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Document

No.

–

A1540

Date

–

January

2014

Revision

–

Uncontrolled

Copy

2.2 General

Safety

Precautions

WARNING!

NEVER APPLY HEAT TO REMOVE THE IMPELLER!

WARNING!

NEVER USE HEAT TO DISASSEMBLE PUMP COMPONENTS!

WARNING!

ALWAYS LOCK OUT POWER TO THE ELECTRIC MOTOR BEFORE
PERFORMANING ANY MAINTENANCE!

WARNING!

NEVER MOVE PUMP WITHOUT PROPER MECHANICAL ASSISTANCE!

WARNING!

FLANGED CONNECTIONS – USE CORRECT FASTENER SIZE AND
MATERIAL!

WARNING!

ENSURE ALL FASTENERS ARE TIGHTENED TO SPECIFIED TORQUE!

WARNING!

ENSURE PROPER PERSONAL PROTECTION EQUIPMENT IS WORN
AT ALL TIMES!

WARNING!

PUMP PARTS MAY HAVE BEEN USED IN THE TRANSPORT OF
HARMFUL AND DANGEROUS CHEMICALS!

WARNING!

WORN PUMP PARTS MAY HAVE SHARP EDGES!

WARNING!

DAMAGED PUMP PARTS SHOULD BE REPLACED TO ENSURE SAFE
AND PROPER PERFORMANCE OF THE PUMP!

CAUTION!

OPERATING THE PUMP WITHOUT CLEANING OUT THE SUMP PRIOR
TO INSTALLATION MAY CAUSE DAMAGE TO THE PUMP ASSEMBLY!

CAUTION!

ALWAYS CALCULATE THE SLURRY SYSTEM OPERATING POINT
PRIOR TO PURCHASING OR INSTALLING A PUMP!

CAUTION!

NEVER STOP THE PUMP WHILE SOLIDS ARE IN THE DISHCARGE
PIPE!

CAUTION!

ENSURE MOISTURE SENSOR RELAY IS PROPERLY INSTALLED AND
OPERATIONAL!

CAUTION!

ENSURE MOTOR OVER TEMPERATURE PROTECT SYSTEM IS
PROPERLY INSTALLED AND OPERATIONAL!

For electric submersible motor General Safety Precautions refer to:

Baldor® - Reliance® AC Submersible Motors

Installation & Operation Manual, MN414

Section 1 General Information

Содержание Vulcan Pumps HDS 100L

Страница 1: ...Document No A1540 Installation Operation and Maintenance Manual HDS Submersible Pumps Agitator ...

Страница 2: ...ump We take pride in every product we build To insure that you receive the highest quality product we have enclosed a quality assurance checklist signed by the Assembler and Shop Foreman For information regarding installation and maintenance please refer to the Operation and Instruction Manual or contact your local distributor Thanks Again Malcolm Morrow ...

Страница 3: ... Mat l RPM Enclosure Ph Hz V Seal Type ADDITIONAL CHECKS Note or check the following information Impeller Trim Impeller Diameter Impeller Balance Impeller Clearance Flanges Covered Painting Discharge Size INSTALLATION OPERATION MANUALS Confirm the following manuals are included with shipment Pump Motor Shop Check By Date__________________ SHIPPING Boxes Secure Proper Skidding Shipping Check By Dat...

Страница 4: ......

Страница 5: ...e Title Date Malcolm Morrow M M President 23 January 2014 Revisions History Revision No Signature Date of Change Change Summary 0 RJ R 23 January 2014 Initial Release Contact Vulcan Pumps LLC 7450 Cahaba Valley Road Birmingham AL 35242 Ph 1 800 624 7069 F ax 1 205 995 9603 www vulcanpumps com ...

Страница 6: ... 4 2 Pump Start Up 16 4 3 Pump Shut Down 17 5 0 Maintenance 18 5 1 Maintenance Safety 18 5 2 Preventative Maintenance 19 5 3 Maintenance Tools and Equipment 19 5 4 Wet End Component Installation 20 5 5 Wet End Component Disassembly 25 5 6 Fastener Assembly Torque Assembly Pre Load 29 6 0 Trouble Shooting 30 6 1 Fault Tracing 30 7 0 Pump Data 32 7 1 HDS Cross Section Bill of Materials 32 7 2 HDS Ge...

Страница 7: ...tive if you have any questions related to the instructions and procedures within this manual 1 2 Transportation Storage WARNING 1 2 1 Transportation The pump is required to be transported in a vertical position in the normal operating orientation The standard shipping packaging is comprised of the pump support stand secured to an open pallet with the pump and motor and motor cables wrapped in shri...

Страница 8: ...embled cleaned and inspected for wear and damage All originally painted parts should be touched up or repainted Pump should be reassembled and stored in an upright position WARNING Pumps must be stored in a long term storage crate Pumps must be stored in a dry environment at temperatures ranging from 10 C 50 F to 49 C 120 F relative humidity must not exceed 60 Minimum winding resistance 5 Meg ohms...

Страница 9: ...l Information 1 4 Warranties Seller warrants that the products covered by this contract conform to applicable drawings and specifications accepted in writing by Seller will be free from defects in material and workmanship will be merchantable and will perform in accordance with the detailed specifications accepted in writing by Seller These warranties extend for a period of twelve 12 months from t...

Страница 10: ...re to connect the thermal overload protection wiring will operate to void all warranties We reserve the right to change the design construction or material of any part without incurring the obligation of installing such changes on pumps already delivered 2 0 Safety Installation and Operational safety is the upmost importance in the design and operation of our pumps It is imperative that the equipm...

Страница 11: ... 1 1 Vulcan Pump Safety Definitions WARNING CAUTION ELECTRICAL 2 1 2 Baldor Reliance Electric Submersible Motor Safety Definitions For electric submersible motor safety definitions refer to Baldor Reliance AC Submersible Motors Installation Operation Manual MN414 Section 1 General Information IF IGNORED COULD LEAD TO SERIOUS INJURY OR DEATH IF IGNORED COULD LEAD TO SERIOUS DAMAGE TO THE PUMP OR AS...

Страница 12: ...ANSPORT OF HARMFUL AND DANGEROUS CHEMICALS WARNING WORN PUMP PARTS MAY HAVE SHARP EDGES WARNING DAMAGED PUMP PARTS SHOULD BE REPLACED TO ENSURE SAFE AND PROPER PERFORMANCE OF THE PUMP CAUTION OPERATING THE PUMP WITHOUT CLEANING OUT THE SUMP PRIOR TO INSTALLATION MAY CAUSE DAMAGE TO THE PUMP ASSEMBLY CAUTION ALWAYS CALCULATE THE SLURRY SYSTEM OPERATING POINT PRIOR TO PURCHASING OR INSTALLING A PUMP...

Страница 13: ...fting The HDS Submersible pumps are equipped with integral lifting lugs designed to support weight of the pump assembly for pump installation and removal The weight of the pump is listed on the pump data sheet in section 7 4 and also located on the pump nameplate Ensure that the lifting capacity of the rigging and lifting equipment is rated to lift the weight of the pump assembly For lifting metho...

Страница 14: ... pump is operating and the motor is drawing amps for more than 15 minutes below the minimum water level then a water jacket is required to cool the submersible motor to prevent the motor from overheating and possibly damaging the electric motor windings Cooling water Supply Water Supply Clean mill duty water free from sand and grit Water Supply Flow Rate 5 10 USGPM 1 14 2 27 M3 hr Maximum Water Su...

Страница 15: ...Relay Vulcan Pumps electric submersible motors come equipped with two moisture sensor probes in the oil chamber Vulcan Pumps requires the installation and operation of an approved moisture sensor relay to qualify for motor warranty Suitable Moisture Sensor Relay Brands and Models Brand Model WARRICK 2810 AMETEK 8040 PUMP SAVER 460 15 100 SLD CAUTION For moisture sensor protection information refer...

Страница 16: ...on Operation Manual MN414 Section 2 Installation Operation 3 4 3 Optional Ground Fault Ground Check Monitoring Vulcan Pumps offers customers the option of ground fault ground check monitoring equipment to comply with regional and industry specific electrical standards The equipment continuously monitors the integrity of the ground wire to protect portable equipment from hazardous voltages caused b...

Страница 17: ...1 P2 W1 RED W2 ORANGE P1 BLACK P2 WHITE GR CONTROL GREEN GR1 GREEN L2 WHITE L1 BLACK L3 RED MOISTURE SENSORS 1 2 SUBMERSIBLE MOTOR HOUSING SHD POWER CABLE SHD CONTROL CABLE THERMOSTATS 1 2 TEMPERATURE DETECTOR OPTIONS STANDARD TWO NORMALLY CLOSED THERMOSTATS OPTION 1 3 THERMISTORS OPTION 2 6 THERMISTORS OPTION 3 6 RTD S ...

Страница 18: ...OTOR T2 T1 T3 P1 P2 W1 RED W2 ORANGE P1 BLACK P2 WHITE GR CONTROL GREEN GR1 GREEN L2 WHITE L1 BLACK L3 RED MOISTURE SENSORS 1 2 SUBMERSIBLE MOTOR HOUSING SHD POWER CABLE SHD CONTROL CABLE THERMOSTATS 1 2 TEMPERATURE DETECTOR OPTIONS STANDARD TWO NORMALLY CLOSED THERMOSTATS OPTION 1 3 THERMISTORS OPTION 2 6 THERMISTORS OPTION 3 6 RTD S DIODE ...

Страница 19: ...construction debris and foreign objects have been removed from the sump Discharge Valve If possible ensure that the discharge valve is closed prior to start up Once the pump is running open the discharge valve 4 2 Pump Start Up It is recommended to commission your Vulcan Pump starting with a clean sump using clean mill water as the medium In cases where there is solids build up in the sump it is r...

Страница 20: ...Cold Temperature Applications If the pump is removed from the sump when it is not being used ensure the following 1 Drain all of the liquid from the wet end components water jacket jet ring and piping Water expands when it freezes and can cause damage to equipment 2 The oil in the motor seal cavity can thicken during standby and some of the elastomers must not be operated in cold temperatures Ensu...

Страница 21: ...d industry specific health and safety standards We recommend the following procedures as a minimum Follow MSDS and Internal Company Documentation for solids liquid mixture safe handling procedures Always wear appropriate personal protection equipment before starting work Flush the pump and parts with a non reactive safe liquid before disassembly Once flushed dismantle the pump parts and clean with...

Страница 22: ...l inspection The motors seal leak detection moisture sensor system protects the motor from damage to the motor components If the Inboard Mechanical Seal fails the moisture sensor system detects the failure and shuts down the pump The motor thermostats protect the motor from damage to the motor components due to overheating If the thermostats detect a high temperature the pump will shut down 5 3 Ma...

Страница 23: ...un Dry Slurry Seal Only Pack the motor lip seal with Teflon Grease Install the Motor Deflector onto the shaft ensure a 0 02 0 5mm gap between the seal chamber cover plate and Motor Deflector Tighten set screws Install the Deflector Gasket 073 2 Install the Impeller Deflector 040 onto the shaft Align the Impeller Deflector with the motor shaft key seat ...

Страница 24: ...rs 901 4 over the Socket Head Cap Screws 901 1 apply Anti Seize thread into the Casing and tighten to specified torque CASINGS REQUIRE THE ASSISTANCE OF LIFTING EQUIPMENT HDS Models 150M 200M Lift the Motor Side Liner 011 into position Insert Lock Washers 901 4 over the Socket Head Cap Screws 901 1 apply Anti Seize thread into the Motor Side Liner and tighten to specified torque MOTOR SIDE LINERS ...

Страница 25: ...t Lock Washers 901 4 over the Socket Head Cap Screws 901 1 apply Anti Seize thread into the Casing and tighten to specified torque CASINGS REQUIRE THE ASSISTANCE OF LIFTING EQUIPMENT Install the Impeller 200 by sliding onto the motor shaft Install the O Rings 104 2 104 3 onto the Shaft Adapter 071 Install the Shaft Adapter into the impeller bore lining up the slot in the Shaft Adapter face with th...

Страница 26: ...ecified torque Impeller Blocking The Impeller 200 will have to be blocked when the Impeller Bolt Fastener 901 3 is being tightened A piece of wood can be used as a wedge between the casing and impeller Apply Anti Seize to the Shaft Adapter 071 Thread the Shaft Extension 258 onto the Shaft Adapter and tighten Install the Washer 901 7 onto shaft extension spigot followed by the O Ring 104 4 The Impe...

Страница 27: ...ver Install the Pump Stand 233 by aligning the mounting holes Insert Lock Washers 901 4 over the Socket Head Cap Screws 901 2 Anti Seize thread into the Casing and tighten to specified torque Align the Suction Screen 209 mounting holes with the Suction Cover 009 Apply Anti Seize to the Countersunk Head Cap Screws 901 6 and thread into the Suction Cover Apply Anti Seize to the Shaft Extension 258 t...

Страница 28: ...gitator 260 Use a box wrench on the Agitator Flats and one on the Shaft Extension Flats Remove the Countersunk Head Cap Screws 901 6 and Suction Screen 209 Remove Socket Head Cap Screws 901 2 Lock Washers 901 4 and Pump Stand 233 Remove the Suction Cover 009 and Suction Gaskets 073 3 DAMAGED PUMP PARTS SHOULD BE REPLACED TO ENSURE SAFE AND PROPER PERFORMANCE OF THE PUMP ...

Страница 29: ...tation while removing the Shaft Extension DO NOT REUSE LOCK WASHER O RINGS Remove the Impeller Bolt Fastener 901 3 and O Rings 104 1 The Impeller will have to be Blocked to prevent rotation while removing the Impeller Bolt Fastener DO NOT REUSE IMPELLER BOLT Remove the Impeller 200 by sliding off the motor shaft Remove the Shaft Adapter and O Rings 104 2 104 3 DO NOT REUSE O RINGS ...

Страница 30: ...5L 100L 150L 75M 100M 200L Remove Socket Head Cap Screws 901 1 and Lock Washers 901 4 and remove the Casing 100 CASINGS REQUIRE THE ASSISTANCE OF LIFTING EQUIPMENT HDS Models 150M 200M Remove the Socket Head Cap Screws 901 1 Lock Washers 901 4 and Motor Side Liner 011 Remove the Casing O Ring 104 5 MOTOR SIDE LINERS REQUIRE THE ASSISTANCE OF LIFTING EQUIPMENT DO NOT REUSE O RING Remove the Impelle...

Страница 31: ...sket 073 2 DO NOT REUSE THE DEFLECTOR GASKET Remove the Drive Key 032 from the key seat DO NOT REUSE THE DRIVE KEY Remove the Impeller Deflector 040 from the motor shaft Motor Models Run Dry Slurry Seal Only Remove the Motor Deflector from the motor Shaft DO NOT REUSE THE MOTOR DEFLECTOR V RING ...

Страница 32: ...ad Size Class Tightening Torque Assembly Pre Load lb ft lb in Nm lbf kN M4 316SS A4 70 1 7 20 2 3 612 2 7 M5 3 4 41 4 6 1002 4 5 M6 5 8 69 7 9 1415 6 3 M8 13 3 18 2600 11 6 M10 26 5 36 4126 18 4 M12 45 7 62 6033 26 9 M16 111 150 11415 50 8 M20 221 300 18389 81 8 Torque Pre Load Values are based on a 0 08 Coefficient of Friction Anti Seize Lubricant ...

Страница 33: ...agram must be used For the electric submersible motor installation operation and maintenance refer to Baldor Reliance AC Submersible Motors Installation Operation Manual MN414 6 1 1 Pump Does Not Start WARNING Is there Power to the Motor Check Main Input Power Control Equipment Power The Main Switch is in the OFFposition Main Fuses Each Phase Voltage Overload Reset Open Circuits Ground Circuit Yes...

Страница 34: ...otor overload cut out setting Solids Liquid Concentration Pump is jammed with debris Check for uneven voltage and amperage on each phase Has the discharge pipe size route or length changed Check Operating Condition System Head Calculation No Yes Check Discharge Piping System Leaks Discharge Valves are fully open and not clogged Solids Liquid Concentration Pump Rotation Pump intake is clogged with ...

Страница 35: ... 2 HDS 50L A 210TYS A1416 7 2 3 HDS 75L A 180TY A1417 7 2 4 HDS 75L A 210TYS A1418 7 2 5 HDS 100L A 180TY A1419 7 2 6 HDS 100L A 210TYS A1420 7 2 7 HDS 150L A 250TY A1421 7 2 8 HDS 150L A 320TYS A1422 7 2 9 HDS 200L A 320TY A1423 7 2 10 HDS 200L A 360TYS A1424 7 2 11 HDS 200L A L360TYS A1425 7 2 12 HDS 75M A 250TY A1430 7 2 13 HDS 75M A 320TYS A1431 7 2 14 HDS 100M A 250TY A1432 7 2 15 HDS 100M A ...

Страница 36: ...M A1274 7 3 14 HDS 150M A 1200 RPM A1277 7 3 15 HDS 150M A 900 RPM A1280 7 3 16 HDS 200M A 1200 RPM A1283 7 4 Pump Data Sheet Name Plate 8 0 Electric Submersible Motor Maintenance WARNING It is required that all electric submersible motor maintenance work should be performed by a Certified Baldor Reliance repair facility For electric submersible motor maintenance refer to Baldor Reliance AC Submer...

Страница 37: ...BER VOLUME GPM IMP TRIM HEAD HP SPEED HZ PHASE INSULATION CLASS V VOLTAGE CURRENT SERVICE FACTOR NET WEIGHT BALDOR RELIANCE INDUSTRIAL MOTOR CAT NO HP AMPS D E BRG O D E BRG SPEC NO VOLTS DESIGN SF AMB HZ DUTY PH TYPE ENCL CODE INSUL CLASS POWER FACTOR MAX CORR KVAR NEMA NOM EFFICIENCY GUARANTEED EFFICIENCY MOTOR WEIGHT SER NO LBS C NEMA NOM CSA QUOTED EFF 100 LOAD SUB IN WATER ONLY 15 MIN IN AIR ...

Страница 38: ...AC Submersible Pump Motors Installation Operating Manual 4 09 MN414 ...

Страница 39: ...Any trademarks used in this manual are the property of their respective owners ...

Страница 40: ...f Contents i MN414 Section 1 General Information 1 1 Overview 1 1 Limited Warranty 1 1 Safety Notice 1 1 Receiving 1 2 Handling 1 2 Section 2 Installation Operation 2 1 Overview 2 1 Installation 2 2 Grounding 2 3 Operation 2 6 ...

Страница 41: ...Section 1 General Information ii Table of Contents MN414 ...

Страница 42: ...ff Verify that the controller is incapable of delivering hazardous voltages and that the voltage at the motor leads is zero before proceeding Failure to observe this precaution may result in severe bodily injury or death WARNING Do not touch electrical connections before you first ensure that power has been disconnected Electrical shock can cause serious or fatal injury Only qualified personnel sh...

Страница 43: ...e rating plate Caution If a HI POT test High Potential Insulation test must be performed follow the precautions and procedure in NEMA MG1 and MG2 standards to avoid equipment damage Caution Never raise or lower the motor pump by the power cords Use lifting eyes provided in the motor casting opposite drive end and attache a cord cable to lift the weight of the motor and pump Failure to lift this mo...

Страница 44: ... deenergize the motor However proper consideration of the application will prevent such an overload Caution Lift using Lift Eyes only Lifting by power cords will cause motor damage Use spreader bar to evenly distribute lift force Angle of lift rope no spreader bar should not exceed 45 from vertical excessive lift angle can damage motor Figure 2 1 Spreader Bar Preferred Lift Method Lift Eye Pump Mo...

Страница 45: ...r Installation Procedure To prevent damage to the motor do not use force to drive pump on drive impeller onto motor shaft or to remove pump from motor shaft 1 Turn off and lockout all power and verify the voltage at the motor starter connectors are zero 2 Connect the motor power leads to the connectors in the motor starter See Grounding Note The motor lead cable assembly for all Submersible Pump M...

Страница 46: ...to a false sense of security Select a motor starter and over current protection suitable for this motor and its application Consult motor starter application data as well as the National Electric Code and or other applicable local codes Adjustable Frequency Power Inverters used to supply adjustable frequency power to induction motors produce wave forms with lower order harmonics with voltage spike...

Страница 47: ...ormandy Ct Royal Oak MI 48073 810 549 4900 The leakage detector control system must be connected for the warranty and the U L listing to be valid For information on the relay see www gemssensors com look for Model 2800 2810 relay It s circuit diagram is shown in Figure 2 3 Figure 2 3 Moisture Sensing Circuit 1 2 3 4 6 5 7 8 9 10 RE Motor W1 W2 Moisture Sensors Test Resistor Test Switch Test Lamp A...

Страница 48: ... terminals 9 and 10 of the 2800 XXX control Control leads should not be installed in the same conduit as power leads Induced voltage can cause false moisture signals Contact Operation Normally open load contacts close and normally closed load contacts open when the sensor probes detect the influx of moisture within the motor Test Procedure A normally closed pushbutton and neon indicating lamp are ...

Страница 49: ...operation may stop for one of the following trip conditions 1 If moisture infiltrates the motor the moisture detector circuit will activate 2 If the motor overheats the Thermal Protection circuit will activate 3 Other condition detected by motor starter over current overvoltage etc if equipped Unbalanced voltage or single phase operation of poly phase motor may cause excessive heating and ultimate...

Страница 50: ...Baldor District Offices ...

Страница 51: ... 2009 Baldor Electric Company MN414 All rights reserved Printed in USA 4 09 BALDOR ELECTRIC COMPANY World Headquarters P O Box 2400 Fort Smith AR 72901 2400 479 646 4711 Fax 479 648 5792 www baldor com ...

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