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Browlee-Morrow Vulcan Pumps HDS Series Installation, Operation And Maintenance Manual

Submersible pumps agitator
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Installation, Operation and Maintenance Manual 
HDS – Submersible Pumps 
Agitator 
Document No. – A1540 
 

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  • Page 1   Installation, Operation and Maintenance Manual  HDS – Submersible Pumps  Agitator  Document No. – A1540   ...
  • Page 2 Thank you for purchasing a Vulcan HDS pump. We take pride in every product we build. To insure that you receive the highest quality product, we have enclosed a quality assurance checklist signed by the Assembler and Shop Foreman. For information regarding installation and maintenance please refer to the Operation and Instruction Manual or contact your local distributor.
  • Page 3 VULCAN SUBMERSIBLE PUMP ASSEMBLY QUALITY ASSURANCE CHECKLIST Important Information for future reference. Do not discard this page! Customer: Customer PO# Manufacurer: Vulcan DOCUMENT NBR BMC-103 Model: HDS EFFECTIVE DATE 1/1/2013 Size: Serial # Shop # COMPONENTS Verify components are present, conduct visual inspection, and confirm assembly. Visual Assembly Casing...
  • Page 5   Approval Name Signature Title Date Malcolm Morrow M.M. President 23 January 2014 Revisions History Revision No. Signature Date of Change Change Summary RJ. R 23 January 2014 Initial Release Contact Vulcan Pumps LLC 7450 Cahaba Valley Road Birmingham, AL 35242 Ph: 1.800.624.7069 F ax: 1.205.995.9603 www.vulcanpumps.com...

  • Page 6: Table Of Contents

      Contents General ............................4 Introduction ..........................4 Transportation & Storage ......................4 Receiving Inspection ......................... 6 Safety ............................7 Safety Definitions ........................8 General Safety Precautions ...................... 9 Installation ........................... 10 Pump Mounting and Positioning ..................... 10 Handling and Lifting ........................ 10 Pipe Connections ........................

  • Page 7: General

      1.0 General   Introduction The Vulcan HDS submersible pump has been designed and manufactured to handle the toughest pumping applications and environments. It is our desire to provide our customers with high quality products and service that exceeds their application expectations. This manual is intended to assist technical personnel with the installation, operation and maintenance of the HDS submersible pump.
  • Page 8   1.2.2.2 Long Term Storage 1.2.2.2.1 New Pump Long Term Storage New pumps being stored more than three months time before installation must adhere to the following procedures:  Notify Vulcan Pumps in writing that the equipment is to be stored more than three months time prior to installation and the proper long term storage procedures have been adhered to.

  • Page 9: Receiving Inspection

      Receiving Inspection Each pump requires inspection immediately upon arrival at site. Ensure that any irregularities and (or) damages caused during the shipping process is reported to the transportation company and Vulcan Pumps. Make any claims for lost or damaged items to the transportation company. Note: Pump Accessories are usually packed in separate boxes, containers and crates.

  • Page 10: Safety

      the contract price for the product. In no event shall Seller be liable for any incidental or consequential damages such as lost profits, loss of use of productive facilities or equipment, expenses or damages incurred in reliance on the product's performance or lost production whether suffered by buyer or any third party.

  • Page 11: Safety Definitions

      Safety Definitions Within this manual the words WARNING!, CAUTION! AND ELECTRICAL! are used to indicate areas where  the installer, operator and maintenance personnel need to exhibit extra care and attention.  2.1.1 Vulcan Pump Safety Definitions WARNING! IF IGNORED COULD LEAD TO SERIOUS INJURY OR DEATH! CAUTION! IF IGNORED COULD LEAD TO SERIOUS DAMAGE TO THE PUMP OR ASSOCIATED EQUIPMENT! ELECTRICAL! IF IGNORED COULD LEAD TO ELECTRICAL SHOCK, BURNS OR ARC FLASH! 2.1.2 Baldor®...

  • Page 12: General Safety Precautions

      General Safety Precautions   WARNING! NEVER APPLY HEAT TO REMOVE THE IMPELLER! WARNING! NEVER USE HEAT TO DISASSEMBLE PUMP COMPONENTS! ALWAYS LOCK OUT POWER TO THE ELECTRIC MOTOR BEFORE WARNING! PERFORMANING ANY MAINTENANCE! WARNING! NEVER MOVE PUMP WITHOUT PROPER MECHANICAL ASSISTANCE! FLANGED CONNECTIONS –...

  • Page 13: Installation

      3.0 Installation Ensure that all regional and industry specific safety standards and procedures are understood and followed prior to and during the installation process. All electrical work must be performed by a certified electrician. Pump Mounting and Positioning The pumps can be directly mounted on the sump floor supported entirely by the pump stand. The sump floor must be level to prevent the pump from tipping over during operation.

  • Page 14: Pipe Connections

      Pipe Connections Discharge piping and hose must be mounted and supported in such a manner that it does not transmit stress to the pump casing. It is recommended that heavy duty, steel wire reinforced elastomeric discharge hose be installed rather than traditional rigid discharge pipe. If rigid discharge pipe is being installed then it is recommended that reinforced expansion joints be incorporated into the discharge line.

  • Page 15: Electrical Installation

      3.3.2 Optional Jet Ring Piping If a jet ring is utilized please contact your local Vulcan Pumps representative for the specific jet ring data sheet. Electrical Installation All electrical installations should conform to all regional and industry specific electrical standards.
  • Page 16   3.4.2 Thermal Device Vulcan Pumps electric submersible motors come equipped with two thermostats as standard that provide Over Temperature Protection. Vulcan Pumps requires the thermostats to be properly installed to the holding coil of the magnetic starter. CAUTION! MOTOR THERMOSTAT OVER TEMPERATURE PROTECTION MUST BE INSTALLED AND OPERATIONAL TO VALIDATE THE MOTORS WARRANTY! ...
  • Page 17   3.4.5 Wiring Schematic (Standard)               SHD POWER CABLE       SHD CONTROL CABLE                                 THERMOSTATS MOTOR   1 &...
  • Page 18   3.4.6 Wiring Schematic (Optional Ground-Fault / Ground-Check Monitoring)               SHD POWER CABLE         SHD CONTROL CABLE                              ...

  • Page 19: Operation

      4.0 Operation   Pump Start-Up Check List Power and Control Check the power and control cables for damage such as cuts and Cables tears in the out cable jacket. Electrical Power Ensure the power supply parameters match the motor nameplate data.

  • Page 20: Pump Shut Down

      Once the pump has found a stable operating condition, monitor the motor amperage draw. If possible monitor the pump discharge pressure and flow rate. It is recommended that amperage draw, discharge pressure and flow rate readings be recorded frequently to identify any changes in the pump performance that could indicate possible problems with the pump or motor.

  • Page 21: Maintenance

      5.0 Maintenance Ensure that all regional and industry specific safety standards and procedures are understood and followed prior to and during the installation process. All electrical work must be performed by a certified electrician. Maintenance Safety   WARNING! ALWAYS LOCKOUT & DISCONNECT POWER TO THE ELECTRIC MOTOR BEFORE PERFORMANING ANY MAINTENANCE! ...

  • Page 22: Preventative Maintenance

      Preventative Maintenance The pump operating condition should be monitored on an ongoing basis. It is recommended that amperage draw, discharge pressure and flow rate readings be recorded frequently to identify any changes in the pump performance that could indicate possible problems with the pump or motor.

  • Page 23: Wet End Component Installation

      Wet End Component Installation                                 Apply Anti Seize to Motor Shaft.   Motor Models: Run Dry Slurry Seal Only    Pack the motor lip seal with Teflon Grease. Install    the Motor Deflector onto the shaft; ensure a 0.02”    (0.5mm) gap between the seal chamber cover plate  and Motor Deflector. Tighten set screws.                       ...
  • Page 24                                 Insert the Drive Key (032) into the key seat.   Install the Impeller Gasket (073.1).                                       HDS Models: 50L, 75L, 100L, 150L, 75M, 100M, 200L  HDS Models: 150M, 200M    Lift the Casing (100) into position.  Insert Lock  Lift the Motor Side Liner (011) into position.  Insert ...
  • Page 25                                 HDS Models: 150M, 200M  HDS Models: 150M, 200M    Position the O‐Ring (073.1) on the Motor Side Liner  Lift the Casing (100) into position.  Insert Lock  (011) spigot.  Washers (901.4) over the Socket Head Cap Screws    (901.1), apply Anti Seize, thread into the Casing and    tighten to specified torque.    CASINGS REQUIRE THE ASSISTANCE OF LIFTING    EQUIPMENT!                     ...
  • Page 26         HDS Model  Impeller Bolt Torque    50L, 75L, 100L  55 lb‐ft  (75 Nm)    150L, 75M, 100M  110 lb‐ft (150 Nm)    200L, 150M, 200M  200 lb‐ft (275 Nm)        Impeller Blocking    The Impeller (200) will have to be blocked    when the Impeller Bolt Fastener (901.3) is    being tightened.  A piece of wood can be used  as a wedge between the casing and impeller.        Install the O‐Rings (104.1) onto the Impeller Bolt    Fastener (901.3), apply Locktite® 262 onto the    Impeller Bolt, thread into the shaft and tighten to    the specified torque.           ...
  • Page 27                                 Install the Suction Cover (009) and Suction Gaskets  Install the Pump Stand (233) by aligning the    (073.3) on the Casing (100).  Verify the clearance  mounting holes. Insert Lock Washers (901.4) over    between the Impeller (200) face and Suction Cover.   the Socket Head Cap Screws (901.2), Anti Seize,    Clearance should be 1/32” – 1/16” (0.8mm –  thread into the Casing and tighten to specified    1.6mm).  Adjust the clearance by adding or  torque.    removing gaskets.  Spin the Impeller to ensure    there is no contact with the suction cover.               ...

  • Page 28: Wet End Component Disassembly

      Wet End Component Disassembly WARNING! WORN PUMP PARTS MAY HAVE SHARP EDGES! WARNING! DAMAGED PUMP PARTS SHOULD BE REPLACED TO ENSURE SAFE AND PROPER PERFORMANCE OF THE PUMP!                        ...
  • Page 29                                 Remove the Shaft Extension (258), Washer (901.7)  Remove the Impeller Bolt Fastener (901.3) and O‐   and O‐Ring (104.4).  The Impeller will have to be  Rings (104.1).  The Impeller will have to be Blocked,    Blocked, to prevent rotation while removing the  to prevent rotation while removing the Impeller    Shaft Extension.  Bolt Fastener.       DO NOT REUSE LOCK WASHER & O‐RINGS!  DO NOT REUSE IMPELLER BOLT!                       ...
  • Page 30                   HDS Models: 50L, 75L, 100L, 150L, 75M, 100M, 200L  HDS Models: 150M, 200M    Remove Socket Head Cap Screws (901.1) and Lock  Remove the Socket Head Cap Screws (901.1), Lock    Washers (901.4) and remove the Casing (100).  Washers (901.4) and remove the Casing (100).  CASINGS REQUIRE THE ASSISTANCE OF LIFTING  CASINGS REQUIRE THE ASSISTANCE OF LIFTING    EQUIPMENT!  EQUIPMENT!                      HDS Models: 150M, 200M  Remove the Impeller Gasket (073.1).   Remove the Socket Head Cap Screws (901.1), Lock  DO NOT REUSE THE IMPELLER GASKET!    Washers (901.4) and Motor Side Liner (011). Remove  the Casing O‐Ring (104.5)    MOTOR SIDE LINERS REQUIRE THE ASSISTANCE OF ...
  • Page 31                       Remove the Drive Key (032) from the key seat.   Remove the Impeller Deflector (040) from the  DO NOT REUSE THE DRIVE KEY!  motor shaft.                         Remove the Deflector Gasket (073.2).   Motor Models: Run Dry Slurry Seal Only    DO NOT REUSE THE DEFLECTOR GASKET!  Remove the Motor Deflector from the motor Shaft.  DO NOT REUSE THE MOTOR DEFLECTOR V‐RING!       Document No. – A1540  Date – 23 January 2014  Revision – 0  Uncontrolled Copy     ...

  • Page 32: Fastener Assembly Torque / Assembly Pre-Load

      Fastener Assembly Torque / Assembly Pre-Load   Assembly Torque / Assembly Pre‐Load  Tightening Torque  Assembly Pre‐Load  Size  Class  kN  lb‐ft (lb‐in)  Nm  lbf  M4  1.7 (20)  2.3  612  2.7  M5  3.4 (41)  4.6  1002  4.5  M6  5.8 (69)  7.9  1415  6.3  M8  13.3  18  2600  11.6  316SS  A4‐70  M10  26.5 ...

  • Page 33: Trouble Shooting

      6.0 Trouble Shooting Fault Tracing Use the following fault tracing logic to aid in troubleshooting the pump and motor; it is assumed that the pump has been previously operating without any problems. Fault tracing should be performed by a licensed Electrician and should conform to all regional and industry specific electrical standards.
  • Page 34   6.1.2 Pump Starts but Motor Trips Out Has the  Check:  discharge pipe   Operating Condition & System Head Calculation  size, route or   Motor Horsepower Requirement  length changed?  Yes  No  Check:   Motor overload cut‐out setting   Solids / Liquid Concentration   Pump is jammed with debris   Check for uneven voltage and amperage on each phase    6.1.3 Pump is Operating with Limited to No Flow Has the  Check:  discharge pipe ...

  • Page 35: Pump Data

      7.0 Pump Data HDS Cross Section & Bill of Materials 7.1.1 HDS 50L-A / A1175 7.1.2 HDS 75L-A / A1181 7.1.3 HDS 100L-A / A1187 7.1.4 HDS 150L-A / A1193 7.1.5 HDS 200L-A / A1199 7.1.6 HDS 75M-A / A1205 7.1.7 HDS 100M-A / A1211 7.1.8 HDS 150M-A / A1217 7.1.9 HDS 200M-A / A1223...

  • Page 36: Hds Performance Curves - Agitator

      HDS Performance Curves - Agitator 7.3.1 HDS 50L-A 1800 RPM / A1235 7.3.2 HDS 50L-A 1200 RPM / A1238 7.3.3 HDS 75L-A 1800 RPM / A1241 7.3.4 HDS 75L-A 1200 RPM / A1244 7.3.5 HDS 100L-A 1800 RPM / A1247 7.3.6 HDS 100L-A 1200 RPM / A1250 7.3.7 HDS 150L-A 1800 RPM / A1253 7.3.8 HDS 150L-A 1200 RPM / A1256...
  • Page 37 Name Plate Data Sheet SUBMERSIBLE DATE SLURRY PUMP MODEL SERIAL NUMBER IMP TRIM VOLUME HEAD Feet SPEED PHASE r/min INSULATION VOLTAGE CURRENT CLASS See tag SERVICE FACTOR NET WEIGHT 1.15 MOISTURE DETECTION RELAY AND MOTOR OVERLOAD PROTECTION MUST BE INSTALLED AND OPERATIONAL AT ALL TIMES TO VALIDATE PUMP WARRANTY.
  • Page 38 AC Submersible Pump Motors Installation & Operating Manual 4/09 MN414...
  • Page 39 Any trademarks used in this manual are the property of their respective owners.
  • Page 40 Table of Contents Section 1 General Information ................1−1 Overview .

  • Page 41: General Information

    Section 1 General Information ii Table of Contents MN414...

  • Page 42: Limited Warranty

    Section 1 General Information Overview This manual contains general procedures that apply to BaldorSReliance Motor products. Be sure to read and understand the Safety Notice statements in this manual. For your protection, do not install, operate or attempt to perform maintenance procedures until you understand the Warning and Caution statements.

  • Page 43: Receiving

    Section 1 General Information Safety Notice Continued Pacemaker danger − Magnetic and electromagnetic fields in the vicinity of current carrying WARNING: carrying conductors and permanent magnet motors can result result in a serious health hazard to persons with cardiac pacemakers, metal implants, and hearing aids. To avoid risk, stay way from the area surrounding a permanent magnet motor.

  • Page 44: Installation & Operation

    Section 2 Installation & Operation Overview Installation should conform to the National Electrical Code as well as local codes and practices. All BaldorSReliance Submersible Pump Motors Include thermal devices as standard. Normally, there are four conditions during which a submersible sewage pump may be operated in gases or vapors.

  • Page 45: Installation

    WARNING: Do not touch electrical connections before you first ensure that power has been disconnected. Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the installation, operation and maintenance of this equipment. WARNING: The Adjustable Speed Controller may apply hazardous voltages to the motor leads after power to the controller has been turned off.
  • Page 46 Grounding In the USA consult the National Electrical Code, Article 430 for information on grounding of motors and generators, and Article 250 for general information on grounding. In making the ground connection, the installer should make certain that there is a solid and permanent metallic connection between the ground point, the motor or generator terminal housing, and the motor or generator frame.
  • Page 47 Moisture Protection The submersible moisture protection system consists of the non−wicking cable cap assembly and the dual moisture sensing probes. The cable cap assembly prevents moisture from wicking through the cable assembly even when the cable jacket has been punctured. Dual moisture sensing probes (Warrick type) extend into the oil chamber located between the tandem mechanical seals.
  • Page 48 Installation (for reference only) Note: Since changes occur, always refer to installation and connection documentation from the manufacturer and follow their procedures. All type 2800−XXX controls are identified by a specific component number which follows the format 2800−XXX where the X’s are replaced by numbers and letters indicative of the A−C supply line voltage and frequency, contact configuration and enclosure.

  • Page 49: Operation

    Section 1 General Information WARNING: Surface temperatures of motor enclosures may reach temperatures which can cause discomfort or injury to personnel accidentally coming into contact with hot surfaces. Protection should be provided by the user to protect against accidental contact with hot surfaces. Failure to observe this precaution could result in bodily injury.
  • Page 50 Baldor District Offices...
  • Page 51 BALDOR ELECTRIC COMPANY World Headquarters P.O. Box 2400 Fort Smith, AR 72901−2400 (479) 646−4711 Fax (479) 648−5792 www.baldor.com © 2009 Baldor Electric Company All rights reserved. Printed in USA MN414 4/09...

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