Manual

Operation & Maintenance ManualThe Sala Series of Vertical Slurry Pumps

VS100 L80

Pump No25101401001-004

Supplier / Order NoMetso Minerals Industries Inc. / 257734

Customer NameGonzales Services Inc.

2005-04-08

Slurry Pump

Kap0 VSen_4.doc JAN 03-W02 Contents 1/2

1. GENERAL

1.1 About this manual 1.2 Transport and storage 1.3 Pump specification 1.4 Customer service

2. DESCRIPTION

2.1 Product and warning signs 2.2 Applications 2.3 Design 2.4 Materials and max. working pressure 2.5 Surface treatment 2.6 General arrangement 2.7 Capacity curves 2.8 Certificates and test results

3. HEALTH AND SAFETY 4. DESCRIPTION OF OPERATION 5. CONTROL SYSTEM 6. INSTALLATION

6.1 General 6.2 Foundation requirements 6.3 Tools required for installation 6.4 Pipe connections and pump sump 6.5 Shaft seal 6.6 Motor and operation

7. STARTING UP

7.1 Checks before starting 7.2 Checks during initial operating period

8. OPERATING INSTRUCTIONS

8.1 Starting 8.2 Stopping

Slurry Pump

Kap0 VSen_4.doc JAN 03-W02 Contents 2/2

9. CARE & MAINTENANCE

9.1 Safety measures 9.2 Preventive maintenance and service schedule 9.3 Tools and special equipment for care and maintenance 9.4 Lubrication instructions 9.5 Removal and fitting of components 9.5.1 Removal and fitting of the pump's hydraulic components 9.5.2 Removal and fitting of bearing assembly 9.5.3 Removal and fitting of shaft and bearing 9.5.4 Removal of the pump's drive 9.5.5 Setting pump clearances 9.6 Fault tracing schedule

10. SPARE PARTS

10.1 Recommended stocks of spare parts 10.2 Stocking of spare parts 10.3 Ordering spare parts 10.4 Spare part drawing 10.5 Parts list 10.6 Special tools

11. APPENDICES

11.1 Tables with specified tightening torques for bolted joints 11.2 Subcontractor's documentation

Slurry Pump

Kap1 VSen_4.doc JAN 02-W09 General 1/1

1. General 1.1 About this manual This manual is a part of the equipment to which it relates. It is written for the use of installers, commissioning engineers, operators and maintainers. It should be kept for the life of the equipment and, in case of re-sale, passed on to any subsequent purchaser. Information contained in this manual is specific to the equipment and is correct at the date of publication. As improvements are continually being made, Metso Minerals reserve the right to make alterations to the equipment design and specification without giving prior notice. Any amendments issued by Metso Minerals should be promptly inserted into this manual. © 2002 — Metso Minerals (Sala) AB. The contents of this manual must not be reproduced without the prior written permission of Metso Minerals (Sala) AB. 1.2 Transport and storage

WARNING! When loading and unloading, follow "Health and safety", Section 3. The pump should be transported and stored in a horizontal position. The weight of the pump, excluding motor and drive, is stated on the "Dimension sheet", section 2.6, and on the weight sign affixed to the pump. If the pump is supplied with motor and drive, the total weight of the pump unit is given on the sign. If the pump has to be stored for a lengthier period before being used, it should be kept in a dry place. The pump should be covered to keep out dust and dirt. If the pump is to be stored for longer than two months, the belt drive should be removed to avoid damage during storage. Unpainted machined surfaces are to be treated with a corrosion inhibiting agent. The pump shaft should be rotated a few turns every month. Certain types of rubber, such as chloroprene rubber (CR), harden at temperatures below +5o. In conditions of extreme cold these types of rubber may harden to such an extent that cracks could develop and handling damage occur. Chloroprene rubber does not regain its normal hardness when the ambient temperature rises but must be reconditioned. Contact Metso Minerals for further information.

Pump VS100 L80 O3 NRPump specification

Headline Description Qty

Order part no: 25101401000Complete pump: SA234703-M3Pump type: VS100 L80 O3 NR 4Product code: 1241Pump no: 25101401001 - 004Frame size:

Wear parts, quality: NATURAL RUBBERSpecial design: Mild steel base plate.

Mild steel discharge pipe with 4" ANSI 150# RF flange.

Painting: MP15

Capacity m³/h: 64Total head m: 8Pump speed rpm:Specific gravity kg/l: 1,09Input power kW:

Motor:Special req.:

Motor supplied by: CustomerDrive supplied by: Customer

Motor sheave:Motor bushing:Pump sheave:Pump bushing:V-belts:

Instruction: 1 ea in English languge with pump. Pdf-file by e-mail fao Jennifer Trujillo

25101401000 Edition 1 JAN 05-W15 General 1/1

Slurry Pump

100mfg_en.doc Edition5 JAN 04-W24 Description 1/1

2.8 Certificates and test results

DECLARATION BY THE MANUFACTURER

PROHIBITION TO PUT INTO SERVICE

We Metso Minerals (Sala) AB, Norrängsgatan 2, 733 25 SALA, SWEDEN declare that the slurry pump

Manufacturer Metso Minerals (Sala) AB Pump type VS100 L80 Pump number 25101401001-004 Year of manufacturing 2005

- is intended to be incorporated into machinery or to be assembled with

other machinery to constitute machinery covered by Directive 98/37/EG, as amended;

- does therefore not in every respect comply with the provisions of this directive;

and that following harmonized standards have been applied

- EN 292-1 Safety of machinery – Basic terminology, methodology - EN 292-2 Safety of machinery – Technical principles and specifications - EN 809 Pumps and pump units for liquids - common safety

requirements

and furthermore declare that it is not permitted to put the slurry pump into service until the machinery into which it is to be incorporated has been found and declared to be in conformity with the provisions of Directive 98/37/EG and with relevant national legislation. This refers to the equipment as a whole, including the machinery referred to in this declaration. A pump delivered with motor has a machine sign with ce-mark. When the pump is delivered without motor the ce-mark has to be affixed when the motor is assembled. The ce-mark is included in the pump delivery.

2004-06-07 in Sala, Sweden

Name: Jan Andersson

Position: General manager, Slurry pump division

Space for ce-mark

Pump type

Pump number

Year of manufacture

Slurry Pump

Kap2 TypeSLen_8.doc JAN 04-W22 Description 1/7

2. Description 2.1 Product and warning signs Machine sign Pump delivered without motor Pump delivered with motor

A machine sign containing information as above is affixed to the pump. A pump delivered with motor has a machine sign with CE-mark. When the pump is delivered without motor the CE-mark has to be affixed when the motor is assembled. The CE-mark is included in the pump delivery. Weight sign

The sign is mounted next to the machine sign. When the pump is supplied without motor and drive, only the weight of the pump is stamped on the sign. In such case the total weight is to be stamped on the sign by the mechanic who fits the motor and drive on the pump.

Weight of motor Weight of V-belt drive Weight of pump Total weight

Space for CE-mark

Pump type

Pump number

Year of manufacture

Slurry Pump


Sign, direction of rotation

215242-1 The sign is mounted on the V-belt guard and shows the direction of rotation viewed from the V-belt guard. Incorrect rotation can seriously damage the pump. The V-belts should always be removed before the motor's direction of rotation is checked. Warning sign for absence of V-belt guard

The V-belt guard must alwaysbe mounted during operation

WARNING

The sign is mounted on the V-belt guard. The V-belt guard should always be fitted when the pump is in operation. If the V-belt guard is to be removed, check that the motor is disconnected from the mains or that the main switch is turned off and locked so that the motor cannot be started inadvertently. The guard must always be refitted before the pump is started.

Slurry Pump


2.2 Applications Metso Minerals Slurry Pumps are primarily designed for pumping abrasive media containing particles. The pump is designed for use up to the largest flow shown on the capacity curve at the rpm in question. If the pumped medium is severely abrasive, the maximum flow should be reduced. Note that the capacity curves in section 2.7 are based on trials with clean water. Under other conditions, contact Metso Minerals for correct dimensioning of the pump. The impeller's diameter, number of vanes, type of impeller and maximum particle diameter are shown at the head of the capacity curve. Maximum particle diameter is the theoretically largest sphere than can pass through the impeller. Note that in practice it is the density of the particle which limits what can be pumped. See also recommendations and limitations in section 1.3 "Pump specifications", section 2.4 "Materials and max. Working pressure", and section 2.6 "Dimension sheet". 2.3 Design The basic version of the pump is supplied: • with semi-open impeller. For max. Working pressure, see section 2.4. Wear parts The main hydraulic parts of the pump consist of casing, casing liner, impeller, inlet, inlet liner and impeller mounting components. These parts are supplied in elastomer material. See section 1.3 "Pump specifications" and section 10.5 "Parts list" for the materials in your pump. Bearing assembly The pump shaft runs in roller bearings. The bearings are mounted in a bearing housing of cartridge type. The complete bearing is axially adjustable in the pump frame and can be removed as a complete unit. Note that the pump shaft consists of two parts. Impeller mounting The impeller has a cylindrical guide and the torque is transmitted by a square hole which fits over the corresponding square end of the shaft. The impeller is then locked by a standard socket cap screw with right-hand thread which is protected from wear by a rubberized cover.

Slurry Pump


Setting up The pump is designed either to be suspended in the lifting fork or mounted on steel beams, for example. In the case of stationary installation, it may be suitable to fit the pump with an enlarged mounting plate and an upward discharge pipe. For different sump depths there are four standard frame lengths: L80, L120, L150 and L180 cm. In the case of deeper sumps the pump can be fitted with an extended lower frame, designated E, and suction pipe. The largest motor than can be mounted on the motor plate is specified in the "Dimension sheet", section 2.6. Noise level At certain installations and operating conditions away from the optimum operating point, the noise level may exceed 70 dBa. Under normal working conditions, however, the pump's motor is the main source of noise. As a rule of thumb, it may be assumed that the total noise level in the majority of properly functioning installations is that of the motor plus 2 dBa. Vibration The pumps are classified as Class IV according to ISO 2372, annex A. When the pump is new the vibration level should not exceed 7.1 mm/second at all bearings. Should the vibration level exceed 18 mm/second the pump must be stopped immediately. Commonly occurring causes of excessive vibration are: • insufficiently tightened retaining elements • poorly tensioned V-belts • misalignment in the drive • impeller blocked by a foreign object.

Slurry Pump


2.4 Materials and maximum working pressure Metso Minerals Slurry Pumps are constructed from materials selected to give excellent wear characteristics over the full range of pumping duties. This section lists the materials of construction and working pressures for STANDARD duty applications. Other materials are also used for specialist applications or as specified by the customer – see section 1.3. Materials of construction Item Material type Material Code Material Standard

Castings, such as bearing housing, cover Grey Cast Iron JL1040 EN 1561

Shaft Steel 1.1191 EN 10083

Frame Motor plate Mounting plate Discharge pipe

Steel 1.0038 EN 10025

Bolts, washers, nuts Steel, galvanized 8.8 ISO 898/1

O-rings Nitrile Rubber NBR -

Gaskets Natural Rubber NR -

Wear parts of Natural rubber For example: Impeller, pump casing, inlet

Impeller core Grey Cast Iron JL1040 EN 1561

Other cores Steel 1.0038 EN 10025

Rubberizing Natural Rubber NR - Wear parts of natural rubber Natural rubber (NR) and polyurethane (PU) (certain pump types) are ideal materials for wear protection when the slurry contains fine particles, i.e. particles up to 3-5 mm. Larger particles can be accepted at low rpm or when occurring together with a large proportion of finer particles. These materials can be used for liquids having temperatures up to 60oCand are resistant to weak acids, alkaline solutions, the majority of organic acids and alcohols. Natural rubber does not withstand petroleum products or ozone. The peripheral velocity of the impeller should not exceed 27 m/sec. Contact Metso Minerals for more detailed recommendations concerning the material's limitations.

Slurry Pump


Maximum working pressure

Working pressure Pump

Size Bar kPa

VS80 O3 (NR) 6 600

VS80 O3D85 (NR) 6 600

VS100 O3 (NR) 6 600

VS100 O3D85 (NR) 6 600

VS150 O4 (NR) 6 600

VS150 O4D85 (NR) 6 600

Slurry Pump


2.5 Surface treatment Standard finish: Protective covers Colour: Yellow Ral 1032 (warning colour) Type: Epoxy powder Film thickness: min. 100 µm Internal wear parts and linings Type: Oil-resistant paint on alkyd base Film thickness: min. 25 µm Other painted surfaces Type: Two-pack oxirane ester Film thickness: min. 120 µm Machined, unpainted surfaces have temporary delivery protection as below Wax-based anti-corrosion agent which leaves a sticky film when the solvent has evaporated. Applied on clean and dry surfaces by spray gun, brush or roller. Removed with white spirit, hot water, alkali or steam. Protective factor at 50 µm: Outdoors about 12-20 months, indoors about 60 months. Recommendations for touch-up and maintenance painting Scraping and wire brushing or sanding followed by degreasing. Priming of protective covers with epoxy primer, about 50 µm. Priming of other painted surfaces with synthetic red lead, about 50 µm. Finish painting with applicable type of paint and film thickness. Two-pack oxirane ester. Min. application temperature + 10oC.

PUMPVS100 O3 Performance curve

124-4-1E HWT 99-W10 Edition 2 1/1

Full impeller dia

330 mm

Vane diameter

330 mm

Vane config

Full

Impeller type

Semi Open

No. of vanes

3

Max sphere

40 mm

Impeller material

Elastomer

Liner material

Elastomer

H (m)

50 100 150 200

10

20

30

40

800

1000

1200

1400

1600 r/min

BEL

30%40%

45%48%

50%51%

51%

50%

48%

P (kW)

Q (m³/h)

50 100 150 200

5

10

15

20

25

30

35

Based on clear water testscorrect for other conditions

800

1000

1200

1400

1600

Slurry Pump

100mfg_en.doc Edition5 JAN 04-W24 Description 1/1

2.8 Certificates and test results

DECLARATION BY THE MANUFACTURER

PROHIBITION TO PUT INTO SERVICE

We Metso Minerals (Sala) AB, Norrängsgatan 2, 733 25 SALA, SWEDEN declare that the slurry pump

Manufacturer Metso Minerals (Sala) AB Pump type VS100 L80 Pump number 25101401001-004 Year of manufacturing 2005

- is intended to be incorporated into machinery or to be assembled with

other machinery to constitute machinery covered by Directive 98/37/EG, as amended;

- does therefore not in every respect comply with the provisions of this directive;

and that following harmonized standards have been applied

- EN 292-1 Safety of machinery – Basic terminology, methodology - EN 292-2 Safety of machinery – Technical principles and specifications - EN 809 Pumps and pump units for liquids - common safety

requirements

and furthermore declare that it is not permitted to put the slurry pump into service until the machinery into which it is to be incorporated has been found and declared to be in conformity with the provisions of Directive 98/37/EG and with relevant national legislation. This refers to the equipment as a whole, including the machinery referred to in this declaration. A pump delivered with motor has a machine sign with ce-mark. When the pump is delivered without motor the ce-mark has to be affixed when the motor is assembled. The ce-mark is included in the pump delivery.

2004-06-07 in Sala, Sweden

Name: Jan Andersson

Position: General manager, Slurry pump division

Space for ce-mark

Pump type

Pump number

Year of manufacture

Slurry Pump

Kap3 VSen_4.doc JAN 02-W09 Health and safety 1/2

3. Health and safety Follow all local health and safety instructions: • Use approved lifting equipment • Fence off the area round the workplace so that unauthorized persons will not be

injured. The weight of the pump, excluding motor and drive, is stated on the "Dimension sheet", section 2.6 and on the weight sign affixed to the pump. If the pump is supplied complete with motor and drive, the total weight of the pump unit will be given on the weight sign. Check the capacity of the lifting equipment against the weight of the pump, motor and drive. The pump should be lifted in accordance with the illustration in the "Dimension sheet", section 2.6. All electrical work must be carried out by a qualified electrician. WARNING! Before starting work, check that the motor is disconnected from the mains or switched off and locked so that it cannot be started unintentionally. WARNING! Freely rotating shaft. When working on or in the vicinity of the shaft with the pump in operation, make sure that all personal equipment is arranged so that it cannot fasten in the rotating parts. Work with care and exercise good judgement. The pump may be used in liquids that are harmful to your health. If this is the case, and to avoid injury to eyes and skin, observe the following points: • Always wear goggles and rubber gloves • Flush the pump thoroughly with clean water before starting work • Rinse the parts in clean water after dismantling them All electrical work must be carried out by a qualified electrician. Max. working pressure The pump is designed for pressures of up to 0.6 Mpa (6 bar).

Slurry Pump

Kap3 VSen_4.doc JAN 02-W09 Health and safety 2/2

Noise level At certain installations and operating conditions away from the optimum operating point, the noise level may exceed 70 dBa. Under normal working conditions, however, the pump's motor is the main source of noise. As a rule of thumb, it may be assumed that the total noise level in the majority of properly functioning installations is that of the motor plus 2 dBa. Installation The largest motor that may be mounted on a standard motor plate is specified on the dimension drawing. See section 2.6. Maintenance A mechanical hoist or the like should be used when lifting parts weighing more than 30 kg. The weights of the pump components are given in the spare parts list. WARNING! Before any work is started, the motor must be disconnected from the mains or the main switch turned off and locked so that the pump cannot be started inadvertently. It will sometimes be necessary to work with the pump in operation when greasing the bearing and adjusting the shaft seal. When working in the vicinity of the freely rotating shaft, make sure that all personal equipment is arranged so that it cannot fasten in the rotating parts. Work with care and exercise good judgement. WARNING! Worn parts may have extremely sharp edges. Wear heavy-duty gloves and use other suitable safety equipment.

Slurry Pump

Kap4 VSen_4.doc JAN 02-W09 Description of operation 1/5

4. Description of operation General Centrifugal pumps work best with minimum wear and other mechanical stress if the operating point is close to the pump's best efficiency point (BEP). To choose a pump that works close to its best efficiency line (BEL), it is important to understand how the pump interacts with the piping system in which it is installed. In simple terms, a pump and its piping system act as two communicating vessels. The piping sysem has a resistance curve that starts at the static delivery head, at zero flow. As the flow increases, the resistance increases with pipe friction. A radial centrifugal pump has a descending discharge/flow curve for each rpm. The pump's operating point (DP) at a given pump speed is the point of intersection between the piping system's resistance curve and the pump's discharge/flow curve. See diagram below.

It is therefore important to calculate the piping system's resistance curve correctly and to take into account the manner in which the admixture of solid particles, for example, affects the curves of the piping system and pump. We recommend using Pumpdim™ for Windows™ for our pump applications. To obtain the best wear properties the pump can be provided with different materials in the parts exposed to the greatest wear.

Slurry Pump


Best efficiency point Pressure conditions in the pump casing are shown in Fig. 1. At the BEP there is even pressure round the impeller, resulting in small radial forces which in their turn exert little load on bearings and cause little shaft deflection. When the pump operates at low capacity and not at BEP, differential pressure builds up over the casing volute. This gives rise to a radial force F on the impeller which is a function of the differential pressure (Pa) and the impeller's projected area (mm2).

When the pump operates at best efficiency point, uniform pressure is obtained in the casing which in its turn eliminates radial forces on the impeller.

When the pump's flow capacity is not utilized, uniform pressure in the pump casing will not be obtained and this results in a radial force F on the impeller.

The magnitude of the radial force F is greatest when the pump runs against closed valve = 0 flow. The force subsequently diminishes up to BEP where it is close to zero. At flows above BEP the force changes direction.

Fig. 1 When the pump is not operating at BEP the bearings will have a shorter service life on account of shaft deflection. In addition, the differential pressure over the impeller gives rise to the transport of slurry between the impeller and the inlet liner, causing rapid wear of the liner.

Slurry Pump


Hydraulic effects of operation at and outside the pump's best efficiency point

Impeller vane inlet Pump casing nose

At best efficiency point

fig. 2


At low load

fig. 2

Slurry Pump


1. The slurry's inflow angle coincides with the impeller's vane angle and no erosive vortices occur.

2. The slurry's flow angle harmonizes with the angle of the pump casing nose and no erosive vortices occur.

3. Abrasion on the impeller vane's discharge side. 4. Vortices occur on the vane's vacuum side. 5. Vortices. 6. Abrasion caused by particles striking and bouncing against the surface.


On overloading

fig. 2

7. Vortices are formed on the discharge side of the impeller vane. 8. Abrasion occurs on the vacuum side of the vane tip. 9. Vortices. 10. Abrasion on the pump casing nose. The way in which the hydraulic work is affected when the pump does not operate at BEP is shown in Fig. 2. This is of decisive importance in slurry pumping. Hydraulic efficiency is a function of hydraulic turbulence - the more turbulence, the less efficiency. In slurry pumping, a high level of efficiency is therefore important Little hydraulic turbulence is formed at BEP and the abrasion is chiefly of a sliding nature, since the differential pressure is low when the slurry passes through the impeller and pump casing. The rate of abrasion is low and the wear is spread evenly over the surfaces. The rasping wear or high-pressure wear that occurs between the impeller and suction side liner is lower, since the evenly distributed hydraulic pressure reduces recirculation.

Slurry Pump


When the full capacity of the pump is not used and its efficiency is less than at BEP, hydraulic turbulence occurs and the solid particles in the slurry strike and rasp the impeller and pump casing. This causes local wear damage and the service life of these components is severely shortened. At the inlet to the impeller the slurry's flow angle is not the same as the pump vane angle, which gives rise to turbulence and results in recirculation of slurry in the channel. At the pump casing nose the flow from the impeller does not harmonize with the shape of the casing, causing turbulence to occur immediately after the pump casing nose. In the worst case, oversized pumps which do not operate at BEP result in bearing breakdown, shaft fracture and unevenly worn inlet and pump casing liners with deep wear marks at the casing nose. Choice of pump size For preference, choose the pump size which operates as close as possible to the pump's best efficiency point (BEP).

Slurry Pump

Kap5 VSen_4.doc JAN 02-W09 Control system 1/1

5. Control system Not included in the delivery.

Slurry Pump

Kap6 VSen_4.doc JAN 02-W09 Installation 1/5

6. Installation 6.1 General Follow local health and safety instructions. Use approved lifting equipment. The weight of the pump, excluding motor and drive, is stated on the "Dimension sheet", section 2.6 and on the weight sign affixed to the pump. If the pump is supplied complete with motor and drive, the total weight of the pump unit will be given on the weight sign. Check the capacity of the lifting equipment against the weight of the pump, motor and drive. The pump should be lifted in accordance with the illustration in the "Dimension sheet", section 2.6. All electrical work must be carried out by a qualified electrician. 6.2 Foundation requirements Pumps with enlarged baseplate are used for stationary installations. The minimum dimensions of the pump sump are given on the dimension sheet, as also are the size of the baseplate and mounting holes. The pump casing should be positioned 2-4 times the diameter of the inlet from the bottom of the pump sump. See illustration below.

6.3 Tools required for installation A fitter's regular toolkit plus suitable hexagonal Allen keys and sockets, a torque wrench and suitable lifting equipment will be adequate for installation. 6.4 Pipe connections and pump sump The sump pumps are designed to be suspended in the lifting fork or permanently mounted on steel beams or the like. An enlarged mounting plate and vertical discharge pipe are available as optional equipment for all pumps that are to be used in stationary installations. The pumps must always be mounted in such a manner that piping does not transmit stresses to the pump, either in cold or hot state. If the pumps are freely suspended in the lifting fork, the discharge pipe must consist of flexible hose. Since the pumps are not self-priming, the pump casing must be filled on starting. Once pumping has started, the pump exhibits good suction capacity, up to 2 - 3 m. Pumps with semi-open impeller should not be used with a suction pipe.

Slurry Pump


Note that the pump's bearing housing must not be submerged. Maximum level, see dimension drawing. Fit the discharge flanges on the pump. For flange and bolt dimensions, see "Dimension sheet", section 2.6. Metso Minerals recommends bolts of strength class 8.8 as per ISO 898/1. When bolts of this strength class are used, see table 11.1a in section 11.1 for the correct tightening torque. 6.5 Shaft seal Type VS sump pumps have no shaft seal. 6.6 Motor and operation WARNING! Before starting any work on the pump, make sure that the motor is disconnected from the mains and cannot be started unintentionally. Mounting the motor on overhead motor plate Determine the weight of the motor as specified by the manufacturer and stamp it on the pump's weight sign as described in section 2.1 "Product and warning signs". Pumps ordered without a motor are supplied with the V-belt guard detached and it must be fitted before the V-belt drive is mounted. • Remove the V-belt guard cover (A) from the lower section (B) • Mount the V-belt guard's lower section (B) on the pump, using the retaining bolts (D) The V-belt guard's lower section has a protection plate (D) for the motor shaft, which is mounted on the motor baseplate. Mark the position of the motor shaft on the protection plate and drill a hole with a diameter that is 10 mm larger than the motor shaft. If the size of the motor is specified in the order, the protection plate will be pre-drilled. The positions are shown in the illustration below.

Slurry Pump


Svedala Pumps & Process

Position the motor on the baseplate. Note that no free part of the motor shaft must protrude outside the V-belt guard. Check that the shafts of the motor and pump are parallel. Mark the motor's mounting holes on the baseplate and lift the motor away. Drill holes in the baseplate, cut threads in them and fit the motor with nuts and bolts in accordance with the motor manufacturer's recommendations. Get a qualified electrician to connect the motor to the mains supply in accordance with the motor manufacturer's instructions. Check the motor's direction of rotation. When viewed from the drive end, the pump should rotate anticlockwise. NOTE: this should be checked with the V-belts removed. Fitting the V-belt pulleys Determine the weight of the complete V-belt drive as specified by the manufacturer and stamp it on the pump's weight sign as described in section 2.1 "Product and warning signs". The V-belt drive requires careful alignment in order to transmit the design power and minimize wear of the drive. • Clean and degrease the shaft, shaft hole, bush and groove surfaces. • Fit the belt pulley to the bush. • Fit the V-belt pulley/bush unit on the shaft and align it in the intended position. The V-

belt pulleys should be positioned as close to the shaft shoulders as the lower section of the V-belt guard allows. Use a straight-edge to check that the V-belt pulley grooves are in alignment.

Slurry Pump


Shafts not parallel Pulleys misaligned

Fitting the V-belts In their production of V-belts, some manufacturers classify them in different length tolerances. It is therefore important to ensure that the V-belts of a given drive all have the same length tolerance. The easiest fitting procedure is as follows: • use the adjustment facilities of the motor baseplate to reduce the centre distance until

the V-belts can be fitted on the pulleys without undue force. • never use a tool to force the V-belts into the grooves. • calculate the peripheral speed of the belt pulley in accordance with

V = peripheral speed [m/s] dd = diameter of small pulley [mm] n1 = speed of small pulley [rpm]

Slurry Pump


• measure the distance between the shafts • use a tensiometer as shown in the figure to measure the force (P) necessary to deflect

the V-belt 16 mm per metre of distance between the shafts when the force is applied at right angles to the V-belts and approximately midway between the pulleys.

• use the adjustment facilities of the motor baseplate to tension the belts to the value of P

in the table below.

• fit the V-belt guard's cover (A).

Belt profile

Small pulley diameter, dd

Deflection force P for arrow height 16 mm/m distance between shafts (N)

V = 0-10 m/s V = 10-20 m/s V = 20-30 m/s

SPZ 67-95 100-

18 26

16 24

14 22

SPA 100-140 150-

32 48

26 40

22 34

SPB 160-265 280-

56 72

50 64

42 58

SPC 224-355 375-

102 132

90 120

80 110

Slurry Pump

Kap7 VSen_5.doc JAN 03-W34 Starting up 1/2

7. Starting up WARNING! Read section 3 "Health and Safety" before starting to carry out any work on the pump. NOTE: Follow applicable parts of these instructions 7.1 Checks before starting Check that all nuts and bolts are tightened to the correct torque. This applies to the foundation, if any, flanged connections and other pump retaining elements. For correct tightening torques, see tables 11.1 a-d in section 11.1. If the pump has not been used for some time, lubricate the bearings, see section 9.4. Remove all foreign objects from the pump and sump. Flush the sump and piping system clean. If the motor has been disconnected from the mains, its direction of rotation should be checked. When viewed from the drive end, the pump should rotate anticlockwise. Follow the instructions in section 6.6. WARNING! Incorrect rotation can seriously damage the pump. The V-belts should always be removed before the motor's direction of rotation is checked. Check that the valves, if any, are open.

Slurry Pump

Kap7 VSen_5.doc JAN 03-W34 Starting up 2/2

7.2 Checks during initial operating period 1. After 100 running hours: WARNING! Before any work is started, check that the motor is disconnected from the mains or switched off and locked so that it cannot be started inadvertently. Check the condition of the drive • In the case of V-belt drive, check the belt tension as the V-belts become slightly

elongated during the initial period of operation, see section 6.6 under the heading "Fitting the V-belts".

• In the case of direct drive, check the shaft coupling's alignment and condition. 2. Keep the area round the pump clean, Follow section 9.2 "Preventive maintenance and

service schedule". 3. Follow the lubricating instructions, section 9.4, and the recommended grades of grease.

Slurry Pump

Kap8 VSen_4.doc JAN 02-W09 Operating instructions 1/1

8. Operating instructions 8.1 Starting 1. Start the pump 2. Check that the pump is running smoothly and steadily. If it is not, see section 9.6 "Fault

tracing schedule" 8.2 Stopping 1. Stop the pump 2. Lift the pump out of the sump to avoid sedimentation of particles round the pump 3. Flush the pump clean If the pump is not going to be used for a lengthier period of time, see "Transport, storage" in section 1.2.

Slurry Pump

Kap9 TypeSLen_4.doc JAN 02-W09 Care and maintenance 1/27

9. Care and maintenance 9.1 Safety measures WARNING! Before any work is started, check that the motor is disconnected from the mains or switched off and locked so that it cannot be started inadvertently. WARNING! Freely rotating shaft. When working on or in the vicinity of the shaft with the pump in operation, make sure that all personal equipment is arranged so that it cannot fasten in the rotating parts. Work with care and exercise good judgement. Follow all local health and safety instructions: • Use approved lifting equipment • Fence off the area round the workplace so that unauthorized persons will not be

injured. The pump may be used in liquids that are harmful to your health. If this is the case, and to avoid injury to eyes and skin, observe the following points: • Always wear goggles • Flush the pump thoroughly with clean water before starting work • Rinse the parts in clean water after dismantling them

Slurry Pump


9.2 Preventive maintenance and service schedule The following routine maintenance schedule specifies the points that should be checked to ensure safe, reliable operation and high availability. The specified checking intervals are general recommendations and should be adapted according to your own experience of the installation in question. Contact Metso Minerals or our representative for further recommendations concerning your installation. Inspection of Action Inspection interval

(hours)

100 500 1000 3000 Pump, motor and drive

Keep the pump unit and the area round it clean and free from slurry and dirt.

X

Pump casing, piping and connections

Check for leakage. Rectify as necessary. X

Pump clearances Check the pump's clearances. Excessive pump clearances could lead to poorer performance and accelerated wear. See section 9.5.5 "Setting pump clearances"

X

Pump wear parts Check the hydraulic components for wear and assess their probable service life. Hydraulic components should be changed if holes are present in the liners or if impeller wear affects performance. NOTE: If the cores in elastomer hydraulic components are visible, accelerated wear can be expected. See section 9.5.1 "Removal and fitting of the pump's hydraulic components".

X

V-belt drive Check the belt tension. See "Fitting V-belts" in section 6.6

X

Direct drive Check the shaft coupling's alignment and condition. X Bolted joints Check the tightening torque of the bolted joints. For the

correct tightening torque, see table 11.1a. X

9.3 Tools and special equipment for care and maintenance A fitter's regular toolkit plus suitable hexagonal Allen keys and sockets and a torque wrench will be adequate for carrying out care and maintenance. Suitable lifting equipment should be available for removing and fitting components.

Slurry Pump


9.4 Lubrication instructions The pump has two lubricating points marked with a lubrication symbol on the "Spare parts drawing", section 10.4, and also with two signs having the same symbol on the pump itself. The lubricating nipples are of a type conforming to SS 2628/DIN 71412 standards. As supplied, the bearings are lubricated with SKF LGMT3 grease having the following basic prerequisites in the composition of the lubricant: Thickening agent: Lithium soap Base oil viscosity at 40oC 120 cST Base oil type: Mineral oil Consistence NLGI: 3 NOTE: If grease from other manufacturers is used, the above basic prerequisites in the composition of the lubricant must be followed, When changing bearings, each bearing and bearing space should be packed with grease in accordance with the table below (grease quantity). For maintenance lubrication the quantity of lubricant in the table below (periodic lubrication) should be applied at each lubrication point. The lubrication intervals depend on operating conditions and pump speed. The pump should be lubricated for the first time after about 300 operating hours and then in accordance with the table below. For correct pump type or section 2.6 "Dimension sheet". Table 9.4a

Pump type

Frame length

Periodic lubrication Grease quantity g/bearing

Pump speed, rpm Grease quantity g/bearing when changing bearings

600-800 800-1000 1000-1200

1200-1500

>1500

Lubrication interval after operating hours for bearing temperature

70oC

VS 80 L80 25 3000 2000 1500 1000 330 L120-180 35 2000 1500 1000 500 850

VS100 L80 25 3000 2000 1500 1000 330 L120-180 35 2000 1500 1000 500 850

VS150 L120 35 3000 2000 1500 1000 500 850 L150-180 100 2000 1500 1000 500 - 2000

Slurry Pump


The specified lubrication intervals are for bearing temperatures up to 70oC. At bearing temperatures above 70oC the bearings must be lubricated more frequently. For each 15oC increase in temperature the above lubrication intervals should be halved. Bearing temperatures around 100oC and above will damage the bearings. NOTE: When the pump is new or when the bearings have been changed and freshly greased, bearing temperature may be slightly high during a running-in period. For this reason, do not check the temperature until the bearings have been in use for about 2 hours of pump operation.

Slurry Pump


9.5 Removal and fitting of components WARNING! Worn parts may have extremely sharp edges. Wear heavy-duty gloves and use other suitable safety equipment. Mechanical lifting equipment should be used when components weighing more than 30 kg have to be lifted. The weights of pump components are given on the "Spare parts drawing", section 10.4. The pump's total weight, excluding motor and drive, is given on the "Dimension sheet", section 2.6, and on the weight sign affixed to the pump. The following section contains a description of how the various parts of the pump are to be removed and fitted. The figure below is an overview of the pump's principal components. A is the pump's hydraulic parts, B (lower frame), C (upper frame), D (shaft with bearing), E (motor) and F (V-belt guard).


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Hydraulic components include the pump casing (2), impeller (3), impeller attachment components (4), inlet (6), casing liner (7) and sealing components for these parts. The shaft (5) is positioned as shown in the figure.

Preparations

Remove the pipe connection and, if necessary, the motor cables. Lift the pump out of the sump, using suitable lifting equipment. Remove the discharge pipes, if any, from the pump casing. To simplify removal, a support plate (G) should be fitted. No support plate is needed for the VS150 L150-180 sizes. For the part number, see section 10.6 under "special tools".

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Set the pump down on a level floor as follows. - position the pump on the pump casing and tilt it as shown in the figure below.


- lower the lifting equipment until the pump is horizontal, as shown in the figure below.

The centre of gravity of the pump will vary, depending on the size of the motor and drive. Place a sturdy supporting frame at A or B, as necessary. - make sure that the pump is stable and firmly positioned.

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9.5.1 Removal and fitting of the pump's hydraulic components The pump can be equipped with hydraulic components of metallic (MetaChrome) or elastomer materials (e.g. rubber or polyurethane). See under "Special tools" in section 10.6 for the part numbers of the requisite lifting tools.

Removal NOTE: The parts should be removed in the order they are named below.

INLET (9) - Attach a lifting device to the inlet as shown in the figure. - Remove the nuts (10) and gasket (8) and lift out the inlet (9). IMPELLER (50) - Remove the plug (1) from the screw cover (2), using a

screwdriver. - Undo the impeller bolt (11) using an Allen key and suitable

ratchet handle. - If the impeller cannot be removed by hand, remove the V-belt

guard and V-belts, see section 9.5.4. Undo the stop screws (41) and use the bolts (43) for adjustment of the bearing housing as a puller (the pump casing wall will then force the impeller off the shaft), see section 9.5.2.

- Screw a support rod (C) into the threaded hole in the end of

the shaft as shown in the figure. For the part number, see the list of tools in section 10.6.

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- Carefully withdraw the impeller (50) along the support rod (C). Take care to prevent it from falling off the support rod.

- Attach a lifting strap to suitable lifting

equipment. Fit the lifting strap round the pump vanes as shown in the figure on the right.

Note that the strap can slide off the vanes. Hold the impeller and pull it off the support rod (C). Lower the lifting device and lay the impeller down immediately below it.

- Remove the support rod (C). - Remove the O-ring (4). PUMP CASING (53) - Fit a lifting strap through the pump casing's (53) cast lifting eyebolt

and attach it to a suitable lifting device. - Remove the bolts (7). Lower the pump casing (53) away from the

frame. - Undo the nuts (5) and washer (55). For removal of "Shaft with bearing", see section 9.5.2. REMOVAL OF LOOSE PUMP CASING LINER (16) - Position the pump casing with the small hole facing up and prise the sealing edge

loose, using a screwdriver as shown in the figure.

- Reverse the pump casing and pull out the loose liner. To make changing the liner

easier, the discharge throat can be cut off with a knife.

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Assembly NOTE: All components should be thoroughly rinsed and cleaned before they are

fitted in place. Change worn components as necessary. FITTING OF LOOSE PUMP CASING LINER - Clamp a blunt handle, such as a hammer handle, in a vice. - Hold the discharge pipe of the pump casing liner against the hammer handle, for

example, as shown in the figure.

- Press the pump casing liner's discharge pipe into the volute as shown in the figure.

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- Prepare a solution of soap and water in a bucket. - Brush or sponge the soap solution onto the inside of the pump casing

and the outside of the pump casing liner. - Place the pump casing liner on top of the pump casing with the liner's

studs in line with the pump casing's through holes.

- Place one foot in the liner. Press in the liner with a hammer handle or the like as

shown in the figure while transferring your body weight onto the foot in the liner. Press the liner into the casing.

- Rotate the liner in the casing so that the studs enter the through holes in the casing.

Use the hammer handle or similar blunt object. -

- Press out the discharge throat with the hammer handle as shown in the figure.

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- Check that the liner's sealing flange is properly positioned in the pump casing's seat.

- Reverse the casing and prise up the liner's sealing edge, using a screwdriver as shown

in the figure below.

- Fit the ring (55) with the nuts (5) as shown in the figure on the right. Later on in this section the position numbers refer in some cases to the figures under "Removal". PUMP CASING (53) - Fit a lifting strap through the pump casing's (53) cast lifting eyebolt

and attach it to a suitable lifting device as shown in the figure, see removal.

- Lift the casing (53) into place and fit the bolts (7). See table 11.1a for the correct tightening torque.

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IMPELLER (50) - Clean the impeller guide and the square drives of the shaft end and impeller. Note that

the hub of a new impeller is treated with corrosion inhibitor which should be washed off. Use hot water, an alkaline solution or white spirit as necessary.

- Lift the impeller back into place using a suitable lifting strap fastened round the pump

vanes and suitable lifting equipment, see the figure under removal. - Lift the impeller into place and make sure that it seals against the O-ring (4). - Fit the impeller bolt (11). - Tighten the impeller bolt (11) to the correct torque, see table 11.1b in section 11.1

under "Impeller bolt tightening torques". Use the hex drive socket supplied with the pump and a suitable torque wrench.

- Adjust the clearance between impeller and casing as described in section 9.5.5 - Check that the impeller clears the pump casing (15) and can rotate freely. If it binds

against the pump casing it must be adjusted forwards, see section 9.5.5 "Setting pump clearances". NOTE: In such case the tightening torque must be checked once again.

- Glue the plug (1) with Bostic 292 or Silicone adhesive in the screw cover (2). Note that

the plug's flange should be fitted facing the impeller bolt (11). INLET (9) - Secure a lifting device to the inlet (9). - Fit the inlet with the nuts (10) and measure how big a gap there is between the inlet

and impeller. - Remove the inlet (9) and fit a sufficient quantity of gaskets (8) between inlet and casing

(15) to obtain clearance L. See table 9.5a in section 9.5.5, "Setting the pump's clearances", for the correct clearance.

- Lift the inlet onto the pump casing (15). - Fit the nuts (10). - For setting the pump clearances, see section 9.5.5, "Setting the pump's clearances" - Fit the pipe connections as described in section 9.5. - On restarting, follow the instructions in section 7 "Starting up". See under "Special tools" in section 10.6 for the part numbers of the requisite lifting tools.

Slurry Pump


9.5.2 Removal and fitting of shaft with bearing The section describes how to remove the complete bearing from the pump frame after the hydraulic parts have been removed. NOTE: Read all through the instructions before starting the work. It is assumed in the instructions that the impeller, inlet, pump casing, pump drive and lower section of the V-belt guard have been removed. See "Removal and fitting of the pump's hydraulic components" in section 9.5.1 and "Removal of the pump's drive" in section 9.5.4.

Removal - Undo the bolt in the clamping joint (42). - Make a mark on the bearing housing and clamping joint (P) so that the bearing housing

will be fitted in the corresponding place on reassembly (see next page). - Remove the locking bolts (41). - Remove the grease nipple on the bearing (23). - Fasten a lifting eyebolt in the shaft's drive end (J). Use the eyebolt supplied with the

pump. Attach a lifting device to the eyebolt, as shown in the figure on the next page. - Pull the bearing assembly horizontally out of the upper frame as shown in the figure.

The bolts (43) could perhaps be tightened to facilitate dismantling. - Rest the bearing on a supporting frame (C) as shown in the figure when the impeller

end (M) of the shaft is in the frame's rear bearing housing support frame (S). Fit a lifting strap with noose round the shaft's impeller end nearest the bearing housing as

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shown in the shaded figure. Lift the bearing out of the frame as shown in the figure below.

See section 9.5.3 for further dismantling of the bearing. Assembly The position numbers under "Assembly" refer to the figures under "Removal". - Screw a lifting eyebolt (J) into the drive end of the shaft. - Fit a lifting strap through the lifting eyebolt (J) and another lifting strap with noose

round the impeller end of the shaft nearest the bearing housing, as shown in the shaded figure.

- Lift the bearing and rest the bearing housing's (D) front bearing position in the frame's

rear bearing housing support frame (S) and on a supporting frame (C) as shown in the figure.

- Remove the lifting strap with noose from the shaft's impeller end and slide the bearing

horizontally into the frame with the lifting strap fitted in the lifting eyebolt (J) as shown in the figure.

- Turn the bearing housing until it is opposite the mark on the clamping joint (P), see

removal. - Fit the grease nipple (23). - Fit the bolts (41) and tighten them to the correct torque. See table 11.1a in section 11.1 - Fit the bolts in the clamping joint (42) and tighten them to the correct torque, see table

11.1c in section 11.1

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- Fit the protection plate, impeller, pump drive and V-belt guard, see "Removal and fitting of the pump's hydraulic components" in section 9.5.1 and "Motor and drive" in section 6.6.

- On restarting, follow the instructions in section 7 "Starting up".

Slurry Pump


9.5.3 Removal and fitting of shaft and bearing The section describes shaft and bearing replacement. NOTE: Read all through the instructions before starting the work. The position numbers in this section refer to the figures below. See also "Spare parts drawing", section 10.4. It is assumed in the instructions that the complete bearing has been removed from the pump's frame, see section 9.5.2 "Removal and fitting of shaft with bearing". Removal - Place the complete bearing on a level surface and make sure that it cannot roll away

or sustain damage.

- Remove the V-ring (20). - Undo the bolts (21) in the slinger (22). - Remove the slinger (22) and O-ring (41). - Remove the T-ring (24). - Remove the grease nipples (23). - Remove the V-ring (27). - Screw a lifting eyebolt (J) into the drive end of the shaft.

Slurry Pump


- Attach a lifting device to the eyebolt (J) and lift up the bearing so that it is suspended vertically. Lift it carefully so that the square end of the shaft is not damaged.

- Rest the bearing in a sturdy supporting frame (H) as shown in the figure above.

Make sure that it is firmly positioned and secure the bearing with the adjusting bolts (I).

- Disconnect the lifting devices. - Remove the bolts (25) as shown in the figure on the previous page. - Remove the cover (26). - Attach the lifting device to the eyebolt and lift the shaft (38) out of the bearing housing

(37). If the bearing (30) is stuck in the bearing housing (37), raise the bearing slightly off the supporting frame and tap the bearing housing with a plastic mallet to drive it down onto the supporting frame. The bearing's (35) shrink-fit inner race (36) accompanies the shaft.

- Rest the shaft on a level surface. - Fit a lifting strap with noose round the bearing housing's (37) "waist". - Lift up the bearing housing and place it horizontally on a level surface. WARNING! Take care to ensure that the bearing housing does not slip out of the noose or tip out of the supporting frame.

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- Remove the key (29). - Prise the lockwasher's (32) locking tab out of the shaft nut's (31) groove. - Remove the shaft nut (31), using a hook spanner. - Remove the lockwasher (32). - Remove the bearing (30) from the shaft using a puller. NOTE: Take care to avoid

damaging the shaft's bearing position. - Remove the shaft spacer (28). - Remove the inner race (36) by cutting a groove in it and splitting it open with a chisel.

NOTE: Take care not to damage the shaft's bearing position.

- Remove the bolts (33). - Remove the cover (34). - Remove the bearing (35), using a puller. Thoroughly wash used parts that are going to be re-used. If the bearings have been removed, discard them and fit new ones. Use a suitable degreasant. Change damaged or worn parts.

Slurry Pump


Assembly The position numbers under "Assembly" refer to the figures under "Removal". Roller bearings are precision components and must be handled with care, observing the utmost cleanliness. If possible, assembly work should be carried out in dry, dust-free premises away from machinery which generates chips and dust. Check that used bearing components are thoroughly clean, degreased and free from dust and dirt. Carry out assembly right away and without interruption as soon as the packaging for the bearings is opened so that they are not exposed to dust and dirt unnecessarily. - Pack the bearing seat (P) with grease. - Fit the bearing (35), using a rubber mallet. - Fit the cover (34). - Fit the bolts (33). Fit the inner race (36) of the bearing (35) on the shaft (38) as follows: - Heat the inner race to 110°C using a heat source giving an even distribution of heat,

such as a heating chamber, induction heating apparatus or an oil bath. NOTE: The ring must not be heated to a temperature above 125°C. Higher temperatures can cause structural transformations in the material, which result in dimensional changes.

- Press the inner ring into place and allow it to cool. - Fit the spacer (28) onto the shaft. - Fit the bearing on the shaft (30). The bearing will slide easier onto the shaft if grease is

used. - Fit the lockwasher (32). - Fit the shaft nut (31), using a hook spanner. - Fit the key (29). - Fit a lifting strap with noose round the bearing housing's (37) "waist". WARNING! Take care to ensure that the bearing housing does not slip out of the noose or tip out of the supporting frame. - Lift the bearing housing vertically in the assembly stand, making sure that it stands firm

and steady. NOTE: Make sure that the bearing housing is facing in the right direction. - Attach the lifting device to the eyebolt and lift the shaft assembly, taking care to avoid

damaging the end of the shaft. - Carefully lift the shaft assembly into the bearing housing. Press grease into the bearing

seat (Q) so that the bearing (30) will slide more easily into place. Help it along with a rubber mallet if necessary.

- Detach the lifting device. - Fit the cover (26). NOTE: Make sure that the lubrication hole in the cover is opposite

the lubrication hole in the bearing housing. - Fit the bolts (25).

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- Fit the V-ring (27). - Fit the grease nipples (23). - Fit the T-ring (24). - Fit the O-ring (41) and slinger (22). - Tighten the bolts (21) in the slinger (22). - Fit the V-ring (20).

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9.5.4 Removal of the pump's drive The section describes how to remove the pump's drive. Fitting the drive is described in section 6.6 "Motor and drive".


- Remove the nuts (50) and lift off the V-belt guard's cover (F). Covers weighing more

than 30 kg are fitted with a lifting eyebolt. - Undo the locknut (51) and unscrew the bolt (52) until the motor baseplate can be

swung in towards the pump, see figure above. - Remove the V-belts (54). - Remove the bolts from the V-belt pulleys and fit them in the clamp bushing's puller

holes. - Remove the V-belt pulleys (53). - Remove the bolts (56) and the lower section (55) of the V-belt guard. For assembly, see section 6.6 "Motor and drive".

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9.5.5 Setting pump clearances The section describes how to adjust the pump for optimum performance and minimum wear. The clearance is adjusted in two stages, first between the back vanes and pump casing K and then between the impeller and inlet/casing inlet L. To allow this adjustment to be made, "shaft with bearing" (D) is axially adjustable.


The position numbers below refer to the figure above. Read all through the instructions before starting the work. - Remove the V-belt cover and remove the V-belts or the drive. See section 9.5.4. Also

remove the inlet, see section 9.5.1. - Undo the clamping joint (42) and locking bolts (60). - Push back the entire "shaft with bearing" assembly (D) so that the impeller's back

vanes make contact with the pump casing. Do this by tightening the bolts (43) while rotating the pump shaft.

- Clearance K is now zero. - Push the "shaft with bearing" assembly (D) forward so that clearance K assumes the

lowest value (see table 9.5a). Do this by slackening the bolts (43). - Lock the bolts (60). - Tighten the clamping joint (42) to the correct torque. See table 11.1c in section 11.1. - Fit the inlet (9) without gasket and measure the gap that occurs between inlet and

casing. - Fit a sufficient quantity of gaskets (8) to obtain clearance L, see table 9.5a. Note that

the gaskets will be compressed when the inlet is fitted. - Fit the inlet, see section 9.5.1.

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When the clearances are correctly adjusted: - check that the impeller can rotate freely. If the impeller cannot be rotated, adjust the

clearance once again. Table 9.5a

Clearance position

Clearance (mm)

K 0,5-1,5 L 1,0-2,0

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9.6 Fault tracing schedule Use the following schedule as a fault-tracing aid. In the instructions it is assumed that the pump and installation have previously been working satisfactorily. WARNING! Fault tracing should be carried out with the power supply disconnected, except for checks that cannot otherwise be performed. Make sure that nobody is in danger of being injured before switching on the power. NOTE: Electrical installation work must be carried out by an authorized electrician. Follow local installation directives and observe "Health and safety", section 3. In order to carry out fault tracing on the electrical equipment it will be necessary to have a universal instrument (multimeter), a test lamp and a circuit diagram. 1. Pump fails to start Is the installation without power?

YES ⇒ NO ⇓

Check that: - The main switch is turned on. - The machine and its fuses are intact. - Operating current present for starting. - Overload cut-out reset. - All phases are live. - No open circuit in motor cable.

Can the pump be started manually?

YES ⇒ NO ⇓

Check the cause: - Fault in level control equipment, if any. - Fault in other monitoring or control

equipment. - Follow the instructions for the monitoring

equipment, if any, and change defective components.

Is the pump jammed?

YES ⇒

NO ⇓ Contact Metso Minerals

- Remove the drive's protection plate and

rotate the pump shaft - Remove the pump and clean behind the

impeller. See section 9.5. Rinse out the pump and sump.

- Remove the drive and check that both motor and pump shaft can be rotated. Change the bearing if necessary. See section 9.5.3 and the motor manufacturer's instructions.

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2. Pump starts but motor overload cut-out trips

Has the flowchart or pipe routing been changed?

YES ⇒ NO ⇓

Change the flowchart and pipe routing or resize the drive, motor and pump according to the new operating conditions.

Is the motor overload cut-out set too low?

YES ⇒ NO ⇓

Check against the motor sign and adjust as necessary.

Is the pump shaft hard to turn or is it jammed?

YES ⇒ NO ⇓ Contact Metso Minerals

- Remove the V-belt guard and check that

the drive can be rotated. - Remove the pump and clean behind the

impeller. See section 9.5. Rinse out the pump and sump.

- Remove the drive and check that both motor and pump shaft can be rotated.

- Change the bearing as necessary. See section 9.5.3 and the motor manufacturer's instructions.

- Check that the pump clearances are correctly adjusted. See section 9.5.5.

3. Pump runs but produces little or no

flow Has the operating data or pipe routing been changed?

YES ⇒ NO ⇓

Change the operating data and pipe routing or resize the drive, motor and pump according to the new operating conditions.

Has any leakage occurred in the installation?

Change or rectify leaky components.

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Check: - Pump direction of rotation, see section 6. With the wrong direction of rotation, the

pump may give up to 60% of the flow it produces with the correct direction of rotation. The bearing and hydraulic components are stressed to a far greater extent if the pump rotates in the wrong direction and the risk of a breakdown is high.

- That the valves, if any, are open and intact. Note that valves on the inlet side should

always be fully open when the pump is running. Special valves of rubber sleeve type which are mounted on the inlet side can be sucked in at high flow rates and block the inlet.

- That the impeller is not clogged. Clean the impeller as necessary. See section 9.5 for

its removal. - That the pump clearance is correctly adjusted, see section 9.5.5. If the correct

clearance cannot be obtained, change worn hydraulic components. - That hydraulic components are so worn that they impair pump performance. Change

worn components. 4. Pump runs unevenly or vibrates Check that the feed to the pump and the pump itself do not suck air.

YES ⇒ NO ⇓

Adjust the feed to the pump or resize the drive, motor and pump according to the operating conditions.

Check that the valves, if any, are open and intact and that the lines are not blocked

YES ⇒ NO ⇓

Rectify

Check that the impeller is not clogged.

Clean the impeller as necessary. See section 9.5 for its removal.

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Kap10 VSen_4.doc JAN 02-W09 Spare parts 1/2

10. Spare parts 10.1 Recommended spare parts stock To maintain as high a level of pump availability as possible, Metso Minerals recommends keeping the following parts in stock. For part numbers, see section 10.3. - Impeller - Pump casing/liner - back liner - Inlet liner/inlet - Bearing assembly - Impeller bolt - Screw cover with plug - Complete set of gaskets and O-rings 10.2 Stocking of spare parts Rubber components should be stored in a cool place, protected from direct sunlight. They should be stored in undeformed state and protected from ozone-generating sources. Ozone is generated by high-tension discharges in switchgear, electric motors, etc. and also in connection with welding. other components should be stored in a dry place, protected from dust and dirt. Certain types of rubber such as chloroprene rubber (CR) harden at temperatures below +5°C. In conditions of extreme cold these types of rubber harden to such an extent that they could develop cracks and be damaged by handling. Chloroprene rubber does not regain its normal hardness when the ambient temperature rises but has to be reconditioned. Machined surfaces of metallic components are treated with corrosion inhibitor before delivery and this must be removed before assembly. 10.3 Ordering spare parts The best way of avoiding misunderstandings and ensuring correct delivery is to provide as extensive information as possible. Therefore state the following in your spare parts order: - Pump type designation and serial number, see the machine sign on the pump. - Designation, material and part number of the part, see example below. Example: 1 impeller, rubber-lined, part No. 310204-M1

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Kap10 VSen_4.doc JAN 02-W09 Spare parts 2/2

10.6 Special tools Part numbers of special tools Pump size Support rod Lifting hook Counter-hold

spanner Lifting eyebolt

1

VS25 - 235303-M1 - - VS50 - 235303-M1 219592-M1 - VS80 219630-M1 235303-M1 - - VS100 219630-M1 235303-M1 - - VS150 219630-M1 235303-M1 - - VS200 228276-M1 235303-M1 - - VS250 - - - 4 x 952828 VS300 - - 219598-M1 - 1 On removal of pump casing liner. Pump size Lifting eyebolt 2 Support plate VS25 952827 235304-M1 VS50 951255 235305-M1 VS80 952828 235306-M1 VS100 952828 235307-M1 VS150 952828 235308-M1 3 VS200 954685 - VS250 954685 - VS300 954685 - 2 On removal of shaft with bearing 3 VS 150 L120 only.

PUMPVS100 L80 Spare part drawing

124-551- JAN 99-W46 Edition 1 2/2

Pump VS100 L80 O3 NRParts list

25101401000 JAN 05W15 Spare partsEdition 1 1/1

Item Part No. Description Qty Unit weightKg

Wear parts015 SA207209M1 Impell er 1 9.40012 SA128692M1 Inlet door 1 30.00013 SA092743M1 Case liner 1 5.00

Bearing assembly parts001 SA220808M1 Bearing/shaft assembly 1 105.00002 SA199226M1 Shaft end 1 5.45201 SA1992251 Shaft 1 48.00206 SA899018100 Key 1 0.15208 SA954177 Nut 1 0.19209 SA954128 Washer 1 0.03213 SA101603A Bearing cylinder housing 1 38.00214 SA101604A End cover 1 2.70215 SA1016381 Distance ring 1 0.27216 SA1102221 End cover 1 2.30217 SA1102232 Flinger 1 0.72218 SA1154731 Distance ring 1 0.82219 SA954033 Bearing 1 2.75220 SA953955 Bearing 1 3.55221 SA950200 Vring 1 0.01222 SA953329 Vring 2 0.01224 SA951624 Screw 2 0.01

Spare partsSA1016421 Gasket 1 0.20

003 SA148491M1 Screw cover 1 0.12004 SA1384763 Plug 1 0.10010 SA092742A Case 1 49.00026 SA1578822 Gasket 1 0.00030 SA953164 Oring 1 0.01041 SA953477 Screw 1 0.20

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Kap11 VSen_4.doc JAN 02-W09 Appendices 1/2

11. Appendices 11.1 Tables with specified tightening torques for bolted joints Table 11 a) Tightening torques for regular bolted joints.

Strength class 8.8 as per ISO 898. Strength class A4-80 as per ISO 3506.

Thread Tightening torque (Nm) ±15%

M5 5,7 M6 9,8 M8 24 M10 47 M12 81 M16 197 M20 385 M24 665 M30 1310 M36 2280

b) Tightening torques for impeller bolts.



M10 53 M16 220 M20 430 M24 735 M30 1480

Slurry Pump

Kap11 VSen_4.doc JAN 02-W09 Appendices 2/2

c) Tightening torques for clamping joints.



M16 115 M20 175 M24 200 M30 300

d) Tightening torques for studs, DIN 939.



M10 29 M12 51 M16 123 M20 240 M24 416

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