HERMETIC-Pumpen CAMR Series User manual

Refrigerant pump
Original operating manual Series CAMR
Edition BA-2010.02
Print no. 1.2 US
HERMETIC-Pumpen GmbH
Gewerbestrasse 51
D-79194 Gundelfingen
Germany
phone [phone]
fax [phone]
[email protected]
http://www.lederle-hermetic.com
We reserve the right to make technical changes.
HERMETIC-Pumpen GmbH ⋅Gewerbestrasse 51 ⋅D-79194 Gundelfingen
Registergericht Freiburg HRB 365 ⋅Geschäftsführer: Dr. Roland Krämer, Christiane Krämer, Nicolaus Krämer

Table of contents
Table of contents
1 About this operating manual ................................................................................. 6
1.1 Target groups ............................................................................................. 6
1.2 Other applicable documents ............................................................................. 6
1.3 Warnings and symbols ................................................................................... 7
2Safety ............................................................................................................ 8
2.1 Intended use ............................................................................................. 8
2.1.1 Prevention of obvious misuse (examples) ............................................................... 8
2.1.2 Residual risks and measures ............................................................................. 9
2.2 General safety instructions ............................................................................... 10
2.2.1 Product safety ............................................................................................ 10
2.2.2 Obligations of the operating company ................................................................... 11
2.2.3 Obligations of personnel ................................................................................. 11
3 Layout and Function ............................................................................................ 12
3.1 Label ...................................................................................................... 12
3.2 Layout ..................................................................................................... 14
4 Transport, Storage and Disposal ............................................................................... 15
4.1 Transport .................................................................................................. 15
4.1.1 Unpacking and inspection on delivery ................................................................... 15
4.1.2 Lifting ..................................................................................................... 16
4.2 Treatment for storage ..................................................................................... 17
4.3 Storage ................................................................................................... 17
4.4 Disposal ................................................................................................... 17
5 Installation and connection .................................................................................... 18
5.1 Preparing the setup ...................................................................................... 18
5.1.1 Checking the ambient conditions ........................................................................ 18
5.1.2 Preparing the installation site ............................................................................ 18
5.1.3 Preparing the foundation ................................................................................ 18
5.1.4 Preparing the pump ...................................................................................... 18
5.2 Planning the piping ...................................................................................... 19
5.2.1 Specifying supports and flange connections ............................................................. 19
5.2.2 Specifying nominal diameters ............................................................................ 19
5.2.3 Specifying pipe lengths .................................................................................. 20
5.2.4 Supply flow speed ........................................................................................ 20
5.2.5 Optimizing cross-section and direction changes ......................................................... 21
5.2.6 Providing safety and control devices (recommended) ................................................... 21
5.2.7 Making provisions for isolating and shutting off pipes .................................................. 21
5.2.8 Allow measurements of the operating conditions ........................................................ 21
5.2.9 Installation Recommendations .......................................................................... 21
5.3 Connecting the pipes ..................................................................................... 25
5.3.1 Keeping the piping clean ................................................................................. 25
5.3.2 Mounting the supply pipe ................................................................................ 25
5.3.3 Installing the vessel outlet ................. ... ..... ... ................... ........ ...................... .. 25
5.3.4 Ensuring stress-free pipe connections .................................................................... 25
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Table of contents
5.4 Electrical connection ..................................................................................... 26
5.4.1 Providing a motor protection switch ..................................................................... 26
5.4.2 Connecting the motor .................................................................................... 26
6Operation........................................................................................................ 27
6.1 Putting the pump into service for the first time ......................................................... 27
6.1.1 Identifying the pump type ................................................................................ 27
6.1.2 Checking the shutdown period ........................................................................... 27
6.1.3 Filling and venting ....................................................................................... 27
6.1.4 Checking the sense of rotation ........................................................................... 27
6.1.5 Switching on .............................................................................................. 28
6.1.6 Switching off .............................................................................................. 28
6.2 Operating ................................................................................................. 29
6.2.1 Switching on .............................................................................................. 29
6.2.2 Switching off .............................................................................................. 29
6.3 Shutting down the pump ................................................................................. 30
6.4 Start-up following a shutdown period .................................................................... 30
6.5 Operating the stand-by pump ............................................................................ 31
7 Maintenance ..................................................................................................... 32
7.1 Inspections ................................................................................................ 32
7.2 Repairs .................................................................................................... 33
7.2.1 Dismounting .............................................................................................. 33
7.2.2 Returning the pump to the manufacturer ................................................................ 35
7.2.3 Installing .................................................................................................. 35
7.3 Ordering spare parts ..................................................................................... 36
8 Troubleshooting ................................................................................................. 37
8.1 Malfunctions .............................................................................................. 37
8.2 Troubleshooting .......................................................................................... 37
9Appendix......................................................................................................... 40
9.1 Recommended spare parts ............................................................................... 40
9.2 Technical specifications ................................................................................... 40
9.2.1 Ambient conditions ....................................................................................... 40
9.2.2 Sound pressure level ..................................................................................... 40
9.3 Safety certificate ......................................................................................... 41
9.4 Declarations in accordance with the EC Machinery Directive ........................................... 42
9.4.1 Declaration of conformity in accordance with the EC Machinery Directive ............................. 42
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Table of contents
List of figures
Fig. 1 Name plate (example) .................................................................................... 12
Fig. 2 Pump type label (on the type plate) ..................................................................... 13
Fig. 3 Motor type label (on the name plate) .................................................................... 13
Fig. 4 CAMR layout (example CAMR 2/3) ....................................................................... 14
Fig. 5 Fastening the lifting gear to the pump unit with base plate ............................................. 16
Fig. 6 Fastening lifting gear to pump unit ...................................................................... 16
Fig. 7 Gate valve ................................................................................................ 20
Fig. 8 Arrangement of vortex breakers at the vessel outlet ..................................................... 21
Fig. 9 Vessel inlet/vessel outlet arrangement ................................................................... 22
Fig. 10 Level monitor arrangement .............................................................................. 22
Fig. 11 Parallel operation arrangement .......................................................................... 22
Fig. 12 Slow pressure/temperature drop ......................................................................... 23
Fig. 13 Automatic venting (single pump - parallel pumps) ...................................................... 24
Fig. 14 Dismounting the carbon bearing ......................................................................... 34
Fig. 15 Declaration of conformity in accordance with the EC Machinery Directive ............................. 42
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Table of contents
List of tables
Tab. 1 Target groups and their duties ........................................................................... 6
Tab. 2 Other applicable documents and their purpose .......................................................... 6
Tab. 3 Warnings and consequences of disregarding them ...................................................... 7
Tab. 4 Symbols and their meaning .............................................................................. 7
Tab. 5 Measures after longer storage/shutdown periods ........................................................ 18
Tab. 6 Measures to be taken if the pump is shut down ......................................................... 30
Tab. 7 Measures depending on the behavior of the pumped liquid ............................................ 30
Tab. 8 Measures for return ....................................................................................... 35
Tab. 9 Malfunction/number assignment ......................................................................... 37
Tab. 10 Troubleshooting list ...................................................................................... 39
Tab. 11 Recommended spare parts ............................................................................... 40
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About this operating manual
1 About this operating manual
This manual:
•Ispartofthepump
• Applies to all pump series listed
• Describes safe and appropriate operation during all operating phases
1.1 Target groups
Target group Duty
Operating company Keep this manual available at all times at the site where the equipment
is operated, even during later use.
Ensure that personnel read and follow the instructions in this manual and the
other applicable documents, especially all safety instructions and warnings.
Observe any additional rules and regulations referring to the system.
Qualified personnel, fitter Read, observe and follow this manual and the other applicable documents,
especially all safety instructions and warnings.
Tab. 1 Target groups and their duties
1.2 Other applicable documents
Document Purpose
Tightening torques Installation of the pump
Performance curve Operating limits
Declaration of conformity Legally binding confirmation that the pump fulfills all requirements of the
applicable EC guideline(s) (→9.4 Declarations in accordance with the EC
Machinery Directive , Page 42).
Dimensional drawing Setup dimensions, connection dimensions, etc.
Brochure Technical specifications, operating limits
Parts list, sectional drawing Ordering spare parts
Maximum support load table Maximum permissible forces and torques at the supports
Technical specification Technical specifications, conditions of operation
Supplier documentation Technical documentation for parts supplied by subcontractors
Tab. 2 Other applicable documents and their purpose
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About this operating manual
1.3 Warnings and symbols
Warning Risk level Consequences of disregard
DANGER Immediate acute risk Death, serious bodily harm
WARNING Potentially acute risk Death, serious bodily harm
CAUTION Potentially hazardous
situation
Minor bodily harm
NOTE Potentially hazardous
situation
Material damage
Tab. 3 Warnings and consequences of disregarding them
Symbol Meaning
Safety warning sign
Take note of all information highlighted by the safety warning sign
and follow the instructions to avoid injury or death.
Instruction
1. , 2. , ... Multiple-step instructions
üPrecondition
→Cross-reference
Information, recommendation
Tab. 4 Symbols and their meaning
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Safety
2Safety
The manufacturer does not accept any liability for damage resulting from disregard
of any parts of this documentation.
2.1 Intended use
• Only use the pump within the limits set by the technical specifications (→tech-
nical specification).
•Liquidpumped
– Onlyusethepumpforpumpingtheagreedliquids(→technical specifica-
tion).
– Observe the specified physical properties of the pumped liquids, such as
temperature, density, viscosity, specific heat and vapor pressure.
• Electric motor
– Only operate the electric motor with the designated voltage and frequency
(→technical specification).
• Conditions of use
– Suction head, system pressure and flow rate must remain within the speci-
fied limits (→technical specification).
2.1.1 Prevention of obvious misuse (examples)
• Pumping liquids containing solids is not permitted.
• Pumping liquids containing impurities is not permitted. It can cause cavitation
and damage to the pump.
• Do not use in areas where there is a risk of explosion.
• Avoid dry running
– Dry running causes severe damage, such as destruction of the sleeve bear-
ingsandpumpcomponents,withinafewseconds.
– Ensure that the pump is always filled with pumping liquid.
– Bleed the pump completely before the initial start-up.
• Avoiding cavitation
– Observe the minimum suction head (→5.2.3 Specifying pipe lengths,
Page 20).
– Fully open the suction-side valve and do not use it to adjust the flow.
– Monitor the suction-side filter.
– Ensure that the flow rate remains within the specified limits (→technical
specification).
• Avoid overheating
– Do not operate the pump while the pressure-side fitting is closed.
– Observe the minimum flow rate (→technical specification).
• Avoid overloading
–Observethemaximumflow rate (→technical specification).
• Remove covers, transport and sealing covers before installation.
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Safety
2.1.2 Residual risks and measures
Residual risk Measures by the operating company
Cuts while working without personal
protective equipment.
Observe warnings in the operating
manual.
Training for personnel.
Provideandusepersonalprotective
equipment.
Electric shock:
• Motor not properly electrically
connected
•Pumpisnot,orincorrectly,
grounded
• Access by unauthorized persons
Observe warnings in the operating
manual.
Training for personnel.
Prevent access by unauthorized
persons.
Burns, frostbite, crushing
•Pumpisinsufficiently protected
from accidental contact
• Access by unauthorized persons
Observe warnings in the operating
manual.
Training for personnel.
Prevent access by unauthorized
persons.
Install protection against accidental
contact.
Injuries due to escaping pumped
liquids when not used in accordance
with specifications.
Observe warnings in the operating
manual.
Training for personnel.
Prevent access by unauthorized
persons.
Provideandusepersonalprotective
equipment.
1.2 US BA-2009.12 Series CAMR 9 / 44

Safety
2.2 General safety instructions
Note the following regulationsbeforecarryingoutanywork.
2.2.1 Product safety
The pump has been constructed according to the latest technology and recognized
technical safety rules. Nevertheless, operation of the pump can still put the life and
health of the user or third parties at risk, damage the pump or other property.
• Only operate the pump when in perfect technical condition and only use as
intended, staying aware of safety and risks, and in adherence to the instructions
in this manual.
• Keep this manual and all other applicable documents complete, legible and
accessible to personnel at all times.
• Refrain from any procedures and actions that would pose a risk to personnel or
third parties.
• In the event of any safety-relevant malfunctions, shut down the pump immedi-
ately and have the malfunction corrected by appropriate personnel.
• In addition to the entire documentation for the product, comply with statutory or
other safety and accident prevention regulations and the applicable standards
and guidelines in the country where the pump is operated.
2.2.2 Obligations of the operating company
Safety-conscious operation
• Only operate the pump when in perfect technical condition and only use as
intended, staying aware of safety and risks, and in adherence to the instructions
in this manual.
• Ensure that the following safety aspects are observed and monitored:
– Adherence to intended use
– Statutory or other safety and accident prevention regulations
– Safety regulations governing the handling of hazardous substances
– Applicable standards and guidelines in the country where the pump is oper-
ated
• Provide personal protective equipment.
Qualified personnel
• Make sure all personnel entrusted with work on the pump have read and under-
stood this manual and all other applicable documents, especially the safety,
maintenance and repair information, before they start any work.
• Organize responsibilities, areas of competence and the supervision of personnel.
• Have all work in all operating phases carried out by specialist technicians only.
• Make sure that trainee personnel only work on the pump under supervision of
specialist technicians.
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Safety
Safety equipment
• Provide the following safety equipment and verify its functionality:
– for hot, cold surfaces: protection against accidental contact for the pump,
provided by the operating company
– ensure appropriate grounding
Warranty
• Obtain the manufacturer’s approval prior to carrying out any modifications,
repairs or alterations during the warranty period.
• Only use genuine parts or parts that have been approved by the manufacturer.
2.2.3 Obligations of personnel
• Observe all warnings on the pump and ensure they are legible.
• Do not remove protection against accidental contact for hot and cold surfaces
during operation.
• Use personal protective equipment whenever necessary.
• Only carry out work on the pump while it is not running.
• Isolate the motor from its supply voltage and secure it against being switched
back on again when carrying out any fitting or maintenance work.
• Reinstall the safety equipment on the pump according to regulations after any
work on the pump.
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Layout and Function
3 Layout and Function
3.1 Label
1
2
3
4
5
6
7
8
9
10
Fig. 1 Name plate (example)
1 Equipment number
2Pumptype
3 Actual impeller diameter [mm]
4 Motor type
5Flowrate[m
3/h], specificdensity[kg/
m3], differential head [m]
6 Nominal pressure [bar], nominal motor output [kW], frequency [Hz]
7 Nominal speed [rpm], phase shift [°], rated current [A]
8 Fluid temperature [°C], nominal voltage [V]
9 Material of pump, year of construction
10 Materials of bearing , protection class
12 / 44 Series CAMR BA-2009.12 1.2 US

Layout and Function
1
2
3
CAMR 2 / 3
Fig. 2 Pump type label (on the type plate)
1Series
2Size
3 Number of stages
1
2
AGX 3.0
Fig. 3 Motor type label (on the name plate)
1Constructiontype
2Size
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Layout and Function
3.2 Layout
6
234 5
87
9
1
Fig. 4 CAMR layout (example CAMR 2/3)
1 Impellers
2Pressurestage
3 Front sleeve bearing
4Topshaft
5 Connection cable
6 Rear sleeve bearing
7 Electrical winding
8Statortube
9Stagecasing
14 / 44 Series CAMR BA-2009.12 1.2 US

Transport, Storage and Disposal
4 Transport, Storage and Disposal
4.1 Transport
Weight specifications (→dimensional drawing, delivery note).
4.1.1 Unpacking and inspection on delivery
1. Unpack the pump/aggregate on delivery and inspect it for damage during trans-
port.
2. Report any damage during transport to the manufacturer immediately.
3. Dispose of packaging material according to pertinent local regulations.
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Transport, Storage and Disposal
4.1.2 Lifting
DANGER
Death or crushing of limbs may be caused by falling loads!
Use lifting gear appropriate for the total weight to be transported.
Fasten the lifting gear as illustrated below.
Do not stand under suspended loads.
Fig. 5 Fastening the lifting gear to the pump unit with base plate
Fig. 6 Fastening lifting gear to pump unit
Lifttheunitinanorderlyf
ashion.
16 / 44 Series CAMR BA-2009.12 1.2 US

Transport, Storage and Disposal
4.2 Treatment for storage
Not necessary for stainless materials.
The preservation applied at the plant lasts for 12 months.
CAUTION Material damage may occur due to inappropriate treatment for storage!
Ensure the pump is treated for storage properly, both inside and outside.
1. Selecting preservatives:
– Compatible with the pump materials
– Compatible with the pumped liquid
2. Use the preservative specified by the manufacturer.
3. All bare metal parts should be treated with preservative, inside and outside.
4.3 Storage
CAUTION Material damage may occur due to inappropriate storage!
Store the pump properly.
1. Close all openings with blank flanges, plugs or plastic covers.
2. Ensure the storage room is:
–dry
– frost-free
– vibration-free
3. Rotate the motor shaft before installing the pump and check that it can move
freely.
4.4 Disposal
WARNING
Risk of poisoning and environmental damage by the pumped liquid or oil!
Usepersonalprotectiveequipmentwhencarryingoutanyworkonthepump.
Prior to the disposal of the pump: Collect and dispose any leaking pumped
liquid in accordance with local regulations.
1. Empty the pump completely and clean it.
2. Dispose of the pump in accordance with local regulations.
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Installation and connection
5 Installation and connection
CAUTION Material damage can be caused by dirt!
Do not remove any covers, transport and sealing covers until immediately before
connecting the pipes to the pump.
5.1 Preparing the setup
5.1.1 Checking the ambient conditions
1. Make sure the required ambient conditions are fulfilled (→9.2.1 Ambient con-
ditions, Page 40).
2. Adhere to system conditions (→brochure, technical specification).
5.1.2 Preparing the installation site
Ensure the installation site meets the following conditions:
– Pump is freely accessible from all sides
–Thereissufficient space for the installation/removal of the pipes and for
maintenance and repair work, especially for the removal and installation of
the pump and the motor
– Pump is not exposed to external vibrations (damage to bearings)
5.1.3 Preparing the foundation
Make sure the foundaction and surface are:
– level
– clean (no oil, dust or other impurities)
– capable of bearing the weight of the pump unit and all operating forces
– ensure the pump is stable and cannot tip over
5.1.4 Preparing the pump
After longer storage/shutdown periods, perform the following measures:
Storage/shutdown
period
Measure
2years If necessary, replace the seals.
Tab. 5 Measures after longer storage/shutdown periods
18 / 44 Series CAMR BA-2009.12 1.2 US

Installation and connection
5.2 Planning the piping
5.2.1 Specifying supports and flange connections
CAUTION Material damage may occur due to excessive forces and torques exerted by
the piping on the pump!
Do not exceed the permissible values (→maximum support load, torque table).
1. Calculate the pipe forces, taking every possible operating condition into
account:
–Cold/warm
–Empty/full
– Unpressurized/pressurized
– Positional changes of the flanges
2. Ensure the pipe supports have permanent low-friction properties and do not
seize up due to corrosion.
5.2.2 Specifying nominal diameters
Keep the flow resistance in the pipes as low as possible.
1. Make sure the nominal suction pipe diameter is ≥the nominal suction branch
diameter.
2. Make sure the nominal vessel outlet diameter is ≥the nominal outlet flange
diameter.
1.2 US BA-2009.12 Series CAMR 19 / 44

Installation and connection
5.2.3 Specifying pipe lengths
Calculate the minimum suction head (→technical specification)
l
min
min
1
Fig. 7 Gate valve
1. emin =NPSH
req. +R Z+S
emin – minimum suction head [m]
Rz– resistance of the supply pipe [m]
S – additional safety factor [m]
2. Maintain the minimum suction head when installing the pump.
3. lmin =5*DN
s
lmin – minimum length of the settling section [mm]
DNS– supply pipe diameter [mm]
4. Maintain the minimum length of the horizontal settling section.
Upstream: Shorter pipes are possible, but may restrict the hydraulic perfor-
mance and/or lead to cavitation.
5.2.4 Supply flow speed
1. Calculate the supply flow speed.
– Optimum speed: 0.3 m/s – 0.5 m/s
2. If necessary, adjust the diameter of the supply pipe.
20 / 44 Series CAMR BA-2009.12 1.2 US