Carver Pump RSA Installation, Operation And Maintenance Instructions
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Carver Pump RSA Installation, Operation And Maintenance Instructions

Multi-stage, centrifugal pump
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RS – Multi-Stage, Centrifugal Pump
Part Number: _______________________________________
Serial Numbers: _____________________________________
These operating instructions contain fundamental information and precautionary notes. Please read the manual
thoroughly prior to installation of unit, electrical connection and commissioning. It is imperative to comply with all
other operating instructions referring to components of individual units.
This manual shall always be kept close to the unit's location of operation or directly on the pump set.
INSTALLATION, OPERATION AND
MAINTENANCE INSTRUCTIONS
I-280
280 – 16.03.EN
Inch Units
For Units Built After December 2015
ATEX REV.0
Inch Units
ATEX

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  • Page 1 I-280 280 – 16.03.EN ATEX Inch Units For Units Built After December 2015 RS – Multi-Stage, Centrifugal Pump ATEX REV.0 Inch Units INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS Part Number: _______________________________________ Serial Numbers: _____________________________________ These operating instructions contain fundamental information and precautionary notes. Please read the manual thoroughly prior to installation of unit, electrical connection and commissioning.
  • Page 2 RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump EC Declaration of Conformity www.carverpump.com MANUFACTURER: CARVER PUMP COMPANY Phone: 1-563-263-3410 2415 PARK AVE. Email: sales@carverpump.com MUSCATINE, IOWA, USA 52761 RS – Multi-Stage, Centrifugal Pump PRODUCT DESCRIPTION: PART NUMBER: SERIAL NUMBER:...
  • Page 3 RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump SERVICE RECORD PAGE Service No. ______________________ Model _________________________ Size and Type _______________ Customer Order No. ____________________________ Date Installed __________________________________ Installation Date Location Application PUMP RATING Capacity _____________________________________ Total Head ____________________________________ Suction Pressure ______________________________ Speed (RPM) __________________________________ Liquid pumped ________________________________ Temperature ___________________________________ Specific Gravity _______________________________ Viscosity ______________________________________...
  • Page 4 RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump NOTES ON INSPECTION AND REPAIRS INSPECTION DATE REPAIR TIME REPAIRS COST REMARKS...

  • Page 5: Table Of Contents

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS TABLE OF CONTENTS SECTION/PARAGRAPH PAGE SECTION/PARAGRAPH PAGE GENERAL DESCRIPTION ....... 1 D. Leveling of Unit .......... 18 A. General Information ........1 E. Grouting ............. 18 B.
  • Page 6 RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump TABLE OF CONTENTS - Continued LIST OF TABLES LIST OF ILLUSTRATIONS NUMBER TITLE PAGE NUMBER TITLE PAGE 1. Fluid Temperature Limits ......5 1. Seal Chamber Dimensions ......11 2. Maximum Allowable Pressures ....6 2.

  • Page 7: General Description

    Instructions is believed to be reliable. In spite of all the This manual is designed to provide sufficient material to efforts of Carver Pump Company to provide sound and properly maintain the total pumping unit. The information all necessary information the content of this manual may...

  • Page 8: Parts Inventory Guide

    Where Carver Pump has supplied only the bare shaft This symbol indicates explosive pump, the Ex rating applies only to the pump.

  • Page 9: Safety Awareness

    Carver Pump and to the modes of operation are prevented. Non- extent permitted by Carver Pump. Original spare parts compliance...

  • Page 10: Unauthorized Modes Of Operation

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump J. UNAUTHORIZED MODES OF OPERATION. The An example of ATEX equipment marking is shown warranty relating to operating reliability and safety of the below. The actual classification of the pump will be unit supplied is only valid if the pumping unit is used in engraved on the nameplate.

  • Page 11: Fluid Temperature Limits

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump In the ball bearing bracket area, the unit surfaces must be freely exposed to the atmosphere and the fan inlet Pump operation with the shut-off valves in flow must be unimpeded. the suction and/or discharge pipes closed is not permitted.

  • Page 12: Maximum Allowable Pressures

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump  Make sure you are NOT grounded while adjusting electrical equipment using Pump liquids over 225˚F (107˚C); pumps measuring equipment. must be equipped with auxiliary cooling.  In general, use only one hand when servicing Pumps of high temperature construction are provided live electrical equipment.

  • Page 13: Equipment Description

    (634) and hex nut (614). Grouting one stage pump then only the 1st stage impeller is used. of this type of base is required by Carver Pump All impellers face the same direction on the shaft.

  • Page 14: Effects Of Fluids

    The liquid may have to be heated prior to starting the pump. When contemplating operation at some viscosity other than that for which the pump was originally designed, check with Carver Pump Company.

  • Page 15: Axial Impeller Alignment Control Dimensions

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump Table 3. Axial Impeller Alignment Control Dimensions Pump Size A Pump Size B Pump Size C Pump Size D Pump Size E Stages (Inches) (Inches) (Inches) (Inches) (Inches) 1.147 1.150 1.267 1.580 2.093 1.144...
  • Page 16 RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump Table 3. Axial Impeller Alignment Control Dimensions - Continued 1 (Discharge Side) 2 - 18 Low NPSH Impeller (Suction) Pump Size A Pump Size B Pump Size C Pump Size D Pump Size E Stages (Inches)

  • Page 17: Seal Chamber Dimensions

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump Figure 1. Seal Chamber Dimensions...

  • Page 18: Shaft Dimensions

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump Table 4. Shaft Dimensions Pump Model At Impeller (Inches) At Coupling (Inches) 1.437 1.250 1.437 1.250 1.437 1.250 1.574 1.500 1.771 1.625 Table 5. Sleeve Bearing Dimensions Sleeve Sleeve Bearing Sleeve Bearing New (Ø...

  • Page 19: Optional Design Pump Mechanical Seal Settings

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump Table 7. Optional Design Pump Mechanical Seal Settings Discharge End (Seal Type 1) Discharge End (Seal Type Suction end (Seal Type 1 or (for reference only) – Inches 8B1) (for reference only) – Pump (from face of box to face of Inches...

  • Page 20: Bearing Frame Water Cooling

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump OPTIONAL DESIGN STANDARD DESIGN END VIEW SIDE VIEW DRAI IN/OUT IN/OUT ¼ NPT ¼ NPT Figure 3. Bearing Frame Water Cooling...

  • Page 21: Permissible Nozzle Loads

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump Table 9. Permissible Nozzle Loads Side Connection Top Connection Side Connection Suction Position A Suction Position B Suction Position C Discharge Position 1 Discharge Position 2 Discharge Position 3 Side Connection Top Connection Size A, B...

  • Page 22: Inspection And Storage

    B. PACKING FOR RETURN. If the pumping unit is necessary to refurbish the pump. sent back to Carver Pump Company for repair, drain the unit, and re-seal all flanges and connections that were Consider a unit to be in storage when: covered or plugged.

  • Page 23: Installation

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump All openings of the assembled unit components are closed and must only be opened when required during installation. All blank parts and surfaces of the pump are oiled or greased (silicone-free oil and grease) to protect them against corrosion.

  • Page 24: Leveling Of Unit

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump rigid support for the base plate. Consequently, E. GROUTING. After the pumping unit has been maintaining the pump to driver alignment is important for leveled and the alignment is correct, grout the unit to the a flexible coupled unit, refer to Figure 9.

  • Page 25: Grouting And Foundation Bolting

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump (If equipped) Figure 7. Grouting and Foundation Bolting Milled Motor Pad Milled Pump Pad Anchor Hole Leveling Screw Figure 8. Unit Leveling...

  • Page 26: Coupling Alignment

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump F. COUPLING ALIGNMENT. The pump and motor shims under the feet or supports of the motor and are connected by a coupling. Alignment is necessary tighten fastening bolts until correct alignment is when the pump or motor are removed from the base.

  • Page 27: Pre-Installation Procedures

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump G. PRE-INSTALLATION PROCEDURES. Never use a straight taper (concentric) reducer in a horizontal suction line because air pockets may form in 1. Check the pump foundation and confirm the the top of the reducer and the pipe. Use an offset bolting surface is flat and the bolt pattern is (eccentric) reducer instead.

  • Page 28: Operation

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump 7. Jog starter switch on motor to check that the VIII. OPERATION. direction of rotation must agree with the arrow stamped on the pump frame or base. A. PRE-START CAUTIONS. 8. Before starting the pump, install closed guards around all exposed rotating parts.

  • Page 29: Starting The Pump

    4. Check for leakage at mechanical seals. applications, consult your local distributor representative from Carver Pump Company. G. STOPPING THE PUMP. E. MINIMUM/MAXIMUM FLOW CALCULATION. 1. If the pump is being stopped for overhaul, slowly Unless otherwise specified in the characteristic curves close the discharge valve.

  • Page 30: Indefinite Shutdown

    Replace defective parts. 4. System head lower than design condition. 4. Adjust system head. Trim impellers to actual condition. 5. Incorrect impeller diameter. 5. Replace impeller or trim impeller to correct diameter. Consult with Carver Pump before trimming impellers.
  • Page 31 5. Check liquid temperature and adjust as high. necessary. 6. Incorrect impeller diameter. 6. Replace impeller or trim impeller to correct diameter. Consult with Carver Pump before trimming impeller. Vibration 1. Foundation bolting loose. 1. Torque bolting to proper values.

  • Page 32: Maintenance

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump Semi-annual Inspection: MAINTENANCE.  Change oil. DO NOT add excess oil.  Check coupling alignment due to settling of Generally the pump does not need continuous foundation. supervision. The pump should always run quietly and ...

  • Page 33: Lubrication Of Motor Bearings

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump the bearing frame (99) with oil (refer to Table 12 for oil B. LUBRICATION OF MOTOR BEARINGS. motor manufacturer’s instructions to be sure motor recommendations) through the breather vent (405) until oil can be seen in the center of the oil view sight (143)*.

  • Page 34: Service And Repair

    Suitable protection devices should be used Factory authorized parts must be used to and/or protective clothing should be worn. safely maintain your Carver Pump. 3. For cartridge mechanical seals (90* or 91*), NOTE reinstall seal clip.

  • Page 35: Disassembly Of Pump With Standard Sleeve Bearing

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump B. DISASSEMBLY OF PUMP WITH STANDARD 4. Starting on the discharge side (Outboard) SLEEVE BEARING. The instructions that follow are an remove gland nuts (615) and gland washers aid for properly trained personnel to service your Carver (646) from the outboard bearing cap stud (631).
  • Page 36 RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump and wear ring (7X) intact. Remove casing O-ring NOTE from interstage casing and discard O-ring. Refer to mechanical seal vendor instructions for 15. Remove impeller key (32A). Remove interstage proper mechanical seal removal procedure. sleeve (58).

  • Page 37: Disassembly Of Pump With Optional Mechanical Seals

    MECHANICAL SEALS. The instructions that follow are bodies from seal glands (17A and 17X*). an aid for properly trained personnel to service your Carver Pump. Refer to Figures 14 and 15 to locate the NOTE pump parts by item number and parts list. If a specific...
  • Page 38 RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump NOTE NOTE IMPORTANT: Check shims between remove rotating element mechanical seal (90*) from sleeve (14A) at this impellers and spacer sleeves. point, especially if mechanical seal is relatively clean and in good working condition. 17.

  • Page 39: Parts Inspection

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump 26. Remove bearing cap bolts (601), bearing cap rings, oil seals/bearing isolators, and locking bolt washers (850), and bearing cap bolt O-ring devices with a nylock feature are to be replaced (89W) from bearing cap (37) and discard O-ring.

  • Page 40: Factory Wear Ring Clearance (Inches)

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump and the low reading of the outside diameter h. Check rotor TIR by placing an indicator on of the back impeller (2A or 2X) wear ring the impeller wear ring wearing surface and exceeds double maximum...

  • Page 41: Reassembly Of Pump With Standard Sleeve Bearing

    The instructions that follow are an aid for properly trained personnel to assemble your CAUTION Carver Pump. Refer to Figures 13 and 15 to locate the pump parts by item number and parts list. If a specific Handle inboard bearing frame bearing isolator sectional assembly drawing exists for a particular job (169) with care.
  • Page 42 RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump NOTE and interstage sleeve (58)] onto previous interstage casing (111). Confirm interstage casing is sitting flat. Rotate pump to a vertical standing position using a fixture that holds the suction casing 22.
  • Page 43 RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump Example – With Standard Sleeve Bearing – RS9-A stage 11 Axial Impeller Alignment setting = .742” Impeller without sleeve = .760” / With sleeve = .760” – No change Add two shims = .020” – Measurement now at .765” – meaning .015” Gap between impeller and sleeve Remove one shim = .010”...

  • Page 44: Bushing Not Torqued Interference

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump Figure 11. Bushing Not Torqued Interference 24. Remove interfering stages keeping close track NOTE of how many shims are between each stage. Remove pump from vertical position and place 25. Slide outboard sleeve (14X) onto outboard end in horizontal position either on a milled flat of shaft (6), aligning keyway in sleeve with surface or a pump base.

  • Page 45: Reassembly Of Pump With Optional Mechanical Seals

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump NOTE 40. Install mechanical seal (90) rotating elements (mechanical seal spring retainer and spring). Install rubber bellow with rotating seal face by Rotate the shaft so the mark (arrow) that was lubricating sleeve (14A) and inside rubber put on during rotor TIR process is pointing down.
  • Page 46 48. Rotate shaft (6) by hand to ensure shaft rotates Carver Pump. Refer to Figures 14 and 15 to locate the freely. Tighten gland nuts (615) on gland (17A). pump parts by item number and parts list. If a specific sectional assembly drawing exists for a particular job then that drawing should be referred to for assembly.
  • Page 47 RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump 6. Install bearing spacer (78) onto shaft (6). 17. Lubricate and install new O-ring (89D) into interstage casing (111). 7. Install bearing frame bearing isolator (169*) into bearing frame (99). 18. Install diffuser assembly [diffuser (5A), wear ring (7X), diffuser bushing (63), and wear ring (7B)] into interstage casing (111).

  • Page 48: Mechanical Seal Not Torqued Interference

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump Figure 12. Mechanical Seal Not Torqued Interference NOTE two bolts (600). Install bearing (16) and install one jam nut (22), leave loose. Every gap that is left in the stack-up to achieve that stage final axial impeller alignment will NOTE compound to every stage after it and will have...

  • Page 49: New Wear Ring Diametrical Clearance Limits (Inches)

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump NOTE of mechanical seal (90*) into inboard gland. Lubricate and install gland O-ring (89H*) on inboard gland (17A). Rotate the shaft so the mark (arrow) that was put on during rotor TIR process is pointing 43.

  • Page 50: Replacement Of Wear Ring

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump bearing cap to bearing frame (99) with bearing CAUTION cap bolts (601). Bearing cap bolt O-ring (89W), and washers (850). 51. Refer to Figure 15 for units that are oil Pump bearing frames should be filled with lube/water cooled or oil lube/air cooled for oil before starting the pumping unit.

  • Page 51: Recommended Spare Parts List

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump Suction Case Wear Ring (7A). NOTE The suction case (9) must be removed from the base to When replacing first wear ring with the standard replace the first stage wear ring (7A). To replace the first first wear ring, (part number beginning with stage wear ring (7A) follow these steps: "00") machining in step 9 is not required.

  • Page 52: Motor

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump 5. Place impeller (2X) on an arbor and mount accomplished on a lathe for composite wear between centers in a lathe or a grinder. Indicate rings. Hardened metal wear rings can be pried front outside impeller hub to within 0.002 TIR out of case.
  • Page 53 RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump Table 19. Recommended Spare Parts List Item Description Item Description Number Number Impeller, First Stage Interstage Sleeve Impeller, Per Stage Bushing, Diffuser Shaft *63X Bushing, Last Stage Diffuser Wear Ring, First Stage *63Y Sleeve Bearing Wear Ring, Interstage Case...
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  • Page 55: Sectional Assembly - Standard Sleeve Bearing

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump NOTE Oil lube air cooled shown. See Figure 15 for other cooling options. Figure 13. Sectional Assembly – Standard Sleeve Bearing 49/(50 blank)
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  • Page 57: Sectional Assembly - Optional Mechanical Seals

    RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump NOTE Oil lube air cooled shown. See Figure 15 for other cooling options. Figure 14. Sectional Assembly – Optional Mechanical Seals 51/(52 blank)

  • Page 58: Cooling Options

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  • Page 59 RS – Multi-Stage, I-280 280 – 16.03.EN Centrifugal Pump Figure 15. Cooling Options 53/(54 blank)
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  • Page 62 2415 Park Avenue, Muscatine, IA 52761 Phone: 563.263.3410 www.carverpump.com RS IOM 208 – 16.03.EN For Units Built After December 2015...

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