Instruction manual for deep pump. Instructions for labor protection during the repair and maintenance of pumps, pumping equipment, valves

The axial force is carried out by two angular contact ball bearings, and the radial load is carried out by a sleeve bearing.

Bearings are lubricated in an oil bath or with an oil scraper ring. The shaft seal is in the form of a mechanical seal.

Section 1. General Information

1-1 Introduction

Centrifugal pumps are designed by professionals to provide you with optimum performance equipment for continuous operation under the most severe conditions in the oil refining, petrochemical, gasoline and LPG plants and other industries. The concept of this equipment was designed with mechanical and hydraulic characteristics that guarantee you reliable, economical and many years of trouble-free operation.

The purpose of this manual is to help you achieve just that with this equipment. To achieve this goal, it is necessary to familiarize with this manual those personnel who are directly responsible for the installation, operation and maintenance of the pumps.

1-2 Equipment check

Immediately upon receipt of this equipment, it is necessary to check its compliance with the transport documents. In the event of damage or shortages, the local agent of the shipping company must be notified immediately. In the event of a delay in notification, it may be difficult to satisfy a complaint about the equipment.

1-3 Protection during transport and storage

Pumps and drives must be protected from damage by dirt, sand and moisture, both during transport and during storage. After the factory test and before transport, the pump is thoroughly cleaned, dried and coated with anti-corrosion agents on the entire internal and on the entire external surface, which can be damaged by moisture. In order to prevent foreign materials from getting inside the pump, all suction and outlet openings, all pipeline openings are closed with metal plugs, which are securely bolted to the flanges. The protection of pipe openings and pipes connected to the pump must be left until the pump unit is ready to start.

When installing the pump and drive for storage, it is necessary to check and fix the plugs for all openings of the pipeline or replace them if necessary with new ones. Shafts, ball bearings and other vital parts that may be exposed to moisture must be periodically checked and, if necessary, renewed their protective coating.

1. If pumps are stored on site in an assembled state, the following storage procedures must be observed.

See "Corrosion Protection Procedures" provided separately.

2. If pumps are stored on site in packaging, they should be stored as follows.

1. The packaging must not be exposed to rain water, etc.
2. Cover the packaging with vinyl sheet and protect from rain, etc.
3. If the storage period exceeds 6 months, check the condition of the equipment for corrosion and, if necessary, spray or fill the equipment with anti-corrosion oil

Section 2 Installation

2-1. Cleaning before installation

1. The bottom surface of the base plate must be free from dust, dirt, oil, grease, etc. in order to achieve proper adhesion between the cement mortar and the base slab.

2-2 Location of the pump.

1. Improper installation site and inadequate foundation preparation will adversely affect the life of the pump. Good foundations are of paramount importance, as they are the first factor in preventing the occurrence of vibration, which in most cases leads to rapid wear and failure of the pump.

2-3 Foundations

1. Foundations may be made of any material strong enough to provide rigid support over the entire surface of the baseplate and absorb all normal loads and shocks that may occur during operation.

The concrete foundation must be poured well in advance to allow proper curing time before the pump loads begin to act.

3. Place the base plate in position by supporting it with shims or set screws and securing it with anchor bolts. There should be a gap of approximately 50 mm between the top of the notched concrete and the base slab for grouting.

4. The foundation bolts must fit into the holes and locations on the base plate, which are determined in accordance with the design installation drawing.

5. Each bolt should be surrounded by a collar, the diameter of which should be 3 times the diameter of the foundation bolts.

After the concrete has been poured, the grommets must be held firmly in place and the bolts must fit into the holes in the base plate.

2-4. Leveling the base plate.

1. In addition to hand tools, the task of leveling and leveling the base plate is solved using the following tools and equipment:

1. Accurate straight edge
2. Foundation (or anchor) bolts
3. Gaskets and wedge gaskets
   Note: For heavy pumps, small metal leveling blocks (approx. 25 mm thick plates with three M12 hex nuts welded on) can be used. These blocks are used to install on each bolt hole in the base plate. See Fig. 2-a.
4. Accurate locksmith level or tooling equipment.
5. Optionally, alignment testing equipment such as an alignment laser or a clamping device capable of measuring to 0.02 mm can be used.

Figure 2-a

2. The baseplate is level with the drive on a level surface prior to shipment.

The base plate simply needs to be installed on horizontally aligned foundations.

Thus, only the mounting surface of the base plate will need to be leveled.

Note: You need to make sure that the foundations have had enough time for the concrete to cure. Otherwise, the foundations may not support the weight of the pump.

3. Align the blocks according to the following methods shown in fig. 2b.

1. Align each block on the foundation using optical alignment equipment and a level.
   
2. Place blocks in four corners. Then proceed with the transverse alignment of the blocks by adjusting the adjusting bolts.
   Align one end of the blocks in direction A-B using the adjusting bolts on the anchor bolts (1) and (7)
   Then follow these steps step by step:
   • Align horizontally in direction A-D on anchor bolts (1) and (6).
   • Align horizontally in direction B-C on anchor bolts (7) and (12).
   • Align horizontally in direction C-D on anchor bolts (6) and (12).
3. Install blocks on both sides of the anchor bolts in the longitudinal direction from (2) through (5) and (8) through (11)
   • Level the blocks on both sides in the longitudinal direction A-D and B-C on each anchor bolt.
   • Level the blocks at each end of the anchor block (2)-(8), (3)-(9), (4)-(10), (5)-(11)
   For horizontal pumps, the nominal level deviation is 0.1 mm/m.

4. When using gaskets or wedge gaskets, spot welding is used and then mortar. See Fig. 2d.

When using adjusting blocks, pour mortar around the blocks. See Fig. 2-c. After curing, the nominal deviation must be checked again.

5. Install the base plate with pump and drive and tighten the anchor nuts. If the baseplate level is measured for confirmation, the level tolerance for horizontal pumps is 0.3 mm/m.

Note: The measuring point must be the machined surface on the base plate.

2-5. Pouring with cement mortar

1. The recommended mortar mix is ​​one part cement to one part pure river sand by weight. Usually 6.6 to 7.6 liters of pure water for every 45 kg of mixture is enough to prepare a normal solution.
2. Execute appropriate wooden formwork to hold the mortar. See Fig. 2-e.
3. Remove water and debris that may have accumulated in the foundation bolt holes.
4. Pour grout through the grout injection holes in the baseplate and direct it between the foundation and the baseplate.
5. Pour mortar until all space between the top of the foundations and the top of the grout holes is completely filled with no air pockets.
6. Verify that the base plate is firmly bonded with mortar by tapping the pan with a steel rod and listening for resonance. A dull sound indicates a solid pour, and a drum sound indicates voids that need to be filled with epoxy mortar.

You need to take the following actions:

1. Drill and enlarge a hole (6.4mm) that should fit the grease fitting.
2. Install the fitting and fill with epoxy grout using a hand gun compatible with the fitting.
3. Tap the plate again and listen to the sound.
4. Remove fittings, plug holes with epoxy grout and level epoxy grout.

Figure 2-e

2-6. Mounting the drive on the base plate (if removed)

1. Install the drive on the drive feet in such a way that the distance between the ends of the pump shaft and the drive shaft would correspond to the data given on the installation drawing.
2. Install the pump and drive shafts in the position shown on the installation drawing. The actuator must be about 3 mm lower before adjustment.

2-7. Alignment of pump and drive alignment. (See Fig. 2-f)

1. Install a dial indicator on the drive coupling half.

The dial indicator bracket must be rigid in order to ensure the accuracy of the dial indicator readings.

2. Set the indicator button on the outer diameter of the pump coupling hub and adjust the hubs with an accuracy of 0.05 mm of the total reading of the dial indicator.

3. Install the indicator button on the end of the pump coupling hub and adjust the parallelism of the ends at all points with an accuracy of 0.05 mm of the total reading of the dial indicator.

4. To check alignment, install a dial indicator on the pump coupling half and take readings on the outside diameter and on the end of the drive coupling hub. Readings must be accurate to 0.05 mm of the total dial indicator reading.

Note: If a steam turbine is used and alignment is done with a cold turbine, the turbine must be centered 0.5 mm below the pump shaft center, or to within 0.1 mm of the total dial indicator reading. Alignment must be done with a hot turbine.

Figure 2-f

2-8. Suction and discharge pipeline.

The piping must be adequately supported close to the pump in order to prevent unforeseen loads from being transferred to the pump once the flange bolts have been tightened and the specified temperature has been reached.

1. Suction pipeline

1. The piping at the suction end must be short, straight and in no case be smaller than the suction port of the pump. If it is impossible to avoid the use of long pipelines, the diameter of the pipeline should be the same or, better, twice the pump inlet. Suction lines must be free from any sudden reductions in size that can cause turbulence, gases or vapors, and pockets or protrusions where gases or vapors can collect must be avoided.
   A properly designed suction line should be as follows:
   I. Have a slight slope from the pump to the source of the fluid being supplied. See Fig. 2-g and 2-h.
   II. Provide bends with a large radius or bends with a large radius. See fig. 2-i.
   III. Provide eccentric adapters for changing the size of horizontal lines. See Fig. 2-i, 2-j and 2-k. The length L of the adapters must be equal to at least twice the diameter of the widest pipe.
2. It is recommended that temporary filters be installed in the suction line to collect scale or other foreign material. See Fig. 2-1.

2. Outlet pipeline

Outlet piping must be of the appropriate size with a minimum number of fittings and bends. There are no fixed rules for determining the diameter of the outlet pipeline, since the diameter depends on the length of the line and on the applied pressure.

Section 3 Operation

3-1. Preparation for work.

1. Fill the bearing housing with oil to the specified level. See section. 4.
2. Disconnect the pump and drive and check the direction of rotation of the drive.
3. Open all valves if cooling, flushing (sealing) and quenching of the pipeline is provided.
4. Fully open the valve at the suction end.
   If the temperature of the pumped liquid exceeds 177°C, the pump must be thoroughly heated up to this temperature.
   Note: Before starting the pump, it is recommended that all points of the pump housing are heated to a temperature that is 30-40°C lower than the temperature of the pumped liquid. If the pump is started at room temperature, the liquid temperature must be raised gradually over 3-4 hours. If this is not possible, the hot liquid must be circulated in the pump for 3-4 hours in order to ensure that the pump heats up before it starts.
   Excessive thermal shocks must be avoided.
5. After the pump has warmed up, try to turn the pump rotor by hand and check the alignment of the pump and drive again.
6. After checking, connect the pump and drive.
7. Open the bleed valve installed on the pump to prevent dry running in any case. The pump body and suction pipe must be filled with liquid.
   Check the opening or closing of the valves installed on the auxiliary pipeline.

3-2. Start

1. Make sure the valves in the suction line are fully open and the valve in the discharge line is fully closed.
   If the pump is above the liquid level, the discharge valve must be closed. If the pump is below the liquid level, the discharge valve must be opened 1 ½ -2 turns.
2. If a minimum flow line is installed, its valve must be opened.
3. Open the outlet valve again (if supplied). After checking the release of gases or air, the exhaust valve must be closed.
4. Start the drive according to the drive instructions and quickly bring the pump speed up to the required speed.
5. As soon as the pump reaches the required speed, slowly open the valve on the discharge line. The pump must not be allowed to operate with a closed valve in the discharge line. The pump must not be allowed to operate at a flow rate below the minimum set value.
6. The temporary suction line filter must be checked periodically to ensure that it is not clogged so as not to cause voids in the pump. It must remain on line for at least 24 hours after the pump is started.
7. The following items should be periodically checked and recorded during operation:

Items to be monitored and recorded	Fine
Suction and outlet pressure	1. Shows normal pressure. 2. Device deviations are small.
Lubricating oil	1. The oil level is above half of the oiler level. 2. The oil is clean.
mechanical seal	1. Mechanical seal leakage is small
Bearing housing temperature	1. The maximum allowable temperature is 90°C (the maximum allowable oil temperature is 82°C)
Vibration	1. See fig. 3-a
Noise	1. There is no abnormal sound change.
External flush line	1. The pressure sensor does not show any abnormal values.
	The surface temperature of the external flush line is approximately equal to the temperature of the external liquid.
Tempering line (water or steam)	Coolant does not splash out of the mechanical seal gland cover
Cooling water line	Cooling water circulation is confirmed by a liquid flow indicator.

Note: If the pump is unstable, it must be stopped. Find out the causes of unstable work.

3-3. Stop

1. Gradually close the valve in the discharge line.
2. Stop the drive immediately.
3. If a minimum flow line is provided, close the discharge valve fully, open the minimum flow valve fully, then stop the actuator immediately.
4. After the pump has completely stopped, it is necessary to completely close the valve in the discharge line and in the minimum flow line.
5. Close all valves once in auxiliary pipelines such as cooling, flushing (sealing) and quenching lines.
6. Completely close the suction valve.

Note:

1. If there is a risk of frost, the cooling piping and seals must be completely drained.
2. When pumping a liquid that can thicken and become solid when stopped, it is necessary to thoroughly clean the inside of the pump after stopping the pump.

3-4. Backup pump.

In order to be able to immediately start the standby pump, the following operations must be performed:

1. Carry out the same work as for the main pump. See points 3-1.
2. In case the pump starts automatically, it is necessary to open the valve in the discharge line and the valve in the minimum flow line, if any.
3. Check weekly that you can freely turn the pump rotor by hand.
4. It is recommended to run the pump at least once a month to make sure it is working properly.

Section 4: Pump Lubrication

4-1. Type of lubricating oils

High quality turbine oil must be used.

4-2. Change of oil

1. Drain the oil from the bearing housing and flush with light oil.
2. Unscrew the drain plug and install the permanent grease fitting horizontally.
3. Fill in oil through the vent hole on the bearing housing so that the oil level reaches the center of the grease fitting connection point. See fig. 4-a.
4. Fill the oiler cap with oil and then quickly insert it into the lower housing.

Repeat the operations until the oil reaches the required level. See Fig. 4b.

Note:

1. Make sure that the oil from the oiler comes down when the oil is supplied by the oiler cap. If the oil in the oiler does not go down, the oil level is sufficient.
2. When the oil level goes down to half the level of the oiler, it is necessary to add oil with the oiler cap.

4-3. Oil change interval.

The oil should normally be changed every 8500 hours of operation or annually.

After one month has passed since the start of operation, the oil must be changed. See list of oils.

4-4. Grease Fitting Method

1. If the oiler is supplied with a wire gauge, the level adjuster must be installed as shown in Fig. 4-c.
2. If the lubricator is supplied without a wire gauge, the lubricator does not need to be adjusted.

Section 5 Maintenance

For mechanical seals and actuators, refer to the relevant instructions.

5-1. Disassembly.

1. Disconnect the auxiliary piping and remove the coupling spacer.
   When dismantling the pump, it is not necessary to disconnect the suction and discharge pipes.
2. Remove the coupling half using the coupling ejector.
3. Rotate the set plate attached to the sealing cover of the mechanical seal into the groove on the shaft sleeve and lock it in this position. Loosen the drive collar of the shaft sleeve.
4. Loosen the set screws holding the deflector ring.
5. Remove the bearing housing as follows:

   Note:

   The ball bearing must be removed with a puller. The ejector must be hooked onto the inner race of the ball bearing.

   (1-1) If the pump is equipped with a thrust ball bearing, disassemble according to the following sequence:

   1. After the bearing housing cover is shifted, it is necessary to remove the bearing housing cover, the bearing housing.
   2. Then the bearing lock nut and washer, bearing thrust washer, thrust ball bearing and bearing spacer.
   3. Bearing housing cover and deflector ring.

   (1-2) If the pump is equipped with plain bearing and thrust ball bearing, disassemble according to the following sequence:

   1. Bearing housing cover, upper bearing housing half, plain bearing upper half and oil ring.
   2. Bearing lock nut and washer, bearing thrust washer, bearing race, thrust ball bearing and bearing spacer.
   3. Plain bearing lower half, oil ring and bearing housing lower half.

   (2-2) If the pump is equipped with a radial plain bearing, disassemble according to the following sequence:

   1. Bearing housing upper and bushing upper
   2. Plain bearing lower part, oil ring and bearing housing lower part.
   3. reflective ring.
6. Remove the nut holding the stuffing box and slide the stuffing box including the mechanical seal assembly, shaft sleeve and removed shaft.

   Note:

   The sealing surface of the mechanical seal is mirror polished and optically flat. These surfaces must be cleaned with the utmost care.

7. Remove the body nut and slide the top half of the body.
8. Remove the rotating element and disassemble according to the following sequence.
9. Impeller lock nut, impeller, impeller key and casing wear rings.

Note:

1. Observe the direction of the bend of the impeller vanes in relation to the shaft in order to properly install the impeller on the assembly.
2. The following parts should not be removed without the need for replacement:
   1. Impeller wear ring
   2. Packing gland bush
   3. Stationary oil slinger - excluding plain bearing if used

5-2. cleaning

After dismantling, clean all parts according to the following sequence:

1. Remove scale or similar deposits with a cleaning solvent.
2. Rinse and blow air through the inside of the housing (2 and 3).
3. Wash the bearings and the inside of the bearing housing in solvent. Use a clean cloth for cleaning.

5-3. Examination

Carefully check all parts according to the following sequence.

1. Check all parts for dirt, wear or damage. The adjacent surfaces of each part must be clean and undamaged.
2. Check shaft for straightness. The shaft must be straight to within 0.025 mm of the total indicator reading.
3. Replace parts that cannot be repaired. If the diametral clearance of rotating parts has reached the limit value, it is necessary to replace them.

5-4. Repair

1. Impeller wear rings.

1. Remove worn wear rings using appropriate tools.
2. Install new rings and tighten set screws.
3. Check diametrical clearance of new wear rings.

2. Stationary oil deflector.

1. Remove worn parts by pushing the plate and tapping with a hammer.
2. Install the new part with a hammer.
3. The stationary oil slinger must be installed in such a way that its drain hole is located at the bottom.

3. Plain bearing

1. Repair, if possible, worn journal bearings by scraping away surface defects on the babbitt-faced side of the pads.
2. If it is not possible to repair worn plain bearings, they must be replaced.

5-5. Reassembly

1. Mount the rotating elements and check the concentricity following the following sequence.

1. Insert the impeller key onto the shaft and push the impeller in.
   Note: The direction of bending of the impeller blades in relation to the shaft must be the same as during disassembly.
2. Install the impeller lock nut and adjust the lock nut to align the impeller and impeller key.
3. Check the concentricity of the rotating element by centering and measuring with a dial indicator. Turn the shaft slowly by hand and take readings on the impeller wear rings and on the shaft. If the total indicator reading does not exceed 0.05 mm, then the assembly was carried out accurately.
4. Outer ring housing.

2. Install the inner assembly on the bottom half of the housing.

Install housing wear rings.

• Check the concentricity and squareness of the rotor, observing the following sequence:
  (1) Install the upper body half (2) with the body gasket and tighten the body nut (926) firmly to prevent leakage at the connector surfaces.
  1. Assemble the thrust bearing and housing as directed in the thrust bearing assembly section.
  2. Assemble the radial bearing and housing as directed in the Radial Bearing Assembly section.
  3. Install the dial indicator firmly on the pump shaft. Check the concentricity of the stuffing box bore and the squareness of the end ends of the stuffing box and bearing housing.
  4. Disassemble both bearing housings.
• Insert the grooved mechanical seal drive-in collar mounting plate onto the shaft sleeve and secure in position. Slide the mechanical seal shaft sleeve assembly and flinger onto the shaft.
• Assemble the bearing housing according to the following sequence:
  Note: Lubricate all surfaces of the bearing when assembling. Ball bearings must be heated in an oil bath to a temperature of 120°-150° and quickly mounted on the shaft.
  1. Thrust bearings
     1. If the pump is equipped with thrust ball bearings, assembly is carried out in accordance with the following sequence:
        1. Install bearing housing cover with gasket. The oil drain hole must be on the underside.
        2. Bearing spacer, thrust ball bearing, bearing thrust washer and bearing lock nut with washer.
        3. Bearing housing and bearing housing cover with gasket. Tighten the nuts holding the bearing housing to the housing evenly.
     2. If the pump is equipped with a sleeve bearing and a thrust ball bearing, assembly is carried out in the following sequence:
        1. Lower half of bearing housing, lower half of plain bearing, oil ring and lower half of stationary oil slinger with oil drain hole.
           Tighten the nuts holding the bearing housing to the housing evenly.
        2. Bearing spacer, thrust ball bearing, bearing race, bearing thrust washer, bearing lock nut and washer and oil ring.
        3. Upper sleeve bearing half, upper bearing housing half with stationary oil slinger upper and gasket, and bearing housing cover with gasket.
        4. Check play in axial direction. Axial play should be within 0.05-0.15 mm.
  2. Radial bearings
     1. If the pump is equipped with deep groove ball bearings, assembly is carried out in the following sequence:
        1. Install bearing housing cover with gasket. The oil drain hole must be on the underside.
        2. Bearing spacer, deep groove ball bearing and bearing retainer.
        3. Bearing housing, outer bearing housing cover with gasket. The oil drain hole of the bearing housing cover must be on the underside. Tighten the nuts holding the bearing housing to the housing evenly.
     2. If the pump is equipped with a radial plain bearing, assembly is carried out in the following sequence:
        1. Lower half of the bearing housing, lower half of the stationary oil slinger with oil drain hole, lower half of the plain bearing and oil ring. Tighten the nuts holding the bearing housing to the housing evenly.
        2. Upper sleeve bearing half and bearing housing upper half with stationary oil slinger upper half and gasket.
• Install the deflector ring with the set screws. The gap between the flinger and the stationary oil slinger should be about 2 mm.
• Bolt the stuffing box cover to the housing. Install the drive-in sleeve of the shaft sleeve, unscrew the mounting plate from the groove of the shaft sleeve and secure in this position.
• Rotate the shaft by hand to make sure that the wear rings and bushings are free and clean.
• Install flexible coupling
• Check alignment of pump and drive. Make appropriate adjustments if necessary.

These replacement periods should be considered as a guideline in order to ensure that the minimum number of spare parts required for on-site maintenance is provided.

№	the name of detail	Replacement terms
1	Seals	After every check
2	wear rings	When the diametrical clearance exceeds the minimum clearance by 100%, or when a significant drop in pump performance is noticeable. (See the minimum clearance check report)
3	Spacers and bushings	Same as for wear rings
4	mechanical seal	Annually (in case of leakage from the mechanical seal after damage to the sealing surface).
5	Shaft bushings	Every two years (when the surface of the shaft sleeve is worn)
6	Bearings (ball bearings)	Every two or three years (when noise and vibration increase or when bearing friction noise is abnormal)
7	Bearing (sleeve)	When the diametral clearance exceeds the minimum clearance by 50%

Section 6 Troubleshooting

Malfunctions, their possible causes and corrective actions

Fluid is not pumping	2) The pump is not primed 3) The suction line is not filled with liquid. 7) The total head is greater than the head for which the pump is designed.
The pump does not pump with the set capacity	1) Wrong direction of rotation 2) The suction line is not filled with liquid. 3) Air leaks in the suction line or stuffing box. 4) The suction pipe at the inlet is not sufficiently immersed in the liquid. 5) Insufficient NPSH available 6) Insufficient pump speed. 7) The total head is greater than the head for which the pump is designed. 8) The viscosity of the liquid is greater than the value for which the pump is designed. 9) Mechanical defects:
The pump does not develop the rated discharge pressure	1) The presence of gases or vapors in the liquid 2) Insufficient pump speed 3) The discharge pressure is greater than the pressure for which the pump is designed. 4) The viscosity of the liquid is greater than the value for which the pump is designed. 5) Wrong direction of rotation. 6) Mechanical defects: a) Worn wearing rings b) Damage to the impeller c) Internal leakage due to defective gaskets
Excessive energy consumption	1) Too high speed. 2) The specific gravity and/or viscosity of the liquid differs from those for which the pump was designed. 3) Mechanical defects: a) Poor alignment. b) Curvature of the shaft. c) Problems with the rotating element. d) Seal too tight.
Vibration	1. Insufficient suction a) The presence of gases or vapors in the liquid b) Insufficient NPSH available c) The suction pipe at the inlet is not sufficiently immersed in the liquid d) Gas or steam pocket in the suction line. 2. Bad alignment 3. Worn or loose bearings 4. Imbalance of the impeller 5. Curvature of the shaft 6. Not strong enough foundation
Overheating of the stuffing box	1. Lack of cooling water on the casings. 2. Lack of external flushing fluid on the stuffing box.
Bearing overheating	1. Oil level too low. 2. Impeller or poor oil quality. 3. The presence of contaminants in the oil. 4. Oil ring damage. 5. Insufficient coolant circulation. 6. Too tight bearings. 7. Poor alignment.
Rapid bearing wear	1. Bad alignment 2. Curvature of the shaft. 3. Vibration. 4. Excessive thrust due to mechanical damage to the pump. 5. Lack of lubrication. 6. Incorrect installation of bearings 7. The presence of contaminants in the oil.

This manual has been developed to organize safe work during the repair and maintenance of pumps, pumping equipment, valves

1. GENERAL REQUIREMENTS FOR LABOR PROTECTION

1.1. This Instruction provides for the basic requirements for the organization of safe work in pumping stations (hereinafter referred to as pumping stations) at oil product supply enterprises.
1.2. When performing work in pump rooms, in addition to the requirements set forth in this Instruction, the requirements of the instructions on labor protection when carrying out gas hazardous and hot work must also be met, and when working at a height of more than 1.5 m above the floor or ceiling, workers must comply with the requirements of the Instruction on labor protection when working at height.
1.3. Persons who have passed a medical examination, training, instruction and testing of knowledge on labor protection are allowed to service the pumping unit.
1.4. When working in pumping stations, in case of violation of labor protection rules, workers may be exposed to toxic substances, elevated temperatures, vibration, and electric current.
1.5. The head of the enterprise entrusts the technical supervision of the operation of pumping stations to a qualified specialist who is responsible for their safe maintenance, keeping a log of the operation of pumping units and pumping station equipment, and taking measures to eliminate detected malfunctions.
1.6. The pump room must be equipped with forced supply and exhaust ventilation, an emergency ventilation system interlocked with an automatic gas analyzer, stationary or portable lifting devices, and an automatic fire extinguishing system.
1.7. In the pump room, instructions for labor protection and fire safety, for the operation of pumping units, a schedule for preventive maintenance of units, a scheme for piping pumps and connections with pipelines and tanks, and a diagram of the electrical part of pumps should be posted under glass.
1.8. Pump rooms must be kept clean and tidy. The trays and floors of the pump room should be regularly washed with water, the accumulation of oil products on the floors should be eliminated. Do not use flammable petroleum products for mopping.
1.9. Do not obstruct passages between pumps with materials, equipment or other objects.
1.10. Storage of lubricants in the pump room is allowed in an amount not exceeding the daily requirement. Lubricant should be stored in special metal or polyethylene containers with tightly closed lids. Storage of flammable liquids in pump rooms is not allowed.
1.11. All open and accessible moving parts of pumping equipment must be equipped with metal protective guards.
1.12. At night, the pump room should have lighting of at least 150 lux.
1.13. For local lighting at night, portable rechargeable lamps in an explosion-proof version with a voltage of no more than 12 V should be used. The lamps are turned on and off outside the pump room, at a distance of at least 20 m.
1.14. It is forbidden to use open fire and smoke in the pump room. Smoking must be provided in specially equipped areas.
1.15. In the pump room for pumping leaded gasoline, a supply of clean sand or sawdust, cleaning materials, bleach, as well as a tank of kerosene for washing hands and parts should be kept.
1.16. In the pump room, it is necessary to have a set of emergency tools, a supply of rechargeable lights, which must be stored in special cabinets in the operator's room.
1.17. Unauthorized persons (not serving the unit) are prohibited from entering the pump room.

2. SAFETY REQUIREMENTS BEFORE STARTING WORK

2.1. Turn on the supply and exhaust ventilation.
2.2. Check the condition of the workplace, the serviceability of tools, devices, mechanisms, the availability of personal protective equipment and primary fire extinguishing equipment. It is forbidden to use faulty tools, devices, mechanisms, personal protective equipment.
2.3. Check the condition of the grounding of pumps, electric motors, electrical equipment, pipelines and other equipment of the pumping station. Casings of pumps pumping oil products must be grounded regardless of the grounding of electric motors located on the same frame with the pumps.
2.4. Before carrying out repair work related to the dismantling of the pumping unit or other equipment of the pumping station, it is necessary to turn off the electricity using the switching equipment and remove the fuses, hang a poster “Do not turn on - people are working!” on the control panel of the units, disconnect the pump from the pipelines by closing the valves.

3. HEALTH REQUIREMENTS DURING WORK

3.1. In the pump room, reliable operation of natural and forced supply and exhaust ventilation should be ensured. It is forbidden to put the pump units into operation when the ventilation is not working, as well as with the guards and safety covers removed, with faulty pressure gauges.
3.2. During the operation of pumping stations, supervision over the tightness of pumps and pipelines should be established. Leakage of oil products through the mechanical and stuffing box seals of pumps above the permissible standards established by the manufacturer must be immediately eliminated.
3.3. All moving parts of the pump must be lubricated regularly. When lubricating, there should be no spreading and splashing of lubricants.
3.4. In case of violations in the pump operation mode (noise, increased vibration, overheating of bearings, leakage of seals, cracks and defects in individual parts, etc.), the pump must be stopped. For troubleshooting purposes, the pump must not be operated.
3.5. The temperature of bearings and seals should be checked at least once an hour. Overheating of bearings above 60 Co is not allowed. Do not cool the bearings or the shaft with cold water, ice, etc.
3.6. When stopping the pump for repair, you must:
- disconnect the electric motor from the power source and put up a poster on the starting device “Do not turn it on - people are working!”;
- disconnect the pump from the pipelines by closing the valves and installing plugs;
- remove the remaining product from the pump;
- make an entry in the operation log indicating the time the unit was stopped for repair.
3.7. Dismantling and repair of the pump must be carried out by order of the head of the enterprise with the issuance of a work permit for the performance of work of increased danger.
3.8. Repair of pumps pumping leaded gasoline is allowed only after internal and external flushing of the housing and all components and parts of the pump with kerosene.
3.9. After washing, the pump housing and parts must be wiped dry with a cleaning cloth.
3.10. When repairing pumps and other work in the pump room, a tool made of a material that excludes sparking upon impact should be used.
3.11. It is not allowed to find people in front of knocked-out or pressed-out parts.
3.12. Workers using electric tools must have an electrical safety group of at least II and an appropriate certificate.
3.13. The change of electric lamps and safety caps in the pump rooms is carried out by an electrician.
3.14. During the operation of pumping units, it is prohibited:
- fix and repair any parts and equipment under pressure;
- remove the fence or its individual parts;
- slow down moving parts with your hands or with the help of other objects (crowbar, pipe, etc.);
- put cleaning material or any other objects impregnated with oil products on the hot parts of pumps and pipelines;
- leave the pumping unit unattended, in the absence of automatic control and alarm systems.

4. REQUIREMENTS FOR LABOR PROTECTION IN EMERGENCY SITUATIONS

4.1. During the operation of pumping stations, emergency situations are possible, including:
— significant leakage of oil products at the operating unit;
- sudden interruption of the supply of electricity or steam;
- strong vibration of the pumping unit;
- overheating and the appearance of smoke from bearings, seals, stuffing boxes in the separation wall;
- fire;
- increased gas content.
4.2. In the event of an emergency, as well as upon detection of any malfunction that disrupts the normal operation of the pump or poses a threat to workers, the pump must be stopped, the valves on the inlet and outlet lines are closed. The management of the enterprise must be notified of the emergency stop of the pump.
4.3. It is forbidden to put the pump into operation until all faults have been eliminated.
4.4. In case of an accident, the victim should be given first aid, call an ambulance by phone 103 and inform the management of the enterprise.
4.5. In the event of a fire or explosion in the pump room, immediately stop all types of pumping, call the fire brigade by phone 101, inform the management of the enterprise, and act in accordance with the emergency response plan.

5. HEALTH REQUIREMENTS ON COMPLETION OF WORK

5.1. After completion of work in the pump room, the workers who performed these works are required to clean the workplace, put in order the tools and working devices.
5.2. Oiled cleaning material should be placed in special metal boxes with lids with its subsequent regeneration or destruction.
5.3. After finishing work with toxic substances, it is necessary to comply with the requirements of personal hygiene.

1. PURPOSE OF THE PRODUCT

1.1 Single-stage centrifugal pumps and units type K are designed to supply water, as well as clean non-aggressive liquids similar to water in viscosity with a pH value (pH) from 6 to 8.5, temperatures up to 105 ° C.
1.2 The unit consists of a pump and an electric motor connected by a flexible coupling and installed on a common foundation frame.
1.3 The pumps included in the unit are made according to the material of the flow part from gray cast iron.
1.4 The units are manufactured in UHL climatic version, placement category 4 according to GOST 15150.
1.5 At the request of the consumer, the units are manufactured with one of the variants of the impeller reduced in outer diameter.
1.6 The units are equipped with electric motors AIR and others in a general industrial version, mounting versions IM1081, IM1001 in accordance with GOST 2479 (mounting version IM2081, IM2001 can be used).
Rated operating mode of motors S1 according to GOST 183. At the request of consumers, it is allowed to complete the unit with engines of other operating modes in accordance with GOST 183.

2. SPECIFICATIONS

2.1 The technical characteristics of the units are given in Table 1.
2.2 The units must be operated within the range of supply of the working part of the characteristics specified in Appendix A.
2.3 Overall dimensions and weight of the units indicated in the figures in Appendix B. Dimensions of the pump parts are shown in Appendix C.
2.4 Operation of the unit in modes other than the operating part of the characteristic is not allowed.
2.5 Bearings are lubricated with oil poured into the pump bracket until it appears in the control hole located on the side of the bracket.

3. PUMP UNIT DEVICE

3.1 Horizontal single-stage electric pump unit type K consists of a pump and a motor mounted on a common foundation plate. The shafts of the pump and the motor are interconnected by an elastic coupling. On fig. 1 shows a general view of pumps K.
3.2 Pump bearings are lubricated with oil poured into the bracket.
3.3 Shaft sealing is provided by gland packing or mechanical seal.

4. SAFETY REQUIREMENTS

4.1 Electric pump units (pumps) must comply with the requirements of GOST 12.1.003, GOST 12.2.003.
4.2 In a conspicuous place of the pump, a red arrow should indicate the direction of rotation of the shaft.
4.3 The coupling connecting the shafts of the pump and the electric motor must have a protective guard painted red.
4.4 It is forbidden to lift the electric pump unit by the eyebolt of the electric motor or by the pump shaft. The electric pump unit should only be lifted in accordance with the slinging scheme, which is indicated on the outline drawing (Appendix A).
4.5 During the operation of the unit, all rotating parts of the unit must be guarded.
4.6 Operation of the electric pump unit without shutoff valves on the suction and discharge lines is not allowed.
4.7 During operation, the unit must be grounded. Grounding - according to GOST 12.1.030, PUE (Chapter 1.7).
4.8 Starting the unit without first filling it with the pumped liquid is not allowed.
4.9 Parts of the unit working under pressure must be tested for strength, material density and tightness of connections. The test pressure must be at least Р=1.5 Рр (where Рр is the operating pressure).
4.10 The pump must be started with the discharge valve closed. The operating time of the pump with the valve closed should not exceed 1.5 minutes.
4.11 Leakage of the pumped liquid through the seal should be monitored regularly. In case of detection of leaks, more than permissible, immediately stop the pump unit and eliminate the malfunction.
4.12 At workplaces in industrial premises during the operation of electric pumping units, if necessary, measures should be taken to reduce noise and vibration in accordance with GOST 12.1.003, GOST 12.1.012 and GOST 12.4.051.
4.13 Only qualified mechanics and locksmiths who know the design of the units and have experience in maintaining, repairing and testing the units in operation, as well as those who have passed the exam for the right to install and maintain this equipment, should be allowed to install and operate electric pump units.

5. PREPARING THE PRODUCT FOR WORK

5.1 After delivery of the electric pump unit to the place of installation, make sure that the unit is complete and that the warranty seals are intact.
The product must be carefully inspected to ensure that it has not been damaged during transport or storage.
5.2 The installation site of the unit must meet the following requirements:

a) it is necessary to provide free space to the pump for its maintenance during operation;
b) the suction and pressure pipelines must be fixed on separate supports. Transfer of loads from pipelines to pump flanges is not allowed;
c) to ensure cavitation-free operation of the pump, the suction pipeline should be as short and straight as possible;
d) a check valve and shut-off valves must be installed on the pressure pipeline. A non-return valve must be installed between the shut-off valve and the pump;
e) at the suction and discharge of the pump, devices must be installed that provide measurement of the pressure of the pumped liquid;
e) a fluid supply must be made to the shaft seal assembly. A drain piping must be installed to drain leaks from the pump. A device for measuring pressure and a valve must be installed on the line for supplying the barrier liquid (up to the device, if viewed in the direction of the liquid flow);
g) on ​​the pressure pipeline in front of the stop valves, install a valve to remove air.

5.3 Depreservation of the pump flow path is mandatory only if it is unacceptable for the preservative composition to get into the pumped liquid, and is carried out by flushing the pump cavity with gasoline or white spirit. In other cases, depreservation of the pump is not required.
5.4 The unit should be installed on the foundation, ensuring the horizontal installation, and, after the mortar has hardened, the foundation bolts must be tightened.
5.5 Connect the suction and pressure pipes to the unit. Permissible non-parallelism of the flanges is not more than 0.15 mm over a length of 100 mm. It is forbidden to eliminate the misalignment of the flanges by tightening the bolts or installing oblique gaskets.
5.6 Test the installed systems for tightness and strength by test pressure according to GOST 356.
5.7 Check the alignment of the pump unit (align if necessary), misalignment should not exceed 0.08 mm for a shaft speed of 750 - 1500 rpm and 0.06 mm for a speed of 1500 - 2900 rpm. Check the alignment accuracy by applying a straightedge to the outer diameters of the coupling in two mutually perpendicular planes.
5.8 Connect the power supply system and check the direction of rotation by test run. The direction of rotation of the pump is indicated by an arrow on the housing.
5.9 The power supply circuit of the drive motor must be protected against overloads.
5.10 Check the operation of the shut-off valves of pipelines and instrument taps. The initial position of the valves and valves before start-up is closed.
5.12 The pump operating under the bay is started in the following order:

b) open the shut-off valves at the suction and fill the pump with the pumped liquid, removing air from it through a valve installed on the pressure pipeline;
c) start the engine;
d) open the pressure gauge on the pressure pipeline;
e) after the pump has created pressure, gradually open the shut-off valves on the pressure pipeline and set the specified operating mode.

ATTENTION: OPERATION WITH CLOSED VALVES FOR MORE THAN 2 MINUTES IS PROHIBITED.

5.13 Starting a pump operating with suction vacuum:

a) supply barrier fluid to the seal, adjust its supply and pressure;
b) open the suction valve, fill the pump and the suction pipeline with the pumped liquid through the fitting installed on the pipeline directly behind the pump.

A non-return valve must be installed in the suction line. Subsequent operations are carried out in accordance with paragraphs "c", "d", "e"" of Section 6.12.
5.14 Stopping the pump:

a) smoothly close the shut-off valves on the pressure pipeline;
b) turn off the electric motor;
c) close the suction valves;
d) during a long stop, drain the pumped liquid from the pump housing;
e) during a long stop, stop the supply of barrier fluid.

6. OPERATING PROCEDURE

6.1 Start the pump according to p.p. 6.13 and 6.14 and set the operating mode with the valve on the pressure pipe.
6.2 During operation, it is necessary to monitor the readings of the instruments, the supply of barrier fluid, as well as the heating of the bearings and the level of lubrication. Sharp fluctuations of the instrument arrows, as well as noise and vibration, characterize the abnormal operation of the pumps. In this case, stop the pump and repair the faults.
6.3 At the end of work, stop the pump according to paragraph 6.14. For short breaks, do not interrupt the supply of barrier liquid to the pump seal.

7. MAINTENANCE

7.1 The following types of maintenance are envisaged:
- daily, periodic (at least 1 time in 3 months).
7.2 During operation, as necessary, wear parts should be replaced.
7.3 After running out of the established resource, overhaul the pump.

Typical malfunctions and methods for their elimination.

Name of malfunction, manifestation, symptoms	Possible reason	Remedy
The console pump does not develop pressure at start-up. The arrows of the manometer and vacuum gauge fluctuate strongly.	- the pump is not sufficiently filled with the pumped liquid; - the liquid level at the suction has dropped below the permissible level, there is air leakage on the suction pipeline; - the resistance of the suction line has increased due to clogging.	- Fill the pump completely. - check the liquid level in the container, check the tightness of the suction line and tighten the connections; - check and clean the suction line.
The console pump does not provide normal flow in the working part of the characteristic.	- reverse direction of rotation of the rotor; - high resistance in the pressure pipeline; - the impeller is worn out or the flow part of the pump is clogged.	- check the direction of rotation of the electric motor; - increase the opening of the valve on the discharge line; - replace the impeller or clean the flow part of the pump.
The pump unit does not provide the required pressure.	- clogging of the channels of the flow part of the pump; - increased or unequal gaps between the housing and the impeller; - supply is more than allowed; - Decreased rotation speed.	- clean the flow part of the pump; - disassemble the pump to check the gaps; - increase the pressure line resistance; - check the electric motor.
Increased leakage through stuffing box or mechanical seal.	- increased pressure of the barrier fluid; - wear of the rubbing pair of seals, wear of the sealing rings of the gland packing; - the pressure at the inlet to the pump is higher than the allowable one.	- check and adjust the supply of barrier fluid; - dismantle the seal and replace parts; - adjust the pressure at the pump inlet.
Overloading of the electric motor of the pumping unit.	- the flow is higher than the calculated one and the pressure is lower than the calculated one; - mechanical friction or damage in the pump.	- close the pressure valve; - check the pump.
Bearing overheating.	- misalignment of the pump shaft with the motor shaft; - bearings are under-lubricated or over-lubricated.	- check and correct the alignment of the shafts; - check bearing lubrication.
Increased noise and vibration of the pump.	- the pump operates in cavitation mode; - insufficient rigidity of fastening of the pump, electric motor; - mechanical damage in the pump, rubbing of rotating parts on stationary parts, wear of bearings; - violation of the alignment of the shafts of the pump and the electric motor.	- close the discharge valve, increase the pressure at the pump inlet. - tighten the fastening of the pump, electric motor, pipelines. - eliminate mechanical damage, replace bearings; - check and center the shafts.

Installation instructions and

operation of the circulation pump

Maintenance instructions

Dear Buyer!
In this chapter "Instructions for maintenance" we want to explain to you the functions and maintenance of fully assembled pumps. Reading the maintenance instructions will make it easier for you to understand the functions of the circulation pump and its maintenance.

Please carefully read the precautions described in the installation and operating instructions.

The pump must be repaired by a WILO service representative.

Pump functions

If the room is not heated enough, then the pump speed is low and the pump must be switched to a higher speed. If, on the contrary, the pump is set at too high a speed, then unacceptable noises occur in the pipelines, and especially in the throttle valves. Noises are eliminated by switching to a lower speed.

Pump Maintenance

When servicing the pump, the following options are available:

Speed ​​switching

Switching the pump to a different speed is carried out using a switch on the terminal box. "3" means the lowest, "1" the highest speed.

Bleeding the pump

The pump must be vented when the heating system and the pump are running, but the heating circuit is still cold. If the pump housing is filled with air, the pump will not deliver water. Normally, the venting takes place by itself after a short operating time. If it is still necessary to bleed the air, follow the steps described in chapter 6.1 "Filling and venting".

Faults

In the event of a malfunction, please contact the WILO customer service.

1. 
   General provisions

The installation and commissioning personnel must be suitably qualified.

1. 
   Application area

Circulation pumps are designed for pumping liquid in a pipe system.

Main applications:

• 
  all heating systems,
• 
  industrial circulation systems (closed),
• 
  RSL pumps only: specially designed for the removal of air from technical systems with high air infusoria.

WARNING: The pumps must not be installed in drinking water systems and in areas where

related food.

1. 
   Technical parameters of pumps
   1. 
      Notation

Heating circulation pump,

wet rotor

RS = Threaded pump

RSL = Vented Pump

RSD = Double pump

Nozzle diameter 30.25 (mm)

Maximum head (m) at Q = 0 sq.m/h

1. 
   Connection and power data

Voltage: 1~230V, +6% / -10%, 50Hz

Maximum power P1: see rating plate

Max. engine speed: see rating plate

Protection class: IP 42

Rotation speed switching: manual in 3 steps

Control unit S2R 3D for switching operating modes according to time

Primary-/Standby or Secondary-/Peak mode: for twin pumps

Motor protection: not required

Nominal diameter DN (connection pipe): 25 (1”), 30 (1-1/4’’)

Max. permissible operating pressure: 10 bar

Min. pressure on suction port *At +50 C: 0.05 bar

At t +95 C: 0.3 bar

At t +110 C: 1.0 bar

Permissible temperature range: -10 C to +110 C

Max. t environment: +40 C
* The values ​​are valid for an altitude of 300 m above sea level, for higher places add 0.01 bar for every 100 meters of altitude.
To avoid cavitation noise, the minimum pressure in the suction port of the pump must be maintained.
Pumped media:

• 
  Heating system water, according to VDI 2035,
• 
  A mixture of water with glycogen in a ratio of 1:1. When glycol is added, the viscosity of the liquid increases, therefore, depending on the percentage of glycol in the mixture, it is necessary to correct the hydraulic parameters of the pump. Only use high quality corrosion protection products (with inhibitor additives) and follow the manufacturer's instructions.
• 
  When using other media (liquids), always consult WILO.

1. 
   Safety

This operating manual contains basic instructions that must be observed during installation and operation and must be read by the installer and operating personnel before installation and commissioning.

It is necessary to fulfill not only the safety requirements that are set out in this section, but also those that are available in the following sections.

1. 
   Symbols in the instruction manual

Instructions contained in the manual, non-observance of which may be dangerous to human life and for the pump are marked with the symbol: !
The electrical voltage warning sign is especially noted:

Safety requirements, non-observance of which leads to damage to the pump and impairing functions, are indicated by the sign:
V attention

1. 
   Service personnel qualification

For installation work, personnel must be suitably qualified.

1. 
   Consequences of non-compliance with safety regulations

Failure to comply with safety regulations can lead to serious consequences for people and for pumps / units. Non-observance of the safety instructions will result in the loss of all rights to compensation for damages.

Possible consequences:

• 
  Failure of important pump functions,
• 
  The occurrence of accidents, through electrical or mechanical influences.

2.4 Safety instructions for operation

To prevent accidents, the relevant requirements must be observed. Avoid electrical damage.
2.5 Safety for inspection and installation work

All inspection and installation work must be carried out by personnel qualified in this field, who have studied the operating manual with sufficient care. A thorough check of the pumps (installation) can only be carried out in a state of complete standstill.

2.6 Unauthorized conversion and production of spare parts

Changes to the design of the pump are only permitted after agreement with the manufacturer. Original spare parts and accessories authorized by the manufacturer are for safety. The use of other spare parts may result in the manufacturer not being held liable for possible consequences.
2.7 Unacceptable methods of operation

The performance and safety of the supplied pump (installation) can only be guaranteed if the requirements of chapter 1 of this manual are fully complied with.

Permissible parameters in the catalog (in the pump table) must not be exceeded under any circumstances.

3. Transportation and storage
attention! -Pumps/plug-in modules with electronic parts must be protected from humidity.

• 
  Permissible storage temperature range from -10 C to +50 C.

4. Description of the product and accessories
4.1 Description of wet running pumps

In wet running pumps, all moving parts, as well as the motor rotor, are washed by liquid. Shaft seals are not required. The fluid lubricates the plain bearings and cools them and the rotor. The pumps do not require service.

Twin pumps are identical and installed in the same housing; they are equipped with an integrated changeover valve. Each pump can work independently, and both pumps can work in parallel.

Twin pumps can be used in two different versions:

• 
  working and standby pump (in case of failure of the main pump, the standby pump is switched on)
• 
  main and peak pump (the latter is additionally switched on at peak load).

In this case, both pumps can differ in installed capacities. The twin pump system can therefore be adjusted to the individual production situation. To control various production situations, the switching device S2R 3D must be connected.

Pump RSL 25/6 designed, moreover, to remove air from the system. It is equipped with a special air collector housing, on which an air vent valve (deaerator) is installed. After installing the pump and loosening the bolts, the air collector must be subjected so that the deaerator is in a vertical position.

Engine protection not required. Even the maximum overload current cannot damage the motor and cause it to block.

Speed ​​changeover:

All pumps have a switch on the terminal box for manual switching to the 3rd speed setting. At the lowest stage, the number of revolutions is reduced by 40 ... 50% of the maximum. Energy consumption will be reduced by 50%.
4.2 Scope of delivery

• 
  Pump included;
• 
  Installation and operation manual.

4.3 Accessories:

The accessories required for the application must be ordered separately.

• 
  connection nuts,
• 
  Switch S2R 3D for twin pumps.

5. Assembly and installation
5.1 Mounting

• 
  The installation should be carried out after completion of all welding and soldering work, and flushing of the pipe system. Contaminants can impair pump performance.
• 
  The pumps must be mounted in easily accessible places so that later inspection or replacement of the pump can be carried out.
• 
  The installation of gate valves is recommended before and after the pump. This eliminates the need to refill the system when replacing the pump. The fitting must be mounted so that water does not get on the electric motor and the terminal box.
• 
  Always install the pump in a circuit with an open expansion tank after the safety line (according to DIN 4751).
• 
  Installation should be carried out on a pipe without mechanical stresses and with a horizontally located pump shaft. Observe the position as shown in fig. 1 and 2.

Figure 1: installation position for types RS/RSD,

Figure 2: installation position for RSL types, when mounting the deaerator (screw thread R 3/8’’) it is necessary to loosen the bolts and turn the body so that the deaerator is directed strictly perpendicularly upwards. When installing the pump in horizontal pipelines, its performance is ~ 25% higher than when installed in a vertical pipeline.

• 
  The arrow on the pump body indicates the direction of flow (fig. 3, pos. 1).
• 
  When connecting the pump to the pipeline, the pump can be fixed with a wrench to the specially provided surfaces against twisting (Fig. 4).
• 
  The motor terminal box must not be pointing downwards as water can get into it. Rotate the motor housing if necessary.

Attention! Do not damage gaskets. Use new gaskets of the appropriate size 86x76x2.0mm.

Attention! In insulated systems, only the pump casing is insulated. Engine and holes Electrical connection must remain open to allow condensate to drain (fig.3, pos.2).

1. 
   Electrical connection

• 
  The electrical connection must be made by a qualified electrician and in accordance with the requirements for working with electrical equipment.
• 
  The electrical connection must be made strictly according to the manual and with a plug connection or multi-pole switch. The minimum distance between contacts is 3mm.
• 
  To ensure protection against water ingress and reduce stress on the sealing nut, an outer diameter cable (eg H 05 VV-F3 G 1.5) must be used.
• 
  When installing the pumps in a system with a water temperature of more than 90 C, a heat-resistant cable must be used.
• 
  The cable must never come into contact with the pipeline or pump housing.
• 
  The type of current and voltage in the network must correspond to the data on the pump plate.
• 
  Make the network connection according to Figure 5.
• 
  The pump/installation must be earthed in accordance with regulations.
• 
  When connecting switching devices from automatic plug-in modules, observe the respective installation and operating instructions.

6. Commissioning
6.1 Filling and venting
Fill the system properly. The removal of air from the pump cavity is carried out independently, after a short-term operation. Short-term dry running does not harm the pump, long dry run will result in pump failure. If direct venting of the pump is required, proceed as follows:

• 
  Turn off the pump
• 
  Close the valve on the pressure line,
• 
  Using a suitable wrench, carefully open the bleed screw (Fig. 6),
• 
  At high fluid temperature and pressure, when the bleed bolt is opened, a hot mass in liquid or gaseous state may spurt out. You can get severe burns.
• 
  Gently push the pump shaft inward,
• 
  Protect electrical parts from escaping water,
• 
  turn on the pump,
• 
  After 15 ... 30 seconds of operation, tighten the air release bolt,
• 
  Open valves again.

attention! The pump can block if the shut-off screw is open and if the operating pressure is insufficient.

ATTENTION - during operation, depending on the temperature conditions, the pump and the liquid medium can be very hot.

• 
  There is a risk of burning when touched!

7. Maintenance
The pumps are maintenance free.
8. Malfunctions, causes and their elimination
8.1 The pump does not work when the power is on

• 
  Check electrical fuse.
• 
  Check voltage at pump (observe type data).
• 
  Check capacitor size (observe type data).

Remedy: Unscrew the central locking bolt and check the stroke of the pump rotor with a screwdriver (Fig. 6).

ATTENTION- At high temperature and pressure in the system, close the valves before and after the pump. Let the pump cool down.
8.2 The pump is noisy

• 
  With cavitation due to insufficient supply pressure. Remedy: Raise the supply pressure within the allowable range.
• 
  Check the number of steady turns, switch to a lower number of revolutions.

If the problem cannot be corrected, please contact your nearest NOCCHI customer service.

Instruction manual for centrifugal pumps

1. General part.

1.1. The mechanic (foreman) of the workshop is responsible for the operation of centrifugal pumps.

1.2. Responsible for timely and high-quality repairs, according to the preventive maintenance schedule and filling in the hours log, is the workshop mechanic.

1.3. The operator is responsible for the operation of centrifugal pumps in shifts.

1.4. All centrifugal pumps must have passports in the prescribed form, repair, operation and operating hours logs, a maintenance schedule and a floor plan with pumps and pipelines marked on it.

1.5. All centrifugal pumps must be assigned a serial number. The number is applied with bright, indelible paint on the pump housing and electric motor, as well as at the pump starter.

1.6. Persons who have completed the training course and passed the exam are allowed to service the pumps.

2. Preparation for launch.

2.1. The pumps are kept clean and in good working order. Before starting, make sure that there are no foreign objects on the pump and electric motor. Check the grounding of the electric motor, the serviceability of the pressure gauges.

2.2. Check if there are any "jamming" in the pump (checked by turning the shaft by the coupling).

2.3. Check if the seal is well packed.

2.4. Check the presence and fastening of the guards of the coupling and the fan of the electric motor.

3. Pump start.

3.1. Close the valve on the discharge pipeline.

3.2. Open the valve on the intake pipeline.

3.3. Turn on the electric motor and make sure that the direction of rotation of the shaft is correct.

3.4. After pressure rises on the pressure gauge from the pump discharge line,

slowly open the valve on the discharge pipeline.

Note: To avoid overheating of the pump, do not work for a long time (more than five minutes) with the valve on the discharge pipeline closed.

4. Pump operation.

4.1. During operation of the pump, monitor the temperature of the bearings and the temperature of the motor.

4.2. Monitor the condition of the stuffing box (the stuffing box in normal mode should not pass more than 10-15 drops per minute).

4.3. Follow the readings of the manometers.

4.4. Stop the pump if:

a) the temperature of the electric motor exceeds 80 С;

b) there is a significant excess of the temperature of the pump housing compared to the temperature of the pumped liquid;

c) bearing temperature exceeds 70°C;

d) significant fluid leakage through the stuffing box;

e) the appearance of smoke from the stuffing box or electric motor;

f) increased noise and vibration in the pump, clutch and electric motor;

g) a significant pressure drop with a closed valve on the discharge pipeline.

5. Stop the pump.

5.1. Close the valve on the pump discharge pipe.

5.2. Switch off the electric motor.

5.3. In an unheated room during the cold season, drain the water from the pump housing and pipelines.

6.1. Operation of the pump in the absence of a coupling guard and an electric motor fan.

6.2. In the absence of grounding of the electric motor.

6.3. With a faulty pump seal.

6.4. With faulty gauges.

6.5. Clean and tighten the stuffing box while the pump is running.

Notify the mechanic of all pump malfunctions and record in a log.

"Reception and delivery of change."

Developed