INSTRUCTION MANUAL SHORT BEARING FRAME ...

File: LG_KUS_EDat: 14.04.00 No: 94-BA 5084E/

INSTRUCTION MANUALSHORT BEARING FRAME, STUFFING BOX

TABLE OF CONTENTSPart II

2.0 Type code explanation

2.1 Flushing water connection2.2 Direction of rotation

2.3 Level control system

2.3.1 Level switches2.3.2 Level control

2.4 Start-up

2.5 Operating troubles2.6 Maintenance and service

2.6.1 General

2.6.2 Visual checks of pump unit2.6.3 Service connections

2.6.4 Sealing systems for soft packed pumps

2.7 Periodic maintenance of stuffing box2.7.1 Regulation of stuffing box

2.7.2 Replacement of packing

2.7.3 Dimensions2.7.4 Replacement of shaft sleeve

2.8 Greasing instructions

2.8.1 Bearing lubrication chart2.8.2 Conversion table

2.9 Alignment and mounting of the pump on base plate

2.9.1 Mounting of base plate

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2.0 TYPE CODE EXPLANATION

Hydraulic sizeBearing frame sizeSealing type BasisMaterial executionBearing frame type

Seal specification (pumpside) Execution-Execution information specification

DDM1W- TT. K SEDS 1W- L S .QEFM 5W- MM.Q

S = Special construction/execution

F = for F-HydraulicK = for K-HydraulicQ = for Q-Hydraulic

. = Filling point

M = Standard (for C,G,M,X-seal)T = Special construction/execution (for T-seal)S = Standard for stuffing box bearing frameC = Stuffing box bearing frame with cartridge seal

0 = Without mech. seal (Pos. 515) / without packing(seal / packing specified by customer)

CG Pump side mechanical seal specificationM (bearing frame with mechanical seal)XT

L = Soft packing standard (only bearing frame with stuffing box)

W = Short bearing frame

1 = Normal, for hydraulic material 1,2 and 35 = Wetted parts stainless steel, for hydraulic mat. 5

S = Bearing frame with stuffing box sealM = Bearing frame with mechanical seal

D = smallest sizeF = larger than DG = larger than Fetc.

See type code explanation for Hydraulic code

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2.1 FLUSHING WATER CONNECTION

Pumps are supplied with a flushing water connection (service connection "F", Fig. 1).For normal sewage application this connection is not used. However, in special cases when pumping highconcentrations of sludge or mud, it should be connected. It will conduct cleaning water between impellerand stuffing box seal, providing periodic removal of accumulated solids.

Flushing water must be pressure-regulated between 0,5 to 1 bar (7 to 14 psi) above pump dischargepressure. Water is controlled by a solenoid valve on a time clock. Adequate duration of each flushing is 60seconds; frequently of flushing must be established for each different installation.

The quantity of flushing water varies according to pumpsize and application: in most cases, flowrates of6-8 litres per minute will be sufficient.

2.2 DIRECTION OF ROTATION

Before start up the pump, powerconnections must be made asindicated in section 2.4. Check thatthe direction of rotation is correct bygiving the unit a starting impulse forone second and noting impellerrotation.

Rotation must be counter-clockwiseviewed from suction end, andclockwise viewed from driving side.

WARNING:If rotation is not correct on multi-speed or multi-pump installations,only change the cable leads of thepump or speed with wrong rotationat its starter in the control panel.DO NOT change the primary powerleads coming into the control panel:This would change the rotation of allpumps or speeds.

3b

direction ofimpeller rotation

Fig. 2

Fig. 1

F

counter clockwise viewedfrom suction end

direction offree shaft end

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2.3 LEVEL CONTROL SYSTEM

Prior to any work on the pump, the power supply must be disconnected either by means of a locked isolatoror by removing the fuses from the panel. It is not safe enough to switch off the control switch. A wiringmistake or a control system malfuction could put the motor back into operation.

2.3.1 LEVEL SWITCHES

- For the on and off levels, use control systems that are appropriate for the pumped liquid.- Use a floating-ball type switch for the high-level alarm, even when there is another type used for the pump

control (this has proven to be the most fail-safe type).- The floating ball for the alarm should be placed at a reasonable distance above the highest pump start

level to avoid false alarms.

2.3.2 LEVEL CONTROL

"ON" and "OFF" levels must be set in such a way as to provide sufficient sump capacity between "ON" and"OFF" so that the pump cannot be switched on more than 10 times per hour. Higher starting frequency maydamage the motor control devices in the panel and will cause excessive power consumption. The followingformula will calculate the required minimum sump capacity:

V = 0.9 x Qp V = sump capacity or volume, between on and off levels (in cubic Z meters)

Qp = pump flow for one pump, in litres/secondZ = number of starts per hour (Z = 10, maximum)

2.4 START - UP

Prior to starting, check that: - Electrical connections of the motor are according to name plate- Level controls are correctly set- Off-level is sufficiently high to prevent air entrance to the pump suction- Suction and discharge gate valves are completely open- Flood pump sump

STARTING OF PUMP

Never start pump against closed valves (except non-return valves).

Start the pump using manual operation. Measure the amperage drawn on each phase leg. Record andverify these readings with the nameplate ratings. If amperage is more than 5 % higher, stop unit andcheck probable causes according to "Operating Troubles" chart, Section 2.5.

Once preliminary checks are complete, place the pump into automatic operation. Cycle the system throughseveral wetwell pumpdowns to observe that level controls are properly set and functioning correctly.Observe that the alarm system and change over switch (if included in control panel) are workingproperly.

Log date and hours meter reading, and set pump for automatic operation. Perform maintenance accordingto Section 2.6.

GENERAL OPERATING CONDITIONS

The pump should not be allowed to operate continuous-duty outside of performance curve: high dischargepressures with low flow or low discharge pressure with high flow. Bearing life is shortened and abrasive wearis accelerated in these operating conditions.

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TROUBLES

POSSIBLE REASONS

1. Pump not sufficient submerged, not vented X2. RPM too low X X3. RPM too high X X X4. Air entrance into suction line X X X X X5. Discharge line clogged / valve closed X X X6. Air or gas in pumped liquid X X X X X X7. TDH too high (higher than calculated) X X X8. Suction head too high X X X9. Insufficient suction head on hot liquids X X X10. Insufficient submergence of suction X X X X X X11. Sludge concentration higher than assumed X X X12. Specific weight of medium higher than assumed X13. Impeller or suction line clogged X X X14. Wrong direction of rotation X X X15. Impeller clearance too high X X16. Damaged impeller X X X17. Motor damage X X X18. Unsuitable lubrication X19. Attachments loose X X20. Pump and motor not aligned X X X21. Bearings worn out X X22. Impeller out of balance X23. Impeller too small X24. Impeller dragging against suction cover X X X25. Thick sludge and tight impeller clearance X26. Air or gas on impeller backside X X

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2.5 OPERATING TROUBLES

No

flow

Flow

not

suf

ficie

nt

Hea

d no

t suf

ficie

nt

Mot

or o

verlo

aded

Vibr

atio

ns

Noi

se

Red

uctio

n of

flow

or h

ead

afte

r sta

rt up

Bea

ring

tem

pera

ture

> 9

0° C

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2.6 MAINTENANCE AND SERVICE

2.6.1 GENERAL

Before doing any work on the pump unit, switch off main isolator switch and remove fuses from panel.

The following checks can be done in the field. When a repair is indicated, send the pump unit to the nearestauthorized Hidrostal service station.

2.6.2 VISUAL CHECKS OF PUMP UNIT

- Check pump and motor for possible mechanical damage.- If pump volume or pressure are not acceptable, check impeller clearance (see manual for hydraulic).- Check overload relay, fuses and time relays (if any) for correct setting.- Check correct function of level control.- Check alignment of coupling according Section 2.9.

2.6.3 SERVICE CONNECTIONS

The service connections that are built into all pumps as standard are listed below. Please refer to Fig. 3and sectional drawings.

552a/552b Flushing Connection "F1" and "F2"

Alternatively or even in addition to the function described in Section 2.1, this connection may be used tomanually bleed the air from the casing prior to start-up, if there is no other place for air to escape throughthe discharge piping. In most cases the connection 552b will be closed and flushing water mixes withproduct pumped. In cases where the solids accumulate, could form lumps, or be fibrous flushing out via552b would be the preferred solution. Connection 552b also permits complete draining of product fromhorizontal bearing frames if required.

131 Greasing point "G1"

Greasing instructions see Section 2.8.

134 Plug "G.O."

Possibility to remove old, excessive grease.

222 Packing flushing connection "Q"

See Section 2.6.4.

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Fig. 3

2.6.4 SEALING SYSTEMS FOR SOFT PACKED PUMPS

GENERALAll pumps factory supplied with a soft packed stuffing box are packed in accordance with Fig. 3.Four flushing/packing lubrication systems are available and may be specified to best suit the pumpingapplication. See Fig. 4 - 7 and Section 2.1 Flushing water connection.Flushing liquids should be at a pressure of approximately 0.5 - 1 bar (7 - 14 psi) above that of the pumpsworking pressure. It is recommended that a flow restrictor be fitted to the flushing line to prevent excessiveflow of sealing liquid, generally, approximately 6-8 litres per hour will be adequate for most applications.

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SYSTEM 1 (Fig. 4)This is recommended when pumping biologicalsludges where due to the consistency and na-ture of the sludge no flushing is necessary.

SYSTEM 2 (Fig. 5)Recommended for general dirty liquids, mudand raw or digested sludge applications. Theflushing liquid is piped through connection No. 1on the pump back cover to the lantern ringthereby inhibiting the entrance of abrasive ma-terial into the packing chamber so reducingwear.This connection can also be used to install avacuum pump.

SYSTEM 3 (Fig. 6)Recommended when pumping raw sewage. Awater repellent grease is supplied by a greaselubricator at the packing chamber throughconnection No. 1 so both preventing thepenetration of solids and helping to lubricate thepacking so reducing wear.Note: NEVER use spring- or other type ofautomatic greaser.

SYSTEM 4 (Fig. 7)This plan connection No. 2 on the pump backcover is used to flush the cavity between theimpeller and the back cover free from anyaccumulating solids. Especially recommendedwhen pumping highly concentrated paper pulp,sludge or mud where due to the degree ofconcentration there may be a tendency todehydrate or sedimentate.E.g.: If the pump should be used in a verticalposition on materials having a natural tendencyto gasify connection No. 2 may also be used tobleed the pump on plant start-up.

2.7 PERIODIC MAINTENANCE OF STUFFING BOX

2.7.1 REGULATION OF STUFFING BOX

The stuffing box should be adjusted to permit a constant dripping, to insure continuous lubrication andcooling to the stuffing box assembly. Excessive adjustment will cause the packing (215) and shaft sleeve(208) to wear. When adjusting the stuffing box gland bolts (220), insure that left and right bolts are uni-formly tightened. Once the stuffing box gland (202) has reached maximum adjustment, do not add pack-ing rings to the gland. Replace the packing rings (215) in accordance with following section.

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2.7.2 REPLACEMENT OF PACKING

Once the stuffing box gland (202) has reached maximum adjustment, it is required to revise all packingrings (215). By replacing only one packing ring to the stuffing box, the lantern ring will be pushed towardsthe pump housing causing higher flow of sealing liquid to the pump, reducing the sealing effect of the frontpacking rings. In most cases the packing rings nearest the impeller will be worn out. Proceed as follows byreferring to Fig. 8 to 12.

1. Disconnect power to the driver, close suction and discharge valves, isolate external service connec-tion to stuffing box seal plate or back cover (200) and drain pump.

2. Remove stuffing box gland bolts (220) and washers (229), slide stuffing box gland (202) towardsbearing frame. Gland to be split and taken away from shaft by removing screws (223). Use an extractor(Fig. 9) to remove the upper packing rings. Remove nuts (221), pull stuffing box casing (201) andlantern ring (204) towards bearing housing. Use an extractor (Fig. 9) to remove the lower packingrings. Inspect the shaft sleeve (208), stuffing box casing (201) and seal plate or back cover (200).Excessive wear of shaft sleeve (208) can cause higher leakage of the stuffing box. Replacement ofshaft sleeve (208) see section 2.7.4. Should the packing be worn out, replace according to paragraphs3 to 4. Clean the shaft sleeve (208), lantern ring (204), stuffing box gland (202) and coat with waterrepellent grease.

3. Prepare the packing rings by quantity and size (see Section 2.7.3 Dimensions). If packing rings arecut from a coil or long length, wrap the packing around a sleeve of the diameter of the shaft sleeve(208) and cut tangentially as shown in Fig. 10. An overlapping split of the packing rings provides bettersealing, refer to Fig. 11. Do not cut ends straight on a flat strip, as the packing rings would never seal(Fig. 12).

4. Using the lantern ring (204), tamp in the lower packing rings (215) towards the impeller and alternatejoints 90° apart. Align lantern ring (204) with the seal water admission port. Fitting stuffing box casing(201) to seal plate or back cover (200) by tightening nuts (221). Using the stuffing box gland (202),tamp in the upper packing rings alternating joints 90° apart. Install stuffing box gland bolts (220) withwashers and adjust to finger tight. Place into operation according to these instructions. Adjust every 10minutes until normal operation has been reestablished.

2.7.3 DIMENSIONS

9a

Fig. 8

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Fig. 9

Fig. 10

Fig. 11 Fig. 12

Fig. 13spanner

10a

2.7.4 REPLACEMENT OF SHAFT SLEEVE (208)

Excessive wear of shaft sleeve can cause higher leakage of stuffing box. Once, if sleeve has to bereplaced, proceed as follows by referring to Fig. 8/13/14.

Remove nut (205) with required tool according to table of Section 2.7.3 Dimension. Loosen and removeshaft sleeve from conical seat of shaft (110) by giving soft strokes to sleeve nearest impeller cone usinga soft mallet. Remove, clean and inspect sealing ring (144) and spacer ring (145) for damage. If necessary,replace sealing ring (144). Clean shaft and new shaft sleeve. To check mounting length of sealing ring(144), first push sleeve without O-ring (216) onto shaft. Sealing ring (144) should be compressed between0.3 - 0.8 mm. If this is not possible, change spacer ring (145) until correct mounting length has beenachieved. Now place sealing ring (144) onto shaft and O-ring (216) into groove of shaft sleeve. O-ring(216) and shaft to be lubricated with seal grease for easy assembly. Conical seats of sleeve to be oillubricated. Push shaft sleeve onto shaft to correct seat. Fasten nut (205) to the shaft with required torqueaccording to table of Section 2.7.3 Dimension.

Bearing frame Cone size A B C D E Ftype quant. length Fig. SW S P Torque

mm mm mm mm mm mm pcs. mm No. mm mm mm NmDDS.WEDS.WFFS.WHFS.WEGS.W 2"FGS.W 2 1/2"HHS.W 3"IIS.WLIS.WILS.WLLS.WMLS.W

- -

8 900

160

1 1/2" 70 1 12 10 69 50 5

- 119

-

14100 mm 5

5 26013

65

46198

tool for nut (205)packing rings

2" 86 1 15 12 95 70 -

Fig. 14, "C" spanner AMF DIN18108 with round spigot

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2.8 GREASING INSTRUCTIONS

For greasing intervals and amounts see bearing lubrication chart (Section 2.8.1). For regreasing bearing

frames, we recommend grease according to following specifications (from KLÜBER LUBRICATION):

FOR BEARING FRAME TYPE: . DS . W - . IS . W . LS . W + . MS . W

BEARING GREASE: STABURAGS ISOFLEX TOPASNBU 8 EP NB 52Mineral-oil based, Synthetic oil based,Barium-complex Barium - complexas thickener. as thickener.

Typical characteristics:Colour: beige beigeApparent dynamic viscosity (approx.): 6000 mPas 5000 mPasOperating temperature range: -30 . . +150 °C -60 . . +160 °CConsistency class (NLGI) 2 2Penetration DIN ISO 2137 (0.1 mm): 280 280Dropping point DIN ISO 2176: > 220 °C > 240 °CCorrosion protection DIN 51802: 0 0 / 1RPM - parameter (n x dm): 500 000 1 000 000

Greasing amount: Overgreasing can cause excessive operating temperature and premature bearingfailure.

Greasing intervals can be used for Horizontal Installation. They should be halved for Vertical Installa-tion or if the following conditions apply: High humidity or contamination, ambient temperature of morethan 40°C or with increased loads which could influence the Bearings. With greasing intervals of morethan 12 months (1 year) pump must be regreased at that time.

Regreasing (whole operation can be done whilst pump is running;see Fig. G.O.): Remove plug 134 to drain old grease. Removeplug 131 (if available; see section 2.6.3; Service connections). Putfresh grease (with suitable device) into greasing connection 131, takecare to avoid contamination. When regreasing is finished, greasingconnection 131 and grease relief connection 134 to be closed againwith plug.

Example to read bearing lubrication chart 2.8.1 (the fields in thetable are marked grey): Bearing frame type DDS1W with a shaft speedof 1500 rpm has a greasing interval of 8500 hours and needs a greaseamount of 28 grams. Converting the greasing interval from hours tomonths see table 2.8.2. It means for our example: For an assumedrunning time of the pump of 18 hrs. / day, it gives an equivalentgreasing interval of 12 months.

HIDROSTAL AG recommends continious regreasing with an automatic, electronic grease dispenserand offers such a product for sale. These can be connected to the potential free contact within the startercontactor by extending the included contact wire. With this it is guaranteed that pump is greased onlyduring running time (if needed). Overgreasing is not possible. Grease dispensers are factory refillable. Iflubricators are ordered from the factory, please indicate correct bearing frame type

Parts identification : 8SB - 125STABU or 8SB - 125ISOFLEXContent approx. : 120 grammsRunning time : 2 weeks to 18 months

For description, installation and operation of this grease dispenser see seperate instruction manual.

Fig. G.O.



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2.8.1 BEARING LUBRICATION CHART CONNECTION 131

2.8.2 CONVERSION TABLE

With conversion tableright, greasing intervallfrom table 2.8.1 can beconverted from hours tomonths.

0 - 2 2 - 6 6 - 12 12 - 18 18 - 24

20002500300035004000450050005500600065007000750080008500 More than 12 months (1 year)900010000110001200013000

12

5.56.577.5

3.54

6.5 5

Greasing interval hours

Running time in hours per day

Equivalent greasing interval in months11 6 4 3

8 612 7 5

1011 712 8

91011 812 9

9.51011

Bea

ring

fram

e si

ze

Shaf

t spe

ed

rpm

Inte

rval

ho

urs

Am

ount

of

grea

se g

ram

s

Bea

ring

fram

e si

ze

Shaf

t spe

ed

rpm

Inte

rval

ho

urs

Am

ount

of

grea

se g

ram

s

Bea

ring

fram

e si

ze

Shaf

t spe

ed

rpm

Inte

rval

ho

urs

Am

ount

of

grea

se g

ram

s

4800 2200 3000 2000 1700 25004200 3000 1800 5000 1500 30003600 3500 1500 5500 1200 40003000 5000 1200 7000 1000 50001800 7500 1000 8000 900 55001500 8500 900 8500 750 60001200 9500 750 9500 600 75001000 10500 1800 3500 500 8000

900 11000 1500 5000 1500 1500750 12000 1200 5500 1200 2000

3500 2000 1000 7000 1000 25003000 3000 900 7500 900 30001800 5500 750 8500 750 35001500 6500 600 9500 600 50001200 8000 500 60001000 9000

900 9500750 10000

FFS . W HFS . W 48

EGS . W FGS . W 60

HHS . W 90 ILS . W LLS . W MLS . W

160

DDS . W EDS . W 28

IIS . W LIS . W 120

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2.9 ALIGNMENT AND MOUNTING OF THE PUMP ON BASE PLATE

The motor, if supplied, is correctly aligned on the baseplate at the factory. However, a certain amount ofmisalignment is possible during transit, and it is therefore necessary to check the alignment between thepump and the driver before putting the unit in operation. The pump shaft should be checked for angularand for parallel alignment (Fig. 15). Inaccurate alignment results in vibration and excessive wear onbearings and mechanical seals. The check for angular alignment must be made by inserting a tapergauge at four points 90° apart, between the coupling faces. The variance in readings must not exceed 0,3mm. To check for parallel alignment, place a straight edge across the coupling rim at the top, bottom andsides. The unit will be in parallel alignment when a straight edge rests evenly on the coupling rim at allpositions.

2.9.1 MOUNTING OF BASE PLATE

The permissible ground load has to be compared with the total weight of the pump. The concrete foundationmust correspond to the guidelines of the strength of foundation and the resistance to pressure.Foundation screws: HIDROSTAL AG recommends the use of chemical anchor screws which are securedwith a 2-part Epoxy resin.

Align pump and base plate horizontally and check the correct position!

ATTENTION:The base plate has to be supported on all 4 edges. If necessary, differences of dimension could becompensated by 2–part flow concrete epoxy resin (self leveling epoxy grout)!

Mark and drill the holes for the foundation screws. Place the foundation screws. Pay attention to thecorrect length of the threaded rod. Allow the required length of time for the epoxy to harden! Screw downthe base plate.

ATTENTION:Tighten the foundation screws with the prescribed torque according to specifications of producers! Checkthis torque during operation occasionally!

Fig. 15

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INSTRUCTION MANUAL SHORT BEARING FRAME ...

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