PLEASE READ THIS INSTRUCTION MANUAL BEFORE INSTALLING,

OPERATING OR SERVICING THE PUMP

Your Reference

Iron Pump Reference

Purpose

:

Pump Type :

Order No.

:

Order No.

:

Art No.

:

Pump No.

:

Project

:

IRON PUMP

Instruction Manual

REVISION: 4

I

nstructions for Installation, Operation, Maintenance and Repair of

Centrifugal pumps Type DHBS and DHBF -/160, 200, 250,315, 400

2

Technical Data

TECHNICAL DATA

Pump

Flow, Q

:

Head (Diff. pressure), H :

Inlet pressure

:

Discharge pressure :

Suction lift

:

Power Duty Point, P :

Power max.

:

Media

:

Media temp.

:

Seal type

:

Impeller no.

:

Coupling type

:

Weight

:

Direction of rotation, Rot.:

Materials

Pump casing

:

Impeller

:

Casing wear ring

:

Shaft

:

Seal

:

Motor

Type

:

Output

:

RPM, n

:

Voltage

:

Weight

:

NB!

:

Type plate

Pump Type

Pump No.

Test pressure, Bar

Flow

Power

Duty Point

Year of manufacture

Direction of rotation

Head (Diff. pressure)

RPM

3

1

Contents

1. CoNTENTs

Chapter Section

Page

1.

Contents

3

2.

General

5

2.1

Introduction

5

2.2

Identification

5

2.3

Directions & Warning signs

5

2.4

Warning symbols

5

2.5

General safety

5

3.

Installation

7

3.1

Condition on delivery

7

3.2

Inspection on delivery

7

3.3

Storage instructions

7

3.4

Lifting instruction

7

3.5

Foundation

8

3.6

Environment conditions

8

3.7

Piping

8

3.8

Piping connections

8

3.9

Electrical installation

8

3.10

Recommended accessories

8

4.

Operation

9

4.1

Start-up procedures

9

4.2

Starting the pump

9

4.3

Stand-by

9

4.4

Pump vibrations

9

4.5

Lubrication

9

4.6

Frost protection

9

5.

Maintenance

11

5.1

Inspections

10

5.2

Assembly and Disassembly

10

5.3

Coupling

12

5.4

Fitting instructions for Mechanical seals

13

5.5

Centrifugal pump wear ring Clearances

14

6.

Spare Parts

15

6.1

Repairs

15

6.2

Returning parts

15

6.3

Decommissioning

15

6.4

Table of Materials

15

6.5

Spare parts drawing for DHBF/DHBS

16

1. CoNTENTs

4

1

Contents

1. CoNTENTs

Chapter Section

Page

7.

Data

17

7.1

Type DHBF/DHBS - Dimensional drawing

17

7.2

Troubleshooting

18

8.

Priming systems

20

8.1

Priming of centrifugal pumps

20

8.2

EA automatic ejector system

21

8.3

VATEC automatic aspirator

22

8.4

PA automatic priming system

23

8.5

Danfoss pressure controller for Priming systems

24

8.6

Wiring diagrams for Priming systems

25

8.7

Spare Parts drawing for P-pump with gear - 1450 RPM

26

8.8

Spare Parts drawing for P-pump – 1750 RPM

27

9.

Motor

28

9.1

General information

28

9.2

Inspection

28

9.3

Insulation resistance check

28

9.4

Handling

28

9.5

Installation

28

9.6

Repair and Maintenance

30

9.7

Spare Parts and Repair

31

9.8

Troubleshooting

32

5

General

2

2. GENErAL

2.1

Introduction

This instruction manual contains relevant

information on installing, operating and

maintaining the pump.

The pump is configured for the specific

customer requirements. The specific pump type

is described in the technical data section.

The personnel in charge of installing,

operating and maintaining the pump must be

properly qualified and trained to carry out the

operations described in this manual. IRON

Pump recommends that you read this manual

before you install and operate the pump as this

will minimize any risk of incorrect handling.

IRON Pump A/S cannot be held responsible

for unauthorized use of the pump.

IRON Pump A/S does not provide any guarantee

if working conditions are inappropriate. If the

working conditions differ from those given in

the technical data sheet, please contact IRON

Pump before putting the pump into operation.

2.2

Identification

Details of the pump identification (type, number

and order No.) are on the front page. The Pump

No. can also be found on the suction flange

and on the Type plate on the pump.

2.3 Directions & Warning signs

Comply with all instructions located on the

pump or motor, such as direction of rotation,

arrows, instruction signs, directions or warning

signs and remember to keep this information

in readable condition.

2.4

Warning symbols

Important machine and safety-related

instructions in this manual are illustrated with

symbols. It is essential that these instructions

are followed to avoid accidents and damages

to machines and/or personnel.

STOP!

This symbol is for all safety instructions which

must be followed to avoid accidental injuries

and hazards to life. Observe these safety

instructions carefully and proceed with great

care.

ELECTRIC POWER!

This symbol signals possible danger due

to presence of current electric power. Only

proceed if the operator is experienced with the

pump and procedures.

CAUTION!

This symbol is used for instructions of particular

importance and signals a risk of damage to

the pump or its components. Proceed only if

the parts or the pump have been assembled

according to the instructions.

2.5

General safety

The following safety instructions apply for both

pumps and motors supplied by IRON Pump

A/S.

Observe:

The safety regulations

•

Accident prevention regulations

•

Country specific safety regulations

•

Guide lines and acknowledged technical

•

rules cited in this operating manual.

Non-compliance with safety regulations will

result in danger to personnel and damage to

the unit, e.g:

Danger to personnel through contact with

•

voltage exceeding 42V.

Failure to observe prescribed methods of

•

transportation, assembly, maintenance

and repair of pump or motor.

When working on the

unit, observe all valid

accident prevention regulations

and generally acknowledged

technical rules!

2. GENErAL

6

2

General

2. GENErAL

2.5.1

Electrical hazards

Do not carry out any installation or maintenance

on the pump or motor while it is operating or

before it has been disconnected. Pumps with

motors must have appropriate connections.

Amp ratings are given in the pump Technical

data sheet and the power supply must be

adequate.

2.5.2

Temperature hazards

Before any maintenance is carried out, be

sure to empty the pump of liquid. If the pump

has been pumping hot liquid, the pump should

be cooled to the surrounding temperature.

As a precaution, the hot parts of the machine

should always be covered to avoid accidental

contact.

2.5.3

Chemical hazards

The pump should always be cleaned before

carrying out any maintenance or repairs. This

will prevent chemical reactions if the pump has

been pumping dangerous liquids.

2.5.4

Dry running

If the pump is not supplied with a priming

device, the pump must never be put into

operation before it has been filled with liquid.

If the pump is supplied with a priming device,

dry running is permissible for a short period

while the pump is primed.

2.5.5

Noise level

Under normal conditions the pump and the

motor will produce a noise level below 80 dB.

The exact noise level depends on motor type,

foundation and environment.

The operator must wear protective gear if the

noise level becomes harmful.

7

Installation

3. INsTALLATIoN

3

3.1

Condition on delivery

IRON Pump products are tested before

delivery to ensure perfect running condition.

A test run is made of the pump using water

to check the performance data stated in the

technical specifications.

3.2

Inspection on delivery

Check your shipment immediately upon arrival.

Make sure that the parts and accessories

received are in accordance with your order.

In the event of damage, defects or deficiency,

immediately report the problem to the transport

company and IRON Pump.

The packaging must be examined to make

sure that it is in good condition to guarantee

protection in storage.

The packaging may only be opened when:

It is seriously damaged.

•

The product is to be stored longer than

•

originally planned.

In all other cases the packaging may only be

opened at assembly. When the packaging has

been removed, the product must be examined

for any deficiencies or defects.

3.3

Storage instructions

The standard packaging protects the pump

against corrosion during land transport and

storage in dry conditions for at least three

months.

If the pump is not installed immediately after

delivery, it must be protected against corrosion,

vibrations, frost and kept in a dry place.

Leave flange covers in place to keep dirt and

other foreign material out of the pump casing.

Turn the pump shaft by hand at regular

intervals of one month, to prevent brinelling of

the bearings and the seal faces, if fitted, from

sticking.

3.3.1

Preservation procedure

Flush the pump with pure hot water and let it

air dry. Close the valves on both sides of the

pump and flush the pump with “Mobil Arma

25” or similar quality. Flushing can be done

through the manometer connections.

3.3.2

Restarting

When starting/restarting the pumps after

storage, it is advisable to fill the pump with hot

water through the manometer connections and

to turn the pump shaft by hand before starting.

Then follow 4.1 Start-up procedures.

3.4

Lifting instruction

Straps are mounted around the flanges.

•

(Lifting chains might damage the surface

of the pump, and are not recommended).

A wooden bar is placed above the motor to

guide the strap.

If the motor has lifting eyes at the top, these

•

can be used to guide the pump so it does

not tip. Otherwise a strap fixes the motor.

3. INsTALLATIoN

8

3

Installation

3. INsTALLATIoN

3.5

Foundation

The pump must be fixed to a rigid foundation

which is substantial enough to absorb vibrations

and to take up stress from the hydraulic strain

and loads from the pipelines.

The pump should be installed with sufficient

accessibility for inspection and maintenance.

The surface of the foundation where the

pump is installed must be level and horizontal.

Damage due to an inadequate or faulty

foundation is not covered by the guarantee.

3.6

Environment conditions

Standard pumps are intended for installion in

dry rooms free from aggressive atmosphere

in temperatures between + 10 and 40

o

C

Installing the pump in other conditions (e.g.

outdoors, in damp rooms etc.) is only allowed

if this is stated in the technical data sheet.

3.7

Piping

Suction and pressure lines must be connected

to the flanges of the pump, free from strain,

as any stresses are taken up at fixed points,

and suitable compensators should therefore

be installed in the pipe system. The flanges

between which the pump is installed must be

absolutely parallel.

To keep pressure loss and flow resistance at

a minimum, tight bends and substantial size

reductions in the piping system should be

avoided.

Loss of pressure in the suction line must be

kept at a minimum in order to avoid cavitation

in the pump. Static suction height + loss of

pressure in the suction line + NPSH value for

the pump + steam pressure must not exceed

10 mWc at sea level. Long suction pipes that

make air pockets possible should be avoided.

3.8

Piping connections

Before installing the pump, the entire piping

must be pressure and leakage tested and

flushed clean before it is connected to the

suction and discharge side of the pump. If

the pressure test takes place with the pump

installed, the testing pressure must not exceed

the testing pressure of the pump, which is

stamped into the pump, usually in the suction

flange. The pump’s gaskets or flanges for the

mechanical shaft seal might otherwise be

damaged.

Check that all other connections to the pump

are in working order, such as lubrication,

priming, heating, cooling media outlet, etc.,

and that the various measuring equipment

has been correctly connected. Take care that

no parts obstruct easy access to the pump for

inspection or replacement of important parts.

3.9

Electrical installation

Connect the cables according to local electrical

regulations and standards, and by authorised

skilled stuff. The pump should be connected

to a motor starter.

Check that there is enough cable to allow the

motor to be removed without disconnecting

the wires. A switch (emergency stop) must be

installed close to the pump.

Kilowatt ratings are given in the pump Technical

data sheet.

3.10 Recommended accessories

As the pump, especially the mechanical

shaft sealing, is designed to run with clean

water without sludge, a suitable filter must be

installed in the suction line.

IRON Pump A/S can supply suitable filters.

9

4. opErATIoN

Operation

4

4. opErATIoN

4.1

Start-up procedures

Ensure that the pump and motor are mounted

according to instructions, all connections are

correct and the necessary screens and guards

are in order.

Check the direction of rotation (marked

•

with an arrow). The motor must turn in the

direction in which the arrow is pointing. If

the direction is wrong, the connections to

the terminals of the electric motor should

be changed.

Check that the pump can be turned by

•

hand.

Check that the motor has been lubricated

•

with grease.

Make sure that the piping is clean and free

•

from foreign objects. Liquid should flow

regularly into the pump.

Check that the pump and suction pipe are

•

filled with liquid. Any air or gas must be

carefully released before start-up.

Check the pump for noise and vibrations

•

immediately after starting. At the normal

head it should have a steady motion

without unusual noise and vibrations after

one minute.

Check the priming device (if any).

•

Check the seal housing for leakages.

•

4.1.1

Pumps with Priming device

Pumps provided with a mechanical priming

pump should be checked for supply/content of

liquid before starting.

The valve on the discharge side of the pump

must be closed during priming.

The operating instructions for the priming

system should be strictly followed (See

Chapter 8).

After priming the pump, open the valve on

the discharge side slowly and adjust it in such

a way that the permissible vacuum is not

exceeded.

4.2

Starting the pump

When the pump is ready, it is started with the

discharge valve closed. After starting, the

discharge valve is slowly opened until the

working point is reached. If the pump runs with

closed valves for a period of the time, it should

be equipped either with temperature control

equipment or recirculation. Running with the

valves closed for a long period can damage

the pump.

Check bearing temperature (max. 105

o

C)

Do not run pump with closed valve on

discharge side for prolonged time.

4.3

Stand-by

If the pump is going to be on stand-by for a

long period, it must be started or rotated at

least once a week to avoid damage to the

mechanical seals.

4.4

Pump vibrations

During operation, be aware that significant

vibrations have a major affect on the pump’s

performance. If vibrations are significant the

pump should immediately be turned of to be

able to locate possible errors.

Never operate the pump without

the coupling guard .

4.5

Lubrication

The pump bearings are closed and not

supposed to be greased.

The motor bearings are greased according

the motor instructions.

4.6

Frost protection

If there are any risk of freezing of the liquid in

the pump, removing the drain plug empties the

pump casing.

10

4. opErATIoN

Operation

4

5.1

Inspections

Before any inspection and maintenance of the

pump, the operator must ensure that the pump

cannot be unintentionally started. The pump

must be stopped, and all electronic contacts

must be disconnected.

The system must be de-pressurized and the

pump must be emptied of liquid. If the pump

has been pumping hazardous liquids, the

liquid must be collected, and the pump should

be flushed with clean water or another suitable

liquid.

It is important to ensure that

the pump does not contain

dangerous amounts of

corrosive, toxic or similar

substances when maintenance

is taking place.

5.1.1

Three-month inspection

Check suction and discharge pressure.

•

Check for unusual noise, vibrations and

•

leakages.

Inspect the motor as per the instructions

•

from the manufacturer.

The mechanical seal must be inspected

•

for leaks by normal pressure at the suction

side. The seal must not leak either during

stand-by or during operation .

Check that the circulation pipe for the

•

mechanical seal is not blocked

If any faults are found during inspection, they

must immediately be corrected, since any

defects can be of major importance for the

functioning of the pump and its life spare.

5.1.2

Twelve-month inspection

Disassemby of the pump is required.

•

Take the pump apart (See 5.2). The

•

rotating parts are checked and repaired if

necessary.

Check the clearance between the impeller

•

and casing wear ring. Normal clearance

is 0,45-0,50 mm. Maximum clearance is

0,8-1,0 mm. depending on the Size and

Capacity (See 5.5).

5.1.3

Lubrication

The pump bearings are greased for lifetime

and do not need no further service.

5.2

Assembly and Disassembly

Study the Spare Parts drawing for the

actual pump before starting disassembly

of the pump.

5.2.1

Rotating unit

Table. Weight of rotating unit

Pump size

(from-to)

Weight

kg

40-40/200-

125-125/250

22

50-50/25-

125-125/250

35

150-150/250-

200-200/250

40

80-80/315-

150-150/315

50

200-200/315-

250-250/3150

60

200-250/400-

300-300/400

94

554

230

906

161
433

321

360

210

412

Spare Parts list

Item

Casing cover

161

Shaft

210

Impeller

230

Radial ball bearing 321

Bearing cover

360

Spare Parts list

Item

O-Ring

412

Mechanical seal

433

Washer

554

Impeller screw

906

11

5. mAINTENANCE

Maintenance

5

5. mAINTENANCE

5.2.2

Disassembly DHBS/DHBF

Table for holes in the casing cover (Item 161)

Threaded hole

for

Threaded hole

for puller bolt

Free hole

in cover

Mounting

hole in cover

Mounting

hole in cover

Dismantling of

cover from motor

stool

Dismantling of

motor stool from

pump casing

Fixing of

motor stool in

pump casing

Fixing of cover

in motor stool

Fixing of cover

in pump casing

A

B

C

D

E

2xM8

2xM8

2xM8

2xM8

12xM12

Max 5 NM

Max 5 NM

10 NM

10 NM

15 NM

Without removing motor:

The rotating unit can be removed without

removing the motor:

Ensure that the pump has been drained of

•

liquid.

Remove circulation pipe (Item 710, Se 6.5)

•

Remove spacer bush (Item 860.6) and

•

coupling flexible steel disc (Item 867) , if

any.

Remove screws marked D+E.

•

Mount puller bolts in holes marked A and

•

lift the casing cover.

Lift the disconnected rotating unit and take

•

it out of the pump.

Gentle disconnection is recommended to

•

prevent any damage to the mechanical

seal. (Use a cloth or the like during of

disasembly/assembly of the rotating unit).

See 6.5

E

A

A

B

B

C

C

D

D

E

E

E

E

E

E

E

12

5. mAINTENANCE

Maintenance

5

With removing motor:

Remove screws marked C + E

•

Remove the circulation pipe (pos. 710)

•

Mount the puller bolts in the holes marked

•

B

Lift the disconnected parts and remove

•

them.

Note:

On mounting the screws are tightened by

hand, then cross-tightened by moments as

stated, in order to balance the cover:

Holes

крепёжных моментов

Bolt size

Nm

C

2-M8

10

D

2-M8

10

E

12-M12

15

OBS! Number of E-holes depends on

pump size.

5.2.3

Assembly DHBS/DHBF

In order to prevent seizures in future repairs,

all joints and bolt threads should be treated

with an appropriate compound (e.g. “Never

Seez”) before assembly.

Before reassembling, clean the inside of

•

the pump casing and paint with appropriate

coating.

Assemble the pump in opposite order of

•

the disassembly (See 5.2.2)

Casing cover (Item 161), with the seat ring

•

of the mechanical shaft seal (Item 433),

must be fitted gently on the shaft

The O-ring (Item 412) must be fitted to the

•

cover.

The rotating unit of the shaft seal ( Item

•

433) is carefully placed on the shaft (Item

210).

The casing wear ring (Item 502) and the

•

impeller must be fitted and tightened by

screws.

Check the clearance between the impeller

•

and casing wear ring. (See 5.5).

Before any up-start, the shaft must be

•

turned by hand in order to check for any

blockages.

When the pump is assembled and all

•

bolts and nuts are in place, they can be

tightened.

5.3

Coupling

Never operate the pump without

the coupling guard .

Please NOTE!

Way of mounting the bolts!

(Only DHBF)

861.1

867
860.6

5.3.1

Mounting of coupling

with flexible steel disk (DHBF)

Clean the shaft ends, and check for burrs.

•

Heating of the coupling half (Item 861.1) to

•

approx. 80

o

C facilitates the mounting of it

on the shaft.

Mount the coupling half (Item 861.1) in line

•

with the motor shaft.

Lock the coupling half by the pivot screws.

•

Mount coupling flexible steel disk (Item

•

867), spacer bush (Item 860.6) and

coupling half (Item 861.1) , clamp the parts

and tighten the screws.

13

5. mAINTENANCE

Maintenance

5

5.3.2

Mounting of coupling

without flexible steel disk (DHBS)

The coupling part on the motor shaft

•

must NOT be axially fixed, considering

the thermal expansion it must be axially

movable.

Clean the motor shaft ends, and check for

•

burrs.

Lubricate the motor shaft end by “Never

•

Seez”, fitting paste or like and push the

coupling half (Item 861.1) up on the shaft

end.

Mount spacer bush (item 860.6) and

•

Coupling half (Item 861.1), clamp the

parts.

5.4

Fitting instructions for

Mechanical seals

A mechanical seal is a very high-precision

product and should be treated with the utmost

care before and during fitting. Do not unpack

until ready for use. The rotating wear ring and

the seat have been lapped to a high degree of

accuracy.

Fitting instructions:

Remove the protective packaging from the

•

seal, check for damage, and wipe clean.

Make sure that the pump is ready and

•

switched off.

The shaft should be clean and free of

•

burrs, and the machined place where the

seat fits must be cleaned very carefully.

Edges should be rounded so that they are

not sharp or penetrating.

Check that the shaft diameter corresponds

•

with the dimension of the seal within a

tolerance of 0.05 mm.

The bore in the casing cover (Item 161)

•

and the seat must be lubricated. Use

only liquid soap, soapy water or glycerine

with ethylene-propylene elastomer. The

elastomer must also be lubricated on

the inside where it slides on the shaft.

Lubricants containing silicone must never

be used.

Press the seat into position with your

•

fingers. If the space is tight, use a bush

when pressing the seat into position. Take

care not to damage the surface of the seat.

For example, use a piece of plastic for

protection between the bush and the seat.

After pressing the seat into position, make

sure that it is fully in place by measuring

the depth with a depth calliper.

Place carefully and by hands the rotating

•

part on the shaft.

Mount the impeller on the shaft.

•

The compressed length after fitting must

•

correspond to the working length of the

size of seal in question given in the table of

measurements.

Be aware of changes that can occur when

•

bearing arrangements and gaskets etc. are

replaced.

Before the pump is started it must be filled

•

with liquid and the air allowed to escape.

Air should be bled frequently during the

period after starting.

When fitting shaft seals, the

instructions should be read

carefully, especially when the

media is dangerous (poisonous,

hot, flammable etc.)

25(ø10-ø25)

41(ø42-ø60)

33.5(ø30-40)

IRON pump STANDARD

07.47.06E

33.5(ø30-40)

41(ø42-ø60)

25(ø10-ø25)

IRON/BURGMANN

07.47.06E

14

5. mAINTENANCE

Maintenance

5

THE CLEARANCES STATED ARE AVERAGE VALUES,
AND MUST IN EACH SINGLE CASE BE COMPARED
WITH THE NEEDS FOR THE NECESSARY OPERATION DATA.

WEAR RING DIAMETER

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1,0

100

200

300

400

CLEAR

ANCE (mm)

WEAR RING DIAMETER (mm)

22531E1

CLEAR

ANCE

5.5

Centrifugal pump wear ring Clearances

15

6. spArE pArTs

Spare Parts

6

6. spArE pArTs

6.1

Repairs

When ordering Spare Parts or requesting our

assistance, please advise the following:

Pump type

•

Serial number (i.e. P.no. DHB ####, from

•

Type plate, it is also stamped in the suction

flange)

IRON Pump A/S order number (5 or 7

•

digits.)

Item No. and description of part (See Spare

•

Parts drawing).

To establish the correct ‘diagnosis’, a brief

description of the breakdown is also required.

Spares are normally available from stock.

If you do the repairs yourself, you are requested

to follow the instructions regarding assembly

and disassembly or to contact our service

department.

6.2

Returning parts

Before returning parts to IRON Pump A/S,

please note that all liquids must be removed

and parts should be cleaned and neutralized.

The sender is liable for damage suffered by

the pump or other goods caused by leaking of

liquid during transport.

6.3

Decommissioning

Do not dump old or used parts. Metal parts

should be recycled as scrap or sent back to

IRON Pump.

When decommissioning the pump, it should be

neutralized and cleaned, and any hazardous

liquids,should be removed and sent to a

recycling facility.

None of the materials in the pump can be

considered hazardous, but we urge you to act

with care and to take the steps needed when

decommissioning the pump or its parts.

6.4

Table of Materials

Table of materials with the total content

calculated as percentage by weight.

DHBS/F

Description

Material

%

Pump casing

See Technical data

38

Casing cover

See Technical data

7

Shaft

AISI 329

4

Impeller

See Technical data

5,5

Casing wear

ring

See Technical data

0.6

Mechanical

seal

Carbon/ceramics

0.3

O-Ring

Viton

0.1

Foot

Cast iron

9

Motor stool

Cast iron

21

Coupling

Cast iron

2.5

Accessories

Steel

1

16

6. spArE pArTs

Spare Parts

6

6.5

Spare parts drawing for DHBS / DHBF

Spare Parts list

Item. No.

Pump casing

101

Casing cover

161

Foot

182

Shaft

210

Impeller

230

Radial ball bearing

321

Motor stool

341

Motor stool, flange

341.1

Spare Parts list

Item No.

Bearing cover

360

O-Ring for pump casing 412

Mechanical seal

433

Casing wear ring

502

Loose collar

505

Washer

554

Pipe

710

Threaded pipe union

731.1

Spare Parts list

Item No.

Threaded pipe union

731.2

Spacer bush

860.6

Coupling half, incl. spacer 861.1

Coupling flex. steel disc 867*

Impeller screw

906

Plug for pressure gauge 910

Drain plug

912

Circlip

932

*) Only DHBF

906

28824E

502

101

230

910

412

505

861.1

341

341.1

On type DHBS

Item 861.1

must NOT be

axially fixed

360

731.2

731.1

710

161

(Only DHBF)

932

321

210

867

860.6

182

554

912

433

17

7. DATA

Data

7

7.1

Type DHBS / DHBF - Dimensional drawing

7. DATA

Dimensions in mm

PUMP

SIZE

FLANGES

PN10, DIN 2501

A

B

E

F

M

øS

T

PUMP

WEIGHT

KG

NV

k

D

ød

40-40/200

40

110

150

4-ø18

125

180

370

280

330

20

18

75

50-50/200

50

125

165

4-ø18

200

80

65-65/200

65

145

185

4-ø18

87

80-80/200

80

160

200

8-ø18

140

225

91

100-100/200

100

180

220

8-ø18

175

250

380

380

440

24

25

111

125-125/200

125

210

250

8-ø18

205

280

121

50-50/250

50

125

165

4-ø18

145

225

135

65-65/250

65

145

185

4-ø18

126

80-80/250

80

160

200

8-ø18

160

250

131

100-100/250

100

180

220

8-ø18

180

280

134

125-125/250

125

210

250

8-ø18

210

460

460

520

181

150-150/250

150

240

285

8-ø22

235

355

228

200-200/250

200

295

340

8-ø22

280

450

232

80-80/315

80

160

200

8-ø18

175

280

207

100-100/315

100

180

220

8-ø18

180

315

217

125-125/315

125

210

250

8-ø18

200

224

150-150/315

150

240

285

8-ø22

220

355

232

200-200/315

200

295

340

8-ø22

315

450

284

250-250/315

250

350

395

12-ø22

335

500

495

369

200-200/400

200

295

340

8-ø22

280

750

408

250-250/400

250

350

395

12-ø22

335

560

451

300-300/400

300

400

460

12-ø22

400

630/560

560

630

26

30

721

The illustrated pump is with standard flange DIN 2501, PN10.
For the remaining dimensions, see dimensioned drawing of the pump.

1/4” PT

1/4” PT

4 - øS

øM

øF

B

B

E

A

BC=K

DN

ød

T

28650

D

18

7. DATA

Data

7

7.2

Troubleshooting

The diagram below describes the most common faults which can occur during operation of the

pumpunit. Should additional information be required, please contact IRON Pump A/S.

Problem

Possible cause

Pump and motor cannot be actuated:

Impeller or shaft blocked.
Motor fault.

Motor running but no pumping effect:

Motor rotation is not transmitted through coupling.
Discharge valve closed.
Non-return valve or other valves are closed.
Suction line closed.
Air in pump casing.
Suction line leaking.
Shaft seal leaking.
Bottom valve defective.
Suction lift too high.
Priming pump defective.

Insufficient capacity:

Wrong direction of rotation.
Number of revolutions too low.
Counter-pressure too high.
Suction line or impeller partly clogged.
Air in pump casing.
Air in pumping media.
Suction lift too high (inlet pressure too low).
Cavitation.
Suction line leaking.
Shaft seal leaking.
Pump worn out.

Pump pressure too high:

Number of revolutions too high.
Impeller oversized.
Specific gravity of pumping media too high.
Viscosity of pumping media too low.
Inlet pressure too high.
Manometer defective.

Capacity too large:

Number of revolutions too high.
Impeller diameter too big.
Counter-pressure too low.

Discharge head too low:

Number of revolutions too low.
Impeller diameter too small.
Specific gravity of pumping media too low.
Viscosity of pumping media to high.
Manometer defective.

19

7. DATA

Data

7

Problem

Possible cause

Power consumption too large:

Motor too small.
Motor fault.
Capacity too large.
Counter-pressure too low.
Electricity supply incorrect.

Pump output decreases or stops:

Suction line leaking.
Shaft seal leaking.
Increasing suction lift.
Filter clogged.
Cavitation.

Irregular running:

Bearings defective.
Motor fault.

Increasing noise level:

Cavitation beginning.
Air in pumping media.
Capacity too large.
Base bolts loosened.
Influences from pipe connections or base.

Leaks:

Cracks in pump casing.
Faulty assembly of pump.
Pipe connections leaking.

Bearing temperature too high:

Defective pump alignment.
Influences from pipeline.
Coupling half is not in line with the motor shaft.
Shaft bent.
Foreign bodies or impurities in bearings.

Pump wears out quickly:

Wrong pump in relation to liquid.
Cavitation.
Shaft bent.
Defective alignment.
Influences through pipe line.

Strong vibrations:

Impurities in pump.
Worn or loose bearings.
Operating the pump at a critical speed.
Unbalanced motor or rotating components.
Loose hold-down bolts or loose or damaged parts.

20

8. prImING sYsTEm

Priming System

8

8.1

Priming of centrifugal pumps

IRON Pump A/S provides three different types

of priming systems for centrifugal pumps.

8.1.1

EA automatic ejector system

Automatic ejector-driven priming system

designed for centrifugal pumps, where dry

running is admissible for a short period of the

time and compressed air is available.

The ejector can be supplied in sizes 1/2” or

3/4” with different capacities. The pressure

controller can be set to fit the pump pressure.

8.1.2

VATEC automatic aspirator

Automatic aspirator designed for centrifugal

pumps where dry running is admissible for

short periods of the time and compressed air

is available.

The ejector can be supplied with different

capacities and different pressure switches for

different pump pressures.

8.1.3

PA automatic priming pump

Automatic priming system driven by a

mechanical vacuum pump. The system is

designed for centrifugal pumps where dry

running is admissible for a short period of the

time.

The pressure controller can be set to fit the

pump pressure.

8.1.4

Mounting of Priming devices

Priming devices must always be connected

to the highest point on the suction side of the

pump/suction line, and there must be no air

pockets in the suction line.

The valve on the pressure side of the pump

must always be closed during priming, or a

spring-loaded counter valve which opens as

soon as 60-70% of the working pressure is

reached must be installed.

The capacity of the priming pump must match

the volume of the pump and the suction pipe

which has to be primed, so that priming will

take no longer than 3 minutes.

8. prImING sYsTEms

21

8

8. prImING sYsTEm

Priming System

8.2

EA automatic ejector system

Automatic ejector system designed for

centrifugal pumps, where dry running is

admissible for short periods of the time.

EAinst11

8.2.1

Function

When the centrifugal pump is turned on, power

is also connected to the automatic ejector

system, and the ejector starts evacuating air

from the suction line and the centrifugal pump

through non-return valve (Item 4) and solenoid

valve (Item 1A).

On the discharge pipe of the main pump, a

spring-loaded counter valve must be mounted

which opens as soon as 60-70% of the working

pressure is reached. As soon as the centrifugal

pump has built up the necessary discharge

pressure, the ejector system is switched off

via the pressure switch. Should the discharge

pressure fall again during pump operation

through gas accumulation, the automatic

ejector system restarts for re-evacuation.

8.2.2 Design
Pressure-controlled priming system with a

compressed air ejector acting as a vacuum

generator.

Components:

Solenoid valve

Item 1

Solenoid valve

Item 1A

Pressure switch

Item 2

Air ejector 1/2” PT or 3/4” PT

Item 3

Non-return valve

Item 4

Filter

Item 5

8.2.3 Installation
The automatic ejector system must be fitted

above the highest point to be evacuated (eg.

the pump casing).

The ejector is supplied with compressed air

at 5-7 bar by solenoid valve (Item 1). The

compressed air passes through the ejector

whose suction side is connected to the suction

side of the pump through solenoid valve (Item

1A) and non-return valve (Item 4). The non-

return valve prevents the compressed air from

being led into the pipe system in the event of an

obstruction of the ejector outlet. The solenoid

valves are electrically connected so that both

valves are open at the current-carrying coil

and closed at the current-less coil.

lmpulse to the solenoid valve is controlled by

the pressure switch, which is connected to the

discharge side of the pump.

The pressure switch must be set to switch off

at 50-70% of the lowest working pressure. The

neutral zone must be set to at least 10% of the

working pressure (See 8.5).

Important note: outlet of air and water from

•

ejector must always have free access to

bilge.

Length of pipe - if any - to be very short.

•

Check that the filter (Item 5) is always

•

clean.

EA-INST4

P

ressur

e swit

ch

connec

tion

3

2

1

1A

5

4

Compressed air 5-7 bar

Outlet

From pump

1400 NL/min
1/2"PT

22

8. prImING sYsTEm

Priming System

8

8.3

VATEC automatic aspirator

Automatic aspirator designed for centrifugal

pumps where dry running is admissible for

short period of the time.

EAinst12

8.3.1

Function

When the centrifugal pump is turned on,

the automatic aspirator will be activated. As

soon as the centrifugal pump has built up the

necessary discharge pressure, the aspirator is

switched off via the pressure switch. Should

the discharge pressure fall again during pump

operation through gas accumulation, the

automatic aspirator restarts for re-evacuation.

8.3.2 Design
Pressure-controlled automatic aspirator with

a compressed air ejector acting as a vacuum

generator. With its polyethylene nozzle

system, the unit is resistant to a high degree to

aggressive fluids (e.g. seawater).

Components:

Compressed air ejector

with integrated shut-off valve

Item 1

Compressed air solenoid valve

Item 2

Pressure switch

Item 3

Terminal box

Item 4

8.3.3 Installation
Connections:

Casing air vent

Item A - G 3/4” PT

Exhaust

Item B - R 1 1/4” PT

Pressure switch

Item C - G 3/8” PT

Cable

Item E - 9 - 13 mm

Compressed air

Item P - G 1/2” (AELD

35-55) /G 1”(AELD 65)

The automatic aspirator is to be fitted above

the highest point to be evacuated (e.g. the

pump casing).

The highest point to be evacuated is connected

to connection A by means of an ascending air

vent pipe.

Exhaust nozzle B must not be shut off.

Compressed air is to be connected to

connection P via manual or controlled shut-off

valve.

The maximum installation height above the

lowest suction side fluid level is 6.5 m after

deducting the dynamic losses of the suction

system.

The pressure range is to be chosen by its

shut-off point, which must be under the lowest

working pressure of the pump. A later change

to another pressure range takes place by

changing the pressure switch module.

E

C

A

B

P

Vatec

1

2

3

4

Exhaust

23

8

8. prImING sYsTEm

Priming System

8.4

PA automatic priming system

Automatic ejector system designed for

centrifugal pumps, where dry running is

admissible for a short period of the time.

PA inst7

8.4.1 Function
When the centrifugal pump is turned on,

power is also connected to the automatic

priming system and the priming pump starts

evacuating air from the suction line and the

centrifugal pump through non-return valve

(Item 6) and solenoid valve (Item 5). On the

discharge pipe of the main pump, a spring-

loaded counter-valve which opens as soon as

60-70% of the working pressure is reached

must be installed.

As soon as the centrifugal pump has built up

the necessary discharge pressure, the priming

pump is switched off via the pressure switch.

Should the discharge pressure fall again during

pump operation through gas accumulation, the

priming pump restarts for re-evacuation.

8.4.2 Design
Pressure-controlled priming system with a

priming pump acting as a vacuum generator.

Components:

Vacuum pump

Item 1

Gearbox (for 50Hz systems)

Item 2

Motor

Item 3

Pressure switch

Item 4

Solenoid valve

Item 5

Non-return valve

Item 6

Filter

Item 7

Outlet to bilge

Item 8

Water tank

Item 9

The power output of the motor is 1.5 kW at

1450 RPM and 1.25 kW at 1750 RPM.

8.4.3

Installation

The priming pump is to be fitted above the

highest point to be evacuated (e.g. the pump

casing).

The impulse to the priming pump and the

solenoid valve is controlled by the pressure

switch, which is connected to the discharge

side of the pump.

The pressure switch must be set to switch off

at 50-70% of the lowest working pressure. The

neutral zone must be set to at least 10% of the

working pressure. (See 8.5).

Important note:

Outlet (Item 8) of air and water from priming

•

pump must always have free access to

bilge.

Length of pipe - if any - to be very short.

•

Check that the Filter (Item 7) always is

•

clean.

Before starting:

Check that the water tank (Item 9) in the

priming pump is filled with water.

Painst8

9

1

2

6

5

8

7

3

4

24

8. prImING sYsTEm

Priming System

8

Data

Pressure controller type RT 200, max. test

pressure 25 Bar.

Instructions

The pressure controller is set by rotating the

knob (Item 5), at the same time reading the

main scale (Item 9). (See Fig. 1).

The differential is set by rotating the differential

adjusting nut (Item 19) to the value indicated

by the use of the monogram (See Fig. 5). The

maximum operating pressure in thus the sum

of the setting pressure and the differential.

Example

To control a priming device for a pump with a

working pressure of 4 Bar.:

Minimum pressure (50%):

0.5 x 4 Bar = 2 Bar.

Differential:

0.1 x 4 Bar = 0.4 Bar.

Connect the priming device to terminals

•

1-2 of the pressure controller.

Set the pressure controller for 2 Bar by

•

rotating the knob (Item 5).

Set the differential adjusting nut (Item 19)

•

(See Fig.3) which is found by reading the

monogram (See Fig. 5).

8.5

Danfoss pressure controller for Priming systems

Bаr

RT 200

0.25

0.4

0.6

0.8

1.0

1.2

Мin.

Маx.

1

2

3

4

5

6

7

8

9

10

Fig. 5

Маx. 70 С

Мin. -40 С

Маx. 100 С

о

о

о

Fig. 4

Bаr

RT 200

0.25

0.4

0.6

0.8

1.0

1.2

Мin.

Маx.

1

2

3

4

5

6

7

8

9

10

Fig. 5

Маx. 70 С

Мin. -40 С

Маx. 100 С

о

о

о

Fig. 4

Bаr

RT 200

0.25

0.4

0.6

0.8

1.0

1.2

Мin.

Маx.

1

2

3

4

5

6

7

8

9

10

Fig. 5

Маx. 70 С

Мin. -40 С

Маx. 100 С

о

о

о

Fig. 4

25

8

8. prImING sYsTEm

Priming System

2

1

1

1A

0

4

1

2

2

2

U

96

95

b

0

4

1

2

a

1

V

W

4

4

6

6

3

5

Main
Pump

Motor

Vatec

230V 50/60Hz

400V 50Hz
440V 60Hz

R S T

TO STARTER

P

440V 60Hz

400V 50Hz

IRON's SUPPLY

440V 50/60Hz

230V 50/60Hz

115V 50/60Hz

Pressostat

Danfoss

TO STARTER

Pump

Motor
Main

R S T

P

Danfoss
Solenoid Valves

TO STARTER

SHIPYARD's SUPPLY

Pump

Priming

Motor

Solenoid Valve

Danfoss

IRON's SUPPLY

whit

e

gr

een/y

ello

w

Pressostat

Danfoss

blue

Motor

Pump

Main

R S T

440V 60Hz

400V 50Hz

115V 50/60Hz
230V 50/60Hz
440V 50/60Hz

EA automatic ejector system

Type VATEC automatic aspirator

Automatic priming system Type PA

P

E010903

8.6

Wiring diagrams for Priming

systems

The customer is responsible for the wiring

being done according to valid regulations.

Care should be taken to ensure, before

connecting the coil to the mains, that the

voltage and the frequency of the coil are in

conformity with those of the mains; 10% over-

or under voltage is permissible in case of

normal frequency.

26

8. prImING sYsTEm

Priming System

8

Spare Parts list

Item No.

Pump casing

101.1

Suction casing

106

Wear plate

135

Shaft for pump

211

Impeller

231

Ball bearing

321

Bearing cover

360.2

Bearing cover

360.3

Bearing cover

360.4

Gasket

400.3

Joint ring

411

Shaft seal ring

420.3

Spare Parts list

Item No.

Shaft seal ring

420.4

Shaft seal ring

420.5

Bearing bush

545

Tank

591

Grease nipple

636

Oil level sight glass

639

Toohted coupling

845

Gear casing

871.1

Cover for gear casing

871.2

Gear wheel drive

872.1

Gear wheel

872.2

Shaft drive

877

8.7

Spare Parts drawing for P-pump with gear - 1450 RPM

P-PUMP, 1450 RPM - with gear

FROM SUCT. SIDE PUMP

OVERFLOW

Control oil level
once a month
Mobilgear 600 xp 68

Lubricate once a month with grease

17730

845

420.5

360.3

321

872.1

321

360.4

420.4

636

106

101.1

231

135

591

411

420.3

420.4

400.3

545

360.2

871.1

639

321

872.2

871.2

H

E

F

211

877

Mobilith SHC100 - 5 gram

27

8

8. prImING sYsTEm

Priming System

Spare Parts list

Item No.

Casing

101.1

Suction casing

106

Wear plate

135

Shaft for pump

211

Impeller - suction stage

231

Motor stool

341

Bearing cover

360

Gasket

400.3

Spare Parts list

Item No.

Joint ring for plug

411

Shaft seal ring

420.3

Shaft seal ring

420.4

Bearing bush

545

Tank

591

Grease nipple

636

Coupling motor side

861.1

Coupling pump side

861.2

8.8

Spare Parts drawing for P-pump – 1750 RPM

OVERFLOW

H

FROM SUCT. SIDE PUMP

420.4

411 400.3

E

420.3

545

360.2 211

341

Lubricate once a month with grease

Mobilith SHC100 - 5 gram

P-PUMP, 1750 RPM

101.1

591

135

231

636

106

15544

861.2 861.1

F

28

9. moTor

Motor

9

9.1

General information

The following instructions refer to all motors

delivered by IRON Pump A/S. Read these

instructions before you transport, install,

operate, maintain or repair motors.

Should additional data be required, consult

the manufacturer or an authorized service

workshop immediately.

IRON Pump A/S cannot be held responsible

for unauthorized use of the motor.

9.2

Inspection

If any damage is observed on delivery, please

notify type of damage immediately to the

transport company. It is important that the

motor is not put into operation if any damage

has been discovered.

Check that all data on the rating plate, especially

voltage and winding connection (star or delta),

are consistent with the order specifications

and pump provided by IRON Pump.

Some motors are protected against bearing

damage during transport by means of a locking

device which must be removed before putting

the motor into operation. When the device

has been removed, turn the shaft by hand to

ensure free rotation.

9.3

Insulation resistance check

Insulation resistance of motors can be lowered

considerably by moisture. Consequently

insulation resistance must be checked after

receipt and inspection or after extended

storage. Insulation resistance of the winding

must be measured to earth and between

phases at 25

o

C. The measured value should

normally exceed the reference value.

Windings should be discharged

immediately after measurement

to avoid risk of electric shock!

The insulation resistance of new winding

is above 10 MΩ. Insulation resistance is

temperature dependent, i.e. if the ambient

temperature is increased/decreased by 20

o

C,

the resistance is halved/doubled respectively.

If the resistance at room temperature is below

the reference value, the windings must be

oven dried at 90

o

C for 12-16 hours followed by

105

o

C for 6-8 hours.

9.4

Handling

9.4.1

Storage

Motors should always be stored in dry

conditions, free from vibrations and dust.

Always remember to store the unit in the

transportation packaging.

Unprotected machined surfaces such as shaft

ends and flanges should always be protected

with an anti-corrosive coating before being

placed in storage.

In order to prevent grease migration, it is

recommended that the motor shaft be rotated

periodically by hand. If the unit is stored for

more than one year, the bearings should be

checked for corrosion before the motor is

installed and put into operation.

9.4.2

Transportation

If the motor is fitted with cylindrical roller

bearings, the rotor must be fixed by use of a

suitable transportation locking device before

any transportation is carried out.

9.4.3

Lifting

Only suspend motors from the lifting eyes

provided. Do not attach any additional load to

the motor as the lifting eyes are only intended

for lifting the weight of the motor.

9.5

Installation

The motors are suitable for indoor installation.

The motors may be operated at heights of

1000 meters above sea level at ambient

temperatures of – 20

o

C to + 40

o

C. Exceptions

are specified on the rating plate.

9.5.1

Ventilation

Normal ambient temperatures should not

exceed 40°C (Marine standard +45 or +50°C)

if standard performance is to be achieved.

Check that the motor has sufficient airflow.

9. moTor

29

9. moTor

Motor

9

Ensure that no nearby equipment, surfaces or

direct sunshine radiate additional heat to the

motor.

9.5.2

Drain Holes

Make sure open drain holes face downwards.

Extremely dusty environments all require drain

holes to be closed.

Incorrect setup may cause damage to bearings

and shaft extensions.

9.5.3

Connecting the motor

Normal motor design has the terminal box on

top with cable entry possible from both sides.

Some motors are available with top-mounted

terminal boxes rotatable 4 x 90°, and some

with side-mounted terminal boxes.

Unused cable entries must be closed.

As well as main winding and earthing terminals,

the terminal box can also contain connections

for thermistors, standstill heating elements,

switches, or PT 100 resistance elements.

Voltage may be connected at

standstill inside the terminal

box for heating elements or

direct winding heating!

Connection diagrams for auxiliary elements

are found inside the terminal box cover or in

additional labels on the motor frame.

The capacitor in single-phase

motors can retain a charge that

appears across the motor

terminals even when the motor

has reached standstill.

Choose cable cross-sections in accordance

with the rated current. Unused cable entries

must be closed by compression glands.

The motor must be out of operation,

disconnected and secured against starting.

This also applies to auxiliary circuits (e.g.

heaters). Make sure that there is no voltage.

The supply cables must be connected

with special care to ensure permanent and

reliable contact. Use suitable terminals for the

connection cables. Supply cables must be

relieved of stress so that no cantilever loads

are exerted on the terminals.

Cable entries which are not used and the

terminal box itself must be sealed against dust

and water. In order to maintain the degree

of protection, always ensure that the original

gaskets are used and that the terminal box is

clean and dry when closing.

9.5.4

Direction of rotation

The motors are normally suitable for both

directions of rotation. Exceptions are indicated

on the rating plate by an arrow. For the desired

direction of rotation, the stator winding is

connected as follows:

Connection of L1,

L2, L3 to:

Direction of

rotation when

viewing drive end:

U1, V1, W1

Clockwise

W1, V1, U1

Counterclockwise

Mode of starting

and winding

Measures to

changing of

rotation direction

Direct-on-line starting and

pole-changing motors with

separate windings

Reverse connections at

motor or switchboard.

Star/delta starting and

pole-changing motors with

Dahlander winding

Exchange two supply cable

conductors at the incoming

supply to the contactor

combination

Test
To check the direction of rotation, quickly

switch the properly connected but uncoupled

motor On/Off.

9.5.5

Y/Δ starting

In order to avoid excessive transient currents

and torques before changing from Y to Δ,

wait until the starting current of the Y stage

has died down or change when rated speed is

reached. Centrifugal pumps are normaly not

suited for star/delta starting.

30

9. moTor

Motor

9

9.6

Repair and Maintenance

Before carrying out any work on the motor,

disconnect it and secure it against restarting.

In motors with greasing device, regrease

bearings with the motor running.

9.6.1

General Inspection

Inspect the motor at regular intervals.

•

Keep the motor clean and ensure free

•

ventilation airflow.

Check the condition of shaft seals and

•

replace if necessary.

Check the condition of connections and

•

assembly bolts.

Check the bearing condition by listening

•

for unusual noise, vibration measurement,

bearing temperature, inspection of spent

grease or SPM nipple monitoring.

9.6.2

Cleaning

Depending on local conditions, air passages

should be cleaned regularly.

9.6.3

Bearing maintenance and

lubrication

Before the First Start of the

motor it must be greased!

Observance of regreasing

intervals is vital for the

operational reliabilty of the

motors!

Under normal operating conditions, motors can

be operated between 2-4.000 hours without

maintenance depending on frame size and

rpm. The maximum period of maintenance-

free operation is four years. However, the

condition of the grease should be checked

occasionally even before this time limit. The

indicated number of service hours is only valid

for operation at rated speed. The bearings

should only be filled 2/3 since a complete

filling of the bearings and bearing covers with

grease leads to increased bearing temperature

and therefore to increased wear.

The ball bearings and the bearing caps

should be washed with petrol or benzene. If

necessary, replace the bearings. Half fill the

spaces between the ball and the roller track

as well as the grease compartments with

grease. Coat shaft bushings in the bearing

caps or end shields with a thin layer of grease.

Permanently greased bearings (2RS and 2Z

bearings) cannot be washed and regreased.

Such bearings must therefore be replaced. To

dismantle the bearings, use pressing screws

or other appropriate devices.

9.6.4

Bearings with regreasing device

and grease slinger

Regreasing interval and required quantity

of grease are indicated on the rating plate.

Bearings and bearing caps must be washed

with petrol or benzene after regreasing twelve

times.

With the outer bearing cap open but the inner

cap screwed on, the rotor should be turned

slowly and grease pressed in through the

regreasing device until approximately half the

empty space between the rolling elements an

the roller tracks is filled with grease.

9.6.5

Lubricants

When regreasing, use only special ball bearing

grease with the following properties:

When regreasing, use only special ball bearing

grease with the following properties:

Good quality grease with lithium complex

•

soap and with mineral or PAO oil

Base oil viscosity 100–160 at 40°C

•

Consistency NLGI grade 1.5–3 *

•

Temperature range -30° - +120°C

•

continuous.

*) For vertically mounted motors or in

hot conditions, a stiffer end of scale is

recommended.

Grease with the correct properties is available

from all major lubricant manufacturers.

Highly loaded or slowly rotating bearings

require EP grease.

31

9. moTor

Motor

9

The following (or similar) high performance

grease can be used:

Esso

Unirex N3

Mobil

Mobilith SHC 100

SKF

LGHQ 3

BP

Energrease LC 2

Shell

Albida EMS 2

9.6.6

Lubrication intervals

The lubricantion intervals are based on

a bearing operation temperature of 80°C

(ambient temperature of 25°C) An increase

in the ambient temperature raises the

temperature of the bearings correspondingly.

The table values should be halved for a 15°C

decrease in bearing temperature and may

be doubled for a 15°C increase in bearing

temperature.

Frame size

Two pole

design

Four and

multipole

design

112 to 315

2000 hrs

4000 hrs

355 to 400

2000 hrs

3000 hrs

9.7

Spare Parts and Repair

Any repair work within the guarantee

period is subject to approval by the motor

manufacturer.

When ordering Spare Parts, the full type must

be designated and the product code as stated

on the rating plate must be specified.

If the motor is stamped with a serial number,

this should also be given.

9.7.1

Rewinding

Rewinding should always be carried out by

qualified repair shops.

32

9. moTor

Motor

9

9.8

Troubleshooting

The diagram below describes the most common faults which can occur during operation of motors.

Should additional information be required, please contact IRON Pump or the motor manufacturer.

Problem

Possible cause

Solution

Motor does not

start:

Blown fuses.

Replace fuses with proper type and rating.

Overload.

Check and reset overload in starter.

Improper power supply.

Check if power supplied is consistent with

motor rating plate and load factor.

Improper line connections.

Check connections with diagram supplied

with motor.

Open circuit in winding or

control switch.

Indicated by humming sound when

switch is closed. Check for loose wiring

connections. Also ensure that all control

contacts are closed.

Mechanical failure.

Check if motor and drive turn freely. Check

bearings and lubrication.

Short circuited stator.

Indicated by blown fuses. Motor must be

rewound.

Poor stator coil connection.

Remove end bells, locate with test lamp.

Rotor defective.

Look for broken bars or end rings.

Motor may be overloaded.

Reduce load.

Motor stalls:

One phase may be open.

Check lines for open phase.

Wrong application.

Change type or size. Consult manufacturer.

Overload.

Reduce load.

Low voltage.

Ensure the rating plate voltage is

maintained. Check connection.

Open circuit.

Fuses blown, check overload relay, stator

and push buttons.

Motor runs and

suddenly stops:

Power failure.

Check fuses, control panel and lines for

loose connections.

Motor does not

come up to speed:

Not applied properly.

Consult supplier for proper type.

Voltage too low at motor

terminals because of line

drop.

Use higher voltage or transformer

terminals or reduce load. Check

connections. Check conductors for proper

size.

Starting load too high.

Check admissible load which motor is

supposed to carry at start.

Broken rotor bars or loose

rotor.

Look for cracks near the rings. A new rotor

may be required as repairs are usually

temporary.

Open primary circuit.

Locate fault with testing device and repair.

Motor takes too long

to accelerate and/or

draws high current:

Excessive load.

Reduce load.

Low voltage during start.

Check for high resistance. Adequate wire

size.

Defective squirrel cage rotor. Replace with new rotor.

Wrong rotation:

Wrong phase sequence.

Reverse connections at motor or

switchboard.

33

9. moTor

Motor

9

Problem

Possible cause

Solution

Motor overheats

while running under

load:

Overloaded.

Reduce load.

Frame or bracket vents may

be clogged with dirt and

prevent proper ventilation of

motor.

Open vent holes and check for a

continuous stream of air from the motor.

Motor may have one phase

open.

Check to make sure that all leads are

properly connected.

Grounded coil.

Locate and repair.

Unbalanced terminal

voltage.

Check for faulty leads, connections and

transformers.

Motor vibrates:

Motor misaligned.

Realign.

Weak support.

Strengthen base.

Coupling out of balance.

Balance coupling.

Driven equipment

unbalanced.

Rebalance driven equipment.

Defective bearings.

Replace bearings.

Bearings not in line.

Line up properly.

Balancing weights shifted.

Rebalance motor.

Discrepancy between

balancing of rotor and

coupling (half key - full key).

Rebalance coupling or motor.

Polyphase motor running

single phase.

Check for open circuit.

Excessive end play.

Adjust bearing or add shim.

Scraping noise:

Fan rubbing fan cover.

Remove interference.

Fan striking insulation.

Clear fan.

Motor loose on bedplate.

Tighten holding bolts.

Noisy operation:

Air gap not uniform.

Check and correct bracket fits or bearing.

Rotor imbalance.

Rebalance.

Bearing balls are

getting hot:

Bent or sprung shaft.

Straighten or replace shaft.

Excessive belt pull.

Decrease belt tension.

Pulleys too far away.

Move pulleys closer to motor bearing.

Pulley diameter too small.

Use larger pulleys.

Misalignment.

Correct by realignment of drive.

Insufficient grease.

Maintain proper quantity of grease in

bearing.

Deterioration of grease or

lubricant contaminated.

Remove old grease, wash bearings

thoroughly in kerosene and replace with

new grease.

Excess lubricant.

Reduce some grease. Bearing should not

be more than 1/2 filled.

Overloaded bearing.

Check alignment, side and end thrust.

Broken ball or rough races.

Replace bearing. First clean housing

thoroughly.

IRON Pump A/S

P.O. Box 527

Generatorvej 10

2730 Herlev

Denmark

www.ironpump.com

Service

Tel.

[phone]

Mob.

[phone]

Fax.

[phone]

E-mail

[e-mail]

Spare Parts

Tel.

[phone]

Mob.

[phone]

Fax.

[phone]

E-mail

[e-mail]

Spares

When requesting our assistance please make

sure to have the following information at

hand:

Pump type

•

Serial number (i.e. P.no. DHB ####, from

•

Type plate, it is also stamped in the suction

flange).

IRON Pump A/S order number (5 or 7

•

digits.)

Item No. and description of part (See Spare

•

Parts drawing).

If you need spares for your IRON Pump A/S,

you can also use the spare parts enquiry form

which can be found on our website.

Created by : IRJ Approved by: MM

Valid from: 2012-02-02

Revision : 4