Professional Documents
Culture Documents
MAINTENANCE INSTRUCTIONS
PUMPS E1 & E
Dear Owner
Congratulations! You have just purchased easy-to-assemble construction
equipment, designed and manufactured with the most advanced technology,
excellent performance and easy maintenance.
The aim of this manual is to inform the user about the details of the
equipment and the proper techniques for Installation, Operation and
Maintenance.
IMBIL recommends the installation and handling of this piece of
equipment according to the technical specifications and instructions of this
Manual. It is also recommended that this piece of equipment be used according
to the service conditions for which it was selected (volumetric flow, total head,
speed, voltage, frequency and temperature).
These procedures will provide a better performance and will ensure a
better durability for the equipment.
n case the equipment needs to be verified or when ordering spare parts, please
indicate the part code, model, pump series and also the series number found
on the identification plate.
NOTE
When you receive the WARRANTY DEED for your equipment, please fill in the
data and send the stub to IMBIL, so that the information exchange
between IMBIL and the client can be facilitated.
INDEX
SAFETY SECTION 1
Before starting the operation, consult the operation manual supplied by
the driving unit manufacturer.
CAUTION
Do not operate the pump with the valve closed in the
pressure line for a long time. This can make the
liquid vaporize and increase the pressure, and also
may cause the pump explosion.
ATTENTION
Never start the pump in the rotation direction
opposite to the indicated in the equipment. This can
make the shaft impeller loosen.
PAGE 1
INSTALLATION SECTION 2
This section offers general recommendations and procedures required for
inspection, positioning and placement of the pump and the piping.
Great part of the information concerns the installations with static elevation, where
the pump is placed above the level of the liquid to be pumped.
In cases of installations with throttled suction, where the liquid feeds the
pump under pressure, some characteristics, such as assembling, piping
configuration and priming must be specifically designed for each situation. If the
pressure provided by the pump regarding performance and safety is critical, make
sure that the admission pressure is limited to 50% of the maximum operation
pressure allowed, as indicated in the pump efficiency curve.
PRE-ASSEMBLING INSPECTION
Before the installation, check if the parts have been damaged during the
transport.
Proceed as follows:
Check if there are cracks, wrinkles, damaged threads or other visible
damage.
Check if there are loose parts. If so, tighten them .
Observe the rotation direction indicated in the pump. Check if the shaft
rotates in the correct direction as indicated.
CAUTION
Start the pump only in the rotation direction
indicated by the arrow located in the pumps bearing
house; otherwise the impeller can loosen from the
shaft and cause serious damage to the pump
Check the levels and lubricate it if necessary. If the pump or the driving unit
has been stored for more than 12 months, some of the components or lubricants
may have exceeded the storing period and must be inspected or replaced in
order to ensure the pumps peak efficiency and performance.
PAGE 2
PUMP POSITIONING
ATTENTION
The assembling of the motor-pump assembly and its
accessories may be seriously damaged if the cables
and chains used to lift or move the assembly are
improperly wound up around the equipment.
Assembling
The unit leveling is essential for proper operation.
The pump must be installed in an accessible site and the nearest as possible
to the liquid to be pumped.
Wedges may be used for the leveling and vibration elimination.
Materials
Either pipes or hoses can be used in the suction and discharge lines.
However, the materials must be compatible with the liquid to be pumped. If a
hose is used for the suction line, this should have a rigid and reinforced wall to
avoid flattening (collapse). The use of junctions in the suction line is not
recommended.
Line Configuration
Keep the suction and discharge lines as straight as possible in order to
minimize head losses due to attrition. Use as least elbows and junctions as
possible and, if necessary, use the long radius type to minimize head loss.
PAGE 3
SUCTION LINES
In order to avoid air pockets, which can affect the priming process, the suction
lines must be as short and straight as possible. When the operation involves
liquid elevation in the suction, the line must always have a rising inclination
towards the pump suction flange. If there is a falling inclination at any point of
the line, air pockets will be formed.
Connections
The suction lines must have the same gauge of the pump suction flange. If
reductions are used, they must be of the eccentric type, installed with the flat
part up in order to avoid air pockets formation. Valves are not usually used in the
suction line. If one is installed, it must have its rod in the horizontal position to
avoid air pockets formation.
Velocity.[m / s] =
Volumetric flow [m
2
Area[m ]
/ s]
PAGE 4
0
0
Velocity [m/s]
PAGE 5
DISCHARGE LINES
Siphoning
Do not finish the discharge line in a level inferior to the level of the liquid being
pumped, unless a siphon-breaking valve is installed in the line. Otherwise, a
siphon action may happen, causing damage to the pump.
Valves
If it is necessary the use of a gate valve in the discharge line, use a valve with
equal diameter or bigger than the pipe diameter, in order to minimize the head
loss by attrition. Never install a gate valve in the suction line.
In case of discharge with increased discharge, the installation of a gate valve
and a check valve is recommended to protect the pump against water hammer
and to prevent reverse rotation when there is a stoppage.
By-pass Lines
During the priming cycle, the suction line air must be released to the
atmosphere through a by-pass line installed between the pump discharge side
and the check valve.
ALIGNMENT
In an assembly started by elastic coupling or V-belt, the assembly must be
performed so that the shafts are aligned and parallel to each other. It is
very important to check the alignment after the pump and piping assembling
before start-up.
The assembly alignment must be checked before start-up. Before checking it,
make sure that the anchor bolts are tightened. The pump base and driving
unit bolts must also be firmly tightened.
CAUTION
Before checking the alignment, disconnect the
driving unit to ensure that it will remain inoperative
during the process.
PAGE 6
ATTENTION
The alignment in one direction can alter the
alignment in another. Check each procedure after
the alignment alteration.
Start-up by Coupling
When using couplings, the axles must be lined up in the plans horizontal and
vertical. Most couplings require specific clearance between the driving shaft
and the driven shaft. Consult the coupling manufacturer manual.
Picture 1 B
Start-up by Belt
When the start-up is performed by belt, the pump and drive shafts must be
parallel, the pulleys aligned to each other, and the belts appropriately stretched.
When the system uses two belts, make sure all of them are equal. The use of
different belts will cause accelerated wear.
PAGE 7
Misaligned: nonshaft
s
Misaligned: nonshaft
s
Picture
1C
Aligned: parallel
aligned pulleys
CAUTION
Never start the pump if the protections are not placed on the rotating parts.
The exposed rotating parts may contact clothes, fingers or tools and cause
serious injury to people.
OPERATION SECTION 3
ATTENTION
Do not use the pump for volatile, corrosive and
inflammable liquids, or others the pump was not
designed for.
The pump rotation and working conditions must be within the efficiency
range.
PRIMING
Install the pump and piping as described in INSTALLATION Section 2. Make
sure the piping is safely assembled. Check if the pump is properly lubricated.
This pump is self-priming but it should never be started unless there is
liquid inside it.
Add liquid inside the pump when:
1. It is being started for the first time.
2. It has not been used for a considerably long time.
INSTALLATION, OPARATION AND MAINTENANCE
PAGE 8
START-UP
Consult the operation and functioning manual provided with the driving unit.
Rotation
The correct direction of the pump rotation is indicated by an arrow in the pump
bearing house. If the pump is started in the opposite direction, the impeller may
loosen from the shaft and damage the equipment severely.
If the pump is started by an electric motor, remove the V-belts or couplings, or
separate the pump from the driving unit before checking the motor rotation
direction. When the motor is operating, observe the shaft rotation direction.
If the rotation direction is incorrect, check the motor manual in
order to know how to invert the rotation.
OPERATION
Lines with By-pass
If the by-pass line is open, the air of the suction line will be unloaded in
the reservoir during the priming cycle. The liquid, then, will keep on circulating
through the by-pass line while the pump is operating.
PAGE 9
Leakage
There must be no leakage in the pump junctions or connections. For this
purpose you should maintain the connections well tightened to obtain the
pumps peak efficiency and performance.
STOPPAGE
Never interrupt the liquid volumetric flow suddenly. If the pumped liquid stops
suddenly, water hammer may be transmitted to the pump and to the piping,
damaging the equipment. Always close all the valves slowly. If the pump is
started by internal combustion motor, reduce the rotation slowly and allow the
motor to idle before stopping.
If the application demands a very high discharge, close the gate valve gradually
before stopping the pump.
INSTALLATION, OPARATION AND MAINTENANCE
PAGE 10
ATTENTION
Before trying to open or repair the pump:
1. Be familiar with this Manual.
2. Turn the driving unit off in order to be sure that the
pump will remain inoperative.
3. Allow the pump to cool off in case of overheating.
4. Check the temperature before opening the
plates, covers or plugs.
5. Close the suction and discharge valves.
6. Allow the release of gas from the pump.
7. Drain the pump.
PAGE 11
LIKELY CAUSE
Insufficient amount of liquid
in the pump.
LIKELY SOLUTION
Add liquid to the pump.
See PRIMING.
PAGE 12
THE PUMP STOPS OR DOES NOT PRODUCE THE SPECIFIED VOLUMETRIC FLOW OR
PRESSURE.
LIKELY CAUSE
Air admission in the suction
line.
LIKELY SOLUTION
Repair the air inlet.
Collapse
covering
hose.
of
of
the internal
the suction
Clogged Impeller.
The rotation of the pump is very
low.
elevation using a
vacuum meter. Reduce the
height and/or losses caused by
attrition in the suction line.
PAGE 13
LIKELY CAUSE
The rotation of the pump is
very high.
LIKELY SOLUTION
Check the driving unit outlet.
Check if the pulleys and the
couplings are correctly sized.
Knocked bearing(s)
PAGE 14
EXCESSIVE NOISE
LIKELY CAUSE
LIKELY SOLUTION
Tighten attachments.
Clogged or damaged
impeller.
PAGE 15
ATTENTION
The pump rotation and the functioning points must be
range shown in the respective curves.
within
the
operation
PAGE 16
CODE
*ANCE
*AO
CA
CL
CPMA
CPMN
CS
ENGR
*EX
*FL
FS
GF
*JUN
*JUN
MN
*PD
PE
*RE
RES
*RO
*ROL
*SM
TA
TI
TM
QUANTITY
01
01
01
01
01
01
01
02
01
01
01
01
01
01
01
01
01
03
01
01
02
01
01
01
01
DESCRIPTION
Centrifuge ring
Oring
Volute Case
Grease fitting
Flap Bigger Counterweight
Flap Smaller Counterweight
Mechanical seal volute case
Greaser
Shaft
Flap
Suction flange
Fixation clamp
Bearing house joint
Volute case joint
Bearing house
Wear plate
Filler cap
Retainer
Vent
Impeller
Bearing
Mechanical seal
Tightening tee
Manhole
Bearing house cover
PAGE 17
PAGE 18
CODE
*ANCE
*AO
CA
CL
CS
*EX
*FL
FS
GF
*JUN
*JUN
MN
OLH
*PD
PE
*PS
*RE
RES
*RO
*ROL
*SF
*SM
TA
TI
TM
VS
QUANTITY
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
03
01
01
02
01
01
01
01
01
01
DESCRIPTION
Centrifuge ring
Oring
Volute case
Grease fitting
Mechanical seal volute case
Shaft
Flap
Suction flange
Fixation clamp
Bearing house joint
Volute case joint
Bearing house
Eye
Wear Plate
Filler cap
Flap support pin
Retainer
Vent
Impeller
Bearing
Flap support
Mechanical seal
Tightening Tee
Manhole
Bearing house cover
Oil level display
PAGE 19
ATTENTION
pump disassembling
PAGE 20
Flap Removal
E 1. Pump:
Remove the nuts and pull the suction flange together with the flap,
inspect the rubber flap and its counterweights.
E 2 Pump:
Remove the flap pin.
Reach the Flap through the front manhole opening and pull the complete
assembly.
Remove the sleeve and the rotating part of the mechanical seal, sliding
the sleeve towards the shaft end.
Use two hard wires with turned ends to remove the stationary parts from
the seal.
Remove the Oring from the sleeve.
PAGE 21
Remove the drain plug from bearing volute cases and drain the lubricant
(E2 only);
Remove the bearing cover and the retainer;
Remove the joint of the bearing house and force the retainer off the cover;
Place a wood block on the shaft end next to the impeller and hit it using a
hammer to remove shaft assembly and bearings from the bearing house;
Clean and check the bearings while assembled;
Clean the bearing house, shaft and components (except bearings)
using cleaning solvent in a soft soaked cloth;
Check all the parts to detect excessive wear or failure and replace
them if necessary;
Clean the bearings completely using new cleaning solvent, dry them with
compressed and filtered air and cover them with thin oil;
Rotate the bearings by hand to check for jolts and or if they are stuck; then
check the balls;
If it is necessary to replace the bearings, use an extractor to remove
them from the shaft;
Push internal oil retainer and release it from the bearing house.
PAGE 22
ATTENTION
When assembling bearings on the shaft, never
press or hit the cover on the balls or on the bearing
cage. Press only the hub.
Clean the mechanical seal cavity and shaft using new cleaning solvent in a
soft soaked cloth;
Check the cavity of the stationary back-up ring, searching for dirt; the
cavity of the stationary seat must be completely cleaned before seal
PAGE 23
installation;
Lubricate the Oring of the sleeve of the shaft (E2 pump) and the Oring
of the stationary seat using a small amount of thin oil;
In case the mechanical seal volute case has been removed, install the
joint of the volute case;
Attach the shaft to the bearing house and attach the bearing house
cover using fixation bolts;
In order to avoid damage to the Oring of the sleeve in the shaft thread (E2
pump), stretch the Oring on to a piece of pipe, install the pipe on the
shaft thread and roll the Oring on the pipe towards the shaft.
Remove the pipe and keep on rolling the Oring through the shaft until
it touches the shaft salience.
Impeller Installation
PAGE 24
Attach the rotating assembly on the pump volute case with the fixation
bolts, do not tighten completely the fixation bolts until the front manhole
is totally assembled and the impeller face clearance has been totally
adjusted;
A clearance of 0.2 to 0.4 mm between the impeller and the wear plate
is recommended in order to reach the pump peak efficiency and
performance;
After the impeller rests on the wear plate, regulate the assembly
by using the regulating bolts.
Reach by hand the flap valve assembling location through the opening of
the manhole and position the valve adapter in the assembling seat in the
suction flange.
Align the adapter with the flange opening and attach the assembly
using the check valve pin.
In case the suction flange has been removed, install the joint, use joint
seal and attach it to the pump volute case using the bolts.
In case the wear plate has been removed and replaced, center it carefully
on the manhole and attach it by using bolts and a pressure washer (the
PAGE 25
wear plate must be concentric to avoid knocking when the front manhole is
assembled).
Replace the Oring and lubricate it using a generous amount of number 2
grease;
Remove scales and particles from the surface, which may interfere or
avoid a good sealing when in contact with the pump volute case.
NOTE
To facilitate a future disassembling, use grease or penetrating oil film on the
manhole salience or any other surfaces that can contact the pump volute
case. This will avoid rust and scales.
Attach the front manhole assembly using the fixation clamp and the
tightening tee.
Make sure that the wear plate does not fasten in the volute case.
Install the key in the shaft and connect it to the driving unit;
Make sure that the protections are installed on the rotating parts;
Install the suction and discharge pipes and open all the valves;
Make sure that all the pipe connections are correctly tightened, supported
and safe;
Make sure the pump and driving unit have been properly lubricated;
Remove the filler cap and fill the pump volute case with clean liquid;
Reinstall the filler cap and tight it up.
LUBRICATION
Mechanical Seal
Before starting the pump, remove the seal grease fitting cap and fill the
mechanical seal
Check regularly the oil level and keep the grease fitting always full..
Bearings
In the E2 model check the oil level regularly by means of the display,
keeping the level in the middle of the display. If necessary, add SAE 30 oil,
INSTALLATION, OPARATION AND MAINTENANCE
PAGE 26
without detergent through the breather hole. Do not keep the level very
high, otherwise it may overheat the bearings and premature faults may
emerge.
Under normal conditions, drain the bearing volute case once a year and fill it
with clean oil. In case the pump is operating continuously or if it is in a place
subject to fast changes in temperature, the oil must be replaced more frequently.
NOTE
Check the lubricant condition regularly in order to detect possible rust or
condensation. This is especially important where there are large variations in
temperature.
When operating under low temperatures, refer to the oil supplier for the proper
type of oil.
In the E 1 model the bearing house is already lubricated in the factory. Under
normal conditions add lithium-based grease using the two bearing houses
greasers every 250 hours of operation or once a month, whatever completes
first.
Under normal conditions, change likewise the grease every 5,000 working hours
or every 12 months, whatever completes first.
In case the pump is operating continuously or if it is in a place subject to
fast changes in temperature, the grease must be replaced more frequently.
When operating under low temperatures, refer to the lubricant supplier for the
proper type of grease.
PAGE 27
ADDRESS: Rua Jacob Audi, 690 - Vila Izaura CEP 13971-045 - Itapira-SP
PABX: (55*19) 3843-9833 - FAX: Depto. Vendas (19) 3863-0714
Customer Service
DDG 0800-148500
www.imbil.com.br