INSTALLATION, OPERATION AND MAINTENANCE MANUAL

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1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL PLEASE READ CAREFULLY YOUR WARRANTY MAY BE VOID IF INSTRUCTIONS ARE NOT FOLLOWED Note: when ordering parts give pump model and serial number Cornell Pump Co SE 130 th Ave; Clackamas, OR USA Phone: Fax:

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3 MODELS NN SOLIDS HANDLING PUMP W/HS18DB HYDRAULIC SUBMERSIBLE FRAME MANUAL 2811 ITEM PAGE Cover Page Index 1 Terms and Conditions Warranty 2-3 Startup Checklist 4 Parts Page 5 Pressure Testing 6 Disassemble and Reassemble Instructions 7-8 Lubrication Instructions 9 Mechanical Seal Instructions Pump Troubleshooting Guide 12 1

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5 CORNELL PUMP COMPANY TERMS AND CONDITIONS OF SALE EXHIBIT 1 Warranty Coverage: 24 months Warranty for Motors, Controls, and other accessories not manufactured by Cornell is provided by the manufacturer of those products. Wear Parts: This limited warranty does not cover parts that by nature of their function require replacement as the result of normal wear and tear (seals, wear rings, wear plates, or other parts subjected to abrasion, cavitation, or corrosion) unless a defect in materials or workmanship can be determined by Cornell. 3

6 Startup Checklist BEFORE THE STARTUP OF ANY PUMP, A CAREFUL CHECK MUST BE MADE TO ENSURE THAT ALL IS IN ORDER 1. Reread all instructions and check for compliance on each point. 2. The pump is shipped without oil in the bearing frame. Oil must be added before starting the pump. See Lubrication Instructions for type and quantity of oil to use. 3. Make sure: a. All fasteners at gasketed surfaces are properly tightened. b. The pump rotates freely by hand. Then check that pump rotational direction is correct. 4. Check the valves for proper position. If the system has a discharge gate valve, start with valve closed. The speed of opening depends upon the size and length of your discharge pipe and capacity of the pump. The valve should not be more than.25" open until the line is filled. The purpose of this procedure is to reduce the possibility of a water hammer or shock if filling is too rapid. 5. Instructions For Pumps with Wear Rings Wear rings are vital for a successful pump operation. Wear rings should be replaced if the clearance has increased to about.030" per side. 6. Cornell Bearing Frames In general, the considerations for a bearing frame are the same for that of electric motors. If the pump is used in winter, provisions must be made for protection of the pump and piping from freezing. If the pump is not used in the winter, the volute should be drained to prevent damage. 7. Check to make sure the screens are in place. A screen or strainer should have a free opening at least three times the area of the suction pipe. 8. Start the driver. If pump is primed or filled with liquid, the pumping will start immediately. Cornell Centrifugal Pump Priming A centrifugal pump is primed when all the internal passages of the pump are filled with the liquid to be pumped. Do not operate any pump without being properly primed unless it has been specifically designed for such operation. When the pump is primed and the unit is started, the pumpage will start to flow immediately. If it does not, recheck the system for complete prime and possible air leaks. Correct the deficiencies and restart. CAUTION If the pumpage does not start immediately, no amount of additional pumping will solve the problem. 4

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8 Pressure Testing CAUTION: DO NOT OPERATE PUMP WHEN AT TEST PRESSURE WARNING: Failure to follow instructions may damage pump and/or result in serious personal injury. MAXIMUM TEST PRESSURE Maximum test pressure should not exceed 125% of shutoff pressure or 150% of design pressure, whichever is greater. Refer to Cornell Catalog for operating pressure limits of your pump. If your calculated test pressure is above these limits, consult factory prior to proceeding. TEST FLUID Liquid may be pumpage or water or any liquid compatible with pump materials. a. Open vent valves on volute. Fill pump gradually with liquid by gravity flow (10 PSI max. pressure). b. Vent air from volute and close vent valve. c. Raise pressure gradually to required test pressure. See Maximum Test Pressure. 6

9 Disassemble and Reassemble Instructions Refer to the parts page for part names and numbers. Disassemble 1. Drain oil from BOTH chambers of the frame body. 2. Remove all capscrews holding volute (2) to backplate (38). Insert two of these capscrews into tapped holes in backplate. Tighten capscrews to jack the volute free of the backplate, exposing the impeller (3). Remove volute. Make sure volute does not fall onto the impeller. 3. Remove impeller lockscrew (12) using a breaker bar. CAUTION: Care should be taken when removing lockscrew to prevent damaging screw head. If breaker bar will not loosen impeller lockscrew, apply heat to the lockscrew for 2-4 minutes. Do not exceed 400 F. CAUTION: Care should be taken when applying heat so as not to receive serious burns. Allow lockscrew to cool and remove with breaker bar. (Lockscrew can be reused with Loctite if not damaged). Remove impeller washer. 4. Space wedges in pairs apart between impeller and backplate. Be sure wedges are placed along impeller vanes. Tap opposed wedges at the same time to force off the impeller. See page for alternate method. Use extreme care or damage to impeller, shaft or bearings will result. Remove impeller and impeller key (28). 5. Remove mechanical seal (40). See mechanical seal instructions. At this point it is probably easier to leave the stationary seat in the backplate until the backplate is removed. If you elect to remove the seat now, use extreme care or it will break (fragile). 6. Unbolt and remove backplate (38) from bracket (4). If the stationary seat has not been removed yet, use extreme care when sliding backplate along shaft to avoid chipping of the mechanical seal seat on the shaft. If the seal is being replaced, carefully remove the stationary seat from the backplate. 7. The suction wear ring (6) can be removed, if necessary, by drilling the ring longitudinally in three places to relieve compression and collapsing the three sections together. Better control is obtained if small pilot holes are first drilled and then enlarged to cut the ring. 8. Remove the seal retaining ring (35) from the shaft. Remove the mechanical seal (40A). Leave the seat in the bearing cover until the bearing cover is removed. CAUTION: Keep this seal separate from the other seal; they are different styles and have different seal faces. 9. Remove the capscrews from the pump end bearing cover (22). Slide the bearing cover off the shaft taking care not to damage the seal stationery seat. 10. Remove the hydraulic motor. Remove the capscrews from the drive end bearing cover (22A). Slide the bearing cover off the shaft. 11. Press the shaft out towards the drive end. The pump end bearing remains in the frame and can now be removed. 12. Remove the bearing locknut (129) and lockwasher (363). Remove the bearings from the shaft with a bearing puller. If the bearings are to be saved, keep them absolutely clean. If contaminated, wash only in clean fluid. CAUTION: Never hammer the shaft or parts attached to the shaft or you will ruin both the shaft and the bearings. 7

10 Reassemble 1. Press the drive end bearings (20) onto the shaft (14). Make sure they are positioned back to back. Pressure should be applied to the inner race. Install the bearing lockwasher (363) and locknut (129). 2. Press the pump end bearing into the frame. Place one of the.010 shims (107A) on the bearing and install the drive end bearing cover (22). 3. Press the shaft into the frame through the drive end until the drive end bearings contact the frame shoulder. 4. Remove the pump end bearing cover and shim. Reinstall the pump end bearing cover (22) with o-ring (59). Make sure the shim is NOT included. Install and tighten the capscrews. 5. Reinstall the shims (107A) in the drive end of the frame (if present when disassembled). If new shaft, bearings, frame, bearing cover are being installed, insert shims to maintain to between bearing and bearing cover. Install the bearing cover (22A) with o-ring (59A). Install and tighten the capscrews. 6. Install the hydraulic motor and o-ring (59C). 7. Install mechanical seal (40A). See seal installation instructions. Install the seal retaining ring (35) in shaft groove. Make sure the spring holder is in place. 8. Place o-ring (59B) on the frame and install backplate (38). 9. Install mechanical seal (40). See mechanical seal instructions. 10. Use shims (107) provided by the factory to obtain clearance between impeller backvanes and backplate. Shims will be sandwiched between impeller and shaft shoulder. 11. Install impeller key (28) and impeller (3). Use long capscrew and several washers to press on impeller. Do not use impeller lockscrew. The threads must be long enough to enter the shaft approximately eight threads or turns by hand. This is necessary to protect the threads in the shaft. After installing impeller, remove long capscrew. 12. Apply Loctite 262 to impeller lockscrew (12) threads and shaft threads. Do not lubricate impeller lockscrew or tapped hole or between the lockscrew and the impeller washer or between the impeller washer and the impeller. This could cause the lockscrew to be over stressed. Install impeller lockscrew and impeller washer (13). Lockscrew should be new if possible. Torque Lockscrew to 135 ft-lb. 13. Install new gasket. For emergency use, old gaskets should be moist and flat. 14. Install volute (2), sliding it carefully over the register. Bolt volute to backplate (38). 8

11 Hydraulic Submersible Lubrication Instructions The frame contains two cavities; both must be filled with oil. The upper cavity lubricates the bearings. The lower cavity lubricates the mechanical seal during run dry operation. To fill: Remove the pipe plugs that are at the same height as the elbows. This will allow the cavities to vent. Add oil through the two elbows in the frame. Fill until oil can be seen in the sight glasses. Install the plugs in the vent and fill openings. Be careful to keep out dirt and moisture. To drain: Remove the plugs at the bottom of each cavity. Unit will need to be placed horizontally to get all the oil out. The type and grade of oil used is very important for maintenance-free operation. Oil used should be a turbine oil equivalent to one of the following manufacturer s products: : ISO VG32 Mobil DTE 797 Lubriplate HO-0 Chevron Turbine Oil GST 32 Shell Turbo T Oil 32 Approximately 8 quarts are required to fill both cavities. Oil Change Frequency 6 months for continuous duty 12 months for intermittent duty 9

12 MECHANICAL SEAL INSTRUCTIONS JOHN CRANE TYPE 1, TYPE 2, AND TYPE 21 SINGLE MECHANICAL SEAL For Cornell Solids Handling Pumps O-RING RETAINER BELLOWS SPRING STATIONARY SEAT STATIONARY SEAL FACE ROTATING SEAL FACE DISC DRIVING BAND The location of the mechanical seals in your pump is shown in the cross-section drawing of the pump. The stationary seats are held in the backplate and in the pump end bearing cover. All other parts of the seals rotate with the shaft and impeller. DISMANTLING THE MECHANICAL SEAL If seal is to be removed, remove the impeller according to the instructions for dismantling the pump. The rotating portion of the seal may now be seen. Slide off the seal spring. Lubricate the shaft and remove the reminder of the rotating portion being careful to avoid damaging the primary seal. The rubber bellows will be firmly attached to the shaft and considerable pressure will be required to remove it. 10

13 INSTALLING THE MECHANICAL SEAL Clean all parts of the pump before starting reassembly. Special attention should be given to the backplate and the impeller hub. - Clean and lubricate the shaft. - Install the stationary seat in the backplate. - Oil the outer surface of the seat and the O ring with a light oil (not grease). Place a cardboard disc on the sealing face to avoid damage. Press it into the backplate or bearing cover using firm steady pressure. Make sure the seat is all the way in. - Wipe the lapped sealing faces of the seat and the primary seal perfectly clean using a very clean lint-free cloth. Use extreme care to avoid marking the seal faces. Slide the rotating portion of the seal, including spring on the shaft. CAUTION: Once the rotating portion has been placed on the shaft, the rest of the installation must be made at once. Delay may result in the rubber bellows seizing on the shaft in the wrong position. Install the impeller. Be sure that the spring slides over the step in the impeller hub. O-RING BACKPLATE SHAFT SLEEVE STATIONARY SEAT ROTATING ELEMENT SPRING Typical assembly for Cycloseal pumps 11

14 PUMP TROUBLESHOOTING GUIDE SYMPTOMS CAUSES CORRECTIONS Failure to pump Pump not properly primed. Speed too low or head too high. Not enough head to open check valve. Plugged suction. Unplug suction. Reduced performance Driver overloaded Excessive noise Premature bearing failure Obstruction in impeller. Excessively worn impeller or wear ring. Wrong direction of rotation. Speed higher than planned. Liquid specific gravity too high. Liquid handled of greater viscosity than water. Too large an impeller diameter. Obstruction in impeller. Worn bearings. Impeller screw loose or broken. Cavitation (improper suction design). Wrong direction of rotation. Worn wear rings. Bent shaft. Water or contaminates entering bearings. Lubrication to bearings not adequate. Wrong type of lubrication. Prime pump correctly. Consult Cornell Factory. Consult Cornell Factory. Remove obstruction. Replace impeller and/or wear ring. See start-up instructions. Reduce speed. Consult Cornell Factory. Consult Cornell Factory. Trim impeller. Remove obstruction. Replace bearings. Replace. Correct suction piping. See start-up instructions. Replace. Replace shaft. Protect pump from environment. See Lubrication Instructions. See Lubrication Instructions. 12

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