lp_1205.05_gb

8/2/2019 LP_1205.05_GB

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This instruction is valid for all standard low pressure pumps:LPD, ACD, ACE, LPE, ACG/UCG, ACF/UCF, LPQ and ABQ

Contents Page

Pump identication 2Installation 3Start-up 8Trouble shooting 10

!

Before commencing any work, read this instruction carefully! Failure to comply

with these instructions may cause damage and personal injury!

Screw pumps

Low pressure pumps

Installation and Start-up Instruction

LP1205.05GB

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These instructions are valid for all low pressure pumps as specied in the Pump identication chart below.

Pump identication

ABQ

LPQ

ACF/UCF

ACG/UCG

ACE

LPE

ACD

LPD 015020

025

025032038

045052060070

080090

100110125

100110125140

160

N

LN

DKN

KL

N

LNP

BL

N

1

6

3

7

45

1

5

I

IN

N

IN

IN

I

V

VT

V

T

VT

RV

R

B

B

B

BF

BF

Y

Y

P

P

EP

EOP

P

OP

A101

A101A327A020A385

A020A084

A087A101

A328

P

J

Q

025032038

DKLN

DKLN

3 NV

T B A101P

IN

RT

Pump name Rotorlead(1)

Shaft-seal

design(1)

Mounting(2)

Valve(3)

Alsovalid foroption

Comments

Pumpunitwithout shaftcoupling

O = max 5 bar

(1) See Product description or Service instruction forspecied pump model

(2) B = Flange mounting F = Foot mounting Y = Vertical foot mounting

(3) E = Without valve G = Valve with external return O = Valve with internal return for reduced pressurerangeP = Valve with internal return for total pressure range

OptionA020 Pump with surface treated casing(s)A084 Pump with lifetime greased ball bearingA087 Pump with CCW-rotation and lifetime greased

ballbearingA101 Pump with CCW-rotation, when not standardA327 Pump with Tuning®A328 Pump with Tuning®A385 A101 + A327

Materialpump-body(1)

Size(1)

O = max 10 bar

Designmodifcation

Pumpunitwithout shaftcoupling

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L P 1 2 0 5 . 0 5 G B Fig. 2 Liing of pump

max 90 ϒ

min 60 ϒ

max 90 ϒ

min 60 ϒ

! Failure to comply with these instructionsmay cause damage and personal injury!

Transport and storage

Always protect the pump against ingress of waterand other impurities. Store the pump in a clean, dryand warm environment. The pump is delivered withthe internals oiled and with protective covers overthe pipe connections and drain openings. Thesecovers should remain in place for as long as possibleduring the mounting and installation procedure butmust be removed before start up.

! All work carried out on the pump has to beperformed in such a manner that risks forpersonal injury are observed!

Lifting of pump

! Allpumpsshouldbeliedwithstrapssecurelyaachedtothepumporpumpunit, so that the center of gravity is located

between the straps in order to avoid tippingof the pump.

Use two eye bolts (M 20) securely fastened to thefront cover for pumps LPQ and ABQ. Pump andconnecting frame are lied together using two eye bolts securely fastened to the top of the connectingframe. (Thread dimension is M 16, except for framesize 600, where it is M 20).

Identification of safety instructions

Non compliance of safety instructionsidentified by the following symbol -could affect safety for persons.

Safety instructions whereelectrical safety is involved,are identified by:

Safety instructions which shall be considered forreasons of safe operation of the pump or pumpunit and/or protection of the pump or pump unititself are marked by the sign:

ATTENTION

max 90 ϒ

min 60 ϒ

Fig. 1 Clean and dry environment.

InstallationBEFORE COMMENCING ANY WORK, READ THIS INSTRUCTION CAREFULLY!

Design limitations and technical data for each pump are found in the Product description. Installation of IMO AB low pressure pumps does not require special skills. However, these instructionspresume that the work is carried out by experienced ers. Maintenance and service instructions , which are specic for each pump are presented in a separatedocument.

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Liing of the complete pump unit with the liingdevice aached to the motor, should be avoided asthe motor’s liing provisions may not be able tocarry the combined weight of the pump and motor.

! Liingacompletepumpunit,usingslingsorhooksaachedtothepumporconnecting

frame may be dangerous since the centreof gravity of the pump unit may be higherthanthepointsofaachments.

Mounting

The pump must be securely mounted on a rmstable foundation and positioned so that it is easilyaccessible for inspection and servicing.

Provisions for collecting oil spillage when servicingthe pump should be considered.

ATTENTION

The installation must always be designedto minimise damage. Should an operationalor functional failure occur. E.g. precautionsshould be considered to collect oil spillagedue to a broken pipe or pump housing,to stop pump operation if overheatingshould occur or if the oil volume is below aminimum tank level.

Alignment and shaft couplings

The pump shall be connected to its driver via aexible sha coupling. Pumps of type ACG/UCGand ACF/UCF may also be driven via gears orpulleys as specied in the Product Description,provided the radial forces are kept within thespecied range.

An angular misalignment of 0.1° corresponds toapprox. 0.2 mm deviation/100 mm.

The coupling and alignment shall be selected not totransmit any axial or radial loads on the sha ends.IMO AB standard couplings shall have a distance

between the coupling halves as per table, g 4. thecoupling halves shall be secured by lock screws.

For other types of couplings, please refer torespective maker’s manual.

!

Wheningtheshacoupling,donotuseahammer or similar as this may damage theballbearingandshaseal.Usesomekindof press tool.

!

When handling liquids that may harm skinuse gloves and/or protective clothing.

! When handling liquids which may involverehazardsappropriateprecautionstoavoid danger are to be taken. Fig 4. Distance between coupling halves.

(IMO AB standard coupling)

Outer diameter Distance between Outer diameter Distance between

of coupling coupling halves of coupling coupling halves

(D mm) (t mm) (D mm) (t mm)

A B A B50 26 2.0 8 148 3.567 40 2.5 16 168 3.582 55 3.0 18 194 3.597 65 3.0 20 214 4.0

112 80 3.5 24 240 4.0128 95 3.5 26

Fig. 3 Alignment of the IMO AB standard coupling

t

D4 ø max 0.3 mm

D6 ø max 0.4 mm

E4 ø max 0.4 mm

max

0.1°

D

See table below An angular

misalignment of 0.1° correspondsto approx. 0.2 mmdeviation/100 mm.

Angularalignment

Distancebetween

coupling halves

Circular

run-out

A

XY

x = y - t

Ø D

t

B

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L P 1 2 0 5 . 0 5 G B Fig. 8 Deaeration

! Measures shall be provided to avoidaccidentalcontactwiththerotatingshacoupling. Any installed coupling guardshallpermiteasyaccesstothepumpshafor maintenance and inspection of thepump bearing and seal housing.

Pipe connections

The pipe work shall be installed and supported sothat no pipe stresses are transfered to the pump body.

The pipe work should be tight in order to avoidleakage and inltration of foreign particles and/orair.

Shut o valves should be installed in both suctionand discharge pipes, so that the pump can behydraulically isolated.

Suction line

The suction pipe should be designed so that thetotal pressure drop, measured at the pump inletange, does not exceed the suction capability of thepump.

Make a proper calculation of the suction lineincluding components such as valves, strainer,pipe bends etc. Generally, the pressure drop in thesuction line should be as low as possible, which isachieved if the suction pipe is short, straight and has

a suitable diameter.The velocity in the suction line should be kept in therange 0.5 - 1.2 m/s. For L.O. circulating systems, werecommend to keep it as low as possible.

The suction line must be equipped with a port thatallows lling the pump before start.

Discharge line

The discharge line should be dimensioned to keepthe velocity in the range 1 - 3 m/s.

Deaeration

In installations with negative suction head, wherethe pump might be started against a pressurizedsystem, a deaeration pipe with an orice (2-3 mmrecommended) has to be installed. The deaerationpipe should be connected to the outlet pipe’s highestpoint. This must also be installed when the pump is usedas an stand-by pump.

Fig.7 Suction line

Fig. 6 Pipe connections

For direct driven pumps the alignment betweenpump and motor shas must be kept within thefollowing limits:

Max run-out Max angular misalignment

(mm) (degrees)

Type LPDand ACD (n/a short coupled)

Other types 0.3 0.1

Fig 5.

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Fig. 11 Liquid trap

Fig. 9 Strainer

Strainer

The pump has to be protected from foreign maer,such as weld slag, pipe scale, etc., that could enterthe pump via the suction line. If the cleanliness ofthe system cannot be guaranteed, a strainer must be installed in the inlet pipe near the pump. Forpractical reasons a suction strainer with 0.6 mm

mesh openings is recommended:

The size of the strainer should be selected so thatit is large enough to allow adequate pressure at thepump inlet. The pressure drop across the strainershould preferably not exceed 0.1 bar at max. owrate and normal operating viscosity. A vacuumgauge between the strainer and the pump inlet isrecommended to indicate when the strainer needscleaning.

Note: The service life of the pump is decisively inuencedby the degree of contamination of the uid being conveyed,

that means, by the number, size and hardness of theabrasive components.

Shaft seal drain

The pump should be installed so that any leakagefrom the sha seal does not become a hazard. As thesha seal has to be lubricated a small amount of oildripping cannot be avoided.

Provisions to collect the leakage from the sha sealmust be made.

A drain pipe can be connected to the drainconnection on the pump, (not applicable to pumpseries LPD). However, when pumping heavy fueloil or any other liquid that is likely to become veryviscous at ambient temperature, we recommend thatthe liquid is allowed to drop freely from the drainopening.

Liquid trap

In some mounting arrangements the pump may notretain the liquid at stand still. In such installationsthe suction pipe should be arranged so it forms aliquid trap together with the pump, keeping thepump half lled with liquid. See g. 11.

Fig. 10 Sha seal drain

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L P 1 2 0 5 . 0 5 G B

bar

Fig. 12 Gauges

Gauges

Gauges for monitoring the pump’s workingconditions are recommended. These gauges should be placed readable as close to the pump’s in- andoutlet anges as possible. On standard pumps,series ACE, LPE, ACG/UCG, ACF/UCF and LPQ,there are gauge connections for both in- and outlet.

Pressure relief valve

All systems with screw pumps must be equippedwith a pressure relief valve installed immediately

adjacent to the pump.In the standard versions of IMO AB low pressurepumps, this pressure relief valve is an integral partof the pump to protect the system against excesspressure.

When liquid is circulated through the valve it heatsup in proportion to the set pressure level and thepercentage of by-passed liquid. 100% by-pass canonly be tolerated for less than about 3 minutes, 50 % by-pass generally for unlimited periods of time.

If more than 50% recirculation is anticipated, a valuespecic to each application should be determined byclosely monitoring the pump body temperature.

If the pump is operating in line with a separatepressure control valve (see g. 13), the seing ofthe relief valve should be high enough so as not tointerfere with the control valve. Likewise, if twopumps are operating in parallel, the seing should be such that interference between the two valves isavoided.

Pressure testing and ushing

The system must be ushed and pressure tested before connecting the pump. If corrosive liquid,such as water is used, the system must bethoroughly drained, dried and protected againstcorrosion aer having been ushed.

! Oilleakagemaymaketheoorslipperyandcause personal injury.

Fig. 13 Pressure relief valve

Fig. 14 External control with pressure relief valve

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Start-upBefore starting

Aer installation and whenever it can be assumedthat the pump has been emptied, the pump must bethoroughly lled with liquid. See g 15.

For ACE Generation 3, LPE Generation 3, ACGGeneration 7 and ACF Generation 4 delivered aer1997, ACF Generation 5 and LPQ the pumps have been ed with deaeration plugs making venting ofthe sha seal compartment easy before start-up.

In installations with positive suction pressure: Aeropening the inlet and outlet valves, simply openthe deaeration plug a few turns until oil sips out.Tighten the plug.

In installation with negative suction pressure: Aeropening the inlet and outlet valves, remove thedeaeration plug and ll the sha seal compartmentwith oil. Fit and tighten the plug. See g. 16.

Note: for LPQ the amount of oil is appr 50 liter.

! Make sure the prime mover is locked outand can not be started accidentally.

Rotate the sha by hand while lling the pump, toensure that the rotor bores and the sha seal cavityis lled. On the smaller pumps: (LPD, ACD, ACE,LPE, ACG/UCG), this is done by rotating the fan onthe electric motor aer removing the fan cover.

! Donotforgettotthemotorfancoveragain

before making start of motor possible.

On the ACF/UCF, LPQ and ABQ pumps, thepump can be turned using the sha coupling.If the suction pipe cannot be completely lled,it is important to ensure that the trapped air isevacuated without any pressure build up. (See g. 8Deaeration).

ATTENTION

Starting a dry pump is likely to cause

damage,especiallytotheshaseal.

Direction of rotation

When the pump is ready to be started, switch themotor briey on and o and check that the drivemotor rotates in the correct direction as indicated bythe rotation arrow.

The arrow is placed on dierent spots depending onthe pump series.

ATTENTION

Don’t mix up with arrow for inlet and outlet!

Fig. 15 Filling the pump

Fig. 17 Direction of rotation

Fig. 16 Deaeration plugs

ACG

ACF

ACE

Deaeration plug

Deaeration plug

Deaeration plugs

Deaeration plug

LPQ

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L P 1 2 0 5 . 0 5 G B

Fig. 18 Adjusting the tuning

3. Turn the upper screw and continue to reduce thenoise level. (If turned too much the noise willincrease again).

4. Repeat item 2. and 3. in order to achieve thelowest possible noise level.

SeingoftuningoftheACG/UCGandACF/UCF:

1. Before starting the seing, check that the seing

screw (8 mm: ACG/UCG, 12 mm: ACF/UCF,socket head cap screw on the discharge side) areclosed.

2. Turn the screw CCW until the noise level becomes the lowest (if turned too much the noisewill increase again).

Once set, the tuning needs no further adjustment,providing the operating conditions stay the same.

NOTE:It´snotpossibletoaccidentallyturnthetuning spindle too far.

! If operating temperature exceeds 60°C(149°F), appropriate measures to avoid skincontact shall be provided.

! Use hearing protections whenever highnoise can be expected from pump, motorand/or environment.

Starting

Check that all valves necessary for the operation arefully opened in both discharge and suction lines.

The rst time, the pump should be started withthe adjusting spindle of the pressure relief valvetightened to half of the available turns (the valveseing is increased when the spindle is turned

clockwise).By monitoring the pressure gauge it can bedetermined when the suction line is primed andthe pump begins to work. Should the pump notoperate normally soon aer start, stop the pumpwithin half a minute. Start again aer about 3-5minutes (the sha seal must have time to cool o)and run for half a minute. This procedure may needto be repeated a couple of times if the suction line isextremely long. Should the pump still not work, itmust be assumed there is a problem in the systemthat needs to be remedied. Check the suction linecalculation on page 5 and/or see ”Trouble shooting”,

page 10.

! Pumps with external ball bearing includinggreasenipple,mustberegreasedaerone hour of running, while the pump isoperating

Setting the pressure relief valve

The seing of the opening pressure is made asfollows: Tighten the valve spindle by rotatingclockwise to the maximum extent. The systempressure is regulated by throling to required value.

The pressure relief valve is eased until the pressureis just beginning to decrease by turning the spindleCCW. The valve is now preset for desired openingpressure. Open the throling valve entirely.

NOTE:ThesetscrewonLPDishiddenbehindaplate.

Adjusting the tuning

The tuning adjustment, which is a standard featureon ACF/UCF and LPQ (option on ACG/UCG andABQ) pumps, is a device for minimizing theeects of dissolved and free air in lube oil systems.The tuning principle is described in the ProductDescription.

The tuning should be adjusted while the pump isworking under normal operating conditions. This isdone by turning the tuning spindle with an Allenkey (size 8 mm for ACG/UCG , 12 mm for ACF/UCFand LPQ ) to a position where the noise level comesto a minimum. On a double acting pump like theLPQ pump, there are two tuning valves, which must be adjusted individually.

Seing of tuning of the LPQ:

1. Before starting the seing check that both seing

screws (8 mm socket head cap screw on thedischarge side) are closed.

2. Turn the lower screw until the noise level obtainsa minimum.(If turned too much the noise willincrease again).

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Trouble shooting

Reverse the terminalconnection on electric motor.

Connecting and discon-

necting of electric cablesmust be done only bypersonnelauthorizedtodo such work.

See above.

Check all componentsin suction line. The inletcondition should be checkedwith a vacuum gauge at thepump inlet.

Check the suction line.

See the chapter on Deaera-tion (see page 5).

See above.

Readjust the pressure reliefvalve to a value abovecounter pressure.

Readjust the pressure reliefvalve.

Check all components in the

suction line (strainers, valvesetc.).

See the chapter on Noise andVibration. ( Page 11).


Check the components in thedischarge line inclusive therecipients.

Check the valve. SeeMaintenance and Serviceinstruction for respectivepump.

Check all components in thesuction line (strainers, valvesetc.).

See the chapter on Noise andVibration. ( Page 11).

Contact your IMO ABrepresentative.

- Electric cables to motorwrongly connected.

- Wrong direction of rotation.

- Suction line is not open orpressure drop in the suctionline is too high.

- Major air leakage into thesuction line.

- The pump cannot evacuate theair through the discharge linedue to excessive counterpressure.

- The pump is not primed.

- The pressure relief valve is set below the counter pressure.

- The pressure relief valve is settoo low (Discharge pressurealso low).

- Something is restricting the

ow in the suction line. (Thiswould usually cause noise).

- The pumped liquid contains asignicant amount of com-pressible gas, such as free air.(This would usually causenoise).

- The pressure relief valve is settoo low.

- Counter pressure in thedischarge line is too low dueto a major leakage.

- The valve piston is stuck inopen position.

- Something is restricting theow in the suction line. (Thiswould usually cause noise).

- The pumped liquid contains asignicant amount of com-pressible gas, such as free air.(This would usually causenoise).

- A too small pump has beenchosen.

Wrong direction of rotation

What to doProblem Cause

Noow

Flow too low

Pressure too low

The pump cannot be primed

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What to doDisturbance CausePressure too high

Drivemotordiculttostartor tends to stop by trippingthe motor overload relay

Noise and vibrations

!

Monitor the pumpfunction and shutdown if any sign ofmalfunction is noticed.

- The pressure relief valve is settoo high.

- The oil is too cold (or hashigher viscosity thananticipated).

- Counter pressure in thedischarge line is too high.

- Counter pressure too high.

- Liquid too cold

- Motor is undersized for theprevailing conditions.

- Electrical power supply faulty.

- Motor overload relay set toolow or is faulty.

- Incorrect seing of Y/D starter.

- The ow to the pump isinsucient.

- Insucient support of pipework.

- Bad alignment

- Air leakage into the suctionline.

- Free air in the liquid or gascavitation.

- Faulty electrical supply.


Reduce the pressure seinguntil operational temperaturehas been reached.

Check the discharge line.

See above: Pressure too high.

Readjust the pressure reliefvalve to a lower value. Thusthe power consumption forthe pumping is relieved andoverloading due to the highviscosity may be avoided.

When the liquid has reachednormal temperature and thusows easily, the relief valve isreset to normal pressure.

Check the motor.

Check the motor and motorconnection.

Readjust or replace the relay.

Readjust the seing of thestarting sequence. The time before the motor overloadrelay is tripped should notexceed 10-15 seconds.

See chapter: The ow is toolow.

Check for pipe vibrations inthe pump connections. Checkthat the pipes are sucientlyclamped.

Check alignment, see page 4.

Check the suction line for airleakage.

For pumps with Tuning:Adjust the Tuning. If this doesnot help or for pumps withoutTuning: Contact your IMOrepresentative or IMO servicedept.

Check all three phases of thesupply.

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