Standart PC-V Series Programming manual

PC-VCENTRIFUGAL SUMP PUMPS
INSTRUCTION for INSTALLATION, OPERATION & MAINTENANCE
E

Instructions for Installation, Operation and Maintenance
Standart Pompa ve Makina San. Tic. A.Ş.
All rights reserved. Can not be copied or reproduced for any purpose without permission.
Subject in the manual can be changed without any prior notice.

iii
ATTENTION
This manual is intended to be a reference guide for users of pumps providing information on
Pump installation and maintenance instructions,
Pumps start-up, operation and shut - down procedures.
IDENTIFICATION OF SAFETY AND WARNING SYMBOLS
Safety instructions in this manual which could cause dangerto life if not observed.
The presence of a dangerous electric current.
Non – observance tothis warning could damage the machine or aect its functions.
GENERAL INSTRUCTIONS
- This manual should be kept in a safe place and ALWAYS be available to the QUALIFIED
operating and maintenance personnel responsible for the safe operation and maintenance
of the pumps.
-Qualied personnel should be experienced and knowledgeable of safety standards.
- To avoid faulty operation and malfunctioning of pumps the instructions in this manual are to be CAREFULLY
studied and followed at all stages of the pump installation and operating life.
-The user is responsible for ensuring that inspection and installation are carried out by authorized and qualied
personnel who have studied this manual carefully.
-The pump should be used ONLY in the operating conditions given on the order for which the pump and
materials of the construction have been selected and tested.
-If the pump is to be used for a dierent application please contact sales oce or representative of the
manufacturer. STANDART POMPA refuses to assume any responsibility if the pump used for dierent applications
without prior written permission.
-If the pump is not to be installed and operated soon after arrival, it should be stored in a clean and dry place
with moderate changes in ambient temperature. Extreme low or high temperatures may severely damage the
pump unless suitable precautions are taken. The user is responsible for the verication of the ambient conditions
where the pump will be stored or installed.
- STANDART POMPA does not guarantee repairs or alterations done by user or other unauthorized personnel.
The use of original spare parts and accessories authorized by manufacturer will ensure safety.
-This manual does not take into account any site safety regulation, which may apply.
SAFETY INSTRUCTIONS
Strictly obey to the following instructions to prevent personal injuries and/or equipment
damages:
-Pump should be used only in the specied operating conditions.
- Any weight, stress or strains on the piping system should not be transmitted tothe pump.
-Electrical connections on the motor or accessories must always be carried out by authorized personnel and
in accordance tothe local codes.
- Any work on the pump should be only carried out when the unit has been brought to standstill.
- Always disconnect the power to the motor and make sure not be switched on accidentally
before working on the pump or removing the pump from installation.
- Any work on the pump should be carried out by at least two persons.
- When approaching the pump always be properly dressed and/or wear safety equipment suitable for the work
to be done.
-Do not work on the pump when it is hot.
-Do not touch the pump or piping with temperatures higherthan 80 ºC. User must take suitable precaution
to warn the persons (e.g. using warning signs, barrier).
- Always be careful when working on pumps that handling dangerous liquids (e.g. acids or hazardous uids).
-Do not work on the pump when the pump and piping connected tothe pump are under pressure.
- After completion of the work always x the safety guards back in places previously removed.
-Do not run the pump in the wrong direction of rotation.
-Do not insert hands or ngers into the pump openings or holes.
-Do not step on the pump and/or piping connected tothe pump.

SPMUPV-CP
A- GENERAL
A1- Pump description
•
PC-V .spmuppmuslagufirtneclacitreveraspmupseires
A2-
Applications
PC-Vseries pumps are suitable for sewage or dirtyand temperatures up to 90ºC. The main application areas,
• Ge neral waste water supply, irrigation,
• Pressurized water supply,
• Circulation,
• Industry,
• Power plants.
A3- Pump Designation
PC-V 513/051
Pump type
Discharge nozzle (DN in mm)
Nominal impeller diameter
Pompa ve Makina San. Tic. A.Ş.
R
TP :
Y:
Q : m³/h
P : kW D : mm
n : rpm
H : m
No :
İDOS 2. Cad. No: 9
Y. Dudullu/ Ümraniye
iSTANBUL /TÜRKİYE
[phone]
1
2
4
6
8
3
5
7
9
1- Pump Type and Size
2- Production Year
3- Serial No
4- Capacity
5- Head
6- Motor Power
7- Impeller Diameter
8- Speed
9- Direction of Rotation
A4- Pump Nameplate
A5- Technical Data
Speed
Discharge Nozzle
: up to 1500 rpm
: DN 40 up to 300 mm
Discharge Flanges : EN 1092-2 / PN 16
Operating Temperature : -10 °C up to 90 °C
Ambient Temperature (max) : 40 ºC
among others, are:

B- UNCRATING, TRANSPORT AND STORAGE
B1- Uncrating
Upon receipt verify that the goods received are in exact compliance with that listed on the packing list.
Check that no visible damage exists on the crate that could have occurred during transportation.
Carefully remove the packaging material and check that pump and accessories (if any) are free from any
markings, stretches and damages, which may have occurred during transportation.
In the event of damage report this immediately to STANDART POMPA’s service department and to the
transport company.
B2- Transport
B2.1- General recommendations
Existing regulations for the prevention of accidents must be followed.
Wearing of gloves, hard-toed boots and hard hats is obligatory for all transport works.
Wooden cases, crates, pallets or boxes may be unloaded with fork-lift trucks or using hoisting
slings, depending on their size, weight and construction.
B2.2- Lifting
Prior to lifting and moving the pump or pump and motor on a comm out the following:
Total weight and center of gravity
Maximum outside dimensions
Lifting points location
The load-bearing capacity must be proper to the weight of the pump or the pump set.
The pump or pump set must always be raised and transported in horizontal position.
It is absolutely forbidden to stand beneath or nearby a raised load.
A load should never remain in a raised position for longer than necessary.
Accelerating and braking during the lifting process must be performed such that there is no danger to persons.
When lifting the pump or complete pump set lift them as shown in below to avoid any
distortion (especially do not use the motor eyebolt for carrying the complete unit).

ATTENTION
ATTENTION
ATTENTION
B3- Storage
If the pump is not to be installed and operated soon after arrival, store the pump in a clean, dry and frost-
free place with moderate changes in ambient temperature.
If the pump has regreaseable bearings, pump extra grease on bearings to prevent moisture from entering
around the shaft.
To prevent the pump from moisture, dust, dirt and foreign materials suitable steps should be taken.
The pump shaft should be revolved periodically (e.g. once a week) to prevent pitting of the bearing surfaces
and the pump from seizing up.
C- INSTALLATION ON SITE
Installation has to be carried out in accordance with EN 60204-1.
The pump should only be installed, levelled up and aligned by skilled personnel. Incorrect installation or
defective foundation could result in troubles. This would not be covered by the warranty.
C1- Bare Shaft Pump
If the pump has been supplied without electric motor and coupling it is necessary to select a proper motor
and coupling before proceeding to the installation of the unit.
The following considerations must be taken into account for selection of motor:
Maximum power absorbed by the pump over the total operating range,
Pump operating speed,
Available power (frequency, voltage, etc.)
Motor type (TEFC, exproof, etc.)
Motor mounting position (foot mounted, nge mounted, horizontal, vertical, etc.)
When selecting coupling nominal motor power and operating speed must be taken into account.
C2- Preparation For Installation
Before installing the pump
Clean the discharge anges thoroughly.
Remove the protective coating from the pump shaft.
If the pump has been in temporary storage remove all the grease from the bearings with grease lubricated
or remove the oil from the bearing house if the pump is oil-lubricated, then clean the bearings with a suitable
cleaning and relubricate ( NOTE: This is not necessary for the pumps with life time grease lubricated
bearings).
C3- Installation Site
The pump must be installed in a frost and dust-free, well-ventilated and non-explosive
environment.
The pump should be installed such that there is space for access, ventilation, maintenance and there is
t space above the pump for it to be lifted.
C3.1- Foundation
The greatest care must be taken in preparing the foundation and mounting the pump set.
Incorrect installation will result in premature wear of pump components and break down of the pump.
The foundation should be heavy enough to reduce vibrations and rigid enough to avoid any twisting or
misalignment. Make sure the concrete foundation has set and solid before mounting the pumpset. The
surface of the foundation should be truly horizontal and pe

C4- Connecting The Piping
C4.1- General
Never use the pump as an anchorage point or as a carrier for the piping.
The pipes should be supported very near the pump. It must be checked that any weight, stress or
strains on the piping system should not be transmitted to the pump. Therefore after completing the piping
installation, the bolt and connection on the discharge nozzle must be loosened to ensure that
there is not any stress on the piping system to the pump.
The nominal sizes of the pump discharge nozzle are no guide to the corrects sizes of
the discharge piping. The nominal bores of the pipes should be same as or greater than those
of the pump nozzles. Never use pipes or accessories which have smaller bore than the pump nozzles.
Particularly strainers, non return valves must be preferred with larger free transition
areas. In general t hould not exceed 3 m/s in the discharge piping.
Pipe joints should be by mean ge nge gaskets of proper size and material. Flange gasket
must be centered between the ange bolts in a such way that there is no interference with the he liquid.
Thermal expansions of the pipework and excessive vibrations should be accommodated by suitable means
so as not to impose any extra load on the pump.
Prevent impurities such as welding beads, scale, sand and tow might be left in pipes while production of
the piping system harms the pump. Seal the pump nozzles by means of blind gasket to stop impurities get in
the pump.After assembling the system all the piping parts must be disassembled, thoroughly cleaned, painted
and reassembled again.
ATTENTION
C4.2- Discharge piping
A control valve should be installed in the discharge pipe, as close to the pump as possible, to regulate the
required nd head.
If the total head of the pump exceeds 10 meters or if discharge line is of appreciable length a non return
valve should be installed between the pump and isolating valve on the discharge line to protect the pump
against water ha t down.
Isolation Valve
Vent Valve
C4.3- Auxiliary pipe connections and accessories
Depending on the application auxiliary pipe connections (for cooling, sealing
f seal, drainage etc. necessary for the pumping system) and/or
accessories to check the operating conditions (pressure gages, temperature
gages etc.) may be made up and laid.
Pressure and vacuum gauges must be properly anchored and connected at
the measuring points located on the pu anges by means of or on the pipes
close t nges approximately 8 mm diameter tubing with pig t
. For safety purposes isolating and vent valves
shou ed before the gages .
Cooling, sea ng of seal piping must be connected only to the
designated connections located on the pump .

If there is a possibility of the pump havi ng to operate a t zero ow (agains t a closed disc harge valve) or near
the closed valve with almos t no ow, then a minimum ow valve (or a by-pass check valve) must be installed
on the disc harge nozzle or on the dischar ge piping right after the pump but before the ow re gulating valve.
In cases w here there is no such a valve operating the pump aga ins t close valve for a long time causes
consi derable dam age on the pump since almos t all the motor power is tr ansformed into thermal energy which
is absorbed by the pumped liquid.
C4.5- El
C4.4
ect ri ca l co nn ec tion s
The electrical motors have to be built in accordance with EN 60034-1.
Enclosures of electrical motors and control systems on the pump unit shall as a minimum
give protection in accordance with EN 60529 IP22. But in determining the degree of protection of
enclosures of electrical motors and control systems on the pump unit the operating and environmental
conditions must be taken into consideration.
Electrical c onnection sh ould be done by a qu onal regulation and motor
manufacturer’s instructions must be observ ed.
Take all safety prec autions listed in “Safety instructions”. Disconnect all power s upplies prior to doing any
work.
The s upply cable mus t be laid in such a way that it never t ouches the pipework, pump and motor casing.
Check voltage, phase and frequency on motor nameplate with the mains.
The electric motor mus t be protected aga ins t overloading by means o f circuit breakers and/or fuses . Circuit
breakers and fuses must be selected in accordance with full load amperage o f the motor appearing on the
motor rating plate.
It is reco mmended to use PTC ( passive t hermal control) on motor, but this is optional depending on cus tomer
requirement. I n case o f using PTC, these s hould be c onnected via co rres ponding terminals in the terminal box
and the PTC sh ould be connected to the thermal trip mec hanism.
Prior to c onnecting the electrical wiring rotate the pump s haft by hand to make sure rotor rotates ea sily.
Connec t the electrical wiring in accord ance with local electrical c odes a nd make sure to gr ound the motor.
The connection diagram c an be found in the terminal box o f the motor or in the instructi on manual.
The mains c onnection on the tagboard de pends on the nominal power of the motor, the power s upply and
the type of connection. The necessary conn ection of the bridges in the terminal box is shown in the following
W2U2V2
U1V1W1
L1L2L3
W1
V2
V1
U2
U1
W2
W1
V2
L1
V1
U2
U1
L2
W2
L3 L1 L2 L3
Y – connection Y / Δ- start
Type of switch
Motor Power
P
N
4 kW Motor Power
P
N
> 4 kW
power supply
3 ~ 400 V
power supply
3 ~ 400 V
direct Y – connection – connection
Y / - start Impossible Remove connecting
bridges
Δ- connection.

Motor Power Y - set time
30 kW
> 30 kW
< 3 sec
> 5 sec
ATTENTION
In the case of three-phase induction motors with Y – – connection it must be ensured that
the change-over points between star and delta follow on from one another very quickly. Longer change-over
times may result in pump damage .
Fix the safety guards back in places. Do not operate the pump before doing so. This is a necessity
for security and job safety.
D- START UP / SHUT DOWN
D1- Preparation
D1.1- Lubrication control
Since the ball bearing of pump is generally life-time grease lubricated type it is maintenance free.
D1.2- Checking the direction of rotation
PC-V type pumps rotate in clockwise when it is looked from coupling to the pump. This direction is already
indicated on the pump nameplate by an arrow. Check this by switching the pump on, then o again immediately.
Fit the coupling guard back in place if you took it out.
D2- Start Up The Pump
Check if the shut o valve in discharge line
Switch on the circuit breaker and run the motor.
Wait until the motor reaches the full speed (on star-delta running motors wait until it switches on delta).
Open the discharge valve slowly while watching the ampermeter on the control panel (if the discharge line
is empty do not turn on the valve fully open on t start up. Turn it on slowly to maintain the value on the
ampermeter is under the rated current value of the motor).
When the valve is fully open, check the pressure on the manometer and see it is the same with the duty
point pressure. If the pressure on the pressure gauge is lower than duty point pressure brings them to the duty
point value by slightly closing the valve. If it is higher value, check your installation, particularly head again.
The pump should be shut down at once and the trouble should be corrected if the pump
is running at its rated speed and found any of the following faults:
Pump doesn’t deliver any water,
Pump doesn’t deliver enough water,
Flow is going down,
Discharge pressure is not enough,
Driver overloaded,
Vibration on pump,
High noise level,
Bearing overheating
ATTENTION

D3- Shut Down The Pump
Slowly close the shut-o valve in the discharge line.
You may shut down the pump without closing the shut-o valve if there is a device for water hammer
protection on the discharge line or the water hammer is not a considerable level.
Switch o he driver. Ensure the pump set runs down smoothly and quietly to a standstill.
Shut o external sealing liquid supply, if supplied, t ng box pressure.
If the set is to remain out of services for a long time close the shut-o valve in the suction pipe.
the auxiliary connections. In the event of frost and/or prolonged standstill, drain the pump or otherwise protect
against freezing.
D4- Checks to be Made While The Pump is Running
The pump must run smoothly, quietly and free from vibration at all times.
The pump must never run dry.
Never run the pump for along period against a closed discharge valve (at
The bearing temperature may exceed the ambient temperature by up to 50º C. But must never rise above
80º C.
The valves in the auxiliary lines must remain open while the pump is running.
The oupling elements should be regularly checked and replaced as soon as they are shown signs
of wear.
Occasionally check the motor current. Stop motor if the amperage is higher than usual; there maybe jamming
or friction in the pump. Make the necessary mechanical and electrical checks.
Stand-By pumps should be run for a short time at least once a week to ensure they are in constant readiness
for operation. Check the integrity of auxiliary connections.
E- LUBRICATION
The pump shaft is supported by water lubricated sleeve bearing in the column pipe casing and grease
lubricated ball bearing on the delivery side.
Periods of re-greasing
The pump bearing ed up with grease before dispatch.
Ball bearing : The grease should be changed after 3000 hours or two years at the longest operation. Use a
high quality lithium soap grease.
The bearing temperature may exceed the ambient temperature by up to 50º C. But never
rise above 80º C.
Do not reuse the bearings following disassembly for maintenance purposes.
ATTENTION

F- DISASEMBLY, REPAIR AND REASSEMBLY


F1- Disassembly






F2- REASSEMBLY
section M
4


.

 .

 9 .

Remark


 90
 4
 0 shaft.
 0
 7 .
Reassemble in accordance with standard engineering practice. You may find the attached drawings useful.
Clean all the parts, replace damaged or worn-out ones.
Coat the seats and screw connections with graphite, silicon or similar slippery substance before assembly.
If you can not find any of the above you may use oil instead (except the pumps for drinking water).
Never use the old o-rings and make sure the new o-rings are the same size as the old
ones.
Reassemble the pump in reverse sequence to dismantling.
ATTENTION

Part
No Part Name Number of pumps in the system
2 3 4 5 6-7 8-9 10+
H- FAULTS, CAUSES AND REMEDIES
G- SPARE PARTS
Pump Type and Size
Motor power and Speed
Prod. Year and Serial Number
Capacity and Head
ATTENTION
FAULTS POSSIBLE CAUSES
PC-V
(PC-V 150 - 315)
(15 kW - 1500 rpm)
(......... - ........)
(......... - ........)
049.1, 049.2
201
046, 036 Shaft Protecting Sleeve

POSSIBLE CAUSES
There may be air existing in pump or
suction pipe
Ingress of air through shaft seal,
suction pipe or suction port. Pump
lifts liquid with air
Air pocket in the suction pipe.
There is air in liquid
Too much suction lift
Pump is working at cavitation
conditions
Insucient manometric head.
Increase at total manometric head.
Pump is operating at lower
manometric head.
Reverse rotation.
Speed is too low.
Speed is too high.
Impeller or check valve or strainer is
clogged.
Impeller or strainer is clogged partially.
Partially clogged impeller.
Worn out and defected impeller.
Mechanical frictions inside the pump.
Excess tightened soft packing.
Bad coupling alignment.
Bearing covers are too tight.
The pumped ow is less than the
minimum ow required.
Existence of excess grease.
Oblique shaft.
Insucient lubrication or lubricating
oil/grease dirty, contaminated.
Unbalanced rotating parts.
Pump runs out of duty range.
The density or viscosity of the liquid
pumped is higherthan that originally
specied.
Defects in motor.
Check the slope of the suction line make sure that there is no reason
for formation of air pockets
Suction pipe is not submerged enough creating vortex. Check liquid
level in suction tank or increase the depth of suction pipe or foot valve
in the liquid.
If no obstruction at inlet check the friction losses of suction line, larger
piping may correct condition. If static lift is too high, the liquid level in
the suction tank must be raised or the pump lowered.
NPSH available is too low. Check liquid level in suction tank, check
suction line for excessive friction losses. Check isolating valve in
suction line to make sure it is completely open.If necessary increase
suction head on pump by lowering the pump.
The actualtotal head is higher than that originally specied. Check the
geodetic total head and friction losses in the discharge line. Larger
piping may correct the condition. Check that valves are fully open.
Check that valves are fully open. Check that there is any obstruction in
discharge pipe.
The actualtotal head is lower than that originally specied. Machine
impeller outer diameter to size advised by supplier.
Check motor rotation with directional arrow on pump casing or
nameplate.
Check the supply voltage and frequency or motor may have open phase.
If possible decrease the pump rotational speed or turn down the impeller
outer diameter to size advised by supplier.
Clean the impeller or check valve or strainer
Clean the impeller or strainer.
Clean the impeller.
Replace impeller.
Check pump rotor for any rotor obstruction or deection.
Loosen the nuts of the packing gland.
Check the coupling rubber and realign the coupling.
Check and make necessary modication on the cover.
Increase the ow. If necessary use by-pass recirculating valve or line.
Remove excess grease.
Check the shaft and replace it if necessary.
Check the amount of oil/grease. Clean the bearings and bearing
housing and relubricate
Check the balance of the rotating parts.
Check the values of operating point.
Use a more powerful motor.
Check any motor defects. The motor may not be ventilated properly
due to a poor location.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
REMEDIES
Check for leaks in suction pipe joints and ttings. Check shaft seal if
necessary increase the pressure of sealing liquid. Check the dept of
suction pipe or foot valve in the liquid and if necessary increase the
depth of them.
Fill pump and suction pipe completely with liquid and repeat the priming
procedure.

I- TIGHTENING TORQUES
J- EXPECTED NOISE VALUES
(*) Without protective sound hood, measured at a distance of 1 m directly above the driven pump, in a free space above a
sound reecting surface.
Tightening Torques
Tightening Torque max (N.m)
Property Classes
Thread Diameter
8.8 10.9
3.0
5.9
10
25
49
85
135
210
300
425
580
730
1100
1450
1970
2530
4.4
8.7
15
36
72
125
200
310
430
610
820
1050
1550
2100
2770
3560
M4
M5
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
M33
M36
Power of Motor
P
(kW)
Sound pressure level (dB
A
) *
(Pump with motor)
1450 rpm 2900rpm
< 0.55
0.75
1.1
1.5
2.2
3
4
5.5
7.5
11
15
18.5
22
30
37
45
55
75
90
110
132
160
60
60
62
63
64
65
66
67
69
70
72
73
74
75
75
76
77
78
79
80
80
80
64
66
66
68
69
70
71
73
74
76
77
78
79
81
82
82
84
85
85
86
86
86
N

K- SECTIONAL DRAWING
001
003
011
012
031
035
036
037
046
049.2
049.1
050
051
060
065
087
088
101
102
201
210
240
393
420
600
801
Volute Casing
Casing Cover
Bottom Cover
Motor Pedestal
Bearing Housing
Bearing Cover
Shaft Protecting Sleeve
Bottom Bearing Cover
Shaft Protecting Sleeve
Sleeve Bearing (bottom)
Sleeve Bearing (intermediate)
Impeller
Intermediate Bearing Housing
Shaft
Impeller Nut
Flexible Coupling
Coupling
Column Pipe
Suction Bowl
Double Row Ball Bearing
Impeller Key
Discharge Pipe
Shaft Nut
O-Ring
Electric Motor
Base Plate
600
012
087
035
201
393
031
801
101
060
088
046
049.1
051
240
210
420 065
001
011
102
003
037
036
049.2
050

EC DECLARATION OF CONFORMITY
Products: PC-V
Manufacturer:
Standart Pompa ve Makina San. Tic. A.Ş.
Machinery
Directive 2006/42/EC and Low Voltage Directive 2006/95/EC.
5
MANUFACTURER DECLARATION OF CONFORMITY
Products: PC-V
Machinery
Directive 2006/42/EC.
5

Right reserved to change without notice.
No responsibility is accepted because of printing errors.
Service and Spare PartsFactory - Center
Organize Sanayi Bölgesi
2.Cad. No:9 34775
İstanbul - TÜRKİYE
Pbx: [phone]
Fax: [phone]
Organize Sanayi Bölgesi
2.Cad. No:9 34775
İstanbul - TÜRKİYE
Pbx: [phone]
Fax: [phone]