DPV installation and operating instruction
Contents
1. 554 01 920 03 NON NN NN XM NN NN Q 30 S I 20040231 11 1 4 Parts drawing DPV 2 4 10 14 18 1525 05 525 08 525 03 525 01 e Je 904 X N _ 5 5 _ 2555 Y gt N 903 411 01 412 04 903 01 31 20040230 F 11 1 5 Parts drawing DPVF 2 4 10 14 18 1D 276705122005 108 02 529 230 525 01 210 90 pp SAE 411 01 4002. 932 525 041 930 920 02 920 01 1882 433 412 06 411 01 39 99000539 J Parts drawing DPVCF 65 11 1 13 88 18 50525 20026 056 90525 066 i 70605 T 0119 16 10719 4 4021 002 90026 50455 60106 00 71 10955 80026 10106 zog H 40 11 1 14 Parts drawing DPLHS 6
3. m 14 6 2 st 15 DMMESLCO daba asa 15 Installation instructions 71 Setingi pihepumpb M 16 7 2 Mounting a motor on the PUMP Lg nda 17 7a Eleetricaliinstallu ubl 20 TA COMMISSIONING 20 Operation S MEST EGO 22 Maintenance 9 1 Jnitroduction irre etre Ee P EIER ER PI DE E are 23 9 2 23 9 3 Maintaining the pump for an extended period of non operation 23 94 Replace DPVE non returti valve 2 cher eere erc eub eeen eves 23 10 Failures 11 10 27 Failure tableroa re dbase 24 Annexes 11 17 Spare part 27 11 2 Technical Specifications u u 42 11 3 Torques of coupling bolts pos 914 01 0000 000000 ener nnne nn nnns 44 11 4 CE declaration of conformity L 45 1 Manual Introduction 1 1 Preface This manual con
4. 20041223 D 11 1 8 Parts drawing DPVF 24 32 45 230 01 VF 24 32 230 02 VF 45 433 0 0 ze 433 412 01 412 01 411 01 d a d 2 d 24 35 20010717 11 1 9 Parts drawing DPVF 24 32 45 with cartridge seal 509 01 SN 412 03 230 01 vr 24 32 230 02 vr 45 525 04 932 930 920 02 g s 2 1 2255 3 5558 m e SIR m s Less x 58585 412 06 411 01 2
5. 3 Gradually open the suction shut off valve until the liquid flows from the fill plug C 4 Close the fill plug 5 Fully open the suction shut off valve 6 Check the rotational direction of the pump 7 Fully open the outlet shut off valve 7 4 2 In an open circuit with a liquid level lower than the pump 0241 24062003 1 Partly loosen the drain plug A For DPVE DPVCF and DPLHS the drain plug must be fully removed Remove the fill plug B from the top bracket 3 Block the entry of the drain plug on the outside of the pump foot Close the outlet shut off valve 5 Fill the pump housing to the maximum through the fill plug with the liquid that is to be pumped gt Screw the drain plug into the pump foot Insert the fill plug in the top bracket Check the rotational direction of the pump Open the outlet shut off valve 7 4 3 After an extended period of non operation or storage During first start up be sure to check the mechanical seals for leakage due to seizure or dehydration of the lubricating film If this is the case please proceed as follows 1 shaft manually or 2 Start up the pump then open and close the outlet shut off valve quickly during operation 3 Check if the mechanical seal is still leaking If the shaft is still leaking 1 Disassemble the mechanical seal 2 Thoroughly clean and degrease the running surfaces 3 Assembl
6. 20030733 19 20 13 Electrically connect the motor 8 7 3 ATTENTION Electrical install gt After connecting the motor according to the diagram always check the rotation direction 7 3 Electrical install Electrical connections WARNING Make sure that the motor specifications N Only authorised personnel is allowed to correspond with the power supply to which the make electrical connections to the pump motor is connected Consult Electrical motor This is in accordance with the diagrams in the annexes for the correct local regulations connection diagram Connect the motor using a motor safety switch 1x 230V 3x 230V 3x 400V 230 400V 400 692V 2482 10082005 PTC connection STM 140 EK ATTENTION All motors 3 kW and up are equipped with a PTC Seen from the top of the motor the thermistor Consult 11 2Technical specifications pump should rotate clockwise B See 42 7 1 1 Indicators In case of a 3 phase Connectthe PTC on a thermistor relais motor the rotating direction can be changed by exchanging two of the three phase wires 7 4 Commissioning WARNING The pump must not be switched on when it is not completely filled up 7 4 1 an open or closed circuit with sufficient supply pressure 0239 24062003 1 Close the suction shut off valve A and the outlet shut off valve 2 Open the fill plug
7. Group Category Zone Pumps Motors 1 2 2 none none S Il 1 G 0 none none 5 D 20 none none 2 G 1 DPV S 2G Eex e T3 DPVCF 2G Eex d T4 DPLHS D 21 none none 3 G 2 DPV S 2G Eex e T3 DPVCF 2G Eex d T4 DPLHS D 22 none none 13 6 Transport 6 1 Transport Transport the pump in the position as indicated on the pallet or packaging Make sure the pump is stable If present observe the instructions on the packaging WARNING Lift the pump if necessary using a hoist and suitable slings Attach the slings to the transport lugs on the packaging where present WARNING The pump must be lifted according to the current hoist guidelines Only qualified personnel are allowed to lift the pump 20050327 WARNING Do not lift the pump by using the frequency converter if placed electrical parts or the motor cover Be sure that the pump is always in balance WARNING All the pumps will turn approximately 2 to 15 degrees Do not remove the lever or protection from the pump before the pump is placed and mounted correctly P gt gt 20050327 14 6 2 Weight Motor Minimum Maxi Minimum Maximum weight mum weight with weight with weight frequency frequency converter converter kW kg kg kg kg 0 37 1 14 18 21 0 55 13 23 20 30 0 75 16 24 23 31 44 19 61 26 68 1 5 25 6
8. 2 Identification service and technical 2 1 Obtaining data and information duijvelaar pompen dp pumps Holland The name plate indicates the type series size main o operating data and identification number Please S quote this information first two lines in all queries repeat orders and particularly when ordering spare parts If you need additional information x instructions exceeding the scope of this manual or in case of damage please contact DP Pumps s nearest customer service centre duijvelaar pompen dp pumps Holland 8 E amp 5 a Pump with motor Indication Meaning DPV 4 40 Pump type ser nr Serial number 19 2004 234567 19 Production week 2004 Production year 234567 Product identification as built file Sic EPDM Ca Rotating part mechanical seal Carbon Sic Stationary part mechanical seal Siliconcarbide EPDM Static sealing O rings EPDM PN 10 Pressure class flange connection Q m h l sec USGPM Nominal capacity see Q H curve above H mWc PSI Nominal head see Q H curve above lom A Nominal current see 2 2 n T min Nominal rotation speed 5 P kW HP Installed motor power on the pump Preq kW HP Required motor power for the pump 1 For pumps delivered with special motors no values are given please use values as indicated on the motor plate The following address data are available for service and technical supp
9. 433 25525 822225 ez A o 3 A 11 1 10 Parts drawing DPVCF 32 45 171 03 509 01 37 20070213 B 11 1 11 Parts drawing DPVCF 32 45 with cartridge seal 411 01 412 06 i i T i 38 20070216 B 11 1 12 Parts drawing DPVF 65 0 509 01 509 03 230
10. N 5 ww ES sown o 9 uw HS 903 903 01 412 04 903 02 411 01 554 02 901 02 41 20040232 D 11 2 Technical specifications gt gt The motor data only applicable for standard motors delivered with the pump and not applicable for explosion proof motors gt gt motors equiped with Table 8 Technical specifications of pumps with 2 pole 1 phase 50 Hz motors 5 0 2 m 5 220V 230V 240 x x E x oO n n E EI z 037 105 63 64 10 2750 16 29 29 29 0 55 075 64 64 10 2750 20 45 45 45 075 1 63 67 10 2750 20 69 69 69 11 15 64 67 10 2750 30 87 87 87 15 2 67 67 10 2750 44 1 11 11 22 3 74 71 10 2820 60 152 152 152 Table 9 Technical specifications of pumps with 2 pole 3 phase 50 Hz motors A x z i 2 3 m
11. 32 20040243 33 J 6EZ0700Z Parts drawing DPVCF2 4 10 18 11 1 6 EUG A i 607106 607966 2 621 P d E 009 m m 907026 266 er 88 187 66 wos 6 01 0 21 lt 062 2 626 20 801 2 10 S25 Z _ V lt i il i 107626 607626 Y l 10 vss 807626 DIe 507026 G0 S25 P 5 T S26 4 cer 10 zir 66935 10 106 S i ud uen t of La 107716 11 1 7 Parts drawing DPVV2 4 10 14 18 1 525 05 525 03 525 08 r 6525 01 210 1 9 43 411 01 412 01 412 01 400 34
12. 220V 230 240V 380 400 420 660V 725V 5 B6 5 a a 21 0 37 0 5 76 60 50 2865 2 5 2 4 2 3 1 5 1 4 1 3 0 55 0 75 82 60 50 2880 2 7 2 6 2 5 1 6 1 5 1 4 075 1 8 60 50 2865 39 37 36 22 21 11 15 83 60 50 280 59 58 55 234 133 3 1 5 2 84 1 69 30 2880 7 6 7 6 7 6 4 4 4 4 4 4 2 2 3 85 6 72 30 2875 10 4 10 4 10 4 6 6 6 3 4 83 6 67 20 2915 13 3 13 3 13 3 7 7 7 7 7 7 4 4 4 4 4 4 4 5 87 3 69 20 2935 16 8 16 8 16 8 9 7 9 7 9 7 5 6 5 6 5 6 5 5 75 86 74 15 2890 20 8 208 208 112 12 12 69 69 659 7 5 10 868 70 12 2880 268 268 268 1155 155 155 80 80 859 4 16 893 74 10 2950 528 528 528 305 30 5 305 176 176 17 6 15 20 90 5 74 10 2920 549 549 549 317 317 317 183 183 183 18 5 25 91 74 10 2930 70 1 701 701 1405 405 405 234 23 4 234 22 30 90 6 87 10 2920 777 771 771 445 1445 445 257 257 257 30 40 93 74 6 2960 1023 975 934 1592 563 536 340 324 N A 37 50 93 74 6 12960 1187 113 5 108 8 687 65 3 622 397 378 N A 42 Table 10 Technical specifications of pumps with 4 pole 3 phase 50 Hz motors i max A A 2 z i 2 s cT EX E ic 220V 230 240 380 400 420 660 692 725V 8 5 n a EI
13. Vertical multi stage centrifugal pumps Installation and operating instructions series DPVE DPV S DPVCF DPLHS DPLHS DPVCF DPV S DPVE Table of Contents 1 Manual Introduction 1 1 1 2 AEN 4 Ue X ES Insee 4 Identification service and technical support 2 1 Obtaining data and information eene nnne 5 2 2 kende 6 2 3 Supplementary documentation 6 Warranty 3 1 ia tele 7 Safety and environment 4 1 4 2 4 3 4 4 4 5 jue 8 SONS 8 Safe prOVISlONS Su uuu EN 8 Safely u u 9 EivVironrmentaliaspecISu su uu u L 9 Pump Introduction Did GSMO cys E 10 5 2 1 2 5 2 ised gach uku le 10 5 9 ANGE resisti erre IM 11 5 4 Explosion Safety rset asas 12 Hr uM 13 Transport 6 1 amp
14. 4 Safety and environment 4 1 General This DP Pumps product has been developed using state of the art technology it is manufactured with utmost care and subject to continuous quality control DP Pumps does not accept any liability for damage and injury caused by not observing the directions and instructions in this manual This also applies in cases of carelessness during the installation procedure use and maintenance of the product Non compliance with safety instructions can jeopardize the safety of personnel the environment and the product itself Non compliance with these safety instructions will also lead to forfeiture of any and all rights to claims for damages For example in particular non compliance can result in failure of important pump system functions failure of prescribed maintenance and servicing practices injury to persons by electrical mechanical and chemical effects hazard of the environment due to leakage of hazardous substances explosions Depending on specific activities extra safety measures may be required Contact DP Pumps if a potential danger arises during use lt ATTENTION The owner of the product is responsible for compliance with the local safety regulations and internal company guidelines lt ATTENTION Not only must the general safety instructions laid down in this chapter on Safety be complied with but also the safety instructions outlined under sp
15. 1 5 6305 27 30 7312 2 2 6305 27 37 7312 3 6306 27 3 4 6306 22 C3 5 5 6308 27 3 7 5 6308 27 3 17 18 7 2 1 Install the motor on pumps supplied 91405 amp without motor with a standard mechanical seal 89 11 03 681 20090321 20090402 1 gt Remove the couplingguards 681 and the coupling shells 862 Remove the sealprotection bracket 89 11 03 and its mounting material For pumps with a taper piece 722 with motor of 5 5 kW or higher the two bolts 914 02 or 901 02 has to be placed back to connect the taper piece to the motor stool Thoroughly clean the motor stool 341 the shaft 210 the coupling shells 862 and the motor shaft Loosely fasten the coupling shells 862 with the coupling pin 560 on the shaft 210 Use the hexagon socket head cap screw 914 01 and the nut 920 01 for this When the pump is equipped with a steel coupling never use the same coupling twice but order a new one Place the motor on the motor stool 341 Tighten the lower bolts of the coupling shells 862 in such way that the coupling slightly clamps around the motor shaft Lift the pump assembly to the maximum upwards position and mark the shaft Use a tyre lever to lift the coupling gt gt For motors of 11 kW or higher block the rotor when adjustments are made to the coupling This ensures that the rotor will not
16. 45 5 4555 455 26 3 26 3 26 3 30 40 0 93 74 6 3552 102 3 93 4 N A 59 2 53 6 N A 34 N A N A 37 50 0 93 74 6 3552 118 7 108 8 68 7 622 N A 39 7 N A N A 43 Table 12 Technical specifications of pumps with 4 pole 3 phase 60 Hz motors i max A 5 c 2 2 E a ic 220V 240 280 380V 420 480 660 725 797V n a d z c 0 55 0 75 73 58 50 1740 4 7 4 3 3 7 2 7 2 5 2 2 0 75 1 74 58 50 1740 6 5 5 4 7 3 8 3 1 2 8 1 1 1 5 76 7 60 30 1685 4 8 4 8 4 8 2 8 2 8 2 8 1 5 2 79 58 30 1690 6 5 6 5 6 5 3 7 3 7 3 7 2 2 3 82 61 20 1710 8 4 8 4 8 4 4 9 4 9 4 9 3 4 78 4 64 20 1715 14 5 14 5 14 5 8 4 8 4 8 4 4 9 4 9 4 9 4 5 85 65 20 1725 17 5 17 5 17 5 10 1 10 1 10 1 5 8 5 8 5 8 5 5 7 5 85 9 64 15 1740 19 8 19 8 19 8 11 5 11 5 11 5 6 6 6 6 6 6 7 5 10 87 64 10 1740 27 27 27 15 6 15 6 15 6 9 9 9 Table 13 Technical specifications STM 140 Value HPC w wo c 2 20 Rin 20 c 9 250 Rin 5 c Q lt 550 Rin 5 0 gt 1330 c Q gt 4000 U VDC 2 5 lt U lt 30 113 Torques of coupling bolts pos 914 01 Material Dimensions Torques Nm Steel M6 16 Steel Cast iron M8 30 Aluminium M8 22 Cast iron M10 70 44 11 4 declaration
17. 77 8 DPVCF 32 65 54 25 44 74 DPVCF 45 80 48 17 31 59 6 DPVCF 65 100 60 21 33 71 6 20070301 DN Moment Nm mm Mx My Mz DPVCF 2 25 700 800 1200 1600 DPVCF 4 32 700 800 1200 1600 DPVCF 10 40 1100 1000 2600 3000 DPVCF 18 50 2200 1300 2600 3600 DPVCF 32 65 2300 1700 2000 3500 DPVCF 45 80 2700 2700 2300 4500 DPVCF 65 100 3300 3600 3000 5700 20070301 The values mentioned the tables above are given for the point at which a maximal tension of between 200 and 205 MPa occurs It is assumed that the 3 forces or the 3 moments as given in the drawing below occur simultaneously 20070301 gt gt Pumps that do not stand steady or stable of their own should be mounted on a ridged and stable base lt ATTENTION Place the pump there where there is the lowest risk for noise nuisance 1 Place and install the pump on a level stable surface in a dry and frost proof room 2 Make sure that sufficient air can reach the cooling fan of the motor For this purpose the free space above the cooling fan should be at least 1 4 of the diameter of the fan cover air intake 3 Install the pump with counter flanges Pumps with non standardised connections counter flanges are delivered separately 4 Installa valve on the supply and on the delivery connection of the pump 5 If there is a chance that when the pump is stand
18. come out of its bearings 20070376 WARNING Correct seal tension max 1 mm lower than the maximum upwards position Position the pump assembly 1 mm lower than the maximum upwards position as mentioned earlier Fully tighten the couplings at the given torque see Torques in the annexes Make sure that the gaps between the couplings are equally divided on both sides see drawing IL 20030733 9 10 Attach the coupling guards 681 with the socket head cap screws 914 05 to the motor stool 341 Connect the electricity supply to the motor see 7 3 Electrical install 7 2 2 Installing the motor on pumps supplied without motor with a cartridge seal 7 o 89 103 RIJ E 7 5597 gt 412 05 OS V 1 Remove the couplingguards 681 and the coupling shells 862 2 Remove the sealprotection bracket 89 11 03 and its mounting material For pumps with a taper piece 722 with motor of 5 5 kW or higher the two bolts 914 02 or 901 02 has to be placed back to connect the taper piece to the motor stool Thoroughly clean the motor stool 341 the shaft 210 the coupling shells 862 and the motor shaft 3 Loosely fasten the coupling shells 862 with the coupling pin 560 on the shaft 210 Use the hexagon socket hea
19. of conformity factory declaration 2 1 according to EN 10204 Undersigned DP Pumps Kalkovenweg 13 2401 LJ Alphen aan den Rijn The Netherlands Tel 31 0 172 48 83 25 Fax 31 0 172 46 89 30 Declares as manufacturer entirely on his own responsibility that the products without motor declaration IIB to which this dec EN 809 machine Machine directive 98 37 EC Vertical multi stage centrifugal pumps Type DPVE DPV S DPVCF DPLHS with motor declaration IIA laration refers is in accordance with the fo EN 809 and low voltage and when applicab Machine directive 98 37 EC EMC directive 89 336 EEC Low voltage directive 73 23 EEC with explosion proof motor declaration llowing standard EN 809 EN 13463 1 and EN 13463 5 according to the provisions of the harmonized norm for pumps and which implies the regulations of le ATEX Machine directive 98 37 EC EMC directive 89 336 EEC Low voltage directive 73 23 EEC ATEX directive 94 9 EC If the pump is used as a stand alone product it is subject to this declaration of conformity If the pump is built in an appliance or is assembled together with other equipment in certain installations then it should not be put into operation until a declaration has been given with respect to the installation or appliance concerned that it complies with the directives listed above Alphen aan den Rijn 18 05 2005 Responsible per
20. 3 32 70 2 2 29 72 38 81 3 43 82 52 91 4 49 86 59 96 5 5 81 120 71 5 130 5 7 5 68 138 78 5 148 5 6 3 Storage Fill the pump with glycol in order to protect it against the risk of frost Storage tambient C 10 40 Max rel humidity 6 3 1 Inspection during storage 80 at 20 C not condensing 1 Turn the shaft every three months and just before putting into operation 15 16 7 Installation instructions 7 1 Setting up the pump Es 8 S 2 Exc OO CO 100089 5 i S Ed ense 4 20050373 Make sure that the pump connections are stress less installed e g no heavy load on the inlet and outlet connections It is to be advised to use pipe compensators see drawing above Only on the condition that the pump is provided with a reinforced cast casing model DPVCF the top down force on the flanges can be in accordance with the table below Table 6 Allowable forces DPVCF Table 7 Allowable moment DPVCF Type DN Force mm Fx Fy Fz DPVCF 2 25 36 6 8 10 4 38 1 DPVCF 4 32 38 7 2 11 40 2 DPVCF 10 40 45 18 20 52 4 DPVCF 18 50 70 25 23
21. 5p to 1mm size of solids pumped Minimum Not cavitating supply pressure Viscosity 1 liquid CSt A higher viscosity may require more motor power Density liq 1000 uid kg m higher density may require more motor power Cooling The space above the cooling fan of the motor must at least be equal to 1 4 of the diameter of the inlet of the cooling fan of the motor in order to have a sufficient supply of air Number of Related to the motor starts Minimum 10 frequency Hz Maximum 60 frequency Hz 1 Using the factory option o ring sealing EPDM E425 the max temp limit is 120 C 2 When pumping water the max allowable liquid temp is 80 3 Higher temperatures are possible at lower pressure For specific limits consult your supplier 4 total of the supply pressure and no load delivery pressure with closed outlet shut off valve may not exceed the maximum working pressure 5 Contact your supplier for more detailed advice DP 50 Hz 60 Hz Qmin in m h 2 0 3 0 3 4 0 6 0 65 6 0 8 0 8 10 1 2 1 4 14 1 0 1 1 18 24 24 24 2 2 2 6 32 4 0 4 0 45 4 6 5 1 65 6 1 6 1 Table 3 Specific applications type application area DPV Drinking water supply systems irrigation systems water treatment systems car wash systems sprinkler systems DPVS Water supply systems for drinking water softened and demineralised water systems for brackis
22. 60 Cover 171 Diffuser 210 Shaft 230 Impeller 341 Motor stool 400 Gasket 411 Joint ring 412 O ring 433 Mechanical seal 471 Seal cover 500 Ring 509 Intermediate ring 837 27 28 number ZN 525 name Spacer sleeve 525 08 Spacer sleeve 529 Bearing sleeve 554 Washer 560 Pin 681 Coupling guard 722 Taper piece flanged 723 Flange 742 Non return valve 800 Motor 801 Flanged motor 802 Motor for close coupling 831 Fan impeller 832 fan hood 833 Terminal box 835 Terminal board 837 Condenser 862 Coupling shell 890 Baseplate fabricated or cast 900 Screw 901 Hexagon head bolt 903 Screwed plug 904 Grub screw 905 Tie bolt 913 Vent plug 914 Hexagon socket head cap scr 920 Nut 930 Safety device 932 Circlip 10 6 Pump shroud 81 37 Terminal box coverplate 29 Parts drawing motor 11 1 2 11 1 3 Parts drawing DPVE 2 4 10 14 wo 1 A 5 2 Mw o joo 5 N aeuum 5 8 www NN WD WD ij S lt lt e 1 d s sss 5
23. Terms of warranty The warranty period is settled by terms of your contract or at least by the general terms and conditions of sales gt gt Modifications or alterations of the product supplied are only permitted after consultation with the manufacturer Original spare parts and accessories authorized by the manufacturer ensure safety The use of other parts can invalidate any liability of the manufacturer for consequential damage gt gt The warranty relating to the operating reliability and safety of the product supplied is only valid if the product is used in accordance with its designated use as described in the following sections of this manual The limits stated in the data sheet must not be exceeded under any circumstances The warranty becomes invalid if one or more of the points below occur buyer makes modifications himself buyer carries out repairs himself or has these carried out by a third party The product has been handled or maintained improperly The product has non original DP Pumps spare parts fitted DP Pumps remedies defects under warranty if the points below are observed Defects are caused by flaws in the design the materials or the production The defect has been reported within the warranty period Other terms of warranty have been included in the general terms of delivery which are available upon request
24. d cap screw 914 01 and the nut 920 01 for this When the pump is equipped with a steel coupling never use the same coupling twice but order a new one 4 Place the motor on the motor stool 341 5 Loosen the three cartridge grub screws 904 one turn 6 Push the hydraulic pump assembly in the lowest position 7 Tighten the three cartridge grub screws 904 firmly to the shaft 20090322 20090402 8 Tighten the lower bolts of the coupling shells 862 so that the coupling slightly clamps around the motor shaft 9 Lift the pump assembly to the maximum upwards position and mark the shaft Use a tyre lever to lift the coupling ATTENTION For motors of 11 kW or higher block the rotor when adjustments are made to the coupling This ensures that the rotor will not come out of its bearings 20070376 WARNING N Correct seal tension max 1 mm lower than the maximum upwards position 10 Position the pump assembly 1 mm lower than the maximum upwards position as mentioned earlier 11 Fully tighten the couplings at the given torque see Torques in the annexes Make sure that the gaps between the couplings are equally divided on both sides see drawing Q tt B 12 Installthe coupling guards 681 with the socket head cap screws 914 05 to the motor stool 341
25. e Too much tension on the pump foot it becomes oval Decrease tension on pip ing Mount the pump foot ten sionless Support the connections Problem Pump is vibrating or noisy Possible cause Coupling mounted incor rectly Possible solution Install the coupling in par allel Checkpoints Faulty setting of the hydraulic assembly Adjust the assembly according to the manual There is no water in the pump Fill and vent the pump No supply Make sure there is suffi cient supply Check for blockages in the supply line Bearings of pump and or motor worn Have the bearings replaced by a certified company Available NPSH too low cavitation Improve suction condition Pump does not work in its working range Select another pump or adjust the system to work within its working range Pump is standing on an uneven surface Level the surface Malfunction Internal blockage in the pump Have the pump inspected by a certified company Pump does not start The motor is running but the pump does not work No voltage on the termi nal clamps Check the power supply Circuit Main switch Fuses Check the motor safety relay Earth leakage switch Protective relay Thermal motor safety switch triggered The pump shaft has been broken The coupling between pump and motor shaft is loose Reset the thermal motor
26. e medium to be pumped Replace the O rings Replace O ring by an O ring with better resistance 11 11 1 Spare part kits Spare part Kit Fan Hood Kit Fan hood 832 Fan Impeller 831 Kit Nr 832 Coupling Kit 4 6 x Nut 920 01 4 6 x hexagon socket head cap screw 914 01 2 x coupling shell 862 coupling pin 560 862 Drain air relief plug Kit Screwed plug 903 01 joint ring 411 01 screwed plug 903 02 joint ring 411 02 903 Stage casing compl with bearing Kit Stage casing with bearing 108 02 bearing sleeve 529 impeller 230 spacer sleeve short 525 01 Spacer sleeve Kit 2 x Spacer sleeve short 525 01 6 x spacer sleeve long 525 03 spacer sleeve 525 08 spacer sleeve seal 525 05 10 5 525 Sealing Kit Mechanical seal 433 2 x O ring 412 01 2 x gasket 400 433 Shaft end Kit Spacer sleeve end 525 04 lock nut 920 02 safety device Nord lock 930 circlip 932 81 88 Flange Kit 2 x Flange 723 4 8 16 x hexagon head bolt 901 03 0 4 8 16 x nut 920 4 8 16 32 x washer 554 03 2 x gasket 400 723 Terminal box kit Gasket 400 02 terminal box 833 terminal board 835 gasket 400 03 terminal box coverplate 81 37 4 x screw 900 833 Capacitor 837 11 1 1 Parts list number ZN name 101 Pump casing 108 Stage casing 1
27. e the mechanical seal again and retry start up If this doesn t solve the shaft leakage replacement of the mechanical seal is necessary 21 8 Operation 8 1 Operation The pump is controlled externally and therefore does not need any operation guidance 22 9 Maintenance 9 1 Introduction 1 Close all pump valves WARNING sd er system Observe the general safety precautions 4 DT luo if i for installation maintenance and repair and Myall YENE I present Regular maintenance is necessary for the correct operation a pump For maintenance of the pump 9 4 Replace DPVE non return please contact your supplier valve 9 2 Lubrication em Standard motors with a maximum power of 7 5 kW are provided with maintenance free sealed bearings Motors with lubricating nipples must be lubricated after 2000 hours If the pump works under extreme conditions such as vibrations and high temperatures the motors must be lubricated more often Use a lithium based 30 C 160 C bearing lubricant about 15 gram 0996 15082003 To replace the non return valve of the pump types When the pump is delivered without a motor and fitted DPVE proceed as follows with an other brand or the standard motor is replaced by an other brand than DP Pumps please consult the maintenance instructions of the motor supplier valve 2 Remove the O ring lt
28. ecific headings 4 2 Users All personnel involved in the operation maintenance inspection and installation of the product must be fully qualified to carry out the work involved Personal responsibilities competence and supervision must be clearly defined by the operator If the personnel in question is not already in possession of the required know how appropriate training and instruction must be provided If required the operator may commission the manufacturer supplier to take care of such training In addition the operator is responsible for ensuring that the contents of the operating instructions are fully understood by the responsible personnel 4 3 Safety provisions The product has been designed with the greatest possible care Original parts and accessories meet the safety regulations Modifications in the construction or the use of non original parts may lead to a safety risk lt ATTENTION Make sure that the product operates within its working range Only then the product performance is guaranteed 4 3 1 Labels on the product The icons warnings and instructions applied to the product are part of the safety provisions The labels may not be removed or covered Labels must remain legible during the entire life of the product Replace damaged labels immediately 4 4 Safety precautions 4 4 1 During normal use Contact the local electricity company for questions about the power supply Shield par
29. egory 2 make sure that the pump is through the pump outlet B on the delivery side under protected against damage from outside increased pressure Check that the motor cable is suitable for the current drawn by the motor See motor type plate Check that the pump is fully filled with the liquid de aerated Do not run the pump dry Check the rotational direction of the motor The C motor has to run clockwise seen from the non driven side This direction is indicated with an arrow on the pump top bracket Make sure that the liquid temperature never exceeds the temperature mentioned in the explosion safety code T3 or T4 See table 4 A 8 Explosion safety12 Avoid overheating of the pump to ensure minimum flow in the pump according with the description in chapter 5 3Working range11 The pumps has to be de aerated again when the pump is taken out of operation some air is gathered in the pump Makesure thatthe pump and the motor shaft are running smoothly and without excessive noise e g no parts are running against each other Make sure that the pump is connected to ground 0304 02072003 Pump inlet Pump outlet Terminal box Fill plug air relief plug Drain plug Table 5 ATEX Categories
30. gt ATTENTION 3 Install a new 2 Also follow the instructions 5 7 2 1 4 Install the new non return valve Mounting a motor on the pump 9 3 Maintaining the pump for an extended period of non operation Turn the shaft every three months This protects the seals from seizure 23 Protect the pump against if there is a risk of frost Proceed as follows 10 Failures 10 1 Problem Leakage along the shaft WARNING Failure table Possible cause Running surfaces of the mechanical seal worn or damaged Possible solution Replace the mechanical seal Observe the general safety precautions before install maintenance and repair Checkpoints Check the pump for dirt abrasive parts New pump seal stuck due to assembly Open and close the outlet shut off valve quickly dur ing operation mechanical seal mounted incorrectly Install the mechanical seal correctly Use water and soap as a lubricant Elastomers affected by medium Pressure too high Use a the right rubber compound for the mechanical seal Use the right type of mechanical seal Shaft worn Replace shaft and mechanical seal Pump has been operating without water Replace the mechanical seal Leakage along the shroud at the top bracket or at the pump foot O ring worn Replace the O ring O ring not resistant to the medium to be pumped Replace O ring by an O ring with better resistanc
31. h water sea water and swim ming pool water however limited with respect to temperature pressure and chlo rine percentage DPVCF Systems for boiler supply and discharge of condensed water DPLHS Reverse osmosis installations and high pressure cleaning systems DPVE Drinking water supply systems 11 12 5 4 Explosion safety lt ATTENTION This sub chapter contains fundamental information which has to be taken in consideration when installing the pump with ATEX permission in a hazardous environment 5 4 1 General Stickers or indicators on the pump sleeve and the motor indicates whether the pump is suitable for use in an environment with risk of explosion It is allowed to install the pump in a zone which is classified in directive 1999 92 EC When in doubt it is compulsory to check the above directive 5 4 2 Indication Ex II 2 G EEx c T3 0038 167363 2512 04112004 Table 4 Explosion safety Indication II Meaning Product group for use above ground with the exception of mine working where there can be danger of explosion due to mine gas and or flammable substances 2 3 Category 2 Equipment in this category is intended for use in areas in which explosive atmospheres caused by mixtures of air and gases vapours or mists or by air dusts mix tures are likely to occur Category 3 Equipment in this category is intended for use in areas in which explosive at
32. he pump is produced in accordance with the current standards and guidelines Use the pump only in a perfect technical state in conformance with the intended use described below The Intended use as laid down in EN 12100 1 is the use for which the technical product is intended according to the specifications of the manufacturer The use of the product has been described in the sales brochure and in the user manual Always observe the instructions given in the user manual When in doubt the product must be used as becomes evident from its construction version and function 5 3 Working range The working range of the pumps in this series can be summarised as follows Table 1 Specification of the working range 6 For standard motors see the technical specifications When the pump is fitted with another motor brand please consult the motor supplier 7 Pumps that are intended for 50 Hz operation may not be connected to 60 Hz 40 50 60 70 80 90 100 110 120 tc Minimum volume flows Q in of Q optimum temperatures t Table 2 Minimum volume flows Qin Pump type gt a Ambient 4 to 40 tempera ture C Liquid tem 15 15 to 100 15 to 120 15 15 perature to 60 to to C 120 803 Maximum 107 16 25 16 25 254 407 working pressure bar Allowable
33. igned to function in an environmentally friendly way during their entire life Therefore when applicable always use biodegradable lubricants for maintenance Y ENVIRONMENTAL INSTRUCTION amp Always act according to the laws by laws regulations and instructions with respect to health safety and the environment 4 5 2 Dismantling Dismantle the product and dispose of it in an environmentally friendly way The owner is responsible for this ENVIRONMENTAL INSTRUCTION amp Ask at the local government about the re use or the environmentally friendly processing of discarded materials 10 5 Pump Introduction 5 1 General 7 Vertical pumps DPVE DPV S The vertical multi stage centrifugal pumps DPVE DPV S DPVCF and DPLHS are produced by DP Pumps 5 2 Intended use The pumps DPVE DPV S DPVCF and DPLHS are suitable to transport and increase the pressure of cold and hot water without wear to parts within the indicated working range The transport of liquids with a different viscosity or density than water is possible as well For this a motor with an adjusted power is used Ask DP Pumps or your distributor for advice 20040265 B DPVCF DPLHS Any other or further use of the pump is not in conformity with its intended use DP Pumps does not accept any liability for any damage or injury that results from this T
34. ing still the medium can flow back it is advised to install a non return valve 6 Make sure that the inlet of the pump is never clogged 7 1 1 Indicators 0237 24062003 The arrow A on the pump foot indicates the flow direction of the liquid The arrow B on the top bracket indicates the rotating direction of the motor 7 1 2 Install bypass Install a bypass if the pump operates against a closed valve The required capacity of the bypass is at least 10 of the optimum volume flow At high operating temperatures a higher volume flow is required Refer to the table Minimum volume flows in the paragraph Working range 7 2 Mounting a motor on the pump gt gt It is to be advised to use special designed DP Pumps motor Before installing an other brand standard IEC norm motor DP Pumps has to be consulted to judge the applicability The motor has to conform to the following conditions Increased power output to limit the standard installed motor power Reinforced bearing at driven end to withstand the axial force Fixed bearing at driven end to minimize the axial play Smooth shaft no key lock to improve the coupling grip and to improve the motor balance The advised bearings per motor type are kW Axial bearing kW Co axial bearing 0 37 6203 2RS C3 11 7309 BEP 0 55 6203 2RS C3 15 7309 BEP 0 75 6204 2RS C3 18 5 7309 BEP 1 1 6204 2RS C3 22 7311
35. mospheres caused by mixtures of air and gases vapours or mists or by air dusts mix tures are likely to occur or if they do occur are likely to do so only infrequently and for a short period only Suitable for an environment that is explosive due to gas vapour or fumes not suitable for an environment that is explosive due to dust EEx c Protection principle type c for products that are constructively safe T4 T3 5 4 3 Temperature class T4 for medium temperatures up to 100 C T3 for medium temperatures above 100 C ATTENTION When there is an ATEX sticker on the pump the pump must only be used for pumping a medium with a conductivity higher than 50 pS m The medium must not be flammable ATTENTION When the pump is placed in an explosion hazardous environment no pump should be opened or disassembled on site Due to the probable creation of sparks during loosening and tightening of nuts and bolts Commissioning check list It is compulsory to check these points prior to put the pump in operation Check if the ATEX data on the motor and the 5 5 Operation pump are in line with the specified category See table SATEX Categories13 The liquid is sucked in through the pump inlet A on When the categories of the motor and the pump the supply side under minimum pressure The pump are different the lowest category is leading increases the pressure The liquid leaves the pump For cat
36. ort DP Pumps service department Kalkovenweg 13 2401 LJ Alphen a d Rijn The Netherlands Tel 31 172 488325 Fax 31 172 468930 Internet www dp pumps com E mail do dp pumps com 2 2 Nominal current The maximum allowable current of the motor is mentioned as on the motor plate This maximum allowable current shows the maximum working range of the motor and can be used to protect the motor WARNING Be careful in using it this way because not only the motor but also the pump has to be protected in its application On the pump plate sleeve sticker this pump current at 400 Volts will be mentioned as nom and can be used to pre set the motor protection switch to protect the pump motor combination duijvelaar pompen dp pumps Holland 2446 13062005 This current value can also be used to determine the proper electrical equipment such as variable frequency drive main switch wiring diameter etc 2 3 Supplementary documentation Apart from this manual the documentation given below is also available Document Date version Code General terms of delivery 10 1998 119 1998 Engineering Reference Book 11 2008 00000329 Technical Data 50Hz 07 2008 97004434 Technical Data 60Hz 07 2008 97004435 Technical Data 60Hz U S 12 2007 97004436 Motec operating instructions 09 2001 BA 8200 motec frequency inverters V3 0 EM See also www dp pumps com 3 Warranty 3 1
37. safety Contact the sup plier if this problem occurs more often Contact the supplier Tighten the connecting screws to the recom mended torque Check if the correct value is set Find the correct value lhom on the motortype plate 26 Problem Pump supplies insufficient capacity and or pressure Possible cause Outlet and or inlet shut off valve is closed Possible solution Open both shut off valves Checkpoints There is air in the pump Vent the pump The suction pressure is insufficient Increase the suction pres sure Pump rotates in the wrong direction Change over L1 and L2 of the three phase supply The suction line has not been vented Vent the suction line Air bubble in the suction line Pump sucks air because of leakage in the suction line Install the suction line with pump end higher than the other end Repair the leakage Too little water consump tion so air bubbles clog up in the pump Make sure the consump tion increases or use a smaller pump The diameter of the suc tion line is too small Increase the diameter of the suction line Capacity of water meter in the supply line is too small Increase the capacity of the water meter Foot valve blocked Clean the foot valve The impeller or the diffuser is blocked Clean the inside of the pump O ring between impeller and diffuser is gone O ring not resistant to th
38. son W Ouwehand technical director 45 dp pumps dp pumps P O Box 28 2400 AA Alphen aan den Rijn The Netherlands t 31 172 48 83 25 f 31 172 46 89 30 dp dp pumps com www dp pumps com 04 2009 BE00000233
39. tains important information for reliable proper and efficient operation Compliance with the operating instructions is of vital importance to ensure reliability and a long service life of the product and to avoid any risks The first chapters contain information about this manual and safety in general The following chapters provide information about normal use installation maintenance and repairs of the product The annexes contain the technical data the parts drawings and the declaration s of conformity Make yourself familiar with the content e Accurately follow the directions and instructions Never change the sequence of the operations to be carried out Keep this manual or a copy of it together with the logbook in a fixed place near the product which can be accessed by all personnel 1 2 Icons and symbols In this manual and in all accompanying documentation the following icons and symbols are used WARNING Danger of electric Voltage Safety sign according to IEC 417 5036 WARNING Operations or procedures if carried out without caution may cause personal injury or damage to the product General hazard sign according to ISO 7000 0434 Is used to introduce safety instructions whose non observance may lead to damage to the product and its functions ENVIRONMENTAL INSTRUCTION Remarks with respect to the environment
40. ts that can become hot in such a way that direct contact is impossible When applicable always place undeformed coupling protection plates to protect the coupling before putting the pump into use Make sure that the coupling protection plates are never in contact with the running coupling Always close the terminal box on the pump 4 4 2 During installation maintenance and repair Only authorised personnel may install maintain and inspect the product and repair electrical components Observe the local safety regulations WARNING Always disconnect the energy supply to the product first before installation maintenance and repairs Secure this disconnection WARNING Surfaces of a pump can be hot after continuous operation WARNING Make sure that no one can be near rotating components when starting a pump WARNING Handle a pump with dangerous liquids with the utmost care Avoid danger for persons or the environment when repairing leakages draining liquids and venting It is strongly recommended to place a relief barge under the pump WARNING Immediately following completion of the work all safety relevant and protective devices must be re installed and or re activated gt gt WARNING N Please observe all instructions set out in the chapter Commissioning Start up before returning the product to service 4 5 Environmental aspects 4 5 1 General The products of DP Pumps are des
41. z 0 55 075 73 58 50 1450 47 4 5 4 3 27 2 6 2 5 0 75 1 74 58 50 1450 6 5 7 5 5 3 8 3 3 3 1 1 1 1 5 76 7 60 30 1405 5 2 5 2 5 2 3 3 3 1 5 2 79 58 30 1410 7 1 7 1 7 1 4 1 4 1 4 1 2 2 3 82 61 20 1425 9 9 9 5 2 5 2 5 2 3 4 78 4 64 20 1430 14 14 14 8 1 8 1 8 1 4 7 4 7 4 7 4 5 85 65 20 1445 17 2 17 2 17 2 9 9 9 9 9 9 5 7 5 7 5 7 5 5 7 5 85 9 64 15 1450 20 8 20 8 208 12 12 12 6 9 6 9 6 9 7 5 10 87 64 10 1450 277 277 277 16 16 16 9 2 9 2 9 2 Table 11 Technical specifications of pumps with 2 pole 3 phase 60 Hz motors I max A z i e 2 2 E il 220V 240 280 380V 420 480 660 725 797 a B n a 0 37 0 5 76 0 60 50 3430 2 5 2 3 2 0 1 5 1 3 1 2 0 55 075 82 0 60 50 3460 27 2 5 2 1 1 6 1 4 1 2 0 75 1 80 0 60 50 3430 3 9 3 6 3 2 2 2 1 8 1 1 1 5 82 0 60 50 3470 5 9 5 5 4 3 3 4 3 2 7 1 5 2 84 1 69 30 3455 78 7 8 7 8 4 5 4 5 4 5 2 2 3 85 6 72 30 3450 10 9 10 9 10 9 163 6 3 6 3 3 4 83 6 67 20 3495 13 6 13 6 13 6 17 9 7 9 7 9 4 6 4 6 4 6 4 5 87 3 69 20 3520 17 2 17 2 17 2 19 9 9 9 9 5 7 5 7 5 7 5 5 7 5 86 74 15 3465 21 21 21 12 1 12 1 12 1 7 7 7 7 5 10 86 8 70 12 3455 26 8 268 26 8 15 5 15 5 15 5 8 9 8 9 8 9 11 15 89 3 74 10 3540 53 7 53 7 53 7 131 31 31 17 9 17 9 17 9 15 20 90 5 74 10 3500 56 3 56 3 56 3 32 5 32 5 32 5 18 8 18 8 18 8 18 5 250 91 74 10 3515 72 1 72 1 72 1 416 416 416 24 24 24 22 300 906 87 10 3500 78 8 78 8 78 8
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