SF RANGE OF CENTRIFUGAL PUMPS FOR VACUUM ASSISTED … Manual.pdf · series pump operators handbook sf range of centrifugal pumps for vacuum assisted self priming applications types

SERIES PUMP OPERATORS HANDBOOK

SF RANGE OFCENTRIFUGAL PUMPSFOR VACUUM ASSISTED

SELF PRIMING APPLICATIONS

Types SF200, SF250, SF300 and SF400

ACME Dynamics, Inc.P.O. Box 1780Plant CityFlorida33564

Telephone:813-752-3137

Fax:813-752-4580

Document No. W77-005E/3 USARevision No. 3Revision Note No. R26413

Date Issued. Sept. 2000Produced at ACME Dynamics, Inc.Plant City, Florida 33564


CONTENTSSection........................................................... Page1 General Information & Safety Instructions.......12 Transport Handling and Storage .....................23 General Description.........................................24 Assembly and Installation................................35 Commissioning and Operation ........................56 Maintenance and Service................................67 Faults and Remedial Action ..........................138 Supplementary Documents ...........................15

8.4 Spare Parts..............................................169 Additional Information....................................20After Sales Service .............................. Back CoverManufacturer Information: (Where applicable)Priming Equipment.................................Appendix ICoupling ...............................................Appendix IIDriver ...................................................Appendix III

Introduction

This manual gives the safety, installation, operation and maintenance instructions for pumps in the ACMEDynamics DYNAPRIME SF range of horizontal, end suction, centrifugal pumps for vacuum assisted self primingapplications.

The ACME Dynamics, Inc. code may identify pumps typically in the form 'SF200DV306'.

This manual applies to the following pump types.

SF200, SF250, SF300 & SF400

Section 1 General Information and Safety Instructions

The products supplied by ACME Dynamics, Inc. have been designed with safety in mind. Where hazardscannot be eliminated, the risk has been minimized by the use of guards and other design features. Somehazards cannot be guarded against and the instructions below MUST BE COMPLIED WITH for safeoperation. These instructions cannot cover all circumstances; YOU are responsible for using safe-workingpractices at all times.

1.1 ACME Dynamics, Inc. products are designed for use in appropriate locations which are to be kept free ofobstructions that may restrict safe access to the controls and maintenance access points.A pump nameplate is fitted to each unit and must not be removed. Loss of this plate could makeidentification impossible. This in turn could affect safety and cause difficulty in obtaining spare parts. Shouldaccidental loss or damage occur, contact ACME Dynamics, Inc. immediately.

1.2 Access to the equipment should be restricted to the personnel responsible for installation, operation andmaintenance and they must be trained, adequately qualified and supplied with the appropriate tools for theirrespective tasks.

1.3 ACME Dynamics, Inc. requires that all personnel that are responsible for installation, operation ormaintenance of the equipment, have access to and study the product instruction manual BEFORE any workis done and that they will comply with all local and industry based safety instructions and regulations.

1.4 Ear defenders should be worn where the specified equipment noise level exceeds locally defined safe


Our policy is one of continuous improvement and we reserve the right to alter specifications without giving notice.

levels. Safety glasses or goggles should be worn where working with pressurized systems and hazardoussubstances. Other personal protection equipment must be worn where local rules apply.

1.5 Do NOT wear loose or frayed clothing or jewelry, which could catch on the controls or become trapped inthe equipment.

1.6 Check and confirm that the manual is the relevant copy by comparing the serial number on the identification

plate with that on the manual.

1.7 Note any limits to the pump application specified in the contract documentation. Operation of the equipmentoutside these limits will increase the risk from hazards noted below and may lead to premature andhazardous pump failure.

1.8 Clear and easy access to all controls, gauges and dials etc. MUST be maintained at all times.

1.9 IMPROPER INSTALLATION, OPERATION OR MAINTENANCE OF THIS ACME Dynamics, Inc.PRODUCT COULD RESULT IN INJURY OR DEATH.

1.10 Within the manual, safety instructions are marked with safety symbols.

HazardThis symbol refers to general mechanical aspects of safety.

HazardThis symbol refers to electrical safety.

This symbol gives warning of a hazard to the pump itself, which in turn could cause a riskto personal safety.

Section 2 Transport Handling and Storage Instructions

2.1 Transport

DYNAPRIME SF pumps are dispatched fully assembled and lubricated except for overseas orders for theSF300 & SF400 pumps, the lubricating oil in the drive end bearing housing is drained. Pumps are protectedagainst corrosion and packed for transport by normal road, rail and sea carriers.

2.2 Handling

Crushing HazardWhen lifting the pump, use lifting equipment having a safe working load rating suitable for the weightspecified. Use suitable slings for lifting any pump not provided with lifting points.

The use of suitable forklift truck and four-chain crane sling equipment is recommended but locally approvedequipment of suitable rating maybe used.

Pumps supplied on pallets may be lifted by forklift truck, to lift from the pallet the pump should be slung asshown.

Pump weight is shown in Section 8.

2.3 Storage

2.3.1 Temporary Storage for up to Six Weeks

ATTENTION

FALIFT1



If the pump unit is not to be used immediately it should be stored carefully in a horizontal position, in asheltered, dry location. Additional rust preventative should be applied to all unpainted carbon steel or castiron parts, and should not be removed until final installation.

2.3.2 Long Term Storage

Shearing HazardDo NOT place fingers or hands etc. into the suction or discharge pipe outlets and do NOT touch theimpeller, if rotated this may cause severe injury. To prevent ingress of any objects, retain the protectioncovers or packaging in place until removal is necessary for installation. If the packaging or suction anddischarge covers are removed for inspection purposes, replace afterwards to protect the pump andmaintain safety.

For SF300 & SF400 pumps, fill the drive end bearing housing with recommended oil to ensure that the shaftand bearings remain rust free.

The pump shaft should be rotated by hand at least five turns every six weeks.

For special protection of the coupling, diesel engine and electric motors, where applicable, refer to themanufacturers' instructions in the relevant appendix.

2.3.3 Exposed or Extreme Conditions Storage

For exposed storage or extreme variants in atmospheric or environmental conditions, please refer to ACMEDynamics, Inc. for special storage instructions to suit the conditions applicable.

Section 3 General Description

ACME Dynamics DYNAPRIME SUPRAFLOW pumps are a range of horizontal centrifugal pumps. The twoor three vane open impeller design will handle dirty water, industrial effluents, and sludge etc, includingsolids.

The mechanical assembly comprises a rigid shaft, supported by grease lubricated pump end bearings andeither grease or oil lubricated drive end bearings with an open vane type impeller mounted in a removablebearing housing assembly. This is attached to an end suction volute casing fitted with a front wear plate.The bearing housing, shaft and impeller assembly can be withdrawn from the volute for maintenancewithout disconnection of pipework or the driver provided that a spacer coupling has been fitted.

The discharge branch is positioned at 45° above the center of the pump volute. This allows the fitting of aball or flap type non-return valve to give a horizontal discharge. The pump is centerline mounted and thevolute is provided with an access point for examination of the impeller.

The pump has been designed for use with an automatic priming system typically one using a vacuum pumpwith a priming tank. As several varieties of priming systems may be fitted, the details and operationinstructions for the particular priming system used are fully described in a separate priming system manual.References to priming functions in this manual apply to all priming systems in general.

The complete assembly is of a rigid construction, being intended for mounting on suitable baseplate withelectric motor or diesel engine driver. A suitable coupling is required to transmit the rotational drive betweenpump and driver.

The shaft is sealed with a vacuum pressure seal. Alternative seals can be supplied by arrangement to suitspecial customer requirements and the liquid being pumped.

The materials of construction are:

Component MaterialImpeller Stainless Steel or Cast iron

(Note - SF400 Cast iron only)Volute Casing Cast Iron



Suction Cover SG Cast IronBackplate Stainless Steel or Cast ironBearing Housing Cast IronShaft Stainless Steel

Nameplate details are shown on the back cover of this manual. Full pump specification can be supplied ona data sheet, if requested.

Section 4 Assembly and Installation

Shearing HazardDo NOT place fingers or hands etc. into the suction or discharge pipe outlets and do NOT touch theimpeller, if rotated this may cause severe injury. To prevent ingress of any objects, retain the protectioncovers or packaging in place until removal is necessary for installation.

4.1 Initial Inspection for Damage

During transport and storage, accidental damage to the pump may have occurred. When the pump is to beinstalled, or in the event of a handling accident, carefully check that no damage has been sustained by thepump before installation and commissioning.

4.2 Preparation for Mounting

Before installation, check that the pump mounting location is suitable for accepting the pump unit. Refer toSection 8, for details of pump installation dimensions or to a certified General Arrangement Drawing, whenavailable.

4.3 Pump Preparation

Abrasion and Entrapment HazardDo NOT touch any moving or rotating parts. Guards are provided to prevent access to these parts, wherethey have been removed for maintenance they MUST be replaced before operating the equipment.

Remove packaging but leave the flange covers in place, check that the impeller rotates freely by hand byturning the shaft.

4.4 Pump Installation

It is recommended that the pump unit be fitted to the baseplate before fitting the motor and coupling. Thedistance between shaft ends should be established to suit the coupling by reference to the manufacturer'sinstructions.

4.5 Shaft Alignment

To minimize the side load on the bearings and to achieve full coupling and bearing life, it is recommendedthat the shafts be aligned as accurately as possible i.e. well below the allowable misalignment of thecoupling. Refer to the coupling manufacturer's instructions or proceed generally thus:

a) Lateral AlignmentMount a dial gauge on the motor shaft or coupling with the gauge running on the outer machined diameterof the pump coupling. Turn the motor shaft and note the total indicator reading.

b) Angular AlignmentMount a dial gauge on the motor shaft or coupling to run on a face of the pumpcoupling as near the outside diameter as possible. Turn the motor shaft andnote the total indicator reading.

c) Confirm Lateral AlignmentMount the dial gauge on the pump shaft or coupling with the gauge running on



the outer machined diameter of the motor coupling. Turn the pump shaft and note the total indicatorreading.

d) AdjustmentThe motor must be shimmed and re-positioned to align the shafts within thecoupling manufacturer's specifications.

e) Alternative MethodIf a dial gauge is not available, calipers or taper gauge may be used to measurethe distance between the coupling flanges at four points around the circumference and a straight edge usedto check the lateral alignment of the outer flange diameters.

ATTENTION

Shaft alignment must be checked again after the final positioning of the pump unit and connection topipework as this may have disturbed the pump or motor mounting positions.

4.6 Suction Pipework

It is recommended that the pump be installed as near to the liquid source as possible

Any rigid pipework should be supported independently and close to the pump so that no strain istransmitted to the pump when the flange bolts are tightened. Use pipe supports at intervals necessary toprovide support. When expansion joints are used in the piping system, they must be installed beyond thepiping supports closest to the pump.

ATTENTION

Collapsible hoses must not be used on the suction side of the pump.

Install piping as straight as possible, avoiding unnecessary bends. Where necessary use long sweep 90°bends or fittings to decrease friction losses.

Make sure that all suction piping joints are airtight. Provide pipe expansions when hot fluids are to bepumped. Where reducers are used, eccentric reducers (tapered side down) are to be fitted in horizontalsuction lines and straight taper reducers in vertical discharge lines. Undulations in the pipe runs or misuseof reducers may cause the formation of air pockets in the pipe and thus prevent the efficient operation ofthe pump.

The suction (and discharge) pipes can be one or two sizes larger than the pump flange connections. Ahorizontal suction line should have a gradual rise to the pump.

A correctly sized filter or strainer must be fitted to hold back larger items.

The suction pipe work should be flushed clean to ensure that site debris is not drawn into the pump when itis commissioned.

4.7 Discharge Pipework

Pipework should be as short and straight as possible to reduce friction head loss.

A non-return valve is usually fitted to prevent the pump from excessive back pressure and reverse rotationand a discharge valve must be fitted to regulate the flow and allow for inspection and maintenance on thepump.The suction and discharge pipework must be independently supported and positioned such that noexcessive forces and moments are exerted on the pump flanges.

Typical Pipework



XFPIPE1.CDR

ATTENTION

Failure to support suction and delivery pipework may result in distortion of the pump casing, with thepossibility of early pump failure.

4.8 Baseplate and Foundations

The pump is designed to be secured to a substantial baseplate to maintain the shaft alignment between thedriver and the pump. The baseplate should be securely located on level ground or mounted on foundations.The shaft alignment should be checked again before commissioning and putting the pump into operation.

Section 5 Commissioning and Operation

Abrasion and Entrapment HazardDo NOT touch any moving or rotating parts. Guards are provided to prevent access to these parts, wherethey have been removed for maintenance they MUST be replaced before operating the equipment.

5.1 Commissioning Checks

These checks must be done after first installation and after pump maintenance, which required removal ofthe rotating assembly.

ATTENTION

On SF300 and SF400 pumps check the level of oil in the bearing housing is at the level mark on the sightglass on the side of the bearing housing. Refer to Section 6.4 - Bearing Lubrication.

ATTENTION

Failure to supply the bearings with specified lubrication may result in damage and premature failure of thepump.

Check that the rotating assembly is free to rotate by hand before connecting the power supply. Also checkthat the piping system has been properly connected with all joints tightened and instrumentation is inposition.

When using an electric motor, connect the electrical supply to the pump unit. Momentarily switch on motorand check direction of rotation. This should be such that the pump assembly turns clockwise when viewedon the driven end. For three phase electric motors, if direction of rotation is incorrect, disconnect the supplyand change over two of three supply wires.

When using a diesel engine verify that the direction of rotation of the engine is correct for the pump byreference to the engine manual.



5.2 Starting Procedure

Open any valves in the discharge pipes to prevent hydraulic lock from occurring. Start the engine or switchon the motor and allow it to build up to full operating speed.

Check that the motor is not overloading, unit is not vibrating or excessively noisy, bearings are notoverheating, and that the pump is developing the correct flow and head requirements.

If the pump is operating at its normal speed, the pump should be shut down at once if any of the followingdefects are found:

a) Excessive vibration.b) Motor runs hot.c) Excessive noise from cavitationd) Pump bearing overheating.

Recommended corrective action for these faults is given in Section 7 Faults and Remedial Action.

5.3 During Operation

Hot Surfaces HazardDo NOT touch surfaces, which during normal running will be sufficiently hot to cause injury. Note that thesesurfaces will remain hot after the pump has stopped, allow sufficient time for cooling beforemaintenance. Be cautious and note that other parts of the pump may become hot if a fault is developing.

Cold Conditions HazardBeware of operating water pumps in temperatures below freezing point, without first checking that thepumped fluid is not frozen and the pump is free to turn. Remember to drain down the pump after stopping.

Hazardous NoiseIn addition to local or site regulations for noise protection, ACME Dynamics, Inc. recommends the use ofPersonal Ear Protection equipment in all enclosed pump rooms and particularly those containing dieselengines.

Hazardous Gases, Mists, Sprays and LeaksBe aware of the hazards relating to the pumped fluid, especially the danger from inhalation of noxious andtoxic gases, skin and eye contact or penetration. Obtain and understand the hazardous substance datasheets relating to the pumped fluid and note the recommended emergency and first aid procedures.

Periodic Checks:a) Vacuum Pressure Seal:

A small amount of leakage may occur but significant leakage indicates seal failure and that replacement isnecessary.

b) Bearings:Check the bearing temperatures do not exceed the maximum levels in the table below. If thesetemperatures are exceeded, the pump should be shut down for investigation, as an increase in bearingtemperature may indicate the early stages of bearing trouble.

Pump Maximum Bearing TemperatureType Non Drive End Drive EndSF200SF250 100°°°°C 100°°°°CSF300SF400 100°°°°C 130°°°°C

c) Noise:

Listen for any unusual noise or an increase in normal sound level.



This may result from:i) Loose fasteners for guards and other equipment.ii) Worn coupling.iii) Cavitation caused by air in the liquid from leaks in the suction pipework.

d) Alignment:Alignment should be checked after the first run and after any maintenance requiring removal ordisconnection of the coupling. For detailed instructions, refer to Section 4.5 - Shaft Alignment

5.4 Stopping Procedure

Refer to the diesel engine instruction manual for the engine stopping procedure. Reduce the engine speedand stop the engine then close any valves in the discharge pipes, or switch off the electric motor and thespeed will reduce quickly, when stopped close the discharge valve.

Section 6 Maintenance and Service

6.1 General Introduction

ACME Dynamics DYNAPRIME pumps will provide many years of trouble free service when maintained inaccordance with these instructions. In the event of failure of the pump it is recommended that ACMEDynamics, Inc. Service Department be called to investigate and carry out repairs. The following instructionsare given to cover the main elements of strip and rebuild but do NOT include instructions for work thatMUST be done by an ACME Dynamics, Inc. Service Engineer.

The following hazards may arise during maintenance work:

Fluid Pressure Jet HazardsCheck and ensure that the pump operates at below the Maximum Working Pressure specified in themanual or on the pump nameplate and before maintenance, ensure that the pump is drained down.

Hazardous MaterialsWear a suitable mask or respirator when working with Packing and Gasket components, which containfibrous material, as these can be hazardous when the fibrous dust is inhaled. Be cautious, if other supplier'scomponents have been substituted for genuine ACME Dynamics parts, these may then contain hazardousmaterials.

Hazardous Gases, Mists, Sprays and LeaksBe aware of the hazards relating to the pumped fluid, especially the danger from inhalation of noxious andtoxic gases, skin and eye contact or penetration. Obtain and understand the hazardous substance datasheets relating to the pumped fluid and note the recommended emergency and first aid procedures.

BEFORE ATTEMPTING ANY MAINTENANCE ON A PUMP, PARTICULARLY IF IT HAS BEEN HANDLING ANYFORM OF HAZARDOUS LIQUID, ENSURE THAT THE UNIT IS SAFE TO WORK ON. THE PUMP MUST BEFLUSHED THOROUGHLY WITH A SUITABLE CLEANSER TO PURGE AWAY ANY OF THE PRODUCT LEFT INTHE PUMP COMPONENTS. THIS SHOULD BE CARRIED OUT BY THE PLANT OPERATOR AND A CERTIFICATEOF CLEANLINESS OBTAINED BEFORE STARTING WORK. TO AVOID ANY RISK TO HEALTH IT IS ALSOADVISABLE TO WEAR PROTECTIVE CLOTHING AS RECOMMENDED BY THE SITE SAFETY OFFICER,ESPECIALLY WHEN REMOVING OLD PACKING WHICH MAY BE CONTAMINATED.

Recommended Maintenance Schedule

For motor or engine maintenance and maintenance of the priming system (when fitted) refer to the separateoperators handbooks included within the pump documentation pack.

PERIOD TASKDaily For SF300 & SF400 pumps,

check the lubricating oil level in



PERIOD TASKbearing housing sight glass andtop up if needed.

Check the bearing temperatures.Check visually for leaks.Check for vibration.

Weekly or170 hours

Check security of all fastenersand hose fittings.

Monthly or700 hours

Apply grease as shown in theschedule in Section 6.4.

6 monthly or4000 hours

For SF300 & SF400 pumps,replace the oil in the drive endbearing housing.

Renew packing in the vacuumpressure seal.

Annually or8000 hours

Check condition of impeller andwear plate.

Check pump bearings.

The above schedule is given for guidance but site-operating conditions may override the suggestedmaintenance intervals. Adjustments to time scales will also have to be made if the pump is idle for longperiods.

6.2 Preparation for Maintenance

Electric Shock & Accidental Starting HazardISOLATE the equipment before any maintenance work is done. Switch off the main supply, remove fuses,apply lockouts where applicable and affix suitable isolation warning signs to prevent inadvertent re-connection.

For diesel driven pumps disconnect the negative battery lead to prevent inadvertent starting.

In order to avoid the possibility of maintenance personnel inhaling dangerous fumes or vapors. It isrecommended that maintenance work be carried out away from the pump location by removal of thebearing housing and shaft assembly to a suitable maintenance area.

It is important to ensure the suitable lifting equipment is available and that the work is carried out in a cleanarea.

6.3 Maintenance of the Vacuum Pressure Seal

The seal is product lubricated and requires only regular inspections for signs of leakage, which whensignificant indicates the need to replace the packing.

To replace the seal packing:

Ensure the volute is drained. A plug in the bottom of the volute is provided for this purpose.

Remove guard from around pump shaft.

Release screws and nuts holding the spring carrier to the rear cover plate and slide the spring carrier alongthe pump shaft. This will automatically withdraw the packing holder.

Remove old packing from packing holder. Examine the spring for signs of corrosion. Replace if necessary.



Cut a length of packing to match the original packing ensuring the ends are square. The packing materialis four ply graphite impregnated braided P.T.F.E.

Place the packing into the holder, butting the two ends first then pressing the remainder of the packing intothe holder. (NB the length of the packing is greater than the circumference of the holder and some difficultymay therefore be experienced)

The packing will protrude slightly from the face of the holder on completion. Slide the seal assembly backalong the shaft to locate on backplate. Tighten securing nuts and screws evenly.

Refit the shaft guard. 6.4 Bearing Lubrication Schedule

Frequency of re-lubrication is dependent on a number of factors, which can vary with the application. Theseinclude operating conditions, frequency and duration of service, environment (humidity, dust & othercontaminants) and operating temperature. The frequency of re-lubrication listed below is therefore forguidance only and should be modified to suit operating conditions.

PUMP TYPE RADIAL BEARINGNon-drive end (NDE)

RADIAL & THRUSTBEARING Drive end (DE)

SF200SF250

GREASE LUBRICATED4 weeks - 700 hours

2.03 oz. grease


6.09 oz. grease

SF300SF400


3.38 oz grease

OIL LUBRICATEDDAILY - Check level and top up as required.

Change oil every 6 months or 4000hours

Recommended LubricantsGrease: Mobile 1 Synthetic HP2-150

Oil:

6.5 Bearing Lubrication & Care a) Bearing Description: The smaller pumps, SF200 and SF250 incorporate a combination of cylindrical roller and angular contact ball

bearings which even at relatively high speed, only require grease lubrication. The larger pumps, SF300 & SF400 due to high axial thrust, use a high capacity taper roller bearing pair at the

drive end which must be oil lubricated at speeds over 1,500rpm, with a grease lubricated pump endbearing. Oil lubrication limits the pump to horizontal (or near horizontal) applications.

b) Initial Lubrication:



Greased bearings are pre-packed with lubricant during pump manufacture or re-assembly. The grease is

thoroughly worked into all parts of the bearing, and the space in the housing is lightly packed to a maximumof two-thirds full.

Oil chambers on the larger pumps are emptied for transport and must be filled with the specified synthetic oil to

the BOTTOM of the sight glass prior to running.

b) Lubrication of Grease Lubricated Bearings: Because of shrinkage and normal loss of grease, re-greasing should be carried out at regular intervals. Clean the

bearing housing nipples and the grease gun nozzle before use. Check the output from the grease gunbeforehand and calculate the correct number of strokes to supply the specified quantity of grease and applyto each bearing position as specified in the lubrication schedule in Section 6.4.

Overfilling can be as harmful to bearings as under-lubrication. If the housing becomes compacted, the grease is

churned by the bearing rolling action leading to overheating and breakdown of the lubricant with subsequentdamage to the bearing.

Immediately after re-lubrication of greased bearings it is normal for the temperature of the housing to rise during

service. This should soon drop to normal under continuous running. If the temperature remains elevatedabove normal or continues to rise, temporarily remove the grease nipples and allow the escape of excessgrease.

c) Lubrication of Oil Lubricated Bearings:

Oil should be topped up when not visible in the pump sight glass. It is IMPORTANT to use the specified oil only. Oil lubrication is complicated by the probability that these pumps may not be operated on a totally horizontal

platform. Sight glasses are provided on both sides of the pump and the oil level should be checked in both to ensure that

the oil level is visible at the bottom of the higher sight glass. 6.6 Impeller Inspection

The pump-casing volute is fitted with a removable cover to allow limited visual inspection only of thepump internals. Ensure that the pump prevented from starting and that the volute has been drained beforeremoving the inspection cover.

6.7 Disassembly of the Pump

Refer to Section 8 - Pump cross-section Drawing.The pump is designed to allow removal of the bearing housing, shaft and impeller assembly withoutdisconnecting the pipework. If the pump is fitted with a spacer coupling, the driver need not be removed.

a) Removal of the Rotating Assembly

Disconnect the drive coupling as per the coupling manufacturer’s instructions, and either remove the pumpcomplete from the baseplate or move the driver or spacer coupling to allow withdrawal of the rotatingassembly without de-mounting the pump volute casing.

Remove any bolts connecting the drive end of the bearing housing (62) to a support from the baseplate andremove the support.

On SF300 & SF400 pumps, drain the oil from the bearing housing by removal of the drain plug (1L).

Support the bearing housing assembly and ensure that suitable lifting facilities are available.

Remove all the screws (1B) from the volute casing (1). Insert two of these screws into the jacking screwpositions and gently tighten to separate the bearing housing (62) from the volute casing.



Remove the bearing housing complete with shaft and impeller from the volute casing and move this rotatingassembly to a clean area for further disassembly.

b) Removal of the Impeller

Support the rotating assembly securely and ensure that suitable lifting facilities are available.

Remove the plastic cap (21X) from the center of the impeller to give access to the impeller retaining screw(21A).

Use the drive shaft keyway to prevent the impeller from turning and loosen the impeller retaining screw.

Using a soft faced mallet, gently tap the impeller to free it from the tapered shaft. When free remove thescrew and using suitable lifting equipment, withdraw the impeller. Extract the impeller key (116) from theshaft and retain for re-assembly.

Do not remove the balance weights (if fitted) from the impeller.

c) Removal of the Backplate and Seal Housing

Remove the screws (36A) securing the backplate (36) to the bearing housing (62).

Carefully withdraw the backplate from the shaft (71) ensuring that the seal components are not damagedon the shaft.

The seal spring carrier (41) may be removed from the backplate at this stage.

d) Removal of the Shaft and Bearings

Remove the pump half coupling from the shaft as per the coupling manufacturer’s instructions.

On SF200 & SF250 pumps:Remove the shaft sealing rings (63R & 64R) from both ends of the bearing housing.

Remove the drive end bearing cap (64) from the bearing housing.

On SF300 & SF400 pumps:Remove the inner shaft sealing ring (63R)

Remove the screws (A62A) to allow the rear bearing housing (B62) to be removed with the shaft.

Using a suitable press, apply pressure to the tapered end of the shaft and push the shaft out from thebearing housing, complete with the drive end bearings and the inner race of the non drive end bearing.Do NOT drive the shaft from the bearing housing using hammer blows as this will damage the bearings andprevent their re-use.

On SF300 & SF400 pumps:Remove the drive end bearing cap (64) from the rear bearing housing (b62).

Using a suitable press, apply pressure to the tapered end of the shaft and push the shaft out from therear bearing housing, complete with the drive end bearings.

Drive end bearings may be cleaned and examined whilst on the shaft.e) To remove the bearings from the shaft:

Unlock the tabwasher (75F) and using a suitable ‘C’ spanner, remove the locknut (75).

Using a collar of suitable diameter, press the drive end bearings (67) off the shaft by applying force to theinner race only.

To remove the inner race of the non-drive end bearing (66), heat may be needed before applying force



using a suitable drift and hammer blows.

The outer race and roller cage of the non drive end bearing (66) may be removed after withdrawal ofscrews (63A) and removal of the non drive end bearing cap (63).

Bearing Specifications:

For SF200 & SF2500 Pumps:

Drive End Bearings SKF 7319

Pump End Bearing SKF nu217

For SF300 & SF400 Pumps:

Drive End Bearings Timken Assy904A3

Pump End Bearing SKF nu2222

Drive end bearings are fitted in matched pairs and must be replaced in pairs. Inspect the bearings for wear,fractures, cracks, corrosion or other damage, which may necessitate bearing replacement.

If the bearings are to be re-used, ensure they are thoroughly flushed with white spirit or similar cleaningfluid, dried and protected to prevent any abrasive media from coming into contact with the races and balls.Bearings should be lightly oiled and wrapped for storage.

Check the shaft (71) for straightness by mounting between centers and measuring the runout with a dialgauge at the coupling, bearings, center, seal and impeller positions. The run-out should not exceed 0.05mm in any of the positions measured.

All parts should be cleaned, inspected for damage and replaced. If pump efficiency has reduced, thesuction cover (2) wear plate and impeller (21) may be replaced, contact the ACME Dynamics, Inc. Partsand Service Departments for supply of new parts.

6.8 Re-assembly of the Pump

The pump unit may be re-assembled in the reverse manner to disassembling. To ensure correct andtrouble free operation, care should be taken on re-assembly and the following precautions taken:

a) Precautions

Cleanliness is important ensure that all pump components together with the working areas, are completelyfree of foreign matter, dirt and dust.All ‘O’ ring grooves, ‘V’ ring housings and mating surfaces for shims are to be properly cleaned and new ‘O’rings, ‘V’ rings and shims fitted. ‘O’ rings and ‘V’ rings should be lubricated lightly to ease assembly.Check the locking washer (75F) for wear or damage and replace if necessary.

It is recommended that only spare parts manufactured by and obtained from ACME Dynamics, Inc. areused during maintenance re-assembly of any DYNAPRIME SF range pump. The company cannot be heldresponsible for any failure, which may cause danger to property or health, arising from the use of spareparts manufactured and supplied by others, these will also invalidate the pump warranty.

When ordering spare parts it is essential to quote the pump serial number from the identification plate andthe required part number(s) as shown in the parts list in Section 8.

If new proprietary parts such as bearings ‘O’ rings and ‘V’ ring seals are to be fitted, ensure they are thecorrect size, grade and quality.

b) Bearing Assembly



When fitting new bearings they should be pre-heated on an induction heater bar to 800C for a short time.This will enable the bearing to be easily slid on the shaft seating and when cool will give a positive shrink fit.Always ensure bearings abut correctly against shaft shoulder and that angular contact ball bearings havebeen fitted ‘back to back’ as shown on the section drawing.

After the shaft, bearings and bearing covers (63 & 64) etc. have been reassembled in the bearing housings(62 and B62) with all the ‘V’ ring seals (B62T and 63S) and circlips (A/B74) etc., the end float of the rotorshould be within the following dimensions.

Rotor End Float 0.13 to 0.18 mm

If the lock nut is used to “push-home” the bearing then a special hook spanner must be used to turn it. Donot use a drift and hammer blows. The tab washer should NOT be in place during this procedure sincethere is a risk of shearing off the inner tab. The nut should be removed when the bearing is fully pushedhome then the tab washer and nut placed in position and tightened to 350-400 Nm and the tab washerlocked.

c) Initial Lubrication

Grease lubricated bearings:Bearings should be cleaned, dried and packed with new grease, on both sides to about two thirds of theircircumference and then rotated several times to spread the grease before installation in the bearinghousing. The drive end bearing cap should also be loaded with new grease to about two thirds full beforerefitting.

Oil lubricated bearings:

° ° °

d) Refitting the Backplate and Seal Assembly

Locate the seal spring carrier (41) complete with seal assembly with packing in position on the shaft (71).

Place the backplate assembly in position over the shaft and align all the fixing holes.

Secure the backplate in position with three fasteners, but do not tighten fully at this stage.

Install the impeller on its’ taper and ensure that it is fully seated in position. Measure the gap between theback of the impeller and the backplate.

Disassemble the impeller and backplate and insert the required thickness of shims (36U) to give aclearance between the backplate and impeller of between 0.5mm and 1.0mm (0.020” and 0.040”)



Refit the backplate and tighten the retaining screws uniformly. Refit the impeller and check the clearancewith feeler gauges and adjust the shims again if necessary.

Locate the seal spring carrier assembly on the backplate and secure in position with screws (41B/C)

e) Refitting the Impeller

Fit the key (116) to the shaft (71) and slide the impeller (21) on to the shaft. Ensure that it sits fully andsquarely on the taper on the shaft.Fit the impeller retaining capscrew (21A) and washers (21F & 12G), lock the shaft using the drive endkeyway and tighten the impeller retaining capscrew to 350 Nm.

Rotate the impeller and visually confirm that it runs true, if not remove, clean all parts and reassemble.

Fit the plastic cap (21X) in the impeller recess.

f) Refitting the Rotating Assembly

Replace any casing plugs removed during dismantling.

Lubricate and install the ‘O’ ring (36R) in its’ groove on the backplate (36).

If the suction cover (2) has been removed, ensure that it has been fitted the correct way round for clockwiseimpeller rotation (looking on the pump drive end).

Fit 3mm (6 x 0.5mm) shims (A62U) between the volute casing (1) and the bearing housing (62) and fit therotating assembly in the volute casing, secure with screws (1B) lightly tightened.

Taking care to prevent pump rotation, reach in through the suction port and using feeler gauges, measurethe average clearance between the impeller vanes and the suction cover (2).

Calculate the amount of shims to be removed to give a final average clearance of between 0.38mm and0.50mm (0.015” and 0.020”).

Disassemble and reduce the shim pack to give this clearance, reassemble and fully tighten all screwsuniformly.

Measure the clearance again and if necessary repeat the procedure to ensure the required clearance isachieved.

6.9 Hydrostatic Testing

After maintenance or repair involving strip down of the pump, a hydrostatic test to a maximum of 1.3 timesthe nominal pump working pressure is recommended.



7.1 Priming System Faults

Check pump drain valve is closed.Check vacuum pump is operating, if not rectify or replace the pump.Disconnect vacuum hose and take avacuum reading, refit the hose andfit vacuum gauge to the pump inletand take another vacuum reading.

Pump Fails to Prime

Are vacuum gaugereadings the same?

Stop pump and listen for air leaks. Stop any air leaks found.Remove vacuum hose and check forcollapsed internal hose lining. Replace hose if faulty.Check air filter for blockage. Clean housing or replace filter.Check non return valve is seating. Remove any debris found.Check the mechanical seals. Replace if leaking or faulty.

NO

Check the suction hose for internalcollapse. Replace any faulty hose.Check suction intake for blockage. Clear blockage, using back flush whereprovided.Check that the static suction lift doesnot exceed the pump capabilities, if so - Reposition pump closer to the liquid level.

YES

Check that the static suction lift does not exceed the pump capabilities, if so- Reposition pump closer to the liquid level.Check that the delivery head is not higher than the pump capability, if so - Raise the pump if possible or install a pump with higher head rating.Check suction intake or pipes for blockage, also check impeller for blockage. Clear blockage, using back flush where provided.Check non return valve is n ot blocked. Remove any debris found.Check that pump speed is correct. Adjust driver to give correct speed.Check the impeller for wear or damage, Replace impeller if worn.Check liquid viscosity and density, if greater than water, the pumped headwill be reduced.

Pump runs with low flow

Check that the impeller is not blocked. Clear any impeller blockage.Check non return valve is not blocked. Remove any debris found.Check for a suction air leak. Cure air leaks as required.

Pump surges with intermittent flow

If further faults are evident, refer to the following pump faultfinding tables

7.2 Pump Fault Finding



POTENTIAL FAULT OR DEFECT:Insufficient liquid delivered.

Liquid delivered at low pressure (Fails to achieve the required delivery head)Loss of liquid after starting.

Excessive vibration.Pump bearings run hotter than normal.

PROBABLE CAUSESSpeed too low.Speed too high.Blockage or Internal collapse of suction or delivery hoseAir leaking into pump casing or priming system.Lubricating oil dirty or contaminated.Foundation not rigid or pump mountings loose or worn.Misalignment of pump and driver.Impeller worn or increased clearancesBearing worn.Rotor out of balance due to blockage or damage.Shaft bent.

CAUSE REMEDIAL ACTIONSpeed too low. Check that the driver is functioning correctly and running at the

required speed.Speed too high. Check that the driver is functioning correctly and running at the

required speed.Blockage or Internalcollapse of suction ordelivery hose

Check hoses. Replace damaged hoses or clear blockage.

Air leaking into pumpcasing or primingsystem.

Check all hose joints, plugs and pipes.Check that the vacuum pressure seal is not leaking.

Bearing lubricating oildirty or contaminated.

Drain the oil, check type of contaminant, if no metal pieces arepresent, flush the bearing housing and refill with new oil. Run thepump and monitor bearing noise and temperature.If metal pieces are present check for shaft movement and if excessivedismantle the pump and replace the pump bearings.

Foundation not rigid orpump mountings looseor worn.

Ensure that the pump driver mounting bolts are tight and the pumpfoundations are secure.

Misalignment of pumpand driver.

Check and realign the pump and driver as specified.

Bearings worn. Remove the bearings, clean and inspect for damage and wear,replace as necessary.

Rotor out of balance. Check the impeller for damage. Replace as necessary.Shaft bent. Check shaft run-out and replace if needed.



Section 8 Supplementary Documents

8.1 Pump Dimensions

For details of pump installation dimensions, please refer to the following General Arrangement drawings:

Pump Size SF200 SF250 SF300 SF400General Arrangement DN 15937 DN 15937 DN 12194 DN 10657Approx. WeightNote - Pump Only 1764 lbs. 1764 lbs. 2205 lbs. 2628 lbs.

8.2 SF Pump Technical Data

8.2.1 Casing Pressure

The maximum casing pressure is 145 PSI.

8.2.2 Direction of Rotation

The direction of rotation is clockwise when viewed on the drive end

8.2.3 Maximum Speed

The maximum operating speed of SF pumps is 2000rpm, except SF400, which is 1800rpm.8.4 Spare Parts8.4.1 SF200& SF250


Pumps 41S

41R

41

47

47A

47R

50

41B, 41F

41C, 41F

41A

41X

51

156

ENLARGED VIEW OFVACUUM PRESSURE SEAL

22

21A1F 2U 116 21 305R

305A305F 305

36U 62U21B

10563A63F 62 105

64A64F

64

71

118

64R

7575F

21A21F21G21X

2R 1 1L 21Y21C

21Z 1B1G

3636A36F36R

63R63S

6366

67

XF200-250XS1

NOTE * The angular contact ball bearing pair are fitted back to back as shown.



Parts List for SF200 & SF250 Pumps

ITEM DESCRIPTION PART No. QTY1 Casing 03796.123 1

1A Screw: M16 x35 21835-310-977-5 8

1B Screw: M16 x 35 21835-310-977-5 8

1F Washer: spring M16 21174-308-927-0 8

1G Washer: spring M16 21174-308-927-0 8

1L Plug: 1"BSP 33335-601-221-8 7

2 Cover: suction 16117.167 1

2R O ring: 379.3mm ID 25157-379-716-7 1

2U Shim 04728 8

21 Impeller Stainless 13119.949 1

21 Impeller Cast Iron 13119.167 1

21A Screw: M16 x 80 21835-320-977-0 1

21B Screw: M8 x 20 07193.342 4

21C Screw: M8 x 40 21835-142-347-8 4

21F Washer: copper M16 07385.981 1

21G Washer: brass M16 08036.424 1

21X Cap: plastic 22612-409-735-8 1

21Y Balance weight 05944.123 2

22 Wear ring 04488.347 1

36 Backplate Stainless 13118.949 1

36 Backplate Cast Iron 13118.167 1

36A Screw: M10 x 70 21863-188-959-3 3

36F Washer: spring M10 21174-306-927-6 3

36R O ring: 379.3mm ID 25157-379-716-7 1

36U Shim 04729 3

41 Spring carrier 05294.123 1

41A Dowel: 8 Dia. x 20 04699.214 1

41B Screw: M10 x 60 06738.977 1

41C Screw: M10 x 25 21835-176-977-1 3

41F Washer: spring M10 21174-306-927-6 4

41R Seal: 94.3mm ID 04634.716 1

41S O ring: 160mm ID 05619.716 1

ITEM DESCRIPTION PART No. QTY41X Spring 04594 1

47 Shaft sleeve 04824.375 1

47A Screw: M6 x 8 21828-096-347-8 3

47R O ring: 59.5mm ID 25154-059-716-1 1

50 Packing holder 04310.459 1

51 Packing: 12.5 sq. 04492 340mm

62 Bearing housing 03874.123 1

62U Shim 04728 24

63 Bearing cap 02362.123 1

63A Screw: M12 x 25 21835-216-977-4 4

63F Washer: spring M12 21174-307-927-3 4

63R Oil seal: V ring 25168-323-000-6 1

63S Oil seal: 85 x 110 25167-374-000-9 1

64 Bearing cap 02989.123 1

64A Screw: M12 x 40 21835-222-977-1 4

64F Washer: spring M12 21174-307-927-3 4

64R Oil seal: V ring 25168-316-000-2 1

66 Brg: cyl roller 85 dia 02368 1

67* Brg: a/con ball 95 dia 03299 1

71 Shaft 02988.314 1

75 Locknut: M95 x 2 23381-034-221-4 1

75F Washer: locking 23381-320-221-0 1

105 Grease nipple:1/8”BSP x 90E

SY9219010 2

116 Key: 14 x 9 x 45 23616-519-265-5 1

118 Key: 14 x 9 x 100 23616-534-265-0 1

156 Plate: anti rotation 04406.221 1

305 Inspection cover 16093.123 1

305A Screw: M12 x 25 21863-216-959-7 2

305F Washer: spring M12 21174-307-927-3 2

305R Gasket 16100.781 1



8.4.2 SF300 & SF400 Pumps

2

116

105

B7464R

1

1A1F

1L

2

2R

2U 21

21A21F21G21X

3636A36F36R

21B

41S

41R

41

4747A

47R

50

41C, 41F

41B, 41F

41A

41X

51

64L

A62

A62U

64

64A64F64S

63

63A63F

6766

71

A74B62T

7575F

B62A62AA62F

103B62S

B62RB62L

B62M

118

156

36U

63S63R

305305A305F305R

ENLARGED VIEW OFVACUUM PRESSURE SEAL VIEW ON DRIVE SHAFT END

1B1G

21Z21Y21C

22

115B62S

XF300-400XS1



Parts List for SF300 and SF400 Pumps

ITEM DESCRIPTION PART No. QTY1 Volute Casing SF300 12082.123 1

1 Volute Casing SF400 10621.123 1

1A Screw: M16 x 45 21835-313-977-6 16

1B Screw: M16 x 50 21863-314-959-6 16

1F Washer: spring M16 21174-308-927-0 16

1G Washer: spring M16 21174-308-927-0 16

1L Plug: 1"BSP 33335-601-221-8 7

2 Cover: suction 13114.167 1

2R O ring: 459.3mm ID 05480.716 1

2U Shim 05461 8

21 Impeller Stainless SF300 13097.949 1

21 Impeller Cast Iron SF300 13097.167 1

21 Impeller Cast Iron SF400 10625.167 1

21A Screw: M20 x 120 21835-408-977-9 1

21B Screw: M10 x 30 07194.342 8

21C Screw: M10 x 50 21835-184-342-2 4

21F Washer: copper M20 08023.981 1

21G Washer: brass M20 08035.424 1

21X Cap: plastic 22612-411-735-7 1

21Y Balance weight 05943.123 2

22 Wear ring 05499.347 1

36 Backplate Stainless SF300 13097.949 1

36 Backplate Cast Iron SF300 13097.167 1

36 Backplate Cast Iron SF400 10626.167 1

36A Screw: M10 x 45 21835-183-977-5 3

36F Washer: spring M10 21174-306-927-6 3

36R O ring: 459.3mm ID 05480.716 1

36U Shim 05479 3

41 Spring carrier 05443.123 1

41A Dowel: 8 dia x 20 04699.214 1

41B Screw: M10 x 60 06738.977 1

41C Screw: M10 x 25 21835-176-977-1 3

41F Washer: spring M10 21174-306-927-6 4

41R O ring: 124.3mm ID 06691.716 1

41S O ring: 190mm ID 06683.716 1

41X Spring 05465 1

47 Shaft sleeve 05463.375 1

47A Screw: M6 x 8 21828-096-347-8 3

47R O ring: 89.5mm ID 25154-089-716-6 1

50 Packing holder 05464.459 1

51 Packing: 12.5 sq 04492 450mm

A62 Brg housing: main 04722.123 1

A62A Screw: M12 x 30 21835-218-977-8 6

ITEM DESCRIPTION PART No. QTYA62F Washer: spring M12 21174-307-927-3 6

A62U Shim 05461 24

B62 Brg housing: rear 04949.123 1

B62L Plug: 1/2"BSP mag 08014 1

B62M Plug: 1/2"BSP 08015 2

B62R Seal 25127-118-000-3 1

B62S Seal 25127-122-000-6 3

B62T Oil seal:125 x 160 25167-419-000-7 1

63 Bearing cap 05454.123 1

63A Screw: M12 x 35 21863-220-959-0 4

63F Washer: spring M12 21174-307-927-3 4

63R Oil seal: V ring 25168-327-000-4 1

63S Oil seal:110 x 140 25167-406-000-1 1

64 Bearing cap 05456.123 1

64A Screw: M12 x 30 21835-218-977-8 4

64F Washer: spring M12 21174-307-927-3 4

64L Plug: 1/8"BSP 25225-801-224-7 1

64R Oil seal: 65 x 85 25167-324-000-4 1

64S O ring: 164.3mm ID 25157-164-716-1 1

66 Bearing: cyl roller 05451 1

67 Brg: 2 row tpr roller 05450 1

71 Shaft 05445.314 1

A74 Circlip: internal 160 05749 1

B74 Circlip: internal 85 05457 1

75 Locknut: M75 x 2 23381-030-221-6 1

75F Washer: locking 23381-316-221-7 1

103 Cap: filler/breather3/4"BSP

08013 1

105 Grease nipple:1/8"BSP x 90Ε

SY9219010 1

115 Window nut 35341-505-221-0 2

116 Key: 18 x 11 x 63 23616-675-265-0 1

118 Key: 18 x 11 120 23613-687-265-2 1

156 Plate: anti rotation 04406.221 1

305 Inspection cover 16.92.123 1

305A Screw: M12 x 25 21863-216-959-7 2

305F Washer: spring M!2 21174-307-927-3 2

305R Gasket 16100.781 1

The following part is not illustrated but is fitted to the sideof the main bearing housing (A62)

Plug: 1 1/2"BSP 25221-388-915-5 1


Section 9 Additional Information

9.1 Standard Metric Nut and Bolt Torque Recommendations

This information is for reference only. The user must check that the torque figures listed here are applicableto the fasteners used. Nuts and bolts should be neither under nor over tightened.

Grade of Approximate Torque (Nm) for Bolt Diameters:

Bolt M5 M6 M8 M10 M12 M16 M20 M24 M30 M36

4.6 2.7 4.5 11 22 38 95 185 320 633 1110

8.8 6.9 11.7 28 56 98 244 476 822 1634 2855

10.9 9.4 15.9 38 77 134 332 646 1120 2223 3885

12.9 11.2 19.1 46.4 92 160 397 775 1342 2666 4660

Note: These torque figures are approximate, and for unplated fasteners only. No allowance has beenmade for special finishes or lubricants, washers or mating surfaces.

Bolt and Nut Grade Combinations

Grade of BOLT 4.6 8.8 10.9 12.9 Note: It is permissible to fit higher

Grade of NUT 4 8 12 12 grade nuts than recommended.

Grade Identification

BOLTS & NUTS - Grade 4.6BS4190 (ISO272, 885, 888 & 4759/1). Grade marking is optional. Normally there will be nomark other than the 'M' thus:

BOLTS - Grade 8.8 BS 3692 (ISO272, 4759/1). Grademarking is mandatory, may alsohave trademarks.

NUTS - Grade 8Indented marks as a clock face, dot at12.00, bar at 8.00, indicates grade 8nut.

High Strength Friction Grip Bolts & NutsBOLT NUT BOLT

Grade10.9

NUTGrade12



Maintenance Record

Date Summary of maintenance & repairs done - replacement parts fitted etc:

Installed & Commissioned

ACME Dynamics, Inc. operates a comprehensive Spares and Service support network throughout the world, and can be



found by calling our main office.

MAIN OFFICE (All Inquires) Telephone: 813-752-3137ACME Dynamics, Inc. Toll Free: 800-622-93553608 Sydney Road Fax line: 813-752-4580Plant CityFlorida33564-1780

JACKSONVILLE OFFICE (North Florida Only) Telephone: 904-262-2405ACME Dynamics, Inc. Fax: 904-262-0210JacksonvilleFlorida32256 Your Local Distributor is:

Visit us on the World Wide Web at:www.acmedynamics.com

E-mail us at:[email protected]@[email protected]

Copies of this manual are available from the ACME Dynamics, Inc. Spares & Service Department by quotingthe manual reference number. W77-005E / 3 USA

Enter details from your pump nameplates here

PUMP TYPE SERIAL No.

CAPACITYL/s

SPEEDrpm

HEADm

