POMPE CUCCHI Series WPP Istruzioni operative

Serie WPP, WPL

GEAR PUMP

OPERATING AND MAINTENANCE MANUAL

POMPE CUCCHI

s.r.l.

POMPE CUCCHI s.r.l.

20090 Opera (MI) - ITALY

Via dei Pioppi, 39

Tel.(+39) 02 57606287 (R.A.)

Fax (+39) 02 57602257

e-mail: cucchi@pompecucchi.it

Pompa ad Ingranaggi - Serie WPP, WPL

Gear Pump - WPP, WPL Series

CONTENTS

GENERAL INFORMATION .........................................................................................................25

1.1

SUPPLY CONDITIONS...................................................................................................25

1.2

MANUFACTURER..........................................................................................................25

1.3

USER MANUAL CONTENT ............................................................................................25

1.4

NAME, TYPE ..................................................................................................................26

1.5

NOISE EMISSIONS ........................................................................................................26

1.6

APPLICATION FIELDS AND LIMITS. ALLOWED AND NOT ALLOWED USES..............26

TRANSPORT, HANDLING, PACKAGING, STORAGE...............................................................27

DESCRIPTION OF THE PUMP AND THE PUMP UNIT.........................................................................27

3.1

GENERAL DESCRIPTION OF THE MACHINE...............................................................27

3.2

WARNINGS ....................................................................................................................27

3.3

PROTECTION DEVICE ..................................................................................................28

3.4

ADDITIONAL DESCRIPTION OF ACCESSORIES .........................................................28

3.4.1

Seal parts............................................................................................................28

3.4.2

Safety valve ........................................................................................................28

INSTALLATION, ASSEMBLY.....................................................................................................29

4.1

SPECIAL ASSEMBLY TOOLS........................................................................................29

4.2

INSTALLATION SITE INFORMATION ............................................................................29

4.2.1

Space requirements for operation and installation...............................................29

4.2.2

Inspection before starting installation ..................................................................29

4.2.3

Foundation details...............................................................................................29

4.2.4

Alignment requirements ......................................................................................29

4.2.5

Suction lift ...........................................................................................................29

4.3

INITIAL INSTALLATION..................................................................................................31

4.3.1

Complete Pump Unit ...........................................................................................31

4.3.2

Free shaft pump..................................................................................................31

4.4

DRIVE UNIT AND ACCESSORY ASSEMBLY ................................................................32

4.4.1

Motor ..................................................................................................................32

4.4.2

Installation of safety and control devices .............................................................32

4.5

ELECTRICAL CONNECTIONS, CONNECTION CABLES ..............................................32

4.6

PIPING............................................................................................................................32

4.6.1

General ...............................................................................................................32

4.6.2

Forces and moments which operate on suction and delivery flanges. .................32

4.6.3

Fastening screw torques .....................................................................................33

COMMISSIONING, OPERATION, SHUTDOWN .........................................................................33

5.1

DOCUMENTATION ........................................................................................................33

5.2

PUMP PREPARATION FOR STARTUP .........................................................................33

5.2.1

Filling / discharge ................................................................................................33

Pompa ad Ingranaggi - Serie WPP, WPL

Gear Pump - WPP, WPL Series

5.2.2

Electrical connections .........................................................................................33

5.2.3

Verifying the direction of rotation .........................................................................33

5.3

SAFETY DEVICES .........................................................................................................33

5.3.1

Mechanical safety devices (guards for rotating parts)..........................................33

5.3.2

Acoustic insulation ..............................................................................................34

5.3.3

Splash-proof cover..............................................................................................34

5.3.4

Regulation on the electric components................................................................34

5.4

COMMISSIONING ..........................................................................................................34

5.4.1

Initial commissioning ...........................................................................................34

5.4.2

Startup after shutdowns ......................................................................................34

5.4.3

Pump system requirements.................................................................................35

5.4.4

Startup/shutdown frequency................................................................................35

5.4.5

Operation and startup with closed valve..............................................................35

5.5

SHUTDOWN...................................................................................................................35

5.5.1

Decommissioning................................................................................................35

5.5.2

Emptying.............................................................................................................35

MAINTENANCE AND INSPECTION ...........................................................................................35

6.1

USE PRECAUTIONS......................................................................................................35

6.2

WEARABLE MATERIALS ...............................................................................................36

6.3

SURVEILLANCE DURING OPERATION ........................................................................36

6.4

PREVENTIVE MAINTENANCE.......................................................................................36

6.5

PUMP DISASSEMBLY AND REASSEMBLY ..................................................................36

6.5.1

Tools...................................................................................................................36

6.5.2

Disassembly/reassembly procedure....................................................................36

FAULTS: CAUSES AND SOLUTIONS .......................................................................................40

WARRANTY CONDITIONS ........................................................................................................42

ALLEGATI/ANNEXES ................................................................................................................43

Pompa ad Ingranaggi - Serie WPP, WPL

Gear Pump - WPP, WPL Series

1. GENERAL INFORMATION

1.1 SUPPLY CONDITIONS

According to agreements with the Customer, the pump can be supplied either as bare shaft

or pump unit. By pump unit we mean the pump coupled with the motor, including reduction

gears and/or speed variators, if any. The coupling can be direct (WPP series, only for bare

shaft pumps) or through bell housing (WPL series).

1.2 MANUFACTURER

The pump Manufacturer is POMPE CUCCHI S.R.L.. You can apply for assistance by send-

ing a request to the following address:

Via dei Pioppi 39 - 20090 OPERA (MI) ITALY

Tel. +39.02.57.60.62.87 (Hunting Line)

Fax +39.02.57.60.22.57

E-mail : sales@pompecucchi.it

1.3 USER MANUAL CONTENT

This user manual provides all the necessary information to ensure a safe and correct use of

the machine. It was written – when applicable – according to point 5.5 of Standard EN 292

part 2-1992 - Machinery Safety; according to point 7 of Standard UNI EN 809-2000 Pumps

and Pump Units for Liquids - Common Safety Requirements - and according to point 1.7.4 of

Directive 98/37/EC 1998 (ex 89/392 EC). In this manual it is constantly referred to safety in-

structions. Such instructions are identified by the following symbols:

It represents the safety instructions contained in this manual,

whose non-observance may compromise safety.

It is shown when electrical safety is essential to worker protection.

It indicates the safety instructions which should be taken into ac-

count for the safe operation of either the pump, the pump unit or

the pump or pump unit protection.

Pompa ad Ingranaggi - Serie WPP, WPL

Gear Pump - WPP, WPL Series

1.4 NAME, TYPE

The pump standard execution is that with brass body, AISI 316 shafts, AISI 316L gears and

shafts, bearing bushes in graphite and ceramic/graphite/NBR mechanic seal. The complete

series covers different executions (AISI 316 body, gears in KK plastic) and different capaci-

ties. Moreover, executions with special mechanic seal or magnetic drive are also provided.

The pump identification is realized through an alphanumeric code (see the following exam-

ple):

- 0WLZ008/NZPFB00: pump type WPLZ, brass execution, rated capacity 8 l/min. at 1500

rpm (displacement 6,2 cm3/rev), shafts made of stainless steel, a gear in KK plastic, stan-

dard mechanic seal, equipped with brass safety valve, with bell housing for coupling with a

Size 80 motor.

1.5 NOISE EMISSIONS

- Reference standard: CEN/TC 197/SC3 N 21 E -fig.8- ISO 3744 on 6 positions

- Measured values:

1 - Equivalent weighted continuous acoustic pressure level

Leq = 80 dB(A);

2 - Maximum weighted instantaneous acoustic pressure

C (peak level) Lpc < 82 dB(C).

- Test conditions: When measuring noise, the pumped liquid (ref. to oil with 30 cP viscosity)

must be introduced into the testing system at a speed of less than 0.8 m/s into pipes. It

must however reach laminar flow regime (thus the speed must be related to the viscosity)

and the conditions outlined in this manual must be respected.

1.6 APPLICATION FIELDS AND LIMITS. ALLOWED AND NOT ALLOWED

USES

Each machine shall be used according to the type of application, operating conditions and

liquid characteristics provided in contract specifications. Each variation which alters the in-

tended use of the pump is forbidden and the User is fully responsible for it (e.g. the use of a

liquid which is corrosive to pump materials rather than the recommended fluid, etc.). For

variations in use within the application limits (e.g. fluid viscosity variations) it is advised to

contact the Manufacturer in advance.

The maximum operating pressure, for pumps in standard execution, is of 15 bar.

In any case, the use of “KK” or alike plastic gears to allow the pump to operate also

with poorly lubricating fluids, requires greater attention to avoid excessive or unex-

pected pressure loads.

It is absolutely forbidden to use the machine in hazardous environments (explosive

atmosphere, etc…), the use of hazardous substances (e.g. fluids with dangerous

gases), in critical conditions (e.g. abnormal temperatures, etc…), which are not sup-

plied with the pump.

For pumps and pump units intended to be used in potentially explosive environ-

ments, please read carefully “Additional instructions for the operation and manage-

ment of pumps and pump units intended to be used in potentially explosive atmos-

pheres (Directive 94/9/EC)”. In case of slipping of the magnetic coupling, the surface

temperature can reach 350°C in a few seconds; therefore, it is necessary to provide a

continuous monitoring of the temperature near the coupling.

Pompe Cucchi S.r.l. declines every responsibility for the consequences arising from an im-

proper use of the machine which does not comply with what prescribed in this manual or

specifically requested when ordering.

Pompa ad Ingranaggi - Serie WPP, WPL

Gear Pump - WPP, WPL Series

2. TRANSPORT, HANDLING, PACKAGING, STORAGE

Pompe Cucchi sells “ex works”. Consequently, transport from the manufacturing shop to the

named place of destination is carried out by the Customer under his own responsibility. For

each transport a suitable standard packaging is ensured or established based on Customer

requirements who, in any case, must give information about the type of shipment to be per-

formed (by land, air, “overseas“).

In case of long stationary periods under critical environmental conditions (such as: high hu-

midity and/or salinity, etc.) the supply shall be stored in a protected environment.

3. DESCRIPTION OF THE PUMP AND THE PUMP UNIT

3.1 GENERAL DESCRIPTION OF THE MACHINE

Essentially the pump consists of two driven pinions which mesh one another inside a cast

main body, thus creating a flow of liquid between the inlet and the outlet.

The fluid containment inside the pump is ensured by a suitable seal part as defined in the

order.

Pumps, series WPL are connected to the motor (shape B34), according to CE standards, by

means of a flexible (or magnetic) coupling and a bell housing, which also acts as safety

coupling guard.

The pump unit series WPL can be equipped with a mechanic reduction gear or a hydraulic

variator to adjust the rotation speed, according to CE standards.

3.2 WARNINGS

Standard construction pumps, as an indication, require a NPSH of approx. 0.4 bar. Always

calculate the maximum available suction lift, in relation to fluid characteristics, suction circuit

and operating conditions. Ensure that gears do not operate when dry. Before starting the

pump for the first time or after long stationary periods, it is advisable to fill the gear spaces

with oil or liquid being pumped through one of the nozzles and rotate the driving shaft by op-

erating manually with a screwdriver on the motor cooling fan. This also makes it possible to

check for even and smooth movement of rotary components and excessive friction. It is rec-

ommended that an overland cut-out set at approx. 10% above the motor current be installed

in the control circuit.

INLET

OUTLET

Pompa ad Ingranaggi - Serie WPP, WPL

Gear Pump - WPP, WPL Series

In our pumps the direction of rotation is clearly shown by an arrow marking the right direc-

tion.

The pump operating temperature in normal working conditions is about 80°C. In special

pump versions, working temperatures of 180°C and more may be achieved. To protect per-

sonnel from dangers due to the temperatures reached during the operation of the machine,

in the event of accidental contact (burn), the User must reduce the external pump tempera-

ture by means of insulation plates, coatings, screens, barriers, etc. As limit reference tem-

perature for the contact surface it is advisable to take 55°C. Below this value, for hot smooth

surfaces in bare metal, there is no burn threshold. For a detailed knowledge of this problem

in relation to different particular cases, the User can read the standard UNI EN 563 Ed.’94,

where burn thresholds are specified for several types of surface according to the “surface

temperature - contact time” parameters.

Liquids to be pumped must not contain abrasive or solid suspension as this will greatly re-

duce the pump life. At this purpose we recommend the installation of a properly sized filter

on the suction line if solids may be present.

When pumps are installed in parallel, the suction lines should be adequately separated to

prevent unnecessary turbulence.

3.3 PROTECTION DEVICE

The bell housing installed by the Manufacturer is made of an aluminium die-casting, fas-

tened to the motor by screws, duly shaped to prevent fingers from coming into contact with

moving parts. It can be removed only by using a proper tool.

3.4 ADDITIONAL DESCRIPTION OF ACCESSORIES

3.4.1 Seal parts

The pump is usually supplied equipped with mechanical seal. If the Customer requires a

particular type of seal, Pompe Cucchi S.r.l. installs the desired seal after verifying if its di-

mensions are compatible with those of the pump. In case the Customer requires only the

seal mark, the Company leaves the Manufacturer to select the type of seal, by giving infor-

mation about the pumped liquid.

3.4.2 Safety valve

The pump can be equipped with a safety valve, with adjustable calibration, installed on the

front of the pump body.

After reaching the calibration pressure, prevailing on the contrast spring reaction, the valve

starts opening by connecting the outlet side and the inlet side of the pump.

The valve function is just to protect the pump from accidental pressure peaks. Its prolonged

opening may imply the pump damaging.

Pompa ad Ingranaggi - Serie WPP, WPL

Gear Pump - WPP, WPL Series

4. INSTALLATION, ASSEMBLY

4.1 SPECIAL ASSEMBLY TOOLS

To assemble the pump you do not need special tools, except for seal extractors (see Main-

tenance).

4.2 INSTALLATION SITE INFORMATION

4.2.1 Space requirements for operation and installation

The space destined by the Customer to the installation of the machine should be enough to

gain access to, install and maintain the pump unit.

4.2.2 Inspection before starting installation

Before installation, the Customer must ensure that the environmental conditions of the se-

lected site comply with requirements specified under the contract.

In particular, unless expressly required and accepted in the order, the installation site should

not be exposed to the following environmental conditions:

- abnormal temperature;

- high humidity;

- corrosive atmosphere;

- explosion and/or fire hazard areas;

- dust, sandstorms;

- earthquakes and other similar external conditions;

- high level of vibrations;

- high altitude;

- flood hazard areas.

4.2.3 Foundation details

When the pump unit is installed, it shall be firmly fixed in place by fastening bolts or by using

other securing methods.

Ground fastening bolts or other securing methods shall be of sufficient strength to prevent

the pump unit from moving accidentally.

4.2.4 Alignment requirements

The alignment operation must not submit the pump unit to axial and radial stress, therefore

the offset must always be lower than the tolerance limits expected for the coupling.

Particular attention should be paid to the alignment of the assemblies equipped with a mag-

netic coupling.

4.2.5 Suction lift

The suction lift, that is the vertical distance between the pump inlet mid-point and the free

surface of the tank to which the pump is attached, must not exceed 5 m to allow pump prim-

ing and avoid cavitation phenomena.

Pompa ad Ingranaggi - Serie WPP, WPL

Gear Pump - WPP, WPL Series

Otherwise, contact our Technical Department.

Each pump must have its own suction pipe; the installation of two or more pumps with a

common suction pipe length causes the pump to work less efficiently.

The length of the suction pipe must be reduced as much as possible to minimize pressure

losses in such segment; higher pressure losses in the discharge line do not adversely affect

the correct operation of the pump (if they do not exceed the delivery limits stamped on rating

plate).

Furthermore, it is necessary to check that siphons are not created in the suction pipe, since

the formation of air pockets generates vibrations and stresses which are not compatible with

the correct operation of the pump and may obstruct the pump priming at startup.

In case of installation below head, the pump does not ensure to be able to intercept the flow

of fluid as a shut-off cock or a proper stop valve.

YES

Pompa ad Ingranaggi - Serie WPP, WPL

Gear Pump - WPP, WPL Series

4.3 INITIAL INSTALLATION

According to the conditions of supply, the pump can be delivered as follows:

4.3.1 Complete Pump Unit

In this case the Customer must stiffly fasten the pump unit in order to ensure the correct axis alignment

in all operating conditions.

We recommend the use of vibration dampers below the motor feet and vibration damping

sections on pipes near pump inlets.

Once the pump unit has been positioned, proceed as described below:

a) connect suction and discharge pipes respectively to the pump inlet and outlet;

b) power the motor, by carefully controlling the compatibility of motor voltage and frequency with those

of the system;

c) open the intake and discharge pipe valves, if any;

d) run the motor for a while to verify that the pump rotates in the direction indicated by the arrow

stamped on the pump.

4.3.2 Bare shaft pump

In this case, before following the steps described at Paragraph 4.3.1, choose the type of mo-

tor and align it to the pump.

The motor must be selected by the Customer depending on the type of operation for which it

is specifically requested (continuous operation, discontinuous operation, repeated startups,

indoor or outdoor installation, explosive atmosphere, critical environmental conditions, alti-

tude, etc.) with power compatible with that required by the pump.

Motor and pump shafts are coupled by flexible or magnetic coupling. The aluminium bell

housing, with centerings both on pump and motor, guarantees a correct alignment.

In case of connection by magnetic coupling it is very important to avoid the generation of ax-

ial loads on the inner magnet, which can cause the premature wear of the bush shim ad-

justments, by leaving the outer magnet free to position itself axially. After connecting the

pump to the engine by the lantern, unscrew the fixing pin of the outer magnet on the crank-

shaft and retighten this last after the magnet has reached its balance position.

While centering the outer magnet, pay special attention to the effects of the magnetic

pull force; in particular beware of fingers (always use safety gloves). Be careful not to

damage magnets by accidental shocks.

You are recommended to use tools in non-magnetic material.

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