Grundfos LSV Series Bedienungsanleitung

LSV

Single-stage vertical split case pump and double-stage vertical split case pump

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

Table of contents

LSV

English (GB)

Installation and operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Deutsch (DE)

Montage- und Betriebsanleitung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

English (GB)

English (GB) Installation and operating instructions

Original installation and operating instructions

These installation and operating instructions

describe LSV.

Sections 1-4 give the information necessary to be

able to unpack, install and start up the product in a

safe way.

Sections 5-10 give important information about the

product, as well as information on service, fault

finding and disposal of the product.

CONTENTS

Page

1. General information

Grundfos LSV vertical split-case pumps are supplied

either as a complete pump with motor, base frame

and approved coupling guard or as a bare-shaft

pump.

These instructions apply to both types.

The LSV pump can be driven by an electric motor or

another type of driver. In the following we assume

that the pump is driven by an electric motor.

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. General information 3

1.1 Hazard statements 3

1.2 Notes 4

2. Receiving the product 4

2.1 Inspecting the product 4

2.2 Temporary storage 4

3. Installing the product 4

3.1 Location 4

3.2 Mechanical installation 4

3.3 Electrical connection 8

3.4 Pipes 9

3.5 Inlet pipe guidelines 11

4. Starting up the product 13

4.1 General information 13

4.2 Prestart checks 13

4.3 Priming 14

4.4 Startup 14

4.5 Alignment 15

5. Product introduction 16

5.1 Applications 16

5.2 Pumped liquids 16

5.3 Identification 17

6. Servicing the product 20

6.1 Contaminated pumps 20

6.2 Operating checks 20

6.3 Maintaining the product 20

7. Taking the product out of operation 22

7.1 Short-term shutdown 22

7.2 Long-term shutdown 22

8. Fault finding the product 23

9. Technical data 26

9.1 Operating conditions 26

9.2 Flange forces and torques 27

10. Disposing of the product 28

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.

English (GB)

1.2 Notes

The symbols and notes below may appear in

Grundfos installation and operating instructions,

safety instructions and service instructions.

2. Receiving the product

2.1 Inspecting the product

The pump is delivered from the factory in a crate or a

wooden box specially designed for transport by a

forklift truck or a similar vehicle.

Upon receipt, check the pump visually to determine

whether any damage has happened to it during

transport or handling.

Check especially for these points:

1. broken or cracked equipment, including base

frame, motor or pump feet and flanges

2. broken motor fan cover, bent eyebolts or

damaged terminal box

3. missing parts.

Parts or accessories are sometimes wrapped

individually or fastened to the equipment.

If any damage or losses have occurred, notify

Grundfos' representative and the carrier's agent at

once.

2.2 Temporary storage

If you do not install or operate the pump soon after

arrival, store it in a clean, dry place with slow,

moderate changes in ambient temperature. Protect

the pump from moisture, dust, dirt and foreign

bodies. Avoid exposing the motor to direct, intense

sunlight, rain, snow, ice and also dust for an

extended period of time. Attach a covering structure

or an additional cover when using or storing the

product outdoors. Follow these precautions before

and during storage:

1. Make sure that the bearings are filled with the

recommended grease to prevent moisture from

entering around the shaft. See section

6.3.3 Lubrication.

2. Make sure that the inlet and outlet ports and all

other openings are covered with cardboard,

wood or masking tape to prevent foreign objects

from entering the pump.

3. Cover the unit with a tarpaulin or other suitable

covering if it is to be stored without a protective

covering.

4. Rotate the shaft two turns every two weeks to

prevent corrosion of the bearing surfaces and the

stuffing box or sticking of the shaft-seal faces.

3. Installing the product

3.1 Location

Install the pump with accessibility for inspection and

maintenance. Allow ample space and headroom for

the use of an overhead crane or hoist sufficiently

strong to lift the unit.

Install the pump as close as possible to the pump

liquid supply, so that the inlet pipe is as short and

direct as possible.

3.2 Mechanical installation

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.

Bolts for LSV bare-shaft pumps have US

threads for which inch tools are required.

Bolts for coupling guard and for mounting

of pump and motor on the base frame

have metric threads.

WARNING

Crushing hazard

Death or serious personal injury

- Make sure that all installations are

performed by persons experienced in

the placement, alignment and

connection of pumping equipment.

English (GB)

3.2.1 Lifting the product

Lift the pump by means of nylon straps and shackles.

Fig. 1 How to lift and handle the LSV pumps

Fig. 2 How to lift and handle the LSV

bare-shaft pumps by means of a U-type

unbuckle

Fig. 3 How to lift and handle the LSV

bare-shaft pumps by means of the pump

flange

WARNING

Crushing hazard

Death or serious personal injury

- Handling must be performed by

qualified persons.

- When unloading the pump, lift equally at

four or more points on the base frame.

Do not lift by the motor or by the pump.

Do not lift by the flanges or by the

eyebolts on the motor.

TM07 3980 0519

TM07 3981 0519TM07 3976 0519

English (GB)

Fig. 4 How to lift and handle the LSV

bare-shaft pumps by means of the pump

flange and hanging ear

Fig. 5 Lifting the motor

3.2.2 Foundation

We recommend that you install the pump on a

concrete foundation, which is heavy enough to

provide permanent and rigid support for the entire

pump. The foundation must be capable of absorbing

any vibration, normal strain or shock. We

recommend that the weight of the concrete

foundation is 3 times the weight of the complete

pump unit. For specific requirements, consult the

contractor, engineer or established industry

standards.

In installations where silent operation is particularly

important, we recommend a foundation that is up to

5 times as heavy as the complete pump unit.

3.2.3 Vibration dampers

Vibration dampers may be required to prevent pump

vibrations from being transmitted to the building or

the pipes. In order to select the right type of vibration

damper, you need this information:

• Forces transmitted through the damper.

• Motor speed. Take the motor speed into account

in case of speed control.

• Desired dampening in percentage. The

recommended value is 70 %.

The choice of vibration dampers differs from

installation to installation. In certain cases a wrong

damper may increase the vibration level. Vibration

dampers must therefore be sized by the supplier of

the vibration dampers.

3.2.4 Expansion joints

Expansion joints provide these advantages:

• absorption of thermal expansion and contraction

of pipes caused by variations in liquid

temperature

• reduction of mechanical influences in connection

with pressure surges in the pipes

• isolation of structure-borne noise in the pipes

(only rubber bellows expansion joints).

Fit the expansion joints at a minimum distance of 2

pipe diameters (DN) away from the pump flange on

the inlet side. This prevents turbulence in the joints

ensuring optimum inlet conditions and minimum

pressure drop on the outlet side.

At flow velocities greater than 2.4 m/s, we

recommend that you fit larger expansion joints

matching the pipes.

TM07 3975 0519TM07 3977 0519

Do not fit expansion joints to make up for

inaccuracies in the pipes, such as centre

displacement or misalignment of flanges.

English (GB)

3.2.5 Building up the foundation

The foundation procedure has three steps:

1. pouring of foundation

2. shimming of base frame

3. grouting.

Pouring of foundation

We recommend the following procedure to ensure a

good foundation:

1. Pour the foundation without interruptions to

within 19-32 mm of the final level. Use vibrators

to ensure that the concrete is evenly distributed.

The top surface must be well scored and grooved

before the concrete sets. This provides a bonding

surface for the grout.

2. Embed anchor bolts in the concrete as shown in

figs. 6-7. Allow enough bolt length to reach

through grout, shims, lower base frame, nuts and

washers.

Fig. 6 Typical anchor bolt design

Fig. 7 LSV anchor bolt installation

Let the foundation cure for several days before the

base frame is shimmed and grouted.

Shimming of base frame

Fig. 8 Shimming of base frame and levelling of

pump

1. Lift or jack up the base frame to the final level

19-32 mm above the concrete foundation, and

support the base frame by means of blocks and

shims, both at the anchor bolts and midway

between bolts. See fig. 8.

2. Level the base frame by adding or removing

shims under the base frame. See fig. 8.

3. Tighten the anchor bolt nuts against the base

frame. Make sure the pipes can be aligned to the

pump flanges without putting strain on the pipes

or flanges.

TM04 0383 0608TM06 6124 0816

5-10 mm

Bolt length

above base

frame

Thickness of

base frame

19 to 32 mm

allowance for

grout

Base frame

Top of

foundation left

rough

Pipe sleeveLugWasher

Wedges and

shims left in

place

Grouted pad for

anchoring or

housekeeping

Anchor bolts for

supporting the base

Wedges or shims,

as required

LSV stands

TM07 4091 0919

English (GB)

Grouting

Grouting compensates for uneven foundation,

distributes the weight of the unit, dampens vibrations

and prevents shifting. Use an approved,

non-shrinking grout. If you have questions or doubts

about the grouting, consult an expert on grouting.

Proceed as follows:

1. Build a strong formwork around the foundation to

contain the grout.

2. Soak the top of the concrete foundation

thoroughly, then remove surface water.

3. Fill the formwork with grout up to the top edge of

the base frame. See fig. 9. Allow the grout to dry

thoroughly before attaching the pipe to the pump.

24 hours is sufficient time with approved grouting

procedure.

4. When the grout has thoroughly hardened, check

the anchor bolt nuts and tighten them if

necessary.

5. Approximately two weeks after the grout has

been poured, or when the grout has thoroughly

dried, apply an oil-based paint to the exposed

edges of the grout to prevent air and moisture

from getting in contact with the grout.

Fig. 9 Sectional view of foundation with anchor

bolt, grouting and base frame

3.3 Electrical connection

The electrical connections must be carried out by an

authorised electrician in accordance with local

regulations.

The operating voltage and frequency are marked on

the motor nameplate.

Make sure that the motor is suitable for the power

supply of the installation site.

Carry out the electrical connections as shown on the

motor nameplate or in the wiring diagram on the

back of the terminal box cover.

For further information, contact the motor supplier.

TM04 0384 0608

5-10 mm

Base frame

Grout

Levelling

wedges or

shims left in

place

Top of foundation

left rough

19 to 32

mm grout

Formwork

DANGER

Electric shock

Death or serious personal injury

- Before you remove the terminal box

cover and before you remove or

dismantle the pump, make sure that the

power supply has been switched off and

that it cannot be accidentally switched

on.

DANGER

Electric shock

Death or serious personal injury

- Whenever you use powered equipment

in explosive surroundings, observe the

rules and regulations generally or

specifically imposed by the relevant

responsible authorities or trade

organisations.

English (GB)

3.3.1 Frequency converter operation

You can connect all three-phase motors to a

frequency converter.

However, frequency converter operation often

exposes the motor insulation system to a heavier

load and causes the motor to be more noisy than

usual due to eddy currents caused by voltage peaks.

In addition, large motors driven via a frequency

converter will be loaded by bearing currents.

When the pump is operated via a frequency

converter, check the following operating conditions:

3.4 Pipes

Inlet and outlet pipe

In order to minimise friction losses and hydraulic

noise in the pipes, choose a pipe that is one or two

sizes larger than the pump inlet and outlet ports.

Typically, flow velocities must not exceed 2 m/s for

the inlet pipe (port) and 3 m/s for the outlet pipe

(port).

Make sure that the NPSH available (NPSHA) is

higher than the NPSH required (NPSHR). NPSH =

Net Positive Suction Head.

3.4.1 General precautions

When installing the pipes, observe these

precautions:

1. Always run the pipes directly to the pump.

2. Do not move the pump to the pipes. This could

make the final alignment impossible and cause

stress to the pump flanges and pipes.

3. When you use expansion joints in the pipe

system, fit the joints at a minimum distance of 2

pipe diameters away from the pump on the inlet

side. This prevents turbulence in the joints, thus

ensuring optimum inlet conditions.

4. Install the pipes as straight as possible and avoid

unnecessary bends. Where necessary, use 45 °

or long-sweep 90 ° fittings to reduce friction loss.

5. Make sure that all pipe joints are tight.

6. Where you use flanged joints, ensure that the

inside diameters match properly.

7. Remove burrs and sharp edges when making up

joints.

8. Make sure that the pipes do not cause stress or

strain in the pump.

9. Provide for expansion of pipe material by means

of expansion joints on both sides of the pump.

10. Always allow sufficient space and accessibility for

maintenance and inspection.

If in doubt whether the supplied motor can

handle frequency converter operation,

contact the motor supplier.

Operating

conditions Action

2-, 4- and 6-pole

motors, frame

size 225 and

larger

Ensure that the non-drive-end

motor bearing is electrically

isolated.

Noise-critical

applications

Fit a dU/dt filter between the

motor and the frequency

converter. It reduces the voltage

peaks and thus the noise.

Particularly

noise-critical

applications

Fit a sinusoidal filter.

Cable length Fit a cable that meets the

specifications laid down by the

frequency converter supplier.

The length of the cable between

the motor and frequency

converter affects the motor

load.

Supply voltage

up to 500 V

Make sure that the motor is

suitable for frequency converter

operation.

Supply voltage

between 500 V

and 690 V

• Fit a dU/dt filter. It reduces

the voltage peaks and thus

the noise.

• Or make sure that the motor

has reinforced insulation.

Supply voltage

of 690 V and

upwards

• Fit a dU/dt filter.

• Make sure that the motor

has reinforced insulation.

Protective covers are fitted to the inlet and

outlet ports to prevent foreign bodies from

entering the pump during transportation

and installation. Remove these covers

from the pump before connecting any

pipes.

Make sure that both the inlet and outlet

pipes are independently supported near

the pump so that no strain is transmitted to

the pump when you tighten the flange

bolts. Use pipe hangers or other supports

with necessary spacing to provide support.

English (GB)

3.4.2 Inlet pipes

Place the pump below system liquid level whenever

possible. This will facilitate priming, assure a steady

liquid flow and provide a positive suction head.

You can avoid many NPSH problems if you install the

inlet pipe properly. See section 3.4.1 General

precautions.

In section 10. Disposing of the product, common

inlet pipe installations are illustrated for two

situations:

• flooded systems

Closed systems and open systems where the

liquid level is above the pump inlet.

• suction lift systems

Closed systems and open systems where the

liquid level is below the pump inlet.

3.4.3 Valves in the inlet pipe

If the pump is operating under permanent suction lift

conditions, install a non-return valve in the inlet pipe

to avoid having to prime the pump each time it is

started. The non-return valve must be of the flap type

or a foot-valve with a minimum of pressure loss.

3.4.4 Outlet pipe

The outlet pipe is usually preceded by a non-return

valve and an isolating or throttle valve. The

non-return valve protects the pump against

excessive counterpressure and reverse rotation of

the pump and prevents backflow through the pump in

case of operational stop or failure of the motor.

In order to minimise friction losses and hydraulic

noise in the pipes, flow velocities must not exceed 3

m/s in the outlet pipe (port).

On long horizontal runs, keep the pipe as level as

possible.

Avoid high spots, such as loops, as they will collect

air and throttle the system or lead to uneven

pumping.

3.4.5 Auxiliary pipes

Drains

Install the drain pipes from the pump casing and

stuffing boxes to a convenient disposal point.

Flushing pipes

• Pumps fitted with stuffing boxes

When the inlet pressure is below the ambient

pressure, supply the stuffing boxes with liquid to

provide lubrication and prevent the ingress of air.

This is normally achieved via a flushing pipe from the

outlet side to the stuffing box. You can fit a control

valve or orifice plate in the flushing pipe to control

the pressure to the stuffing box.

If the pumped liquid is dirty and cannot be used for

flushing the packing rings, we recommend a

separate clean, compatible liquid supply to the

stuffing box at 1 bar above the inlet pressure.

• Pumps fitted with mechanical seals

Seals requiring recirculation will normally be

provided with a flushing pipe from the pump casing.

3.4.6 Measuring instruments

To ensure continuous monitoring of operation, we

recommend that you install pressure gauges on the

pump inlet and outlet flanges. The pressure gauge

on the inlet side must be capable of measuring

vacuum. The pressure tappings must only be opened

for test purposes. The measuring range of the outlet

side pressure gauge must be minimum 20 % above

the maximum pump outlet pressure.

When measuring with pressure gauges on the pump

flanges, note that a pressure gauge does not register

dynamic pressure (velocity pressure). The diameters

of the inlet and outlet flanges are different, and this

results in different flow velocities in the two flanges.

Consequently, the pressure gauge on the outlet

flange will not show the pressure stated in the

technical documentation, but a value which may be

lower.

The sizing and installation of the inlet pipe

is extremely important.

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