Grundfos LFE Installation And Operating Instructions Manual

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Installation And Operating Instructions Manual

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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 Polytac
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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Grundfos LFE Installation And Operating Instructions Manual

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