(070)Pumps manual.pdf

FRV40-226-070-010

DESCRIPTION, OPERATION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

Pumps Manual Model: Various

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

50-SPNA-1-00031

PUBLISHED BY DIRECTION OF NOAA

FRV40-226-070-010

DESCRIPTION, OPERATION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

Model: Various

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

PUBLISHED BY DIRECTION OF NOAA

09 MAR 2007

RECORD OF CHANGES

Change No.

Date Title and/or Brief Description Signature of Validating Officer

APPROVAL AND PROCUREMENT RECORD PAGE

APPROVAL DATA FOR: FRV40-226-070-010

TITLE OF MANUAL: Pumps Manual

APPROVAL AUTHORITY: NOAA

Contract Ship Qty Of Building Number Applicability Manuals Yard

50-SPNA-1-00031 FRV40-226 2 EA Halter Marine Inc.

REMARKS:

CERTIFICATION: It is hereby certified that FRV40-226-070-010 to be provided under contract 50-SPNA- 1-00031 has been approved by the approval data shown above.

Date:________________ Chand. LLC Mathews, LA

CAGE CODE: 0D5X4

VALIDATION PERFORMANCE

Title of Publication

Contractor Sub-Contractor(If Performing Validation)

Halter Marine Inc.

Contract No. (s) and Purchase Orders, If Applicable

Chapter Section Paragraph Date Check here if Validation Not validated Completed

Contents of this manual have been validated and certified to be applicable to the equipment furnished under the above procurement as specified for Validation.

Name & Authority of Validating Officer: Signature of Validating Officer:

FOREWORD

This manual is intended to clearly and accurately reflect the actual configuration of the installed equipment described for the FRV40-225 Pumps. Users are urged to report instances noted wherein the manual does not achieve this objective.

This technical manual provides the instructions necessary to operate, to perform maintenance on and troubleshooting of the Pumps. The text is broken down as follows:

Section 1- Potable Water Pump Section 2- Hot Water Circulation Pump Section 3- Chilled Water Circulation Pump Section 4- Oily Waste Transfer Pump, Waste Oil Circulation Pump and Lube Oil Transfer Pump Section 5- Dedicated Fire Pump and Fire/Bilge/Ballast Pumps Section 6- Fuel Oil Transfer Pump Section 7- Seawater Wash Down; Seawater Cooling; and Auxiliary Seawater Cooling Pumps Section 8- Egg Sampling Pump Section 9- Scientific Seawater Pump Section 10- General Pump Information Section 11- General Motor Information

DanLe Section 12 - Potable Water Pressure Tank (Clayton Mark)

DanLe Section 13 - Lube Oil Hand Pump (Blackmer)

SECTION 1

POTABLE WATER PUMP

AMPCO MODEL KC2 (1-1/4 X 1 X 5.5)

WITH EMERSON MODEL H574 ELECTRIC MOTOR

POTABLE WATER PUMP DETAILS

The Potable Water pumps provided for the FSV40/R224 are Ampco Pumps Model KC2 (1-1/4 X 1 X 5.5) constructed of bronze, operating under the following parameters: 27 gpm @ 120tdh, 2hp@ 3500 rpm.

The pumps are driven by Emerson Motor Company electric motors model H574 (Part Number 897848-00) operating at 2 hp, 575 volt, 3 phase power. The motor is totally enclosed fan cooled (TEFC), marine duty. A 120 volt space heater is provided with the closed coupled unit. Detailed motor nameplate data is provided on the pages that follow.

Further documentation (i.e., pump data sheets, performance curves, maintenance instructions) is supplied within this section to further describe the equipment provided.

Ampco Centrifugal

Pumps Data Sheet

Model KC2 11/4 x1

M A T E R I A L S P E C I F I C A T I O N S

WEIGHT APPROX.

WEIGHT

HP

1/2

1-1/2

FRAME

56J

56J

56J

56J

56J

(LBS)

PART NAME NICKEL ALUMINUM BRONZE STAINLESS STEEL

Casing AMPCO® 483 316 Stainless Cover AMPCO® 483 316 Stainless

Impeller AMPCO® 483 316 Stainless Bracket Steel Steel

KC2 1.25x14/99 6/7/02 10:00 AM Page 1

Potable Water Pump

Pumps

Ampco Pumps

Company 4424 West Mitchell Street

Milwaukee, Wisconsin 53214

PHONE (414) 643-1852

FAX (414) 643-4452

Model KC2 11/4 x1

KC2 1.25X1 4/99

Curves show approximate characteristics based on clear 68° water.

Rated point is guaranteed.

Standard K Series pumps have threaded NPT connections and are mounted on 56J frame motors.

Seal options include Type 21 and Type 9 with choice of sealing materials.

KC2 1.25x14/99 6/7/02 10:00 AM Page 2

Potable Water Pump

I N S T A L L A T I O N A N D M A I N T E N A N C E O F AMP C O C E N T R I F U G A L P U MPS

INSTRUCTIONS

The care required of this pump, while nominal, is very impor-tant. We recommend a careful review of the installation and maintenance covered in this instructional pamphlet to ensure extended trouble-free service.

LOCATION

The motors used on Ampco pump units have been selected as the best for the anticipated environment. For greatest service life, mount the pump and motor where the environment is rela-tivity clean, dry, and non-corrosive. Standard totally enclosed motors may be installed where dirt, moisture and mild corro-sion are present or in outdoor locations. Specialty motors may be required for moist, corrosive, or explosive environments.

Motor drain plugs (if not equipped with automatic drains) must be removed periodically to drain accumulated condensation.

Pump units should be located where daily visual inspection is possible and no surrounding structure interferes with ventilat-ing air over or through the motor.

KC2/KP2 PUMPS

INSTALLATION

Installation of Ampco pumps should be made as close to the supply of liquid as possible, with short and direct suction pip-ing. Avoid high points in the piping where air pockets can form. The suction and discharge piping should be simple with the connections properly aligned to prevent any strain from being placed on the pump casing. Provisions should be made for pipe expansion and contraction in services handling hot or cold liquids. Base-mounted pedestal pumps must be realigned AFTER installation and piping is completed.

ROTATION

Check direction of rotation BEFORE starting the pump.

Correct rotation is counter clockwise as viewed from the pump inlet. Incorrect rotation may cause catastrophic failure. Close coupled pumps will be equipped with single phase motors properly sequenced or with three phase motors labeled to indi-cate required power sequence ABC or CBA for correct rotation.

Use a phase sequence indicator to identify power source sequence. For base mounted pumps disconnect the coupling and check motor rotation while disconnected from the pump.

MAINTENANCE

Daily observation of Ampco pumps while in operation is the ounce of prevention needed to extend the service life.

Mechanical seals are selected for maximum life with due con-sideration to the economy of the installation. The seal is the only expendable item. Other pump parts are designed for indefinite life expectancy, except as they may be corroded and/or eroded by aggressive products or by misapplication such as undersizing, oversizing, cavitation, etc. Bearings on some pedestal pumps and some motors are prelubricated and require no additional lubrication. Schedule for regreasing other types of bearings will vary, depending on size speed, duty, and environment. For guidance, a steady running, indoor installa-tion in a relatively clean atmosphere at 40C (104F) ambient should not require grease for two years. Care should also be taken not to over grease motors. Pumps handling corrosive or otherwise aggressive solutions should be flushed with clean water after each use because stagnant conditions are usually most corrosive. In seawater, Ampco Alloy pumps provide cathode protection for stainless steel parts. To prevent crevice corrosion and pitting, drain and then flush out the pump with fresh water when inactive for periods greater then one week.

Ampco KC2 and KP2 pumps fitted with standard mechanical seals have all-metal seal parts of 316 stainless steel, carbon rotating face, ceramic stationary seat, and Buna-N elastomers.

Other seal types are supplied when specified. Optional materi-als such as Viton, EPDM, or Teflon elastomers, Tungsten Carbide, Silicon Carbide, or Ni-Resist faces can be supplied when requested. The mechanical seal should be replaced at the first sign of leakage where the shaft enters the pump. Leakage may cause motor bearing damage. Also, since the primary seal surfaces are lapped to precise flatness, the seal should be replaced whenever the pump is dismantled to the point of sepa-rating the seal faces. Always keep a replacement seal kit on hand. It includes a complete seal along with the gasket and o-ring required to rebuild the pump.

There may be other pump assemblies, parts and seal arrange-ments not shown or otherwise described in this pamphlet, that require the same philosophy of seal positioning. It is suggested that highlights of these instructions be applied while paying close attention to parts arrangement during dismantling.

Service

DWUNTLC AND REPLACE PARTS KB FOLLOWS:

attempting any service on the pump or motor, discon-nect or lock out electrical power to tne pump motor. If the pump and motor are to be removed as a unit, note the wiring configuration, Use colored or numbered tape to mark the wire connections of the motor and power source, to retain correct direction of rotation when reconnecting. Incorrect rotation may cause catastrophic failure.

It is recommend that the complete unit be removed and ser-viced on a workbench. For the close-coupled KC2 disconnect the power marking the wires for reconnection. For the base mounted KP2, disengage the coupling and remove the pump and pedestal.

1. Remove the suction cover by unbolting the four capscrews (9/16 wrench). Note the condition of the gasket, which will adhere either to the suction cover or the casing.

2. Unscrew the impeller from the shaft, turning in a counter-clockwise direction. Loctite used during assembly may require heating impellers of all type KC2 and KP2 to assist in removal. Apply approximately 350F heat to the center of the impeller. A screwdriver slot on the motor shaft oppo-site the pump is provided for steadying the shaft. Use of a

(' strap wrench on the impeller hub is recommended to pre-vent marring. Otherwise, file or polish out wrench marks before reusing impeller.

The fluid end of the pump is now sufficiently dismantled for completing most repairs and replacements, including the mechanical seal.

3. If it is necessary to repair or replace the motor of a close coupled assembly or the bearing adapter of a pedestal assembly, unbolt the capscrews fastening the pump to motor or pedestal, thus disengaging the casing and bracket.

The mechanical seal is the only expendable pump part. It is suggested that the complete mechanical seal, both stationary and rotating members, be replaced whenever dripping or leakage occurs at the shaft, or whenever parts are removed to the point of separating the primary sealing surfaces.

4. Remove the rotating parts of the mechanical seal from the impellers shaft like extension (see drawing). The seals flexi-ble bellows may stick tightly to the impeller stem. Bathe in oil to soften the adhesive, or cut away with knife. Remove the o-ring from the shaft I.D.

5. The stationary seat and its cup gasket or o-ring may be removed while the casing is in an assembled position with a wire hook (coat hanger wire). Insert the hook between the I.D. of the seat and the shaft and pull forward, or remove the casing and press out the seat.

6. Thoroughly clean impeller stem, seat cavity and motor shaft with solvent and dry with a clean cloth.

An anti-seize lubricant was originally applied to the I.D. of the impeller that fits over the shaft and is retained by an o-ring.

Either preserve this lubricant or add fresh lubricant to the I.D., not the shaft, and replace the o-ring. One drop of oil applied on the shaft will prevent the o-ring from binding on the shaft while assembling the impeller.

7. Lightly oil bore and finger press stationary seat with gasket or o-ring into its cavity. Seat (usually ceramic) is fragile. Do not abuse.

8. Clean the polished face of the stationary seat with a lint-free cloth or tissue, and lightly coat this surface with an SAE-10 or equivalent oil. Care should be taken that the cleansing material and the oil are free of foreign particles. Do not use grease or allow grease onto the sealing surfaces.

9. Place the rotating portion of the mechanical seal on the shaft like extension of the impeller that may be lightly oiled (SAE 10W-30) to facilitate sliding of the bellow by softening an adhesive film on the seal (Use soap, glycerin, etc. if oil is not permitted i.e. EPDM). Do not use grease, as this would pre-vent the adhesive film from resetting. Final adherence to the impeller stem is essential for shaft, impeller, and seal to rotate as a unit. First place the spring retainer and spring over the impeller shaft. Then press the carbon rotating sub-assembly down the impeller shaft until it engages the spring. Do not continue to slide the assembly down the shaft once the rotating assembly has engaged the spring.

Inspect the carbon sealing face and remove any foreign par-ticles with a lint-free cloth or tissue. Do not allow grease on the sealing surfaces.

10. Place the impeller with mechanical seal in place on the drive shaft. A slight extra push is required to start the o-ring onto the shaft. Proceed to screw the impeller clockwise onto the treaded shaft, utilizing the slot on the opposite end of the shaft to steady the shaft. Hand tighten or use a strap wrench, or other non-marring device such as a jar opener.

11. The pump assembly is completed by reinstalling the suction cover plate and its gasket. Be sure casing and gasket sur-faces are relativity clean and free of foreign particles.

12. Your pump is now ready to be reinstalled into its accompa-nying pipe system and the motor reconnected.

One way to damage a new seal is to run it dry. Be sure the pump is in place and primed before operating or checking rotation.

NOTE: Starting motor in direction of unthreading impeller will result in jamming and damaging bearing and possibly other motor and pump parts. Motor connections should have been marked to avoid this possibility. Also, an economical phase sequence indicator win identify your A-B-C connections. If a reassembled pump unit is not going to be put back in service immediately, or if there is a real possibility for incorrect start up rotation, a suitable thread-locking compound may be used (i.e.

Loctite #271).

I N S T A L L A T I O N A N D M A I N T E N A N C E O F A M P C O C E N T R I F U G A L P U M P S

DanLe

DWUNTLC AND REPLACE PARTS KB FOLLOWS:

DISMANTLE AND REPLACE PARTS AS FOLLOWS:

Single Mechanical Seal T-21

I N S T A L L A T I O N A N D M A I N T E N A N C E O F AMPCO C E N T R I F U G A L PUMPS

Troubleshooting and Applications

COMMON TROUBLES AND THEIR CAUSES

It is to the users advantage to be familiar with a systematic pro-cedure to determine reasons and causes for unsatisfactory pump operation. The following list of troubles and causes is intended to assist users in determining the cause of any pump-ing trouble. Faulty installations can then be corrected and a clear description given the manufacturer if assistance is required. Human judgment should not be relied on to measure operating conditions. Use proper instruments to measure val-ues of pressure, suction lift, speeds, temperature rise of motors, etc. When motor speeds are incorrect, check connections and measure voltage at motor terminals.

1. No liquid delivered

a. Pump and suction line not completely primed

b. Speed too low

c. Required discharge too high

d. Suction lift too high

e. Impeller, piping, or fittings completely plugged up

f. Wrong direction of rotation

2. Not sufficient capacity

a. Air leaks in suction pipe or shaft seal

b. Speed too low

c. Required discharge head too high

d. Suction lift too high or insufficient NPSH available

e. Impeller, piping, or fittings partially plugged

f. Insufficient positive suction head for hot water or other volatile liquids

g. Liquid viscosity too high

h. Mechanical problems - wear rings worn, impeller damaged, shaft seal defective

i. Wrong direction of rotation

j. Suction pipe entrance too close to surface of liquid

k. Air pockets in pipe high points

3. Not sufficient pressure

a. Speed too low

b. Mechanical problems - wear rings worn, impeller dam aged, shaft seal defective

c. Small impeller diameter

d. Air or gas in liquid

e. Wrong direction of rotation

f. Air pockets in pipe high points

4. Pump operates for a while, then quits

a. Leaky suction line

b. Air leaking in through shaft seal

c. Suction lift too high or insufficient NPSH available

d. Air or gas in liquid

e. Suction piping and fittings not completely freed of air during priming

f. Air pockets in pipe high points

5. Pump takes too much power

a. Speed too high

b. Pumping too much water because required head is lower than anticipated

c. Viscosity and/or specific gravity is higher than specified

d. Mechanical problems - binding at wear rings from distortion due to piping strains, shaft bent, impeller rubbing casing, stuffing box too tight

e. Wrong direction of rotation

SOME TYPICAL APPLICATIONS

Your Ampco Pump was selected for a specific service. Other Ampco pump styles are available to successfully handle many additional applications including the following partial list. Ask you Ampco representative for complete information.

abrasive slurries mineral water activated carbon filter slurries molasses acetone alum solution amide solution anodizing solutions beer beer filter slurry (diatomaceous earth) brine solutions cane juice carbon suspension carbon tetrachloride caustic chromic acid cleaning solutions dye deionized water ethylene glycol fatty acid fermentation gas formaldehyde glycerin hydrofluosilicic acid hydrofluoric acid lard oil and fatty acid luminescent solutions marine sanitary service marine water desalting equipment nitric acid oleic acid phosphoric acid plating solutions potassium acetate polyethyl benzene salt water (oil field) sludge fuel sodium chloride sodium fluoride sodium hydroxide solvent spin bath solution (rayon) starch sugar liquor stillage with solids sulfuric acid tall oil tea vinegar vegetable oil vinyl liquor water solutions (corrosive and/or abrasive) whey wort (beer and molasses) yeast cream

Consult Ampco for applications not listed.

AMPCO PUMPS

4424 W. Mitchell Street

Milwaukee, Wisconsin 53214

(414) 643-1852 Telephone • (414) 643-4452 Fax www.ampcopumps.com

I N S T A L L A T I O N A N D M A I N T E N A N C E O F A M P C O C E N T R I F U G A L P U M P S

K-MAN 8/00

U.S. Electrical Motors Installation and Maintenance Manual

SAFETY FIRST

High voltage and rotating parts can cause serious or fatal injury. Safe installation, operation, and maintenance must be performed by qualified personnel. Familiariza-tion with and adherence to NEMA MG2, the National Electrical Code (NEC) and local codes is required. It is important to observe safety precautions to protect personnel from possible injury. Personnel should be instructed to:

1. Be familiar with the equipment and read all instructions thoroughly before installing or working on equipment.

2. Avoid contact with energized circuits or rotating parts.

3. Disconnect all power sources before initiating any maintenance or repair.

4. Act with care in accordance with prescribed procedures in handling and lifting this equipment.

5. Be sure unit is electrically grounded in accordance with code requirements.

6. Be sure equipment is properly enclosed or protected to prevent access by children or other unauthorized personnel in order to prevent possible accidents.

7. Be sure shaft key is fully captive before unit is energized.

8. Avoid contact with capacitors until safe discharge procedures have been completed.

9. Provide proper guarding for personnel against rotating parts and applications involving high inertia loads which can cause overspeed.

10. Avoid extended exposure to equipment with high noise levels.

INSPECTION AND HANDLING

Inspect unit to make sure no damage has occurred during shipment. Check nameplate for correct speed, horsepower, voltage, Hertz, and phase for conformance with power supply and equipment. WARNING: Units should be lifted using all eyebolts or lugs if provided. These eyebolts or lugs are provided for lifting this unit only and must not be used to lift any additional weight. Lifting angle, from shank of eyebolt, must not exceed 30° for machines with single and 45° for machines with multiple lifting means. Replacement eyebolts must be per ASTM A489 or equivalent.

All eyebolts must be securely tightened. Be careful not to touch overhead power lines with lifting equipment. Failure to observe this warning may result in serious personal injury.

STORAGE

Units should be stored indoors, in a clean, dry location & winding should be protected from excessive moisture absorption. NOTE: If motors are to be stored for more than one year, refer to U.S. Electrical Motors. If gear and belt transmission units are to be stored for more than six months, refer to U.S. Electrical Motors.

LOCATION

WARNING: Use only UL Listed Hazardous Location Motors for service in Hazardous Locations as defined in Article 500 of the NEC. Units should be located in a clean, well-ventilated area. WARNING: Units should be located in a suitable enclosure to prevent access by children or other unauthorized personnel to prevent possible accidents.

INSTALLATION / MOUNTING

Mount units on a firm, flat surface sufficiently rigid to prevent vibration. Drive belts and chains should be tensioned in accordance with supplier recommendations.

Couplings should be properly aligned and balanced. For belt, chain and gear drive selection refer to the drive or equipment manufacturer. For application of drive equipment refer to applicable information in NEMA MG1.

Motors have been dynamically balanced using a half key the same length as the full key shipped with the motor. If pulley keyway length is less than this length, rework long key by removing one-half of excess length between pulley and end of key to maintain balance.

Do not restrict motor ventilation. Unless otherwise specified on nameplate, motor is designed for operation in accordance with NEMA MG1 “Usual Service Conditions” which states an ambient temperature range of -15°C to 40°C (5°F to 104°F). Stan-dard grease lubricated units are suitable for operation within this temperature range, special lubricants may be required for ambient temperatures outside of the range.

NOTE: Motors operating under rated load and allowable ambient conditions may feel hot when touched; this is normal and should not be cause for concern. When in doubt, measure frame surface temperature and confer with nearest office. Enclosed motors normally have condensation drain openings. Insure that drain openings are properly located and open (plugs removed) for the motor mounting position. Drain openings should be at the lowest point of end brackets, frame housing and terminal housing when the motor is installed. This may require modification of motor to accomplish. If unit appears wet, and/or has been stored in a damp location, dry out thoroughly and check for adequate insulation resistance to ground before operating.

WARNING: Guards should be provided for all exposed rotating parts to prevent possible personal injury. Keep fingers and foreign objects away from ventilation and other openings. Applications involving high inertia loads may damage equipment due to motor overspeed during coast shutdown. Such applications should be referred to U.S. Electrical Motors.

CAUTION: Do not force drive coupling or other equipment onto shaft, as bearing damage may result

POWER SUPPLY AND CONNECTIONS

The power supply must agree with values on nameplate. Terminal voltage should not vary more than ±10% of nameplate voltage at rated frequency. Unbalanced line voltage, greater than one percent, can cause overheating. Do not exceed the continuous rated load amperes on the nameplate. Starting controls and overload protection should be properly sized in accordance with the NEC and the control manufacturer’s recommendations.

Motor connections should be made by following instructions on connection diagram.

Determine direction of rotation before connecting driven equipment. If direction of rotation label is supplied, operate only in specified direction. Rotation may be reversed on three phase motors by interchanging any two line connections. On single phase motors, interchange leads per connection diagram on motor. Wiring of units, controls and grounding shall be in accordance with local and NEC requirements.

WARNING: Failure to properly ground unit may cause serious injury to personnel.

Where unexpected starting could be hazardous to personnel, do not use automatic reset starting devices.

USE OF VARIABLE FREQUENCY DRIVES

Electric motors can be detrimentally affected when applied with variable frequency drives (VFD’s). The non-sinusoidal waveforms of VFD’s have harmonic content which causes additional motor heating; and high voltage peaks and short rise times, which result in increased insulation stress, especially when long power cable lengths are used. Other effects of VFD’s on motor performance include reduced efficiency, increased load current, vibration and noise. Standard motors utilized with VFD’s must be limited to those application considerations defined in NEMA MG-1 Part 30.

NEMA MG-1 Part 31 defines performance and application considerations for Definite Purpose Inverter fed motors. To insure satisfactory performance and reliability, U.S.

Electrical Motors offers and recommends nameplated inverter duty motor products which meet the requirements of NEMA MG-1 Part 31. The use of non-inverter duty motors may result in unsatisfactory performance or premature failure, which may not be warrantable under the Terms and Conditions of Sale. Contact your U.S. Electrical Motors Field Sales Engineer for technical assistance for motor selection, applications and warranty details.

10 Pin Bendix Wiring Pin # Function

D +VDC

F COM

A A

B B

C Z

H A'

J B'

K Z'

E N/C

9 Pin Sub-D Wiring Pin # Function

1 +VDC

2 A

3 A'

4 B

5 B'

6 Z

7 Z'

8 N/C

9 COM

Vector Blower / Encoder Connection

OIL LUBRICATION

Most oil lubricated units are shipped without oil. Refer to instruction manual with unit for specific type and grade of oil to be used, change interval and level. If lubrication instructions specify synthetic oil, do not substitute. WARNING: For applications in the food and drug industry (including animal food), consult the petroleum supplier for lubricants that are acceptable to the Food & Drug Administration and other governing bodies.

MAINTENANCE

Inspect units at regular intervals. Keep units clean and ventilation openings clear of dust, dirt or other debris. Lubricate units per this operating instruction sheet and instruction plate on unit. Excessive lubrication may damage the unit. Do not over-grease. WARNING: Disconnect all power sources to the unit and discharge all parts which may retain an electrical charge before attempting any maintenance or repair. Screen and covers must be maintained in place when unit is in operation. Failure to observe this warning may result in personal injury.

U.L. Listed Motors For Use in Hazardous Locations: Repair of these motors must be made by the manufacturer or manufacturer’s authorized service station approved to repair U.L. Listed motors. The U.L. listing applies to the electric motor only and not to the belt or gear transmissions or other devices that may be connected to the motor.

GREASE LUBRICATION INSTRUCTIONS

Units are prelubricated at the factory and do not require initial lubrication. Relubricating interval depends upon speed, type of bearing and service. Refer to Table 1 for suggested regreasing intervals. Operating conditions may dictate more frequent lubrications. Motor must be at rest and electrical controls should be locked open to prevent energizing while motor is being serviced. (refer to section on Safety). If motor is removed from storage, refer to storage procedures.

To relubricate bearings, remove the drain plug. Inspect grease drain and remove any blockage with a mechanical probe taking care not to damage bearing. CAUTION: Under no circumstances should a mechanical probe be used while the motor is in operation. Add new grease at the grease inlet, refer to Table 1 for replenishment quantities. New grease must be compatible with grease in the motor (See Caution Note). Run the motor for 15 to 30 minutes with the drain plug removed to allow purging of any excess grease.

Shut off unit and replace the drain plug. Return motor to service. CAUTION: Overgreasing can cause excessive bearing temperatures, premature lubricant breakdown and bearing failure. Care should be exercised against overgreasing.

TABLE 1

Recommended Grease Replenishment Quantities & Intervals

(For Lubrication of Units in Service) Bearing Number - Common Bearing Number - AFBMAX Grease Lubrication Interval

62XX 63XX XXBC02 XXBC03 Fl. Oz. 3600 RPM 1800 RPM 1200 RPM 6203 - 6207 6303 - 6306 17 - 35 17 - 30 0.2 2 years 3 years 3 years 6208 - 6212 6307 - 6309 40 - 60 35 - 45 0.4 1 year 2 years 2 years 6213 - 6215 6310 - 6311 65 - 75 50 - 55 0.6 1 year 2 years 2 years 6216 - 6220 6312 - 6315 80 - 100 60 - 75 1.0 6 months 1 year 2 years 6221 - 6228 6316 - 6320 105 - 140 80 - 100 1.8 6 months 1 year 1 year

For motors mounted vertically or in hostile environments, reduce intervals shown by 50 percent.

Refer to motor nameplate for bearings provided on a specific motor. For bearings not listed in the table above, the amount of grease required may be calculated by the formula:

G = 0.11 x D x B where: G = Qty of grease in fluid ounces; D = Outside diameter of bearing (inches); B = Width of bearing (inches)

TABLE 2

Recommended Greases

THE FOLLOWING GREASES ARE INTERCHANGEABLE WITH THE GREASE AS PROVIDED IN UNITS SUPPLIED FROM FACTORY (unless stated otherwise on a lubrication nameplate provided on motor).

Manufacturer Grease (NLGI No. 2) Exxon Mobil Polyrex EM

Chevron USA Inc. SRI No. 2

CAUTION: Greases of different bases (lithium, polyurea, clay, etc.) may not be compatible when mixed. Mixing such greases can result in reduced lubricant life and premature bearing failure. When necessary, prevent such intermixing by disassembling the motor, removing all old grease from bearings and housings (including all grease fill and drain holes). Inspect and replace damaged bearings. Fill bearing housings and bearings approximately 30% full of new grease. Remove any excess grease extending beyond the edges of the bearing races and retainers. Refer to Table 2 for recommended greases.

RENEWAL PARTS & WARRANTY SERVICE

When inquiring for renewal parts, call the U.S. Electrical Motors Parts Department (Memphis, Tennessee) or a Parts Stocking Distributor. For warranty service call the nearest U.S. Motors Authorized Service Station. Give them complete nameplate data including ID number, etc. Request installation & maintenance manuals by product name.

©2000 U.S. Electrical Motors - Prices, specifications and ratings subject to change without notice. Printed in the U.S.A

REGIONAL OFFICES PHONE FAX

DOMESTIC U.S. SALES (888) 637-7333 (314) 553-1101

INTERNATIONAL SALES (314) 553-3185 (314) 553-2135

MONTREAL, QUEBEC/CANADA (800) 361-5509 (514) 332-5912

TORONTO, ONTARIO/CANADA (905) 475-4670 (905) 475-4672

IN109-34K 11/00

REGIONAL OFFICES PHONE FAX

MONTERREY, MEXICO (52) 8-389-1312 (52) 8-389-1310

CARACAS, VENEZUELA (58) 02-2377522 (58) 02-2329727

BOGOTA, COLOMBIA (57)1- 439-5420 (57)1- 439-5417

SECTION 2

HOT WATER CIRCULATION PUMPS

AMPCO MODEL KC2 (1 X 3/4 X 5)

WITH EMERSON MODEL H574 ELECTRIC MOTOR

HOT WATER CIRCULATING PUMP DETAILS

The Hot Water Circulating pumps provided for the FSV40/R224 are Ampco Pumps Model KC2 (1 X 3/4 X 5) constructed of nickel aluminum bronze, operating under the following parameters: 13.2 gpm @ 22tdh, 1/2hp@ 1750 rpm.

The pumps are driven by Emerson Motor Company electric motors model F009 (Part Number 391846-631) operating at 1/2 hp, 575 volt, 3 phase power. The motor is totally enclosed fan cooled (TEFC), marine duty. A 120 volt space heater is provided with the closed coupled unit. Detailed motor nameplate data is provided on the pages that follow.

Further documentation (i.e., pump data sheets, performance curves, Pumps Data Sheet

Model KC2 1x3/4 Nickel Aluminum Bronze

M A T E R I A L S P E C I F I C A T I O N S

WEIGHT APPROX.

WEIGHT

HP

1/2

3/4

FRAME

56J

56J

56J

56J

(LBS)

PART NAME NICKEL ALUMINUM BRONZE

Casing AMPCO® 483 Cover AMPCO® 483

Impeller AMPCO® 483 Bracket Steel

KC2 1x.75(NAB) 4/99 6/7/02 9:51 AM Page 1

Hot Water Circulation Pump

Pumps

Ampco Pumps

Company 4424 West Mitchell Street

Milwaukee, Wisconsin 53214

PHONE (414) 643-1852

FAX (414) 643-4452

Model KC2 1x3/4 Nickel Aluminum Bronze

KC2 1x.75 (NAB) 4/99

Curves show approximate characteristics based on clear 68° water.

Rated point is guaranteed.

Standard K Series pumps have threaded NPT connections and are mounted on 56J frame motors.

Seal options include Type 21 and Type 9 with choice of sealing materials.

KC2 1x.75(NAB) 4/99 6/7/02 9:51 AM Page 2

Hot Water Circulation Pump

I N S T A L L A T I O N A N D M A I N T E N A N C E O F A M P C O C E N T R I F U G A L P U MPS

INSTRUCTIONS

The care required of this pump, while nominal, is very impor-tant. We recommend a careful review of the installation and maintenance covered in this instructional pamphlet to ensure extended trouble-free service.

LOCATION

The motors used on Ampco pump units have been selected as the best for the anticipated environment. For greatest service life, mount the pump and motor where the environment is rela-tivity clean, dry, and non-corrosive. Standard totally enclosed motors may be installed where dirt, moisture and mild corro-sion are present or in outdoor locations. Specialty motors may be required for moist, corrosive, or explosive environments.

Motor drain plugs (if not equipped with automatic drains) must be removed periodically to drain accumulated condensation.

Pump units should be located where daily visual inspection is possible and no surrounding structure interferes with ventilat-ing air over or through the motor.

KC2/KP2 PUMPS

INSTALLATION

Installation of Ampco pumps should be made as close to the supply of liquid as possible, with short and direct suction pip-ing. Avoid high points in the piping where air pockets can form. The suction and discharge piping should be simple with the connections properly aligned to prevent any strain from being placed on the pump casing. Provisions should be made for pipe expansion and contraction in services handling hot or cold liquids. Base-mounted pedestal pumps must be realigned AFTER installation and piping is completed.

ROTATION

Check direction of rotation BEFORE starting the pump.

Correct rotation is counter clockwise as viewed from the pump inlet. Incorrect rotation may cause catastrophic failure. Close coupled pumps will be equipped with single phase motors properly sequenced or with three phase motors labeled to indi-cate required power sequence ABC or CBA for correct rotation.

Use a phase sequence indicator to identify power source sequence. For base mounted pumps disconnect the coupling and check motor rotation while disconnected from the pump.

MAINTENANCE

Daily observation of Ampco pumps while in operation is the ounce of prevention needed to extend the service life.

Mechanical seals are selected for maximum life with due con-sideration to the economy of the installation. The seal is the only expendable item. Other pump parts are designed for indefinite life expectancy, except as they may be corroded and/or eroded by aggressive products or by misapplication such as undersizing, oversizing, cavitation, etc. Bearings on some pedestal pumps and some motors are prelubricated and require no additional lubrication. Schedule for regreasing other types of bearings will vary, depending on size speed, duty, and environment. For guidance, a steady running, indoor installa-tion in a relatively clean atmosphere at 40C (104F) ambient should not require grease for two years. Care should also be taken not to over grease motors. Pumps handling corrosive or otherwise aggressive solutions should be flushed with clean water after each use because stagnant conditions are usually most corrosive. In seawater, Ampco Alloy pumps provide cathode protection for stainless steel parts. To prevent crevice corrosion and pitting, drain and then flush out the pump with fresh water when inactive for periods greater then one week.

Ampco KC2 and KP2 pumps fitted with standard mechanical seals have all-metal seal parts of 316 stainless steel, carbon rotating face, ceramic stationary seat, and Buna-N elastomers.

Other seal types are supplied when specified. Optional materi-als such as Viton, EPDM, or Teflon elastomers, Tungsten Carbide, Silicon Carbide, or Ni-Resist faces can be supplied when requested. The mechanical seal should be replaced at the first sign of leakage where the shaft enters the pump. Leakage may cause motor bearing damage. Also, since the primary seal surfaces are lapped to precise flatness, the seal should be replaced whenever the pump is dismantled to the point of sepa-rating the seal faces. Always keep a replacement seal kit on hand. It includes a complete seal along with the gasket and o-ring required to rebuild the pump.

There may be other pump assemblies, parts and seal arrange-ments not shown or otherwise described in this pamphlet, that require the same philosophy of seal positioning. It is suggested that highlights of these instructions be applied while paying close attention to parts arrangement during dismantling.

Service

DWUNTLC AND REPLACE PARTS KB FOLLOWS:

attempting any service on the pump or motor, discon-nect or lock out electrical power to tne pump motor. If the pump and motor are to be removed as a unit, note the wiring configuration, Use colored or numbered tape to mark the wire connections of the motor and power source, to retain correct direction of rotation when reconnecting. Incorrect rotation may cause catastrophic failure.

It is recommend that the complete unit be removed and ser-viced on a workbench. For the close-coupled KC2 disconnect the power marking the wires for reconnection. For the base mounted KP2, disengage the coupling and remove the pump and pedestal.

1. Remove the suction cover by unbolting the four capscrews (9/16 wrench). Note the condition of the gasket, which will adhere either to the suction cover or the casing.

2. Unscrew the impeller from the shaft, turning in a counter-clockwise direction. Loctite used during assembly may require heating impellers of all type KC2 and KP2 to assist in removal. Apply approximately 350F heat to the center of the impeller. A screwdriver slot on the motor shaft oppo-site the pump is provided for steadying the shaft. Use of a

(' strap wrench on the impeller hub is recommended to pre-vent marring. Otherwise, file or polish out wrench marks before reusing impeller.

The fluid end of the pump is now sufficiently dismantled for completing most repairs and replacements, including the mechanical seal.

3. If it is necessary to repair or replace the motor of a close coupled assembly or the bearing adapter of a pedestal assembly, unbolt the capscrews fastening the pump to motor or pedestal, thus disengaging the casing and bracket.

The mechanical seal is the only expendable pump part. It is suggested that the complete mechanical seal, both stationary and rotating members, be replaced whenever dripping or leakage occurs at the shaft, or whenever parts are removed to the point of separating the primary sealing surfaces.

4. Remove the rotating parts of the mechanical seal from the impellers shaft like extension (see drawing). The seals flexi-ble bellows may stick tightly to the impeller stem. Bathe in oil to soften the adhesive, or cut away with knife. Remove the o-ring from the shaft I.D.

5. The stationary seat and its cup gasket or o-ring may be removed while the casing is in an assembled position with a wire hook (coat hanger wire). Insert the hook between the I.D. of the seat and the shaft and pull forward, or remove the casing and press out the seat.

6. Thoroughly clean impeller stem, seat cavity and motor shaft with solvent and dry with a clean cloth.

An anti-seize lubricant was originally applied to the I.D. of the impeller that fits over the shaft and is retained by an o-ring.

Either preserve this lubricant or add fresh lubricant to the I.D., not the shaft, and replace the o-ring. One drop of oil applied on the shaft will prevent the o-ring from binding on the shaft while assembling the impeller.

7. Lightly oil bore and finger press stationary seat with gasket or o-ring into its cavity. Seat (usually ceramic) is fragile. Do not abuse.

8. Clean the polished face of the stationary seat with a lint-free cloth or tissue, and lightly coat this surface with an SAE-10 or equivalent oil. Care should be taken that the cleansing material and the oil are free of foreign particles. Do not use grease or allow grease onto the sealing surfaces.

9. Place the rotating portion of the mechanical seal on the shaft like extension of the impeller that may be lightly oiled (SAE 10W-30) to facilitate sliding of the bellow by softening an adhesive film on the seal (Use soap, glycerin, etc. if oil is not permitted i.e. EPDM). Do not use grease, as this would pre-vent the adhesive film from resetting. Final adherence to the impeller stem is essential for shaft, impeller, and seal to rotate as a unit. First place the spring retainer and spring over the impeller shaft. Then press the carbon rotating sub-assembly down the impeller shaft until it engages the spring. Do not continue to slide the assembly down the shaft once the rotating assembly has engaged the spring.

Inspect the carbon sealing face and remove any foreign par-ticles with a lint-free cloth or tissue. Do not allow grease on the sealing surfaces.

10. Place the impeller with mechanical seal in place on the drive shaft. A slight extra push is required to start the o-ring onto the shaft. Proceed to screw the impeller clockwise onto the treaded shaft, utilizing the slot on the opposite end of the shaft to steady the shaft. Hand tighten or use a strap wrench, or other non-marring device such as a jar opener.

11. The pump assembly is completed by reinstalling the suction cover plate and its gasket. Be sure casing and gasket sur-faces are relativity clean and free of foreign particles.

12. Your pump is now ready to be reinstalled into its accompa-nying pipe system and the motor reconnected.

One way to damage a new seal is to run it dry. Be sure the pump is in place and primed before operating or checking rotation.

NOTE: Starting motor in direction of unthreading impeller will result in jamming and damaging bearing and possibly other motor and pump parts. Motor connections should have been marked to avoid this possibility. Also, an economical phase sequence indicator win identify your A-B-C connections. If a reassembled pump unit is not going to be put back in service immediately, or if there is a real possibility for incorrect start up rotation, a suitable thread-locking compound may be used (i.e.

Loctite #271).

I N S T A L L A T I O N A N D M A I N T E N A N C E O F A M P C O C E N T R I F U G A L P U M P S

DanLe

DWUNTLC AND REPLACE PARTS KB FOLLOWS:

attempting any service on the pump or motor, disconnect

DISMANTLE AND REPLACE PARTS AS FOLLOWS:

Single Mechanical Seal T-21

I N S T A L L A T I O N A N D M A I N T E N A N C E O F AMPCO C E N T R I F U G A L PUMPS

Troubleshooting and Applications

COMMON TROUBLES AND THEIR CAUSES

It is to the users advantage to be familiar with a systematic pro-cedure to determine reasons and causes for unsatisfactory pump operation. The following list of troubles and causes is intended to assist users in determining the cause of any pump-ing trouble. Faulty installations can then be corrected and a clear description given the manufacturer if assistance is required. Human judgment should not be relied on to measure operating conditions. Use proper instruments to measure val-ues of pressure, suction lift, speeds, temperature rise of motors, etc. When motor speeds are incorrect, check connections and measure voltage at motor terminals.

1. No liquid delivered

a. Pump and suction line not completely primed

b. Speed too low

c. Required discharge too high

d. Suction lift too high

e. Impeller, piping, or fittings completely plugged up

f. Wrong direction of rotation

2. Not sufficient capacity

a. Air leaks in suction pipe or shaft seal

b. Speed too low

c. Required discharge head too high

d. Suction lift too high or insufficient NPSH available

e. Impeller, piping, or fittings partially plugged

f. Insufficient positive suction head for hot water or other volatile liquids

g. Liquid viscosity too high

h. Mechanical problems - wear rings worn, impeller damaged, shaft seal defective

i. Wrong direction of rotation

j. Suction pipe entrance too close to surface of liquid

k. Air pockets in pipe high points

3. Not sufficient pressure

a. Speed too low

b. Mechanical problems - wear rings worn, impeller dam aged, shaft seal defective

c. Small impeller diameter

d. Air or gas in liquid

e. Wrong direction of rotation

f. Air pockets in pipe high points

4. Pump operates for a while, then quits

a. Leaky suction line

b. Air leaking in through shaft seal

c. Suction lift too high or insufficient NPSH available

d. Air or gas in liquid

e. Suction piping and fittings not completely freed of air during priming

f. Air pockets in pipe high points

5. Pump takes too much power

a. Speed too high

b. Pumping too much water because required head is lower than anticipated

c. Viscosity and/or specific gravity is higher than specified

d. Mechanical problems - binding at wear rings from distortion due to piping strains, shaft bent, impeller rubbing casing, stuffing box too tight

e. Wrong direction of rotation

SOME TYPICAL APPLICATIONS

Your Ampco Pump was selected for a specific service. Other Ampco pump styles are available to successfully handle many additional applications including the following partial list. Ask you Ampco representative for complete information.

abrasive slurries mineral water activated carbon filter slurries molasses acetone alum solution amide solution anodizing solutions beer beer filter slurry (diatomaceous earth) brine solutions cane juice carbon suspension carbon tetrachloride caustic chromic acid cleaning solutions dye deionized water ethylene glycol fatty acid fermentation gas formaldehyde glycerin hydrofluosilicic acid hydrofluoric acid lard oil and fatty acid luminescent solutions marine sanitary service marine water desalting equipment nitric acid oleic acid phosphoric acid plating solutions potassium acetate polyethyl benzene salt water (oil field) sludge fuel sodium chloride sodium fluoride sodium hydroxide solvent spin bath solution (rayon) starch sugar liquor stillage with solids sulfuric acid tall oil tea vinegar vegetable oil vinyl liquor water solutions (corrosive and/or abrasive) whey wort (beer and molasses) yeast cream

Consult Ampco for applications not listed.

AMPCO PUMPS

4424 W. Mitchell Street

Milwaukee, Wisconsin 53214

(414) 643-1852 Telephone • (414) 643-4452 Fax www.ampcopumps.com

I N S T A L L A T I O N A N D M A I N T E N A N C E O F A M P C O C E N T R I F U G A L P U M P S

K-MAN 8/00

SAFETY FIRST

High voltage and rotating parts can cause serious or fatal injury. Safe installation, operation, and maintenance must be performed by qualified personnel. Familiariza-tion with and adherence to NEMA MG2, the National Electrical Code (NEC) and local codes is required. It is important to observe safety precautions to protect personnel from possible injury. Personnel should be instructed to:

1. Be familiar with the equipment and read all instructions thoroughly before installing or working on equipment.

2. Avoid contact with energized circuits or rotating parts.

3. Disconnect all power sources before initiating any maintenance or repair.

4. Act with care in accordance with prescribed procedures in handling and lifting this equipment.

5. Be sure unit is electrically grounded in accordance with code requirements.

6. Be sure equipment is properly enclosed or protected to prevent access by children or other unauthorized personnel in order to prevent possible accidents.

7. Be sure shaft key is fully captive before unit is energized.

8. Avoid contact with capacitors until safe discharge procedures have been completed.

9. Provide proper guarding for personnel against rotating parts and applications involving high inertia loads which can cause overspeed.

10. Avoid extended exposure to equipment with high noise levels.

INSPECTION AND HANDLING

Inspect unit to make sure no damage has occurred during shipment. Check nameplate for correct speed, horsepower, voltage, Hertz, and phase for conformance with power supply and equipment. WARNING: Units should be lifted using all eyebolts or lugs if provided. These eyebolts or lugs are provided for lifting this unit only and must not be used to lift any additional weight. Lifting angle, from shank of eyebolt, must not exceed 30° for machines with single and 45° for machines with multiple lifting means. Replacement eyebolts must be per ASTM A489 or equivalent.

All eyebolts must be securely tightened. Be careful not to touch overhead power lines with lifting equipment. Failure to observe this warning may result in serious personal injury.

STORAGE

Units should be stored indoors, in a clean, dry location & winding should be protected from excessive moisture absorption. NOTE: If motors are to be stored for more than one year, refer to U.S. Electrical Motors. If gear and belt transmission units are to be stored for more than six months, refer to U.S. Electrical Motors.

LOCATION

WARNING: Use only UL Listed Hazardous Location Motors for service in Hazardous Locations as defined in Article 500 of the NEC. Units should be located in a clean, well-ventilated area. WARNING: Units should be located in a suitable enclosure to prevent access by children or other unauthorized personnel to prevent possible accidents.

INSTALLATION / MOUNTING

Mount units on a firm, flat surface sufficiently rigid to prevent vibration. Drive belts and chains should be tensioned in accordance with supplier recommendations.

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