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Sundyne LMV-801S Installation, Operation & Maintenance Manual

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Installation, Operation
& Maintenance Manual
Sundyne Pumps
Model:
LMV-801S
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SA-07-11-92, Rev Orig
Oct 2015

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Summary of Contents for Sundyne LMV-801S

  • Page 1 Installation, Operation & Maintenance Manual Sundyne Pumps Model: LMV-801S SA-07-11-92, Rev Orig Oct 2015...
  • Page 2 Warranty Sundyne LLC warrants to Buyer for a period of twelve (12) months from the date of being placed in service (but not to exceed eighteen (18) months after the date of shipment) that the equipment at the time of shipment will be free from defects of design, material and workmanship.
  • Page 3 As indicated in the ATEX Directive 94/9/EC, It is the responsibility of the user of the pump to indicate to HMD Sealless Pumps the Zone and Corresponding group (Dust or Gas) that the pump is to be installed within. Service Americas Sundyne LLC Tel: +1-303-425-0800 14845 W. 64 Avenue...
  • Page 4 Sundyne LLC http://www.sundyne.com SA-07-11-92, Rev Orig October 2015...
  • Page 5 Revisions October 2015 Original Release Sundyne LLC http://www.sundyne.com SA-07-11-92, Rev Orig October 2015...

  • Page 6: Table Of Contents

    Single Operation.......... 26 Application or Use..........7 Parallel Operation........26 Temperature Classification - (ATEX Directive OPERATION & CONTROL....27 94/9/EC) .............7 Operation of Sundyne Pumps ...... 27 INSTALLATION ........9 Suction Conditions........27 Minimum Flow Conditions ......27 Inspection ............9 Entrained Gases.......... 27 System Head Curve ........
  • Page 7 LMV801S Pump Cross Section (No Disassembly - Stage 4 – Casing and Secondary Containment) ......102 Diffusers............62 Index..........103 ASSEMBLY OF PUMP ...... 64 Assembly - Stage 1 – Casing and Diffuser ..65 Sundyne LLC http://www.sundyne.com SA-07-11-92, Rev Orig October 2015...

  • Page 8: Introduction

    Authorized Service Center or a listed performance and competitive efficiencies in a Sundyne location. compact unit that is easy to maintain. Sundyne Note: Parenthetical numbers included in the pumps are single stage and are closely coupled text correspond to item numbers on the (OH4).

  • Page 9: Text Symbols

    Instruction and Operation Manual Text Symbols In accordance with general safety and handling, RECOMMENDED: Text accompanied by OSHA 1910.145, BS EN 809 and other local this symbol indicates recommended directives, the following warning symbols and usage. signs are used in this manual. REMINDER: Text accompanied by this DANGER: Text accompanied by this symbol indicates a reminder to perform...

  • Page 10: Equivalent Terms

    Instruction and Operation Manual Equivalent Terms To assist in global understanding the following equivalent terminology is used: - Used in this manual Also known as Alignment Pad Support Gasket Bush Radial Bearing or Journal Bearing Bearing Assembly Power Frame Containment Shell Shroud Gasket Joint...

  • Page 11: Equipment And Safety Precautions

    Attention must be given to the safe handling of prior to any installation, maintenance, all items. This applies to both installation and or repair of a Sundyne pump. Failure to maintenance. Where pumps, pump units, or follow safety precautions may lead to...

  • Page 12: Ensuring Electrical Safety

    Wearers of these implants should take extreme caution EXPLOSION/FIRE HAZARD when in proximity to a Sundyne sealless pump. The assembled pump Never use an acetylene torch, open presents no known problems, however...

  • Page 13: Pre-Commission Checklist

    Familiarizing Yourself with the Pump  Verify that the auxiliary piping conforms to Sundyne standards, as indicated in Before servicing and starting up the Sundyne the detailed specifications pump, carefully review all information on the  Verify all switch and instrument...

  • Page 14: General

    Each pump is designed for operation at the conditions stated on the pump label (Fig 1). Should the need arise to operate the pump outside of the conditions indicated on the pump label, Sundyne should be contacted to check and confirm that the pump can be operated safely at the revised operating conditions.
  • Page 15 Instruction and Operation Manual Table 1 Maximum Surface Maximum Surface Temperature Class Temperature (C) Temperature (F) Example: The pump is pumping a liquid with a temperature of 120C (248⁰F). The pump is close coupled and therefore does not have an external oil lubricated bearings. The maximum ambient temperature in which the pump may operate is 30C (86⁰F) Condition 1 equates to 120C + 20C = 140C (284⁰F).

  • Page 16: Installation

    These will consist If your Sundyne pump will not be operated for a  The pump will be packed in a wooden period of time exceeding six months from the crate.

  • Page 17: Installation Guidelines

    Prior to installation it is recommended that the Recommended Long-Term Storage pump is inspected by a Sundyne engineer and Procedures that the commissioning is similarly supervised. It is recommended that the pump should be left...

  • Page 18: Electrical Installation & Grounding

    Instruction and Operation Manual Fig. 2 Electrical Installation & Grounding Electrical connection of the pump motor, to a suitably rated power supply shall be carried out by electrically skilled persons or staff. Care should be taken to ensure that the motor electrical connection will not overload the power supply.

  • Page 19: Suction And Discharge Piping

    Instruction and Operation Manual Suction and Discharge Piping Good practice dictates that there should be a minimum straight length of pipe on the suction flange of the pump equal to ten times the suction pipe diameter. This is to allow the liquid to flow into the pump casing without turbulence.
  • Page 20 Instruction and Operation Manual Ensure that all joints in the suction pipework are airtight. Install suction piping, elbows, eccentric reducers (flat side up as in Fig 6) and all other fittings so that no air pockets can be created within the suction system. Position of eccentric reducer when liquid is below pump centerline.

  • Page 21: Pitfalls To Avoid On Suction Pipework

    Instruction and Operation Manual Pitfalls to Avoid On Suction Pipework Avoid the use of valves that have high friction loss. Avoid the use of in-line filters (with the exception of the commissioning period) Avoid pipework layouts that promote vortices at the liquid level in the supply vessel. Avoid the use of multiple spring type check valves.

  • Page 22: Discharge Pipework

    Instruction and Operation Manual Discharge Pipework The discharge pipework and its related equipment does not normally have as great an influence on pump performance as the suction pipework. There are, however, some points to watch with discharge pipework to ensure efficient pump operation. In a manner similar to the suction pipework, provision must be made to support the discharge pipework and any other equipment.

  • Page 23: Protection Systems

    Instruction and Operation Manual Protection Systems To minimize the effect of process or system malfunction the LMV 801S Sealless Pump can be provided with various fail safe devices to increase plant security. The type of instrumentation or safety devices offered depends on the properties of the process liquid, the application and plant operating procedures.

  • Page 24: Liquid Sensing Probe

    For guidance on the availability of protection systems for a specific pump range, please refer to Fig. 11 and Table 2. If you have a specific requirement, contact Sundyne/HMD to discuss the available options in more detail. SA-07-11-92, Rev Orig...
  • Page 25 Instruction and Operation Manual Fig. 11: Protection Systems (Typical) Power Control Monitor Liquid Level Probe Vapour View Temperature Sensing Device Differential Pressure (DP) Switch Table 2: Availability of Instrumentation Model Prefix Power Temperature Differential Pressure Liquid Secondary Vapour Control Sensing Pressure Tight Sensing...

  • Page 26: Precautions

    Instruction and Operation Manual Precautions Installation Considerations A significant proportion of all pump problems occur during the commissioning period. There are a number of reasons for these problems and usually they are not as a result of poor materials, bad workmanship or design of the pump.
  • Page 27 Instruction and Operation Manual Fig. 13 shows how the temporary filter is installed in the system. It is important that all the gauges (PG1, PG2 and PG3) are installed; PG2 and PG3 will indicate if the filter is blocking and PG2 and PG1 will monitor the differential head across the pump to check that the pump is achieving duty.

  • Page 28: Commissioning

    General  Open vent line a second time to purge remaining air, close vent line The LMV-801S pump is a vertical in-line type pumps and is normally close coupled to the Pump is now ready for direction of rotation drive motor. Prior to initial start-up, special check.

  • Page 29: Start Up

    The differential pressure should now be checked by subtracting the suction pressure gauge reading from the discharge pressure gauge The LMV-801S pump must never be run reading and the answer is the differential against a closed discharge valve. pressure in absolute terms.

  • Page 30: Operating Guidelines

    DO NOT ALLOW THE PUMP TO CAVITATE minutes. To guard against this a Power Control Piping changes, process temperature, changes Monitor (PCM) can be supplied by Sundyne/ in the level of liquid in the suction supply tank HMD. can change the NPSH available resulting in cavitation.
  • Page 31 REMOVAL OF PROTECTION DEVICES No protection device such as condition monitoring equipment, or guards supplied by THERMAL SHOCK Sundyne/HMD should be removed from the Pumps should not be subject to thermal shock equipment without prior approval. unless specifically designed for this, because...
  • Page 32 It is essential that the pump is only run in the flow passages and the wearing of components. direction specified by Sundyne/HMD. Failure to do this may result in excessive heating of the DEBRIS product and subsequent damage to the pump.

  • Page 33: Controlling The Pump During Startup

    Note: Do not operate the pumps at their peak the pump can fill with liquid. head capability. Sundyne recommends that separate flow Parallel Operation controls be used on each pump to provide a lower minimum flow range than is achieved by To prevent back-flow, place check valves in the pressure control.

  • Page 34: Operation & Control

    If you have entrained gas,  Proper suction piping, see suction piping contact Sundyne for further instruction. section.  Liquid reaching the impeller eye must System Head Curve...

  • Page 35: Parallel Operation

    Instruction and Operation Manual In Figure 17, two pumps operating in parallel will Note: In Figure 15, the curve for pump A has never have exactly the same performance a significant angle of intersection with curves. At the design point (Q1), with the valve system curves D and E.

  • Page 36: Servicing

    The timing for maintenance of the liquid end. It is suggested that after initial Sundyne/HMD Sealless pump is established commissioning, the pump should be inspected primarily by the liquid end bearing bush system.

  • Page 37: Fault Finding

    (Section Fault Finding). No special tools are required to dismantle a Sundyne/HMD Sealless Pump and no special skills are required as the pump is simple in design and robust in construction. Refurbishing is by replacement and no attempt should be made to repair pump components by welding and re-machining.
  • Page 38 Instruction and Operation Manual Flow Chart 1 PUMP FAILURE CHECK THE MAGNET COUPLING DIRECTION OF PULLED OUT OF STEP ROTATION ROTATION ROTATION ROTATE BY CORRECT IN-CORRECT HAND CHANGE TWO OF THE PRIME THREE PHASES LIGHT PRIMING PRIMING IMPOSSIBLE NORMAL HEAVY (LOCK) LEAKAGE OF FOOT A CHECK SHUT OFF...
  • Page 39 Instruction and Operation Manual Flow Chart 2 PUMP FLOWRATE OR HEAD DEFICIENCY CHECK THE DIRECTION OF ROTATION ROTATION ROTATION IN-CORRECT CORRECT CHANGE TWO OF CHECK SHUT-OFF THE THREE PHASES PRESSURE WITH DISCHARGE VALVE FULLY CLOSED SHUT-OFF SHUT-OFF PRESSURE PRESSURE DEFICIENT NORMAL FULLY OPEN IMPELLER OR NECK...
  • Page 40 Instruction and Operation Manual Flow Chart 3 MOTOR CURRENT HIGH CHECK THE DIRECTION OF ROTATION ROTATION ROTATION IN-CORRECT CORRECT CHANGE TWO OF MEASURE CURRENT THE THREE PHASES WITH DISCHARGE VALVE FULLY CLOSED ABNORMAL NORMAL HEAVY RESISTANCE SPECIFIC GRAVITY OR OVER RATE OF IS FELT WHEN VISCOSITY OF FLOW...
  • Page 41 Instruction and Operation Manual Flow Chart 4 EXCESSIVE NOISE AND VIBRATION CHECK THE DIRECTION OF ROTATION ROTATION ROTATION IN-CORRECT CORRECT CHANGE TWO OF LOCATE SOURCE OF THE THREE PHASES NOISE AND VIBRATION INSIDE THE PUMP CHECK THE SUCTION GAUGE READING HIGHER LOWER FROM...

  • Page 42: Pump Diagnostics

    Instruction and Operation Manual Pump Diagnostics Several system factors may affect the  Control characteristics performance of the pump. These factors are:  Temperature These factors as well as internal problems must  be considered when analyzing pump system Specific gravity performance.
  • Page 43 Instruction and Operation Manual Situation/Symptom Possible Cause Investigative/Corrective Action Corrosion and/or erosion of diffuser throat (may If edge of throat is no longer sharp and smooth also be accompanied by corrosion/ erosion of or has opened in size, head-rise may be diffuser and cover surface adjacent to impeller).

  • Page 44: Maintenance

    Instruction and Operation Manual Maintenance General Safety Before disassembling a pump all relevant and appropriate safety precautions must be taken. SEEK ADVICE FROM YOUR SAFETY REPRESENTATIVE OR THE MANUFACTURER IF YOU HAVE ANY DOUBTS. Care should be taken in assembling magnetic components due to their attraction with ferrous materials.

  • Page 45: Tools Required

    Instruction and Operation Manual Tools Required The table of tools shown below is fully comprehensive and allows for complete strip-down and re-build of pump. Tool List 3/16” 7/32” ¼” Hexagon Bit Socket and / or 5/16” Hexagon Key 3/8” ½” 8 mm (IEC Motors) ¾”...

  • Page 46: Lifting Points

    Over 1650 lbs (750 kg) Lifting Lugs Sundyne recommends the use of swivel hoist rings for the handling of parts and assemblies as demonstrated in the following section. Use of other lifting devices may result in harm to the user or damage to equipment.

  • Page 47: Disassembly Of Pump

    DISASSEMBLY OF PUMP Before working on Pump ensure it is drained and decontaminated. When disassembling Pump, it is recommended that each set of fasteners be individually bagged. Tie a tag to each bag with fastener Reference number (REF) written on tag. Reference numbers are taken from the Cross Sectional Drawing and Parts List, and are contained in brackets ( ) in this manual.

  • Page 48: Disassembly - Stage 1 -Removal Of Pump From Pipe Work

    Disassembly Stage 1 – Removal of Pump from Pipe Work Disassembly - Stage 1 -Removal of Pump from Pipe Work 1.01 Complete pump should be lifted with Lifting Lugs (98.98) that were originally supplied with the pump. To fit Lifting Lugs first remove grub screws (45.S53) from webs of Motor Adaptor (45.45).
  • Page 49 Disassembly Stage 1 – Removal of Pump from Pipe Work 1.04 Remove Retention Screws (98.S11), Washers (98.W11) and Lifting Lugs (98.98) from Motor Adaptor (45.45). 15/16” AF for NEMA motors 24 mm AF for IEC motors 1.05 Image shows complete pump ready disassembly.

  • Page 50: Disassembly - Stage 2 - Motor And Motor Support (Close Coupled)

    Disassembly - Stage 2 - Motor and Motor Support (Close Coupled) 2.01 Attach suitable lifting gear to lifting eyes either side Electric Motor Ensure motor lifting eyes are capable of lifting the additional weight of Motor Adaptor (45.45), Drive Adaptor (52.52) and Outer Magnet Ring (51.51). This extra weight is shown as Motor Adaptor weight on customer specific installation drawing.
  • Page 51 Disassembly – Stage 2 – Motor and Motor Support 2.04 Fit 2 off Eye Bolts to tapped holes in webs of Motor Adaptor (45.45). These Eye Bolts should be positioned in between the Lifting Eyes of electric motor and on the same side as the motor terminal box.
  • Page 52 Disassembly – Stage 2 – Motor and Motor Support 2.07 To dismantle the assembly further if required Loosen and remove 2 off Screws (52.S41) holding Outer Magnet Ring (51.51) to Drive Adaptor (52.52). ¼” Hex 2.08 Pull Outer Magnet Ring (51.51) from location in Drive Adaptor (52.52).
  • Page 53 Disassembly – Stage 2 – Motor and Motor Support 2.11 NEMA Motors Remove Motor Adaptor (45.45) from Adaptor Plate (45.16). 2.12 NEMA Motors NEMA motors are face mounted, an Adaptor Plate (45.16) will always be mounted to the front face of the NEMA motor.
  • Page 54 Disassembly – Stage 2 – Motor and Motor Support 2.15 IEC Motors WITHOUT Adaptor Plate Remove Motor Adaptor (45.45) from Motor. Image not available 2.16 IEC Motors WITH Adaptor Plate A separate Adaptor Plate (45.16) is only required for the largest motors. Loosen and remove Nuts (45.N15) and Washers (45.W15) that retain Motor Adaptor (45.45) to Adaptor Plate (45.16).
  • Page 55 Disassembly – Stage 2 – Motor and Motor Support 2.19 IEC Motors WITH Adaptor Plate Remove Adaptor Plate (45.16) from Motor. Image not available SA-07-11-92, Rev Orig October 2015...
  • Page 56 Disassembly – Stage 2 – Motor and Motor Support 2.20 Remove Draw Screws (52.S42) from Drive Adaptor (52.52). IEC Motors – 8 mm Hex NEMA 143TC to 215TC – 7/32” Hex NEMA 254TC to 365TSC – 5/16” Hex A large screw driver or similar tool can be used behind the flange between one of the screws and the Drive Adaptor body to prevent the Drive Adaptor from turning.

  • Page 57: Disassembly - Stage 3 - Magnet Drive Unit

    Disassembly - Stage 3 – Magnet Drive Unit 3.01 The image shows Magnet Drive Unit mounted to pump Casing (41.41). The next stage is to work on the Magnet Drive Unit so first it must be removed from the pump Casing. 3.02 Loosen and remove 12 off Nuts (41.N11) and Washers (41.W11).
  • Page 58 Disassembly – Stage 3 – Magnet Drive Unit 3.04 Fit 2 off Eye Bolts to tapped holes in outside of top flange of Coupling Housing (43.43) Attach suitable lifting gear to Eye Bolts and withdraw Magnet Drive Unit from pump Casing (41.41).
  • Page 59 Disassembly – Stage 3 – Magnet Drive Unit 3.07 Remove 12 off Cap Screws (43.S55) from Adaptor Ring (16.16). 5/16” Hexagon 3.08 Lift away Adaptor Ring (16.16). Lifting gear can be used BUT be careful not to topple unit if ring is reluctant to become free. Alternatively remove Eye Bolts and re-fit Jacking Screws (16.S51), Adaptor Ring may be lifted by hand after jacking free.
  • Page 60 Disassembly – Stage 3 – Magnet Drive Unit 3.11 Remove Gasket (20.17) from shoulder Containment Shell (20.20) and discard. Gasket may have been left in Adaptor Ring (16.16). Find Gasket and discard. 3-12 Remove 3 off Cap Screws (20.S41) from Casing Plate (14.14).
  • Page 61 Disassembly – Stage 3 – Magnet Drive Unit CAUTION - strong magnetic attraction of ferrous objects to Inner Magnet Ring. 3.15 Stand assembly upright on the Inner Magnet Ring (37.37) with impeller (06.06) uppermost. For ZeroLoss Containment Shell the Inner Magnet Ring (37.37) has a protruding nut and must be supported either side of the nut.
  • Page 62 Disassembly – Stage 3 – Magnet Drive Unit 3.18 Remove Tab Washer (02.05A) and Impeller (06.06) from Pump Shaft (02.02). 3.19 Remove 3 off Screws (14.S45) from Casing Plate Cover (14.40). 7/32" or 1/4" Hex 3.20 Fit 2 off Screws (14.S45) to recessed tapped holes provided and lift away Casing Plate Cover (14.40).
  • Page 63 Disassembly – Stage 3 – Magnet Drive Unit Note that Front Thrust Washer (07.07A) is located in back of Thrust Washer Holder (07.07) and may drop out of its location when the Thrust Washer Holder is removed. Care must be taken to avoid damage to Thrust Washer which is made of Silicon Carbide.
  • Page 64 Disassembly – Stage 3 – Magnet Drive Unit 3.22 Remove Front Thrust Washer (07.07A) from its location in Thrust Washer Holder (07.07). Note that if Thrust Washer (07.07A) is in good condition it can be left in place in the Thrust Washer Holder (07.07).
  • Page 65 Disassembly – Stage 3 – Magnet Drive Unit 3.25 Remove 4 off Bush Holder Screws (14.S41). Fit 2 off Screws to tapped holes for jacking if required. Only two of the tapped holes will have correct thread for the screws. 3/16"...
  • Page 66 Disassembly – Stage 3 – Magnet Drive Unit 3.28 Turn over Inner Magnet Ring (37.37) and hold in a vice with soft jaws fitted. Turn assembly clockwise until key (02.K31) locks against jaw before fully tightening vice. Turn down tab on Coupling Washer (02.05) and loosen but do not remove Coupling Nut (02.36).
  • Page 67 Disassembly – Stage 3 – Magnet Drive Unit 3.31 If the Back Thrust Washer (37.12) has been removed then also remove and discard Alignment Pad (37.39) from Inner Magnet Ring (37.37). 3.32 Hold main body of Pump Shaft (02.02) in a vice with soft jaws.
  • Page 68 Disassembly – Stage 3 – Magnet Drive Unit 3.34 Remove O-Rings (02.OR1) from their grooves on both ends of Shaft and discard. Put all parts disassembled so far in clean, dry, safe place until rest of Pump has been stripped. Magnet Drive Unit is now completely disassembled SA-07-11-92, Rev Orig October 2015...

  • Page 69: Disassembly - Stage 4 - Casing And Diffusers

    Disassembly - Stage 4 – Casing and Diffusers Casing with Diffuser fitted, ready for disassembly Image not available 4.01 Fit 3 off Eye Bolts to tapped holes in top face of Diffuser (33.33). Attach suitable lifting gear and lift Diffuser from pump Casing (41.41).
  • Page 70 Disassembly – Stage 4 – Casing and Diffusers 4.03 Remove O-Ring (33.OR2) from Diffuser (33.33) and discard. 4.04 Remove O-Ring (41.OR1) from bottom face of Casing (41.41) and discard. 4.05 High head hydraulics are fitted with a Cone Extension in the side wall of pump Casing (41.41) positioned in line with the discharge nozzle.

  • Page 71: Assembly Of Pump

    ASSEMBLY OF PUMP To prevent leaks, ensure all Jacking Screws used to disassemble the Pump are either removed or withdrawn to their original position during assembly. Make sure all machined surfaces are clean and free from debris, bumps, bruises and scratches. Note that small errors of alignment near the motor are magnified further away from the motor where the Outer Magnet Ring (51.51) will be running with close clearances to other components.

  • Page 72: Assembly - Stage 1 - Casing And Diffuser

    Assembly - Stage 1 – Casing and Diffuser 1.01 Fit new pins (41.49B) to bottom face of Casing (41.41) if required. Hammer Punch 1.02 Ensure machined cone in Cone Extension is clean and free of debris. Replace Cone Extension into cavity in wall of Casing (41.41) and ensure it is flush with Casing bore.

  • Page 73: Sa-07-11-92, Rev Orig

    1.04 Fit new O-Ring (14.OR1) in bottom corner of bore of Casing (41.41). Stretch O-Ring by hand before fitting to ensure it is pushed up to Casing inside diameter. This will prevent it getting pinched when the Diffuser (33.33) is fitted. 1.05 Fit 3 off Eye Bolts to tapped holes in top face of Diffuser (33.33) and fit suitable lifting gear.

  • Page 74: Assembly - Stage 2 - Magnet Drive Unit

    Assembly - Stage 2 – Magnet Drive Unit 2.01 Hold main body of shaft in vice fitted with soft jaws. Fit O-Rings (02.OR1) into their grooves on both ends of Pump Shaft (02.02). Ensure Pump Shaft centre hole and cross-holes are clear of sludge or solidified product.
  • Page 75 Assembly – Stage 2 – Magnet Drive Unit 2.04 Fit new Back Thrust Washer (37.12). Note that one side may have grooves. ENSURE PLAIN SIDE IS FACE UP. Ensure Back Thrust Washer locates correctly over Thrust Washer Drive Pin (37.49). Some Thrust Washers are plain on one side and grooved on the other.
  • Page 76 Assembly – Stage 2 – Magnet Drive Unit 2.07 After fitting Pump Shaft (02.02), pack clean lint-free rag around Pump Shaft and down onto Back Thrust Washer (37.12). This will prevent Back Thrust Washer falling from its location during handling of the Inner Magnet Ring (37.37).
  • Page 77 Assembly – Stage 2 – Magnet Drive Unit 2.10 Fit Coupling Nut (02.36) to Pump Shaft (02.02). Tighten finger tight. EFT HAND THREAD Tighten in an ANTI-CLOCKWISE direction 2.11 Turn over Inner Magnet Ring (37.37) and hold in a vice with soft jaws fitted. Turn assembly anti-clockwise until key (02.K31) locks against jaw before fully tightening vice.
  • Page 78 Assembly – Stage 2 – Magnet Drive Unit For ZeroLoss Containment Shell (20.20) the Inner Magnet Ring (37.37) must be supported either side of the protruding nut. 2.14 Fit Bush Holder (09.09) to Casing Plate (14.14) and align off-set retention holes. Fit Bush Holder retention Screws (14.S41) and tighten evenly by hand.
  • Page 79 Assembly – Stage 2 – Magnet Drive Unit Ensure location groove is clean and free from burrs, dents etc. before inserting new Front Thrust Washer when re-building. Rotate Thrust Washer from side-to-side about Pin to ensure Thrust Washer is seated correctly. 2.17 Tip assembly over and lower Casing Plate (14.14) onto bench.
  • Page 80 Assembly – Stage 2 – Magnet Drive Unit 2.18 Slide Thrust Washer Holder assembly (07.07) over Pump Shaft (02.02) and up to Shaft Sleeve (02.86). Stand assembly vertically again. Ensure Thrust Washer (07.07A) remains seated correctly in Thrust Washer Holder during fitting. Fit Casing Plate Cover retention Screws (14.S45) to tapped holes provided in back of Thrust Washer Holder to aid assembly.
  • Page 81 Assembly – Stage 2 – Magnet Drive Unit 2.21 NO INDUCER OPTION Fit Impeller Tab Washer (02.05A) and Impeller Fastener (02.03). LEFT HAND THREAD Do not fully tighten at this stage. 2.22 INDUCER OPTION Occasionally an Inducer (76.01) will be fitted in place of the Impeller Fastener.
  • Page 82 Assembly – Stage 2 – Magnet Drive Unit 2.24 METAL CONTAINMENT SHELL OPTION Lower Containment Shell (20.20) into Coupling Housing (43.43). Align retention screw holes in Coupling Housing with tapped holes in rear of Containment Shell Image not available flange. 2.25 METAL CONTAINMENT SHELL OPTION Fit Retention Screws (20.S42) through Coupling...
  • Page 83 Assembly – Stage 2 – Magnet Drive Unit 5/16” Hex 35 Nm (26 lbf-ft) 2.28 ZEROLOSS CONTAINMENT SHELL OPTION Fit O-ring (20.OR1) to groove in metallic flange. Image not available O-ring will need to be slightly stretched in order to fit into groove, this can easily be done by hand.
  • Page 84 Assembly – Stage 2 – Magnet Drive Unit 2.31 Carefully lower Casing Plate and rotating assembly into bore of Containment Shell (20.20). Align retention screw holes with tapped holes in flange of Containment Shell. For ZeroLoss Containment Shell ensure O-Ring has already been fitted between flange and shell.
  • Page 85 Assembly – Stage 2 – Magnet Drive Unit 2.33 Tighten Impeller Fastener (02.03) or Inducer (76.01), whichever is fitted LEFT HAND THREAD Tighten in an ANTI-CLOCKWISE direction Bend Tab Washer (02.05A) to ensure Impeller Fastener or Inducer does not come loose. 3/4"...
  • Page 86 Assembly – Stage 2 – Magnet Drive Unit 2.35 Fit new Gasket (20.17) up to shoulder on flange of Containment Shell (20.20). Ensure Gasket seating face is free from dents and scratches etc. Ensure Gasket lies within the diameter of seating face or it may be damaged when Adaptor Ring (16.16) is fitted.
  • Page 87 Assembly – Stage 2 – Magnet Drive Unit 2.38 Replace Jacking Screws (16.S51) with Eye Bolts. Attach suitable lifting gear and lower Adaptor Ring (16.16) over Casing Plate (14.14) and up to front face of Coupling Housing (43.43). 5/16” Eye Bolts x 2 Soft Mallet Position so that vent hole in outer diameter of Casing Plate lines up with vent flange on Adaptor...
  • Page 88 Assembly – Stage 2 – Magnet Drive Unit 2.41 Fit 1 off Eye Bolt to tapped hole in flange of Coupling Housing (43.43). Use a second lifting device to raise the Magnet Drive Unit into a horizontal position. ½” Eye Bolt 2.42 Remove Eye Bolts from Casing Plate (14.14) and replace with jacking Screws (16.S51).
  • Page 89 Assembly – Stage 2 – Magnet Drive Unit 2.44 Lower Magnet Drive Unit onto pump Casing (41.41). Take care to keep Drive Unit vertical when fitting, especially if an Inducer (76.01) is fitted. Align Eye Bolt hole in Coupling Housing flange with discharge nozzle of Casing Guide pins may be fitted to aid alignment.
  • Page 90 Assembly – Stage 2 – Magnet Drive Unit STAGE 1 & 2 COMPLETE MAGNET DRIVE UNIT FITTED TO CASING SA-07-11-92, Rev Orig October 2015...

  • Page 91: Assembly - Stage 3 - Motor & Motor Support (Close Coupled)

    Assembly - Stage 3 – Motor & Motor Support (Close Coupled) 3.01 Fit taper ring part of Drive Adaptor (52.52) over motor shaft. Ensure taper is correct way round to match taper on Drive Adaptor body. Apply anti-seize compound to bore of taper ring. 3.02 Fit Drive Adaptor to motor shaft.
  • Page 92 Assembly – Stage 3 – Motor & Motor Support 3.04 Attach magnetic base to front face of motor to check run-out of Drive Adaptor (52.52). Set Dial Test Indicator to run in front bore which is the location for Outer Magnet Ring (51.51). Tighten Retention Screws (52.S42) in a sequence that will keep run-out within limits.
  • Page 93 Assembly – Stage 3 – Motor & Motor Support 143TC to 145TC – 5/16” Hex – 60 Nm (44 lbf-ft) 182TC to 286TSC – 3/8” Hex – 150 Nm (111 lbf-ft) 324TC to 365TSC – ½” Hex – 280 Nm (206 lbf-ft) 3.08 NEMA Motors Fit Eye Bolts and suitable lifting gear to webs of...
  • Page 94 Assembly – Stage 3 – Motor & Motor Support 3.11 IEC Motors WITH Adaptor Plate retention Screws (45.S42) and Washers (45.W15). Tighten down evenly from side to side. No image available 250 Frame motor with require addition of Nuts (45.N15) and Washers (45.W15). 24 mm AF 185 Nm (136 lbf-ft) 3.12...
  • Page 95 Assembly – Stage 3 – Motor & Motor Support 3.15 IEC Motors WITHOUT Adaptor Plate Fit Screws (45.S42) and Washers (45.W15) that retain Motor Adaptor (45.45) to motor. Frame 225 2 pole motor will also require Nuts (45.N15) and Washers (45.W15). No image available Tighten evenly from side to side.
  • Page 96 Assembly – Stage 3 – Motor & Motor Support 3.19 Set magnetic base on mounting face of Motor Adaptor (45.45). Check run-out of Bump Ring at front end of Outer Magnet Ring (51.51). Maximum allowable run-out 0.25 mm (0.010”) If run-out is high, remove Outer Magnet Ring, rotate through 180°...
  • Page 97 Assembly – Stage 3 – Motor & Motor Support 3.21 Position motor terminal box relative to pump nozzles and lower Motor Assembly onto Coupling Housing (43.43). Guide Outer Magnet Ring (51.51) into Coupling Housing and over Containment Shell (20.20). Ensure assembly is suspended vertically before lowering.
  • Page 98 Assembly – Stage 3 – Motor & Motor Support 3.23 Remove lifting gear from motor. Pump is now fully assembled and ready to be re- installed into pipework. SA-07-11-92, Rev Orig October 2015...

  • Page 99: Assembly - Stage 4 - Re-Install Pump

    Assembly - Stage 4 – Re-Install Pump 4.01 Fit lifting lugs (98.98) to motor Adaptor (45.45) with High Tensile Retention Screws (98.S11) and Washers (98.W11). Each new pump is furnished with the above lifting equipment. 2 off Lifting Lugs for pumps up to 750 kg (1650 lbs). 4 off Lifting Lugs for pumps over 750 kg (1650 lbs).
  • Page 100 Assembly – Stage 4 – Re-Install Pump 4.04 Re-fit grub screws (45.S53) to webs of Motor Adaptor (45.45). This will prevent corrosion of retention holes for Lifting Lug fasteners. 5/16” Hex Hand tight Pump is now ready for commissioning Refer to Installation & Operating Manual for correct venting and start-up procedure. SA-07-11-92, Rev Orig October 2015...

  • Page 101: Replacement Of Bushes & Thrust Pad

    If visibly worn or damaged it is strongly recommended that Bushes and Pad are renewed before re-assembling Pump. Alternatively a complete new assembly can be purchased from Sundyne or their authorised representatives. Read the whole of this Section thoroughly before proceeding with Bush and Pad replacement.
  • Page 102 Replacement of Bushes & Thrust Pad 1.04 Bush Holder Sleeve will need to be inverted to allow second Bush to fall out. After removing both Bushes and Back Thrust Pad, allow Bush Holder Sleeve to cool, then ensure Bush and Pad locations in Bush Holder are clean and free of damage before proceeding.
  • Page 103 Replacement of Bushes & Thrust Pad 1.07 Hold Bush in place with one hand using thin metal strip. Grasp body of Bush Holder Sleeve with the other hand using metal tongs or appropriate heat resistant gloves. 1.08 Turn assembly over whilst holding first Bush in place.
  • Page 104 Replacement of Bushes & Thrust Pad 1.10 Carefully place weight on Back Thrust Pad. Allow assembly to cool in draught free atmosphere. Do not attempt to artificially accelerate cooling as this may result in damage to Bushes or Pad. Check temperature of assembly with temperature touch probe.

  • Page 105: Quick Reference Torque Settings

    Installation and Operation Manual Quick Reference Torque Settings Left Torque Setting Reference Thread Description Tool Size Hand Number Size Thread lbf-ft 3/4" AF 02.03 Fastener (Impeller Narrow Line) 1/2" UNF Deep Socket 1-1/8" AF 02.03 Fastener (Impeller Wide Line) 1/2" UNF Deep Socket Retention Nut (Inner Magnet 02.36...
  • Page 106 Installation and Operation Manual Left Reference Thread Description Tool Size Hand Torque Setting Number Size Thread Retention Screw (Adaptor Plate) 5/16” Hex Key 3/8” 143TC to 145TC Frame Motor 3/8” 45.S42 Hex Key NEMA or IEC Motors ½” 182TC to 286 (WITH Adaptor Plate) TSC Frame Motor...

  • Page 107: Pump Parts List

    Installation and Operation Manual Pump Parts List Table 13. Pump Parts List of a Typical Build LMV-801S Parts List Item Item Description Description 02.02 Pump Shaft Assembly 37.37 Inner Magnet Ring 02.03 Impeller Fastener 37.12 Thrust Washer (top) 02.05 Coupling Washer 37.39...
  • Page 108 Installation and Operation Manual LMV801S Pump Cross Section (No Secondary Containment) Figure 17. Pump Cross Section of a Typical Build SA-07-11-92, Rev Orig September 2015...

  • Page 109: Lmv801S Pump Cross Section (No Secondary Containment)

    Motor and Motor Support Removal, 43 NPSH, 14 Adaptor Plate and Housing Removal, 45 Operating Guidelines, 23 Adaptor Ring Installation, 80 Operation of Sundyne Pumps, 27 Adaptor Ring Removal, 52 Outer Magnet Ring Installation, 88 Auxiliaries, 6 Outer Magnet Ring Removal, 45...
  • Page 110 Sundyne Sundyne European Sundyne HMD Sealless Sundyne Marelli Pumps Headquarters Headquarters Pumps Ctra. Madrid-Toledo, KM.30.8 45200 Illescas 14845 West 64 Avenue Sundyne International S.A. Brampton Road Toledo, Spain Arvada, Colorado 80007 13-15 Blvd. Eiffel – B.P. 30 Hampden Park Industrial Estate...

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