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Waukesha 200 series Operation, Maintenance And Parts Manual Download Page 2

95-03009

THIS PAGE IS INTENTIONALLY LEFT BLANK

 

7-12-96

Summary of Contents for 200 series

Page 1: ...Read and understand this manual prior to installing operating or maintaining this pump Waukesha Centrifugal Pumps Model 200 Series OPERATION MAINTENANCE PARTS LIST Effective Date October 9 1999 ...

Page 2: ...95 03009 THIS PAGE IS INTENTIONALLY LEFT BLANK 7 12 96 ...

Page 3: ...arge valves closed Do Not open vent or drain valves or remove plugs while system is pressurized Do Not remove casing clamp while system is pressurized Do Not overtighten casing clamp Moderate tightening only SAFETY General Safety Instructions Waukesha Centrifugal pumps has been designed to be safe and reliable when properly used and maintained Do Not operate pump beyond the rated conditions for wh...

Page 4: ...rely in place WARNING 33 61 33 62 4 18 97 SAFETY Operators and maintenance personnel must follow safety measures Failure to observe the instructions in this manual could result in severe personal injury or machine damage Throughout this manual the words Warning Caution and Note are used to indicate procedures or situations which require special operator attention WARNING Identifies a serious hazar...

Page 5: ...laim of damages in connection with the sale of products In no event shall Seller be liable for any special consequential incidental or indirect damages including without limitation attorneys fees and expenses nor shall Seller be liable for any loss of profit or material arising out of or relating to the sale or operation of the products based on contract tort including negligence strict liability ...

Page 6: ...CE Cleaning and Repair Disassembly 19 Water Cascade 19 Type 1 Seal 20 Backplate Assembly 21 Backplate Impeller Assembly Clearance 21 Type 4 Seal 21 MOTORS Baldor Motor Maintenance 24 U S Electrical Motors Maintenance 25 SEALS 26 Seal Kits 26 Seals All Pumps 28 Recommended Spare Parts 28 Commercial Seals 29 Metric Pump Notes 27 28 Motor Shims 28 PARTS LISTS 2045 COMPONENTS 30 2065 COMPONENTS 31 206...

Page 7: ...l components are interchangeable between models All seal assemblies utilize an externally mounted balanced rotary seal for longer seal life and better sealing capability The stationary seal face is reversible and replaceable 200 Series pumps are designed for a broad range of sanitary and industrial applications Sanitary models are designed for clean in place and meet U S D A and 3A Standards MANUA...

Page 8: ...PE 1C SEAL ASSEMBLY SEAT RETAINER STATIONARY SEAL L GASKET Figure 3 SPRINGS 3 TABBED WASHER ROTARY SEAL O RING SLINGER 142 215JM L GASKET STATIONARY SEAL 1 4 20 X 3 CAP SCREWS 4 L GASKET TABBED WASHER O RING ROTARY SEAL O RING TABBED WASHER SPRING RETAINER TYPE 4 SEAL ASSEMBLY Figure 4 MOTOR SHIMS O RING SPRINGS 3 SEAT RETAINER SPRINGS 3 ROTARY SEAL O RING PLUG HOUSING ...

Page 9: ...eller Retainer 316L Stainless Steel Shaft Seal Single Mechanical external balanced Type 1 Rotary Seal Material Carbon Stationary Seal Siliconized Graphite Elastomers FDA approved Viton Finish All product contact surfaces provided with a sanitary polish 150 Grit Industrials unpolished Motor Adapter Bracket Cast Iron Paint Two part epoxy TNEMEC 104 Sky Blue 104 BB 42 on motor bracket and motor if or...

Page 10: ...6 500 514 517 459 494 482 638 639 213JM 21 91 22 50 22 60 21 72 23 05 22 55 23 88 23 91 557 572 574 552 585 573 607 607 215JM 21 91 22 50 22 60 21 72 23 05 22 55 26 56 26 59 557 572 574 552 585 573 675 675 254JM 25 47 26 06 26 17 25 53 26 87 26 43 27 63 27 66 647 662 665 648 682 671 702 703 256JM 27 81 27 92 25 53 26 87 26 43 29 38 29 41 706 709 648 682 671 746 747 284JM 28 44 27 66 29 00 28 50 29...

Page 11: ...6 8 0 1 5 13 18 25 5 12 5 527 395 203 38 335 648 317 326JM 20 75 15 56 8 0 1 5 13 18 25 5 12 5 527 395 203 38 335 648 317 INSTALLATION Figure 6 Note 1 Dimensions X Y C apply to pumps with clamp connection 2 SANITARY and INDUSTRIAL MODELS Industrial models begin with U AB 4 18 97 MODEL INLET OUTLET X Y Z INCH INCH INCH INCH INCH MM MM MM MM MM 2045 1 5 1 5 3 88 1 81 2 25 40 40 98 46 57 2045 2 0 1 5...

Page 12: ... inspection during operation 4 Motor must be protected from flooding PUMP LEVELING Level pump by loosening set screws and adjusting leg height Figure 7 SUCTION inlet supply AND DISCHARGE PIPING VALVES NOTE Properly support supply and discharge piping to the pump to prevent strain on the pump casing Figure 8 LINE SIZE Use line size equal to or larger than connection size on pump especially the inle...

Page 13: ... application requirements best pump operation is with supply line sloped slightly upward toward pump to prevent trapped air if system must drain into pump casing keep downward slope to a minimum or priming problems may occur SHUTOFF ISOLATION VALVES Install shutoff valves to isolate pump from supply and discharge lines to allow pump service without draining system Figure 12 FOOT VALVE If pump is i...

Page 14: ...ket head cap screws Figure 13 NOTE Length of plastic hose between the water cascade block and first fitting must be enough to allow removal of impeller and backplate assembly with hose attached The water cascade block must be above the seal on the assembled backplate to flow water onto the seal face NOTE To prevent hose contact with rotating shaft and seal parts during operation pull excess hose t...

Page 15: ...lation CLEAN PUMP AND PIPING Disassemble pump and clean all product contact parts and seal parts prior to first operation Follow instructions Disassembly for Cleaning and Repair in the MAINTENANCE section of this manual Flush and clean all system piping and process equipment separately This will eliminate any foreign material which could have accumulated during installation Plant workers will also...

Page 16: ...ws from vent valves 5 Close vent valves than outside supply line Use a type of check valve system to keep supply line and pump casing flooded with liquid Otherwise the pump must be primed before each operation See Figure 12 6 Start pump motor DISCHARGE VALVE CHECK VALVE SUPPLY VALVE SHUTOFF VALVE OUTSIDE SUPPLY BY PASS LINE SHUTOFF VALVE DISCHARGE VALVE DISCHARGE VALVE CHECK VALVE PUMP CHECK 7 Che...

Page 17: ...eaning center establish all manual safe procedures to avoid automatic start up while servicing equipment in the circuit OPERATION CONSIDERATIONS Any system devices to control flow rate must be installed in the discharge line not the supply line Restriction in the supply line may cause cavitation and pump damage Water hammer in the system can damage the pump and other system components Water hammer...

Page 18: ...sket damaged or worn Seal not installed correctly Carbon seal worn or damaged Inlet Outlet connection loose or no gasket Casing clamp loose NOT ENOUGH LIQUID DELIVERED Impeller diameter too small for duty Discharge head too high Suction lift too high Air leak in supply or at seal area Wrong direction of rotation Pump not primed Speed too slow low voltage wrong frequency wrong motor Suction or disc...

Page 19: ...selected a smaller impeller may be required or a higher motor horsepower may be required AMMETER TEST If uncertain about pump selection and application the electrician should temporarily install an ammeter in the electrical service to determine motor load Operate pump under process conditions and check motor amp draw versus nameplate full load rating If amp draw exceeds motor rating a system chang...

Page 20: ...S A Consult Waukesha Cherry Burrell if assembly cannot be removed from motor shaft by hand Telephone 800 252 1218 B Motor shaft shims may fall off motor shaft or hang up inside the deflector BE SURE TO PLACE ALL SHIMS BACK ON MOTOR SHAFT C Handle the impeller backplate assembly with care to prevent damage to seal components 7 Remove deflector loosen set screws 2 in spring retainer and slide retain...

Page 21: ...p screws evenly Figure 23 BACKPLATE IMPELLER ASSEMBLY 4 Place impeller on a clean flat surface shaft end up and slide the assembled backplate onto the impeller shaft Figure 24 Note Avoid hitting the stationary seal against the impeller shaft It could break the seal 5 Carefully place the rotary seal in position over the impeller shaft and down against the stationary seal Figure 24 4 Lubricate and s...

Page 22: ...n 2 set screws in the spring retainer and lift off rotating seal components rotary seal O ring washer spring retainer springs and washer There ARE SIX SPRINGS 3 UP and 3 DOWN 6 Use backplate to slide rotary seal next to backplate up the impeller shaft approximately 1 1 2 inches With the backplate resting on the impeller push the rotary seal toward the backplate until the O ring is free Remove the ...

Page 23: ... Figure 33 5 Loosen 2 set screws in the spring retainer and lift off rotating seal components rotary seal O ring washer spring retainer springs and washer There ARE SIX SPRINGS 3 UP and 3 DOWN 6 Use backplate to slide rotary seal next to backplate up the impeller shaft approximately 1 1 2 inches With the backplate resting on the impeller push the rotary seal toward the backplate until the O ring i...

Page 24: ...lush ports facing away from the backplate place seat retainer on housing and tighten in place with four 4 hex screws BE SURE TO TIGHTEN SCREWS EVENLY UNTIL FULL METAL TO METAL CONTACT IS MADE ON BACKPLATE AND SEAT RETAINER 7 Check impeller backplate clearance with the backplate held firmly in position against motor adapter the clearance between the backplate and impeller vanes should be 030 inch F...

Page 25: ...24 95 03009 MAINTENANCE SEE PAGE 34 MOTOR MOUNTS ELECTRIC MOTORS ...

Page 26: ...25 95 03009 MAINTENANCE SEE PAGE 34 MOTOR MOUNTS ELECTRIC MOTORS ...

Page 27: ...etric dimensions on the outer diameter of the impeller shaft to allow use of metric seal assemblies in areas where only metric seal replacements are available on short notice or where a larger system uses all metric seal materials in its operations WAUKESHA 200 SERIES CENTRIFUGAL PUMPS BASIC SEAL KIT TYPE 1 SEAL SANITARY INDUSTRIAL PUMP MODEL MODEL KIT CONTAINS QTY 2045 2065 2085 2105 CARBON SEAL ...

Page 28: ...00 5 172XA 2065LV SM BORE INDUSTRIAL 6 500 5 172X 2065LV SM BORE SANITARY 6 500 5 174XA 2065LV LG BORE INDUSTRIAL 6 500 5 176XA 2065 SM BORE INDUSTRIAL 6 500 5 176X 2065 SM BORE SANITARY 6 500 5 178XA 2065 LG BORE INDUSTRIAL 6 500 5 178X 2065 LG BORE SANITARY 6 500 5 180XA 2065HV SM BORE INDUSTRIAL 6 500 5 180X 2065HV SM BORE SANITARY 6 500 5 182XA 2065HV LG BORE INDUSTRIAL 6 500 5 182X 2065HV SM ...

Page 29: ...143JM 215JM 010 THK 35 2 143JM 215JM 020 THK 35 3 143JM 215JM PART NO MOTOR SHAFT SHIM QTY PER ASS Y MOTOR NEMA FRAME SIZE A S R E Q D 22 SEE PAGE 26 FOR ADDITIONAL METRIC INFORMATION To determine if you have a metric impeller measure the outside diameter of the impeller shaft 1 693 000 43mm 004 2 8 18 19 3 SEALS 16 22 9 22 1 6 7 11 10 9 5 4 10 9 5 10 6 7 11 8 2 5 TYPE 1 1C SINGLE SEAL includes 1 ...

Page 30: ...29 95 03009 AVAILABLE SEALS FOR 200 SERIES PARTS LISTS Figure 38 ...

Page 31: ...2 X 1 1 2 N P T FEMALE 301 58MX CASING 2 X 1 1 2 N P T MALE 301 58WX CASING 2 X 1 1 2 WELD 301 58QX CASING 2 X 1 1 2 Q CLAMP 2 5 80X IMPELLER 4 1 2 DIA 5 170X IMPELLER 114mm DIA 3 129 773X RETAINER IMPELLER Figure 39 PARTS LISTS 5 6 SEALS 1 11 3 2 9 10 4 7 8 12 Trimmed impellers are same part number specify diameter to 1 16 inch 1 59mm increments ITEM PART NO NAME 4 V70214 O RING VITON E70214 O RI...

Page 32: ...ASINGS 2065 COMPONENTS close coupled ITEM PART NO NAME 1 301 8KX CASING 2 1 2 X 2 S CLAMP MP 301 8BX CASING 2 1 2 X 2 BEVELED SEAT 301 8HX CASING 2 1 2 X 2 FEMALE l LINE 301 8JX CASING 2 1 2 X 2 MALE l LINE 301 8QX CASING 2 1 2 X 2 Q CLAMP 301 8WX CASING 2 1 2 X 2 WELD 301 8MX CASING 2 1 2 X 2 N P T MALE 301 8NX CASING 2 1 2 X 2 N P T FEMALE 301 8FX CASING 2 1 2 X 2 150 LB FLANGE 2 109260 IMPELLER...

Page 33: ... 64FX CASING 2 1 2 X 1 1 2 FLANGE 301 64WX CASING 2 1 2 X 1 1 2 WELD 301 64HX CASING 2 1 2 X 1 1 2 FEMALE l LINE 301 64JX CASING 2 1 2 X 1 1 2 MALE l LINE 301 64QX CASING 2 1 2 X 1 1 2 Q CLAMP 2 1 1 2 X IMPELLER 6 1 2 DIA 143 215JM MOTOR 1 1 2 X IMPELLER 165mm DIA 143 215JM MOTOR 5 160X IMPELLER 6 1 2 DIA 254JM AND LARGER MOTOR 5 174X IMPELLER 165mm DIA 254JM AND LARGER MOTOR Figure 41 5 6 SEALS 1...

Page 34: ...26 28 METRIC NOTES PAGE 34 INDUSTRIAL CASINGS 2085 COMPONENTS close coupled ITEM PART NO NAME 1 301 5BX CASING 3 X 2 1 2 BEVELED SEAT 301 5EX CASING 80mm X 65mm DIN 301 5FX CASING 3 X 2 1 2 FLANGE 301 5HX CASING 3 X 2 1 2 MALE I LINE 301 5JX CASING 3X 2 1 2 FEMALE I LINE 301 5KX CASING 3X2 1 2 CLAMP 301 5NX CASING 3 X 2 1 2 N P T FEMALE 301 5MX CASING 3X2 1 2 N P T MALE 301 5WX CASING 3 X 2 1 2 WE...

Page 35: ... 2 X 1 1 2 N P T MALE 301 18WX CASING 2 X 1 1 2 WELD 301 18QX CASING 2 X 1 1 2 Q CLAMP 2 1 1 2 X IMPELLER 8 1 2 DIA 143 215JM MOTOR 1 1 2 X IMPELLER 216mm 143 215JM MOTOR 1 1 2 X IMPELLER 8 1 2 DIA 254JM AND LARGER MOTOR 1 1 2 X IMPELLER 216mm 254JM AND LARGER MOTOR REFER TO 2085 FOR OTHER COMPONENTS MOTOR MOUNTS PART NO FRAME 1 2 3 4 5 A INCH 355 1 56 55 1 4 1 30 30 43 28 30 22 3 355 2 143 55 2 4...

Page 36: ... SEALS KITS PAGE 26 28 METRIC NOTES PAGE 34 INDUSTRIAL CASINGS 2105 COMPONENTS Close coupled ITEM PART NO NAME 1 301 28BX CASING 4 X 4 BEVELED SEAT 301 28EX CASING 100mm X 100mm DIN 301 28FX CASING 4 X 4 FLANGE 301 28HX CASING 4 X 4 FEMALE l LINE 301 28JX CASING 4 X 4 MALE l LINE 301 28KX CASING 4 X 4 S CLAMP 301 28NX CASING 4 X 4 N P T FEMALE 301 28MX CASING 4 X 4 N P T MALE 301 28WX CASING 4 X 4...

Page 37: ...1 2 150 LB FLANGE 301 7KXA 301 7BXA 301 7HXA 301 7JXA 301 7QXA 301 7WXA 301 7MXA 301 7NXA 301 7FXA 301 18KXA 301 18BXA 301 18HXA 301 18JXA 301 18QXA 301 18WXA 301 18MXA 301 18NXA 301 18FXA 301 5KXA 301 5BXA 301 5HXA 301 5JXA 301 5QXA 301 5WXA 301 5MXA 301 5NXA 301 5FXA U2085 3 X 2 1 2 INDUSTRIAL CASING 3 x 2 1 2 S CLAMP MP CASING 3 x 2 1 2 BEVELED SEAT CASING 3 x 2 1 2 FEMALE l LINE CASING 3 x 2 1...

Page 38: ...gements Stand epoxy coated cast iron stand pedestal stand attaches under motor adapter or bearing housing Base OPTIONAL epoxy coated channel base used in style B C arrangements See page 39 Figure 3 STYLE C Bearing housing and base with stand attached to bearing housing for use with foot mounted T frame motors Pump and motor are mounted and supported independently STYLE B Figure 2 Bearing housing m...

Page 39: ... 15HP 3500 RPM SM B SM B SM B SM B 20HP 1750 RPM LG B 20HP 3500 RPM SM B SM B SM B SM B 25HP 1750 RPM LG B 25HP 3500 RPM LG B LG B 30HP 1750 RPM LG B 30HP 3500 RPM LG B LG B 40HP 1750 RPM LG B 40HP 3500 RPM LG B 50HP 1750 RPM LG B 50HP 3500 RPM LG B 60HP 3500 RPM LG B 75HP 3500 RPM LG B NOTE SM B SMALL BORE LG B LARGE BORE LENGTH WIDTH 20 STYLE A Only 24 32 38 50 MOTOR HP RPM INSTALLATION BASE Bas...

Page 40: ...39 95 03009 THIS PAGE IS INTENTIONALLY LEFT BLANK INSTALLATION DIMENSIONS Style A 7 12 96 ...

Page 41: ...2 0 5 2 4 44 1 94 3 94 P2065HV 3 0 2 0 17 93 21 30 2 0 5 2 4 44 1 94 3 94 P2085LV 2 0 1 5 17 19 20 42 1 0 4 2 6 69 1 75 4 50 P2085 2 0 2 5 18 41 21 90 1 0 4 2 5 63 2 53 5 06 P2085 4 0 2 5 17 91 21 40 1 0 4 2 5 63 2 03 5 06 P2105 4 0 22 57 3 2 6 94 2 86 6 75 P2105 6 0 22 60 3 2 6 94 2 90 6 75 NOTE DIMENSIONS X Y B APPLY TO PUMPS WITH CLAMP CONNECTIONS 3 2 1 1 4 KEYWAY SM BORE 1 25 1 4 KEYWAY LG BOR...

Page 42: ...Remove the coupling covers cap screws Loosen the set screws on the pump coupling Figure 5 3 Style B Remove bolts from adapter and stand Remove housing and stand as a unit Style C Remove stand housing assembly than remove end cap See Figure 10 for end cap 3 Push the shaft and bearing assembly out of the housing from the impeller end Figure 7 4 Remove the retaining ring and press the bearings off th...

Page 43: ... above disassembly procedure with the added step of installing new O rings in the seal rings on Small Bore Units and Large Bore Units Figure 10 shows seal position at motor end Seals at pump end face inward TIGHTEN SETSCREWS WHEN INSTALLING OUTER SEAL ASSEMBLIES Figure 9 NOTE It is recommended that all rubber parts be replaced whenever a unit is dismantled for inspection or repair Lubricate with a...

Page 44: ...emoving socket head cap screws holding adapter to the back plate Figure 12 PUMP ASSEMBLY 1 Place shims backplate and impeller on the shaft assembly Hand tighten the impeller retainer bolt on the shaft 2 Check the space between the back of the impeller and the backplate with a feeler gage 030 nominal while holding the backplate tight against the bearing housing flange Any axial movement of the shaf...

Page 45: ...GS SPACERS Figure 18 Connect flushing fluid and flood seal Turn the shaft manually to be sure shaft rotates without the impeller hitting Figure 18 LUBRICATION Waukesha Series 200 Pedestal Pumps are lubricated with GOA Micro Plate 555 Lithium Complex Grease Use only NLGI grade 2 Lithium Complex thickened greases to replenish bearing grease supply Grease fittings in Figure 19 NOTE Mixing greases tha...

Page 46: ...ET SCREW 2 TO FASTEN SEAL ASSEMBLY TO SHAFT D CAP SCREW TO FASTEN CARTRIDGE SEAL TO ADAPTER JOHN CRANE CARTRIDGE SEAL TYPE 88 The following pictorial list of cartridge seals is provided to assist in identifying some of the seals provided with the Model 200 centrifugal pumps Use of these cartridges requires a cartridge seal adapter A typical installation layout is shown at the bottom of the page Se...

Page 47: ...29 25 24 30 19 23 32 33 34 14 27 28 29 23 22 26 20 23 32 33 34 14 1 17 6 7 9 18 16 15 14 13 11 9 7 6 17 13 21 5 3 2 4 14 1 17 6 7 9 18 PARTS LIST SMALL BORE ASSEMBLY 16 15 11 13 STYLE C SMALL BORE STYLE B SMALL BORE Figure 21 Figure 22 7 7 96 ...

Page 48: ...LL BORE ITEM STYLE MOTOR PART NO DESCRIPTION ITEM STYLE MOTOR PART NO DESCRIPTION 35 37 38 36 CARTRIDGE ADAPTER Figure 23 39 Page 26 36 pump components CARTRIDGE SEAL RECOMMENDED SPARE PARTS 4 18 97 27 B C 56 11 37 COUPLING HALF 625 W B C 143 11 101 COUPLING HALF 875 5S B C 145 11 101 COUPLING HALF 875 5S B C 182 11 102 COUPLING HALF 1 125 5S B C 184 11 102 COUPLING HALF 1 125 5S B C 213 11 103 CO...

Page 49: ...T LARGE BORE ASSEMBLY Figure 25 27 28 29 25 31 24 30 19 23 32 33 34 16 15 11 13 14 27 28 29 23 22 26 21 23 32 33 34 14 1 17 6 8 10 18 16 15 14 13 11 9 7 6 17 13 20 5 3 2 4 14 1 17 6 8 10 18 STYLE C LARGE BORE Figure 26 STYLE B LARGE BORE 7 12 96 ...

Page 50: ... LARGE BORE ITEM STYLE MOTOR PART NO DESCRIPTION ITEM STYLE MOTOR PART NO DESCRIPTION 25 B C 364TC 43 137 SPACER ADAPTER 364TC B C 365TC 43 137 SPACER ADAPTER 364TC 26 C ALL 23 97 END CAP HOUSING LB 27 B C 213 11 103 COUP HALF 1 375 6S B C 215 11 103 COUP HALF 1 375 5S B C 254 11 41 COUP HALF 1 625 7S B C 256 11 41 COUP HALF 1 625 7S B C 284 11 105 COUP HALF 1 875 7S B C 286 11 105 COUP HALF 1 875...

Page 51: ...se give the following information Invoice number and date Quantity Part Number from parts list Exact reason for return Your Distributor will provide a Return Goods Authorization Returns will not be accepted without advance authorization EQUIPMENT INFORMATION Any correspondence concerning pump will require the following information be documented PRODUCT NAME MODEL___________________________________...

Page 52: ...37 LBS 39 LBS 60 LBS 54 LBS 78 LBS 254 256JM 37 LBS 39 LBS 41 LBS 63 LBS 57 LBS 79 LBS 284 326JM 51 LBS 53 LBS 71 LBS 64 LBS 82 LBS WEIGHTS CENTRIFUGAL 200 SERIES PUMP AND PEDESTAL WEIGHTS ADD 5 LBS FOR PUMPS WITH DOUBLE SEAL BASE WEIGHT ADD TO PEDESTAL WEIGHT MOTOR SMALL BORE LARGE BORE 48 30 LBS 56 30 LBS 143 145T 31 LBS 182 184T 32 LBS 50 LBS 213 215T 33 LBS 50 LBS 254 256T 40 LBS 52 LBS 284 28...

Page 53: ...611 SUGAR CREEK ROAD DELAVAN Wl 53115 U S A CUSTOMER SERVICE TELEPHONE 1 800 252 5200 OR 262 728 1900 TOLL FREE TELEFAX 1 800 252 5012 OR 262 728 4904 Effective Date October 7 1999 95 03009 ...

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