TSURUMI PUMP LH4110W -51 61 Submersible High-Head Extra High-Head Dewatering Pumps Instruction Manual

TSURUMI PUMP LH4110W -51 61 Submersible High-Head Extra High-Head

Dewatering Pumps

BE SURE TO READ FOR YOUR SAFETY

Be sure to thoroughly read and understand the SAFETY PRECAUTIONS given in this section before using the equipment in order to operate the equipment correctly. The precautionary measures described in this section are intended to prevent danger or damage to you or to others. The contents of this manual that could possibly be performed improperly are classified into two categories: WARNING, and CAUTION. The categories indicate the extent of possible damage or the urgency of the precaution. Note however, that what is included under CAUTION may at times lead to a more serious problem. In either case, the categories pertain to safety-related items, and as such, must be observed carefully.

• Operating the equipment improperly by failing to observe this precaution may possibly lead to death or injury to humans.
• Operating the equipment improperly by failing to observe this precaution may possibly cause injury to humans and other physical damage.
• Gives information that does not fall in the WARNING or CAUTION categories.

PRECAUTIONS TO THE PRODUCT SPECIFICATIONS

CAUTION: Do not operate the product under any conditions other than those for which it is specified. Failure to observe the precaution can lead to electrical leakage, electrical shock, fire, or other problems.

PRECAUTIONS DURING TRANSPORT AND INSTALLATION

PRECAUTIONS DURING TEST OPERATION AND OPERATION

PRECAUTIONS DURING MAINTENANCE AND INSPECTION

NAME OF PARTS

Model LH6110 / 8110

Model LH4110W

PRIOR TO OPERATION

When the pump is delivered, first perform the following checks.

Inspection
While unpacking, inspect the product for damage during shipment, and make sure all bolts and nuts are tightened properly.

Specification Check
Check the model number to make sure it is the product that was ordered. Be certain it is the correct voltage and frequency.

Example of nameplate

1. Submersible pump
2. Built in motor protector
3. Serial number
4. Model
5. Frequency
6. Max. total head
7. Min. total head
8. Max. flow rate
9. Discharge bore
10. Phase
11. Rated voltage
12. Rated current
13. Rated output power
14. Insulation class
15. Max. liquid temperature
16. Weight without cable
17. Speed of rotation
18. IP degree of protection
19. Max. immersion depth
20. Direction of rotation

Accessory Check
Verify that all accesessory items, are include in the package.

• Operation Manual ……………………….. 1

Product Specifications

Do not operate this product under any conditions other than those for which it is specified. Failure to observe this precaution can lead to electrical shock, electrical leakage, fire, water leakage or other problems.

Major Standard Specifications

Fluid| Property| Rain Water, Ground Water, Sand laden Water,

0 ~ 40°C

---|---|---

Pump

| Impeller| Close-Type
Shaft Seal| Double Mechanical Seal
Bearing| Ball Bearing

Motor

| Specifications| Dry type Submersible Induction Motor, 2-Pole
Insulation| Class F
Protection System (Built-in)| Miniature Protector
Leak Sensor (Built-in)| Electrode
Lubricant| Turbine Oil VG32
Connection to Piping| JIS 10K Flange, JIS 20K Flange

Standard specifications (50/60Hz)

Model| Bore mm| Phase| Starting Method| Output kW| Max.HEAD

m (feet)

| Max3 .CAPACITY

m /min(GPM)

| Weight kg
---|---|---|---|---|---|---|---
LH6110| 150| 3| Star Delta| 110| 177/184 (581/604)| 3.0/2.7 (793/713)| 1210
LH8110| 200| 3| Star Delta| 110| 107/114 (351/374)| 6.5 (1717)| 1210
LH4110W| 100| 3| Star Delta| 110| 216/230 (709/755)| 2.0 (528)| 1270

INSTALLATION

CAUTION

• Do not use this pump in liquids other than water, such as oil, salt water, or organic solvents.
• Use with a power supply voltage tolerance within ± 5% of the rated voltage.
• Do not use in water temperatures outside the range of 0 ~ 40°C, which can lead to failure, electrical leakage or shock.
• Do not use in the vicinity of explosive or flammable materials.
• Use only in fully assembled state.

Preparing for installation

Before installing the pump at a work site, you will need to have the following tools and instruments ready:

• Insulation resistance tester
• AC voltmeter
• AC ammeter (clamp-on type)
• Bolt and nut tighteners
• Power supply connection tools (screwdriver or box wrench)

Precautions in installation

• When installing the pump, pay close attention to its center of gravity and weight. If it is not lowered into place correctly, it may fall and be damaged or cause injury.
• Do not under any circumstances install or move the pump by suspending it from the cabtyre cable. The cable may be damaged, causing electrical leakage, shock, or fire.

1. Avoid dropping the pump or other strong impact. Lift the pump by attaching a rope or chain to the eye bolts.
2. Install the pump in a location with sufficient water level, where water collects readily.
3. Run the piping as straight as possible, and avoid having the piping load applied directly to the pump.
4. The piping should be able to withstand the recoil when the pump is started up.
5. On the flange specification and water depth pressure resistance, see the chart on maximum allowable water pressure.
6. If the actual pump head (vertical life) is high, install a check valve along the piping path.
7. Install the piping in such a way that it can be dismantled readily from outside.
8. Arrange the piping so that air will not collect in it.
9. When performing pipe construction, make sure welding sparks or paint do not contact the pump.
10. Use the pump in the upright position and on a flat surface. To prevent the pump from becoming submerged in mud, mount it on a block or other firm base if nesessary.

ELECTRICAL WIRING

Performing electrical wiring

• Electrical wiring should be performed by a qualified person in accordance with all applicable local regulations. Failure to observe this precaution not only risks breaking the law but is extremely dangerous.
• Incorrect wiring can lead to electrical leakage, electrical shock or fire.
• Always make sure the pump is equipped with the specified overload protectors and fuses or breakers, so as to prevent electrical shock from an electrical leak or pump malfunction.

Grounding

WARNING

• Do not use the pump without first grounding it properly. Failure to ground it can lead to electrical shock from an electrical leak or pump malfunction.
• Do not attach the grounding wire to a gas pipe, water pipe, lightening arrestor or telephone grounding wire. Improper grounding can result in electrical shock.
• If it is necessary to extend the cabtyre cable, use a core size equal to or larger than the original. This is necessary not only for avoiding a performance drop, but to prevent cable overheating which can result in fire, electrical leakage or electrical shock.
• If a cable with cut insulation or other damage is submerged in the water, there is a danger of water seeping into the motor causing a short. This may result in damage to the pump, electrical leakage, electrical shock, or fire.
• Be careful not to let the cabtyre cable be cut or become twisted. This may result in damage to the pump, electrical leakage, electrical shock, or fire.
• If it is necessary to submerse the connection leads of the cabtyre cable in water, first seal the leads completely in a molded protective sleeve, to prevent electrical leakage, electrical shock, or fire.

Connecting the cabtyre cable

• Before connecting leads to the terminals, make certain the power supply is turned off (circuit breaker, etc.), to avoid electrical shock, shorting, or unexpected starting of the pump, leading to injury.
• Do not use the pump if the cabtyre cable is worn or damaged, which can result in electric shock, shorting, or fire.

Connect the leads of cabtyre cable to the control panel terminals as shown in the diagram, being careful not to let the leads become twisted together.

Electrical circuit diagrams

OPERATION

Before starting

1. Make sure once again that the product is of the correct voltage and frequency rating.
2. Confirm the wiring, supply voltage, circuit breaker capacity, and motor insulation resistance. Reference insulation resistance = 20 MΩ or greater.
3. The setting on the circuit breaker or other overload protector should be made in accord with the rated currency of the pump.
4. When powering the pump with a generator, do not share the generator with other equipment.

Operation

• The pump may become very hot during operation. Be careful not to contact the pump accidentally to avoid being burned.
• To avoid serious injury, do not insert a finger or any other object in the pump inlet holes.
• When the pump is not used for an extended period, be sure to turn off the power (circuit breaker, etc.). Deterioration of the insulation may lead to electrical leakage, electrical shock, or fire.
• In case of a power outage, turn off the power to the pump to avoid having it start unexpectedly when the power is restored, presenting serious danger to people in the vicinity.

Operation water level

• Do not operate the pump below the C.W.L. (Continuous Running Water Level). Failure to observe this condition may result in damage to the pump, electrical leakage or electrical shock.
• The table shows the C.W.L. for different output classes. Be careful not to allow the water level to drop below the applicable limit.

Motor protection system

• During inspections or repairs, always be sure to turn off the power. Sudden unexpected starting of the pump can cause electrical shock, shorting, or serious injury.
• Always determine the cause of the problem and resolve it before resuming operation. Simply repeating cycles of stopping and restarting will end up damaging the pump.
• Do not continue operation at very low water level, or while the strainer stand is clogged with debris. Not only will performance sufffer, but such conditions may cause noise, heavy vibration, and malfunctioning.

Miniature Protector
This protector is embedded inside the motor coil. If the coil should overheat for any reason, bending of the bimetal of the miniature protector triggers a signal, which in turn causes an extermal circuit in the starting console or control panel to shut off the motor current. When the temperature returns to normal, the protector is automatically reset, but restarting is controlled from the starting console or control panel.

Water Leak Sensor
Models with output of 110kW have a water leak sensor electrode in the oil compartment. If water leaks into the oil chamber due to wear of the mechanical seal, the water leak probe sends a signal to the dedicated circuit (prepared by the user) in the external starting panel or control panel and triggers a display, warning, and stops the pump to prevent the water from leaking into the motor.

MAINTENANCE AND INSPECTION

Regular maintenance and inspections are a necessity for continued efficient functioning of the pump. If any abnormal conditions are noticed, refer to the section on Troubleshooting(p.18) and take corrective measures immediately. It is recommended that a spare pump be kept ready in case of any problems.

Prior to inspection

1. Washing the pump
   Remove accumulated matter from the surface of the pump and wash it with clean water. Take special care to remove any debris from the impeller.

2. Inspecting the pump exterior
   Look for any peeling or chipped paint, and make sure the nuts and bolts are fastened tightly. Any cracks in the surface should be repaired by cleaning that area, drying it and then applying a touchup coating.

Regular Inspection

Measure power voltage                 Power supply voltage tolerance (within ±5% of the rated voltage)

Monthly

| Measure insulation resistance  Reference insulation resistance = 1MΩ or greater

Note: If the insulation resistance has become notably lower than the precious inspection, an inspection of the motor will be necessary.

Pump inspection  A noticeable drop in performance may indicate wear in the impeller,etc., or else clogging of the strainer stand, etc. Remove the clogged debris, and replace any worn parts.

Half-yearly

| Inspection of lifting chain or rope         Replace if damage, corrosion, or wear has occurred to the chain

or the rope. Remove if foreign object is attaching to it.

Oil inspection           Check the oil every 6 months or after 3,000 hours of use, whichever comes first.

Note: Refer to details of oil inspection and oil change (p.12)

Yearly

| Change oil               Change the oil every 12 months or after 6,000 hours of use, whichever comes first.

Note: Refer to details of oil inspection and oil change (p.12) Change mechanical seal

Note: Specialized know-how is required for inspecting and replacing the mechanical seal.

Consult with your nearest dealer or Tsurumi representative.

Every

2 to 5 years

| Overhaul                  This should be carried out even if there are no problems with the pump.

The frequency depends on how continuously the pump is in use.

Note: Consult with your nearest dealer or Tsurumi representative regarding overhauls.

Storage
When the pump is out of use for an extended period, wash it and dry it thoroughly, then store it indoors.

Oil inspection and Oil change
When the pump is tilted for inspecting or changing the oil, pay careful attention to the center of gravity and weight of the pump. When lowering the pump, fasten the chain or rope to the eyebolts providerd for this purpose. Failing to lower the pump completely may result in damage or injury if the pump is dropped.

Refilling bearing grease
Models with output 110kW require that bearing grease be refilled periodically. With the pump standing upright, supply grease at the grease nipple on the bearing housing side of lower bearing (M25 screw), and at the grease nipple at the upper part of the motor for models with an upper bearing (PT1/4). The table shows the different bearing types, specified amount of grease, initial supply of grease, and refill frequency.

Note: Greasing generally is good for around 3,000 hours of use, but this can vary depending on the use conditions.

“RAREMAX SUPER”(Kyodo Yushi Co.Ltd), or equivalent *1

| Upper: 370g (13.06 oz.)| Upper: 30g (1.06 oz.)
Lower: 320g (11.28 oz.)| Lower: 60g (2.12 oz.)
Item| *1
---|---
Soap Type| di-Urea
Base Oil Type| Mineral Oil
Viscosity(40℃ / 104℉)| 96mm2/s(cSt)
Viscosity(100℃ / 212℉)| 10.5mm2/s(cSt)
Temperature Range| -40 to 150℃ / -40 to 302℉
Dropping Point| 253℃ / 487℉
Penetration NLGI grade| 2 to 3
Penetration (60 strokes 25℃ / 77℉)| 260
Penetration (100,000 strokes 25℃ / 77℉)| 365 max.

Replacement Parts
The table lists the parts that need to be replaced periodically. Replace these using the recommended frequency as a guideline.

first.
Bearing Grease| At overhaul
Packing, O-Ring| Each time pump is disassembled or inspected
Oil Seal| When the lip is worn, and each time pump is disassembled or inspected
Labyrinth Ring| When it becomes worn.
Shaft Sleeve| When it becomes worn.
Cathodic Protection Plate| When it becomes corroded.

DISASSEMBLY AND REASSEMBLY

WARNING

• Before disassembling the pump, first detach the cabtyre cable from the receptacle or terminals, after making certain the power supply (circuit breaker, etc.) is turned off. To avoid electrical shock, do not work with wet hands. Never check the operation of any parts (impeller rotation, etc.) by turning on the power while the unit is partially assembled. Failure to observe these precautions may result in serious accident.
• Do not disassemble or repair any parts other than those designated here. If repairs are necessary in any other than the designated parts, consult with your nearest dealer or Tsurumi representative. Improper repairs can result in electrical leakage, electrical shock, fire, or water leaks.
• After reassembly, always perform a test operation before resuming use of the pump. Improper assembly will cause the pump to malfunction, resulting in electrical shock or water leaks. The procedure for disassembly and reassembly is shown here to the extent necessary for impeller replacement. A specialized environment and facilites are necessary for work on the mechanical seal and the motor parts. Contact your nearest dealer or Tsurumi representative in the event such repairs are necessary.

LH6110/8110 Disassembly

1. Remove the strainer stand.
   Remove the hex. nuts at the bottom of pump, then remove the strainer stand from the pump.

2. Remove the lower pump casing.
   Remove the hex. nuts and spring washers, then remove the lower pump casing from the pump.

3. Remove the impeller.
   With a box spanner or other tool, remove the hex. double nuts and plain washers, then remove the impeller, impeller adjusting washer and lower shaft sleeve from the shaft.

4. Remove the upper pump casing.
   Remove the hex. nuts and spring washers to remove the upper pump casing.

5. The upper shaft sleeve can be removed easily once the upper pump casing is removed.

6. When absolutely necessary, the mechanical seal can be removed by first removing the oil casing.

Exploded View [ LH6110 / 8110 ]

Reassembly
Reassembly can be performed by reversing the steps for disassembly.

Note: After reassembling the pump, be sure to fll it with the required amount of oil. Replace the packing and o-ring with new parts. Replace any other worn or damaged parts as well.

After attaching the impeller, and again after assembly is completed, check to make sure the impeller rotates smoothly and that is does not rub against the suction mouth.

LH4110W Disassembly

1. Remove the strainer stand.
   Remove the hex. bolts at the bottom of pump, then remove the strainer stand from the pump.

2. Remove the lower pump casing.
   Remove the hex. nuts and spring washers, then remove the 1st lower pump casing from the pump.

3. Remove the impeller.
   Remove the hex. double nuts and plain washers, then remove impeller, impeller adjusting washer, and the lower shaft sleeve from the shaft.

4. Remove the middle pump casing.
   Remove the hex. nuts and spring washers, then remove the middle pump casing from the pump.

5. Remove the impeller.
   Now remove the impeller, the impeller adjusting washer, and the middle shaft sleeve from the shaft.

6. Remove the upper pump casing.
   Remove the hex. nuts and spring washers, then remove the upper pump casing from the pump and lift the upper shaft sleeve from the shaft.

7. When absolutely necessary, the mechanical seal can be removed by first removing the oil casing.

Exploded View [ LH4110W ]

Reassembly

Note

• Assemble the three pump casings (uppper, middle, and lower casings) in such a manner that each rib provided on the periphery of these three casings matches each other in a straight line. If they are not properly aligned, pumping will not be possible.
• After reassembling the pump, be sure to fll it with the required amount of oil. Replace the packing and o-ring with new parts. Replace any other worn or damaged parts as well.
• See the manual that comes with the replacement mechanical seal for further derails.
• The mouth rings are press-ft into the upper pump casing and the lower pump casing, and the labyrinth rings are press-ft into the upper pump casing and the middle pump casing; so it is necessary to replace the related pump casing(s) together when worn.
• Apply liquid gasket (Three Bond TB1207B or equivalent) on the middle pump casing and the lower pump casing when assembling the pump. The place to be applied is the top part of each casing (It is flled with black in the drawing below).

TROUBLESHOOTING

Before ordering repairs, carefully read through this operation manual, then repeat the inspection. If the probrem remains, contact your nearest dealer or Tsurumi representative.

Pump Will not start

| 1)   Power is off.

2)  Cabtyre cable is cut or not connected properly.

3)   Impeller is clogged.

| 1)   Restore power.

2)   Repair/replace the cable or fix the connection.

3)   Inspect the pump and remove any debris.

Pump stops soon after starting (Motor protector operates)

| 1)   Impeller is clogged.

2)   Low voltage.

3)   Wrong power frequency.

4)  Extended operation with a clogged strainer.

5)   Faulty motor.

6)   Excessive sand is discharged.

| 1)   Remove any debris.

2)  Provide the rated voltage,or make sure the cabtyre cable extension is the proper standard.

3)   Check the name plate, and replace the pump.

4)   Remove debris from the strainer.

5)   Repair or replace the motor.

6)  Place the pump on a block or other base to prevent sand from being sucked into it.

Poor lift or discharge capacity

| 1)   Worn out impeller.

2)   Sharply bent or clogged hose.

3)   Strainer stand clogged or buried.

4)   Motor direction is reversed

| 1)   Replace.

2)  Straighten out any sharp bends. Enclose the pump with a screen to keep away debris.

3)  Remove debris from the strainer stand or place a block under the pump.

4)   Interchange power supply leads(p.9).

Pump generates noise or vibration| 1)  Grease in the bearing is running out or insufficient.

2)   Damaged motor bearing.

| 1)   Add grease.

2)   Contact dealer and replace motor.

The following information is required when ordering repairs or making other inquiries.

Product model|
---|---
Manufacturing number|
Purchase date|
Remarks|

Disposal Product
Properly dispose of the product by disassembling it, presorting the contents, and sending them to the waste material treatment site.

PRIOR TO OPERATION

Major Standard Specifications

Applicable Liquids| Property| Rain Water, Ground Water, Sand laden Water, 0 ~ 40oC
---|---|---

Pump

| Impeller| Double-suction, Close-Type
Shaft Seal| Double Mechanical Seal
Bearing| Upper: Radial Roller Bearing

Lower: Angular Ball Bearings, Back-to-back Duplex

Motor

| Specifications| Dry type Submersible Induction Motor, 2-Pole
Insulation| Class F
Protection System (Built-in)| Miniature Protector
Leak Sensors (Built-in)| Electrode and Float
Lubricant| Turbine Oil VG32
Connection to Piping| JIS 10K Flange

Standard specification

Model| Bore mm| Phase| Starting Method| Output kW| Max. Head m (feet)| Max. CAPACITY

m3/min (GPM)

| Weight kg
---|---|---|---|---|---|---|---
LH12185| 300| 3| Star Delta| 185| 94.5 (310)| 14.0 (3698)| 1965

INSTALLATION

Maximum allowable water pressure

ELECTRICAL WIRING

Connecting the cabtyre cable

WARNING: Before connecting leads to the terminals, make certain the power supply is turned off (circuit breaker, etc.), to avoid electrical shock, shorting, or unexpected staring of the pump, leading to injury.

Connect the leads of cabtyre cable to the control panel terminals as shown in the diagram, being careful not to let the leads become twisted together .

**Electrical circuit diagrams

** MAINTENANCE AND INSPECTION

Inspecting Oil
Remove the oil plug and tilt the pump to drain a small amount of oil. If the oil is milky white or has water mixed in with it, the mechanical seal may be faulty. In this case the pump will need to disassembled and repaired.
Replacing Oil
Remove the oil plug and drain all the oil, then replace it with the specified amount.

Replacing bearing grease
Models with output 185kW require that bearing grease be replaced periodically. With the pump standing upright, supply and drain grease at the grease nipple on the bearing housing side of lower bearing, and at the grease nipple on the motor bracket side of upper bearing. The table shows the different bearing types, specified amount of grease, initial supply of grease, and replaced frequency.

Note: Greasing generally is good for around 3,000 hours of use, but this can vary depending on the use conditions.

__

LH12185

| “RAREMAX SUPER” (Kyodo Yushi Co.Ltd) or equivalent 1| Upper: 270g ( 9.52 oz.)| Upper: 300g (10.58 oz.)
Lower: 370g (13.15 oz.)| Lower: 400g (14.11 oz.)
Item| 1
---|---
Soap Type| di-Urea
Base Oil Type| Mineral Oil
Viscosity (40oC / 104oF)| 94mm2/s (cSt)
Viscosity (100oC / 212oF)| 10.5mm2/s (cSt)
Temperature Range| -40 to 150oC / -40 to 302oF
Dropping Point| 253oC / 487oF
Penetration NLGI grade| 2 to 3
Penetration (60 strokes 25oC / 77oF)| 260
Penetration (100,000 strokes 25oC / 77oF)| 365 max.

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