Grundfos LS 500-300-490E User manual

LS
Large LS models, flow range is greater than 3000 m3/h
Installation and operating instructions
GRUNDFOS INSTRUCTIONS

LS
English (GB)
Installation and operating instructions ..................................4
3
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
4
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.
5
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
6
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.
7
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.
1
2
9
3
6
4
57
8
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
8
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.
1
2
3
4
5
6
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.
9
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.
1
2
3
4
5
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
10
English (GB)

5. Piping
5.1 General precaution
Do not use pump as a support for piping.
• Use pipe hangers or other supports at proper
intervals to provide complete piping support near
the pump.
• Both suction and discharge piping should be
independently supported and properly aligned so
that no strain is transmitted to the pump when
flange bolts are tightened.
• Do not spring or force piping when making any
connections.
• Make sure piping is as straight as possible,
avoiding unnecessary bends and fittings.
5.2 Suction piping
The sizing and installation of suction piping is
particularly important. It must be selected and
installed in a manner that minimizes pressure loss
and permits sufficient liquid flow into the pump during
starting and operation. Many NPSH problems can be
traced directly to improper design of suction piping
systems. Observe the following precautions when
installing suction piping:
• Suction piping should be as straight as possible,
and ideally the pipe length should be at least
seven times the pipe diameter. Short suction
piping can be the same diameter as the suction
opening. Longer piping should be one or two
sizes larger (depending on length), reducing to the
diameter of the pump suction opening.
• Use an eccentric reducer, with the eccentric side
down, when reducing the pipe diameter to the
diameter of suction opening.
1
5
3
2
4
6
TM061436
Suction piping eccentric vs. concentric
Pos. Description
1 Right
2 Wrong
3 Taper is down
4 Air pocket
5 Eccentric reducer
6 Concentric reducer
• At no point should suction piping be smaller in
diameter than the pump suction opening.
• Horizontal suction lines should follow an even
gradient, if possible. A gradual upward slope to
the pump is recommended for suction lift
conditions.
11
English (GB)

• Avoid any high points, such as pipe loops, that
may create air pockets and throttle the system or
produce erratic pumping.
1
2
3
TM078826
Suction piping (Avoid high points)
Pos. Description
1 Right
2 Wrong
3 Air pocket
• Install a valve in the suction line to isolate the
pump during shutdown and maintenance, and
facilitate pump removal.
• Gate valve should be installed in place where is
not easy to create air pocket.
• During pumping operation, valves on suction line
must always be at full open.
5.3 Discharge piping
• Short discharge piping can be the same diameter
as the pump discharge opening. Longer piping
should be one or two sizes larger depending on
length.
• Any high points in discharge piping may entrap air
or gas and thus retard pump operation. So an air
vents should be installed to exhaust air in the
pump.
• An even gradient is best for long horizontal runs of
discharge piping.
• Install a valve near the discharge opening to
prime and start the pump. The discharge gate
valve is also used to isolate the pump during
shutdown, maintenance, and facilitate pump
removal.
• If the possibility of liquid hammer exists, (i.e.
check valves are used) close the discharge gate
valve before pump shut down.
The selection and installation for reducer
should base on the national standard.
5.4 Pressure gauges installation
Pressure gauges properly sized for the range of
operation, should be installed in gauge taps on the
pump suction and discharge nozzles.
5.5 General information of shaft sealing
• Grundfos offers both mechanical shaft seals and
stuffing boxes as a means to seal the shaft.
• Pumps with stuffing boxes are normally packed
before shipment. If the pump is installed within 60
days after shipment, the packing material will be
in good condition for operation with a sufficient
supply of lubrication. If the pump is stored for a
longer period, it may be necessary to repack the
stuffing boxes. Refer to section Stuffing box
replacement, each side. The stuffing box must be
supplied at all times with a source of clean, clear
liquid to flush and lubricate the packing.
• When pumps are equipped with mechanical shaft
seals, no maintenance or adjustment is required.
Related information
10.3 Replacing the stuffing
5.6 Packing gland adjustment
• Make sure the flushing fluid lines are connected
and their valves are open. After pump start-up,
with the pump running, the packing gland should
be adjusted to permit 40 to 60 drops per minute
leakage, this is required for shaft sleeve
lubrication.
• The packing gland should be tightened evenly to
provide uniform compression on the packing
material. Do not operate packing dry, and do not
over tighten packing gland to eliminate leaking as
the shaft sleeve will become damaged. After initial
start-up, additional packing and adjustment may
be required until the packing is properly seated.
12
English (GB)

5.7 Mechanical shaft seals
All LS pumps that are equipped with mechanical shaft
seals are matched to conditions for which the pump
was sold. Observe the following precautions to avoid
seal damage and obtain maximum seal life:
• Do not exceed temperature or pressure limitations
for the mechanical shaft seal used.
DO NOT run the pump dry or against a
closed valve. Dry operation will cause seal
failure within seconds.
• Exhaust air in the seal cavity and pipes before
pump starting.
• Clean and purge suction piping in new
installations before installing and operating pump.
Pipe scale, welding slag and other abrasives can
cause rapid seal failure.
• The mechanical shaft seal does not leak at all
during normal operation, therefore if any
appreciable leakage occurs; the seal should be
removed, inspected and if necessary replaced.
• Mechanical shaft seals should be stocked as
spare parts to reduce equipment down time.
5.8 Coupling alignment
Check shaft alignment once again after pump
installation is completed. The following anchoring and
alignment procedures are typical and, if performed
with care, should result in a smooth running, trouble-
free installation.
• If the pump and motor were shipped mounted on
the pump base as an assembly, remove the
coupling guard.
• The pump and motor were accurately aligned at
the factory, but handling during shipment usually
alters this pre-alignment. Use a small straight
edge and feeler gauges or a dial indicator or a
laser. To choose one of the following three
methods to perform alignment.
WARNING
Crushing of hands
Death or serious personal injury
‐To protect personnel from rotation
machinery, always install coupling
guards after installation is complete
before starting the pump.
5.8.1 Aligning the pump and motor with a
straightedge ruler
1. Make a rough alignment of pump and motor, and
tighten the screws in the base frame to the correct
torque.
TM038340
See the table Tightening torques.
2. Make a mark on the coupling, for instance with a
marker pen.
TM082476
3. Hold a straightedge ruler against the coupling,
and determine the inaccuracy, if any, with a feeler
gauge.
TM038300
13
English (GB)

4. Turn the coupling 90°, and repeat the
measurement with straightedge and feeler gauge.
TM082477
• If the measured values are less than 0.13 mm,
the alignment is complete. Go to step 8.
5. Adjust the position of the motor. Loosen the
screws that hold the motor in place.
TM038321
6. Insert shims with the required thickness.
TM038322
7. Tighten the screws to the correct torque. Go to
step 3, and check the alignment once more.
TM038324
8. Check the gap S2 both vertically and horizontally.
TM038325
• If the air-gap width is within the tolerances, the
alignment is complete.
• If not, go to step 6.
See the table Air-gap width S2.
5.8.2 Aligning the pump and motor with a dial
indicator
1. Make a rough alignment of pump and motor, and
tighten the screws in the base frame to the correct
torque.
TM038340
See the table Tightening torques.
2. Make a mark on the coupling, for instance with a
marker pen.
TM082476
14
English (GB)

3. Fasten a dial indicator to the hub of coupling
guard, make sure the dial indicator is on the outer
circumference of coupling guard.
TM082486
4. Turn the motor coupling and measure the
deviation along circumference on 0°, 90°, 180°
and 270°.
TM082487TM082488
TM082489
5. Adjust the position of the motor. Loosen the
screws that hold the motor in place.
TM038321
6. Insert shims with the required thickness.
TM038322
7. Tighten the screws to the correct torque. Go to
step 3, and check the alignment once more.
TM038324
15
English (GB)

8. Check the gap S2 both vertically and horizontally.
TM038325
• If the air-gap width is within the tolerances, the
alignment is complete.
• If not, go to step 6.
See the table Air-gap width S2.
5.8.3 Aligning the pump and motor with a laser
equipment
1. Make a rough alignment of pump and motor, and
tighten the screws in the base frame to the correct
torque.
TM038340
See the table Tightening torques.
2. Fasten one laser bracket to the pump coupling.
TM082478
3. Fasten the other laser bracket to the motor
coupling.
TM082479
4. Place laser unit S, stationary, on the stationary
part and laser unit M, movable, on the movable
part.
TM038305
5. Interconnect the laser units, and connect one
laser unit to the control box.
TM082480
6. Make sure that the laser units are at the same
height.
TM082481
16
English (GB)

7. Measure the distance between the white lines on
the laser units.
TM038309
8. Enter the distance.
TM038308
9. Measure the distance between the S unit and the
centre of the gap between the couplings.
TM038310
10. Enter the distance.
TM038311
11. Measure the distance from the S unit to the first
screw on the motor.
TM082482
12. Enter the distance.
TM038313
13. Measure the distance from the S unit to the rear
screw on the motor.
TM038314
14. The control box shows that the laser units must be
turned to position 9 o'clock.
TM038315
17
English (GB)

15. Turn the laser units to position 9 o'clock.
TM082483
16. Confirm on the control box.
TM038319
17. Turn the laser units to position 12 o'clock. Confirm
on the control box.
TM082484
18. Turn the laser units to position 3 o'clock. Confirm
on the control box.
TM082485
19. If the measured values are less than 0.13 mm, the
alignment is complete. Go to step 24.
TM038320
20. Loosen the screws that hold the motor in
place. Adjust the position of the motor.
TM038321
21. Insert shims with the required thickness.
TM038322
22. Tighten the screws to the correct torque again.
TM038324
18
English (GB)

23. Repeat the alignment until the values are within
the tolerances. Go to step 14.
TM038320
24. Check the gap S2.
TM038325
See the table Air-gap width S2.
5.8.4 Tightening torques
Refer to this tightening torques table when align the
motor and pump.
Description Dimensions Tightening
torque [Nm]
Hexagon head
screw
M4 3 ± 10%
M6 9 ± 10%
M8 21 ± 10%
M10 41 ± 10%
M12 72 ± 10%
M14 114 ± 10%
M16 177 ± 10%
M18 244 ± 10%
M20 345 ± 10%
M22 470 ± 10%
M24 597 ± 10%
5.8.5 Pin coupling air-gap width S2
Measure S2 all the way around the
coupling. The maximum permissible
deviation between the largest and the
smallest measurement is 0.13 mm.
After the installation is finished, tighten the
screws connecting the flange, feet and the
anchor bolts according to the tightening
torques. Anti-loose method should be
applied.
Outside coupling
diameter [mm]
Air-gap width S2 [mm]
Standard coupling
Nominal Tolerance
90 3 mm ± 0.5
150 3 mm ± 0.5
220 4 mm ± 0.5
260 5 mm ± 0.5
320 5 mm ± 0.5
If the coupling and motor are not supplied by
Grundfos, make sure to follow the coupling
manufacturer’s instructions.
WARNING
Crushing of hands
Death or serious personal injury
‐To protect persons from rotating
machine parts, always install all guards
after the installation is complete and
before starting the pump.
19
English (GB)

5.9 Spacer coupling installation
5.9.1 Preparation
• Check the spacer coupling for possible transport
damage and missing parts. Clean the spacer
coupling components.
• Proper lifting and assembling devices should be
on hand.
5.9.2 Installing the spacer coupling
Make sure the spacer coupling is clean.
Make sure the keys fit in key slots between
shafts and hubs properly with a small
clearance over the top to keep dynamic
balance.
1
23456
7
TM082157
Spacer coupling
Pos. Description
1 Hub
2 Bolt
3 Lock nut
4 Sleeve
5 Disc pack
6 Spacer
7 Hub
1. Install the hub on the shaft. Make sure the shaft
end align with the hub end. If necessary, place
limit blocks to limit the gap between coupling and
shaft shoulder. Use shaft lock nut or end plate to
secure the hub axially. To achieve clearance fit,
install the hub on the shaft directly and use soft
hammer to hit the hub gently.
After the installation of hubs, apply rust
prevention to the hubs immediately.
2. Use dial indicator to check hub circumference and
end face. Adjust the hub alignment according to
the measurements. The deviation of hub
circumference and end face mustn't exceed 0.05
mm. For hub flange diameter bigger than 250 mm,
the maximum deviation is 0.08 mm. Reinstall the
hub if the deviation exceeds the limit. Refer to
section Tightening torques for spacer coupling.
3. Place the motor and the pump in working position
and measure the distance F between the two hub
surfaces of the motor and pump. Take four
readings along circumference with 90° interval
and calculate the average value. Adjust the
position of the motor and pump until the value of F
meets the dimension Ls in the assembly drawing,
Ls is the distance between pump shaft end and
motor shaft end. The deviation should be from 0
mm to 0.4 mm.
F
TM082166
4. Choose one of the following methods that suits
best for the installation:
a. Use professional aligning apparatus.
b. Use the dial indicator to measure the deviation
of the circumference and the end face.
Determine the location of shafts by analyzing
the measurements, and then adjust the shafts
based on the results. See section on Accepted
misalignment.
In order to improve the precision, use two dial
indicators that locate equidistant to axis to
measure the deviation of the end face.
TM082161
20
English (GB)