Calpeda NM, NMS, NM4, NMS4 Manual

GENERAL INFORMATION

Before using the product carefully read the information contained in this instruction manual, the manual should be kept for future reference.
Italian is the original language of this instruction manual, this language is the reference language in case of discrepancies in the translations. This manual is part of the essential safety requirement and must be retained until the product is finally de-commissioned.
The customer, in case of loss, can request a copy of the manual by contacting Calpeda S.p. A. or their agent, specifying the type of product data shown on the label of the machine (see Marking) Any changes, alterations or modifications made to the product or part of it, not authorized by the manufacturer, will revoke the "CE declaration" and warranty.
Do not use in ponds, tanks or swimming pools or where people may enter or come into contact with the water. Read carefully the installation section which sets forth:

• The maximum permissible structural working pressure.
• The type and section of the power cable.
• The type of electrical protection to be installed.

Symbols

To improve the understanding of the manual, below are indicated the symbols used with the related meaning.

	Information and warnings that must be observed, otherwise there is a risk that the machine could damage or compromise personnel safety.
	The failure to observe electrical information and warnings, could damage the machine or compromise personnel safety.
	Notes and warnings for the correct management of the machine and its parts.
	Operations that could be performed by the final user. After carefully reading of the instructions, is responsible for maintenance under normal conditions. They are authorized to affect standard maintenance operations.
	Operations that must be performed by a qualified electrician. Specialized technician authorised to affect all electrical operations including maintenance. They are able to operate with in the presence of high voltages.
	Operations that must be done performed by a qualified technician. Specialized technician able to install the device, under normal conditions, working during "maintenance", and allowed to do electrical and mechanical interventions for maintenance. They must be capable of executing simple electrical and mechanical operations related to the maintenance of the device.
	Indicates that it is mandatory to use individual protection devices - hand protection.
	Indicates that it is mandatory to use individual protection devices - eye protection.
	Operations that must be done with the device switched off and disconnected from the power supply.
	Operations that must be done with the device switched on.

Manufacturer name and address

Manufacturer name: Calpeda S.p. A.
Address: Via Roggia di Mezzo, 39 36050 Montorso Vicentino - Vicenza / Italia
www.calpeda.it

Authorized operators

The product is intended for use by expert operators divided into end users and specialized technicians. (see the symbols above).
It's forbidden, for the end user, carry out _{operations which must be done only by} specialized technicians. The manufacturer declines any liability for damage related to the non-compliance of this warning.

Technical assistance

Any further information about the documentation, technical assistance and spare parts, shall be requested from: Calpeda S.p. A..

TECHNICAL DESCRIPTION

Pump designation = NM, NMS, NM4, NMS4
Closecoupled centrifugal pumps; electric motor with extended shaft directly connected to the pump up to 15 kW for NM4 and 30 kW for NM, new bracket construction for standard motors (stub-shaft construction) from 18,5 to 75 kW for NM4 and 37 to 75 kW for NM with integrated thrust bearing.
Pump casing with axial suction and radial delivery on top, main dimensions and performance according to EN 733.
NM..: version with pump casing and lanter bracket in cast iron.
B-NM..: version with pump casing and lanter bracket/casing cover in bronze. (the pumps are supplied fully painted).

Intended use

Standard construction
For clean liquids, non-explosive and non-flammable, without abrasives, which are non-aggressive for the pump materials (contents of solids up to 0.2%).
Liquid temperature from -10°C to +90°C. With seal rings in EPDM the pump is not suitable for use with oil.

Special construction
For clean liquids, non-explosive and non-flammable, without abrasives, which are non-aggressive for the pump materials (contents of solids up to 0.2%) with the following characteristics:

• Cooling mixtures with temperatures from 0 to -30°C.
• Water with temperatures from 90°C to 140°C.
• Oil with temperature up to 200°C and / or maximum density of 30 cSt.

Improper use

The device is designed and built only for the purpose.
Improper use of the device is forbidden, as is use under conditions other than those indicated in these instructions. Improper use of the product reduces the safety and the efficiency of the device, Calpeda shall not be responsible for failure or accident due to improper use.

Marking

The following picture is a copy of the name-plate that is on the external case of the pump.

0. Manufacturer

1. Type
2. Delivery
3. Head
4. Rated power
5. Supply voltage
6. Frequency
7. Nom. motor current
8. Rotation speed rpm
9. Operation Duty
10. Insul. class
11. Certifications
12. AAAA Year of manufacture

12. XXXX Serial number
13. Weight
14. Notes
15. Voltage
16. % Load
17. Power factor
18. Efficiency
19. Protection
20. Motor Efficiency
21. Pump Efficiency
22. Capacitor

TECHNICAL FEATURES

Technical data

Dimensions and weight (see technical catalogue).
Nominal speed 1450/1750/2900/3450 rpm Protection IP54 (IP 55 for NMS, NMS4) Supply voltage / Frequency:

• up to 240V 1~ 50/60 Hz
• up to 480V 3~ 50/60 Hz

Check that the mains frequency and voltage correspond to the electrical characteristics shown on the indicator plate.
The electric data marked on the label are referred to the nominal power of the motor. Rated motor power

Maximum permissible working pressure (PN) up to 100 m (10 bar), 160 m (16 bar) pump in ductile iron.
The max. inlet water pressure: PN (Pa) - Hmax (Pa).

Operating conditions

Installation in well ventilated location protected from the weather, with ambient temperature of -10°C to +40°C.
Relative humidity: from 10% to 55% non-condensing.
Maximum altitude 1,000 m above sea level.

SAFETY

General provisions

Before using the product it is necessary to know all the safety indications.
Carefully read all operating instructions and the indications defined for the different steps: from transportation to disposal.
The specialized technicians must carefully comply with all applicable standards and laws, including local regulations of the country where the pump is sold.
The device has been built in conformity with the current safety laws. The improper use could damage people, animals and objects. The manufacturer declines any liability in the event of damage due to improper use or use under conditions other than those indicated on the name-plate and in these instructions.
Follow the routine maintenance schedules and the promptly replace damaged parts, this will allows the device to work in the best conditions.
Use only original spare parts provided from Calpeda S.p. A or from an authorized distributor.
Don't remove or change the labels placed on the device.
Do not start the device in case of defects or damaged parts.
Maintenance operations, requiring full or partial disassembly of the device, must be done only after disconnection from the supply.

Safety devices

The device has an external case that prevents any contact with internal parts.

Residual risks

The appliance, designed for use, when used in-line with the design and safety rules, doesn't have residual risks.

Information and Safety signals

For this kind of product there will not be any signals on the product.

Individual protection devices

During installation, starting and maintenance it is suggested to the authorized operators to consider the use of individual protection devices suitable for described activities.
During ordinary and extraordinary maintenance interventions, safety gloves are required.

Signal individual protection device

HAND PROTECTION
(gloves for protection against chemical, thermal and mechanical risks).

EYE PROTECTION
(glasses for protection from chemical, thermal and biological risks)

TRANSPORTATION AND HANDLING

The product is packed to maintain the content intact. During transportation avoid to stack excessive weights. Ensure that during the transportation the packed cannot move.
The transport vehicles must comply, for the weight and dimensions, with the chosen product (see technical catalogue dimensions and weights).

Handling

Handle with care, the packages must not receive impacts.
Avoid to impact onto the package materials that could damage the pump.
If the weight exceeds 25 Kg the package must be handled by two person at the same time (see technical catalogue dimensions and weights). Raise the pump-motor unit slowly (fig.1), making sure it does not move from side to side in an uncontrolled way, to avoid the risk of imbalance and tipping up.
(fig. 1)

Storage

The appliance must be stored in a dry place, protected from shocks and preferably in its original packaging. Respect the following storage conditions:

• Ambient temperature from -10°C to +70°C
• Relative humidity: from 10% to 90% non-condensing.

INSTALLATION

Dimensions

For the dimensions of the device (see technical catalogue).

Ambient requirements and installation site dimensions

The customer has to prepare the installation site in order to guarantee the right installation and in order to fulfill the device requirements (electrical supply, etc...).
The place where the device will be installed must fulfill the requirements in the paragraph. It's Absolutely forbidden to install the machine in an environment with potentially explosive atmosphere.

Unpacking

Inspect the device in order to check any damages which may have occurred during transportation.
Package material, once removed, must be discarded/recycled according to local laws of the destination country.
Raise the pump-motor unit slowly (see paragraph fig.1), making sure it does not move from side to side in an uncontrolled way, to avoid the risk of imbalance and tipping up.

Installation

These pumps must be installed with the rotor axis horizontal and feet downwards.
Place the pump as close as possible to the suction source (with consideration given to the NPSH value). Provide space around the pump for motor ventilation, to allow for checking of shaft rotation, for filling and draining the pump and to allow for collection of the liquid to be removed.
When the pump is used in air-conditioning or cooling systems it is necessary to provide a draining of the condensate that may happen in the lantern bracket. In these cases it is necessary to install the pump with the rotor axis in horizontal position.
In cases where thermal insulations are used never cover the lantern bracket.

Pipes
Ensure the insides of pipes are clean and unobstructed before connection.
ATTENTION: The pipes connected to the pump should be secured to rest clamps so that they do not transmit stress, strain or vibrations to the pump.
The inside diameter of the pipe-work depends on the desired flow.
Provide a diameter assuring a liquid flow not greater than 1.5 m/s for suction and 3 m/s for delivery. The pipe diameters must never be smaller than the pump connection ports.

Suction pipe
The suction pipe must be perfectly airtight and be led upwards in order to avoid air pockets.
Use an eccentric transition piece to join the suction connection with a horizontal pipe of larger diameter
(fig. 2).

With a pump located above the water level (suction lift operation), fit a foot valve with strainer which must always remain immersed or a check valve on the suction connection.
With a pump located below water level (inflow under positive suction head) install a gate valve.

Delivery pipe
Fit a gate valve in the delivery pipe to adjust delivery, head, and absorbed power.
Install a pressure gauge.
With a geodetic head of over 15 m fit a check valve between the pump and the gate valve in order to protect the pump from water hammering. With a variable frequency drive, the check valve must be installed before the pressure transducer.

Alignment of pump-motor unit
ATTENTION: a misalignment between pump feet and motor feet could cause vibration and early wear of elastic bearings, the seal and other internal parts.
Make sure the rotor turns freely when moved by hand. Insert 1 mm thickness under the feet of the pump casing, then thicken the motor until alignment is obtained. For adjustment loosen or remove the screws where necessary and add calibrated plates under the motor feet if necessary.

Electrical connection

Electrical connection must be carried out only by a qualified electrician in accordance with local regulations.
Follow all safety standards.
The unit must be properly earthed (grounded). Connect the earthing (grounding) conductor to the terminal with the marking.
Compare the frequency and mains voltage with the name-plate data and connect the supply conductors to the terminals in accordance with the appropriate diagram inside the terminal box cover.
ATTENTION: with motor power rating ≥ 5.5 kW avoid direct starting. Provide a control panel with stardelta starting or an other starting device.
ATTENTION: never allow washers or other metal parts to fall into the internal cable opening between the terminal box and stator. If this occurs, dismantle the motor to recover the object which has fallen inside.
If the terminal box is provided with an inlet gland, use a flexible power supply cord of the H07 RN-F type with section of cable not less than (par. 13.3 TAB 1). If the terminal box is provided with an inlet bushing, connect the power supply cord through a conduit. For use in swimming pools (not when persons are in the pool), garden ponds and similar places, a residual current device with IΔN not exceeding 30 mA must be installed in the supply circuit.
Install a device for disconnection from the mains (switch) with a contact separation of at least 3 mm in all poles.
With a three-phase motor install an overload protection device with curve D appropriate for the rated current of the pump.
Single-phase NMM, are supplied with a capacitor connected to the terminals and (for 220-240 V - 50 Hz) with an incorporated thermal protector.

Operation with frequency converter

Adjust the frequency converter so that the limiting values of min. 25 Hz and max. nominal frequency (50 or 60 Hz).
It is necessary to install a dv/dt filter at the output of converter if the power cable is longer than 2 meters. It is necessary to install a dv/dt filter or an insulated bearing if both of the following conditions are met:

• frequency converter has a PWM frequency higher than 8 kHz;
• nominal power >7,5 kW if 2-pole motor or nominal power >4 kW if 4-pole motor.

Furthermore, it is necessary to install a dv/dt filter or an insulated bearing in all the cases where the drive has a working frequency ^𝑓𝐿<4/5^𝑓𝑁 for a time higher than 1/3^𝑇 where T is defined in 24 hours and ^𝑓𝑁 is the nominal motor frequency (i.e. higher than 8 hours per day).
In any condition the dv/dt limit curve prescribed in the technical appendix of Calpeda catalogue must not be exceeded furthermore, the minimum working frequency must guarantee fluid pumping and comply the manufacturer's prescriptions.
Voltage peaks or increased acoustic noise can be abated by installing a dv/dt filter between the frequency converter and the motor.

STARTUP AND OPERATION

Preliminary checks before start-up of the pump

The pumps may contain small quantities of residual water from testing.
When pumping drinking water, the pump must be flushed thoroughly with clean water before startup in order to remove any foreign matters, such as preservatives, test liquid, or grease.
Do not start-up the device in case of damaged parts.

First starting

ATTENTION: never run the pump dry. Start the pump after filling it completely with liquid.
When the pump is located above the water level (suction lift operation) fill the suction pipe and the pump through the priming hole Fig. 3.
Fig. 3 Filling.

When the liquid level on the suction side is above the pump (inflow under positive suction head), fill the pump by opening the suction gate valve slowly and completely, keeping the delivery gate valve open to release the air. Check that the shaft turns by hand.
With a three-phase motor check that the direction of rotation is as shown by the arrow on the pump casing, otherwise, disconnect electrical power and reverse the connections of two phases. With a suction lift operation it may be necessary to wait a few minutes for the pump to prime. Check that the pump works within its field of performance, and that the absorbed current shown on the name-plate is not exceeded.
Otherwise adjust the delivery gate valve or the setting of any pressure switches.
Never run the pump for more than five minutes with a closed gate valve.
Do not touch the fluid when its temperature is higher than 50°C.
Burn hazard. Due to high temperature of the fluid, the pump casing and the motor may reach temperatures higher than 50°C.
DO NOT TOUCH these parts unless with suitable protective devices or wait and make sure they have completely cooled.
The faces of the mechanical seal are lubricated by the pumped liquid. A small amount of liquid may therefore leak out during the normal operation of the pump. During the first start-up, or after replacing the mechanical seal, there may be a more significant leak.
Some liquids (e.g. water) evaporate after leaking out so the leak is not visible. Other liquids (e.g. oil) do not evaporate, so some drops are visible. This does not affect the mechanical seal.

Starting Pumps with packing seal
First loosen the gland slightly so that the seal is decompressed.

Switch off of the pump

The appliance must be switch off every time there are faults. (see troubleshooting).
The product is designed for a continuous duty, the switch off is performed by disconnecting the power supply by means the expected disconnecting devices. (see paragraph "Electrical connection").

MAINTENANCE

Before any operations it's necessary to disconnect the power supply.
If required ask to an electrician or to an expert technician.
Every maintenance operations, cleaning or reparation executed with the electrical system under voltage, it could cause serious injuries to people.
If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualified persons in order to avoid a hazard.
In case of extraordinary maintenance, or maintenance operations that require part-removing, the operator must be a qualified technician able to read schemes and drawings.
It is suggest to register all maintenance operation executed.
During maintenance keep particular attention in order to avoid the introduction of small external parts, that could compromise the device safety.
It is forbidden to execute any operations with the direct use of hands. Use water-resistant, anti-cut gloves to disassemble and clean.
During maintenance operations external personnel is not allowed.
Maintenance operations that are not described in this manual must be made only by special personnel authorized by Calpeda S.p. A.
For further technical information regarding the use or the maintenance of the device, contact Calpeda S.p. A.

Routine maintenance (Standard construction)

Before every maintenance operations disconnect the power supply and make sure that the device could not accidentally operate.
Burn hazard. Due to high temperature of the fluid, the pump casing and the motor may reach temperatures higher than 50°C.
DO NOT TOUCH these parts unless with suitable protective devices or wait and make sure they have completely cooled. When the pump remains inactive it must be emptied completely if there is a risk of freezing Fig. 4.

Before restarting the unit, check that the shaft is not jammed and fill the pump casing completely with liquid.

Routine maintenance (Special construction)

Wear protective glasses for splashes.

Maintenance Pumps with packing seal

First loosen the gland slightly so that the seal is decompressed. Then adjust the gland, leaving a regular leakage-drip, which indicates proper lubrification.
The packed gland must be replaced when its sealing properties have considerably decreased. A compressed, hardened and dry packing causes the shaft to wear.

Bearings lubrication

Up to frame size 250 the motors have prelubricated bearings and they do not require any relubrication. From frame size 280 the motors have grease nipples. A relubrication at regular intervals (about 4000 h) is recommended only in heavy working conditions, with high ambient temperatures. An excess of grease is harmful. Use lithium base grease for high temperatures.

Dismantling the system

Close the suction and delivery gate valves and drain the pump casing before dismantling the pump.

Dismantling the pump

Close the suction and delivery gate valves and drain the pump casing before dismantling the pump. For dismantling and reassembly see construction in the cross section drawing.
The motor and all internal parts can be dismantled without removing the pump casing and pipes. By removing the nuts (14.28) the motor can be taken out complete with the impeller.

Pumps with IP 55 protection

To always assure IP 55 degree of protection, it is necessary to check the following points:

• Before starting the motors, carefully control the position of the gasket between terminal box and its cover. For cable of small size, use a protective covering between cable and cable gland.
• When disassembling the end shields of the motors, restore the existing joint using the sealing glue LOCTITE type 510 or other equivalent sealing system, if any, and check the perfect assembly of the sealing ring on the shaft.

SPARE PARTS

Spare-parts request

When ordering spare parts, please quote their designation, position number in the cross section drawing and rated data from the pump name plate. The spare parts request shall be sent to CALPEDA S.p. A. by phone, e-mail. Changes reserved.

Troubleshooting

Turn off the power supply before performing any operations.
Do not allow the pump or motor to run when dry even for a short period
Strictly follow the user instructions and if necessary contact an authorised service centre