EBARA FSA User manual

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EBARA End Suction Volute Pump
MODEL
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1.
Safety Information and Introduction
1
2.
Installation
2
3.
Operation
4
4.
Maintenance and Service
5
5.
Replaceable Parts
6
6.
Troubleshooting
7
7.
Contruction
8
8.
Disassembly and Assembly
9
FS9003 506-R3
)6$
Section

- 1 -
Safety Information and Introduction
This pump should only be serviced by a qualified person or a factory trained person.
This instruction manual includes necessary items for installation, operation and maintenance.
Read this manual carefully to ensure correct installation, operation and maintenance.
Be sure to keep this instruction manual on hand for future reference.
Design of this EBARA pump is based on superior engineering and long experience. To prevent trouble and provide
satisfactory operation and long life, it is important to understand the EBARA pump thoroughly by careful study of this manual.
If any questions arise regarding this manual, please direct them to EBARA INDONESIA.
Specification
Be careful not to exceed the given specifications in the use of your products.
Check the following points upon receipt of your pump:
(1) The pump exactly what you ordered? Check the
nameplate. It is especially important that you check
whether the pump is to be used with 50 Hz.
(2) Has any damage occurred during shipment? Are any
bolts or nuts loose?
(3) Have all necessary accessories been supplied? (For
a list of standard accessories see Construction.)
We recommend that you keep a spare pump on hand in
case of emergencies. Keep this instruction manual in a
safe place for future reference.
Standard Optional
Description 2 poles model 4 poles model 2 poles model 4 poles model
Name Clean water
Liquid Temperature 0 to 100 oC (32 to 212 oF)
10 bar (10.2 kgf/cm2) for standard flange JIS 10K RF 16 bar (16.3 kgf/cm2)
Max. Working Pressure 16 bar (16.3 kgf/cm2) for standard flange JIS 16K RF
Synchronous Speed 3000 min-1 1500 min-1
Installation Indoors Outdoors
Impeller Enclosed
Shaft seal Mechanical seal Gland Packing
Sealing Self flushing External flushing
Construction
Bearing Sealed ball bearing Oil bath (some models only)
Suction < φ 150 mm, except 100x65 FSKA : JIS 10K RF 16 bar : JIS 16K RF; DIN PN-16
100x65 FSKA : JIS 16K RF DIN PN-16
Suction = φ 150 mm, except below models : JIS 10K RF 16 bar : JIS 16K RF; DIN PN-16
150x100 FSKA; 150x100 FSNA : JIS 16K RF DIN PN-16
Suction = φ 200 mm, except below models : JIS 10K RF 16 bar : JIS 16K RF; DIN PN-16
200x150 FSLA; 200x150 FSNA : JIS 16K RF DIN PN-16
Flange
Suction & Discharge
Suction = φ 250 : JIS 16K RF DIN PN-16
Casing Cast Iron Ductile Cast Iron (FCD)
Impeller Bronze Casting (CAC406/BC6) Cast iron; Ductile Cast Iron (FCD)
Shaft 403 Stainless steel 304; 316 Stainless steel
Gland Packing : Teflon (PTFE) impregnated
Material
Seal Mechanical Seal: Ceramic/Carbon/NBR Mechanical Seal : SiC/SiC
Bare shaft Priming funnel ; valve; Companion Flange
Accessories With motor Common base, Coupling, Coupling guard Priming funnel ; valve; Companion Flange
WARNING
Before handling this pump, always disconnect the power first. No open flame or use sparkable
electrical devices or flames in a septic (gaseous) or possible septic sump.
Do not work under heavy Suspended object unless there is a positive support under it to stop its fall in
event of sling or, hoist failure. Disregard of this warning could result in personal injury.
CAUTION
CAUTION
(Kg/cm
2
=98,6 kPa)
Note : Refer to the Standard Specification if you have purchased a standard model. We also offer pumps with optional features
according to customer demand.
Be careful not to exceed the given specification on the use of your pump.

- 2 -
Installation
Check the following before beginning installation :
All electric work should be performed by a qualified electrician and all national and local electrical codes
must be observed.
1. Location
(1) This pump should be installed indoors. If it is to be
used outdoors, some type of roof or covering will be
required to protect the pump from the weather.
(2) Install where inspection and maintenance can be
easily performed.
(3) Provide suitable enclosure to prevent entry of
unauthorized persons.
(4) Install pump as close to water source as possible.
Suction height (height from surface of liquid to
center of pump) should be as low as possible, and
suction piping should be short.
(5) Suction head should be less than 6 meters in certain
cases, such as with hot water, suction head must be
lower. To minimize suction piping loss, excessive
use of elbows and valves should be avoided.
2. Piping
(1) Use adequate support for suction and discharge
piping to prevent pump and motor from becoming off
center.
(2) A check valve must be installed between the pump
and the discharge valve in the following cases.
When suction piping is long; when actual head is
high; when pump is automatic; when water is being
pumped to pressure tank; and when two or more
pumps are in parallel operation.
(3) Install an air-release valve in piping to prevent the
unavoidable formation of air pockets due to
construction. Note, however, that an air-release
valve must not be installed where pressure may drop
below atmospheric pressure since the valve may
suck in air instead of expelling it.
(4) To reduce effect of water hammer install such a
device as a quick-closing check valve.
(5) Suction system:
1. The end of the suction piping should be
submerged to a depth of at least twice the
diameter (D) of the piping, and should be at a
distance between 1 to 1.5 times the diameter of
the piping from the bottom of the pit.
2 Install a foot valve at the end of the suction
piping to block the entrance of foreign matter.
3 Suction piping should be inclined upward lover
1/1001 in relation to the pump to prevent forma-
tion of air pockets. Pipe joints must be tight so
that there will be no possibility of air suction.
4 Keep suction piping as short and straight as
possible. Do not attach a sluice valve.
5 Suction pipe sizes and suction reducer sizes
should be as indicated in Table 1. Install the
suction reducer as shown in Fig. 1 to prevent
the formation of air pockets. The suction
reducer is available as a separate special
accessory.
(6) For the influx system, we recommend that you install
a cutoff valve on the suction piping to facilitate
disassembly and inspection.
Coupling guard
Min. water level
.
Suction total head
(within 6 m)
Foot valve
1 - 1.5D
Keep short and straight
to prevent formation
of air pockets Flexible joint
Check Valve
Sluice valve
Discharge pipe
Piping support
D
1 - 1.5D
Over 2D
Piping Support
Suction pipe
PUMP MOTOR
Model Foot valve,
suction pipe size Suction reducer size
50 x 40 FSA 50 -
65 x 50 FSA 65 -
80 x 65 FSA 100 100 x 80
100 x 80 FSA
100 x 65 FSA 125 125 x 100
125 x 100 FSA 150 150 x 125
150 x 125 FSA
150 x 100 FSA 200 200 x 150
200 x 150 FSA 300 x 200
250 x 200 FSA
300
300 x 250
Before insulation resistance measurement, always disconnect the power first.
WARNING
Fig. 1
Table 1

- 3 -
Installation
3. Centering
Though the pump and driver have been centered in
the factory, the common bed may be distorted when
the foundation bolts are inserted during installation.
Adjust by placing tapered liners underneath the
bed, and center so that the shaft coupling is within
the range indicated in fig. 2.
To center a pump that has been purchased without
a driver and which is to be directly driven, insert
liners under the drive, and center so that the shaft
coupling is within the range indicated in Fig2.
CAUTION
The coupling guard must be removed to make centering adjustment. Be sure to replace before beginning
operation.
CAUTION
Measure the insulation resistance. The value should be more than 1 mega ohm. While making
The measurement, keep the power supply cable off the ground.
CAUTION
Before installation check rotation. Correct rotation is clockwise when viewed from motor side.
Read ELECTRICAL WIRING.
4. Electrical Wiring.
(1) Refer to Fig. 3 for correct wiring It is important that
wiring be correct and that motor is properly
grounded.
(2) Check the following points before turning on
operation switch :
1 Is the fuse the right type ?
2 Is the wiring correct ?
3 Has motor been grounded ?
4 With a three-phase motor check for a loose or
completely detached connection Operating on
only two terminals will result in phase omission,
causing motor burn out.
(3) Terminal voltage in motors bearing the EBARA
nameplate may be within ±10% of the rated
voltage exceeding this range will lead to breakdown
(4) Overloading the motor beyond the prescribed limit
will reduce its efficiency, is not economical and will
eventually lead to motor malfunction.
We recommend that a protective motor relay be in-
stalled to prevent burnout caused by overloading.
Less than
0.05 mm A A-B measurements
0.1 mm of each other
Gap between
coupling is set
at 2 ~ 4 mm.
Fig.2
WARNING
Check that the power is locked off and disconnected before working on pump.
All electric work should be performed by a qualified electrician and all notional
and local electrical codes must be observed.

- 4 -
Operation
1. Before starting
To rotate by hand, remove the motor end cap and
turn slot on shaft end with a screwdriver.
(1) Turn pump by hand to check for smooth
rotation. If movement is sluggish or uneven,
components inside the pump may be rusted
or the gland packing may be too tight.
(2) Remove the coupling bolts and briefly
operate the motor alone to check rotation
direction. The pump should rotate in a
clockwise direction when seen from the
motor side.
Replace coupling bolts after inspection is
completed.
(3) Prime the pump. Operating the pump without
prime will cause breakdown.
Open air-release valve and prime pump. If
the piping is already full of water the pump
can be supposed to be filled up to the
discharge outlet, open the suction valve,
discharge valve and air-release valve to
prime.
(4) Rotate the pump by hand when priming to
remove internal air from casing.
2. Operation :
CAUTION
Check rotation. Correct rotation is clockwise when viewed from top of motor. Pump should be
started with gate valve closed, then the operator should open the valve gradually.
(1) Close the air-release valve and discharge
valve after priming has been completed. If
there is a suction valve, open completely.
(2) Turn operation switch on and off two or three
times to check operating condition. Attach
shaft coupling guard after operation check
has been completed.
(3) Begin continuous operation and gradually
open discharge valve.
(4) Check that pressure, current, vibration and
noise (refer to Maintenance and service) are
at normal levels. Both the pressure gauge and
compound gauge cocks should be kept closed
except at specified times. Leaving them open
may lead to malfunction.
(5) If there is no check valve on the discharge
piping, close the discharge sluice valve slowly
when stopping pump operation. Turn off
operation switch after the sluice valve has
been completely closed.
(6) Subsequent operation can proceed without
checks, if all conditions are normal.

- 5 -
Maintenance and Service
Check pressure, output, voltage, current, vibration, and other specifications. Unusual readings may indicate a
problem requiring immediate service. Contact your local EBARA INDONESIA representative as soon as possible.
Ensure that pump operation switch is off
before making inspections; the pump may
suddenly start if it is automatic operation type.
1. Daily inspection
(1 ) Pressure or current variations, abnormal
vibration or noise are signs of malfunction.
Refer to Troubleshooting and make
necessary repairs as soon as possible. We
recommend that you keep a record of daily
operating conditions so that you will be able
to detect early signs of trouble.
(2) The maximum allowable bearing operating
temperature should not exceed 80° C.
(3) There should be no leakage if shaft sealing
mechanical seal is normal. Replace entire
seal if there is leakage. Gland packing
leakage should be kept down to a steady
drip or trickle (approx. 20 ml/min.) Do not
tighten excessively or unevenly, or when
pump is stopped.
(4) Fig. 4 indicates the normal level of vibration
when installation and piping are correct.
Excessive vibration may be due to conditions
such as *15 (incorrect centering.) defective
piping or loose foundation bolts. Inspect
carefully.
In the event that special vibration control
measures are necessary, EBARA has the
following available upon request: (the
EBARA vibration absorber) the EBARA Flex
(a flexible joint) and the EBARA pipe silencer
(pressure pulsation absorber).
2. Carefully observe the following points:
(1) Operating the pump for an extended period
of time with the discharge valve closed will
eventually cause pump components to be
damaged.
Care should, therefore, be taken.
(2) Too frequent starting and stopping of the
pump will eventually cause damage. Keep
pump-starting frequency to a minimum.
(3) Be sure to turn off operation switch in event
of power failure. It is dangerous to leave the
switch on as the pump will suddenly start
when power is restored.
3. Carefully observe the following when the
pump is to be stored or remain idle for any
length of time.
(1) Water remaining inside an idle pump will
freeze in cold weather and cause the pump
casing to burst. Be sure to insulate pump or
drain water completely.
(2) Operate any auxiliary pumps occasionally to
maintain best usable condition.
WARNING
Disconnect power cable from power source before servicing unit.
Normal maintenance should be done by qualified personnel.
Fig. 4

- 6 -
4. Replaceable parts
(1) Replace parts indicated in following chart as necessary.
Replaceable part Packing Mechanical Seal Coupling rubber Sealed ball
bearing “O” ring
Replacement guide When no
longer able to
control
leakage.
When there is
leakage.
When rubber is
no longer effective
when rubber shows
sign of wear
When wear is
uneven.
When there is
an abnormally
loud sound or
grease flow.
Whenever
disassembling
for inspection.
Average replacement
frequency Annually Annually Annually
Once every 2
to 3 years -
The above average replacement frequency is for normal operating conditions.
(2) The replaceable parts for this pump are as follows :
Packing, mechanical seal, and “O” ring
Model Mechanical Seal O-Ring/ Gasket Gland Packing Size
mm
Qty of Gland
Packing Ball Bearing
50x40 FSHA FH-25 Gs-225 41x25x8 4 6305 ZZ
65x50 FSHA Gs-225
65x50 FSJA FH-25 Gs-275 41x25x8 4 6305 ZZ
80x65 FSGA Gs-180
80x65 FSHA FH-25 Gs-225 41x25x8 6305 ZZ
80x65 FSJA Gs-275
80x65 FSKA FH-35 Gs-335 51x35x8
4
6307 ZZ
100x65 FSKA EA-262-40 Gs-335 56x40x8 4 6208 ZZ
100x80 FSGA FH-25 Gs-275 41x25x8 6305 ZZ
100x80 FSHA Gs-225
100x80 FSJA FH-35 Gs-275
100x80 FSGCA Gs-185
100x80 FSHCA EA-262-35 Gs-225
51x35x8 4 6307 ZZ
125x100 FSJCA EA-262-40 Gs-275 56x40x8 6208 ZZ
125x100 FSKA FH-35 Gs-335 51x35x8 4 6307 ZZ
125x100 FSLA EA-262-45 Gs-425 65x45x10 5 6309 ZZ
150x100 FSKA EA-262-50 370x320x0.8T 70x50x10 4 6310 ZZ
150x100 FSNA EA-262-55 560x515x0.8T 75x55x10 5 6312 ZZ
150x125 FSHA Gs-225
150x125 FSJA EA-262-35 Gs-275 51x35x8 4 6307 ZZ
150x125 FSKA Gs-335
150x125 FSLA EA-262-45 Gs-425 65x45x10 5 6309 ZZ
200x150 FSHA EA-262-35 Gs-225 51x35x8 4 6307 ZZ
200x150 FSJA EA-262-45 Gs-275 65x45x10 6309 ZZ
200x150 FSKA Gs-335
200x150 FSLA EA-262-55 450x415x0.8T 75x55x10 6312 ZZ
200x150 FSNA EA-262-65 560x515x0.8T 90x65x12.5
5
6313 ZZ
250x200 FSLA EA-262-65 480x440x0.8T 90x65x12.5 6313 ZZ
250x200 FSNA EA-262-75 615x550x0.8T 104x75x14.5 5 6315 ZZ
Coupling bolts
Coupling dia. 100 112 125 140 160 180 200 224 250 280 315
CLAB-( ) 10 10 14 14 14 14 20 20 25 25 28
Number 4 4 4 6 8 8 8 8 8 8 10
Ex. For coupling dia. 140 use CLAB-14x6

- 7 -
Troubleshooting
CAUTION
All service should be done by factory trained or qualified personnel only.
Trouble Cause Remedy
Motor does not start (1) Motor malfunction.
(2) Power source malfunction.
(3) Rotating parts in contact, rusted, burnt out.
(4) Foreign matter clogging contacting parts.
(1) Repair motor.
(2) Inspect, repair, or consult power company.
(3) Manually rotate, reassemble. Have
repaired in specialist shop.
(4) Remove foreign matter.
Pump is operating but
there is no water
discharge Does not
obtain specified
discharge volume
(1) Pump not primed.
(2) Valve closed, insufficiency open.
(3) Excessive piping loss.
(4) Suction height too high for pump.
(5) Cavitations.
(6) Rotation direction reserved.
(7) Rotation speed low.
•Wrong number of poles in motor.
•60 Hz pump being used in 50 Hz area.
•Voltage drop.
(8) Impeller clogged.
(9) Piping clogged.
(10) Air Suction.
(11) Foot valve or suction piping end not submerged
sufficiently.
(12) Discharge piping leakage.
(13) Impeller corroded.
(14) Impeller worn.
(15) Casing ring worn.
(16) Liquid temperature too high. Volatile liquid.
(1) Prime.
(2) Open Valve.
(3) Re-examine original plan.
(4) Re-examine original plan.
(5) Consult specialist.
(6) Correct rotation direction.
(7) Check with tachometer.
•Check nameplate and change.
•Check nameplate and change.
•Check power source and remedy.
(8) Remove foreign matter.
(9) Remove foreign matter.
(10) Inspect, repair suction piping, shaft sealing.
(11) Extend suction piping and submerge end to
sufficient depth.
(12) Inspect, repair.
(13) Check quality of liquid and consult specialist.
(14) Replace impeller.
(15) Replace casing ring.
(16) Re-examine original plan.
Water Discharge
but soon stops
(1) Insufficient priming.
(2) Air suction.
(3) Air pocket in suction piping.
(4) Suction height too high for pump.
(1) Prime sufficiently.
(2) Inspect, repair suction piping, shaft sealing.
(3) Reinstall piping.
(4) Re-examine original plan.
Overloads (over current) (1) Head low. Excessive volume flow.
(2) Rotation speed low.
•Wrong number of poles in motor.
•50 Hz pump being used in 60 Hz area.
(3) Rotating parts in contact. Shaft bent.
(4) Liquid density, viscosity too high.
(1) Partially close discharge valve.
(2) Check with tachometer.
•Check nameplate and change.
•Check nameplate and change.
(3) Have repaired in specialist shop.
(4) Re-examine original plant.
Pump vibrates
Excessive noise.
(1) Piping vibration.
(2) Rotation direction reserved.
(3) Rotating parts in contact. Shaft bent.
(4) Cavitations.
(5) Excessive discharge volume.
(6) Insufficient discharge volume.
(7) Excessive pump operation with discharge.
valve Insufficiently open.
(1) Reinforce piping support.
(2) Check with arrow and rewire.
(3) Have repaired in specialist shop.
(4) Consult specialist.
(5) Partially close discharge valve.
(6) Operate at specified flow level.
(7) Open sufficiently.
Excessive leakage from
shaft seal.
(1) Damage mechanical seal.
(2) Excessive influx pressure.
(3) Incorrect installation of packing.
(4) Damaged packing.
(5) Shaft or sleeve worn.
(6) Excessive influx pressure.
(7) Shaft bent.
(8) Excessive water flushing pressure.
(1) Replace piping support.
(2) Re-examine original plan.
(3) Reinstall.
(4) Replace packing.
(5) Replace with new parts.
(6) Re-examine original plan.
(7) Have repaired in special shop.
(8) Adjust to appropriate pressure.
Shaft sealing overheats (1) Packing too tight.
(2) Packing tightened unevenly.
(3) Inappropriate water flushing pressure, volume.
(4) Shaft sleeve worn.
(5) Lantern ring positioned incorrectly.
(6) Excessive influx pressure.
(1) Adjust
(2) Adjust
(3) Adjust to correct pressure and flow.
(4) Replace with new part.
(5) Correct position.
(6) Re-examine original plan.

- 8 -
Construction
1. Sectional View
This drawing represents standard model FS. There may be some variations according to model.
Mechanical Seal Type (Standard) Gland Packing Type (Option)
Model FH
111-5 Mating Ring Ceramic
111-4 Seal Ring Carbon
111-3 Friction Ring NBR
111-2 Coil Spring
111-1 Spring Holder
Stainless
Steel
1
No. Part Name Material Qty
119 Gland
Packing - 4 or 5
091 Gland
085 Lantern Ring
Bushing
Bronze 1
No. Part Name Material Qty
207 Plug Steel
111 Mechanical Seal -
107-2 Casing Ring
107-1 Casing Ring Bronze
1
095 Stay Steel 1
056 Ball Bearing - 2
053 Bearing Cover
051 Bearing Housing
Cast
Iron
048 Impeller Nut Brass
031 Shaft Stainless
Steel
021 Impeller Bronze
011 Casing Cover Cast
1
001 Casing Iron
No. Part Name Material Qty

- 9 -
Disassembly and Assembly
1. Disassembly
When disassembling pump, have a piece of
cardboard or plywood ready to place the parts
on as you work. Do not pile parts on top of each
other. They should be laid out neatly in rows the
"O" ring and gasket cannot be used again once
they are removed. Have replacement parts
ready.
Disassemble In the following order, referring to
the sectional view.
Be sure to cut off power source before
beginning disassembly.
(1) Drain all water from casing.
(2) Remove the motor from the common base.
Inspect shaft coupling rubber and replace if
excessively worn.
(3) Remove the casing cover bolts, and remove
casing cover and shaft bearing frame from
casing. You will now be able to inspect the
inside of the pump. Check for wear and other
abnormal signs. Replace casing ring when
wear approaches 1 mm.
(4) Remove impeller nut (right hand thread) and
impeller washer (some models do not have
one), and remove impeller from casing. If the
impeller is rusted and will not come loose, tap
its end lightly with a wooden hammer to
release.
(5) Remove the impeller key from the main shaft
(some models do not have a key), the casing
cover from the shaft bearing frame, and the
deflector from the main shaft.
Mechanical seal type: At this point in
disassembly, the fixed portion of the
mechanical seal is attached to the casing cover
and the rotating portion to the main shaft. The
fixed portion of the mechanical seal can be
removed by pushing it out of the shaft hole in
the casing cover with a screw driver of similar
tool.
Gland packing type: Remove the packing
gland from the casing cover and take out the
packing and lantern ring bushing (some models
do not have a lantern ring bushing).
(6) Remove the shaft bearing cover from the shaft-
bearing frame and take out the main shaft.
Inspect condition of the shaft bearing and
replace if it does not rotate smoothly.
2. Assembly
Re-assemble in reverse order of disassembly.
Re-assemble of following points.
(1) Gland packing type: Replace gland packing
with new packing, shifting joints 180° until
last joint is on the bottom.
Mechanical seal type: Wipe contacting part of
mechanical seal with a dry cloth.
(2) Replace "O" ring with a new one.
(3) Replace all parts that are excessively worn or
damaged.
(4) Tighten all bolts evenly.
Please obtain "O" rings, gland packing and
other parts from pump dealer. The table of
dimensions is given in "Maintenance".
CAUTION
All Service should be done by factory trained or qualified personnel only.
Be sure to cut off power source before beginning disassembly.

- 10 -
MEMO :