Grundfos BMS hs Montageanleitung

BMS

BMS hs, BMS hp, BMST and BMSX

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

English (GB)

English (GB) Installation and operating instructions

Original installation and operating instructions

These installation and operating instructions describe Grundfos

BMS.

Sections 1-5 give the information necessary to be able to unpack,

install and start up the product in a safe way.

Sections 6-12 give important information about the product, as

well as information on service, fault finding and disposal of the

product.

CONTENTS

Page

1. General information

1.1 Hazard statements

The symbols and hazard statements below may appear in

Grundfos installation and operating instructions, safety

instructions and service instructions.

The hazard statements are structured in the following way:

1.2 Notes

The symbols and notes below may appear in Grundfos

installation and operating instructions, safety instructions and

service instructions.

1. General information 2

1.1 Hazard statements 2

1.2 Notes 2

2. Receiving the product 3

2.1 Transporting the product 3

2.2 Inspecting the product 3

3. Installing the product 3

3.1 Reading guide 3

3.2 Foundation 3

3.3 Mechanical installation 3

3.4 Electrical installation 9

4. Commissioning the product 11

4.1 Checking the power supply 11

4.2 BMS hs pump 12

4.3 BMS hp pump 13

4.4 BMST system 14

4.5 BMSX system 14

4.6 Low-pressure flow control 16

5. Handling and storing the product 17

6. Product introduction 17

6.1 Nameplate 17

6.2 Pumped liquids 17

6.3 Filtration 17

6.4 Flushing and salinity 17

7. Servicing the product 18

7.1 Motor bearings 18

7.2 Preventive maintenance 18

8. Starting up the product after standstill 19

8.1 Frequency of starts and stops 19

9. Taking the product out of operation 19

9.1 BMS hs pump 19

9.2 BMS hp pump 20

9.3 BMST system 20

9.4 BMSX system 21

9.5 Flushing 21

10. Fault finding the product 22

10.1 BMS hs and BMST 22

10.2 BMS hp 23

10.3 Pressure exchanger of BMSX 24

11. Technical data 25

12. Disposing of the product 25

Read this document before installing the product.

Installation and operation must comply with local

regulations and accepted codes of good practice.

DANGER

Indicates a hazardous situation which, if not avoided,

will result in death or serious personal injury.

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious personal injury.

CAUTION

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate personal injury.

SIGNAL WORD

Description of hazard

Consequence of ignoring the warning.

- Action to avoid the hazard.

Observe these instructions for explosion-proof

products.

A blue or grey circle with a white graphical symbol

indicates that an action must be taken.

A red or grey circle with a diagonal bar, possibly with

a black graphical symbol, indicates that an action

must not be taken or must be stopped.

If these instructions are not observed, it may result in

malfunction or damage to the equipment.

Tips and advice that make the work easier.

English (GB)

2. Receiving the product

2.1 Transporting the product

The pumps are supplied from the factory in proper packing in

which they must remain until installation.

2.2 Inspecting the product

1. Check that the pump has not been damaged during

transportation.

2. Check that the type designation corresponds to the order. See

the pump nameplate.

3. Compare the motor voltage and frequency details on the

motor and frequency converter nameplates with the power

supply available.

3. Installing the product

3.1 Reading guide

When installing the products, read the instructions in the table

below.

3.2 Foundation

Construct the foundation to safely support the booster system or

pump(s) under all conditions. The pump and motor must be

installed on the same level.

The foundation must be strong enough to support the weight of

both units.

3.2.1 Vibration damping

Use the vibration dampers supplied with the BMS hs pump.

3.3 Mechanical installation

3.3.1 BMS hs pump

The pump can be mounted directly on the floor or on a base

frame (accessory).

Fig. 1 BMS hs pump

Location

To ensure sufficient cooling of the motor, leave a free space of

minimum 100 mm behind the non-drive end of the motor.

Lifting and handling the motor

Use straps when lifting the motor, and lower it down slowly.

Fig. 2 Example of how to lift the motor

During delivery and storage, never preserve the

pumps with glycerine or similar liquids which are

aggressive to the pump materials.

System/

pump Step Action Section

BMS hs

1Mechanical

installation 3.3.1 BMS hs pump

2Electrical

installation 3.4.1 BMS hs pump

3 Commissioning 4.2 BMS hs pump

BMS hp

1Mechanical

installation 3.3.2 BMS hp pump

2Electrical

installation 3.4.2 BMS hp pump

3 Commissioning 4.3 BMS hp pump

BMST

1Mechanical

installation 3.3.3 BMST system

2Electrical

installation 3.4.3 BMST system

3 Commissioning 4.4 BMST system

BMSX

1Mechanical

installation 3.3.4 BMSX system

2Electrical

installation 3.4.4 BMSX system

3 Commissioning 4.5 BMSX system

TM05 9569 4113

WARNING

Falling objects

Death or serious personal injury

- Observe local regulations concerning limits for

manual lifting or handling.

- Use straps on the motor, and do not lift in the fan

guard.

- Make sure that the crane is suitable for the job.

Use certified and approved lifting equipment. See

nameplate.

TM05 9235 3613

If you do not follow these instructions, there is a risk

of warping or crushing some of the equipment such

as the terminal box, cover or drip cover.

English (GB)

Motor installation

The motor must be leveled. If there is a gap between the

foundation and the motor, use a spirit level, a feeler gauge and

shims to level the motor. Then secure the motor by means of

suitable screws depending on the foundation.

Direction of rotation

Connect the power supply and check the direction of rotation.

See section 3.4 Electrical installation. The direction of rotation

must correspond to the direction under normal operation. See the

installation and operating instructions for the motor.

Lifting and handling the bare shaft pump

Hoist the bare shaft pump into place, and lower it down slowly.

Fig. 3 How to lift the pump

In order to make the pump fit the motor flange, fit the pump

support foot delivered with the product. Lower the pump until the

support foot reaches the floor.

Assembling the motor and the pump

If necessary, you can change the position of the inlet pipe later.

See section Position of the inlet pipe.

Fig. 4 Position of drain holes

Alignment of the motor and the pump

Align the motor and pump before you tighten the screws. To

ensure correct installation, follow this procedure.

Use vibration dampers.

WARNING

Electric shock

Death or serious personal injury

- The electrical installation must be carried out by an

authorised person in accordance with local

regulations.

TM05 9236 3613

When assembling the pump and motor, make sure

the inlet pipe points upwards ( position 12 o'clock )

and the drain holes point downwards.

TM06 0964 1314

Inlet pipe

Drain holes

Step Description Picture

Fit all four screws

for motor and pump

connection.

Do not tighten the

screws yet.

TM05 9234 3613

Adjust the gap by

means of a feeler

gauge or similar

tool. Tighten one

screw by hand.

TM05 9232 3613

Adjust the gap 180 °

opposite the screw

you just tightened.

Do not tighten the

screw. Move the

pump to adjust the

gap.

TM05 9251 3613

Move the pump, and

adjust the gap by

means of the feeler

gauge. Tighten the

screw by hand. If

the inlet pipe has to

be turned, see

section Position of

the inlet pipe.

TM05 9345 3613

When the gap has

been adjusted,

cross-tighten all

screws to 33 Nm.

TM05 9346 3613

Fasten the support

foot to the

foundation.

TM05 9345 3613

The support foot must not impose any tension on the

pump.

English (GB)

Position of the inlet pipe

To change the position of the pipe, follow this procedure.

Flushing the system

Pipe connection

Both the inlet and the outlet pipes are fitted with clamp liners for

Victaulic couplings and must be supported close to the end of the

pipe.

Fig. 5 Pipe support

When fitting the Victaulic couplings, allow a gap of 3.5 mm

between the two pipes.

Fig. 6 Gap between pipes

Step Description Picture

1Loosen M10 and

M12 screws.

TM05 9347 3613

Mark up the pump

sleeve and union

nut.

TM05 9573 4013

Turn the inlet pipe

to the required

position, and make

sure the union nut

follows.

TM05 9343 3613

4 Check the marking.

TM05 9342 3613

Fit all screws

again. Tighten all

screws to 33 Nm.

TM05 9343 3613

Fasten the support

foot to the

foundation.

TM05 9345 3613

7Check the position

of the drain holes.

TM06 5336 4715

Drain holes

To avoid impurities in the pump, flush the pipes

before you connect the pump inlet and outlet pipes.

TM05 9230 3613

WARNING

Pressurised system

Death or serious personal injury

- Avoid stress in the pipe system.

TM05 9344 3613

3.5mm 3.5mm

3.5mm

Service connector

English (GB)

Service connector installation

In order to facilitate service of the pump and motor, install the

delivered service connector in the system.

1. Fit the two rubber parts.

2. Install the service connector.

Fig. 7 Position of rubber parts

3. Move the two rubber parts over the service connector.

Fig. 8 Position of service connector and rubber parts

4. Fit the Victaulic couplings and tighten the bolts to 33 Nm.

Fig. 9 Victaulic couplings

In case of a BMS hs pump, you are now ready for electrical

installation. See section 3.4.1 BMS hs pump.

In case of a BMST system, see section Lifting and handling the

BMT pump.

In case of a BMSX system, see section BMS hp pump

installation.

3.3.2 BMS hp pump

Fig. 10 BMS hp pump

Motor and pump installation

The pump and motor must be installed on the same level. If there

is a gap between the foundation and the motor or the pump, use a

spirit level, a feeler gauge and shims to level the motor. Then

secure the motor and the pump by means of suitable screws (4 x

M10) depending on the foundation.

Lifting and handling the pump

Hoist the pump into place.

Fig. 11 Example of how to lift the pump

TM05 9339 3613TM05 9340 3613TM05 9341 3613

TM06 1045 1414

We recommend that you use vibration dampers.

WARNING

Falling objects

Death or serious personal injury

- Observe local regulations concerning limits for

manual lifting or handling.

- Use straps for lifting the pump, and do not lift in the

fan guard.

- Use certified and approved lifting equipment. See

nameplate.

TM07 3141 4718

English (GB)

Position of the inlet pipe

To change the position of the pipe, follow this procedure.

Flushing the system

Pipe connection

Both the inlet and the outlet pipe are fitted with clamp liners for

Victaulic couplings and must be supported close to the end of the

pipe.

Fig. 12 Pipe support

When fitting the Victaulic couplings, allow a gap of 3.5 mm

between the two pipes.

Fig. 13 Gap between pipes

3.3.3 BMST system

A BMST system consists of a BMS hs as primary pump and a

BMT as secondary pump. The BMT pump is driven by the high-

pressure concentrate from the membrane and used as feed pump

for the primary BMS hs pump.

Fig. 14 BMST system

Fig. 15 BMT pump

BMS hs pump installation

See section 3.3.1 BMS hs pump.

Lifting and handling the BMT pump

1. Hoist the pump into place, and lower it down slowly.

2. Install and secure the pump.

3. Support the pump close to the turbine, using the bracket

behind the turbine housing.

4. Use a clamp or similar device at the other end. See the

example in fig. 14.

BMT pump installation

The BMT pump must be level. If there is a gap between the

foundation or frame and the BMT pump, use a spirit level, a feeler

gauge and shims to level the pump. Then secure the pump by

means of suitable screws depending on the foundation or frame.

Flushing the system

Pipe connection

See section Pipe connection of the BMS hs pump.

Step Description Picture

1Loosen all eight

bolts in the flange.

TM06 0962 1314

Turn the inlet pipe

to the required

position. Tighten all

screws to 33 Nm.

TM06 0963 1314

Check the position

of the drain holes,

they must point

downwards

TM06 5336 4715

To avoid impurities, flush the pipes before you

connect the pump inlet and outlet pipes.

TM06 0959 1214

WARNING

Pressurised system

Death or serious personal injury

- Avoid stress in the pipe system.

TM06 0960 1214

Drain holes

3.5mm

TM05 9334 3613TM05 9350 3613

Use vibration dampers.

To avoid impurities, flush the pipes before you

connect the pump inlet and outlet pipes.

English (GB)

BMT and BMS hs pump installation

The inlet and outlet pipes are fitted with clamp liners for Victaulic

couplings.

To ensure correct installation, follow this procedure.

The concentrate from the turbine must flow freely to a drain under

all operating conditions. The height above the water level in the

drain must be at least 300 mm. The tube from the turbine to the

drain must have the same diameter in its entire length. The drain

must be larger than the tube and open so that the concentrate, a

mixture of air and water (foam), can escape freely.

Fig. 16 Drain from Pelton turbine

3.3.4 BMSX system

A BMSX system consists of a BMS hs pump as high-pressure

pump and a BMS hp pump as booster pump. The pressure

exchanger of BMSX is installed in order to recover energy from

the high-pressure concentrate.

Fig. 17 BMSX system

BMS hs pump installation

See section 3.3.1 BMS hs pump.

BMS hp pump installation

See section 3.3.2 BMS hp pump.

Step Description Picture

The turbine is

driven by the high-

pressure

concentrate from

the membrane.

Connect the high-

pressure outlet to

the turbine inlet of

the BMT pump.

TM05 9334 3613

2Connect the BMT

pump inlet.

TM05 9375 3613

Connect the BMT

pump and the BMS

hs pump.

TM05 9336 3613

Connect the hose

(∅300) to the outlet

of the turbine

housing with a

strap.

Lead the hose to a

drain tank, drain

channel or a similar

drain.

Fit the end of the

hose above the

highest possible

water level in the

drain. The hose

must be supported.

TM05 9337 3613

TM05 9474 5107

The concentrate outlet must be free under all

operating conditions. If an outlet pipe is connected to

the concentrate outlet, this pipe must have an air

outlet.

TM05 9569 4113 - TM07 2946 4518

TM05 9571 4113 - TM06 1045 1414

Min. 300 mm

Min. 30°

English (GB)

Lifting and handling the pressure exchanger of BMSX

Fig. 18 Pressure exchanger of BMSX

Use suitable straps when lifting the unit. Carefully hoist the

pressure exchanger into place, and lower it down. Secure the

unit(s) to a frame, and ensure a stress-free installation.

Flushing the system

Pipe connection of the pressure exchanger

Low-pressure and high-pressure inlet and outlet pipes are fitted

with clamp liners for Victaulic couplings. See the pipe location on

the unit.

Both the inlet and the outlet pipes must be supported close to the

end of the pipes.

Fig. 19 Horizontal and vertical support of pipes

When fitting the Victaulic couplings, allow a gap of 3.5 mm

between the two pipes. See fig. 13.

3.4 Electrical installation

The electrical connection must be carried out by an authorised

electrician in accordance with local regulations and the wiring

diagrams for the motor protection, starter and monitoring devices

used. Make the electrical connections in the terminal box.

Wiring must be done according to the wiring diagram supplied

with the Grundfos product.

3.4.1 BMS hs pump

Mains and signal cables

See the quick guide or installation and operating instructions for

the drive or the motor.

In case of a BMS hs pump, you are now ready for commissioning.

See section 4.2 BMS hs pump.

Gr-1015354

WARNING

Falling objects

Death or serious personal injury

- Observe local regulations concerning limits for

manual lifting or handling.

- Make sure that the crane is suitable for the job.

Use certified and approved lifting equipment. See

nameplate.

To avoid internal damage, do not lift the pressure

exchanger by the ports or put undue strain on the

port fittings.

Thoroughly flush associated pipes with water filtered

to 5 microns before installing the PX unit. Foreign

material may cause damage.

TM05 9348 3613

WARNING

Pressurised system

Death or serious personal injury

- Avoid stress in the pipe system.

The PX unit must not be supported by its pipe fittings

nor must the PX unit be allowed to support pipes or

manifolds.

DANGER

Electric shock

Death or serious personal injury

- Connect the pump to an external mains switch

placed close to the pump and to a motor-protective

circuit breaker or a frequency converter.

- It must be possible to lock the mains switch in OFF

position (isolated). Type and requirements as

specified in EN 60204-1, 5.3.2.

- The pump must be earthed.

DANGER

Electric shock

Death or serious personal injury

- Before starting any work on the product, make

sure that the power supply has been switched off

and that it cannot be accidentally switched on.

English (GB)

PM motor

For the PM motor, see the cable sizing table below. This table is

given for reference only, and it must under no circumstances be

used instead of the current local standards.

Pn:Nominal power.

In: Nominal current.

ILM:Maximum continuous line current permitted in motor mode

(power drawn by the motor).

(1) The value of the rated current and the motor cable cross-

sections are given for reference only. As a reminder, the motor

rated current permitted varies according to the switching

frequency and the temperature.

(2) For 110 kW and higher power, there are two wires on each

phase, so six wires are used in total.

(3) 170M: Bussmann fuses.

(4) The power cable cross-sections are given for reference only

for a current corresponding to the value of the Ico current at 3

kHz, a maximum length of 50 m, output frequency less than

100 Hz and an ambient temperature of 40 °C. We recommend

screened multi-core power cables. See fig. 20. The values

supplied are typical values.

Fig. 20 Screened multi-core cable

(5) The PE conductor cross-section must be not less than half of

the associated phase conductor cross-section assuming that

the same material is used.

AC motor

For BMS systems supplied with AC motor, see recommendations

from VFD manufacturer.

Software

The Grundfos BMS hs pump is supplied with the required

software configuration file, if the VFD is supplied by Grundfos.

You can find the number of the software configuration file on the

small sticker placed below the control panel in the control cabinet

for the frequency converter.

See also the configuration reference guide supplied with the

product.

3.4.2 BMS hp pump

See the quick guide or installation and operating instructions

supplied with the product.

See the nameplate to identify the motor type and type of control

board.

Default settings for BMS hp motor:

• minimum speed: 1700 rpm

• maximum speed: 3600 rpm

• setpoint input: 4-20 mA

• relay: alarm.

3.4.3 BMST system

For electrical installation, see section 3.4.1 BMS hs pump.

3.4.4 BMSX system

For electrical installation, see sections 3.4.1 BMS hs pump and

3.4.2 BMS hp pump.

Product

number Power drive model

Mains supply Motor(1)

[kW]

ILM

[A] Recommended

fuse(3)

Cable cross

section

[mm2](2)(5)

[kW]

[A]

Cable cross

section

[mm2](2)(4)(5)

380-440 V 440-480 V

96943883 FC-202P45K IP55 380-480 V 45 90 80 gG-100 3 x 50 + PE 44 84.5 3 x 50 + PE

96943884 FC-202P55K IP55 380-480 V 55 106 105 gG-160 3 x 50 + PE 52 97.5 3 x 50 + PE

96943885 FC-202P75K IP55 380-480 V 75 146 130 aR-200 3 x 150 + PE 70 127.0 3 x 150 + PE

96943886 FC-202P90K IP55 380-480 V 90 177 160 aR-250 3 x 150 + PE 85 156.0 3 x 150 + PE

99292227 FC202P110K IP54 380-480 V 110 204 183 170M2620 6 x 95 + PE 100 183.0 6 x 95 + PE

99292229 FC202P160K IP54 380-480 V 160 304 291 170M4015 6 x 95 + PE 140 264.0 6 x 95 + PE

99292229 FC202P160K IP54 380-480 V 160 304 291 170M4015 6 x 95 + PE 160 316.0 6 x 95 + PE

99292230 FC202P200K IP54 380-480 V 200 381 348 170M4016 6 x 185+ PE 180 363.0 6 x 185 + PE

TM06 5337 4715

Do not change any settings without guidance from

Grundfos Service.

If not controlled by a 4-20 mA signal, the external

setpoint input must be disabled by the remote

control.

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