Grundfos LS 500-300-490E Bedienungsanleitung

Large LS models, flow range is greater than 3000 m3/h

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

English (GB)

Installation and operating instructions ..................................4

Table of contents

English (GB) Installation and operating instructions

Original installation and operating instructions

Table of contents

1. General information ............. 5

1.1 Hazard statements .............. 5

1.2 Notes ..................... 5

2. Delivery and handling ............ 6

2.1 Receiving ................... 6

2.2 Handling.................... 6

2.3 Temporary storage .............. 7

3. Mechanical installation ........... 8

3.1 Location .................... 8

3.2 Foundation .................. 8

3.3 Pump flexible installation and connection .. 9

4. Electrical installation ............10

4.1 Motors, general ................10

5. Piping .....................11

5.1 General precaution ..............11

5.2 Suction piping .................11

5.3 Discharge piping ...............12

5.4 Pressure gauges installation .........12

5.5 General information of shaft sealing .....12

5.6 Packing gland adjustment ..........12

5.7 Mechanical shaft seals ............13

5.8 Coupling alignment ..............13

5.9 Spacer coupling installation .........20

5.10 Installing coupling guard ...........23

6. Operation ...................25

6.1 Priming ....................25

6.2 Pre-start checklist ...............25

6.3 Motor rotation .................25

6.4 Starting the pump ...............25

6.5 Pump shutdown................26

6.6 Short duration shutdown ...........26

6.7 Extended period shutdown ..........26

7. Pump identification .............26

7.1 Nameplate...................26

8. Lubrication and maintenance .......27

8.1 Motor lubrication ...............27

8.2 Pump lubrication ...............27

8.3 Stuffing box packing shaft seal-water

lubrication ...................30

8.4 Packing maintenance .............30

9. Disassembly for maintenance .......30

10. Bearing, seal and packing

replacement .................30

10.1 Bearing replacement .............30

10.2 Mechanical shaft seal replacement .....31

10.3 Replacing the stuffing.............31

11. Disassembly and assembly of LS

pumps ....................32

11.1 Dismantling the pump.............32

11.2 Assembly of LS pumps ............33

12. Component inspection ...........33

13. Ordering parts ................33

14. Construction .................34

14.1 Structure type 1 ................34

14.2 Structure type 2 ................36

14.3 Structure type 3 ................38

14.4 Structure type 4 ................40

15. Fault finding the product ..........41

15.1 The pump delivers no liquid .........41

15.2 The pump does not deliver enough liquid ..41

15.3 The pump does not create enough

pressure ....................42

15.4 The pump loses liquid after running for a

short time ...................43

15.5 The pump consumes too much power ....43

15.6 The motor is overloaded ...........44

15.7 Vibrations ...................44

15.8 Cavitation noise ................45

15.9 The pump bearings are overheated .....45

15.10 The pump operates for a short time and

then stops ...................45

16. Disposing of the product ..........46

English (GB)

1. General information

Read this document before you install the

product. Installation and operation must

comply with local regulations and accepted

codes of good practice.

1.1 Hazard statements

The symbols and hazard statements below may

appear in Grundfos installation and operating

instructions, safety instructions and service

instructions.

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.

The hazard statements are structured in the following

way:

SIGNAL WORD

Description of the hazard

Consequence of ignoring the warning

• Action to avoid the hazard.

1.2 Notes

The symbols and notes below may appear in

Grundfos installation and operating instructions,

safety instructions and service instructions.

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. Delivery and handling

2.1 Receiving

• Check pumping unit for shortage and damage

immediately upon arrival. Pump accessories when

required are packaged in a separate container

and shipped with the unit.

• If equipment is damaged in transit, promptly report

this to the carrier's agent. Make complete

notations on the freight bill to speed satisfactory

adjustment by the carrier.

• Unload and handle the unit with a sling.

2.2 Handling

2.2.1 Pump and motor using common baseplate

DANGER

Overhead load

Death or serious personal injury

‐Do not lift unit by eye bolts on the

motor.

TM062206

Lifting pump with low-voltage motor

TM062207

Lifting pump with high-voltage motor

2.2.2 Separate baseplate for pump and motor

TM062208

Lifting separate pump with baseplate

TM062209

Lifting low-voltage motor with baseplate

English (GB)

TM062210

Lifting high-voltage motor with baseplate

2.3 Temporary storage

• If the pump is not to be installed and operated

soon after arrival, store it in a clean, dry area of

moderate ambient temperature.

• Rotate the shaft by hand periodically to coat

bearing with lubricant to prevent oxidation and

corrosion.

• If the pump is stored more than six months, it

must be checked and cleaned before it is put into

operation.

• Follow motor manufacturer's storage

recommendations where applicable.

English (GB)

3. Mechanical installation

All installations should be performed by personnel

experienced with the placement, connection, and

alignment of pump equipment. The following

instructions are general in nature, and may not deal

with the specifics of your installation. Read these

instructions thoroughly before installing and operating

your LS pump. Successful operation depends on

careful attention to the procedures described in this

manual. Keep this instruction manual handy for future

use.

3.1 Location

• Locate the LS pump as close to the suction supply

as possible. Use the shortest and most direct

suction piping practical. Refer to section Suction

piping.

• Locate the pump below system level wherever

possible. This will facilitate priming, assure a

steady liquid flow, and provide a positive suction

head.

• Make sure sufficient NPSH (Net Positive Suction

Head) is provided at the suction end by

considering the pump's location in relation to the

entire system.

The correct pump location can provide a

safety pump operation. Available NPSH

must always. 0.5 - 1.0 m higher than the

required NPSH specified on the pump

performance curve.

• Always allow sufficient accessibility for

maintenance and inspection. Provide a clear

space with ample head room for use of a hoist

strong enough to lift the unit.

• Make sure a suitable power source is available for

the pump motor. Electrical characteristics should

match those specified on the motor data plate.

• Avoid pump exposure to sub-zero temperatures to

prevent pump liquid form freezing. If freezing

conditions exist during shutdown periods, see

sections Short duration shutdown and Extended

period shutdown for specific recommendations.

Related information

5.2 Suction piping

6.6 Short duration shutdown

6.7 Extended period shutdown

3.2 Foundation

LS pumps should be permanently installed on a firm,

concrete foundation mounting pad of sufficient size

(over 200 mm) to dampen any vibration and prevent

any deflection or misalignment. The pad may float on

springs or be a raised part of the equipment room

floor. The foundation should be poured without

interruption to 18-35 mm below the final pump

elevation. The top surface should be well scored or

grooved before the concrete sets to provide a suitable

bonding surface for the grout. Anchor bolts should be

set in pipe sleeves for positioning allowance, as

shown in fig. Anchor bolt installation. Allow enough

bolt length for grout, lower base plate flange, nuts and

washers. Allow the foundation to cure several days

before proceeding with pump installation.

For pump and motor directly connected,

the foundation weight is 3-5 times of pump

unit; for pump and diesel engine directly

connected, the foundation weight is 5-8

times of pump unit.

TM078842

Anchor bolt installation

Pos. Description

1 Grout

2 Base plate

3 Finished grouting

4 Allowance for grout: 18-35 mm

5 Dam

6 Grout

7Top of foundation leave rough clean & wet

down

8 Wedges or shims left in place

9 10 mm

English (GB)

3.2.1 Securing the baseplate

• After the concrete pad has been poured and set,

lower the pump base plate over the anchor bolts

and rest it on loose adjustment wedges or shims

placed near each anchor bolt and at intervals not

to exceed 610 mm along each side.

• Shims or wedges must be placed to raise the

bottom of the base 20-30 mm above the pad,

allowing clearance for grout. Level the pump

shaft, flanges, and base plate using a spirit level,

adjusting the wedges or shims, as required.

• Check to make sure that the piping can be aligned

to the pump flanges without placing any strain on

either flange.

• After pump alignment has been established,

attach nuts on foundation bolts and tighten them

just enough to keep the unit base plate from

moving. Construct a form or dam around the

concrete pad and pour grout in and around the

pump base, as shown in section Foundation.

Grout compensates for uneven foundation,

distributes the weight of the unit, and prevents

shifting. Use an approved, non-shrinking grout.

Allow at least 24 hours for this grout to set before

proceeding with piping connections.

• After the grout has thoroughly hardened, check

the foundation bolts and tighten if necessary.

Recheck the pump alignment after the foundation

bolts are secured.

Related information

3.2 Foundation

3.3 Pump flexible installation and

connection

There are two methods for pump flexible installation:

• Using damper and soft connector.

• Using anti-vibration pad and soft connector.

3.3.1 Using damper and soft connector

In order to prevent the vibration transfer to the nearby

buildings, we suggest to use the damper to segregate

the pump base from nearby buildings. If the pump

installed on the damper base, soft connectors must

be installed to the inlet and outlet pipe, it is propitious

to the pump's operation.

TM061441

Base with damper and soft connector

Pos. Description

1 Damper base

2 Pipe support

3 Damper

4 Outlet

5 Inlet

6 Soft connector

Do not install the pump base plate on the

damper directly.

The selection and installation of damper

and damper base should follow the

supplier.

English (GB)

3.3.2 Using anti-vibration pad and soft connector.

Another way is to use the anti-vibration pad to

segregate the pump base from nearby buildings (see

fig. Pump with anti-vibration pad), and soft connectors

must be also installed to the inlet and outlet pipe. It is

easy to connect, but the effect is not as good as using

damper.

TM061442

Pump with anti-vibration pad

Pos. Description

1 Pipe support

2 Outlet

3 Inlet

4 Soft connector

5 Anti-vibration pad

4. Electrical installation

4.1 Motors, general

• All electrical installations should be accomplished

by qualified electrician. Disconnect and lock out

the electrical power source, before starting any

installation or service work.

• Read and match the starting and overload control

devices with motor nameplate information. Always

follow control manufacturer's instructions for

proper installation and connection.

• Grease lubricated motors are fully lubricated at

the time of manufacture and do not require further

lubrication if prompt installation follows. If the

motor has been in storage for six months or

longer, refer to section Motor lubrication and

lubricate the motor before starting.

Related information

8.1 Motor lubrication

English (GB)

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