing the oil.
28
Maintenance
Action 1. Check that the following requirements are met: The cable entry must be firmly tightened into its bottom-most position. MSHA pump version: The inner cable entry must be tightened so that the clearance between the entrance flange and the MSHA cover is >3.175 mm (1/8 in.). Use a feeler gauge to check the clearance. MSHA pump version: The lock washer lips must be folded to secure the cable entry screws. The seal sleeve and the washers must conform to the outside diameter of the cables. 2. Cut off a piece of the cable so that the seal sleeve closes around a new position on the cable. 3. Replace the seal sleeve, if necessary. 1. 2. 3. 4. 5. Check that the inspection screw is properly tightened. Remove the inspection screw. Drain all liquid, if any. If there is oil in the inspection chamber, then check that the inner mechanical seal is not damaged. If necessary, contact an authorized service shop. If there is water in the inspection chamber, then do the following: a. Check that the O-ring is not damaged. b. Check that the cable entry does not have any leakage.
Inspection chamber1
Cable
1. If the outer jacket is damaged, replace the cable. 2. Check that the cables do not have any sharp bends and are not pinched. Cooling system If the flow through the system has been partly restricted, then rinse and clean. Level sensors or 1. Check the functionality. other sensor 2. Repair or replace any damaged equipment. equipment 3. Clean and adjust the equipment. Starter 1. Check the condition and functionality. equipment 2. Contact an electrician, if necessary. Insulation 1. Check the insulation between: resistance in the Phasephase on the stator stator Phaseearth (ground) The insulation should be > 1 megohm. Use a 1000-VDC megger to test the insulation. 2. If the resulting value is < 1 megohm, then contact an authorized service shop.
Major overhaul
For a major overhaul, take this action in addition to the tasks listed under Inspection. Service item Action Support and main bearing Replace the bearings with new bearings. Mechanical seal Replace with new seal units.
Regardless of individual applications, the inspection chamber should not be inspected less frequently than the intervals for normal applications and operating conditions at media (liquid) temperatures <40C (104F).
29
Maintenance
1
1. 2.
2
Inspection screw Oil screw
Figure 6: Symbols
Empty the oil 1. 2. Lay the pump on its side. Lock the pump with supports to prevent it from rolling over. Remove the oil screw. There are two oil screws. Either screw can be used for drainage, but it is easier to drain the oil if both oil screws are removed.
WARNING: The oil housing may be pressurized. Hold a rag over the oil plug to prevent oil from spraying out. 3. Turn the pump so that the oil hole faces downwards and let the oil run out.
Fill with oil 1. 2. 3. 4. Replace the oil screw O-ring. Put one of the oil screws back and tighten it. Turn the pump so that the oil hole faces upwards and fill with new oil. Quantity: 0.94 L (0.99 qt.) Put the oil screw back and tighten it.
30
Maintenance
1.
2. 3. 4.
Remove the suction cover. Remove the O-ring. Loosen the impeller: a) Lock the impeller to prevent rotation. Use pliers, a screwdriver, or similar. b) Remove the impeller screw and washer.
31
Maintenance
Figure 7: MT
Figure 8: HT
5.
Remove the impeller: a) Lock the impeller to prevent rotation. Use pliers, a screwdriver, or similar. b) Turn the adjustment screw counterclockwise until the impeller breaks free from the shaft. Use an 8 mm hexagon bit adapter (Allen socket) with a 100 mm (4 in.) extension.
1.
32
Maintenance
2.
Loosen the impeller: a) Lock the impeller to prevent rotation. Use pliers, a screwdriver, or similar. b) Remove the impeller screw and washer.
3.
Remove the impeller: a) Lock the impeller to prevent rotation. Use pliers, a screwdriver, or similar. b) Turn the adjustment screw counterclockwise until the impeller breaks free from the shaft. Use an 8 mm hexagon bit adapter (Allen socket) with a 100 mm (4 in.) extension.
33
Maintenance
3.
4. 5.
Grease the threads of the screw and the washer. The proper lubrication of the screw and washer is lubricating grease for assembly of bolts etc., for example, Kluber ALTEMP Q NB 50 or equivalent. Check that the impeller screw is clean and easy to screw into the shaft end. This is to prevent the shaft from rotating with the impeller screw. Assemble the conical sleeve and the impeller onto the shaft.
34
Maintenance
6.
Mount the suction cover with its O-ring and tighten. Tightening torque: 44 Nm (32.5 ft-lbs)
7.
8.
Check that the impeller can rotate easily. If not, the adjustment screw and the conical sleeve have not been aligned, and the shaft may have been displaced relative to the main bearing. Turn the adjustment screw clockwise until the impeller makes contact with the suction cover. Tighten a further 1/8 turn, 45. This will ensure the correct clearance between the impeller and the suction cover in the next step. Use an 8 mm hexagon bit adapter (Allen socket) with a 100 mm (4 in.) extension.
35
Maintenance
9.
Fasten the impeller: a) Place the washer on the impeller screw. b) Lock the impeller to prevent rotation. Use pliers, a screwdriver, or similar. c) Tighten the impeller screw. Tightening torque: 22 Nm (16.2 ft-lbs) d) Tighten a further 1/8 turn, 45. The screw will be loaded to its yield point and the load capacity of the joint will be higher. e) Check that the impeller can rotate easily.
Figure 9: MT
Figure 10: HT
10. Mount the strainer and the nuts. Tightening torque: 22 Nm (16.2 ft-lbs)
36
Maintenance
3.
4. 5.
Grease the threads of the screw and the washer. The proper lubrication of the screw and washer is lubricating grease for assembly of bolts etc., for example, Kluber ALTEMP Q NB 50 or equivalent. Check that the impeller screw is clean and easy to screw into the shaft end. This is to prevent the shaft from rotating with the impeller screw. Assemble the conical sleeve and the impeller onto the shaft.
37
Maintenance
6.
7.
Check that the impeller can rotate easily. If not, the adjustment screw and the conical sleeve have not been aligned, and the shaft may have been displaced relative to the main bearing. Fasten the impeller: a) Place the washer on the impeller screw. b) Lock the impeller to prevent rotation. Use pliers, a screwdriver, or similar. c) Tighten the impeller screw. Tightening torque: 22 Nm (16.2 ft-lbs) d) Tighten a further 1/8 turn, 45. The screw will be loaded to its yield point and the load capacity of the joint will be higher. e) Check that the impeller can rotate easily. Fit the discharge connection: a) Mount the pump housing and the stand. b) Fit and tighten the discharge connection.
8.
38
Troubleshooting
Troubleshooting
Introduction Follow these guidelines when troubleshooting the pump: Disconnect and lock out the power supply except when conducting checks that require voltage. Make sure that no one is near the pump when the power supply is reconnected. When troubleshooting electrical equipment, use the following: Universal instrument multimeter Test lamp (continuity tester) Wiring diagram
The pump does not start automatically, but can be started manually.
39
Troubleshooting
Cause
Remedy The impeller The sump in order to prevent the impeller from clogging again.
If the problem persists, contact the local ITT service shop. Always state the serial number of your pump when you contact ITT, see Product Description (page 11).
The pump is unable to empty the Check that: sump to the stop level. There are no leaks from the piping and/or discharge connection. The impeller is not clogged. The non-return valve(s) are functioning properly. The pump has adequate capacity. For information: Contact the local ITT service shop. There is a malfunction in the level-sensing equipment. Clean the level regulators. Check the functioning of the level regulators. Check the contactor and the control circuit. Replace all defective items.
If the problem persists, contact the local ITT service shop. Always state the serial number of your pump when you contact ITT, see Product Description (page 11).
If the problem persists, contact the local ITT service shop. Always state the serial number of your pump when you contact ITT, see Product Description (page 11).
40
Troubleshooting
The insulation between the 1. phases and ground in the stator is defective. 2. The density of the pumped fluid is too high.
Make sure that the maximum density is 1100 kg/m3 (9.2 lb/US gal) Change the impeller, or Change to a more suitable pump. Contact the local ITT service shop.
The ambient temperature exceeds The pump must not be used for such an application. the maximum ambient temperature. There is a malfunction in the overload protection. Replace the overload protection.
If the problem persists, contact the local ITT service shop. Always state the serial number of your pump when you contact ITT, see Product Description (page 11).
41
Troubleshooting
NOTICE: Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in equipment damage. Cause Remedy
The impeller rotates in the wrong If it is a 3-phase pump, transpose two phase leads. direction. If it is a 1-phase pump: Contact the local ITT service shop. One or more of the valves are set Reset the valves that are set in the wrong position. in the wrong positions. Replace the valves, if necessary. Check that all valves are correctly installed according to media flow. Check that all valves open correctly. The impeller is difficult to rotate by hand. The pipes are obstructed. The pipes and joints leak. There are signs of wear on the impeller, pump, and casing. The liquid level is too low. Clean the impeller. Clean out the sump. Check that the impeller is properly trimmed. Clean out the pipes to ensure a free flow. Find the leaks and seal them. Replace the worn parts. Check that the level sensor is set correctly. Depending on the installation type, add a means for priming the pump, such as a foot valve.
If the problem persists, contact the local ITT service shop. Always state the serial number of your pump when you contact ITT, see Product Description (page 11).
42
Technical Reference
Technical Reference
Application limits
Data Media (liquid) temperature Description Maximum temperature 40C (104F) Warm media (liquid) version: Maximum temperature 70C (158F) Warm liquid has certain operational limitations, which are stated on a plate on the pump. 58 Maximum density: 1100 kg/m3 (9.2 lb. per US gal.) 20 m (65 ft.) For specific weight, current, voltage, power rating, and speed of the pump, see the data plate on the pump. For starting current, see Motor data (page 43). For other applications, contact the nearest ITT representative for information.
pH of the pumped media (liquid) Media (liquid) density Depth of immersion Other
Motor data
Feature Motor type Frequency Supply Starting method Maximum starts per hour Code compliance Rated output variation Voltage variation without overheating Voltage imbalance tolerance Stator insulation class Description Squirrel-cage induction motor Standard version: 50 or 60 Hz MSHA version: 60 Hz 3-phase Direct on-line 30 evenly spaced starts per hour IEC 60034-1 10% 10%, provided that it does not run continuously at full load 2% H (180C [360F])
43
Technical Reference
Voltage (V) 220 D 230 D 240 D 380 D 380 Y 400 D 400 Y 415 D 440 D 500 D 550 D 660 Y 690 Y 1,000 Y DS, 50 Hz Motor type: 4 pole 1,400 rpm 3.2 kW (4.3 hp) Voltage (V) 220 D 230 D 240 D 380 D 400 D 400 Y 415 D 440 D 500 D 550 D BS/KS, 60 Hz Motor type: 2 pole 3,480 rpm 4.4 kW (5.9 hp) Voltage (V) 200 D 208 D 220 D 220 D parallel 220 Y parallel 230 D 230 Y parallel 240 D 240 Y parallel 380 D 380 Y 380 Y parallel 400 D 440 D
Rated current (A) 13 13 13 7.4 7.3 7.3 7.3 6.9 6.9 6.0 5.3 4.3 4.2 2.9
Rated current (A) 13 13 13 7.6 7.6 7.6 7.2 7.4 6.0 5.5
Starting current (A) 127 133 104 123 103 109 110 115 114 63 60 71 67 49
44
Technical Reference
Voltage (V) 440 D serial 440 Y serial 460 D 460 D serial 460 Y 460 Y serial 480 D 480 Y serial 575 D 575 Y 600 D 600 Y DS, 60 Hz Motor type: 4 pole 1,700 rpm 4.5 kW (6.0 hp) Voltage (V) 200 D 208 D 220 D 220 D parallel 220 Y parallel 230 D parallel 230 D parallel 230 Y parallel 240 D 240 Y parallel 380 D 380 Y parallel 400 D 440 D 440 D serial 440 Y serial 460 D 460 D serial 460 Y serial 480 D 480 Y serial 575 D 600 D
Rated current (A) 7.3 7.4 7.1 8.3 6.9 7.3 7.1 7.5 5.8 5.5 5.9 5.3
Rated current (A) 20 19 18 18 18 17 17 17 17 17 10 10 10 8.9 8.9 8.8 8.6 8.6 8.6 8.5 8.5 6.9 6.8
45
Technical Reference
46
Technical Reference
47
Technical Reference
48
Technical Reference
49
Technical Reference
Performance curves
Test standard Pumps are tested in accordance with ISO 9906, HI level A.
50
Technical Reference
10
12
14
16 Q [l/s]
51
Technical Reference
MT
5 4 3 2 1 0 0 4 8 12 16 20 24 Q [l/s]
52
Technical Reference
53
Technical Reference
P2 [kW] / [hp] 5 4 3 2 1
428, DS
MT
8 6 4
54
Technical Reference
MT
HT
16 12 8
253, BS
228, BS
30
35
18
55
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