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INNOMAG ® U-MAG™ Sealless chemical

1. 29 Page 2 of 40 U MAG ENGLISH 26999990 10 14 Page 6 12 Drive End Disassembly 29 6 13 Drive End Assembly 30 6 14 Wet Drive End Assembly 32 6 15 Gasoline Engine 33 Troubleshooting 34 7 1 Faults causes and remedies 34 PARTS LISTS AND DRAWINGS 37 8 1 Sectional drawing 37 8 2 Parts interchangeability 38 8 3 General arrangement drawing 39 OER Ti CATION ve 39 10 OTHER RELEVANT DOCUMENTATION AND MANUAL 39 10 1 Supplementary User Instruction manuals 39 10 2 Change notes 39 10 3 Additional sources of information 39 FLOWSERVE da INDEX Page Additional information 10 3 39 Se 6 11 2 EE EN 29 ATEX marking 1 6 4 2 7 CE marking and approvals 1 2 4 Certification 9 39 Change notes 10 2 39 Commissioning and operation 5 19 Compliance ATEX 1 6 4 1 7 Configurations
2. FLOWSERVE INNOMAG U MAG Horizontal close coupled fluoropolymer lined sealless chemical process pumps PCN 26999990 10 14 E Original instructions Experience In Motion USER INSTRUCTIONS Installation Operation Maintenance FLOWSERVE TABLE OF CONTENTS Page 1 INTRODUCTION AND SAFETY 4 CACC AM mm 4 1 2 CE marking and approvals 4 1 3 Disclaimer srice aani 4 t4 Copyright 4 1 5 Duty conditions 4 Eo uc E E 5 1 7 Nameplate and safety labels 9 1 8 Specific machine performance 9 1 9 Noise level 9 2 TRANSPORT AND STORAGE 9 2 1 Consignment receipt and unpacking 9 2 2 Liege esistini niidina nerin danan 10 Zid LMM sap a Aaea 10 24 Tio ris LE 11 2 5 Recycling and end of product life 11 3 DESCRIPTION nnnc rennes 11 3 1 Configurations 11 3 2 Nomenclature 11 3 3 Nameplate 11 3 4 Design of major parts 13 3 5 Performance and operating limits 13 4 INSTALLATION eee 14 4 1 Location 14 4 2 Part Assemb
3. installation of dowel pins for the following motor sizes 100L and 112M The pin installation is permanent Check the configuration for your motor before you begin a IEC 80 amp IEC 90 do not require dowel pins b IEC 100L and 112M require 6 dowel pins installed into the unpainted dowel pin holes Firmly pound the 6 dowel pins in with a hammer until they are firmly seated The properly installed dowel pin will be flush with the adapter 1340 face Figure 6 25 c IEC 132 motors require an adapter plate To install align the inner holes on the adapter plate with the holes on the bottom of the adapter 1340 Insert and tighten the 4 bolts to the adapter plate Figure 6 26 M FLOWSERVE d Once properly configured align the 4 holes on the riser block with the 4 holes on the adapter 1340 e Align the 4 holes on the support foot 3134 with the 4 holes on the riser block f Insert and tighten the 4 riser screws g Align the bolt holes on the motor with the threaded holes on the adapter 1340 or adapter plate if installed h Insert tighten the 4 bolts 6570 1 with lock washers 6541 through the motor flange into the adapter 1340 or adapter plate if equipped i Remove plug 6569 from the adapter 1340 j Note the placement of the set screws on the outer magnet assembly 0230 in relation to the key notch before installation Set screw A will be directly across from the ke
4. Additional compression may be required to stabilize the baseplate Page 16 of 40 U MAG ENGLISH 26999990 10 14 h After all four stilts have been assembled position the baseplate in place over the floor cups 7 under each stilt location and lower the baseplate down to the floor i Level and make final height adjustments to the suction and discharge pipe by first loosening the top nuts and turning the bottom nuts to raise or lower the baseplate j Recompress the top spring to the compression established in step g and lock the nuts in place k It should be noted that the connecting pipelines must be individually supported and that the spring mounted baseplate is not intended to support total static pipe loads Figure 4 4 STILT BOLT BOTTOM SPRING 31 4 in 83 mm OD X 4 in 102 mm FL CUPS JE eme TOP SPRING ER 2 in 51 mm OD X 4 in 102 mm FL CUPS amp NUTS ee 5 FLAT WASHER Guss LOCK WASHER FLOOR CUP 7 0 o 0 Z i Y FEA I in 25 mm Approx Initial Height QU NZ The remaining steps are as listed for new grouted baseplates 4 4 Grouting Where applicable grout in the foundation bolts Foundation bolts should only be fully tightened when the grout has cured After adding pipework connections and rechecking the pump alignment the baseplate should then be grouted in accordance with good engineering prac
5. START THE PUMP WITH THE DISCHARGE VALVE PARTLY OPENED Unless otherwise instructed at a specific point in the User Instructions This is recommended to minimize the risk of overloading and damaging the pump or motor at full or zero flow Pumps may be started with the valve further open only on installations where this situation cannot occur The pump outlet control valve may need to be adjusted to comply with the duty following the run up process See section 5 Commissioning start up operation and shutdown x SUCTION VALVES TO BE FULLY OPEN WHEN PUMP IS RUNNING Running the pump at zero flow or below the recommended minimum flow continuously will cause damage to the pump Never operate this pump with the suction and or discharge valve closed as this may lead to N h surface temperatures AN wau llawi The direction of rotation is clockwise when viewed from the motor end Rotation of the motor must be checked prior to starting the pump according to section 5 1 AX CAUTION Do NOT RUN THE PUMP AT ABNORMALLY HIGH OR LOW FLOW RATES Operating at a flow rate higher than normal or at a flow rate with no back pressure on the pump may overload the motor and cause cavitation Low flow rates may cause a reduction in pump bearing life overheating of the pump instability and cavitation vibration A camen CAUTION NEVER EXCEED THE MAXIMUM DESIGN PRESSURE MDP AT THE TEMPERATURE SHOWN ON THE PUMP NAMEPLATE AND INCLUDED IN SECTIO
6. 3 23 Running the pump 5 4 20 SLUUSRRIM 5 Safety action 1 6 3 5 Safety markings 1 6 1 5 Safety warnings 1 4 Sectional drawing general 8 1 37 Sectional drawings 8 37 Shaft alignment check 4 8 19 SOUPCES 10 S eres 39 Spare parts 6 3 23 Specific machine performance 1 8 9 Starting the pump 5 3 20 Stilt mounted baseplate 4 3 3 1 15 Stop start frequency 5 4 2 20 Stopping and shutdown 5 5 20 Storage 2 4 11 Storage of spares 6 3 2 23 Supplementary user instructions 10 1 39 ThermicSense 4 7 1 3 19 Tools required 6 4 23 Transport and storage 2 9 Troubleshooting 7 34 FLOWSERVE label 1 INTRODUCTION AND SAFE
7. 3 1 11 Copyright 1 4 4 Design of major parts 3 4 13 Direction of rotation 5 1 19 Disassembly 6 6 24 Disclaimer 1 3 4 Drawings B 37 Duty conditions 1 5 4 Electrical connections 4 6 18 End of product life 2 5 11 Examination of parts 6 7 25 Fastener torques 6 5 23 Faults causes and remedies 7 1 34 Final checks 4 8 19 Flange pressure rating 3 5 2 13 Foundation 4 3 rrrrnrnnrnnnnnnvrvrnnnnrnennrnnnnnennnnnnsnee 15 General 1 1 4 General arrangement drawing 8 3 39 General assembly drawings 8 37 Grouting 4 4 16 Handling 2 2 10 Hydraulic mechanical and electrical du
8. 3 4 in socket spanner wrench tighten the jack bolt to free the outer magnet assembly Figure 6 19 e Carefully remove the outer magnet assembly 0230 f Remove 4 screws from the adapter 1340 9 Remove the adapter 1340 from the motor 6 12 2 IEC Drive End Disassembly a b C Remove the metal pipe plug 6569 from the top of the adapter 1340 Locate and loosen the 2 set screws on the on the outer magnet assembly 0230 with a 5mm T Handle allen wrench as shown in Figure 6 18 Attach the jack screw plate TLG 2042 Sl with 2 M8 x 1 25 x 30 mm screws into the treaded holes inside the IEC outer magnet assembly 0230 Page 30 of 40 U MAG ENGLISH 26999990 10 14 Figure 6 20 Insert a M12 x 1 75 x 100 mm jack bolt into the center of the jack screw plate TLG 2042 SI and tighten the center jack bolt to free the outer magnet assembly 0230 Carefully remove the outer magnet assembly 0230 Remove 4 screws from the adapter 1340 Remove the adapter 1340 from the motor 6 13 Drive End Assembly The Outer Magnet Assembly 0230 contains very strong magnets Do not use blunt force on front face of the outer magnet assembly If difficult verify motor shaft meets manufacture s tolerances and is free of burrs 6 13 1 NEMA Drive End Assembly e Align the 4 holes on the support foot 3134 with the 4 holes on the adapter 1340 Insert and tighten the 4 riser screws Lin
9. 994 IS 060 OVIN IS 0060 ddV 99s V 1 Li Sulysng 3uiy 194585 9 Sulu JeIM 4asty YIM pajdnod 23I VIN3N 4e 0JD 1sniul uiw seam Sapnyouy Jeam sapnpu eus dwing s pnpul 03 79 VW3N 350 D 33I VIN3N paldnoz sop 23I VIN3N Ajquassy Ajquassy Sunny Ajquassy Ja adu ayajdwio jays 1UIWUILELUO JUIWUIEIUO 1euSe N 191nO NE LAM GN3 3AIYG Ajquiassy Juise Jajdepy 1e d SUNUNOIN awel4 JOOW 8 2 Parts interchangeability i FLOWSERVE flowserve com Page 38 of 40 FLOWSERVE label 8 3 General arrangement drawing The typical general arrangement drawing and any specific drawings required by the contract will be sent to the Purchaser separately unless the contract specifically calls for these to be included into the User Instructions If required copies of other drawings sent separately to the Purchaser should be obtained from the Purchaser and retained with these User Instructions 9 CERTIFICATION Certificates determined from the Contract requirements are provided with these Instructions where applicable Examples are certificates for CE marking ATEX marking etc If required copies of other certificates sent separately to the Purchaser should be obtained from the Purchaser for retention with these User Instructions 10 OTHER RELEVANT DOCUMENTATION AND MANUALS 10 1 Supplementary User Instruction manuals Supplementary instruction determined from the contra
10. REQUIRED TO AVOID POTENTIAL HAZARDS WHICH GIVE A RISK OF EXPLOSION The responsibility for compliance with maintenance instructions Is with the plant operator To avoid potential explosion hazards during maintenance the tools cleaning and painting materials used must not give rise to sparking or adversely affect the ambient conditions Where there is a risk from such tools or materials maintenance must be conducted in a safe area It is recommended that a maintenance plan and schedule is adopted See section 6 Maintenance FLOWSERVE label 1 7 Nameplate and safety labels 1 7 4 Nameplate For details of nameplate see the Declaration of Conformity or separate documentation included with these User Instructions 1 7 2 Safety labels J218JZ250 S FLOWSERVE nas WARNING ESSENTIAL PROCEDURES BEFORE STARTING n ENSURE ALL EXTERNAL CONNECTIONS TO INSTALL AND OPERATE EQUIPMENT IN THE PUMP SHAFT SEALING AND DRIVER ACCORDANCE WITH THE INSTRUCTION d ARE CONNECTED AND OPERATIONAL MANUAL SUPPLIED SEPARATELY FULLY PRIME UNIT AND SYSTEM ENSURE GUARDS ARE SECURELY IN DO NOT RUN UNIT DRY PLACE FAILURE TO FOLLOW THESE PROCEDURES MAY RESULT IN PERSONAL INJURY AND OR EQUIPMENT DAMAGE ENSURE CORRECT DIRECTION OF ROTATION J218JZ265 KONTROLLE VORGESCHRIEBENER DREHRICHTUNG HIERZU KUPPLUNGSZWISCHENSTUCK ENSURE CORRECT DRIVER DIRECTION OF ROTATION WITH COUPLING ELEMENT PINS REMOVED O
11. Retaining Ring Back Stationary 1300 65701 Screw 3300 1 Valve Thrust Control 6541 Lock Washer 1340 Adapter 6569 3134 Support Foot 4590 1 Drain Flange 1500 2 Wear Ring Back Stationary Particulate Control Ring 4590 2 PTFE Drain Gasket 3041 2 Thrust Collar 4590 3 Neoprene Drain Gasket Not shown in diagram Page 37 of 40 U MAG ENGLISH 26999990 10 14 15 9160 OVI onbJo u8 H W SZET TY is ST60 O W ee see p07 6t 5 neq non IIS yT60 OVW AGE IS ZT60 OYN 1 S06 N S Ie38p 104 A10326j J NSUO p 1si eJe SUOIJEUNSIJUOD e JON IS TT60 OVIN IS SO6O dGV ESSI suondo puepue s 10 aie UMOUS s1aquunu Hed Z AeJ8 ul umous sued dulnd 2419 T IS TC60 O VIN 1 0 60 O VIN 1 6060 O VIN 9 XZ XS Z v1 VV 000 0V60 9S9 VV 000 0t60 VINI 1 9060 O VIN anbJo u3IH YS SZ T 403 TZ soma s 4030W DI NEAP Y 3Jeus SZ T 403 Z anbJo uSIH eys T 403 TX Sees 401000 EPUOH 3jeus T 4034 X 2 9 XST XE EN VV 0T0 0 60 5S2 VV 000 0 60 VIAI 15 2060 OVW onbJo u3IH O19 rSz 13 fe 9 XS T XZ IN VV 000 0160 9S2 VV 000 0T60 VAI 15 8060 O VIAL anbio u8 H DIS ETT TQ C MO 4 MOT S XT X S 1 NN VN 000 S060 5S5 IS S060 OVI Fo STZ MO 4 MOT S XT X S 1 WIN VIN 000 S060 5S5 IS r060 OVI OTTO 3 mor MOT S XT XST In W 000 S060 559 VY NOY OPN 15 2050 OVN oser 3 uS XT XST On VV 000 S060 5S2 VV 100 0060 31S 1S 0060
12. Verify flow with instrumentation or batch cycle time and l l f adjust as needed Measure value and check maximum Operation at high capacity permitted Remedy or CONSULT FLOWSERVE BEEN B Mechanical troubles l Check the flange connections and eliminate strains using Misalignment due to pipe strain elastic couplings or a method permitted Tighten mounting bolts on pump feet and baseplate Piping or pump not properly anchored Confirm that the suction and discharge pipes are properly supported per Hydraulic Institute recommendations Check setting of baseplate tighten adjust grout base as Improperly designed foundation required fel lele Partially clogged impeller is unbalanced Open pump and clear blockage from the impeller If burning smell coming from back of pump the outer magnet is installed incorrectly Confirm that the groove on Rotating part rubbing on stationary part internally the outer magnet assembly lines up with the edge of the adapter Re align and replace components as necessary Check and CONSULT FLOWSERVE if necessary Bearings worn Replace bearings fe jeje Wearing ring surfaces worn Replace worn wear ring surfaces e lee Impeller damaged or eroded Replace or CONSULT FLOWSERVE fe Abrasive solids in liquid pumped Abrasive solids in liquid pumped solids in liquid pumped Check and CONSULTFLOWSERVE and CONSULT FLOWSERVE Excessive thrust caused by a mec
13. a T handle hex key at the end of the retaining ring 6810 1 g Gently tap the retaining ring 6810 1 into position Figure 6 8 h With a soldering iron melt the two plastic ends together FLOWSERVE Nes 6 9 Containment Shell 3500 Repair Unless there is visual damage to the particulate control ring 1500 2 removal is not necessary and is not part of the normal inspection procedure If the particulate control ring 1500 2 is damaged it must be replaced 6 9 1 Particulate Control Ring 1500 2 Removal a With small channel lock pliers grip the old particulate control ring near one of the notches and pull it out Figure 6 9 EN je 6 9 2 Particulate Control Ring 1500 2 Installation a Align the notches on the outer edge of the new particulate control ring with the containment shell s molded keys and press in place Figure 6 10 6 9 3 O Ring 4610 Installation a Check the o ring 4610 for dirt or deformation before placing on the containment shell 3500 Replace the o ring if necessary Page 27 of 40 U MAG ENGLISH 26999990 10 14 b Secure the containment shell 3500 composite side down An empty adapter 1340 works well to hold the containment shell 3500 in place if nothing else is available c Attach one side of the o ring 4610 around the containment shell 3500 rim d Slide your index fingers around the containment shell 3500 on the o ring s 4610 surfa
14. more information Devices techniques to help monitor the pump externally a Install pressure gauges on the suction and discharge b Regularly monitor the process conditions c Use the motor s fan to check for free rotation d Usea shaft power monitor to protect the pump as well as monitor pump performance e Check vibration noise level and surface temperature to confirm satisfactory operation For preventative maintenance schedule recommendations that are specific to your application please contact your authorized local distributor If ABRASIVE SOLIDS are present within the fluid additional wear of the pump should be expected Intervals between inspections should be shortened compared to usual times 6 2 2 Routine inspection daily weekly The following checks should be made and the appropriate action taken to remedy any deviations a Check operating behaviour Ensure noise vibration and bearing temperatures are normal b Check that there is no abnormal fluid leak from the pump c Check any auxiliary equipment or supplies are functioning correctly LI Refer to the manuals of any associated equipment for routine checks needed FLOWSERVE Land 6 2 3 Periodic inspection six monthly Check foundation bolts for security of attachment and corrosion LH Refer to the manuals of any associated equipment for periodic checks needed 6 3 Spare parts 6 3 1 Ordering of spares Flowserve keeps records
15. of all pumps that have been supplied When ordering spares the following information should be quoted 1 Pump serial number 2 Pump size 3 Part name taken from section 8 4 Part number taken from section 8 5 Number of parts required The pump size and serial number are shown on the pump nameplate To ensure continued satisfactory operation replacement parts to the original design specification should be obtained from Flowserve Any change to the original design specification modification or use of a non standard part will invalidate the pump safety certification 6 3 2 Storage of spares Spares should be stored in a clean dry area away from vibration Inspection and re treatment of metallic surfaces if necessary with preservative is recommended at 6 monihly intervals 6 3 3 Recommended spares For two years operation as per VDMA 24296 Number of same size pumps Designation including stand by 2 3 4 5 6 8 9 10 Impeller 2200 em C 2 qme Containment 3500 srenassemoiy 1 2 00e 3041 2 1500 1 1 20 6810 1 4610 Gasket O ring 1 2 3 30 Outer Magnet Assembly Powerend 1 2 Suction Ring Kit Page 23 of 40 U MAG ENGLISH 26999990 10 14 6 4 Tools required A typical range of tools that will be required to maintain these pumps is listed below 6 4 4 Readily available in standard tool kits and dependent on pump size e 8 10 mm
16. pumps contain extremely strong magnets The use of non magnetic tools and work surface is highly recommended The work area must be clean and free of any ferrous particles The following procedures assume the drive end and wet end are separated Refer to section 6 6 1 Drive Wet End Separation if the motor and pump are connected 6 6 2 1 Wet End Disassembly Piped Up a Remove the drain bolts 6570 1 if the pump has a drain Drain the pump and individually decontaminate each component in accordance to all federal state local and company environmental regulations b Loosen and remove 6 socket head cap screws 6570 1 with an 8 mm 5 16 in hex key c Grasp the containment shell 3500 and pull the assembly including impeller 2200 containment shell 3500 and containment ring 3830 back in a straight line until it is clear of the casing 1100 Figure 6 3 ATTA NES a Remove the containment shell 3500 and impeller 2200 from the containment ring 3800 NOTE This step is optional as removal of the containment ring may be very difficult on pumps that have been in service for long periods of time Page 25 of 40 U MAG ENGLISH 26999990 10 14 e Lift and remove the impeller 2200 from the containment shell 3500 6 6 2 2 Wet End Disassembly in Shop a Place a piece of cardboard or a shop towel on the workspace to protect the plastic on the suction flange b Laythe wet end face down on the
17. random induced current generating a spark the baseplate must be properly grounded Page 8 of 40 U MAG ENGLISH 26999990 10 14 has Avoid electrostatic charge do not rub non metallic surfaces with a dry cloth ensure cloth is damp Additional requirement for metallic pumps on non metallic baseplates When metallic components are fitted on a non metallic baseplate they must be individually earthed If so equipped to prevent a potential hazard from mechanical contact the coupling guard must be non sparking For ATEX the coupling must be selected to comply with European Directive 2014 34 EU previously 94 9 EC which remains valid until April 20 2016 during the transition Correct coupling alignment must be maintained 1 6 4 6 Preventing leakage The pump must only be used to handle liquids for which it has been approved to have the correct corrosion resistance Avoid entrapment of liquid in the pump and associated piping due to closing of suction and discharge valves which could cause dangerous excessive pressures to occur if there is heat input to the liquid This can occur if the pump is stationary or running Bursting of liquid containing parts due to freezing must be avoided by draining or protecting the pump and ancillary systems If leakage of liquid to atmosphere can result in a hazard install a liquid detection device or secondary containment 1 6 4 7 Maintenance to avoid the hazard CORRECT MAINTENANCE IS
18. ring and thrust collar 3041 2 6 7 4 Gasket O ring 4610 After dismantling discard and replace 6 7 5 Impeller 2200 The bearing 3300 can be easily replaced if damaged however the wear ring is molded in place and is not user replaceable see section 6 10 If wear ring is damaged the impeller will need to be replaced 6 7 6 Outer Magnet 0230 Wipe the inside of the outer magnet assembly 0230 clean from all foreign particles 6 8 Casing 1100 Repair 6 8 1 Casing Thrust Collar 3041 2 Removal Unless there is visual damage to the front thrust collar removal is not necessary and is not part of the normal inspection procedure a Insert a flathead screwdriver into the casing notch opposite the weld and force out the retaining ring 6810 1 Figure 6 5 b Liftout the thrust collar 3041 2 with your fingers Pull the retaining ring 6810 1 free and remove the locking pin 6 8 2 Casing Thrust Collar 3041 2 Installation a Insert and align the casing thrust collar SiC 3041 2 keyway with the keyway notch in the casing 1100 b Insert the locking pin into one keyway notch Page 26 of 40 U MAG ENGLISH 26999990 10 14 c Insert the keyed end of the retaining ring 6810 1 into the remaining keyway Figure 6 6 d Press the retaining ring 6810 1 into the casing groove e Trim the retaining ring 6810 1 end so it slightly overlaps the drive pin Figure 6 7 f Lineupthe tip of
19. rotation should be re checked in case the supply phasing has been altered FLOWSERVE Lad 5 2 Priming and auxiliary supplies 5 2 1 Auxiliary supplies CAUTION Ensure all electrical hydraulic pneumatic sealant and lubrication systems as applicable are connected and operational 5 2 2 Filling and priming Ensure inlet pipe and pump casing 1100 is completely full of liquid before starting continuous duty operation Priming may be carried out with an ejector vacuum pump interceptor or other equipment or by flooding from the inlet source When in service pumps using inlet pipes with foot valves may be primed by passing liquid back from the outlet pipe through the pump 5 3 A camo the pump a CLOSE the discharge valve Fully open the suction valve Pump requires a flooded suction b Ep not operate pump with suction valve closed Operating pump more than a few minutes after suction valve closed may cause bearing failure c Fully open discharge valve to complete priming Turn back the discharge valve until it is 1 4 to 1 2 open d CX continuous operation against a closed discharge valve may cause pump to overheat e Start motor and check the outlet pressure f Ifthe pressure is satisfactory SLOWLY open the outlet valve AUTION Do not run the pump with the outlet valve closed for a period longer than 10 seconds h IfNO pressure or LOW pressure STOP the pump Refer to section 7 Trou
20. separately with the equipment or attached to side walls of the box or equipment Each pump wet end has a unique serial number Check that this number corresponds with that advised Always use this number in correspondence and when ordering spare parts or further accessories 2 2 Handling Boxes crates pallets or cartons may be unloaded using fork lift vehicles or slings dependent on their size and construction 2 3 Lifting A A crane must be used for all pump sets or components in excess of 25 kg 55 Ib Fully trained personnel must carry out lifting in accordance with local regulations Slings ropes and other lifting gear should be positioned where they cannot slip and where a balanced lift is obtained The angle between sling or ropes used for lifting must not exceed 60 A CAUTION To avoid distortion the pump unit should be lifted as shown N CAUTION Pumps and motors often have integral lifting lugs or eye bolts These are intended for use in only lifting the individual piece of equipment i sat Do not use eye bolts or cast in lifting lugs to lift pump motor and baseplate assemblies AN Care must be taken to lift components or assemblies above the center of gravity to prevent the unit from flipping 2 3 1 Lifting Wet End The wet end should be lifted by sling around the pump discharge nozzle using a choker hitch pulled tight as shown in Figure 2 1 Page 10 of 40 U MAG ENGLISH 26999990 10 14 Fig
21. strainers must be removed shortly before start up When the pump is installed below the source of supply a valve should be installed in the suction line to isolate the pump and permit pump inspection and maintenance However never place a valve directly on the suction nozzle of the pump Refer to the Centrifugal Pump IOM Section of the H I Standards for additional recommendations on suction piping See section 10 Refer to section 3 4 for performance and operating limits 4 5 3 Discharge piping Install a valve in the discharge line This valve is required for regulating flow and or to isolate the pump for inspection and maintenance When fluid velocity in the pipe is high for example 3 m s 10 ft sec or higher a rapidly closing discharge valve can cause a damaging pressure surge A dampening arrangement should be provided in the piping 4 5 4 Allowable nozzle loads Maximum forces and moments allowed on the pump flanges vary with the pump size and type To minimize these forces and moments that may if excessive cause misalignment hot bearings worn couplings vibration and the possible failure of the pump casing the following points should be strictly followed e Prevent excessive external pipe load e Never draw piping into place by applying force to pump flange connections e Do not mount expansion joints so that their force due to internal pressure acts on the pump flange Contact your local Flowserve Sal
22. suction flange in the work area c Loosen and remove the 6 socket head cap screws 6570 1 on the containment ring 3830 with an 8 mm 5 16 in hex key d Slightly rotate the containment ring to make it easier to grip e Lift the containment ring 3830 with your fingers while holding down the containment shell 3500 with your thumbs Figure 6 4 f Liftthe containment shell straight 3500 up from the impeller 2200 g Carefully lift and remove the impeller 2200 from the casing 1100 6 7 Examination of parts Used parts must be inspected before assembly to ensure the pump will subsequently run properly In particular fault diagnosis is essential to enhance pump and plant reliability 6 7 4 Casing 1100 lining Inspect the casing 1100 lining for any abrasion cracks or delamination Casing 1100 replacement is necessary if lining is breached Minor scratches or cuts less than 0 1 mm 0 040 in depth are acceptable 6 7 2 Silicon Carbide SiC When inspecting the pump internals check all Silicon Carbide SiC parts for cracks chips and scoring marks Minor chips less than 0 5 mm 0 020 in are acceptable If replacement of any part is required M FLOWSERVE follow the procedures in the repair sections of this manual Carefully clean and inspect all internal parts 6 7 3 Containment Shell 3500 Use a torch flashlight to inspect inside the containment shell 8500 particulate control
23. to any pipes lt I Q 4 5 1 Suction and discharge piping Never use pump as a support for piping Ensure piping and fittings are flushed before use A Ensure piping for hazardous liquids is arranged to allow pump flushing before removal of the pump Take into account the available NPSH which must be higher than the required NPSH of the pump All piping must be independently supported accurately aligned and preferably connected to the pump by a short length of flexible piping The pump should not have to support the weight of the pipe or compensate for misalignment It should be possible to install suction and discharge bolts through mating flanges without pulling or prying either of the flanges All piping must be Page 17 of 40 U MAG ENGLISH 26999990 10 14 tight Pumps may air bind if air is allowed to leak into the piping If the pump flange s have tapped holes select flange fasteners with thread engagement at least equal to the fastener diameter but that do not bottom out in the tapped holes before the joint is tight The following is the recommended procedure for attaching piping to the U MAG pump see section 6 5 for torque values e Check the surface of both flanges pump pipe to ensure they are clean flat and without defects e Lubricate the fasteners e Hand tighten all of the fasteners in a crisscross pattern e The fasteners should be torqued in increments based a crisscro
24. unit the controller starter electrical details will also be supplied within the controller starter For electrical details on pump sets with controllers see the separate wiring diagram See section 5 1 Direction of rotation before connecting the motor to the electrical supply AUTION For close coupled pumps it is necessary to wire the motor with flexible conduit of sufficient length to allow the motor power end assembly to be moved back from the casing 1100 for maintenance 4 7 Protection systems The following protection systems are recommended particularly if the pump is installed in a potentially explosive area or is handling a hazardous liquid If in any doubt consult Flowserve If there is any possibility of the system allowing the pump to run against a closed valve or below minimum continuous safe flow a protection device should be installed to ensure the temperature of the liquid does not rise to an unsafe level FLOWSERVE label If there are any circumstances in which the system can allow the pump to run dry or start up empty a power monitor should be fitted to stop the pump or prevent it from being started This is particularly relevant if the pump is handling a flammable liquid If leakage of product from the pump or its associated sealing system can cause a hazard it is recommended that an appropriate leakage detection system is installed To prevent excessive surface temperatures at bearings it
25. 1100 UBO See Figure 3 1 for pump identification codes 3 3 Nameplate Every U MAG pump unit has a nameplate to provide information on your pump The nameplates are located on the adapter with a second tag containing just the pump serial number affixed to the casing discharge flange It is recommended that the purchaser record the serial number and use it for reference when requesting information service or parts from your supplier Permanent records for this pump are kept by the serial number and it therefore must be used with all correspondence and spare parts orders Tag includes the following e Pump Model Number Example UO e Pump Code Example U013711100 UBO e Serial Number Example 44001 e Impeller Diameter Max Impeller Diameter mm or in e Duty Point Flow TDH m hr m or US gpm ft e Process Liquid Specific Gravity and Temperature C or F U MAG ENGLISH 26999990 10 14 FLOWSERVE da l e Pump RPM Pump power kW or hp Duty The typical nomenclature above is the general guide Point to the U MAG configuration description Identify e Design Pressure barg or psig 38 C 100 the actual pump size and serial number from the F pump nameplate Check that this agrees with the e Customer Pump Tag applicable certification provided e Process Liquid Being Pumped Figure 3 1 U MAG PUMP IDENTIFICATION CODE Wet End Uo 137 1 1 1 0 0 U B 0 Drive End Models Suction x Dischar
26. Follow the steps for the NEMA drive end assembly in section 6 13 1 to complete assembly Figure 6 31 Page 33 of 40 U MAG ENGLISH 26999990 10 14 FLOWSERVE aged 7 TROUBLESHOOTING 7 1 Faults causes and remedies The following is a guide to troubleshooting problems with Flowserve INNOMAG U MAG pumps Common problems are analyzed and solutions offered Obviously it is impossible to cover every possible scenario If a problem exists that is not covered by one of the examples refer to one of the books listed in Section 10 Aaditional Sources of Information or contact a Flowserve sales engineer distributor or representative for assistance FAULT SYMPTOM Pump overheats and seizes U Pump vibrates or is noisy U Pump requires excessive power U Pump loses prime after starting Insufficient pressure developed Insufficient capacity delivered U Pump does not deliver liquid Y POSSIBLE CAUSES POSSIBLE REMEDIES A System troubles Check complete filling Re prime pump and verify that Pump not primed or filled with liquid suction pipe is full of liquid Check the suction pipe for high points that can trap air Pump or suction pipe not completely filled with VE EE as liquid p Confirm that any discharge valves or control valves are not FHH bre IE O A Ea stuck shut Inspect discharge pipe for blockage Confirm that any suction valves or control valves are not Suction pipe clogged or valve shut st
27. N 3 5 2 N CAUTION Driver may overload and de couple if pumpage specific gravity is greater than originally assumed Prolonged running while de coupled will damage driver and impeller magnets x Decoupling the pump may lead to increased surface temperatures FLOWSER lt AN CAUTION Never change conditions of service without approval of authorized Flowserve distributor Excessive amounts of dust collected on the pump housing may lead to an increase in surface temperature possibly exceeding temperature limits May require regular cleaning Always have this service manual available during any installation or maintenance 1 6 4 Products used in potentially explosive atmospheres Measures are required to Avoid excess temperature Prevent build up of explosive mixtures Prevent the generation of sparks Prevent leakages Maintain the pump to avoid hazard The following instructions for pumps and pump units when installed in potentially explosive atmospheres must be followed to help ensure explosion protection For ATEX both electrical and non electrical equipment must meet the requirements of European Directive 2014 34 EU previously 94 9 EC which remains valid until April 20 2016 during the transition Always observe the regional legal Ex requirements eg Ex electrical items outside the EU may be required certified to other than ATEX eg IECEx UL 1 6 4 1 Scope of compliance Use equipment only
28. THERWISE Q KUPPLUNGSBOLZEN ENTFERNEN ANDERENFALLS ERNSTHAFTE SCH DEN SERIOUS DAMAGE MAY RESULT VERIFIER LE SENS CORRECT DE CCJ ROTATION DU MOTEUR POMPE DESACCOUPLEE ENTRETOISE DEMONTEE NE PAS SUIVRE CETTE RECOMMANDATION PEUT CONDUIRE A DE GRAVES DOMMAGES POUR LA POMPE ZORG VOOR JUISTE ROTATIERICHTING VAN DRIJFAS WAARBIJ DE KOPPELELEMENTEN PENNEN VERWIJDERD ZIJN VERZUM KAN ERNSTIGE SCHADE TOT GEVOLG HEBBEN J218 268 PUMP MUSS AUF FESTEM FUNDAMENT STEHEN KUPPLUNGSH LFTEN KORREKT AXIAL AUSRICHTEN DANN PUMPE AUF GRUNDPLATTE FESTSPANNEN UND ANSSCHLUSSLEITUNGEN BEFESTIGEN TOLERANZEN S BEDIEUNGSANLEITUNG ENSURE UNIT ON A FIRM FOUNDATION AND THAT COUPLING FACES ARE IN CORRECT ALIGNMENT PRIOR TO AND AFTER BOLTING BASEPLATE DOWN AND FIXING PIPEWORK SEE MANUAL FOR TOLERANCES g S ASSURER QUE LE GROUPE ELECTROPOMPE EST FERMEMENT INSTALLE SUR SON MASSIF VERIFIER ZORG DAT POMPEENHEID OP EEN STEVIGE ONDERGROND OPGESTELD STAAT EN DAT KOPPELING CORRECT UITGELIJNT IS ZOWEL VOOR ALS NADAT DE GRONDPLAAT MET BOUTEN IS VASTGEZET EN DE LEIDINGEN GEINSTALLEERD ZIJN ZIE HANDLEIDING VOOR TOELAABARE SPELINGEN LE LIGNAGE DE L ACCOUPLEMENT AVANT ET APRES FIXATION DU SOCLE ET DE LA TUYAUTERIE VOIR LES TOLERANCES D ALIGNMENT SUR LA NOTICE 1 8 Specific machine performance For performance parameters see section 1 5 Duty conditions Where performance data has been supplied separately
29. TY 1 1 General These instructions must always be kept close to the product s operating location or directly with the product Flowserve products are designed developed and manufactured with state of the art technologies in modern facilities The unit is produced with great care and commitment to continuous quality control utilizing sophisticated quality techniques and safety requirements Flowserve is committed to continuous quality improvement and being at service for any further information about the product in its installation and operation or about its support products repair and diagnostic services These instructions are intended to facilitate familiarization with the product and its permitted use Operating the product in compliance with these instructions is important to help ensure reliability in service and avoid risks The instructions may not take into account local regulations ensure such regulations are observed by all including those installing the product Always coordinate repair activity with operations personnel and follow all plant safety requirements and applicable safety and health laws and regulations These instructions must be read prior to installing operating using and maintaining the equipment in any region worldwide The equipment must not be put into service until all the conditions relating to safety noted in the Instructions have been met Failure to follow and apply the present user instru
30. bility t High Torque Option Price Adder G Gas Engine Motor Impeller Casing Retaining Casing Containment Shell H Hydraulic Motor SAE Body Casting Lining Rings Drain Lining Composite S 0 CF ETFE D I ETFE CF ETFE No CF ETFE Aramid 1 CF ETFE D I ETFE CF ETFE Yes CF ETFE Aramid C 2 PFA D 1 PFA PFA No PFA Aramid Rev Date 4 17 2014 Not an exhaustive list Available options subject to change without notice Consult factory for availability and pricing Page 12 of 40 FLOWSERVE label 3 4 Design of major parts Adapter Containment Ring Shaft amp O Ring Casing Outer Magnet Assembly Containment Shell Impeller 3 4 41 Pump casing Ductile iron armor with bonded ETFE lining The U MAG pump casing is designed with a horizontal centerline end inlet and a top outlet For ease of maintenance the pump is constructed so that pipe connectors do not have to be disturbed when internal maintenance is required back pull out 3 4 2 Impeller Integrally molded one piece impeller inner rotor The impeller is fully shrouded closed with fully open suction and the inner rotor is fitted with Neodymium lron Boron NdFeB magnets 3 4 3 Wetted Bearings System The standard material for the bearing is carbon and the shaft is alpha sintered silicon carbide SiC The system is comprised of a shaft which is cantilever mounted into the containment shell and a rotating bushing mounted in the impeller The impeller s wear r
31. bled position the baseplate in place over the floor cups 4 under each stilt location and lower the baseplate to the floor h Level and make final height adjustments to the suction and discharge pipe by first loosening the top nuts and turning the bottom nuts to raise or lower the baseplate J Tighten the top and bottom nuts at the lock washer 3 first then tighten the other nuts j l should be noted that the connecting pipelines must be individually supported and that the stilt mounted baseplate is not intended to support total static pipe load Figure 4 3 H ms HO T MN D STILT BOLT D NUTS 3 LOCK WASHER 4 FLOOR CUP 4 3 3 2 Stilt spring mounted baseplate assembly instructions Refer to Figure 4 4 a Raise or block up baseplate pump above the floor to allow for the assembly of the stilts b Setthe bottom nuts 4 above the stilt bolt head 1 This allows for 51 mm 2 in upward movement for the final height adjustment of the suction discharge flange c Assemble the lock washer 6 flat washer 5 and bottom spring cup assembly 2 down over the stilt bolt 1 d Assemble the stilt bolt bottom spring up through hole in the bottom plate and hold in place e Assemble top spring cup assembly 3 down over stilt bolt f Assemble flat washer 5 lock washer 6 and nuts 4 on the stilt bolt g Tighten down top nuts compressing the top spring approximately 13 mm 0 5 in
32. bleshooting for fault diagnosis 5 4 Running the pump AN Care must be taken when operating pump oafety gloves are essential Loose clothing must not be worn Page 20 of 40 U MAG ENGLISH 26999990 10 14 5 4 1 Normal vibration levels alarm and trip For guidance pumps generally fall under a classification for rigid support machines within the International rotating machinery standards and the recommended maximum levels are based on those standards Alarm and trip values for installed pumps should be based on the actual measurements taken on the pump in the fully commissioned as new condition Measuring vibration at regular intervals will then show any deterioration in pump or system operating conditions Horizontal pumps Horizontal pumps Vibration velocity lt 15 kW gt 15 kW unfiltered mm s in sec r m s Normal N lt 3 0 0 12 lt 4 5 0 18 Alarm N x 1 25 lt 3 8 0 15 lt 5 6 0 22 Shutdown trip N x 2 0 lt 6 0 0 24 lt 9 0 0 35 Where a unit is utilized in a vertical shaft configuration with a duck foot bend onto the pump suction the following apply Vertical configurations Vibration velocity unfiltered mm s in sec r m s 710028 Alarm Nx1 25 lt 9 0 0 35 Shutdown trip Nx2 0 lt 14 2 0 56 5 4 2 Stop start frequency Pump sets are normally suitable for the number of equally spaced stop starts per hour shown in the table below Check capability of the driver and co
33. ce forcing it down into position while holding it with your thumbs The o ring 4610 will snap into place Figure 6 11 6 10 Impeller Repair 6 10 1 Bushing Removal This procedure requires 100 mm 4 in length of 3 4 in Schedule 40 PVC Pipe A l Make sure the bushing removal tool is perfectly centered to prevent damaging the inside of the impeller 2200 We recommend placing a shop towel under the impeller 2200 to prevent damage to the SiC bushing 3300 when it falls free CAUTION a Center the impeller on an arbor press wear ring 3043 side up b Center the PVC bushing tool on the bushing 3300 c Place something soft such as a shop towel underneath the impeller 2200 to catch the bushing 3300 as it falls d Carefully press the bushing 3300 down until it dislodges and falls from the impeller 2200 FLOWSERVE Nes Figure 6 12 E 6 10 2 Bushing Installation a Line up the bushing s 3300 locking groove with the molded key inside the impeller 2200 Figure 6 13 b Insert the bushing 3300 making sure to maintain alignment while inserting into the arbor press Make sure the bushing removal tool is perfectly centered to prevent damaging the inside of the impeller 2200 We recommend placing a shop towel under the impeller to prevent damage to the impeller front wear ring 3043 c Center the PVC pipe on the bushing and press the bushing 3300 into p
34. classification Tx is used when the liquid temperature varies and when the pump is required to be used in differently classified potentially explosive atmospheres In this case the user is responsible for ensuring that the pump surface temperature does not exceed that permitted in its actual installed location Avoid mechanical hydraulic or electrical overload by using motor overload trips temperature monitors and or a power monitor and make routine vibration monitoring checks In dirty or dusty environments make regular checks and remove dirt from areas around close clearances bearing housings and motors Where there is any risk of the pump being run against a closed valve generating high liquid and casing external surface temperatures fit an external surface temperature protection device 1 6 4 4 Preventing the build up of explosive mixtures ex ENSURE THE PUMP IS PROPERLY FILLED AND DOES NOT RUN DRY Ensure the pump and relevant suction and discharge pipeline system is totally filled with liquid at all times during the pump operation so that an explosive atmosphere is prevented If the operation of the system cannot avoid this condition fit an appropriate dry run protection device for example liquid detection or a power monitor To avoid potential hazards from fugitive emissions of vapor or gas to atmosphere the surrounding area must be well ventilated 1 6 4 5 Preventing sparks To avoid the potential hazard from
35. ct requirements for inclusion into User Instructions such as for a driver instrumentation controller sub driver seals sealant system mounting component etc are included under this section If further copies of these are required they should be obtained from the purchaser for retention with these User Instructions Where any pre printed set of User Instructions are used and satisfactory quality can be maintained only by avoiding copying these they are included at the end of these User Instructions such as within a standard clear protection envelope 10 2 Change notes If any changes agreed with Flowserve Solution Group are made to the product after its supply a record of the details should be maintained with these User Instructions Page 39 of 40 U MAG ENGLISH 26999990 10 14 10 3 Additional sources of information Reference 1 NPSH for Rotodynamic Pumps a reference guide Europump Guide No 1 Europump amp World Pumps Elsevier Science United Kingdom 1999 Reference 2 Pumping Manual 9 edition T C Dickenson Elsevier Advanced Technology United Kingdom 1995 Reference 3 Pump Handbook Igor J Karassik et al McGraw Hill Inc New York 1993 Reference 4 ANSI HI 5 1 5 6 Sealless Rotodynamic Pumps for Nomenclature Definitions Application Operation and Test Heference 5 ANSI B31 3 Process Piping flowserve com FLOWSERVE label Your Flowserve factory contact Flowserve INNOMAGO S
36. ctions Is considered to be misuse Personal injury product damage delay or failure caused by misuse are not covered by the Flowserve warranty 1 2 CE marking and approvals It is a legal requirement that machinery and equipment put into service within certain regions of the world shall conform with the applicable CE Marking Directives covering Machinery and where applicable Low Voltage Equipment Electromagnetic Compatibility EMC Pressure Equipment Directive PED and Equipment for Potentially Explosive Atmospheres ATEX Where applicable the Directives and any additional Approvals cover important safety aspects relating to machinery and equipment and the satisfactory provision Page 4 of 40 U MAG ENGLISH 26999990 10 14 of technical documents and safety instructions Where applicable this document incorporates information relevant to these Directives and Approvals To confirm the Approvals applying and if the product is CE marked check the serial number plate markings and the Certification See section 9 Certification 1 3 Disclaimer Information in these User Instructions is believed to be complete and reliable However in spite of all of the efforts of Flowserve Corporation to provide comprehensive instructions good engineering and safety practice should always be used Flowserve manufactures products to exacting International Quality Management System Standards as certified and audited by external Quality Assu
37. d for example liquid pumped temperature or duty it is requested that the user seeks the written agreement of Flowserve before start up FLOWSERVE Lans 1 6 Safety 1 6 1 Summary of safety markings These User Instructions contain specific safety markings where non observance of an instruction would cause hazards The specific safety markings are DANGER This symbol indicates electrical safety instructions where non compliance will involve a high risk to personal safety or the loss of life A This symbol indicates safety instructions where non compliance would affect personal safety and could result in loss of life This symbol indicates hazardous and toxic fluid safety instructions where non compliance would affect personal safety and could result in loss of life 9 This symbol indicates Pacemaker safety instructions where non compliance would affect personal safety and could result in loss of life This symbol indicates safety instructions where non compliance will involve some risk to safe operation and personal safety and would damage the equipment or property Ex This symbol indicates explosive atmosphere zone marking according to ATEX Itis used in safety instructions where non compliance in the hazardous area would cause the risk of an explosion a This symbol is used in safety instructions to remind not to rub non metallic surfaces with a dry cloth ensure the cloth is damp It is used in sa
38. data storage media mechanical watches hearing aids and speakers Keep magnets away from devices and objects that could be damaged by strong magnetic fields IN paneer NEVER DO MAINTENANCE WORK WHEN THE UNIT IS CONNECTED TO POWER A GUARDS MUST NOT BE REMOVED WHILE THE PUMP IS OPERATIONAL DRAIN THE PUMP AND ISOLATE PIPEWORK BEFORE DISMANTLING THE PUMP The appropriate safety precautions should be taken where the pumped liquids are hazardous x NEVER use heat risk of explosion to disassemble any portion of the pump Cx HIGH TEMPERATURES may be present Pump surface temperature is directly related to the temperature of the working fluid Never operate pump above the rated temperature of 121 C 250 F FLOWSERVE label A HANDLING COMPONENTS Many precision parts have sharp corners and the wearing of appropriate safety gloves and equipment is required when handling these components To lift heavy pieces above 25 kg 55 Ib use a crane appropriate for the mass and in accordance with current local regulations AA Personal Protection Equipment suitable for the conditions and environment must be worn at all times THERMAL SHOCK Rapid changes in the temperature of the liquid within the pump can cause thermal shock which can result in damage or breakage of components and should be avoided HOT and cold PARTS If hot or freezing components or auxiliary heating supplies can present a danger to operators and persons en
39. e c On systems with high static head speed reduction is limited Avoid running the pump at a speed which gives low or zero flow d Do not run at a low speed and flow rate which lets solid settle out of suspension in the pipe work e Do not use a VFD for a fixed flow requirement it will introduce power losses k Select high efficiency motors If replacing a standard motor with a high efficiency motor it will run faster and the pump could take more power Reduce the impeller diameter to achieve energy reduction m If the pump system pipe work or equipment is changed or process duty is changed check that the pump is still correctly sized n Periodically check that the pipe system has not become corroded or blocked o Periodically check that the pump is operating at the flow head and power expected and that the efficiency has not reduced with erosion or corrosion damage 4 INSTALLATION Equipment operated in hazardous locations must comply with the relevant explosion protection regulations See section 1 6 4 Products used in potentially explosive atmospheres 4 1 Location The pump should be located to allow room for access ventilation maintenance and inspection with ample headroom for lifting and should be as close as practicable to the supply of liquid to be pumped Refer to the general arrangement drawing for the pump set 4 2 Part Assemblies The supply of motors and baseplates are optional As a result it is the respon
40. e amount of air or gas in liquid Excessive amount of air or gas in liquid amount of air or gas in liquid Page 34 of 40 U MAG ENGLISH 26999990 10 14 FLOWSERVE Ensi FAULT SYMPTOM Pump overheats and seizes U Pump vibrates or is noisy U Pump requires excessive power U Pump loses prime after starting Insufficient pressure developed Insufficient capacity delivered U Pump does not deliver liquid Jefe Air or vapor pocket in suction line Check suction line design for vapor pockets Je Air leaks into suction ine Check suction pipe is airtight gt e e ee intet of suction pipe insutficiently submerged Check system desi n O O Z fele e Speed too low GONSULTFLOWSERVE fe Speedtoohign si Speed too high Speed too high CONSUTFLOWSERV FLOWSERVE Total head of system higher than differential head CONSULT LONE AE TRU er system losses Increase impeller size or motor speed of pump Remedy or CONSULT FLOWSERVE Check system losses Decrease impeller size or motor Total head of system lower than pump design head speed Remedy or CONSULT FLOWSERVE j fel Specific gravity of liquid different from design Viscosity of liquid differs from that for which Check and CONSULT FLOWSERVE designed f f Measure value and check minimum permitted Operation at very low capacity Remedy or CONSULT FLOWSERVE
41. e up the adapter 1340 holes with the threaded holes on the motor Insert 4 bolts 6570 1 with lock washers 6541 and tighten until no gap is present between the adapter 1340 and the motor mounting face Note the placement of the set screws on the outer magnet assembly 0230 in relation to the drive pins before installation Set screw A will be M FLOWSERVE directly across from the drive pins Set screw B will be perpendicular to the drive pins Figure 6 21 f Align outer magnet assembly 0230 drive pins with the key groove on the motor shaft g Use a ruler straight edge or visually align the groove on the outer magnet assembly 0230 with the outer edge of the adapter 1340 Figure 6 22 h Remove metal plug 6569 from the top of the adapter 1340 i Looking through the top plug hole on the adapter 1340 line up the row of drive pins on the outer magnet assembly 0230 with the hole as shown in Figure 6 23 Figure 6 23 Page 31 of 40 U MAG ENGLISH 26999990 10 14 j Rotate the outer magnet assembly 0230 by 180 Visually inspect concentricity of the outer magnet assembly 0230 with adapter 1340 k Tighten the visible set screw A as shown in Figure 6 18 Rotate the outer magnet assembly 0230 90 counterclockwise to locate and tighten set screw B m Install the metal plug 6569 on the adapter 1340 6 13 2 IEC Drive End Assembly The IEC adapter requires the
42. ealless Pumps 409 S Vista Ave Addison IL 60101 Phone 630 543 4240 Fax 630 543 4245 Email InnomagSales flowserve com Your local Flowserve representative Flowserve Pump Division 3900 Cook Boulevard Chesapeake VA23323 1626 USA Telephone 1 757 485 8000 Fax 1 757 485 8149 Flowserve Pumps Flowserve GB Limited Lowfield Works Balderton Newark Notts NG24 3BU United Kingdom Telephone 24 hours 44 1636 494 600 Sales amp Admin Fax 44 1636 705 991 Repair amp Service Fax 44 1636 494 833 Email newarksales flowserve com To find your local Flowserve representative please use the Sales Support Locator System found at www flowserve com flowserve com U MAG ENGLISH 26999990 10 14 FLOWSERVE REGIONAL SALES OFFICES USA and Canada Flowserve Corporation 5215 North O Connor Blvd Suite 2300 Irving Texas 75039 5421 USA Telephone 1 937 890 5839 Europe Middle East Africa Flowserve Corporation Parallelweg 13 7878 AH Etten Leur The Netherlands Telephone 31 76 502 8100 Latin America Flowserve Corporation Martin Rodrigues 4460 B1644CGN Victoria San Fernando Buenos Aires Argentina Telephone 54 11 4006 8700 Fax 54 11 4714 1610 Asia Pacific Flowserve Pte Ltd 10 Tuas Loop Singapore 637345 Telephone 65 6771 0600 Fax 65 6862 2329
43. eration of Pumps The pump supplied will have been selected from Flowserve s extensive product line to have optimum efficiency for the application If supplied with an electric motor then the motor will meet or exceed current legislation for motor efficiency However it is the way the pump is operated which has the greatest impact on the amount and cost of energy used during the operating life of the pump The following are key points in achieving minimum operating cost for the equipment a Design the pipe system for minimum friction losses b Ensure that the control system switches off the pump when not required c In a multi pump system run the minimum number of pumps d Try to avoid systems which by pass excess flow e Avoid as far as possible controlling pump flow by throttle valves f When commissioned check that the pump operates at the duty specified to Flowserve g If it has been found that the pump head and flow exceed that required trim the pump impeller diameter h Ensure that the pump is operating with sufficient NPSH available i Use variable speed drives for systems which require variable flow A VFD for an induction motor is a particularly effective way of achieving speed variation and energy cost reduction j Notes for VFD usage Page 14 of 40 U MAG ENGLISH 26999990 10 14 a make sure that the motor is compatible with VFD b Do not over speed the pump without checking the power capability with Flowserv
44. es office Distributor or Representative for further details 4 5 5 Auxiliary piping The connections that are to be piped up will have been fitted with protective metal or plastic plugs which will need to be removed 4 6 Electrical connections DANGER Electrical connections must be made by a qualified Electrician in accordance with relevant local national and international regulations Page 18 of 40 U MAG ENGLISH 26999990 10 14 Ex It is important to be aware of the EUROPEAN DIRECTIVE on potentially explosive areas where compliance with IEC60079 14 is an additional requirement for making electrical connections A It is important to be aware of the EUROPEAN DIRECTIVE on electromagnetic compatibility when wiring up and installing equipment on site Attention must be paid to ensure that the techniques used during wiring installation do not increase electromagnetic emissions or decrease the electromagnetic immunity of the equipment wiring or any connected devices If you have any doubt contact Flowserve for advice LN pancer The motor must be wired up in accordance with the motor manufacturer s instructions normally supplied within the terminal box including any temperature earth leakage current and other protective devices as appropriate The identification nameplate should be checked to ensure the power supply is appropriate A A device to provide emergency stopping must be fitted If not supplied pre wired to the pump
45. factors such as temperature and materials may influence this data If required a definitive statement for your particular application can be obtained from Flowserve 3 5 1 Operating limits Normal maximum ambient temperature 40 C 104 F Normal minimum ambient temperature 20 C 4 F Maximum pump speed refer to the nameplate 3 5 2 Pressure Temperature Rating The pump pressure and temperature limits are included in the Figure 3 2 The standard U MAG casing has a universal slotted flange bolt pattern which accommodates ANSI ISO and JIS piping flange standards Optional drilling arrangements include ANSI Class 150 ISO PN 16 and JIS 10K Find the maximum allowable pressure for the supplied pump given the flange drilling pattern and operating temperature A The maximum discharge pressure must be less than or equal to the P T rating Discharge pressure may be approximated by adding the suction pressure to the differential pressure developed by the pump FLOWSERVE label Figure 3 2 Temperature C F Pressure bara psig _ Pressure barg psig ISO Jis 14 14 14 14 14 Slotted 293 203 203 203 203 e 172 172 172 162 155 Claes deg 250 250 250 235 225 80 PN 16 16 16 16 16 232 232 232 232 232 15 14 14 14 14 14 se 203 203 203 203 203 3 5 3 Energy Efficiency Op
46. fall over and injure people or damage property Do not attach sling ropes to shaft These pumps use carbon or ceramic silicon carbide components Do not drop the pump or subject it to shock loads as this can damage the internal ceramic components 2 4 Storage otore the pump in a clean dry location away from vibration Leave piping connection covers in place to keep dirt and other foreign material out of pump casing The pump may be stored as above for up to 6 months Consult Flowserve for preservative actions when a longer storage period is needed Page 11 of 40 U MAG ENGLISH 26999990 10 14 2 5 Recycling and end of product life At the end of the service life of the product or its parts the relevant materials and parts should be recycled or disposed of using an environmentally acceptable method and local requirements If the product contains substances that are harmful to the environment these should be removed and disposed of in accordance with current regulations Make sure that hazardous substances are disposed of safely and that the correct personal protective equipment is used The safety specifications must be in accordance with the current regulations at all times 3 DESCRIPTION 3 1 Configurations The U MAG chemical process pumps are fluoropolymer lined magnetically coupled single stage centrifugal pumps 3 2 Nomenclature The pump size will be etched on the nameplate as in this example U01251
47. fety instructions where non compliance in the hazardous area would cause the risk of an explosion Note T ERE indi gt This sign is not a safety symbol but indicates an important instruction in the assembly process 1 6 2 Personnel qualification and training All personnel involved in the operation installation inspection and maintenance of the unit must be qualified to carry out the work involved If the personnel in question do not already possess the necessary knowledge and skill appropriate training and instruction must be provided If required the operator may Page 5 of 40 U MAG ENGLISH 26999990 10 14 commission the manufacturer supplier to provide applicable training Always coordinate repair activity with operations and health and safety personnel Follow all plant safety requirements and applicable safety and health laws and regulations 1 6 3 Safety action This is a summary of conditions and actions to help prevent injury to personnel and damage to the environment and to equipment For products used in potentially explosive atmospheres section 1 6 4 also applies C U MAG pumps contain extremely strong permanent neodymium magnets which could affect the functioning of pacemakers and implanted heart defibrillators If you wear these devices keep sufficient distance to magnets Magnets produce a far reaching strong magnetic field They can damage laptops computer hard drives credit and ATM cards
48. ge x Nominal Impeller Diameter Drive Torque Option 0 Standard Torque 1 High Torque UO 1 5 x 1x 5 3 25 6 13 40 x 25 x 127mm 83 156 mm UL UM UN 1 5 x 1 x 5LF 3 25 6 13 40 x 25 x 127mm 83 156 mm NEMA C Face U1 2x 1 5 x 6 3 25 6 13 50 x 40 x 152mm 83 156 mm U3 3x 2 5x 6 4 50 6 13 80 x 65 x 152mm 114 156 mm U4 2 5x 2x 6 3 50 6 13 65 x 50 x 152mm 89 156 mm Ht 2 IEC B5 N 90S L 100L 112M P t R 132 Carbon Graphite C SiC SiC SiC DLC SiC Notes SiC Spiral Groove SiC SiC Grooved DLC SiC For 1 25 hydraulic motor Impeller Diameter 137 mm divide by 25 4 for inches ex 137 25 4 5 39 in Impeller trim for U MAG models must be specified in mm Bearing System Bushing Shaft Pump QO S W Ss alo O Q 8 N Q 8 o Material Guide Wear Ring Thrust Collar CF Carbon Fiber Impeller Casing Containment Shell D I Ductile Iron CF PTFE SiC CF PTFE ETFE Ethylenetetrafluoroethylene SiC SiC SiC PTFE Polytetrafluoroethylene PFA Perfluoroalkoxy Gasket All Gaskets are 0 210 square cross section equivalent to standard 363 O Rings SiC Silicon Carbide Ceramic 1 FEP FKM Fluorocarbon 2 FKM Fluorocarbon EPDM Ethylene Propylene IVA e WY WY e C ANSI ISO JIS Universally Slotted 1 ANSI Class 150 S Standard Material Options C Consult Factory for Availa
49. hanical failure e and CONSULT FLONSERVE i wear condition of impeller its clearances and liquid inside the pump passages l Open the pump Replace parts as needed ne Pump maximum temperature exceeded CONSULT FLOWSERVE Page 35 of 40 U MAG ENGLISH 26999990 10 14 FLOWSERVE Ensi FAULT SYMPTOM Pump overheats and seizes U Pump vibrates or is noisy U Pump requires excessive power U Pump loses prime after starting Insufficient pressure developed Insufficient capacity delivered U Pump does not deliver liquid POSSIBLE CAUSES POSSIBLE REMEDIES C Motor electrical problems ele fee Wrong direction of rotation Reverse 2 phases at motor terminal box Jel Motor running on 2 phases oniy Checksupplyandfuse gt e e Motor running too stow Check motor terminal box connections and voltage Page 36 of 40 U MAG ENGLISH 26999990 10 14 FLOWSERVE Ensi 8 PARTS LISTS AND DRAWINGS 8 1 Sectional drawing 3300 1 3300 1500 2 2200 2100 6810 1 6569 BeA f ff OL TUN A G sr f PEAN 7277 0717 878 UG ZZ NOn 3043 Z 4 pa 6541 A ZZ 6570 1 Y 1340 4590 1 4590 3 3500 3830 4610 4590 2 6 2100 Shaft 282 0230 MagnetAssembly Outer 8a 3043 Wear Ring Front Rotating 235 3300 Bushing Bearing 9a 6810 1 Retaining Ring Front Stationary 239 3830 Ring Containment 9b 68102
50. he lifting of the part to be serviced When air or compressed inert gas is used in the maintenance process the operator and anyone in the vicinity must be careful and have the appropriate protection Do not spray air or compressed inert gas on skin Do not direct an air or gas jet towards other people FLOWSERVE label Never use air or compressed inert gas to clean clothes Before working on the pump take measures to prevent an uncontrolled start Put a warning board on the starting device with the words Machine under repair do not start With electric drive equipment lock the main switch open and withdraw any fuses Put a warning board on the fuse box or main switch with the words Machine under repair do not connect Never clean equipment with flammable solvents or carbon tetrachloride Protect yourself against toxic fumes when using cleaning agents DR operating with CHARGABLE LIQUIDS with conductivities of lt 10 8 S m inert gases e g nitrogen must be used to flush the pump Before removal of the pump it is recommended to wait one hour to allow static peak charges to be eliminated ALWAYS make certain that no toxic or flammable fumes vapors remain in the pump casing 1100 or surrounding area 6 2 Maintenance schedule It is recommended that a maintenance plan and schedule is adopted in line with these User Instructions to include the following a Any auxiliary systems installed mu
51. hex key across flats 5 16 3 8 in hex key across flats 15 19 mm spanner and socket 9 16 3 4 in wrench and socket 3 16 in T Handle Allen Wrench 5 mm T Handle Allen Wrench Wire Cutter Soldering Iron Range of screwdrivers Soft mallet Jackscrew Bolts a ASME outer magnet 0230 1 2 in 13 x 4 1 2 in b IEC outer magnet 0230 2 M8 1 25 x 30 mm M12 1 75 x 100 mm jackscrew and jackscrew plate TLG 2042 Sl Needle Nose Pliers Arbor Press Lathe Caliper Hobby Knife Torque Wrench 6 4 2 Flowserve INNOMAG specialized equipment e Bushing Installation Removal Tool a 19mm 8 4 in Schedule 40 PVC pipe 100mm 4 in long e Impeller Trimming Sleeve a Part TLG 2033 AA 6 5 Fastener torques Fastener Screw size Torque Nm Ibfft M8 5 16in M10 3 8in All except where otherwise M12 1 2in stated M1 6 5 8in M20 3 4in N CAUTION Non metallic gaskets incur creep relaxation before commissioning the pump check and retighten fasteners to tightening torques stated FLOWSERVE 6 6 Disassembly The preventative maintenance and disassembly procedures are intended for use during standard field inspection or service The disassembly can take place while the pump is piped up or in a maintenance shop If at all possible it is recommended to perform all repairs using the shop procedures to reduce the risk of damage to the SiC parts A Lock out driver power to p
52. in the zone for which it is appropriate Always check that the driver and pump equipment are suitably rated and or certified for the classification of the specific atmosphere in which they are to be installed Where Flowserve has supplied only the bare shaft pump the Ex rating applies only to the pump The party responsible for assembling the ATEX pump set shall select the coupling driver and any additional equipment with the necessary CE Certificate Declaration of Conformity establishing it is suitable for the area in which it is to be installed The output from a variable frequency drive VFD can cause additional heating effects in the motor and so for pumps sets with a VFD the ATEX Certification for the motor must state that it is covers the situation where electrical supply is from the VFD This particular requirement still applies even if the VFD is in a safe area Page 7 of 40 U MAG ENGLISH 26999990 10 14 1 6 4 2 Marking An example of ATEX equipment marking is shown below The actual classification of the pump will be engraved on the nameplate II 2 GD c IIC 135 C T4 Equipment Group Mining II Non mining Category 2 or M2 high level protection 3 normal level of protection Gas and or dust G Gas D Dust c Constructional safety in accordance with EN13463 5 Gas Group IIA Propane typical IIB Ethylene typical IIC Hydrogen typical Maximum surface tempera
53. ing is carbon as standard and runs against the casing thrust collar which is SiC 3 4 4 Containment Ring One piece ductile iron part aligns and supports the containment shell to establish the pressure boundary of the pump Allows servicing of the motor without opening the liquid end of the pump 3 4 5 Outer Magnet Assembly One piece ductile iron housing fitted with Neodymium lron Boron NdFeB magnets One common outer rotor for each motor frame and a visual alignment groove allows for ease of axial alignment 3 4 6 Containment Shell and O Ring The containment shell is comprised of an aramid fiber composite outer housing and an ETFE liner The shell includes a fully confined O ring groove which establishes the gasket interface with the casing Page 13 of 40 U MAG ENGLISH 26999990 10 14 3 4 7 Adapter Mates pump to motor Design allows the use of multiple motors with one adapter 3 4 8 Driver The driver is normally an electric motor Different drive configurations may be fitted such as internal combustion engines turbines hydraulic motors and driving via couplings belts gearboxes drive shafts etc 3 4 9 Accessories Accessories may be fitted when specified by the customer 3 5 Performance and operating limits This product has been selected to meet the specifications of the purchase order See section 1 5 The following data Is included as additional information to help with your installation It is typical and
54. is recommended that temperature or vibration monitoring is carried out 4 7 1 Auxiliary equipment instrumentation Contact your local Flowserve Sales office Distributor or Representative for more details 4 7 1 1 Leak detection An intrinsically safe optical leak detection system is available for U MAG pumps 4 7 1 2 Temperature probe An optional ThermicSense temperature probe can be installed on the casing drain to monitor the internal fluid in the casing 1100 4 7 1 3 ThermicSense Installation The ThermicSense thermowell will be packaged separately for protection during shipping and must be assembled before use For wiring refer to the thermocouple sensor manufacturer s instructions a Verify that rubber gasket o ring is secured to temperature sensor tip b Insert temperature sensor tip into the thermowell and hand tighten c Use a 1 2 in wrench to fully secure the sensor to the thermowell Do not over tighten d Adjust direction of sensor sheathing before tightening compression fitting e Ensure sensor tip is fully pressed into thermowell The sensor must be fully inserted to get an accurate reading f Hand tighten the compression fitting o Use a 1 2 in wrench to fully tighten the ression fitting and secure sensor sheathing Do not over tighten the fitting h Affix the PTFE drain gasket to thermal well Page 19 of 40 U MAG ENGLISH 26999990 10 14 i Insert the completed ThermicSe
55. ithout a gap c Insert and tighten the 4 socket head cap screws to hold the adapter to the wet end Torque the socket head cap screws to 27 Nm 20 Ibfeft d Insert and tighten any support foot 3134 and motor foot screws to secure the assembly to the base 6 14 2 In Shop Assembly a Holding the wet end by the suction and or discharge flange carefully insert the wet end into the drive end in a straight line as shown in Figure 6 30 b Insert and tighten the 4 socket head cap screws to hold the adapter to the wet end Torque the socket head cap screws to 27 Nm 20 Ibfeft U MAG ENGLISH 26999990 10 14 FLOWSERVE Figure 6 30 6 15 Gasoline Engine Innomag products are only compatible with certain gasoline engine designs Contact your local Flowserve Sales office Distributor or Representative for further details 6 15 1 Gasoline Engine Disassembly a Follow the steps for NEMA drive end disassembly in section 6 12 1 to remove the wet end and outer magnet assembly 0230 b Remove 4 screws from the adapter 1340 c Remove the adapter 1340 from the engine mounting plate d Loosen and remove the 4 small socket head cap screws on the mounting plate e Remove the mounting plate from the engine 6 15 2 Gasoline Engine Assembly a Center the mounting plate on the engine and align the holes b Insert and tighten the 4 socket head cap screws connecting the mounting plate to the engine c
56. l parts are free of dirt metallic particles etc a With the casing 1100 face down insert the impeller 2200 b When the impeller 2200 is in place rotate it by hand to make sure it spins freely c Align the shaft 2100 in the containment shell 3500 with the bushing 3300 and lower the containment shell 3500 into place d Place the containment ring 3830 over the containment shell 3500 refer to Figure 6 4 e Align the containment ring 3830 so that the four inner adapter 1340 bolt holes are on the right and left side of the pump refer to Figure 6 17 f Insert six socket head cap screws 6570 1 with lock washers 6541 into the six containment ring 3830 bolt holes g Tighten the six socket head cap screws 6570 1 with an 8 mm 5 16 in hex key and torque to 27 Nm 20 Ibf ft 6 12 Drive End Disassembly The outer magnet assembly 0230 contains very strong magnets Use caution inserting the jack screw Under normal circumstances a visual inspection and wiping clean the inside of the outer magnet is sufficient 6 12 1 NEMA Drive End Disassembly a Remove the metal pipe plug 6569 from the top of the adapter 1340 FLOWSERVE b Locate and loosen the 2 set screws on the on the outer magnet assembly 0230 with a 3 16 in T Handle allen wrench Figure 6 18 Ad c Inserta1 2 in 13 x 6 in jack bolt into the center of the NEMA outer magnet assembly 0230 d Using a
57. lace When properly inserted the bushing 3300 should be flush with the bottom ledge of the impeller 2200 6 10 3 Front Rotating Wear Ring 3043 The U MAG impeller wear ring 3043 is not user replaceable Contact your Flowserve representative for repair or replacement Page 28 of 40 U MAG ENGLISH 26999990 10 14 6 10 4 Impeller Trimming Place the trimming sleeve Part TLG 2033 FM over the impeller 2200 to protect it from damage Figure 6 14 a Using a calipers measure the current diameter of the impeller 2200 b Insert the impeller 2200 into the lathe and tighten the jaws c Setthe trim 6 mm 1 4 in less than the current diameter If you have never trimmed an impeller 2200 before then we recommend only cutting 3 mm 1 8 in at a time d Trim the first pass at a slow speed e Use the hobby knife to clean off the loose plastic on the impeller 2200 in order to get an accurate measurement Figure 6 15 f Check the diameter again with the caliper g Set the lathe for 6 mm 1 4 in less than the current diameter measurement h Trim this layer at a slow speed i Clean off any loose plastic that would interfere j with your diameter measurements Use the caliper to measure the current diameter FLOWSERVE Nes k Repeat the proceeding four steps until you reach the desired diameter Chamfer the front and back outer edges of the impeller 2200 m L
58. lies 14 4 3 Foundation 15 4 4 Grouting 16 AS PIPINO EEE 17 4 6 Electrical connections 18 4 7 Protection systems 18 4 8 Final checks 19 5 COMMISSIONING START UP OPERATION AND SHUT DOW WN irae itec tocco s ioris voces 19 5 1 Direction of rotation 19 5 2 Priming and auxiliary supplies 20 5 3 Starting the pump 20 5 4 Running the pump 20 5 5 Stopping and shutdown 20 5 6 Hydraulic mechanical and electrical duty 21 6 MAINTENANCE 21 eMC ETE 21 6 2 Maintenance schedule 22 p ODAC Aer 23 6 4 Tools required 23 6 5 Fastener torques 23 6 6 DIS4SSembVauumsamienasmnesaunnm avmsn 24 6 7 Examination of parts 25 6 8 Casing 1100 Repair 26 6 9 Containment Shell 3500 Repair 27 6 10 Impeller Repailr 27 6 11 Wet End Assembly
59. nse assembly into the casing drain and insert 1 2 in 13 bolts with lock washers j Tighten bolts evenly to maintain alignment and torque to 13 5 Nm 10 Ibfeft k Install wire leads to appropriate temperature monitor per manufacturer instructions and guidelines 4 8 Final checks Alignment between the pump shaft and motor shaft is built in by precise machining of the parts that position these shafts Parallel alignment of 0 18 mm 0 007 in and angular alignment of 0 002 mm mm 0 002 in in can be expected Check the tightness of all bolts in the suction and discharge pipework Check also the tightness of all foundation bolts 5 COMMISSIONING START UP OPERATION AND SHUTDOWN CAUTION These operations must be carried out by fully trained and qualified personnel AA Personal Protection Equipment suitable for the conditions and environment must be worn at all times 5 1 Direction of rotation Correct rotation is indicated by the arrow on the casing 1100 Improper rotation will not damage the pump however performance is greatly reduced Rotation may be determined by viewing the motor s fan AUTION Do not bump the motor to test rotation or run the pump without the suction completely flooded Dry running can damage the pump in a matter of seconds if the pump is not equipped with dry run bearings CAUTION If maintenance work has been carried out to the site s electricity supply the direction of
60. ntrol starting system before commissioning Maximum stop starts Up to 15 20 10 Between 15 20 and 90 120 10 Above 90 120 O 5 j Where duty and standby pumps are installed it is recommended that they are run alternately every week 5 5 S and shutdown a Close the discharge valve but ensure that the pump runs in this condition for no more than a few seconds b Stop the Op oump C camos For prolonged shut downs and especially when ambient temperatures are likely to drop below freezing point the pump must be drained or otherwise protected FLOWSERVE label 5 6 Hydraulic mechanical and electrical duty This product has been supplied to meet the performance specifications of your purchase order however it is understood that during the life of the product these may change The following notes may help the user decide how to evaluate the implications of any change If in doubt contact your nearest Flowserve office 5 6 1 Specific gravity SG Pump capacity and total head in metres feet do not change with SG however pressure displayed on a pressure gauge is directly proportional to SG Power absorbed is also directly proportional to SG It is therefore important to check that any change in SG will not overload the pump driver or over pressurize the pump 5 6 2 Viscosity For a given flow rate the total head reduces with increased viscosity and increases with reduced viscosity Als
61. o for a given flow rate the power absorbed increases with increased viscosity and reduces with reduced viscosity It is important that checks are made with your nearest Flowserve office if changes in viscosity are planned 5 6 3 Pump speed Changing pump speed effects flow total head power consumed NPSHk noise and vibration Flow varies in direct proportion to pump speed head varies as speed ratio squared and power varies as speed ratio cubed The new duty however will also be dependent on the system curve If increasing the speed it is important therefore to ensure the maximum pump working pressure is not exceeded the driver is not overloaded NPSHa gt NPSH_p and that noise and vibration are within local requirements and regulations 5 6 4 Net positive suction head NPSH NPSH available NPSHA is a measure of the head available in the pumped liquid above its vapour pressure at the pump suction branch NPSH required NPSHg is a measure of the head required in the pumped liquid above its vapour pressure to prevent the pump from cavitating It is important that NPSHa gt NPSHg The margin between NPSH gt NPSHpr should be as large as possible If any change in NPSH A is proposed ensure these margins are not significantly eroded Refer to the pump performance curve to determine exact requirements particularly if flow has changed Page 21 of 40 U MAG ENGLISH 26999990 10 14 If in doubt please consult your neares
62. oken Page 24 of 40 U MAG ENGLISH 26999990 10 14 Figure 6 1 a Remove the bolt s connecting the support foot 3134 to the base and any bolts connecting the motor to the base b Remove the four adapter socket head cap screws 6570 1 with an 8mm 5 16 in hex key CAUTION Removing the close coupled motor requires significant care The magnetic coupling between the impeller and outer drive magnets is very strong The next step requires the magnetic field to be broken It is recommended to have a second person with non metallic spacers to place between the adapter 1340 and containment ring 3830 to assist in disassembly c Firmly hold the drive end which includes the adapter 1340 outer magnet assembly 0230 and the motor and with smooth continuous force pull it away from the wet end Pull the drive end back at least 150 mm 6 in Figure 6 2 d Turn the drive end to the side to allow space for disassembly of the wet end FLOWSERVE EE 6 6 2 Wet End Disassembly Skin eye and respiratory protection are required when handling hazardous and or toxic fluids When draining precautions must be taken to prevent injury or environmental contamination ESTA l Ensure suction and discharge valves are completely closed Drain the pump and individually decontaminate each component in accordance to all federal state local and company environmental regulations A canon Flowserve INNOMAG
63. oosen the jaws and remove the Impeller 2200 n Remove the trimming sleeve and trim any remaining loose plastic with a hobby knife 6 11 Wet End Assembly 6 11 1 Piped Up Assembly Thoroughly clean all parts before assembly Make sure all parts are free of dirt metallic particles etc With U MAG pumps we highly recommend following the shop assembly procedure Section 6 11 2 to minimize the chance of damaging the SiC Due to the brittle nature of SiC all assemblies must be handled with care to avoid chipping or cracking a Align and slide the impeller 2200 onto the pump shaft 2100 located inside the containment shell 3500 b Insert the assembled impeller 2200 and containment shell 3500 into the containment ring 3830 c Insert the assembly as one piece into the casing 1100 Figure 6 16 d Align the containment ring 3830 so that the four inner adapter 1340 bolt holes are on the right and left side of the pump Figure 6 17 e Insert and tighten 6 socket head cap screws 6570 1 with lock washers 6541 Torque the Socket head cap screws 6570 1 to 27 Nm 20 Ibfeft Page 29 of 40 U MAG ENGLISH 26999990 10 14 Figure 6 17 Q f Align the drive end and push it straight in until it meets the wet end g Tighten the four adapter socket head cap screws and torque to 27 Nm 20 Ibf ft 6 11 2 In Shop Assembly Thoroughly clean all parts before assembly Make sure al
64. or grouted installation are designed to use the grout as a stiffening member Stilt mounted baseplates on the other hand are designed to provide their own rigidity Therefore the designs of the two baseplates are usually different Page 15 of 40 U MAG ENGLISH 26999990 10 14 Regardless of the type of baseplate used it must provide certain functions that ensure a reliable installation Three of these requirements are e The baseplate must provide sufficient rigidity to assure the assembly can be transported and installed given reasonable care in handling without damage It must also be rigid enough when properly installed to resist operating loads e The baseplate must provide a reasonably flat mounting surface for the pump and driver Uneven surfaces will result in a soft foot condition Experience indicates that a baseplate with a top surface flatness of 1 25 mm m 0 015 in ft across the diagonal corners of the baseplate provides such a mounting surface Therefore this is the tolerance to which we supply our standard baseplate Some users may desire an even flatter surface which can facilitate installation and alignment Flowserve will supply flatter baseplates upon request at extra cost For example mounting surface flatness of 0 17 mm m 0 002 in ft is offered on the Flowserve Type E Ten Point baseplate in Figure 4 1 e The baseplate must be designed to allow the user to final field align the pump and driver to wi
65. rance organizations Genuine parts and accessories have been designed tested and incorporated into the products to help ensure their continued product quality and performance in use As Flowserve cannot test parts and accessories sourced from other vendors the incorrect incorporation of such parts and accessories may adversely affect the performance and safety features of the products The failure to properly select install or use authorized Flowserve parts and accessories Is considered to be misuse Damage or failure caused by misuse is not covered by the Flowserve warranty In addition any modification of Flowserve products or removal of original components may impair the safety of these products in their use 1 4 Copyright All rights reserved No part of these instructions may be reproduced stored in a retrieval system or transmitted in any form or by any means without prior permission of Flowserve 1 5 Duty conditions This product has been selected to meet the specifications of your purchase order The acknowledgement of these conditions has been sent separately to the Purchaser A copy should be kept with these instructions The product must not be operated beyond the parameters specified for the application If there is any doubt as to the suitability of the product for the application intended contact Flowserve for advice quoting the serial number If the conditions of service on your purchase order are going to be change
66. revent accidental start up that could result in serious personal injury Lock out and or disconnect power Shut off all valves controlling flow to and from the pump Isolate the pump from the system and relive any remaining system pressure Refer to Safety section before dismantling the oump Before dismantling the pump for overhaul ensure genuine Flowserve INNOMAG replacement parts are available Refer to sectional drawings for part numbers and identification See section 8 Parts lists and drawings When operating with chargeable liquids with conductivities of lt 10 8 S m inert gases e g nitrogen must be used to flush the pump Before removal of the pump it is recommended to wait one hour to allow static oeak charges to be eliminated A canon When handling hazardous and or toxic fluids skin eye and respiratory protection are required If pump is being drained precautions must be taken to prevent injury or environmental contamination 6 6 1 Drive Wet End Separation Flowserve INNOMAG pumps contain extremely strong magnets The use of non magnetic tools and work surface is highly recommended The work area must be clean and free of any ferrous particles ECI Wet end and drive end separation requires significant care The magnetic coupling between the impeller 2200 and outer drive 0230 magnets is very strong This process requires the magnetic field between the outer drive and impeller to be br
67. sibility of the installer to ensure that the motor is assembled to the pump and aligned as detailed in section 4 5 and 4 8 FLOWSERVE Ladd 4 3 Foundation A pump should be located near the supply of liquid and have adequate space for operation maintenance and inspection Baseplate mounted pumps are normally placed on a concrete foundation which has been poured on a solid footing The foundation must be able to absorb any vibration and to form a permanent rigid support for the pumping unit a Prepare site Inspect foundation for dirt oil chips water etc and remove any contaminants b Install mounting bolts using hole pattern determined by baseplate size Sleeve type and J type bolts are commonly used to allow movement for final bolt adjustment Follow best company standards and practices 4 3 1 Protection of openings and threads When the pump is shipped all openings are covered This protection covering should not be removed until installation If for any reason the pump is removed from service this protection should be reinstalled 4 3 2 Rigid baseplates overview The function of a baseplate is to provide a rigid foundation under a pump and its driver that maintains alignment between the two Baseplates may be generally classified into two types e Foundation mounted grouted design Figure 4 1 e Stilt mounted or free standing Figure 4 2 Figure 4 1 Figure 4 2 Baseplates intended f
68. ss pattern e See torque chart in Section 6 5 o The first increment should be 75 of full torque o Thesecond increment should be at the full torque o Verify that the torque value of the 1 fastener is still at the full torque value Re torque all fasteners after 24 hours or after the first thermal cycle e Re torque all fasteners at least annually 4 5 2 Suction piping To avoid NPSH and suction problems suction piping must be at least as large as the pump suction connection Never use pipe or fittings on the suction that are smaller in diameter than the pump suction size Figure 4 5 illustrates the ideal piping configuration with a minimum of 10 pipe diameters between the source and the pump suction In most cases horizontal reducers should be eccentric and mounted with the flat side up as shown in Figure 4 6 with a maximum of one pipe size reduction Never mount eccentric reducers with the flat side down Horizontally mounted concentric reducers should not be used if there is any possibility of entrained air in the process fluid Vertically mounted concentric reducers are acceptable In applications where the fluid is completely de aerated and free of any vapour or suspended solids concentric reducers are preferable to eccentric reducers Figure 4 5 Figure 4 6 a SUCTION N AO 3 lt W A 8988 um 9 FLOWSERVE label Avoid the use of throttling valves and strainers in the suction line Start up
69. st be monitored if necessary to ensure they function correctly b Check for any leaks Pump is designed to be leak free any leak is abnormal c Check that the duty condition is in the safe operating range for the pump d Check vibration noise level and surface temperature to confirm satisfactory operation e Check dirt and dust is removed from areas around close clearances and motors Our specialist service personnel can help with preventative maintenance records and provide condition monitoring for temperature and vibration to identify the onset of potential problems If any problems are found the following sequence of actions should take place a Heferto section 7 Troubleshooting for fault diagnosis Page 22 of 40 U MAG ENGLISH 26999990 10 14 b Ensure equipment complies with the recommendations in this manual c Contact Flowserve if the problem persists 6 2 1 Preventive Maintenance Guidelines Different applications call for different preventative maintenance schedules Applications that involve pumping abrasives or applications that are likely to precipitate solids should be examined on a regular basis to ensure that accumulating solids if any are removed There are many factors that can necessitate periodic preventative maintenance and inspection but for clean continuously operating services preventative maintenance can usually be done without disassembling the pump See recommended spare parts list for
70. t Flowserve office for advice and details of the minimum allowable margin for your application 5 6 5 Pumped flow Flow must not fall outside the minimum and maximum continuous safe flow shown on the pump performance curve and or data sheet 6 MAINTENANCE 6 1 General A It is the plant operator s responsibility to ensure that all maintenance inspection and assembly work is carried out by authorized and qualified personnel who have adequately familiarized themselves with the subject matter by studying this manual in detail See also section 1 6 2 AA Personal Protection Equipment suitable for the conditions and environment must be worn at all times Any work on the machine must be performed when it is at a standstill Itis imperative that the procedure for shutting down the machine is followed On completion of work all guards and safety devices must be re installed and made operative again Before restarting the machine the relevant instructions listed in section 5 Commissioning start up operation and shut down must be observed Oil and grease leaks may make the ground slippery Machine maintenance must always begin and finish by cleaning the ground and the exterior of the machine If platforms stairs and guard rails are required for maintenance they must be placed for easy access to areas where maintenance and inspection are to be carried out The positioning of these accessories must not limit access or hinder t
71. tering the immediate area action must be taken to avoid accidental contact If complete protection is not possible the machine access must be limited to maintenance staff only with clear visual warnings and indicators to those entering the immediate area If the temperature is greater than 80 C 175 F or below 5 C 23 F in a restricted zone or exceeds local regulations action as above shall be taken HAZARDOUS LIQUIDS When the pump is handling hazardous liquids care must be taken to avoid exposure to the liquid by appropriate siting of the pump limiting personnel access and by operator training If the liquid is flammable and or explosive strict safety procedures must be applied FA enn PREVENT EXCESSIVE EXTERNAL PIPE LOAD Do not use pump as a support for piping Do not mount expansion joints unless allowed by Flowserve in writing so that their force due to internal pressure acts on the pump flange x Never loosen flange connection while system is under pressure N CAUTION Always make certain pressure gages indicating lights and safety devices are working AN ALWAYS know the EMERGENCY STOP location for the pump Page 6 of 40 U MAG ENGLISH 26999990 10 14 CAUTION NEVER RUN THE PUMP DRY Use diamond like coated DLC parts for additional protection from dry running DLC does not guarantee dry run protection x Never start this pump without proper prime EX must be full of liquid
72. thin their own particular standards and to compensate for any pump or driver movement that occurred during handling U MAG pumps have a close coupled configuration only and alignment is achieved by the mating of precision machined surfaces See section 4 8 for more information 4 3 3 Stilt and spring mounted baseplates Flowserve offers stilt and spring mounted baseplates See Figure 4 2 for stilt mounted option The low vibration levels of U MAG pumps allow the use of these baseplates provided they are of a rigid design The baseplate is set on a flat surface with no tie down bolts or other means of anchoring it to the floor General instructions for assembling these baseplates are given below For dimensional information please refer to the appropriate Flowserve Sales print 4 3 3 1 Stilt mounted baseplate assembly instructions Refer to Figure 4 3 a Raise or block up baseplate pump above the floor to allow for the assembly of the stilts b Predetermine or measure the approximate desired height for the baseplate above the floor c Set the bottom nuts 2 above the stilt bolt head 1 to the desired height d Assemble lock washer 3 down over the stilt bolt FLOWSERVE abel e Assemble the stilt bolt up through hole in the bottom plate and hold in place f Assemble the lock washer 3 and nut 2 on the stilt bolt Tighten the nut down on the lock washer g After all four stilts have been assem
73. tice Fabricated steel folded steel and cast iron baseplates can be filled with grout Polycrete baseplates cannot be grouted in the same way see their User Instructions 71569284 E for installation and use If in any doubt please contact your nearest service center for advice Grouting provides solid contact between the pump unit and foundation prevents lateral movement of vibrating equipment and dampens resonant vibrations 4 4 1 Baseplate Inspection a Completely clean the underside of baseplate FLOWSERVE label b Inspect for any damage that would impede proper installation or future use of the baseplate c Confirm baseplate hole pattern for proper mounting bolt installation d Lower the baseplate carefully onto mounting bolts Caution Must adhere to proper transport and lifting procedures e Level the baseplate using shims and or wedges Use machinist s levels to maintain a flat and level surface QE LE SS gt a 4 Max difference across length 3 2 mm 0 125 in Max difference across width 1 5 mm 0 059 in Secure baseplate using mounting bolts to prevent unwanted movement during operation Torque bolts to appropriate company standards and practices Perform final inspection to verify that baseplate is securely mounted level and ready to be used 4 5 7 AN A Protective covers are fitted to both the suction and discharge flanges of the casing and must be removed prior to connecting the pump
74. to the purchaser these should be obtained and retained with these User Instructions 1 9 Noise level Attention must be given to the exposure of personnel to the noise and local legislation will define when guidance to personnel on noise limitation is required and when noise exposure reduction is mandatory This is typically 80 to 85 dBA The usual approach is Page 9 of 40 U MAG ENGLISH 26999990 10 14 to control the exposure time to the noise or to enclose the machine to reduce emitted sound You may have already specified a limiting noise level when the equipment was ordered however if no noise requirements were defined then attention is drawn to the following table to give an indication of equipment noise level so that you can take the appropriate action in your plant Pump noise level is dependent on a number of operational factors flow rate pipework design and acoustic characteristics of the building and so the values given are subject to a 3 dBA tolerance and cannot be guaranteed Similarly the motor noise provided in the table below is pump and motor noise that is typically expected from standard and high efficiency motors when on load directly driving the pump Note that a motor driven by an inverter may show an increased noise at some speeds If a pump unit only has been purchased for fitting with your own driver then the noise levels in the table should be adjusted for the driver level obtained from the s
75. ture Temperature Class see section 1 6 4 3 1 6 4 3 Avoiding excessive surface temperatures ENSURE THE EQUIPMENT TEMPERATURE CLASS IS SUITABLE FOR THE HAZARD ZONE Pumps have a temperature class as stated in the ATEX Ex rating on the nameplate These are based on a maximum ambient of 40 C 104 F refer to Flowserve for higher ambient temperatures The surface temperature on the pump is influenced by the temperature of the liquid handled The maximum permissible liquid temperature depends on the ATEX temperature class and must not exceed the values in the table that follows Maximum permitted liquid temperature for pumps emperature class Maximum surface Temperature limit of to EN13463 1 temperature permitted liquid handled T6 85 C 185 F 65 C 149 F 15 100 C 212 F 80 C 176 F 115 C 239 F 180 C 356 F T4 135 C 275 F T3 200 C 392 F T2 300 C 572 F T1 450 C 842 F The table only takes the ATEX temperature class into consideration Pump design or material as well as component design or material may further limit the maximum working temperature of the liquid 275 C 527 F 400 C 752 F FLOWSERVE label The temperature rise at the bearings and due to the minimum permitted flow rate is taken into account in the temperatures stated The operator is responsible to ensure that the specified maximum liquid temperature is not exceeded Temperature
76. ty 5 6 21 Inspection 6 7 2 25 Installation 4 14 LINO Le 10 Location 4 1 14 Maintenance 6 21 Maintenance schedule 6 2 22 Name nomenclature 3 2 11 Nameplate 1 7 1 and 3 3 9 11 Page 3 of 40 U MAG ENGLISH 26999990 10 14 Page Noise level 1 ET ne EEn 9 Nozzle loads 4 5 4 18 Operating limits 3 5 1 13 Ordering spare parts 6 3 1 23 Part assemblies 4 2 14 Parts interchangeability 8 2 38 Parts lists 8 37 Performance 3 5 13 PIONO A D LLL aS u aaa qa 17 Priming and auxiliary supplies 5 2 20 Protection systems 4 7 18 Qualification and training 1 6 2 5 Receipt and unpacking 2 1 9 Recommended spares 6 3 3 23 miele Es ERREA 11 Replacement parts 6
77. uck shut Check strainer device Inspect suction pipe for blockage Head requirement higher than anticipated or Confirm than discharge line is not blocked or valve is not undersized impeller Pump casing and pipes stuck shut Pump may require a larger impeller to overcome immediately before and after the pump heat up system head le e Clogged impeller Clogged impeller Open pump and clear blockage from impeller I pump Open pump and clear blockage from impeller I clear blockage from impeller Open pump and clean blockage from grooves in between fel fol Clogged thrust balancing passages in impeller pe andl bachings Shut off pump Verify that the motor spins smoothly by hand If motor will not spin by hand open pump for inspection If motor spins by hand confirm that the impeller is sized for Decoupled Impeller operating conditions and liquid specific gravity Verify the viscosity of the liquid is not too high Note that the impeller and or outer magnet may be weakened if overheated Calculate volume of the suction pipe It is recommended Suction pipe volume too large for priming that the priming chamber volume should be 3 times the chamber suction pipe volume Decrease suction pipe volume Move pump closer to source e e Suction ift too high or level too low Insufficient margin between suction pressure and Check NPSHa gt NPSHpr proper submergence losses at vapor pressure e e ee Excessiv
78. upplier Consult Flowserve or a noise specialist if assistance is required in adjusting the values It is recommended that where exposure approaches the prescribed limit then site noise measurements should be made The values are in sound pressure level Lpa at 1 m 3 3 ft from the machine for free field conditions over a reflecting plane Typical sound pressure level Pump and Motor LpA at 1 m 3 3 ft reference 20 uPa dBA Pump Series 2900 1750 rpm rpm 75 65 U MAG Notes 1 values are for the maximum usable motor size 2 for 1180 and 960 rpm reduce 1450 rpm values by 2 dBA For 880 and 720 rpm reduce 1450 rpm values by 3 dBA 3 Choosing a fan cooled motor will increase noise levels 4 Placing valves orifices or flow meters near a pump will increase noise levels inside the pump For estimating sound power level Lwa re 1 pW then add 14 dBA to the sound pressure value 2 TRANSPORT AND STORAGE 2 1 Consignment receipt and unpacking Immediately after receipt of the equipment it must be checked against the delivery shipping documents for FLOWSERVE label its completeness and that there has been no damage in transportation Any shortage and or damage must be reported immediately to Flowserve and must be received in writing within one month of receipt of the equipment Later claims cannot be accepted Check any crate boxes or wrappings for any accessories or spare parts that may be packed
79. ure 2 1 2 3 2 Lifting pump and motor assembly For pump and motor sling around the pump discharge nozzle and around the outboard end of the motor frame using choker hitches pulled tight The sling should be positioned so the weight is not carried through the motor fan housing Figure 2 2 Figure 2 2 Maximum 60 2 3 3 Lifting pump motor and baseplate assembly If the baseplate has lifting holes cut in the sides at the end Type D Type E bases and Type A when provided insert lifting S hooks at the four corners and use slings or chains to connect to the lifting eye Do not use slings through the lifting holes For other baseplates sling around the pump discharge nozzle and around the outboard end of the motor frame using choker hitches pulled tight The sling should be positioned so the weight is not carried through the motor fan housing Figure 2 3 FLOWSERVE abel Figure 2 3 Assembled units and their components are heavy Failure to properly lift and support this equipment can result in serious physical injury and or equipment damage Lift equipment only at the specifically identified lifting points Lifting devices such as eyebolts slings and spreaders must be rated selected and used for the entire load being lifted AN Crush hazard The unit and the components can be heavy Use proper lifting methods and wear steel toed shoes at all times ends Make sure that the unit cannot roll or
80. y notch Set screw B will be perpendicular to the key notch Figure 6 27 k Make sure a key is installed in the motor shaft keyway Align the key groove on the outer magnet assembly 0230 with the key on the motor shaft and install Use a ruler straight edge or visually align the groove on the outer magnet assembly 0230 with the outer edge of the adapter 1340 m Look inside the outer magnet assembly 0230 and rotate it until the motor key points away from the plug hole Set screw A should now be visible through the hole on the adapter 1340 Page 32 of 40 U MAG ENGLISH 26999990 10 14 n Tighten set screw A with the 5 mm T handle allen wrench Figure 6 29 o Rotate the outer magnet assembly 0230 by 90 counterclockwise to locate and tighten set screw B p Replace the metal plug 6569 on the adapter 1340 and drive end assembly is complete 6 14 Wet Drive End Assembly Assembling the close coupled motor requires significant care The magnetic coupling between the impeller and outer drive magnets is very strong It is recommended to have a second person with non metallic spacers to place between the adapter 1340 and containment ring 3830 to assist in assembly 6 14 1 Piped Up Assembly a Line up the drive end with the wet end ensuring proper motor and adapter height relative to the wet end b Carefully slide the motor forward until it engages with the containment ring 8830 w

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INNOMAG ® U-MAG™ Sealless chemical