Grundfos LCSE Installation And Operating Instructions Manual

GRUNDFOS INSTRUCTIONS

LFE, LCSE

End-suction, frame-mounted pumps with integrated VFD

End-suction, close-coupled, split-coupling pumps with integrated VFD

Installation and operating instructions

Table of contents

2

LFE, LCSE

English (US)

Installation and operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Notice d'installation et de fonctionnement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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Instrucciones de instalación y operación . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

3

English (US)

English (US) Installation and operating instructions

Original installation and operating instructions

These installation and operating instructions describe LFE,

LCSE.

Sections 1-5 give the information necessary to be able to unpack,

install and start up the product in a safe way.

Sections 6-30 give important information about the product, as

well as information on service, fault finding and disposal of the

product.

CONTENTS

Page

1. Limited warranty

4

2. General information

5

2.1 Symbols used in this document

5

2.2 Other important notes

5

3. Receiving the product

5

3.1 Unpacking the product

5

3.2 Inspecting the product

5

3.3 Temporary storage after delivery

5

4. Installing the product

6

4.1 Location

6

4.2 Horizontal pump foundation

6

4.3 Securing the base plate

6

4.4 Mechanical installation

7

4.5 Electrical connections

9

4.6 Motors

9

5. Starting up the product

10

5.1 Priming

10

5.2 Pre-start checklist

10

5.3 Motor direction of rotation

10

5.4 Starting the pump

10

5.5 Voltage and frequency variation

10

6. Storing and handling the product

10

7. Product introduction

11

7.1 Applications

11

7.2 Pumped liquids

11

7.3 Pump identification

11

8. Servicing the product

11

8.1 Maintaining the product

11

8.2 Lubricating the product

11

8.3 Disassembling the pump

13

8.4 Replacing the shaft seal (LCSE pumps)

14

8.5 Replacing the wear ring

14

8.6 Reassembling the pump

14

8.7 LFE, exploded view and parts list

15

8.8 LCSE, exploded view and parts list

16

9. Taking the product out of operation

17

9.1 General procedure

17

9.2 Short-term shutdown

17

9.3 Long-term shutdown

17

10. Fault finding

18

11. PACO MLE motors

20

11.1 Pumps without factory-fitted sensor

20

11.2 Pumps with pressure sensor

20

11.3 Settings

20

12. Installing the motor

20

12.1 Motor cooling

20

12.2 Outdoor installation

20

13. Electrical connection

21

13.1 Three-phase pumps, 3-10 hp

21

13.2 Three-phase pumps, 15-30 hp

23

13.3 Signal cables

26

13.4 E-pump electrical connections

26

13.5 Bus connection cable

28

14. Modes

28

14.1 Overview of modes

28

14.2 Operating mode

28

14.3 Control mode

29

15. Setting up the pump

29

15.1 Factory setting

29

16. Setting by means of control panel

29

16.1 Setting of operating mode

29

16.2 Setpoint setting

30

17. Setting by means of R100

30

17.1 Menu OPERATION

32

17.2 Menu STATUS

33

17.3 Menu INSTALLATION

35

17.4 Typical display settings for constant-pressure E-pumps

42

17.5 Typical display settings for analog-input E-pumps

43

17.6 Grundfos GO Remote

44

18. Setting by means of PC Tool E-products

45

19. Priority of settings

45

20. External forced-control signals

45

20.1 Start/stop input

45

20.2 Digital input

46

21. External setpoint signal

46

22. Bus signal

47

23. Other bus standards

47

24. Indicator lights and signal relay

47

25. Emergency operation (only 15-30 hp)

49

26. Insulation resistance

50

27. Maintaining and servicing the motor

50

27.1 Cleaning of the motor

50

27.2 Relubrication of motor bearings

50

27.3 Replacement of motor bearings

50

27.4 Replacement of varistor (only 15-30 hp)

51

27.5 Service parts and service kits

51

28. Technical data

51

28.1 Technical data - three-phase pumps, 3-10 hp

51

28.2 Technical data - three-phase pumps, 15-30 hp

52

28.3 Other technical data

53

29. Installing the product in the USA and Canada

54

29.1 Electrical connection

54

29.2 General considerations

54

30. Disposing of the product

54

English (US)

4

1. Limited warranty

New equipment manufactured by seller or service supplied by

seller is warranted to be free from defects in material and

workmanship under normal use and service for a minimum of

twelve (12) months from date of installation, eighteen (18) months

from date of shipment, unless otherwise stated in product warranty

guide (available upon request). In the case of spare or

replacement parts manufactured by seller, the warranty period

shall be for a period of twelve months from shipment. Seller's

obligation under this warranty is limited to repairing or replacing, at

its option, any part found to its satisfaction to be so defective,

provided that such part is, upon request, returned to seller's

factory from which it was shipped, transportation prepaid. Parts

replaced under warranty shall be warranted for twelve months

from the date of the repair, not to exceed the original warranty

period. This warranty does not cover parts damaged by

decomposition from chemical action or wear caused by abrasive

materials, nor does it cover damage resulting from misuse,

accident, neglect, or from improper operation, maintenance,

installation, modification or adjustment. This warranty does not

cover parts repaired outside seller's factory without prior written

approval. Seller makes no warranty as to starting equipment,

electrical apparatus or other material not of its manufacture. If

purchaser or others repair, replace, or adjust equipment or parts

without seller's prior written approval, seller is relieved of any

further obligation to purchaser under this paragraph with respect

to such equipment or parts, unless such repair, replacement, or

adjustment was made after seller failed to satisfy within a

reasonable time seller's obligations under this paragraph. Seller's

liability for breach of these warranties (or for breach of any other

warranties found by a court of competent jurisdiction to have been

given by seller) shall be limited to: (a) accepting return of such

equipment exw plant of manufacture, and (b) refunding any

amount paid thereon by purchaser (less depreciation at the rate of

15 % per year if purchaser has used equipment for more than

thirty [30] days), and canceling any balance still owing on the

equipment, or (c) in the case of service, at seller's option, redoing

the service, or refunding the purchase order amount of the

service or portion thereof upon which such liability is based.

These warranties are expressly in lieu of any other warranties,

express or implied, and seller specifically disclaims any implied

warranty of merchantability or fitness for a particular purpose, and

in lieu of any other obligation or liability on the part of the seller

whether a claim is based upon negligence, breach of warranty, or

any other theory or cause of action. In no event shall seller be

liable for any consequential, incidental, indirect, special or

punitive damages of any kind. For purposes of this paragraph, the

equipment warranted shall not include equipment, parts, and work

not manufactured or performed by seller. With respect to such

equipment, parts, or work, seller's only obligation shall be to

assign to purchaser the warranties provided to seller by the

manufacturer or supplier providing such equipment, parts or work.

No equipment furnished by seller shall be deemed to be defective

by reason of normal wear and tear, failure to resist erosive or

corrosive action of any fluid or gas, purchaser's failure to properly

store, install, operate, or maintain the equipment in accordance

with good industry practices or specific recommendations of

seller, including, but not limited to seller's installation and

operation manuals, or purchaser's failure to provide complete and

accurate information to seller concerning the operational

application of the equipment.

Prior to installation, read these installation and

operating instructions. Installation and operation

must comply with local regulations and accepted

codes of good practice.

The use of this product requires experience with and

knowledge of the product. Persons with reduced

physical, sensory or mental capabilities must not use

this product, unless they are under supervision or

have been instructed in the use of the product by a

person responsible for their safety. Children must not

use or play with this product.

CAUTION

Successful operation depends on careful attention to

the procedures described in this manual. Keep this

manual for future use.

5

English (US)

2. General information

2.1 Symbols used in this document

The text accompanying the three hazard symbols DANGER,

WARNING and CAUTION will be structured in the following way:

Example

2.2 Other important notes

3. Receiving the product

3.1 Unpacking the product

3.2 Inspecting the product

• Check that the product received is in accordance with the

order.

• Check that the voltage, phase and frequency of the product

match the voltage, phase and frequency of the installation site.

See section 7.3 Pump identification.

• Check the product for defects and damage immediately upon

arrival. Any accessories ordered will be packed in a separate

container and shipped with the product.

• If any equipment is damaged in transit, promptly report this to

the carrier's agent. Make complete notations on the freight bill.

3.3 Temporary storage after delivery

• If the product is not to be installed and operated immediately

after receiving it, store it in a clean, dry area at a moderate

ambient temperature.

• Rotate the shaft by hand periodically, at least weekly, to coat

the bearing with lubricant to retard oxidation and corrosion.

• Follow the motor manufacturer's storage recommendations

where applicable.

• During storage and transport maintain an ambient temperature

from -13 to +158 °F (-25 to +70 °C) for the E-motor. At

temperatures below the prescribed temperature, the E-motor

must be equipped with a anti-condensation heater. This could

be an external heating element or an incorporated functionality

of the E-motor.

DANGER

Indicates a hazardous situation which, if not avoided,

will result in death or serious personal injury.

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious personal injury.

CAUTION

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate personal injury.

SIGNAL WORD

Description of hazard

Consequence of ignoring the warning.

- Action to avoid the hazard.

DANGER

Electric shock

Death or serious personal injury.

- Before starting any work on the product, make

sure that the power supply has been switched off

and that it cannot be accidentally switched on.

A blue or grey circle with a white graphical symbol

indicates that an action must be taken to avoid a

hazard.

A red or grey circle with a diagonal bar, possibly with

a black graphical symbol, indicates that an action

must not be taken or must be stopped.

If these instructions are not observed, it may result

in malfunction or damage to the equipment.

Notes or instructions that make the work easier and

ensure safe operation.

WARNING

Overhead load

Death or serious personal injury

- Do not lift the unit by the eye bolts on the motor.

Unload and handle the unit with a sling.

English (US)

6

4. Installing the product

4.1 Location

• Locate the pump as close as possible to the liquid supply. Use

the shortest and most direct inlet pipe practical. Refer to

section 4.4.2 Inlet pipe.

• Locate the pump below system level wherever possible. This

will facilitate priming, assure a steady liquid flow, and provide

a positive inlet pressure.

• The net positive suction head (NPSH) available must always

be equal to or exceed the required NPSH specified on the

pump performance curve. Make sure the required NPSH is

provided at the inlet.

• Always allow sufficient accessibility space for maintenance

and inspection. Provide a clearance of 24 in. (610 mm) with

ample head room for use of a hoist strong enough to lift the

product.

• Electrical characteristics must match those specified on the

motor nameplate, within the limits covered in section

5. Starting up the product.

• Do not expose the product to sub-zero temperatures to

prevent the pumped liquid from freezing and to prevent

damage to the e-motor. If there is frost during shutdown

periods, see sections 5. Starting up the product and 9.2 Short-

term shutdown.

4.2 Horizontal pump foundation

Install horizontal pumps permanently on a firm, raised concrete

foundation of sufficient size to dampen any vibration and prevent

any deflection or shaft misalignment. The foundation may float on

springs or be a raised part of the equipment room floor.

Proceed like this:

1. Pour the foundation without interruption to 0.75 - 1.5 in. (20-

35 mm) below the final pump level. Leave the top of the

foundation rough. Then clean and wet it down.

2. Score and groove the top surface of the foundation before the

concrete sets to provide a suitable bonding surface for the

grout.

3. Place anchor bolts in pipe sleeves for positioning allowance.

See fig. 1.

4. Allow enough bolt length for grout, lower base plate flange,

nuts, and washers.

5. Allow the foundation to cure several days before proceeding

to install the pump.

4.3 Securing the base plate

When the raised concrete foundation has been poured and

allowed to set, proceed as follows:

1. Lower the pump base plate over the anchor bolts and rest it

on loose adjustment wedges or shims placed near each

anchor bolt and at intervals not exceeding 24 in. (610 mm)

along each side.

2. Place the shims or wedges so that they raise the bottom of the

base 0.75 - 1.25 in. (20-32 mm) above the foundation,

allowing clearance for grout.

3. Level the pump shaft, flanges, and base plate using a spirit

level, adjusting the wedges or shims, as required.

4. Make sure that the pipes can be aligned to the pump flanges

without placing any strain on either flange.

5. For LFE, after pump alignment has been established, put nuts

on foundation bolts and tighten them just enough to keep the

base plate from moving.

6. Construct a formwork around the concrete foundation and

pour grout inside the base plate, as shown in fig. 1. The grout

will compensate for uneven foundation, distribute the weight

of the pump, and prevent shifting.

Fig. 1 Anchor bolt installation

7. Allow at least 24 hours for this grout to set before proceeding

with pipe connections.

8. After the grout has thoroughly hardened, check the foundation

bolts and tighten them if necessary. Recheck the pump

alignment after tightening the foundation bolts.

LFE pumps require grouting in order to ensure a

stable pump and motor shaft alignment.

LCSE pumps do not require alignment or grouting.

TM 05 4775 4713

Use an approved, non-shrinking grout.

GroutBase plate

Finished grouting

0.75 - 1.25 in.

allowance

(20-32 mm)

for grout

Formwork

Pipe sleeve

Washer

Lug

Top foundation

Wedges or shims

left in place

0.25

in.

7

English (US)

4.4 Mechanical installation

4.4.1 Piping

• Make sure that both the inlet and outlet pipes are

independently supported and properly aligned so that no strain

is transmitted to the pump when flange bolts are tightened.

• Make sure the pipes are as straight as possible, so as to avoid

unnecessary bends and fittings. Where necessary, use 45 ° or

long-sweep 90 ° pipe bends to decrease friction loss.

• Where flanged joints are used, make sure that inside

diameters match properly and that mounting holes are aligned.

• Do not apply force to pipes when making any connections!

4.4.2 Inlet pipe

The inlet pipe must be selected and installed in a manner that

minimizes pressure loss and permits sufficient liquid flow into the

pump during starting and operation.

Observe the following precautions when installing the inlet pipe:

Fig. 2 Inlet pipe

• Run the inlet pipe as direct as possible, and ideally, make sure

the length is at least ten times the pipe diameter. A short inlet

pipe can be the same diameter as the inlet port. A long inlet

pipe must be one or two sizes larger (depending on length)

than the inlet port, and with a reducer between the pipe and

the inlet port.

• Use an eccentric reducer, with the tapered side down. See fig.

2.

• If possible, run a horizontal inlet line along an even gradient.

We recommend a gradual upward slope to the pump under

suction lift conditions, and a gradual downward slope for

positive inlet pressure conditions.

• Avoid any high points, such as pipe loops (see fig. 3), as this

may create air pockets and throttle the system or cause erratic

pumping.

• Install a gate valve in the inlet line to be able to isolate the

pump during shutdown and maintenance, and to facilitate

pump removal. Where two or more pumps are connected to

the same inlet line, install two gate valves to be able to isolate

each pump from the line.

• Always install gate or butterfly valves in positions that prevent

air pockets.

• During pumping operation, the valves on the inlet line must

always be fully open.

• Install properly sized pressure gauges in the tapped holes on

the pump inlet and outlet flanges.

Pressure gauges will enable the operator to monitor the pump

performance and determine whether the pump conforms to the

parameters of the performance curve. If cavitation, vapor

binding, or other unstable operating situations occur, pressure

gauges will indicate wide fluctuation in the inlet and outlet

pressures.

Fig. 3 Air pocket prevention

Do not let the pump support the pipes. Use pipe

hangers or other supports at proper intervals to

provide pipe support near the pump.

TM06 1087 1614

Eccentric

reducer

Concentric

reducer

Tapered side is down

Air pocket

Correct

Wrong

At no point must the diameter of the inlet pipe be

smaller than that of the pump inlet port.

Do not use globe valves, particularly when NPSH is

critical.

TM06 1088 1614

Air pockets

Correct

Wrong

English (US)

8

4.4.3 Outlet pipe

• A short outlet pipe can be the same diameter as the pump

outlet port. A long outlet pipe must be one or two sizes larger

than the outlet port, depending on the length.

• An even gradient is best for long horizontal outlet pipes.

• Install a gate valve near the outlet port to be able to isolate the

pump during shutdown and maintenance, and to facilitate

pump removal.

• Any high points in the outlet pipe may entrap air or gas and

thus retard pump operation.

• If water hammer occurs (i.e. if check valves are used), close

the outlet gate valve before pump shutdown.

Shaft seals

The pumps are available with stuffing boxes with packing rings or

mechanical shaft seals.

Stuffing boxes

The stuffing boxes are normally packed before shipment.

If the pump is installed within 60 days after shipment, the packing

material will be in good condition for operation with a sufficient

supply of lubricating liquid.

If the pump is stored for more than 60 days, it may be necessary

to repack the stuffing boxes.

The stuffing box must be supplied at all times with a source of

clean, clear liquid to flush and lubricate the packing rings.

Packing gland adjustment

With the pump running, adjust the packing gland to permit 40 to

60 drops per minute for shaft lubrication. After initial start up,

additional packing and adjustment may be required.

Mechanical shaft seals

Mechanical shaft seals require no maintenance or adjustment.

End suction pumps equipped with mechanical shaft seals are

matched to the operating conditions for which the pump was sold.

Observe the following precautions to avoid shaft seal damage

and obtain maximum shaft seal life.

Clean and purge the inlet pipe in new installations before

installing and operating pump. Pipe scale, welding slag and other

abrasives can cause rapid shaft seal failure.

4.4.4 Coupling alignment of LCSE pumps

No alignment of the pump and motor is required.

4.4.5 Coupling alignment of LFE pumps

The pump and motor were accurately aligned from factory, but

handling during shipment could alter this pre-alignment.

1. If the pump and motor were shipped mounted on a common

base frame as an assembly, remove the coupling guard.

2. Checking parallel alignment

Place a straight edge across both coupling rims at the top, the

bottom, and both sides. See fig. 4. After each adjustment,

recheck all features of alignment. Parallel alignment is correct

when the measurements show that all points of the coupling

faces are within ± 0.005 in. (0.127 mm) of each other. If

misalignment is detected, loosen the motor and shift or shim

as necessary to re-align. Then re-tighten the bolts. Always

align the motor to the pump as pipe strain will occur if the

pump is shifted. Never reposition the pump on the base frame.

Fig. 4 Checking parallel alignment

Do not run the pump dry or against a closed valve!

Dry running will cause seal failure within minutes.

Do not exceed the temperature or pressure

limitations for the mechanical shaft seal used.

TM05 4794 2613

9

English (US)

3. Checking angular alignment

Insert a pair of inside callipers or a taper gauge at four points

at 90 ° intervals around the coupling. See fig. 5. Angular

alignment is correct when the measurements show that all

points of the coupling faces are within ± 0.005 in. (0.127 mm)

of each other.

– If misalignment is detected, loosen the motor and shift or

shim as necessary to re-align. Then re-tighten the bolts.

Always align the motor to the pump as pipe strain will occur

if the pump is shifted. Never reposition the pump on the

base frame.

Fig. 5 Checking angular alignment

• Check shaft seal alignment once again after final pipe

connections to the pump have been made, motor wiring has

been checked, correct direction of rotation has been

established, and pipes have been filled with liquid.

• Leave the coupling guards off until the pump priming

procedure has been completed.

• Install the coupling guards after installation has been

completed to protect personnel from rotating machinery.

4.5 Electrical connections

4.6 Motors

See also section 11. PACO MLE motors.

The motor control circuit must include the following components

in order to comply with the National Electrical Code:

Motor disconnecting device

• Install a motor disconnecting device that is capable of

disconnecting both the controller (motor starter) and the motor

from their source of power.

• Locate the disconnecting device in such a way that the

controller (motor starter) can be seen from the disconnecting

device. In all cases, the distance from the disconnecting

device to the controller must be less than 50 ft (15.24 m).

• In most installations the disconnecting device will be a circuit

breaker or fusible disconnect switch.

Motor short circuit and ground fault circuit interrupter

• A short circuit and ground fault circuit interrupter is usually a

circuit breaker or fusible disconnect switch.

• Select the circuit breaker or fuse in accordance with applicable

local and state electrical codes in addition to the National

Electrical Code.

Motor controller with current protection (magnetic starter)

• Install these components in accordance with applicable local

and state electrical codes in addition to the National Electrical

Code.

4.6.1 Wiring

• Mount the control panel or the motor starter(s) close to the

pump to provide convenient control and easy installation.

• Wire panel or starter(s) to motor(s) and pilot device(s).

Wires to the motor(s) must be sized for at least 125 % of the

motor nameplate full load amps. We recommend AWG #16

Type THW stranded wire for wiring of pilot devices, such as

float switches.

• Check that the voltage, phase and frequency of the incoming

power source correspond to the voltage, phase and frequency

of the motor(s).

• Make sure that the starters are suitable for operating the pump

motors on the voltage, phase and frequency available.

TM05 4795 2613

DANGER

Electric shock

Death or serious personal injury

- The electrical installation must be carried out by a

qualified electrician in accordance with local

regulations and the manuals provided with the

electrical accessories.

DANGER

Electric shock

Death or serious personal injury

- Before starting any work on the product, be sure

the power supply has been switched off and that it

cannot be accidentally switched on.

DANGER

Explosive environment

Death or serious personal injury

- Observe the rules and regulations generally or

specifically imposed by the relevant responsible

authorities or trade organizations in relation to

running powered equipment in an explosive

environment.

English (US)

10

5. Starting up the product

5.1 Priming

• End suction pumps are non-self-priming, and must be

completely primed, i.e. filled with liquid, before starting.

• If the pump will be operated with a positive inlet pressure,

prime it by opening the inlet valve and allowing liquid to enter

the pump housing. Open the air vents at this time, and make

sure all air is forced out of pump by the liquid before closing

the air vents.

• Rotate the shaft by hand to free entrapped air from the

impeller passageways.

• If the pump will be operating with a suction lift, priming must

be accomplished by other methods. Use foot valves or

ejectors, or fill the pump housing and the inlet line manually

with liquid.

5.2 Pre-start checklist

Make the following inspections before starting your end suction

pump:

1. Make sure the inlet and outlet pipes have been cleaned and

flushed to remove dirt and debris.

2. Double check the direction of rotation is clockwise. Operating

in reverse will destroy the impeller and shaft.

3. Make sure all wiring connections to the motor and starting

device are in accordance with the wiring diagram.

4. If the motor has been in storage for a long time, either before

or after installation, refer to the motor instructions before

starting.

5. Check the voltage, phases, and frequency with the motor

nameplate. Turn the impeller by hand to make sure it rotates

freely.

6. Tighten the plugs in the gauge and drain holes. If the pump is

fitted with pressure gauges, keep the gauge cocks closed

when they are not in use.

7. Check the inlet and outlet pipes for leaks, and make sure all

flange bolts are securely tightened.

5.3 Motor direction of rotation

5.4 Starting the pump

1. Install the factory-provided coupling guard on coupled

products.

2. Fully open the gate valve (if any) in the inlet line, and close

the gate valve in the outlet line.

3. Fill the inlet line with liquid and completely prime the pump.

4. Start the pump.

5. Immediately make a visual check of the pump and inlet pipe

for pressure leaks.

6. Immediately after the pump has reached full operating speed,

slowly open the outlet gate valve until complete system flow is

achieved.

7. Check the outlet pipe for pressure leaks.

8. If the pump is fitted with pressure gauges, open gauge cocks

and record pressure readings for future reference. Verify that

the pump is performing in accordance with the parameters

specified in the performance curves.

9. Check and record voltage, amperage per phase, and

kilowatts, if a wattmeter is available.

5.5 Voltage and frequency variation

The motor will operate satisfactorily under the following voltage

and frequency variations, but not necessarily in accordance with

the standards established for operation under rated conditions:

• The voltage variation may not exceed 10 % above or below

the rating specified on the motor nameplate.

• The frequency variation may not exceed 5 % above or below

the motor rating.

• The sum of the voltage and frequency variations may not

exceed 10 % above or below the motor rating, provided the

frequency variation does not exceed 5 %.

6. Storing and handling the product

See sections 3.3 Temporary storage after delivery, 9.2 Short-term

shutdown and 9.3 Long-term shutdown.

Never run the pump dry in the hope that it will prime

itself. The result will be serious damage to the shaft

seals, pump wear rings and shaft sleeves.

WARNING

Product failure

Death or serious personal injury

- Do not operate the product above the nameplate

conditions.

Never check the motor direction of rotation unless

the pump and motor couplings have been

disconnected and physically separated. Failure to

follow this instruction can result in serious damage

to the pump and the motor if the direction of rotation

is wrong.

DANGER

Moving machine parts

Death or serious personal injury

- Mount an approved coupling guard before

operating the product.

11

English (US)

7. Product introduction

This data booklet describes:

• LFE end-suction, frame-mounted pumps with integrated VFD

• LCSE end-suction, close-coupled, split-coupling pumps with

integrated VFD.

7.1 Applications

We recommend the integrated VFD end suction pumps for these

applications:

• commercial and industrial cooling systems

– pumping both primary and secondary cooling water

• condenser water systems

• district cooling systems

• water distribution systems

• irrigation systems.

7.2 Pumped liquids

Clean, thin, non-aggressive liquids, not containing solid particles

or fibers. Do not pump liquids that will attack the pump materials

chemically.

7.3 Pump identification

Pumps are identified by catalog and serial numbers (LFE

nameplate shown in fig. 6). These numbers are stamped on the

pump nameplate as shown in fig. 6, affixed to each pump volute

casing, and should be referred to in all correspondence with

Grundfos.

Fig. 6 Nameplate

8. Servicing the product

8.1 Maintaining the product

8.2 Lubricating the product

8.2.1 Lubricating the motor

Always follow the motor manufacturer's lubricating instructions, if

they are available, and periodically check grease fittings and

drain plugs for leaks. Use the standard lubrication interval. See

the installation and operating instructions or the lubrication plate

on the E-motor. If the lubricating instructions are not available,

refer to the table below for recommended lubricating intervals.

TM 06 1036 1414

CAT#: 21-20709-133L01-25E1MS1

STOCK#: 91893522

SER#: 1971001000

GPM: 234

TDH: 88

MFD BY GRUNDFOS CBS INC 34014412

IMP

DIA

5.11

:

WARNING

Moving machine parts

Death or serious personal injury

- Before any inspection, maintenance, service or

repair of the product, make sure the motor controls

are in the "OFF" position, locked and tagged.

Recommended lubricating intervals

Motor rpm Motor hp Operating conditions

Standard Severe Extreme

1750

and below

3.00-7.50 3 yrs 1 yr 6 mo

10-30 1-3 yrs 6 mo-1 yr 3 mo

above 1750 all hp 6 mo 3 mo 3 mo

Standard conditions:

Operating 8 hours per day operation, normal or light load, clean

air, 100 °F (37 °C), maximum ambient temperature.

Severe conditions:

Operating continuously 24 hours, shock loads or vibrations,

poor ventilation, 100-150 °F (37-65 °C), ambient temperature.

Extreme conditions:

Continuous operation, heavy shocks or vibrations, dirt or dust in

the air, extremely high ambient temperature.

English (US)

12

8.2.2 Lubricating the pump

Grease lubrication

In the standard configuration, LFE pumps with horizontal bearing

frames have sealed-for-life bearings (requiring no lubrication).

For customized pumps with regreasable bearings, use an

approved grease and proceed as described below.

• Remove the drain plug, if any, and the filler plug. Add clean

lubricant until grease appears at the drain hole or along the

pump shaft. On pumps with drain hole, all old grease can be

purged. In such cases, the drain hole must be left unplugged

for several minutes during pump operation to allow excess

grease to be forced out.

• Lubricate the pump bearings at 1-3 month intervals,

depending on the severity of the environment. Pumps in a

clean, dry, moderate temperature (100 °F (37 °C) maximum)

environment must be regreased at 3-month intervals.

Oil lubrication

LFE pumps with oil lubricated bearings are fitted with a

transparent reservoir, a constant-level oiler, that maintains the oil

level about the centerline of the bearing. See fig. 7.

• Follow a regular maintenance program. When necessary,

renew the oil supply in the reservoir of the constant-level oiler.

• Change the oil after the first 200 hours of operation. To change

the oil, remove the drain plug at the bottom of the bearing

cover and the filler plug, that also acts as a vent plug, at the

top of the bearing frame. After draining the oil, replace the

fittings and refill the reservoir with an acceptable oil from the

table List of acceptable oil lubricants on page 12. After the first

oil change, the oil must be changed again at 2000 hours and

then at intervals of 8000 hours or once a year, thereafter.

Fig. 7 Oil lubrication

Approved grease lubricants

Manufacturer Lubricant

Shell Dolium

p

R

Exxon Polyrex

p

Chevron

SRI GreaseNLGI 2

Black Pearl - NLGI 2

Philips Polytacറ

Texaco Polystar RB

Do not over-grease! Too much grease can cause

overheating and premature bearing failure.

TM06 1089 1614

List of acceptable oil lubricants

Lubricant manufacturer Bearing oil brand name

Aral Refining Co.

Aral Oil CMU

Aral Oil TU 518

British Petroleum Co.

BP Energol

TH 100-HB

Calypsol Oil Co.

Calypsol Bison Oil

SR 25 or SR 36

Standard Oil Co.

Chevron

Hydraulic Oil 11

Circulating oil 45

Esso Corp

Esso-Mar 25

Teresso 47

Esstic 50

Fina Oil Co.

Fina hydran 34

Fina Cirkan 32

Gulf Refining Co.

Gulf Harmony 47

Gulf Paramount 45

Socony Mobil Oil Co.

Vac hlp 25

Mobulix D.T.E. 25

Shell Oil Co. Shell Tellus oil 29

Sundco Oil Co. Sunvis 821

The Texas Co.

Texaco ursa oil P 20

Dea viscobil sera 4

Oil level

13

English (US)

8.3 Disassembling the pump

8.3.1 Preparations before disassembling the pump

Complete disassembly instructions are outlined below. Proceed

only as far as required to perform the maintenance work needed.

1. Switch off the power supply.

2. Drain the system.

3. Flush the system, if necessary.

4. For closed coupled units: Remove the motor fixation bolts.

8.3.2 Disassembling the liquid end

1. Remove the pump housing screws (8B).

2. Remove the back pull-out bearing frame (20Y) from the pump

housing (1A).

3. Remove the impeller screw (8A).If necessary, use a strap

wrench around the impeller or shaft to prevent rotation.

4. Use an appropriately sized puller aligned behind the impeller

vanes to remove the impeller (3A) from the shaft (6A).

5. Remove the impeller key (12A).

6. Remove the back plate screws (8D). Remove the back plate

(2K) and the seal housing (26P).

7. Place the seal housing on a flat surface and press out the

shaft seal (14A).

8. If the shaft sleeve (5A) requires replacement, heat it evenly to

approximately 350 °F (176 °C) to loosen the thread-locking

fluid. Twist the sleeve off the shaft (6A).

8.3.3 Disassembling the bearing frame (LFE)

1. Remove the slinger (13G).

2. Remove the lip seal(s) (14S), if any.

3. Remove the bearing housing locking ring (61K).

4. Press or tap on the pump end of the bearing-shaft assembly

until one bearing is out.

5. When one bearing is out, remove the second locking ring

(61F), then remove the complete bearing-shaft assembly from

the bearing housing.

6. Remove the shaft locking ring (61C) and press off the

bearings.

7. Press new bearings onto the shaft; remember to press only on

the inner race of the bearings while pressing them on.

8. Assemble the bearing frame in the reverse procedure used for

disassembling.

9. Observe the following when reassembling the bearing frame.

– Replace the lip seals (14S) if they are worn or damaged.

– Replace the bearings (18A) and (18B) if they are loose,

rough or noisy when rotated.

– Check the shaft (6A) for shaft runout at the sleeve (5A) area.

Maximum permissible runout is 0.002 in. (0.0508 mm) total

indicator runout.

DANGER

Electric shock

Death or serious personal injury

- Before starting any work on the product, be sure

the power supply has been switched off and that it

cannot be accidentally switched on.

CAUTION

Toxic material

Minor or moderate personal injury.

- Wash down the pump before doing any work on it.

DANGER

Hot, caustic, flammable or toxic materials,

including vapors

Death or serious personal injury

- Be extremely cautious when venting and/or

draining hazardous liquids.

- Wear protective clothing when there are caustic,

corrosive, volatile, flammable, or hot liquids.

- DO NOT breathe toxic vapors.

- DO NOT allow sparks, open fire, or hot surfaces

near the equipment.

WARNING

Moving machine parts

Death or serious personal injury

- Do not insert a screwdriver between the impeller

vanes to prevent rotation.

English (US)

14

8.4 Replacing the shaft seal (LCSE pumps)

1. Complete preparations listed in section 8.3 Disassembling the

pump.

2. Remove the coupling guard screws (8E).

3. Remove the coupling guard (34F).

4. Remove the nut (35E) and the bolt (8E) that hold the coupling

halves together.

5. Pry apart the coupling halves (23D), remove the coupling key

(12B).

6. For pumps with lubrication lines, unscrew the tubing

connector from the pipe tee of the air vent assembly. Thread

sealing compound was applied to the threads during factory

assembly, and the resulting bond may retard but will not

prevent manual disassembling.

7. Remove the seal housing cap screws and slide the seal

housing (2N) up the shaft to remove it.

8. Remove the shaft seal (14A) manually from the shaft (6A).

Apply water-soluble lubricant to the shaft, if necessary, to

ease the removal of the shaft seal. Pull the seal head

assembly manually from the shaft, using a slight twisting

motion (as necessary) to loosen bellows from shaft.

9. Remove and discard the shaft seal spring and the shaft seal

retainer.

10. Remove and discard the shaft seal seat from the seal housing

(2N) and thoroughly clean the inside cavity of the seal

housing.

11. The interior surface of the bellows on a new shaft seal is

coated with a bonding agent that adheres to the motor shaft.

When the old shaft seal is removed, the bonding agent no

longer exists and the bellows may crack or split during

removal. We always recommend that you install a new

mechanical shaft seal if it becomes necessary to remove the

existing shaft seal from the shaft.

12. Clean and lubricate the shaft (6A) with a water-soluble

lubricant and make sure no sharp edges can cut or scratch

the bellows of the new shaft seal.

13. Press the new shaft seal seat firmly into the seal housing.

Avoid direct contact between the seal face and metallic or

abrasive objects, and wipe the seal face clean after

installation to ensure an abrasive-free sealing surface.

14. Slide the new shaft seal (14A) onto the shaft by applying even

pressure to the shaft seal.

15. Install the shaft seal housing (2N) on the shaft.

16. See the reassembly instructions in section 8.6 Reassembling

the pump.

8.5 Replacing the wear ring

1. Complete preparations in sections 8.3.1 Preparations before

disassembling the pump and 8.3.2 Disassembling the liquid

end.

2. Remove the rotating assembly.

3. Remove the pump housing (1A) from the pipes, if necessary,

to facilitate easy access to the interior of the pump housing. If

necessary, remove the flange bolts at the pipes.

4. Remove a worn wear ring (4A) by drilling two holes slightly

smaller than the width of the wear ring into the exposed edge

of the wear ring. Insert a chisel into the holes to completely

sever the wear ring at the holes and break the wear ring into

two halves for easy removal.

5. Clean the wear ring cavity in the pump housing prior to

installing a new wear ring to ensure a properly aligned fit.

6. To reassemble, press fit the new wear ring squarely into the

pump housing cavity. Tap the wear ring into place to make

sure it is pressed home into the cavity.

8.6 Reassembling the pump

1. Clean all parts before reassembly.

2. Refer to the parts list to identify required replacement items.

3. Specify the pump serial or catalog number when ordering

parts.

4. Reassemble the pump in the reverse procedure used for

disassembling.

5. Observe the following when reassembling the pump:

– All mechanical seal components must be in good condition

or leakage may result. We recommend that you replace the

complete shaft seal.

– Install new shaft sleeves by bonding them to the shaft with a

thread-locking fluid.

6. Re-install the coupling guards on coupled pumps.

Mark or measure the original position of the pump

coupling on the motor side.

Do not use metal tools on the wear ring surfaces.

Use only rubber, rawhide, wood or other soft

material to prevent damage to the wear ring.

WARNING

Moving machine parts

Death or serious personal injury

- Reinstall approved coupling guards and make sure

they are in place prior to operation.

15

English (US)

8.7 LFE, exploded view and parts list

* If applicable

TM06 6570 1816

Pos. Description Pos. Description Pos. Description

1A Pump housing 11F Gasket 20A Base plate

2K Backplate 12A Key 20Y Bearing frame

3A Impeller 12B Key 23A Coupling hub

4A Wear ring 13G Slinger 26P Seal housing

4F* Balance wear ring 14A Shaft seal 34A Coupling guard

5A Shaft sleeve 14S Lip seal 61C Locking ring

6A Shaft 16A Drain plug 61F Locking ring

8D Cap screw 18A Bearing, inboard 61K Locking ring

10A Washer 18B Bearing, outboard 65A Motor

11A Gasket

English (US)

16

8.8 LCSE, exploded view and parts list

TM06 4401 2215

Pos. Description Pos. Description

1A Pump housing 15A Locating ring

2N Shaft seal housing 16A Drain plug

3A Impeller 17E O-ring

4A Wear ring 20A+20B Base plate rails

4F Balance wear ring 20C Base plate

6A Pump shaft 20D Pump support

8B Cap screw 21A Motor stool

8C Screw 22A Stud

8D Screw 23D Coupling halves

8E Bolt 24H Bushing

8F Screw 34A Washer

8G Screw 34B Washer

8H Cap screw 34C Washer

8I Cap screw 34D Washer

8J Screw 34E Washer

8N Screw 34F Coupling guard

11A Gasket 35E Nut

12A Key 35F Nut

12B Key 65A Motor

14A Shaft seal

17

English (US)

9. Taking the product out of operation

The following shutdown procedures will apply for the L pumps in

most normal shutdown situations. If the pump will be inoperative

for a long time, follow the storage procedures in section 9.3 Long-

term shutdown.

9.1 General procedure

• Always close the outlet gate valve before stopping the pump.

Close the valve slowly to prevent hydraulic shock.

• Disconnect and lock off the power to the motor.

9.2 Short-term shutdown

• For overnight or temporary shutdown periods under non-

freezing conditions, the pump may remain filled with liquid.

Make sure the pump is fully primed before restarting.

• For short or frequent shutdown periods under freezing

conditions, keep the liquid moving within the pump housing

and insulate or heat the pump exterior to prevent freezing.

9.3 Long-term shutdown

• For long shutdown periods, or to isolate the pump for

maintenance, close the inlet gate valve. If no inlet valve is

used and the pump has positive inlet pressure, drain all liquid

from the inlet line to stop the liquid flow into the pump inlet.

Remove the plugs in the pump drain and vent holes, as

required, and drain all liquid from the pump housing.

• If there will be freezing conditions during long shutdown

periods, completely drain the pump and blow out all liquid

passages and pockets with compressed air. Freezing of the

pumped liquid can also be prevented by filling the pump with

antifreeze solution.

English (US)

18

10. Fault finding

DANGER

Electric shock

Death or serious personal injury

- Before starting any work on the product, be sure

the power supply has been switched off and that it

cannot be accidentally switched on.

CAUTION

Toxic material

Minor or moderate personal injury.

- Wash down the pump before doing any work on it.

DANGER

Hot, caustic, flammable or toxic materials,

including vapors

Death or serious personal injury

- Be extremely cautious when venting and/or

draining hazardous liquids.

- Wear protective clothing when there are caustic,

corrosive, volatile, flammable, or hot liquids.

- DO NOT breathe toxic vapors.

- DO NOT allow sparks, open fire, or hot surfaces

near the equipment.

Fault Cause Remedy

1. Outlet pressure is too low. a) The speed of rotation is too low. Reestablish correct speed and direction of

rotation.

b) The system pressure is lower than

anticipated.

Check the system curve.

c) There is air or gas in the pumped liquid. Remove the air from the pumped liquid.

d) The wear rings are worn. Replace the wear rings.

e) The impeller is damaged. Repair or replace the impeller.

f) The impeller diameter is too small. Replace the impeller with one of the correct

diameter.

g) Wrong direction of rotation. Interchange two wires in the power supply.

h) The pump has lost its prime. Re-prime the pump.

i) There is insufficient NPSH. Restore required NPSH.

j) Passages are restricted. Clean the impeller and pump housing

passages.

k) Joints or the stuffing box are leaking. • Tighten the joints or the stuffing box gland.

• Replace the shaft sleeve.

• Replace the gaskets.

2. Insufficient inlet pressure. a) The inlet line is drawing air. Tighten the connections.

b) The suction lift is too high or there is

insufficient NPSH.

Reduce the suction lift or restore required

NPSH.

c) Air or gas is trapped in the pumped liquid. Remove the trapped air/gas from liquid.

d) The strainer is clogged. Clean the strainer.

3. Noise level has increased. a) Poor alignment of the pump.

Inlet and outlet pipe clamps are loose.

• Ensure proper alignment of the pump and

the motor.

• Support the inlet and outlet pipes.

• Make sure the vibration dampers, flexible

pipes, and conduit connectors are installed

correctly.

b) Cracked foundation. Repair the foundation.

c) Worn ball bearings. • Replace the worn bearings.

• Renew the lubrication.

d) The motor is unbalanced. • Disconnect the motor and operate it alone.

• Remove large pieces of debris, such as

wood or rags from the pump.

• Clean out the pump, if necessary.

e) Hydraulic resonance. • Alter the resonant pipes.

• Change the pump speed.

• Insert a pulsation damper on the pump or the

pipes.

• Insert a flow straightener.

19

English (US)

4. Insufficient flow. a) The pump is not primed. Prime the pump.

b) The system pressure exceeds the shut off

pressure.

• Increase the liquid level on the inlet side.

• Open the isolating valve in the inlet pipe.

c) The rotation speed is too low. Reestablish the correct speed of rotation.

d) The suction lift is too high or there is

insufficient NPSH.

Reduce the suction lift or restore required

NPSH.

e) The strainer or impeller is clogged. Clean the strainer and impeller passages.

f) Wrong direction of rotation. Reestablish the correct direction of rotation.

g) Leaking joints. Tighten the joints.

h) Broken shafting or coupling. Repair or replace damaged parts.

i) Closed inlet valve. If the inlet valve is closed, open it slowly.

j) There is not enough inlet pressure for hot

or volatile liquids.

Reestablish required inlet pressure.

k) Foot valve is too small. Replace the foot valve.

l) Worn or damaged hydraulic parts. Repair or replace the worn parts.

m) Excessive clearance between the wear

surfaces.

See section 8.5 Replacing the wear ring.

5. Pump loses its prime after

starting.

a) Joints or the stuffing box are leaking. • Tighten the joints or the stuffing box gland.

• Replace the shaft sleeve.

• Replace the gaskets.

b) The suction lift is too high or there is

insufficient NPSH.

Reduce the suction lift or restore required

NPSH.

6. Excessive power required. a) The speed of rotation is too high. Reduce the speed of rotation.

b) The pump is operating beyond its

recommended performance range.

Set the duty point in accordance with the

recommended performance range.

c) The specific gravity or the viscosity of the

pumped liquid is too high.

If less flow is sufficient, reduce the flow on the

outlet side, or fit the pump with a more powerful

motor.

d) The shaft is bent. Replace the shaft.

e) Stuffing-boxes too tight. Retighten the stuffing box if possible.

Alternatively, repair or replace the stuffing box.

f) Impeller clearances are too small causing

rubbing or worn wear surfaces.

Adjust the impeller clearance, if possible, or

replace the wear ring.

g) There is an electrical or mechanical defect

in the motor.

Contact your local service center for

diagnostics.

h) The pump is restricted in its rotation. Remove any obstacles or replace any worn

parts.

i) Incorrect lubrication of the motor. Reestablish correct lubrication of the motor.

Fault Cause Remedy

English (US)

20

11. PACO MLE motors

Grundfos E-pumps have standard motors with integrated variable

frequency drive. The pumps are for a single-phase or three-phase

power supply connection.

11.1 Pumps without factory-fitted sensor

The pumps have a built-in PI controller and can be set up for an

external sensor enabling control of the following parameters:

• pressure

• differential pressure

• temperature

• differential temperature

•flow rate

• liquid level in a tank.

From the factory, the pumps have been set to control mode

uncontrolled. The PI controller can be activated by means of the

Grundfos GO Remote or R100.

11.2 Pumps with pressure sensor

The pumps have a built-in PI controller and are set up with a

pressure sensor enabling control of the pump outlet pressure.

The pumps are set to control mode controlled. The pumps are

typically used to hold a constant pressure in variable-demand

systems or differential pressure in closed-loop applications.

11.3 Settings

The description of settings apply both to pumps without factory-

fitted sensor and to pumps with a factory-fitted pressure sensor.

Setpoint

The desired setpoint can be set in three different ways:

• directly on the pump control panel

• via an input for external setpoint signal

• by means of the Grundfos GO remote or wireless remote

control.

Other settings

All other settings can only be made by means of the Grundfos GO

Remote or R100.

Important parameters such as actual value of control parameter,

power consumption, etc. can be read via the Grundfos GO

remote or R100.

If special or customized settings are required, use Grundfos PC

Tool E-products. Contact Grundfos for more information.

12. Installing the motor

The pump must be secured to a firm, raised concrete foundation

by means of bolts through the holes in the flange or baseplate.

12.1 Motor cooling

To ensure sufficient cooling of motor and electronics, observe the

following requirements:

• Make sure that sufficient cooling air is available.

• Keep the temperature of the cooling air below 104 °F (40 °C).

• Keep cooling fins and fan blades clean.

12.2 Outdoor installation

When installed outdoors, the pump must be provided with a

suitable cover to avoid condensation on the electronic

components. See fig. 8.

Fig. 8 Examples of covers

Remove the drain plug pointing downwards in order to avoid

moisture and water build-up inside the motor.

Vertically mounted pumps are IP55 after removal of the drain

plug. Horizontally mounted pumps change enclosure class to

IP54.

In order to retain the UL/cUL approval, follow the

additional installation procedures on page 54.

TM00 8622 0101 - TM02 8514 0304

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