er — CN 9003 INSTRUCTION MANUAL EBARA HORIZONTAL SPLIT CASING CENTRIFUGAL PUMP MODEL CSA & CNA Contents ™@ Safety information and introduction @ Introduction @ Installation @ Operation @ Maintenance ™ Disassembly and Assembly 1 Troubleshooting‘sparkable electrical devices, in personal injury. A warnne . ‘Before handling this pump, always disconnect the power first, No open flame or use : Do not work under heavy suspended object unless there is a positive support under it to stop it's fall in event of sling or hoist failure. Disregard of this warning could result ‘This pump should only be serviced by a qualified person or a factory trained person. A caution ‘This instruction manual includes neccessary items for installation, operation and maintenance. ‘Read this manual carefully to casure correct installation, operation and maintenance. Be sure to keep this instruction manual on hand for future reference. A cavrion Be carefully not to exceed the given specifications is the use of your products. Introduction ‘Thanks you for your purchase of this EBARA Model CSA/CNA Horizontal Split Casing Pump. EBARA has manufactured this pump with due care so that it can be operated with case. However, if itis not property operated, unexpected accidents may result. Accordingly, you are requested to operate this pump according to this instruction manual and to keep this manual for reference. Installation If the pump is installed property and maintained with due care, it can be operated quietly and safety for a long time. Install the pump and connect piping with reference to the following items. 1, Unpacking Uport arrival of the pump at site, check the following (1) Check that the pupm is as ordered by referring to the nameplate. @) Check for possible shipping damage and loosed nuts or bolts. (3) Check for missing accessories. If defects are found, contact your nearest service representative, referencing the items listed on name plate. (4) Handle carefully without damage to the units. 1 Tollift the pump, suspend with cable as shown in Fig 1, 90 that londing in even. Please do not use excessive large size cable. 2 Handle with care so that piping, valves, Instruments, etc, are not broken. WE casnd 3, Lifting hook bolts attached to upper casing are used for their removal only. ‘They must not be used for lifting the ‘entire pump unit, (©) Istorage is required after unpacking, place the pump indoors without fail. Before pump ipment, the couplings, flanges, shafts and other external machined pump surface have usually been coated with rust preventative oil (NOX-RUST 366) Internal components have also been coated ® with rast preventative oil (RUST-VET 377). When the pump is stored for extended periods, hermetically seal all openings after inserting, dry agent (Siticagel) or rust-proof . ‘agent (Dyana). Use thincer to remove the internal coating before operation.ES 3. Cautions On Piping 2. Installation Site (2) Select a pamp site, easy for malatenance and (1) As suction discharge pipe lond applied to the ne pump causes eccentricity, both pipes should (2) Provide a suitable barrier to prevent entry of be provided with adequate support. tanauthorized pervons arcued pomp. (2) Minimum number of suction elbows with (3) Insta the prep as elo to tbe water oupply an bend radius as large as possible may be possible, As high suction head many cause installed at some distance from pump inlet. vibration, noise and pump failure, the suction head ie) should be re-checked. Since the suction head ia) eaten # Gente veree Feeese. oe Ia Se ised Wiicusa eases ae Ue prevention when the discharge pipe is too stall the pump in reference to RE NSPH Jong, actual head is high, water is fed Pressure tank, or when two or more pumps 1. Install the check valve between the pump and the sluice valve. (4) If there is danger of water hammer, a quick closing check valve should be installed on the discharge side. (5) Ifa pipe of different diameter than pump ised, an eccentric type reducer stalled so as not to produce any air Pocket. (Fig.3) (Required Net Positive Suction Head) so that average net positive suction head (AV.NSPH) is are operated in paral larger thet the Required NPSH. Fig. 3 Pump suction pipe ‘Suction pipe for positive suc (1) Install a foot valve at the end of suction pipe, and connect the pipe as shown in Fig. 4 The foot valve must be ondered separately. (2) Connect horizontal portion of pipe with a gradient of more than 1/100 toward pump, as shown in Fig. 4. (3) Ensure that flange does not permit air intake. Suction pipe for influx or force feed (1) Install a sluice valve on the suction pipe between the pump and tank as shown in Fig. 5. Sluice valves should be installed with their handles facing sideways so as not to produce q Fig. 4 any air pockets Fig. 6. (2) Connect horizontal portion of pipe with a gradient of more than 1/100 toward pump, as shown in Fig. 5. Fig. 6 o -Cihmp-(3) Determine the position and height of the pump Level by using the casing machined surfaces, to obtain a horizontally of 0.1 mm/m as the reference value. The pump height can be easily adjusted with taperliners. (4) After installing anchor bolts, pour mortar into the anchor bolts holes and allow to be harden. Mortar will harden in about 4 days, although this period more or less differs according to the open air temperature, humidity and the compound ratio. (5) After the mortar has hardened, arrange the liners used in paragraph (1) as close to and on cither side of the anchor bolt. If the distance between anchor bolt exceeds I m, install additional liners between these anchor bolts. Installation ‘The pump has been aligned with driver before shipment. However, adjusment for alignment is necessary at the site. Install and center according to the following procedure. (1) After chipping the foundation, arrange one parallel liner an two taper liners on both sides of the anchor bolt hole of the base as shown In Fig. 7. (2) Place the pump plus common bed on these liners, and install the anchor bolt In the anchor bolt hole. Infection bole Fig. 8 (© First centering ® Perform centering while adjusting the taper liners. Axial center offset and surface deflection of After mortar has harden, tighten anchor bolts securely again, and connect pump suction and couplings must be within the allowances shown in Fig. 9, while using a flat gauge, taper gauge, thickness gauge, or dial gauge as shown in Fig. 9. Be careful since these values very considerably according to whether anchor bolts are tight or loose. Install the driver on the base by placing. several liners, so that driver is mostly 1 to 2 mm ing. If shaft coupling offset exceeds 0.2 mm as a result of pipe connections, disconnect pipe connections and adjust pipe supports. Repeat this adjustment until piping is correct. (9) Second centering After piping has been completed correctly, set the axial center offset of the shaft couplings of Migher than base surface. the pump and driver to less then the value shown in Fig. 9. Adjust this value by (7) After completion of centering, securely tighten ‘exchanging shims between the driver and anchor blots and pour mortar around the pump. Pour mortar into the space of the bed seat. ‘common bed as required. A CAUTION ‘The coupling guard must be removed to make centering adjustment. Be sure to replace before beginning operation. ME canara‘A. Axial center offset CJ ‘Shaft Coupting For t size, refer to outline drawing. ‘Flexible shaft coupling ‘Measure this value in two vertical and Gear coupling lateral directions respectively. ht, Fle. Se B. Shaf coupling defletion allowance Le) ‘Shaft Coupling 3 Pare Flexible shaft coupling | TWi0] Measure this value in two vertical and i As ‘Gear coupling TOOT} lateral directions respectively. dc, B rs 5. Electrical Wiring A WARNING ‘Check that the power is locked off and disconnected before working on pump. All electric work should be performed by a qualified electrician and all national ‘and local electrical codes must be observed. A CAUTION Measure the insulation resistance. The value should be more than I mega ohm. While und. Power supply equipment and wiring for the motor ‘must be in accordance with the instruction manual for the motor, alectrical equipment technical standards, and existing regulations. Incomplete wiring and grounding by an unqualified persons is ‘against the law and very dangerous. Operation A cavtion Before installation check rotation. Read ELECTICAL WIRING. In order to prevent electric shocks, install a short circuit breaker according to local regulations. This breaker must be supplied by customer. A motor protective device, to prevent damage to the motor due to overload, etc., sholud be installed. A caution (Check rotation. Pump should be started with gate valve closed, than the operator should open the valve gradually. 1. Cautions Before Starting Operation (2) Turn the pump by hand and check for ‘smooth rotation. If pump rotation is difficult or uneven, it may be caused by internal rust etc. Locate cause and eliminate. (2) Operate the driver only by inching operation so as to confirm direction of rotation. Then, connect the shaft coupling and install shaft coupling guard. WE canna ) Prime the pump. Never operate the pump without prime. Open the air vent plug or valve mounted on the pump discharge side. 0 as to axhaust air or other gus completely, and confirm thet pump is fully primed. Turn the pump shaft manually to discharge air and gas. After priming has been completed, close the discharge valve. @SS Start Operation and Stop (2) Ensure that suction valve is filly open and ‘the discharge valve is fully closed. @) Turn the start switch off and on once or ‘twice to ensure the pump is operating normally. If there are no malfunctions, the Pump may be placed in continuous ‘operation since pump shut-off operation causes rapid liquid temperature rise inside pump, with resultant damage, shut-off ‘operation should be confined to short periods. Gradually open discharge valve and set to Prescribed operation point. Check each part of the pump and driver for current voltage, lubrication of each part, rotation noise, vibrations, discharge and suction pressures, ete. If there is a possibility that foreign substances may be introduced into the pump, during the initial stages of operation, provide a temporary strainer on the suction side, just before the pump. Provide a pressure gauge between the strainer and the pump to monitor pressure drop due to strainer. Increased Pressure drop indicates strainer clog, so Pump must be stopped and strainer cleaned. If suction pressure becomes low due to excessive pressure drop there is danger of pump burn-out. Do not remove strainer until all foreign substances are completely removed from the system and Piping. @ @ Maintenance A CAUTION Disconnect power cable from power source before servicing unit. ‘Normal maintenance should be done by qualified personnel. (5) Re-check pump and driver 30 to 60 minutes after start. (©) During stop operation, gradually close the discharge valve before turning off the prime mover. 3, Shut-down and Emergency Shut-down (1) When the pump stops due to power failure, turn of switch and close discharge valve. (This prevents sudden start of pump when power Is restored). (2) For emergency shut-down, switch off electric power and close discharge valve. 4, Standby Pump For standby pump operation, fully open the suction and discharge valve. Fill the pump with Liquid so that suction pressure is applied. Stop reverse pressure with check valve only, and start the pump as is, when restating. In order to maintain best operating conditions for the pump the following maintenance and checks should be provided, Pressure gauge and compound gauge cocks should be closed except when taking readings. This will prevent instrument damage. (1) Supply and replacement of bearing lubricant, ‘To supply grease, fill from the upper nipple with the amount and at the intervals shown in Table 1, Excessive grease will cause overheat. Apllicable grease should be "Shell Albania No.3" or equivalent. ME canna Lower than 7.5kW | Less than 6 times per hour AL kW-22KW | Leas than 6 times per hour Higher than 26 kW | Less than 6 times per ho (2) Temperature on the bearing casing should not exceed room temperature plus 40°C or 80°C. If this temperature is exceeded, stop operation immediately and check. (3) Do not start the pump frequently, otherwise the pump may be damaged. Suppress the starting frequency as follows.UCFC206E CUCFC206C | CUCFC208C UCKC208E ‘CUCFC 212 UCC212E CUCFC210C UCFGC210E 39 er S.A gr Supplied ‘3000 - 4000 | 3000 - 4000 | 3000-4000 | 3000-4000 | 3000 - 4000 hrs hrs brs brs hrs Table 1 (4) Pressures, current, vibrations, noises etc. which differ greatly from normal values are a symptom of trouble. take counter measure immediately. For this purposed, it is (8) Turn off the switch without fail before checking pump. (© Turn the pump shaft by hand once every week if the pump is stopped for a long time. ‘CUCFC214C recommended that records be kept. (7) To prevent freeze and subsequent damage to Check the following items. pump during cold weather operation, drain ‘© Suction and discharge pressures pump or provide insulation, © Current value and deviation (8) Consumable parts. © Bearing temperature (max 80 °C on bearing Replace parts under the following conditions casing) as shown in Table 2. ‘Vibrations (on bearings and pump casing) Noises Part Reason for change Change frequency Mechanical Seal If leak cannot be stopped Every 1-2 Years Shaft coupling rubber Wom, deteriorated, wom on one side ‘Annually Bearing Noticeable noise, abnormal noise Ever 2 to 3 years Gaskets Each disassembly Table 2 ‘The above change frequency indicates standard values when the pump is operated normally.Disassembly and Assembly 1. Description of structure 291 [GREASE NIPPLE 156 | LOCK PIN 136 | BEARING WASHER 129 [BEARING NUT 117 | GASKET (CASING) 111-2 [ MECHANICAL SEAL I11-T_[ MECHANICAL SEAL 107-2 CASING WEAR RING (CCP SIDE) 107-1_[ CASING WEAR RING (CP SIDE) (093___| DEFLECTOR (053-2_| BEARING COVER (053-1_| BEARING COVER 051-2_| BEARING UNIT ‘@i-1_[ BEARING UNIT 0st [IMPELLER NUT '039-2_| COUPLING KEY ‘039-1 | IMPELLER KEY 031__| SHAFT 02 IMPELLER SIDE COVER 11-1 SIDE COVER (006 | CASING-LOWER HALF [004 | CASING-UPPER HALF FART PART NAME NO. Standard model 042-2 [SHAFT SLEEVE (CCP SIDE) (042-1 | SHAFT SLEEVE (CP SIDE) ‘018-2 [BEARING SUPPORT (CCF SIDE) 018-1 | BEARING SUPPORT (CP SIDE) 124 |GLAND BOLT 119-2 _ [GLAND PACKING (CCP SIDE) 119-1__ | GLAND PACKING (CP SIDE) 091 [GLAND 090 [LANTERN RING PART PART NAME NO. Gland Packing Type (Option)Prior to disassembly prepare cardboard or plywood sheet upon which to place disassembled parts. Avoid piling parts on top of each other. Since casing gaskets and side cover gaskets cannot be reused after disassembly, prepare replacements in advance. Observe the following procedure for disassembly. Before disassembly it is necessary to turn off power, close discharge and suction valves, (close valves in minimum flow piping) and open casing drains to completely drain pump. (1) Remove all auxiliary piping around pump. (2) Remove coupling connections. (3) Remove bolts of side cover. (4) Remove bolts holding upper and lower casing (two of them are reamer bolts) (8) Lift off upper casing. (6) Remove bolts for bearing housing. (7) Remove as a unit such rotating components as impeller and liner ring. (8) Place shaft on wooden support and remove shaft coupling, bearing and side cover. (9) Remove mechanical seal (10) Remove impeller nut and impeller. Disassembly is now complete. LT uUEUNUUTWunneeneer . Disassembly . Checks (2) Checks liner ring for contact, galling and water. (2) Cheek for bent shaft (if liner ring contacts). (3) _ Replace bearings if they show excessive wear. (Check impeller for corrosion, wear and cracks. (5) _ Replace shaft sleeves and gland packings if scratched or worn. It is recommended that bearings and oil seals be replaced once every year or so. 4, Assembly (1) Assembly is in the reverse order of disassembly Clean all parts with solvent and assemble after thorough checks for corrosion or scratches. (2) During assembly replace all used gaskets. (3) Securely tigten impeller nut set screw bolt and bearing nut (4) At mechanical seal assembly, special tool which provided by maker, should be used,Trouble Shooting A CAUTION Alll services should be done by factory trained or qualified personal only. —] __| Syupioms ‘Countermeasures Prime mover does not rotate or rotates with hum. ‘Specified displacement not obtained | Water pumped, but soon stops. Lace (© Defective prime mover. © Defective power supply. © Contacts, rust or seizure of rotating parts. © Foreign matter in motor. ‘Oncomplete, no prime. OStuice valve closed, half ope © Actual head is higher than total head of pump. ° Excessive suction height. ‘OReverse rotation direction. Low rotation speed No. of poles of motor differs. *Low voltage. OF oot valve or strainer clog. Olmpeller clog. Pipe clog. Air lock in suction pipe. Air suction JoDischarge pipe leak. Jotmpeller corrosion. }© Excessive impeller wear. JO Excessive liner ring wear. Jorxcessive pipe loss. }o Excessive liquid temperature. JeCavitation. JoActual head higher than total pump head. lOExcessive suction height. fotasufficient prime. loAir suction. JOAir lock suction height. JOExcessive suction height, [OExcessive rotation. No. of poles of motor differ. JoVoltage drop and considerable unbalance between phases. © Repair or replace. © Cheek and repair. © Manually rotate pump, disassemble clean, reassemble © Repair in specialist shop. ° d. © Prime. © Open sluice valve. © Recheck plan 0 Recheck plan. (© Correct connections, referring to arrow] indications Check with tachometer, © Check nameplate. © Check power supply. ‘Remove foreign matter ORemove foreign matter ORemove foreign matter. ORemove air. ‘Check and repair suction pipe and shaft seal. ‘Check submersion depth at end of foot} valve and suction pipe. ©Check and repair ‘Check liquid quality, and repair. oR: Replace. ‘Recheck plan. Recheck plan. Contact specialist. ‘ORecheck plan. Recheck (oPrime. Check and reir suction pipe abd sl s Reconnect piping. ORecheck plan. ‘OCheck with tachometer. Check nameplate. Contact company.ST Trouble Shooting Symptoms —_ Causes ‘Countermeasures Overload. ‘OLow head or excessive water flow. | Reduce opening of discharge valve ‘Centering misaligament ‘0 Center again. (Foreign matter in pump. ORemove foreign matter. © Liner ring wear. Replace. © Bearing damage. Replace. © Contact of rotating parts or bent | Repair in specialist shop. shaft. ‘Bearing overheat. © Insufficient lube of. ‘Replenish. ‘Reduce oll supply. Replace bearing unit. Replace bearing unit. Replace bearing unit. Center again. Replace bearing unit. © Stop cut-off operation. © Excessive lube oil. © Improper lube oil. © Deteriorated lube oil. © Contaminated lube oil. © Centering misalignment. © Bearing damage. © Excessive time cut-off o ‘Inadequate foundatior © Installation and centering failure. conditions. ‘Replace bearings. ‘o Reduce discharge valve opening. ‘0 Operate pump with specified flow. ‘oRemove foreign matter. Correct, referring to arrow. © Repair in specialist. © Contact specialis: © Modify piping. © Bearing damage. ‘OE xcessive water flor © Discharge volume too smi ‘olmpelier clog. ‘o Reverse rotation. ‘Rotary part touches or bent shaft. © Cavitation. 0 Vibrati Water leak from shaft seal. "OMechanical seal assemble failure. | © Mount mechanical seal correctly. Mechanical seal damage. oReplace. Shaft and mechanical seal wear. Replace. © Bent shaft Repair in specialist shop. ‘Shaft coupling rubber wear” | © Defective installation and centering, [© Check and correct discrepancies © Shaft coupling rubber damaged. __| 0 Repl WE canna‘Al specifications subject to change without prior notice. CN 9003-101003/2/1000