Lowara e-HM series Installation and operating instructions

Installation, Operation and
Maintenance Manual
e-HM Series
Multistage Horizontal Pump Unit

Table of Contents
1 Introduction and Safety..............................................................................................................3
1.1 Introduction.......................................................................................................................... 3
1.1.1 Purpose of this manual.................................................................................................3
1.1.2 Supplementary instructions.........................................................................................3
1.2 Safety..................................................................................................................................... 3
1.2.1 Danger levels and safety symbols.............................................................................. 3
1.2.2 User safety......................................................................................................................4
1.2.3 Protection of the environment.................................................................................... 4
1.2.4 Sites exposed to ionizing radiations...........................................................................5
2 Transport and storage................................................................................................................6
2.1 Handling of the packed unit............................................................................................... 6
2.2 Unit inspection upon delivery............................................................................................ 7
2.2.1 Inspect the package..................................................................................................... 7
2.2.2 Unpacking and inspection of the unit........................................................................ 7
2.3 Unit handling........................................................................................................................ 7
2.4 Storage.................................................................................................................................. 8
2.4.1 Storage of the packed unit.......................................................................................... 8
2.4.2 Long-term storage of the unit..................................................................................... 8
3 Product Description....................................................................................................................9
3.1 Designation...........................................................................................................................9
3.2 Data plate..............................................................................................................................9
3.2.1 Marks of safety approval............................................................................................11
3.3 Denomination of the main components.........................................................................12
3.4 Intended use.......................................................................................................................13
3.4.1 Pumped liquids...........................................................................................................13
3.5 Improper use......................................................................................................................14
3.5.1 Examples of improper use.........................................................................................14
3.5.2 Examples of improper installation............................................................................14
3.6 Use in water distribution networks for human consumption....................................... 14
4 Installation................................................................................................................................. 16
4.1 Precautions......................................................................................................................... 16
4.2 Mechanical installation......................................................................................................16
4.2.1 Installation area...........................................................................................................16
4.2.2 Permitted positions.................................................................................................... 17
4.2.3 Fastening of the unit...................................................................................................17
4.2.4 Reducing vibrations....................................................................................................17
4.3 Hydraulic connection........................................................................................................ 18
4.3.1 Guidelines for the hydraulic system......................................................................... 18
4.4 Electrical connection......................................................................................................... 20
4.4.1 Ground.........................................................................................................................20
4.4.2 Guidelines for electrical connection........................................................................ 20
4.4.3 Guidelines for the electric panel...............................................................................20
4.4.4 Motor guidelines.........................................................................................................21
4.4.5 Operation with frequency converter........................................................................22
5 Operation.................................................................................................................................. 23
5.1 Precautions......................................................................................................................... 23
Table of Contents
e-HM Series Installation, Operation and Maintenance Manual 1

5.2 Filling - Priming.................................................................................................................. 24
5.2.1 Positive suction head installation..............................................................................24
5.2.2 Suction lift installation................................................................................................ 24
5.3 Checking the direction of rotation (three-phase motors).............................................25
5.3.1 Wrong rotation direction........................................................................................... 25
5.4 Start-up................................................................................................................................26
5.4.1 Settling of the mechanical seal................................................................................. 26
5.5 Stopping............................................................................................................................. 27
6 Maintenance..............................................................................................................................28
6.1 Precautions......................................................................................................................... 28
6.2 Maintenance every 4000 hours of operation or every year......................................... 28
6.3 Long periods of inactivity..................................................................................................29
6.4 Ordering spare parts.........................................................................................................29
7 Troubleshooting....................................................................................................................... 30
7.1 Precautions......................................................................................................................... 30
7.2 The unit does not start...................................................................................................... 30
7.3 The differential protection device (RCD) is activated....................................................30
7.4 The motor thermal overload protection or the fuses trigger when the unit starts....30
7.5 The thermal motor protection trips................................................................................. 31
7.6 The unit runs but there is little or no flow rate............................................................... 31
7.7 When turned off, the unit turns in the opposite direction............................................31
7.8 The unit produces excessive noise and/or vibrations...................................................31
7.9 The unit starts up too frequently (automatic start/stop)............................................... 32
7.10 The unit never stops (automatic start/stop)..................................................................32
7.11 The unit is leaking............................................................................................................32
7.12 The motor becomes excessively hot.............................................................................33
7.13 The frequency converter (if present) is in error mode or turned off.........................33
8 Technical references................................................................................................................ 34
8.1 Operating environment.................................................................................................... 34
8.1.1 Temperature................................................................................................................34
8.1.2 Relative air humidity................................................................................................... 34
8.1.3 Elevation...................................................................................................................... 34
8.2 Temperature of pumped liquid....................................................................................... 34
8.3 Operating pressure........................................................................................................... 35
8.4 Maximum hourly start-ups................................................................................................ 35
8.5 Protection class.................................................................................................................. 35
8.6 Electrical specifications..................................................................................................... 35
8.7 Permitted tolerances for the supply voltage.................................................................. 35
8.8 Noise level.......................................................................................................................... 35
8.9 Materials..............................................................................................................................36
9 Disposal..................................................................................................................................... 37
9.1 Precautions......................................................................................................................... 37
10 Declarations............................................................................................................................ 38
10.1 EC Declaration of Conformity (Original).......................................................................38
10.2 EU Conformity Declaration (n. EMCD08)..................................................................... 38
11 Warranty.................................................................................................................................. 39
11.1 Information....................................................................................................................... 39
Table of Contents
2 e-HM Series Installation, Operation and Maintenance Manual

1 Introduction and Safety
1.1 Introduction
1.1.1 Purpose of this manual
This manual provides information on how to do the following in the correct manner:
• Installation
• Operation
• Maintenance.
CAUTION:
This manual is an integral part of the unit. Make sure to have read and understood the
manual before installing the unit and putting it to use. The manual must always be made
available to the user, stored in the proximity of the unit, and well kept.
1.1.2 Supplementary instructions
The instructions and warnings of this manual apply to the standard unit as described in
the sale documentation. Special version pumps may be supplied with supplementary
instruction manuals. For situations not considered in the manual or in the sales document,
contact Xylem or the Authorised Distributor.
1.2 Safety
1.2.1 Danger levels and safety symbols
Before using the unit, the user must read, understand and comply with the indications of
the danger warnings in order to avoid the following risks:
• Injuries and health hazards
• Damage to the unit
• Unit malfunction.
Danger levels
Hazard level Indication
DANGER: It identifies a dangerous situation which, if not avoided,
causes serious injury, or even death.
WARNING: It identifies a dangerous situation which, if not avoided,
may cause serious injury, or even death.
CAUTION: It identifies a dangerous situation which, if not avoided,
may cause small or medium level injuries.
NOTICE: It identifies a situation which, if not avoided, may cause
damage to property but not to people.
1 Introduction and Safety
e-HM Series Installation, Operation and Maintenance Manual 3

Complementary symbols
Symbol Description
Electrical Hazard:
Electrical hazard
CAUTION:
Magnetic hazard
Hot Surface:
Hot surface hazard
1.2.2 User safety
Strictly comply with current health and safety regulations.
WARNING:
This unit must be used only by qualified users. Qualified users are people able to
recognise the risks and avoid hazards during installation, use and maintenance of the unit.
Inexperienced users
WARNING:
For EU countries: this appliance can be used by children aged from 8 years and above
and persons with reduced physical, sensory or mental capabilities or lack of experience
and knowledge, provided that they are being supervised and have been instructed on the
use of the appliance in a safe way and understand the hazards involved. Children shall not
play with the appliance. Cleaning and user maintenance shall not be carried out by
children without supervision.
WARNING:
For countries outside the EU: this appliance is not intended for use by persons (including
children) with reduced physical, sensory or mental capabilities, or lack of experience and
knowledge, unless they are being supervised and have been instructed on the use of the
appliance by a person responsible for their safety. Children should be supervised to
ensure that they do not play with the appliance.
1.2.3 Protection of the environment
Disposal of packaging and product
Comply with the current regulations on sorted waste disposal.
Leaking of fluid
If the unit contains lubricating fluid, take appropriate measures to prevent the dispersion
of leaks into the environment.
1 Introduction and Safety
4 e-HM Series Installation, Operation and Maintenance Manual

1.2.4 Sites exposed to ionizing radiations
WARNING: Ionizing radiation hazard
If the unit has been exposed to ionizing radiations, implement the necessary safety
measures for the protection of people. If the unit needs to be despatched, inform the
carrier and the recipient accordingly, so that appropriate safety measures can be put in
place.
1 Introduction and Safety
e-HM Series Installation, Operation and Maintenance Manual 5

2 Transport and storage
2.1 Handling of the packed unit
WARNING: Crushing hazard (limbs)
The unit and its components may be heavy: risk of crushing.
WARNING:
Always wear personal protective equipment.
WARNING:
Check the gross weight marked on the packaging.
WARNING:
Handle the unit in compliance with the current regulations on "manual load handling", to
avoid undesirable ergonomic conditions causing risks of back-spine injury.
WARNING:
Take appropriate measures during transport, installation and storage to prevent
contamination from external substances.
Depending on the model, the Manufacturer delivers the unit and its components in:
1. A cardboard box, or
2. A cardboard box with wooden base.
The type 2 packaging is intended for transport with a forklift truck; the lifting points are
indicated in the figure.
EHM_M0014_A_ot
12
Figure 1: Packed product lifting points
2 Transport and storage
6 e-HM Series Installation, Operation and Maintenance Manual

2.2 Unit inspection upon delivery
2.2.1 Inspect the package
1. Check that quantity, descriptions and product codes match the order.
2. Check the packaging for any damage or missing components.
3. In case of immediately detectable damage or missing parts:
– accept the goods with reserve, indicating any findings on the transport document,
or
– reject the goods, indicating the reason on the transport document.
In both cases, promptly contact Xylem or the Authorised Distributor from whom the
product was purchased.
2.2.2 Unpacking and inspection of the unit
CAUTION: Cut and abrasion hazard
Always wear personal protective equipment.
1. Remove packing materials from the product.
2. Release the unit by removing the screws and/or cutting the straps, if fitted.
3. Check the unit for integrity and to make sure that there are no missing components.
4. In case of damage or missing components, promptly contact Xylem or the Authorised
Distributor.
2.3 Unit handling
The unit must be harnessed and lifted as shown in the figure.
EHM_M0015_A_ot
Figure 2: Lifting of the unit
WARNING:
Use cranes, ropes, lifting straps, hooks and clasps that comply with current regulations
and that are suitable for the specific use.
NOTICE:
Make sure that the harnessing does not hit and/or damage the unit.
2 Transport and storage
e-HM Series Installation, Operation and Maintenance Manual 7

WARNING:
Lift and handle the unit slowly to avoid stability issues.
WARNING:
During handling, make sure to avoid injury to people and animals, and/or damage to
property.
2.4 Storage
2.4.1 Storage of the packed unit
The unit must be stored:
• In a covered and dry place
• Away from heat sources
• Protected from dirt
• Protected from vibrations
• At an ambient temperature between -40°C and +60°C (-40°F and 140°F), and relative
humidity between 5% and 95%.
NOTICE:
Do not place heavy loads on top of the unit.
NOTICE:
Protect the unit from collisions.
WARNING:
Take appropriate measures during transport, installation and storage to prevent
contamination from external substances.
2.4.2 Long-term storage of the unit
1. Follow the same instructions for the storage of the packed unit.
2. Empty the unit by removing the drain plug. This operation is essential in exceptionally
cold environments; any residual liquid in the unit could otherwise have an adverse
effect on its condition and performance.
EHM_M0009_A_ph
Figure 3: Drain plug
For further information about preparation for long-term storage, please contact Xylem or
the Authorised Distributor.
2 Transport and storage
8 e-HM Series Installation, Operation and Maintenance Manual

3 Product Description
3.1 Designation
Multistage horizontal centrifugal pump unit with threaded ports, non-self-priming.
3.2 Data plate
The data plate is a label showing:
• The main unit details
•Identification code
11 12 13 14 15 16 17 18
19 110 111 112 113 114 115
EHM_M0003_A_sc
Figure 4: Data plate
Position
number
Description
1 Head range
2 Flow rate
3 Pump unit type
4 Protection degree
5 Frequency
6 Power consumption
7 Serial number (date+progressive number)
8 Pump unit code
9 Maximum temperature of pumped liquid (for usage in compliance with EN 60335-2-41)
10 Maximum ambient operating temperature
11 Maximum operating pressure
12 Minimum head
13 Weight
14 Electrical data
15 Maximum temperature of pumped liquid (for usage outside the scope of EN 60335-2-41)
3 Product Description
e-HM Series Installation, Operation and Maintenance Manual 9

11
EHM_M0004_A_sc
1 0 H M E 0 3 S 1 5 M 0 2 V B E X X X / _
12 13 14 15 16 17 18 19 110 111 112 113 114 115
Figure 5: Identification code
Position
number
Description Notes
1 Rated flow rate 10 = m³/h
2 Series name HM
3 Motor operation Empty = standard asynchronous motor
H = with Hydrovar®
X = other drivers
E = e-SM
4 Number of
impeller
03 = 3 impellers
5 Material P = AISI 304 stainless steel with Noryl™impellers
S = AISI 304 stainless steel
S = AISI 316 stainless steel
6 Motor rated
power
kW x 10
7 Phase M = Single-phase
T = Three-phase
8 Power supply
voltages
50 Hz standard
asynchronous motor:
5H = 1x220-240V
5D = 1x110-120V
5R =
3x220-240/380-415V
5V =
3x380-415/660-690V
5P =
3x200-208/346-360V
5S =
3x255-265/440-460V
5T =
3x290-300/500-525V
5W = 3x440-460/-V
5Z1= 3x500-525/-V
60 Hz standard
asynchronous motor:
6F = 1x220-230V
6B = 1x110-115V
6C = 120-127V
6E = 1x200-210V
6P =
3x220-230/380-400V
6R =
3x255-277/440-480V
6V = 3x440-480/-V
6U =
3x380-400/660-690V
6L =
3x110-115/190-200V
6N =
3x200-208/346-360V
6T =
3x330-346/575-600V
6Z2= 3x575/-V
Power supply e-SM:
02 = 1x208-240V
04 = 3x380-460V
05 =
3x208-240/380-460V
Asynchronous bi-
frequency motor:
BR = 3x230/400V 50Hz
3x265/460 V 60 Hz
BV = 3x400/690V 50Hz
3x460/-V 60Hz
9 Mechanical seal
rotating part
Q = Silicon carbide(Q1)
V = Aluminum oxide (ceramic)
10 Mechanical seal
fixed part
Q = Silicon carbide(Q1)
B = Resin impregnated carbon
1For uses outside the scope of EN 60335-2-41
2For uses outside the scope of EN 60335-2-41
3 Product Description
10 e-HM Series Installation, Operation and Maintenance Manual

Position
number
Description Notes
11 Elastomers E = EPDM
V = FPM
K = FFPM (Kalrez®)
12 General
characteristics
Empty = none
A = Schuko plug + 3 m cable
B = British standard plug + 2 m cable
A = Australian standard plug + 2 m cable
D = Documents or certificates on specific request
E = Passivated and electro-polished
F = Motor oversized by 2 sizes
L = Seal housing + locking pin
V = Air relief valve
Z = other
13 General
characteristics
Empty = none
P = PTC in the coil
S = Condensation heater
D = Without condensation drain plugs
U = UL approval (cURus)
F = Mechanical seal internal flushing
Z = Other, or several combined characteristics
14 Connections3Null = Threaded
V = Victaulic®
Z = Other, or several combined characteristics
15 Null = None
Letter assigned by the manufacturer
Other = see technical catalogue
3.2.1 Marks of safety approval
The presence of an electric safety approval mark, for example IMQ, TUV, IRAM, only refers
to the pump unit.
3In case of no further special configuration characters on the right, this character will be nil, otherwise it will be “X”
3 Product Description
e-HM Series Installation, Operation and Maintenance Manual 11

3.3 Denomination of the main components
EHM_M0001_A_ds
12
7
8
6
9
10
3
2
14
11
5
18
19
Figure 6: Pump unit with close-coupled body
Position
number
Description Position
number
Description
1 Pump body 8 Elastomers
2 Impeller 9 Filling plug
3 Diffuser 10 Wear ring
4 Pump shaft 11 Drain plug
5 Motor adapter 12 Motor
6 Seal housing 18 Suction port
7 Mechanical seal 19 Discharge port
3 Product Description
12 e-HM Series Installation, Operation and Maintenance Manual

EHM_M0002_A_ds
2
12
5
7
8
11
9
3
6
17
13
14
15
16
10
4
18
19
Figure 7: Pump unit with body with sleeve
Position
number
Description Position
number
Description
2 Impeller 11 Drain plug
3 Diffuser 12 Motor
4 Pump shaft 13 Shaft sleeve and bush
5 Motor adapter 14 Head
6 Seal housing 15 Ring with foot
7 Mechanical seal 16 Tie rod
8 Elastomers 17 Outer sleeve
9 Filling plug 18 Suction port
10 Wear ring 19 Discharge port
3.4 Intended use
• Pressure boosting and water supply systems
• Washing and cleaning sector, including washing of vehicles
• Circulation of hot and cold liquids, for example water or water & glycol, for heating,
cooling and air conditioning systems
• Water treatment applications
• Handling of moderately aggressive liquids.
3.4.1 Pumped liquids
• Hot water
• Cold water
3 Product Description
e-HM Series Installation, Operation and Maintenance Manual 13

• Clean liquids
• Fluids chemically and mechanically compatible with the materials of the pump unit.
Observe the operating limits in Technical references on page 34.
3.5 Improper use
WARNING:
The unit was designed and built for the use described in the section Intended Use. Any
other use is prohibited, as it could compromise the safety of the user and the efficiency of
the unit itself.
DANGER:
It is prohibited to use this unit to pump flammable and/or explosive liquids.
DANGER: Potentially explosive atmosphere hazard
It is prohibited to start the unit in environments with potentially explosive atmospheres or
with combustible dusts.
3.5.1 Examples of improper use
• Pumping liquids not compatible with the construction materials of the unit
• Pumping hazardous, toxic, explosive, flammable or corrosive liquids
• Pumping drinking liquids other than water, for example wine or milk
• Pumping liquids containing abrasive, solid, or fibrous substances
• Using the unit for flow rates exceeding the flow rate indicated in the data plate.
3.5.2 Examples of improper installation
• Explosive and corrosive atmospheres
• Areas where the air temperature is very high and/or there is poor ventilation
• Outdoor without protection from weather conditions.
3.6 Use in water distribution networks for human consumption
If the unit is intended for water supply to people and/or animals:
WARNING:
It is prohibited to pump drinking water after use with other fluids.
WARNING:
Take appropriate measures during transport, installation and storage to prevent
contamination from external substances.
WARNING:
Remove the unit from its packaging just before installation to prevent contamination from
external substances.
3 Product Description
14 e-HM Series Installation, Operation and Maintenance Manual

WARNING:
After installation, run the unit for a few minutes with several users open in order to wash
the inside of the system.
3 Product Description
e-HM Series Installation, Operation and Maintenance Manual 15

4 Installation
4.1 Precautions
Make sure you have read and understood the safety instructions in the Introduction and
Safety chapter before starting work.
WARNING:
Always wear personal protective equipment.
WARNING:
Always use suitable working tools.
WARNING:
When selecting the place of installation and connecting the unit to the hydraulic and
electric power supplies, strictly comply with current regulations.
When connecting the unit to a public or private aqueduct, or to a well for the supply of
water for human and/or animal consumption:
WARNING:
It is prohibited to pump drinking water after use with other fluids.
WARNING:
Remove the unit from its packaging just before installation to prevent contamination from
external substances.
WARNING:
Observe all the provisions of the authorities and companies concerned.
4.2 Mechanical installation
4.2.1 Installation area
• If possible, place the unit in a raised position in relation to the floor.
• Make sure that any leaks will not cause flooding to the installation area or submerge
the unit.
• Observe the instructions given in Operating environment on page 34.
Air clearance between a wall and the motor fan grille
• To ensure suitable ventilation: ≥ 100 mm.
• To permit inspection and removal of the motor: ≥ 300 mm. If the space available is any
less, refer to the technical catalogue.
4 Installation
16 e-HM Series Installation, Operation and Maintenance Manual

4.2.2 Permitted positions
EHM_M0005_A_sc
Figure 8: Unit position
4.2.3 Fastening of the unit
1. If present, remove the plugs covering the suction and discharge ports.
2. Place the unit on a level and sturdy surface.
3. Using a spirit level, make sure that the unit is level.
4. Align the suction and discharge ports to their piping.
5. Fasten the units using bolts (4 or 6 depending on the model), tightening at a torque of
10 Nm (88 lbf-in).
NOTICE:
Only for models with body with sleeve, if the temperature of the pumped liquid exceeds
50°C (122°F), only fasten bolts A; see the figure below.
EHM_M0013_A_ph
A
B
Figure 9: Fastening of the unit
4.2.4 Reducing vibrations
The motor and the flow of liquids in the pipes may cause vibrations, which can be
exacerbated by incorrect installation of the unit and pipes. See Hydraulic connection on
page 18.
4 Installation
e-HM Series Installation, Operation and Maintenance Manual 17

4.3 Hydraulic connection
DANGER:
All the hydraulic and electrical connections must be completed by a technician
possessing the technical-professional requirements outlined in the current regulations.
WARNING:
Piping must be sized to ensure safety at the maximum operating pressure.
WARNING:
Install appropriate seals between the unit couplings and the pipings.
4.3.1 Guidelines for the hydraulic system
Refer to the representative hydraulic diagrams; see the figures below.
EHM_M0016_A_sc
11
55
6
8
74 2 2 4
44
9
3
Q
1
12
Figure 10: Positive suction head installation diagram
EHM_M0017_A_sc
7
11
5
4
4 2 2
5
4
8
10
3
Q
4
9
1
13
Figure 11: Suction lift installation diagram
4 Installation
18 e-HM Series Installation, Operation and Maintenance Manual