Pentair ISO PRO Bedienungsanleitung

ISO PRO

ISO 5199 Standard

Centrifugal Pumps

Installation, Operation and Maintenance Manual

These instructions must be read prior to installing, operating, using and maintaining

this equipment.

ISO PRO Centrifugal Pump

CONTENTS

SECTION 1

SECTION 2

SECTION 3

SECTION 4

SECTION 5

SECTION 6

SECTION 7

SECTION 8

Introduction and Safety .................................................. 4

Pump Construction ......................................................... 9

Pump Lubrication ...........................................................13

Transport and Storage ...................................................15

Installation ......................................................................18

Commissioning and Operation .................................... 24

Maintenance and Servicing .......................................... 28

Pump Troubleshooting ................................................. 37

INSTALLATION, OPERATION

AND MAINTENANCE MANUAL

Section 1................................................................Introduction and Safety

ISO PRO Centrifugal Pump

1. GENERAL

Pentair Southern Cross is committed to continual quality improvement. We are available at your

service to answer any technical question and provide further information about the product relating to

its Installation, Operation, Repair and Fault diagnostic services.

The instructions in this manual are intended to provide relevant information to the installer and

operator to work with the product. Operating the product in compliance with these instructions is

important to help ensure reliability in service and avoid risks.

Local regulations are not accounted for in these instructions. Ensure such local regulations are

observed by all, including those installing the product. Always coordinate repair activity with operations

personnel, and follow all plant safety requirements and applicable safety and health laws and

regulations.

2. DISCLAIMER

The information in this manual is considered to be reliable. In spite of all the efforts made by Pentair

Southern Cross to provide relevant information, not all circumstances can be accounted for. The

content in this manual may appear insufcient in some areas. Contact Pentair Southern Cross for

more information relating to your specic application if need be.

Pentair Southern Cross products are manufactured in compliance with ISO9001:2008 International

Quality Management System Standard. Parts and Accessories have been designed, tested and

incorporated into the products to help ensure their continued product quality and performance in

use. Use of Non-Pentair Southern Cross supplied parts and accessories may adversely affect the

performance and safety features of the products. Failure to properly select, install or use authorized

Pentair Southern Cross parts and accessories is considered as misuse.

Damage or failure caused by misuse is not covered by Pentair Southern Cross warranty. In addition,

any unauthorized modication to Pentair Southern Cross products or removal of original components

may impair the safety of these products in their use and will be unwarrantable.

3. PERSONNEL QUALIFICATION AND TRAINING

All personnel involved in the operation, installation, inspection and maintenance of the unit must

be qualied to carry out the work involved. If the personnel in question do not already possess the

necessary knowledge and skill, appropriate training and instruction must be provided.

Always coordinate repair activity with operations and health and safety personnel, and follow all plant

safety requirements and applicable safety and health laws and regulations.

These instructions must always be kept close to the product’s

operating location or directly with the product.

Section 1................................................................Introduction and Safety

ISO PRO Centrifugal Pump

4. SUMMARY OF SAFETY MARKINGS

This document contains specic safety markings relating to various user instructions. The specic

safety markings are:

A symbol to indicate safety instructions where non-compliance would affect personal

safety and could result in loss of life.

A symbol to indicate electrical safety instructions where non-compliance would affect

personal safety and could result in loss of life.

A symbol to indicate explosive atmosphere marking. It is used in safety instructions

where non-compliance in the hazardous area would cause the risk of an explosion.

A symbol to indicate safety instructions where non-compliance will involve some risk

to safe operation and personal safety and would damage the equipment or property.

A symbol to indicate “hazardous and toxic uid” safety instructions where non-

compliance would affect personal safety and could result in loss of life.

This sign indicates a Critical Instruction the Installer / Operator need to consider and

follow.

Section 1................................................................Introduction and Safety

ISO PRO Centrifugal Pump

5. MANDATORY SAFETY ACTION

DRAIN THE PUMP AND ISOLATE PIPEWORK BEFORE DISMANTLING THE PUMP

The appropriate safety precautions should be taken where the pumped liquids are hazardous.

NEVER DO MAINTENANCE WORK WHEN THE UNIT IS CONNECTED TO POWER

ENSURE CORRECT LUBRICATION

HAZARDOUS LIQUIDS

When the pump is handling hazardous liquids care must be taken to avoid exposure to the liquid

by appropriate setting of the pump, limiting personnel access and by operator training. If the

liquid is ammable and/or explosive, strict safety procedures must be applied.

Gland packing must not be used when pumping hazardous liquids.

START THE PUMP WITH OUTLET VALVE PARTLY OPENED

This is recommended to minimise the risk of overloading and damaging the pump and motor at

full or zero ow. The pump outlet control valve may need to be adjusted to comply with the duty

following the run-up process. (See section 5, Commissioning start-up, operation and shutdown.)

NEVER RUN THE PUMP DRY

INLET VALVES TO BE FULLY OPEN WHEN PUMP IS RUNNING

Running the pump at zero ow or below the recommended minimum ow continuously will cause

damage to the pump itself and to the seal. Restriction of suction may cause cavitation resulting in

damage to the pump.

PREVENT EXCESSIVE EXTERNAL PIPE LOAD

Do not use pump as a support for piping. Pipe supports and expansion couplings recommended.

DO NOT RUN THE PUMP AT ABNORMALLY HIGH OR LOW FLOW RATES

Operating at a ow rate higher than normal or at a ow rate with no back pressure on the pump

may overload the motor and cause cavitation. Low ow rates may cause a reduction in pump/

bearing life, overheating of the pump, instability and cavitation/ vibration.

HANDLING COMPONENTS

Many precision parts have sharp corners and the wearing of appropriate safety gloves and

equipment is required when handling these components. To lift heavy pieces above 25 kg (55 Ib)

use a crane appropriate for the mass and in accordance with current local regulations.

GUARDS MUST NOT BE REMOVED WHILE THE PUMP IS OPERATIONAL

The unit must not be operated unless coupling guard is in place. Failure to observe this warning

could result in injury to operating personnel.

THERMAL SHOCK

Rapid changes in the temperature of the liquid within the pump can cause thermal shock, which

can result in damage or breakage of components and should be avoided.

DO NOT APPLY HEAT TO REMOVE IMPELLER

Trapped lubricant or vapor could cause an explosion.

Section 1................................................................Introduction and Safety

ISO PRO Centrifugal Pump

6. SAFE NOISE LEVEL

ISO PRO pump noise level is dependent on a number of factors – the type of driver used, the

operating conditions, pipe-work design and acoustic characteristics of the building. The below table is

a guide to calculating the noise level for a pump unit with any given driver.

Approximate Noise Level Table

Driver Sound Level dB(A) Correction For Unit - Add to motor noise level dB(A)

60 - 64 12.0

65 - 69 10.0

70 - 74 8.0

75 - 79 6.5

80 - 84 5.0

85 - 89 4.0

If pump unit noise level exceeds 85 dBA attention must be given to prevailing Health and Safety

Legislation, to limit the exposure of plant operating personnel to the noise. The usual approach is

to control exposure time to the noise or to enclose the machine to reduce emitted sound. You may

have already specied a limiting noise level when the equipment was ordered, however if no noise

requirements were dened then machines above a certain power level will exceed 85 dBA. In such

situations consideration must be given to the tting of an acoustic enclosure to meet local regulations.

7. LEAKAGE PREVENTION

The pump must only be used to handle liquids for which it has been approved to have the correct

corrosion resistance. Avoid entrapment of liquid in the pump and associated piping due to closing of

suction and discharge valves, which could cause dangerous excessive pressures to occur if there is

heat input to the liquid. This can occur if the pump is stationary or running.

Bursting of liquid containing parts due to freezing must be avoided by draining or protecting the pump

and ancillary systems.

8. SAFETY NOTE

a. Read the instruction manual before installation, operation and maintenance of the equipment.

Check and conrm that the manual is relevant copy by comparing pump type on the nameplate and

with that on the manual.

b. The products supplied by Pentair Southern Cross have been designed with safety in mind. Where

hazards cannot be eliminated, the risk has been minimized by the use of guards and other design

features. Some hazards cannot be guarded against and the instructions below must be complied

with for safe operation. These instructions cannot cover all circumstances; You are responsible for

using safe working practices at all times.

c. Pentair Southern Cross products are designed for installation in designated areas, which are to

be kept clean and free of obstructions that may restrict safe access to the controls and maintenance

Section 1................................................................Introduction and Safety

ISO PRO Centrifugal Pump

access points. A Pump Duty Nameplate is tted to each unit and must not be removed. Loss of

this plate could make identication impossible. This in turn could affect safety and cause difculty in

obtaining spare parts.

d. Access to the equipment should be restricted to the personnel responsible for installation, operation

and maintenance of pump unit, adequately qualied and supplied with appropriate tools for their

respective tasks.

e. Pentair Southern Cross requires that, all personnel that are responsible for installation, operation or

maintenance of the equipment, have access to and study the product instruction manual before

any work is done and that they will comply with all local and industry based safety instructions and

regulations.

f. Hearing protection should be worn where the specied equipment noise level exceeds locally

dened safe levels. Safety glasses or goggles should be worn when working with pressurised

systems and hazardous substances. Other personnel protection equipment must be worn where

local rules apply.

g. Do not wear loose clothing or jewelry which could catch on the controls or become trapped in the

equipment.

h. Note the ‘Limits of product application – permissible use’ specied in the manual.

i. Operation of the equipment beyond these limits will increase the risk from hazards noted below and

may lead to premature and hazardous pump failure.

j. Clear and easy access to all controls, gauges and dials etc., must be maintained at all times.

Hazardous or ammable materials must not be stored in pump rooms unless safe areas or racking

and suitable containers have been provided.

k. Improper Installation, Operation or Maintenance of this Pentair Southern Cross Product could result

in Injury or Death.

Section 2.......................................................................Pump Construction

ISO PRO Centrifugal Pump

1. CONFIGURATIONS

Southern Cross ISO-PRO is a single stage, horizontal, end suction process pump with overhung

impeller and radially split casing. ISO-PRO is fully Compliant with ISO 5199. The range is designed for

continuous service in clean water pumping applications.

2. NOMENCLATURE AND NAME PLATE

A typical example of a Southern Cross Pump Name Plate is shown below.

2.1 Serial Number

The pump serial number is stamped on the name plate as shown above. A typical serial number is

described below.

2.2 Pump Size

2.3 Impeller Diameter (mm)

Actual outside diameter of the impeller in millimeters (if blank, the impeller is full-size)

Form No. QF-035

Date

Issue No. 03

eg:- 03K2010A03

01 to 31 A = January 2010 A = Toowoomba 3rd pump

B = February P = Perth assembled on this day

C = March etc

2. Size

eg:- 60x40-315

eg:- 310

eg:- MHB15C-F Starline

"Item Code" of pump (from work order)

PRHG3A ISO PRO

PSFA1A ISO Sovereign

AUSGD2E AUS ISO

eg:- CZ5CMW Materials pump constructed from

C Z 5 C M W X

29/05/2013

Actual outside diameter of the impeller in millimetres (If blank,

the impeller is full-size)

1. Serial Number

3. Impeller Diameter (mm)

4. Model

5. Construction Code

CENTRIFUGAL PUMP SPECIFICATION PLATE

Su ﬂange

nominal bore

Discharge ﬂange

nominal bore

Impeller nominal

outside diameter

STARLINE

AUS ISO

ISO SOV

ISO PRO

Day of Month

03 K2010 A 03

Month Year Assembly Loca on Pump Series Number

Casing/Backplate

C - Cast Iron

S - 316 Stainless

Z - Zinc Free Bronze

N - Ni Resist

A - ADI

M - SGI (Malleable)

P - Alum Bronze

R - 2RK65

X - Exotic Material

Impeller Material

C - Cast Iron

S - 316 Stainless

Z - Zinc Free Bronze

N - Ni Resist

A - ADI

M - SGI (Malleable)

P - Alum Bronze

R - 2RK65

X - Exotic Material

Shaft Material

2 - 420 Stainless

3 - 316 Stainless

4 - 431 Stainless

5 - 316 Cast Stainless

6 - SAF2205

X - Exotic Material

Seal Type

C - Nitrile Mech. Seal

V - Viton Mech. Seal

E - Empty Pack Gland

P - Packed Gland

H - Hard Faced Seal

S - Single Cartridge Seal

D - Double Cartridge Seal

X - Special

Bearing Type

G - Grease Lubed

M - Motor Pump

O - Oil Lubed

P - Prepacked

Wear Rings

W - Wear Rings Fitted

Leave blank if none fitted)

Bearing Housing

X - Denotes Mk2 bearing

housing of 2013

(leave blank for older housing)

03K2013A03

65X40-315

310

MHB15C-F CZ5CMW

03K2013A06

100X65-250

200

AUSGD2BE CZ2CPX

03K2013A09

50X32-200

180

PSFA1ACC4CPX

03K2013A01

150X125-315

304

PRHG3A CC4XOWX

bar

Section 2.......................................................................Pump Construction

ISO PRO Centrifugal Pump

2.4 Model

“Item Code” of pump (from work order)

2.5 Construction Code

This code denes construction material of various components in the pump.

3. DESIGN OF MAJOR PARTS

3.1 Pump Casing (All Pump Types)

The Casing type is Foot Mounted, ISO vertical, Centerline, End Suction, Top Discharge, one piece

solid construction. A wear ring may be mounted in the casing to provide a close running clearance with

the impeller Neck ring.

3.2 Impeller (All Models)

The impeller is a single suction, radial / Mixed ow, closed design. The impeller is dynamically

balanced, keyed to the shaft. Renewable Neck rings can be press t onto the impeller hubs (front and

back) where needed. Double curvature impeller blades, provide highly efcient suction performance,

higher speed capabilities and greater performance for reduced running costs and maintenance.

Impeller is taper mounted and keyed to shaft and secured by Lock Washer and Impeller nut for

positive locking.

3.3 Lock Washer (All Pump Types)

Lock washers are assembled between impeller and impeller nut. These Lock washers are

manufactured by Nord-Lock. NORD-LOCK is a pair of washers with a wedge-locking action meeting

DIN 25201 which is a unique method using tension instead of friction. The NORD-LOCK bolt securing

system uses geometry to safely lock impeller onto the pump shaft.

3.4 Shaft (All Pump types)

The shaft is made of high grade stainless steel. It is precision machined over its entire length and has

generous llet radii at each change of section to reduce stress concentrations. Water slinger prevents

intrusion of pumped uid into shaft bearing.

3.5 Heavy Duty Bearing Housing

The pump has positively located dual bearings.

Form No. QF-035

Date

Issue No. 03

eg:- 03K2010A03

01 to 31 A = January 2010 A = Toowoomba 3rd pump

B = February P = Perth assembled on this day

C = March etc

2. Size

eg:- 60x40-315

eg:- 310

eg:- MHB15C-F Starline

"Item Code" of pump (from work order)

PRHG3A ISO PRO

PSFA1A ISO Sovereign

AUSGD2E AUS ISO

eg:- CZ5CMW Materials pump constructed from

C Z 5 C M W X

29/05/2013

Actual outside diameter of the impeller in millimetres (If blank,

the impeller is full-size)

1. Serial Number

3. Impeller Diameter (mm)

4. Model

5. Construction Code

CENTRIFUGAL PUMP SPECIFICATION PLATE

Su ﬂange

nominal bore XDischarge ﬂange

nominal bore

Impeller nominal

outside diameter

STARLINE

AUS ISO

ISO SOV

ISO PRO

Day of Month

03 K2010 A 03

Month Year Assembly Loca on Pump Series Number

Casing/Backplate

C - Cast Iron

S - 316 Stainless

Z - Zinc Free Bronze

N - Ni Resist

A - ADI

M - SGI (Malleable)

P - Alum Bronze

R - 2RK65

X - Exotic Material

Impeller Material

C - Cast Iron

S - 316 Stainless

Z - Zinc Free Bronze

N - Ni Resist

A - ADI

M - SGI (Malleable)

P - Alum Bronze

R - 2RK65

X - Exotic Material

Shaft Material

2 - 420 Stainless

3 - 316 Stainless

4 - 431 Stainless

5 - 316 Cast Stainless

6 - SAF2205

X - Exotic Material

Seal Type

C - Nitrile Mech. Seal

V - Viton Mech. Seal

E - Empty Pack Gland

P - Packed Gland

H - Hard Faced Seal

S - Single Cartridge Seal

D - Double Cartridge Seal

X - Special

Bearing Type

G - Grease Lubed

M - Motor Pump

O - Oil Lubed

P - Prepacked

Wear Rings

W - Wear Rings Fitted

Leave blank if none fitted)

Bearing Housing

X - Denotes Mk2 bearing

housing of 2013

(leave blank for older housing)

03K2013A03

65X40-315

310

MHB15C-F CZ5CMW

03K2013A06

100X65-250

200

AUSGD2BE CZ2CPX

03K2013A09

50X32-200

180

PSFA1ACC4CPX

03K2013A01

150X125-315

304

PRHG3A CC4XOWX

bar

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