Series ES 04 Hydro. Index Page 1. Handling and intermediate storage 1 Handling 4 1.2 Unpacking 4 13 Intermediate etorage “4 1.4 Preservation. 4 2. Description. 2.1 Designation 14 2.2 Construction “4 2.3 Mounting arrangements “4 24 Installation possibilities. 6 25 Dimensions, weights, centres of gravity, capacity. 6 26 Installation requirements. 6 3. Mounting/installation 3.1 Proiminary checks. 8 32 Instalation 6 33°iping 6 4. Commissioning/shut-down .. 4.1 Commissioning 42 Safely precautions 43Starup 4.4 Shutdown 6. Maintonaneo/eorvicing.. 5:1 Safety Notices. 5.2 Maintenance and inspection 5.3 Disassembly and assembly instructions 18 7. Appendix. 7.4 Permissible pump pressure. 19 7.2 Pemissible branch loads. 20 7.3 Pars list. a 7.4 Sectional crawings. 2Series £5 04 Hydro ‘These instructions must be read in conjunction with the ‘separate User's Safety Manual and the Motor Operating In- structions. 1. Handling and intermediate storage 14 Handling + Always take the weight and centre of gravity into consideration + Never use the motor eye bolts when slinging as- ssembled pump sets. Examples fo traneport of pump unt Proper handing 1.2. Unpacking (Check tha the delivery is complete and undamaged. Any miss- ing parts or damage must be confimed by the carier on the original eight note and reported to us immediately. 13 Intermediate storage + Seal tne suction and delivery branches, using closure caps, plugs or blank flanges. + Store in dy, dust fee conditions protected from fost or ex + Tum the rotating assembly onthe shat or coupling a few times every 2 weeks and eave ina different angular positon + Long-term storage (over 3 month) preservation required, * Long-term storage (over 2 years) renaw the lubricants before instaling the pum, 1.4 Preservation \f requested, we will preserve your pumps before delivery or at site, Please contact our service department, 2. Description Centifugal pumps of pump series ES are single-stage, non- selfpiming pumps in bloc design. They are avaliable in to it ferent executions: 41. Execution BS with special motor 2. Execution B with IEC standard motor Please see the contractual documents for details ofthe sup- plied design 24 Designation ES 32-160 1/8 +3012 tee Nominal ranch Sameer Vom nt ae Impeller configuration Execution Nominal capacity Po [kM Number of poles Example For a descristion of mounting arrangements, see paragraph 23, 22 Construction Please refer also to the sectional drawings in paragraph 7.4 224 Pump casing ‘The pump easing ie equipped with a euction side wearng rng Cn discharge side, the casing cover isthe wear part At disas- sembly of motor, mechanical sea, impeller and pumo shaft the casing stays in the piping (process construction. 22.2 Impeller forms ‘Tre pumps are equipped with closed radial impellers. For some pump sizes alternatively Vortex impellers (F) or two-channel Impellers (2) are available. 22.3 Shaft and bearings For pumps with IEC standard motor (exeeution B) the pump Shaft is connected via a rigié coupling to the motor shat. For pumps with special motors (execution BS) the impellers drect- Iy mounted to the extended motor shat. The cirect-coupled mo- ters bearing the pump part 224 Shaft sealing The fited shaft sealing arrangements are described in detail in tte contract documentation, ‘Aconstant venting of the mechanical seal area has to be en- sured 23. Mounting arrangements a5 B35 ol}Series ES 04 Hydro. 2.4 Installation possibilities 2.5 Dimensions, weights, centres of gravity, capacity Information on request For weights refer to the contract documentation 2.6 Installation requirements + Protect moiors and pumps from the weather. + Ensure thatthe workplace is adequately venilatediheated! ‘cooled and observe noise protection requirements + Check that the transport! taking away of the pump set or is ‘components to rom installation site is possible without dan- ‘ger of accident ‘Openings must be large enough + Adequately rated liting equipment must be available, 2.6.1 Space required for operation and maintenance + Ensure Ural sufficient space, a leas tom 2 sides, sft ‘subsequent maintenance requirements. This space should have, for reason of good accessibility, min. 0.8 m width + The set should be easily accessible from all sides. + The motor cooling fan requires adequate clearance arounc ‘the cowl, Ensure that the air init and outlet areas are unk: structed. 262 + Concrete plinths must be adequately supported in order to ‘ensure installation safe and functional - Foundation length: min. 100 mm longer than the suppertirg ‘surface. Foundations + Width: The fixing bolts should be at least 100 mm infront of| the edge ofthe foundation. + The depth ofthe foundation should be sufficient to prevent frost and ta be on frm ground, + Plinthe whioh reot on 9 ctuctural lor or ceiling chould bein fegrated into the original construction using bridging rein- forcement. + Foundations ehould contain eufcient mass in order to damp- fen eeonant vibrations 263 Supply connections Check that all supplies lke power, water and drainage neces- sary for installation and later operation are avaliable inthe form required 3. Mounting/installation Care and attention to detail during installation are essen- {ial for a trouble.free operation. Incorrect procedures dur. ing installation may create hazards for personnel or property oF lead to premature failure of the pump. 3.4 Preliminary checks Check that the dimensions ofthe pintvfoundation are in ac cordance withthe drawings, 32 Installation ‘This pump arrangement may be inetaled on a pith, concrete foundation, structured steehvork or direct in the pipeline, de- Pending upon pump size and local conditions. 3.2.1. Pumps with dise coupling (B) + The pump set ehould be mounted and aligned ae per para, 32. Pumps supplied without motor: Pumps without mounted motor are delivered with an assembly ‘accessory implement which prevents a movement ofthe shaft resulting possibiy in smashing the mechanical seal. The as- sembly accessory implement may not be removed uni the pump shaf is firly connected withthe motor shaft. Fr this, Please proceed as folows: + Place the motor-side coupling haif on the motor shat. Align axially. Observe setting dimensions (see table for toleranc- 23). + Spotl the motor shatt through thread of coupling halt (depth and diameter of driling coresponcing tothe set screw og point) + Screw in set screw with dog point and tighten well + Mount motor on drive lantam and bring the to coupling dee halves into ine + Tighten connecting screws ofthe disc coupling and drive lan- ‘em (tightening moment for connection serews of coupling halves see table 1), The dise coupling nuts are to be secured by sticking Thread frm) Tightening moment [NM] Me 36 M2 125 M6 305 Table Tightening manent for coupling sorsSeries £5 04 Setting dimensions: Seng Motorsce | Pumltotortange | gmensons Soin 55: 960 25 = too. tot 259 © te25-teoM 203 % ‘sone 30 i 20. ‘0 i Table 2: Setng dimensions ‘Setting dimensions 204, ‘Sketch for seiing dimensions 33. Piping 'Non-binding suggestions for proper design and instalation of ‘he pipawnr (he avact design nthe pinawans mut romain the responsibilty ofthe project manager! 33.1 General + Provide suppor forthe piping on both sides of the pump and attach it unsizessed onto the pump. Please observe the max. permissible branch loads (refer to para. 7.2). + After piping connection please check pump on well running + Use bellow expansion joints with near reducers. + Alterations inthe length ofthe piping caused by harsh tem- peratures and other strains can be pravantad by the use of| relnneyce wi bails ito of Ure pon «The pipework should be short and direct and changes of di- rection should be avoided where possible. 33.2 Suction Pipe + The maximum flow rate Is 2 mis (at max. permissible ca- pacity). + Do ot ita row of quarter bends on diferent lve. 5 The pipe shouldbe lai at an inened angle othe pump (at least 1%) «The pipework must be completely vented and sealed + Provide a separete suction pipe for esen pum. + hen operating the pump i sucton mse vithou foot valve, provide a vacuum instalation + Ensure that ne gas can accurate in the suction pipe Hydro Intructione for laying the suction branch + Minimum submergence (1): Hm= 940 + Hm minimum submergence low rate when pumping maximum capacity local gravitational constant = 9.81 mis* «The distance fom te feo ofthe container (2) must be at least nal me clameter of he plpe. 33.3 Inlet pipe 1 SSret + Should be laid as the suction pipe but with the pipe at an an- gle sloping away trom the pump (at least 1%). + Fit aretum flow stop before the pump, 334 Discharge pipe + Lay piping at an angle sloping upwards. + Flow rate approx. 3 mis (note the fallin meters). + Ensure thatthe piping is free of taht spots. + The pipes must be laid so that the danger of solids blocking ‘other pumps is avoided. + Flange and piping must be designed in accordance with the ‘maximum pressure. + Avoid gas accumulation and vent high points if necessary. + Differing pipe ciameters cause variations in fow rate and therefore need to be avoided, + Install a sluice valve and return flow stop,Series ES 04 Hydro. 335 + Observe the relevant directives. + Adhere fo permitted nominal pressure levels for individual ‘components. + Consider the overlapping of pump pressures at pumps in stalled in series Pressure tests 33.6 Auxiliary pipe connections ‘Sealing and flushing medi * Connect the pipes. + Install @ regulating valve and a magnet valve (losed without ‘current, + Blocking and nushing pressure mustbe atleast0.S ar above the maximum pressure of the pump. + Sotthe amounts of blocking and flushing media withthe reg- lating valve ‘Quench media: + Discharge media without pressure into the quench chamber 4. Commissioning/shut-down 4° Commissioning Before switching on the pump ensure thatthe folowing poins hhave been chackes and carried out + Check that he fastening bolts of pump and motor are secu, 1 Check that the inctallaien ofthe pump aneutee acy aeeote te the functional controls. + Check the non-return valve of pump oni tightness, 414 Shaft sealing Observe any specific instructions, cross-sections, dimension sheets or appencices. For pumps with a single mechanical seal with quench arrange ‘ment and quench reservoir: Depending on te liquid to be ‘pumped the quench reservoirshould be filed to halts capacty \with water or other liquid. 44.2 Filing and venting + Close the discharge isolation valve an, ifted, open the int isolating valve. + Fillthe pump with the liquid to be purnped, and totally vent. If ranged for onaration ana suction it than use a filing finn cr pipe. + If vent screws are present on the suction or pressure side of the casing, open them to let air escape. + Incase of filed discharge pipe, the pump can befiled touch the delivery non-return vaive by-pass or iting lever (i ited). + Turn the pump shar several umes by hang, The pump is ‘vented when air bubbles no longer escape from the ver holes. + Fillthe auxiliary valves for sealing and flshing media with ‘water and purge the system of any air. Close the screw plus Ian the vent phage + Pumps fitted with mechanical seal: Open the vent plugs of the seal cavity (where fitted), Fil the seal cavity wth water ‘and purge the syster of ar + Pumps fitted with mechanical seal and quick aerator: Loosen sealing cap of air intake catch before commissioning (approx. 2 turns). Do not remove cap completely to avoid dit penetration. + Before atartng cheok the ceal eavity for trapped air. The eel may be sericusly damaged by dry running! After checking, re- place the plugs. + Function of a mechanical seal: Two side faces rub against each other and are lubricated by a iqud fl at the same time In the case of single-action mechanical seals, the film is formed by @ pumping medium. leakage of between 0.2 and ‘5 mlm ie possible depending on running smootmess, pres- sure, rotational speed and shaft diameter (mechanical seals ‘are wearing paris for which no guarantee can be given). aaa A CAUTION, + The motor must be provided with motor protection switch. + The electricity supply and frequency provided must match the motor nameplate detals. + The motor terminal links must be posttionecto suit the supply and the proposed starting arrangement. 444 - Checking the aretion of rotation The rection ofrtaton hast be conform wth wth recto of rotation erow on the pump. Use rolay field meter. nt avai- off and immedistely stopped. tTtherotaton nas fo be revered, then arange for his tobe car ted oul by an elecian. Do not run pump counter to its given aparation drection (ivac- tion arrow on casing), 42. Safety precautions Donot operate the pump act before fing guards for ‘moving parts such asthe coupling etc. If guards are ‘ot delivered with pump then they must be provided by the instaler before operation. Donot reach under Flactreal eannections Electrical installations may only be carried out by {qualified personnel in compliance with IEEE Regula- tions and Statutory Requirements cuards with hands! 43. Startup 43.1 Initial startupirestarting + Stat the pump only if itis fly primed and when there is dis- charge system pressure. + Open the sealing and fushing valves. + Ifthe discharge pipework i emply: ~ Close the delivery isolating valve completely before open- ing itsignty, Start the pump. = Observe the delivery pressure gauge and motor ammeter and gradually open the discharge valve as the system pressure increases. Take care to open the valve lowly ‘and ne! too wideSeries £5 04 Hydro When the systemis filed and vented check the duty point ‘The pump unit may only be operated within the duty range confirmed, We recommend t record the operation data at the intial start-up ina protocol 43.2 Functional check + Confirm that the readings of the pressure and vacuum gaug- 188 and the motor ammeter, together with that ofthe flow me- ter (f fted) correspond tothe data specified in the contract documentation, + Check the operating data at all operating states possible in the system (parallel operation of pumps, other delivery put- poses, etc) + Record readings for future reference. + Check the bearing temperature. A temperature of 50°C above Ure abn vemperature is acceptable closed at non-return valve installed at suction side. Under such conditions the pump contents wil be rapidly veporised and very high pressures generat fc. These may exceed the bursting pressure ofthe 43.3 Closed valve operation pump casing, creating a serious hazard to personnel Never run the pump with the suction and discharge isolating valves closed or withthe discharge valve and property 44 Shutdown 441 Switching off + Close the isolating valve inthe discharge pip. + non-return valve above which a corresponding pressure is buitay the quid column makes the actuation ofa discharge side valve unecessary. + Close the addtional valves. 442 + Iffrostis anticipated, drain any pumps or pipework notin us (Flake other precautions to prevent damage from frost + ter pumping polluted media and to prevent cortasion when ‘ot in use the pumps should be drained and, if necessary, fasleed 5. Maintenance/servicing 5.1 Safety Notices + Never work on the set unti the electricity supoly hhas been disconnected completely It must be im- possible forthe set to be started inadvertently + Always wear safety gloves when assembiing!strip- ping the pumps or when adjusting glands. 5.2. Maintenanee and inepeetion 52.1 Lubricant and greasing intervals. + Grade of grease: Lithium-based grease according to DIN £51825, non-ageing, non-acdie, non-corroding, water-resit ant witha workina temperature of-30 to #130°C. penetration rate of 2 to 3, working penetration of 265 10 295 and a dripping temperature of approx. 190°C. + Recommended commercially-available grades of greasé ~ UNIREX N2, (ESSO) ~ OPTIMOL OLISTA LONGTIME or OLIT 2, (OPTIMOL) = GLISSANTO 20, (DEA) ~ ENERGREASE MSLS-EP2, (BP) 52.11 Electric motor with regreasing facility The bearings are filed at vrorks with grease. Grease nipples en ale the regreasing ofthe bearings from outside. For greasing intervals, grade of grease and capacity please refer to the ramepiate 5212 Electric motor without regreasing facility + Grease filing at works, + Maintenance interval for bearing exchange: '2000 rpm = 10000 working hours ‘1450 rpm = 20000 working hours + At excessive heating of motor bearings (more than 50°C above ambient temperature) please check the grease lubrica- tion. Grease should be exchanged every 9 years due to ma- turing 52.2 Monitoring the pump during operation For satisfactory operation carry out the following checks as rou- tine + Monitor the smooth running ofthe pump. In case of unusual sttong vibrations immediately swtch off ne unitana check tor reason (impeller damage, foreign matters, clogging, et.) + leakage occurs at shaft clean, inspect and if necessary re- place the mechanical seal. A leakage of between 0.2 and Smlh is possible depending on running smoothness, pres- sure, rolational speed and shaft diameter (mechanical seals {are wearing parts for which no guarantee can be given). + Regularely check local reacings, the best each working day, and immediately react to any large deviations. + At regular intervals, the best once @ week, check all meas: lured and recorded operating values and note down in 2 unit ‘easeb0ok. Determine the maintenance intorval en the basis ofthe tend (data development) + Pressure gauge with three way cock: Only open the th way cock in order to abtain a gauge reading and close itim- mediately afterwards + It pumping highly corrosive andlor abrasive medi, the components containing pressure should be inspected regu- lary o avoid unexpected fare. The interval between in- spections should be short intially and may be extended as ‘experience is gained. 2. uisassemoly ana assemoty structions. ‘Stripping and assembly should only be carried out by qual- Wad parsnnnal and with reference ta the relevant sectional sawings (see para. 7.4) The stripping sequence will be ‘cear from the drawing. + When disassembling the impeller: The pump ceasing remains connected tothe pipework. += When disassembling the pump easing: secure the pump easing and pipework against fling down,Series ES 04 6. Problems: Causes and Remedi 41) Output iow or no output at all, 2) Excessive output 3) Motor overioad and thermistor stops. 44) Water hammer in the system '5) Repeated mechanic damages after short period Hydro. 2) [8) [49 5) [Problem [Remedy [Excessive draw-down in sump, excessive ™ Check the system design and pipe sizing = Chock tho eattinge and operaton of lvel controle Pump not completely primed [Airlock in suction pipe Vent the pump + Check shaft sealing arrangements for air ightness | Prime the suction pipe Check suction pipework and valves for air tghiness Excessive delvery pressure = Open up restricting valves '- Check system design for excessive pressure losses: = Modify pump (after consulting the manufacturer) Insufficient delivery pressure * Check the system design + Restrict discharge valve [wrong rotation Pipowork, fitings or pump clogged * Comet rotation Remove deposits or obstructions Pump intemal worn | Replace worn parts [Speed too low = Check electrical instalaion ‘Speed too high = Check electrical installation Motor two phasing * Check electrical installation [Set misaligned * Check alignment Eliminate loads from pipework and realign set Excessive density of pumped medium [system design * Fita more powerful motor (after consuling the manufacturer) Examine system design, remedy the cause [System default = Fault dagnosie after inspection 7. Appendix TA. Permissible pump pressure Table 3 Probleme ‘Maximum admissible final pump pr -sure® [bar] type pump media temperature 20°C to +110°C | pump media temperature +110°C to +140°C eaptiy pares maueor eapiny parts maue of EN-GJL.250 cusnt0.c EN-GJL-250 cusnt0.c 32-126 to 100-250, 70 @ 8 6 100-315 to 150-400 10 7 é 4 Table 4: fal rossure of bumD * The maximum permitted final pump pressure [bar] consists ofthe intake pressure and the pump delivery head at zero capacitySeries ES 04 Hydro 7.2. Permissible branch loads wominalwats Tas | az | ao | so | os | oo | 100 | ua | 1 | a Fx 20 | 30 | 50 | eo | roo | 900 | 200 | veo0 | 1e00 | 200 = |8e| Fw | 300 | 400 | 500 | 650 | eco | 1000 | 1350 | 1700 | 2000 | 2700 2 |5=| re | 250 | ao | 00 | s50 | 650 | a00 | 1100 | ra00 | 1700 | 2150 = Zry | 450 | 600 | soo | 1050 | 1250 | 1600 | 2100 | 2600 | 200 | 4200 8 Myx_| soo | sz | seo | 00 | 50 | soo | 600 | roo | eso | 1300 | gg[ ime [te [wo [ceo [aso [ao [oo [aco [coo | coo | 00 S| s2[ mz | 230 | 200 | 250 | 300 | 300 | 400 | 450 | 600 | 700 | 1000 ‘Em, | 420 | 440 | 450 | 550 | 600 | 700 | a0o | 1050 | 1300 | 1900 Fax_| 300 | 400 | s00 | 660 | #00 | 1000 | 1350 | 1700 | 2000 | 2700 g_|_ Fa | 20 | 30 | 450 | eo0 | 700 | a0 | 1200 | 1600 | 1000 | 2400 $|5=[ rz | 20 | 200 | «00 | ss0 | 650 | o00 | 1100 | 1300 | 1700 | 2150 g Zr, | 480 | 600 | 800 | 1050 | 1250 | 1600 | 2100 | 2600 | 3200 | 4200 & mx | 300 | s20 | 350 | 400 | 450 | 500 | 600 | 700 | 950 | 1000 3 | 8e[ ma [veo [90 [200 [aso [aso [300 | a00 [soo [coo | 900 S2[_ m2 | 230 | 240 | 250 | 300 | 300 | 400 | 450 | 600 | 700 | 1000 Em, | «20 | aa | #50 | 560 | 600 | 700 | #00 | 1050 | 1300 | 1900 Tale 5 moxinun arisable bah ode ‘Sheth akong brah odeSeries ES 04 Hydro. 73. Parts list ‘VOMA No. [Description ‘VOMA No. [Description 102.1 |yolute casing with foot 507 water thrower 1022 [volute casing without foot 605 [protection cise 161 [easing cover 801 flange motor 210___|shar 819 extended motor shaft 230 |impeler [861.1 [coupling half (motor side) 341 |lanterned distance pisce 8612 coupling half (oump side) 400 [fiat gasket 922 impeller nut “433 |mechanical seal 3401 key 502 [easing wear ring 9802 key 2Series £5 04 Hydro 74 Sectional drawings 7.44 Execution BS with special motor / 861.4