Erduro BTS ENGINEERING Fluid Solutions BTKF-I User manual

SINGLE STAGE
USER MANUAL
BTKF-I
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- You should absolutely obey the followng safety nstructons.
- Never touch the pump and ppes havng temperature more than 80 ºC. Necessary
precautons should be taken for warnng users. (E.g Warnng sgns and sgnboards )
- Never operate pump n reverse drecton.
- Do not walk over pump pr ppes whch are connected to pump.
- Any operaton whch wll be done n pump should be performed by at least two
staffs.
- No works should certanly be done over wthout stoppng pump group.
- Power comng to pumps should be off and you should be sure that t wll not operate
agan before you make any work
- Absolutely nstall the safety guards whch were dsmounted before after work n
pump has finshed.
- Tensons and crcks n ppe system absolutely should not reach to pump.
- Do not make any operaton whle pump and ppes whch are connected to pump are
under pressure.
- Cloths of personnel who wll work over should be sutable and/or they should use
safety equpments.
- Never do any operatons when pump s stll hot.
- Electrcal connecton related wth pump and auxlary equpments should be sutable
wth local rules and made by authorzed personnel.
- Operate pump wth only specfied condtons.
- Do not nsert your hand and fingers nto holes and spaces over pump body.
- Be always careful whle workng wth pumps dschargng hazardous lquds.
SAFETY INSTRUCTIONS
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BTKF-I Seres Pumps are centrfugal pumps havng horzontal shaft, separable radal
body, are sngle staged, scroll cased has closed mpellor, and can be connected to
straght ppe.
Usage Areas of Motor Water Pump
Pumps are sutable for dschargng lquds whch are low vscose, whose flow
temperature s up to 110ºC and whch are clean or a lttle drty. (Max20mg/dm³) . In
addton to others; man applcaton areas are:
- Heatng and Coolng Systems
- Water Supply
- Fre Extngushng Plants
- Water Supply and Crculaton Systems n Industral Plants
Explanaton of Pump Codes
BTKF-I 40/200
Pump Type
Rated Dameter of Dscharge Flange (DN-mm)
Number of Stages(pece)
Techncal nformaton
Speed : Up to3600 d/d rpm
Dscharge Flange :DN40 …DN200
Sucton And Dscharge Flange : TS EN 1092-2,EN 1092-2-EQV /PN16
Operatonal Temperature :-10ºC…110ºC
Ambent Temperature (Maxmum) :+40ºC
Body Pressure :16 Bars
Isolaton Class :F
Protecton Class :IP55
Motor Connecton :3 Phase-380 V-50 Hz
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BTKF-1 SERİES PUMPS
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- Check whether all materals n delvery lst are sent. .
- If there s damage durng shppng please notfy ERDURO Shppng Department
and Transportaton company.
- If there are mssng materals, mmedately nform ERDURO Shppng Department.
-. Check whether packagng s damaged durng transportaton.
- Please carefully take out packaged pump and accessores (f any). Check whether
they are damaged durng transportaton.
General warnngs.
Absolutely obey the followng rules durng transportaton.
-. Use proper wooden crane, forklft, or hostng mechansms For unloadng or
loadng wooden cases, packages, boxes and palettes dependng on ther weght and
volume.
- Wear gloves, hard tp shoes and helmet durng carryng works.
- Never stay under hostng mechansm whle loadng or unloadng pumps.
Pump and Motor Group Loadng/Unloadng
Before loadng/unloadng pump group please determned the followng propertes.
- Please find the lftng ponts.
- Please consder total weght and centre of gravty.
- Please consder the packagng external dmensons
- Durng loadng/unloadng make acceleratng and brakng operatons as t shall not
cause any damage for workng personnel.
- Load lftng capacty should be sutable wth pump and pump group weght.
- You should never stay under or near lfted load.
SHIPPING OF PUMPS
CARRYING
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- Pump should be hosted as t s ndcated n Fgure 1 -1 and Fgure 1 -2 for not
causng any damage n pumps. Motor hangng rng should absolutely
not be used
whle lftng complete group.
- Load should be kept n lfted poston more than requred tme.
- Pump and pump group should always be lfted and carred n horzontal poston
Fgure 1 Pump carryng
STORAGE
- If pump group s not mmedately nstalled, t should be stored n a place whch s
clean dry and does not nclude freezng and exploson rsk.
- If pump bearng are type whch should be greased, they should be extra greased for
preventng entry of mosture to bearngs around shaft
- Pump should be protected from mosture, dust, drt and foregn objects by coverng
wth sutable materal.
- Pump shaft should be rotated a few turns (e.g once a week) for preventng pttng
around pump bearng surfaces and jammng of shaft.
INSTALLATION
Installaton of pump to ts place and connecton setup and balance should only be
done by expert personnel. Faled nstallaton and pump ground may cause falures.
Ths stuatons are not covered wth warranty
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Before nstallng the pump n ts place,
Sucton and dscharge flanges should properly be cleaned.
ATTENTION- Pump should be nstalled n a locaton where there s not exploson and
frost hazard and has good ar condtonng.
- There should be enough area around pump for reachng pump easly, for
mantenance and there should be enough space and heght to lft the pump f
necessary.
-Pump sucton ppe should be as short as possble.
If BTKF-I pumps are nstalled over a ppe whch s well supported or over ground by
means of base plate.
-BTKF-I pumps can be mounted to flat ppes vertcally or horzontally.
Flow can be from upwards to downwards or reverse n pumps whch are connected
vertcally. (Provded that pump flow drecton has been connected correct)
Motor axs can be n vertcal or horzontal poston n pumps whch are connected to
horzontal ppe motor should never reman below the horzontal plane.
Pump whch s nstalled over a pump ground can be mounted to a flexble ppe by
means of base plate.
ATTENTION:- You should be carefully work at pump nstallaton ground preparaton
and nstallaton of pump group nto ts place. Incorrect and careless nstallaton
causes early wearng of pump parts and falures.
- Pump ground should be so heavy to absorb vbratons and sturdy to prevent bends
and adjustments defects. Ground concrete should completely be soldfied,
completed ts plug tme and proper stud bolts are placed n pump frame fixng holes
and proper fixng lugs should be placed for usng n makng connectons wth weldng.
Concrete and plate upper surface should be horzontal and very smooth.
-Place the pump group over concrete ground and put or remove steel wedges under
frame and adjust the flanges. Provde that pump shaft completely n horzontal
poston.
-Tghten the anchorage stud bolts properly.
Installaton of Ppe Lne Installaton
-Nomnal dameter of pump dscharge and sucton pumps are not an ndcator for
correct dameters for dscharge and sucton ppes.
- It should be controlled that crcks and stresses and ppe weght do not effect pump.
GENERAL
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- Flow rates generally should not exceed 2m/s n sucton ppe and 3 m/s dscharge
ppe.
- Especally bottom backwater valve, slt trap,
filter and check valves and smlar
elements should be chosen to havng a larger passng area.
- For ths reason, bolts of dscharge and sucton flanges should be loosen and t
should be controlled whether ppe system exerts a stress over pump.
-- Ppes and accessores havng dameter less than pump openng dameter should
absolutely not be used.
- Never use pumps as a support pont or carrer for a ppe nstallaton.
- Ppe system should be supported from ponts whch are close to pump. Fgure 2.
- Proper expanson equpments should be used for preventng addtonal forces to
pump whch may occur because of expanson n systems whch operate n over
vbrant and hot lquds.
- Hgh speeds cause decrease n pressure whch wll cause cavtatons condtons
and excess frcton losses n dscharge ppe.
- Weldng burrs, metal partcles, whch may occur durng ppe equpment producton
sand, and oakum and smlar foregn objects may present nsde pump. Sucton and
dscharge flanges should be closed wth gasket wthout hole for preventng those
materals enter nto pump durng nstallaton. At the end of nstallaton, all ppe parts
should be dsmounted, cleaned and dyed and nstalled agan. If drt retaned s used
at pump sucton lne, t should be removed and cleaned after first few days of
operaton and nstalled agan.
Fgure 2
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- Ppe connectons should be made by flanges. Flanges gaskets should be produced
from sutable materal and should have sutable dmensons. Gaskets whch wll be
used between flanges should be centered for not preventng water flow.
Fgure 3
Sucton and Dscharge Ppe Connectons
- If pump s suppled from a tank whch s hgher than pump, there should be an
solaton valve n sucton ppe whose axs wll be n horzontal poston. Ths valve
should be completely open whle pump s n operaton and should never be used as
flow rate adjustment valve. (Attenton: Closng valve may cause pump operaton wth
cavtatons. )
- Sucton ppe should absolutely be mpermeable and should not be arranged to
cause any ar wall. In ths case f a tank s suppled from a tank whch s hgher than
pump, (sucton hgh nstallaton) sucton ppe should be slghtly decreasng sloped
towards pump and suppled from a tank whch s lower than pump, sucton ppe
should be slghtly ncreasng sloped towards pump.
- Sharp bends should not be used, sudden drecton changes and cross secton
narrowng should be avoded and sucton ppe should be short as possble for
keepng pump frcton losses as low as possble. If there s need of cross secton
change n horzontal sucton ppe, an ntermedate eccentrc concal part whose flat
type s at upper sde should be used.
-. If pump dschargng heght s more than 10 m or dschargng lne s very long, a
check valve should be placed over dschargng ppe between pump and solaton
valve for protectng pump aganst water mpulses and reverse flows durng stop.
- A control valve whch s close to pump should be connected for flow rate and
dscharge heght adjustment.
- If pump dschargng heght s more than 10 m or dschargng lne s very long, a
check valve should be placed over dschargng ppe between pump and solaton
valve for protectng pump aganst water mpulses and reverse flows durng stop.
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d1: Sucon Opening Pressure
Meter Connecon
d2: Discharge Opening Pressure
Meter Connecon
By-Pass Valve Connecton
-. A by-pass valve should be places over dscharge ppe just after pump and before
adjustment valve or outlet flange of pump f there s a case that pump wll operate n
condtons that pump dscharge valve s completely closed(that s wth zero flow rate)
or almost closed (that s wth very small flow rate). If such valve s not used and
pumps operates wth closed valve for a long tme, power whch s provded by motor
wll completely transform nto heat energy and pass nto dscharged lqud. Ths may
cause over heatng and abnormal falures n pump.
ELECTRICAL CONNECTIONS
- Electrcal connectons should be done by authorzed electrcans
Natonal nstructons, regulatons and nstructons of motor manufacturers should be
obeyed.
- Power cables should absolutely be nstalled as not havng contact wth ppe
nstallaton, pump and motor body.
- Motor shaft should be rotated by hand before makng electrcal condtons to control
whether t rotates easly.
- It s recommended to use PTC(Passve Thermal Control-Thermstor) n motors.
However usage of those depends on customer.
- Electrcal motors should be protected aganst overloadng by crcut breakers and/or
fuses. Crcut breakers and/or fuses should be selected wth respect to full load
values those are wrtten n nameplate on motor.
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- Compare and control voltage, ampere and frequency values whch are gven n
motor nameplate wth lne values.
- Motor connecton scheme can be found n motor termnal box or n handbook.
- Motor electrcal connectons should be done accordng to local Electrcal
Regulatons and earthng connecton should absolutely be done.
- Protecton class of motor body and control system cases n pump should be at least
EN 60529 IP 22. In addton to ths, protecton class of motor bodes and control
systems n pump group should be determned accordng to operatonal and
envronmental condtons.
- Safety precautons whch are determned n "Safety Instructons" should be appled.
All power connectons should be dsconnected before startng to any work.
-However usage of those depends on customer. If PTC s used ends of those should
be connected to motor termnal box and later should be connected to PTC control
devce n motor control panel.
- Motor connecton type changes accordng to motor mans power and connecton
type. Necessary connecton types of jumpers n termnal box are dsplayed n Table 1
and Scheme 1a -1b and 1c
Scheme 1a Scheme 1b Scheme 1c
Start Type Motor Power
PN<4kW
Motor Power
PN >4kW
Mans Power
3~400V
Mans Power
3~400V
Drect Y-connecton (1b) Δ-connecton (1a)
Y/ Δ Star Delta Impossble Remove Jumpers (1c)
Table 1
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Attenton! Transton tme from star to delta should be short n star-delta connected
motors. In case that t s long damages may occur n pump and motors.
Motor Power Y-
Setup tme
<30 kW
>30 kW
<3 seconds
<5 seconds
Table 2
- After all abovementoned operatons are completed, pump rotor should be rotated a
few turns for beng sure that t rotates easly.
- All safety guards should be nstalled nto ther places. Pump should absolutely be
not operated after ths operaton s made. Ths s oblgatory for safety.
FIRST START
Controls Before Operaton
- If there s bottom back flow water valve n pump wth depth sucton; one of the plugs
n flanges s opened and sucton ppe and pump s filled wth water and ts ar s
taken.
- Ths case does not cause problem n force feed pumps. Dscharge valve s closed
placement type of pump s consdered and one of the plugs n flanges s opened and
pumps sucton valve s slowly opened and pump s completely filled and ar s
completely removed.
- If system ncludes vacuum pump, rse of water n sucton pump by means of
vacuum pump and fillng pump s provded. When water reaches the hghest level
pump s started.
- Pump motor bearngs are "Lfetme Greased " bearngs so they do not need any
control.
-Be sure that there s water n water tank and/or source.
-Be sure that pump and sucton ppe s completely filled wth water.
-ATTENTION! Never let pump run n dry condtons.
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Determnaton of Rotaton Drecton
- BTKF-I type pumps rotates n clockwse drecton when you look from motor towards
pump. Ths drecton s shown wth an arrow n pump body. Pump s operated for a
short whle and checked whether t rotates n correct drecton. If protecton guard s
unnstalled durng ths operaton, t should mmedately be nstalled after ths
operaton.
Startng Pump
- Check that sucton valve s open and dscharge valve s closed.
- Close the crcut breaker and start the motor.
- Wat motor to reach full speed. (Wat motor to pass delta n motors operaton wth
star-delta)
- Observe the ammeter n panel and slowly open dscharge valve. (If dscharge ppe
s empty n first start, do not open dscharge valve completely and open n controlled
way by controllng that value n ammeter s lower than motor rated values.)
-After valve s completely opened control the value whch s read from ammeter
whether t s same wth the value at operatonal pont. If the ammeter value s less
than operatonal value adjust t by closng the valve. If t s greater check the
nstallaton and statc heght.
ATTENTION: If any of followng problems occur whle pump operates n nomnal
speed; pump should mmedately be stopped and trouble should be elmnated.
1) Pump operates wth over vbraton.
2) Pump and motor connecton bearngs have over temperature.
3) Pressure s not enough.
4) Pump dscharges no water.
5) Flow rate contnuously decreases.
6) Motor operates overloaded
7) Pump operates wth very much nose.
8) Pump does not dscharge sufficent water.
Controls to be Made Whle Pump s Runnng
- Snce pumps have mechancal seal t does not need any mantenance. A few
amount of water may leak from mechancal seal but t s so small that t can not be
notced. If the amount of water comng from mechancal seal ths means that seal
surface s abraded and needs to be replaced. Lfetme of mechancal seal s manly
depends on cleanness of dscharged water.
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- Motor current should sometmes be controlled from ammeter over electrcal panel
whch controls the motor. If current values are more than motor nameplate values
there may be frcton or squeezng n pump. Pump should mmedately be stopped
and mechancal and electrcal controls should be done.
- If there are spare pumps n system, ths type of pumps should be run for a short
whle at least once a week and controlled whether read for operaton. Control wth
auxlary elements f any.
- Pump should absolutely be run n closed valve condton (zero flow rate) for a long
tme.
- Pump should operate slent and wthout operaton.
- Bearng temperatures should never exceed ambent temperature (more than 50ºC
It should never exceed 80ºC
- Never operate pump wthout water.
LUBRICATION
- Snce motor bearngs ARE "Lfetme Greases" t does not need any mantenance.
DISMOUNTING PUMP AND REPAIR
ATTENTION!-Always dsconnect the electrcal connectons before start any operaton
over pump and be sure that you have taken necessary precautons to prevent to
operate mstakenly.
DISMOUNTING PUMPS
- Close the solaton valves n sucton and dscharge lnes.
- Unnstall the safety guards.
-Separate the pump group from ppe system by unnstallng the pump sucton and
dscharge flange (and auxlary ppes f any) connectons.
-Separate scroll case from mechancal seal box. Be careful not to gve harm to
mechancal seal whle dong ths operaton.
-Unnstall the mpellor nuts and remove the mpellor wedge. Use rust solvent f
necessary.
-Take the ntermedate bushng.
-Carefully remove the rotatng parts of mechancal seal.
-Separate the mechancal seal box, and carefully remove the fixed elements of
mechancal seal.
-Unnstall the motor carrer.
13

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-Unnstall the pump shaft set screws and rgd couplng shaft bolts dependng on
connecton type.
-Separate pump shaft from motor shaft.
Installaton of Pump
-. Pump nstallaton operaton s made by reverse order of pump dsmountng
process.
- Before startng to nstallaton operaton, apply lubrcous materals such as graphte,
slcone or smlar slppery substances over contact surfaces or bolt surfaces. If you
can not find those substances use lqud ol. (drnkng water pumps excludng)
- Do not use gaskets whch you had removed. Use new ones havng same
dmensons. Be careful that new gaskets and O-rngs are n same dmensons.
-Place the motor as ts shaft end wll be upper sde and connect the motor carrer to
motor.
- Insert the pump shaft to the motor shaft by sldng.
-Place the seal box over motor carrer.
-Place the fixed elements of mechancal seal nto seal housng.
-Insert the rotatng parts of mechancal seal over pump shaft by sldng and place the
ntermedate bushng.
-Place the mpellor wedge and nsert the mpellor and connect the mpellor nuts.
-Connect the scroll case.
-Place the pump group over frame. Connect the sucton and dscharge ppes (and
auxlary ppes f any.)
-Connect the conductor plate f any.
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Fgure 5
Seals
-BTKF-I type pumps are always produced wth mechancal seal.
-Water leakage does not occur n a mechancal seal whch properly works. Generally
f there s not any vsble water leakage seals do not need mantenance. Besdes ths
mpermeablty of mechancal seals should regularly be controlled.
-Absolutely obey the nstructons of manufacturers where mechancal seals are used.
never operate the seal n dry condtons.
15

Fgure 6
1) Impellor
2) Carrer Foot
3) Scroll Case
4) Mechancal Seal
5) Dscharge Openng
6) Splash rubber
7) Pump Shaft
8) Motor
9) Sucton Openng
CROSS SECTION DRAWINGS
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16

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Table 3
1
There s ar n lqud Swrls occur snce depth of submerson ppe s
not enough and there fore ar can not be
absorbed. Control the lqud level n sucton tank
and ncrease the depth of bottom/sucton ppe
back water valve.
2
Ar pocket n sucton ppe Control the slope of sucton ppe and whether
there are sutable places for formaton of ar
pockets, f any make necessary correctons.
3
There may be ar n pump
and/or sucton lne
Fll pump or sucton ppe completely wth lqud
and repeat the start process
4
Ar s not absorbed from
seal, sucton ppe, or
connectons. Pump absorbs
lqud whch s mxed wth ar
Control all connectons n sucton ppe. Check
seals. If necessary feed seals wth pressurzed
water. Check the submerson depth of sucton
ppe pr deep back water valve and ncrease
submerson depth f necessary.
FAILURES POSSIBLE REASONS
Started pumps never dscharges water 3-6-8-12-11-14
Flow rate decreases or no water s dscharged 4-2-7-15
Motor s overloadng 9-10-16-22
Bearngs have over temperature 17
There s vbraton n pump 13-18-21-19
Nose level s hgh 1-5-20
17
SPARE PARTS
- ERDURO warrants to provde the spare parts for BTKF-I Seres pumps for 5(five)
years begnnng from producton date. You can always easly obtan the spare parts
you need.
- In spare parts order, t wll be sufficent for you to nform the followng values whch
are wrtten n pump nameplate.
Pump Type : BTKF-I 40/200
Motor Power(P) and Revoluton(n) :5,5 kW - 2900 d/d
Producton Year and Seral No : 12/2011 - 201112-001
Flow rate(Q) and Manometrc Heght (Hm): 15 m³/h - 44 mSS
REASONS FOR FAILURES AND TROUBLE SHOOTING
type pumps, possble reasons
(Table 3 ) and trouble shootng methods (Table 4 ) are gven.
ATTENTION! Control the accuracy of all measurement gauges before startng to
elmnate the falure operaton.
In ths chapter falures which can be seen BTKF-I

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5
Pump operates wth
cavtatons
NPSH of plant s very low. Check the water level
n sucton tank. Check whether there are over
frcton losses n sucton lne. Check whether
solaton valve n sucton lne s completely open.
If necessary place the pump n low levels and
ncrease the load of pump at sucton sde
6Sucton depth s very much
If there s no obstacle whch may cause cloggng
control the frcton losses of sucton lne. If
necessary use a sucton ppe havng larger
dameter. If statc sucton depth s too much you
should rase the heght of water level n sucton
tank or pump should be places n lower levels.
7
Increase n dscharge heght Check whether valves are completely open. Check
whether there s an obstacle whch may cause
cloggng n dscharge ppe.
8
Pumps dscharge heght s
nsufficent
Actual dscharge heght of plant s hgher than gven
values. Check the total statc heght and frcton
losses of dscharge ppe. Usng ppes havng
greater dameter may be soluton. Check whether
valves are completely opened.
9
Pump s operatng at lower
dscharge heght
Dscharge heght of plant s lower than gven
values. Lathe the mpellor dameter accordng to
manufacturer suggestons
10
Speed very much Decrease the motor revoluton f possble or Lathe
the mpellor dameter accordng to manufacturer
suggestons
11
Pump rotates reverse Check rotaton drecton of motor whether t s
same wth the drecton whch s ndcated n pump
body or nameplate
12
Impellor partally clogged Clean the mpellor
13 Impellor, check valve or filter
clogged
Clean Impellor, check valve or filter
14 Impellor, partally filter clogged
Clean Impellor, or filter
15 Mechancal frcton n pump Check whether there are any obstacle or bend n
pump rotor
16 Flow rate s less than pumps
necessary flow rate
Increase the flow rate, use by pass valve or lne f
necessary
17 Worn or malfunctoned
mpellor
Replace the mpellor
18 Imbalanced rotatng parts Adjust the balance of rotatng parts
19
Pump operates out of ts
operaton regon
Check the operatonal regon values
20
Shaft s bend Check the shaft and replace f necessary
21
Motor Falure Check the motor,. Motor s not sutable for ts ar
condtonng poston
Table 4
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INSTALLATION TYPES
Fgure 7
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SCREW DIAMETER
MAXIMUM TIGHTENING MOMENT(Nm)
CLASS PROPERTIES
8.8 10.9
M4 3 4,4
M5 5,9 8,7
M6 10 15
M8 25 36
M10 49 72
M12 85 125
M14 135 200
M16 210 310
M18 300 430
M20 425 610
M22 580 820
M24 730 1050
M27 1100 1550
M30 1450 2100
M33 1970 2770
M36 2530 3560
TIGHTENING MOMENT
20