Grundfos LM Series User manual

Series LM/LP

Single Stage In-Line

Centrifugal Pumps

Installation and Operating Instructions

Please leave these instructions with the pump for future reference.

Table of Contents:

Page #’s

Checking the Condition of the

Pump...................................... 2

Pre-Installation........................ 2

Installation Procedures........2-3

Electrical..............................4-5

Starting the Pump................5-6

Operating Parameters.........6-9

Troubleshooting.................9-13

Notes...............................14-15

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Checking the Condition of the Pump

Examine the components carefully to make sure no damage has occurred during shipment.

The Grundfos LM/LP pump should remain in its shipping carton until it is ready to be installed. This

carton is specially designed to protect it from damage. During unpacking and prior to installation,

care should be taken to ensure the pump is not dropped or mishandled. Immediately report in writ-

ing any damage to the transportation company and ask to have it inspected. Do not destroy packing

materials until shipment is inspected and the claim settled.

Pre-Installation Checklist

Before beginning installation procedure, check that the proper operating conditions for the

pump are present.

Is This The Correct Application For The Pump?

The Grundfos LM/LP series pumps are designed to handle a wide range of applications

including:

•Chilled and hot water circulation

•Condenser and cooling water circulation

•Water pressure boosting

•Pumping of water-glycol mixtures up to 50% solutions

• Solarthermaluids

•Other thin, clean, nonexplosive and non-greasy liquids

Maximum Operating Conditions

Temperature Ranges:

Minimum temperature: +5°F (-15°C)

Maximum temperature: 250°F (121°C)

Maximum Working Pressure: 175 PSI (12 Bars)

Installation Procedures

Select Pump Location

Thepumpshouldbelocatedinadry, well ventilated area which is not subject to freezing or extreme

variation in temperature. Care must be taken to ensure the pump is mounted at least six (6) inches

(152 mm) clear of any obstruction or hot surfaces. The motor requires an adequate air supply to

prevent overheating and should not be totally enclosed. For open systems requiring suction lift,

the pump should be located as close to the water source as possible to reduce pumping losses.

Pump Support

LM/LPpumpsaresuitableforoor,wallordirectpipelinemounting.Concreteorsimilarsolidfoun-

dationmaterialshouldbeusedforoormounting.Adequatesteelbracketsshouldbeusedforwall

mounting. The pipe on each side of the pump must be adequately supported for pipeline mounting.

The LM/LP pumps (except 3.0 LP6 and 4.0 LP5) have two tapped holes in the bottom of the pump

housing to allow the pump to be secured to a mounting bracket. Make sure the pump is secure to

themountingbracketandthemountingbracketisrmlyattachedtotheoororwall.

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Pipework

Arrowsontheangesofthepumpvoluteindicate

the ow direction of water through the pump.

GrundfosLM/LPmodelpumpscanbemountedin

eithertheverticalorhorizontalposition.The pump

can be installed with the motor in all positions be-

tween vertical and horizontal but the motor/pump

shaft must never fall below the horizontal plane.

See Figure 1. In open systems, install suction

piping to minimize friction losses and avoid air

pockets. See Figure 2. Size discharge piping to

reduceuidvelocitiesandminimizefrictionlosses.

It is suggested that isolation valves be installed on

eachsideofthepumptoavoiddraining the system

if the pump needs to be cleaned or repaired. It is

also suggested that a check valve be installed in

thedischargepipe.Apluggedteeorcappedpipe

should be mounted in the suction line to ll the

pump and pipe before start-up especially if the

system is not pressurized.

The pump and/or piping should be adequately supported on both sides to reduce thermal and me-

chanicalstressesonthepump.Ifpumps are installed close tonoisesensitiveareas,itisadvisableto

use pump and piping vibration isolators to prevent vibration from being transmitted to the structure.

Abypassorpressurereliefvalveshouldbeinstalledinthedischargepipeifthereisanypossibility

the pump may operate against a closed valve in the discharge line. Circulation through the pump

isrequiredtoensureadequatecoolingandlubricationofthepump.SeeTableAforminimumow

rates. The bypass should be routed back to a heat dissipating source or to a drain depending on

the liquid being pumped and local codes. Control of the bypass can be made by using a pressure

relief valve or thermostatic control valve.

Figure 2 - Suction Piping

Installation Procedures

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Electrical

All electrical work should be performed by a qualied technician in accordance with the

latest edition of the National Electrical Code, local codes and regulations.

WARNING

THESAFEOPERATIONOFTHISPUMPREQUIRESTHATITBEGROUNDEDINACCOR-

DANCEWITHTHENATIONALELECTRICALCODEANDLOCALGOVERNINGCODESOR

REGULATIONS.CONNECTTHEGROUNDWIRETOTHEGROUNDINGSCREWINTHE

TERMINALBOXANDTHENTOTHEACCEPTABLEGROUNDINGPOINT.

DO NOT START THE PUMP (EVEN TO CHECK THE DIRECTION OF ROTATION) UNTIL IT

HAS BEEN FILLED WITH WATER. Severe damage may be caused to the pump if it is run dry.

Figure 3- Motor Terminal Box Positions (Top View)

Motor

Grundfos LM/LP Pumps are supplied

withheavy-duty1750RPM(LMMod-

els)or3450RPM(LPModels),O.D.P,

NEMACframemotorsselectedtoour

rigid specications. T.E.F.C. motors

are also available. Motors for other

voltages and frequencies are available

on a special order basis.

Position of

Terminal Box

The motor terminal box can be turned

to any of four positions in 90° steps. To

rotatetheterminalbox,remove the four

bolts securing the motor to the pump

(do not remove the shaft coupling),

turn the motor to the desired location;

replace and securely tighten the four

bolts. See Figure 3.

Verify Electrical

Requirements

Vericationofthe electrical supply should be made to be certain the voltage, phase and frequency

match that of the pump motor. The proper operating voltage and other electrical information can

be found on the motor nameplate. These motors are designed to run on ±10% of the nameplate-

rated voltage. For multi-voltage motors, the motor should be internally connected to operate on

the voltage closest to the 10% rating, i.e., a 208 voltage motor wired per the 208 volt connection

diagram. Wiring connection diagrams can be found on plates attached to the motor.

If voltage variations are larger than ±10%, do not operate the pump.

Field Wiring

Wire sizes should be based on the current carrying properties of a conductor as required by the

latest edition of the National Electrical Code or local regulations.

Direct on line (D.O.L.) starting is approved due to the extremely fast run-up time of the motor and

the low moment of the inertia of pump and motor. If D.O.L. starting is not acceptable and reduced

starting current is required, an auto transformer or resistance starter should be used.

It is suggested that a fused disconnect be used for each pump where service and stand by pumps

are installed.

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Motor Protection

A. Single-Phase Motors:

With the exception of 7½ and 10 HP motors which require external protection, single phase LM/

LP pumps are equipped with multi-voltage, open-drip proof (O.D.P.) squirrel-cage induction motors

with built-in thermal protection.

B. Three-Phase Motors:

LM/LP Pumps with three-phase motors must use the proper size and type of motor-starter to en-

sure the motor is protected against damage from low voltage, phase failure, current imbalance and

overloads.Aproperlysizedstarterwithmanualresetandambient-compensatedextraquicktrip

in all three legs should be used. The overload should be sized and adjusted to trip at the full-load

current rating of the motor. If the motor is lightly loaded, the overload should be resized or adjusted

toalowervalue.Undernocircumstancesshouldtheoverloadsbesettoahighervaluethanthe

full load current shown on the motor nameplate. This will void the warranty.

Starting the Pump the First Time

After the pump has been installed, wired and the system lled, the following procedures must

be performed. Do not start the pump before priming or venting. Never operate the pump dry.

Priming

Electrical

Figure 4

pipe if one has been provided as suggested in the Installation Procedures section, Page 2. If no

othermeanstollthesuctionlinehasbeenprovided,removeoneofthegaugetappingplugsin

thepumpangesandpourwaterintotheholeusingafunnelorhosewithadapter.Allairinpump

and suction line must be purged prior to start-up.

Check the Direction of Rotation

1. Switch power off;

2. Checktomakesurethepumphasbeenlledandvented;

3. Removethecouplingguardandrotatethepumpshafttobecertainitturnsfreely.Replace

the coupling guard;

To prime the pump in a closed system

or an open system where the water

source is above the pump, close the

pump isolation valves and open the

airventscrew. See Figure 4. Gradually

open the suction side isolation valve

until a steady stream of airless water

runsoutofthe air venthole.Tightenthe

airventscrewandcompletely open the

isolation valves.

Inopensystems where the water level

is below the pump inlet, the suction

pipe and pump must be filled and

vented of air before starting the pump.

Closethedischargeisolationvalveand

open the air vent screw and suction

valve (if one is installed). Fill suction

linethroughthepluggedteeorcapped

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4. Verifythattheelectricalconnectionsareinaccordancewiththewiringdiagramonthemotor;

5. Switch the power on and observe the direction of rotation. WHEN VIEWED FROM THE MO-

TOR END, THE PUMP SHOULD ROTATE COUNTERCLOCKWISE;

6. Toreversethedirectionofrotation,rstswitchOFFthesupplypower;

7. On three-phase motors, interchange any two power leads at the load side of the starter. On

single-phase motors, see connection diagram on nameplate. Change wiring as required;

8. Switch on the power again and check for proper motor rotation.

Starting and Adjusting

Before starting the pump, please check that the:

1. Pump is primed;

2. Direction of rotation is counterclockwise when viewed from the motor end;

3. Allpipingconnectionsaretightandadequatelysupported;

4. Suction line isolation valve is completely opened, in a valve has been installed.

For initial starting:

1. The isolation valve in the discharge pipe should be closed and gradually opened after the

pump is turned on. Opening this valve to fast may result in some water hammering in the

discharge pipe. During operation, be sure this valve is completely open;

2. Checkandrecordthevoltageandamperageofthemotor.Adjustthemotoroverloadsifre-

quired;

3. Check and record operating pressures if pressure gauges have been installed;

4. Check all controls for proper operation. If pump is controlled by a pressure switch, check and

adjust the cut-in and cut-out pressure. If low-water level controls are used, be sure the low-

level switch is properly adjusted so the pump cannot run if the pump should break suction.

Operating Parameters

Grundfos LM/LP in-line centrifugal pumps installed in accordance with these instructions and sized

forcorrectperformancewilloperateefcientlyandprovideyearsofservice.Thepumpsareproduc-

tion lubricated and do not require any external lubrication or inspection. The motors will require

periodic lubrication as noted in the following Maintenance Section.

Undernocircumstancesshouldthepumpbeoperatedforanyprolongedperiodsoftimewithout

owthroughthepump.Thiscanresultinmotorandpumpdamageduetooverheating.Aproperly

sizedreliefvalveshouldbeinstalledtoallowsufcientwatertocirculatethroughthepumptoprovide

adequate cooling and lubrication of the pump bearing and seals.

Pump Cycling

Pump cycling should be checked to ensure the pump is not starting more than 20 times per hour

on ½ to 5 HP models; 15 times per hour on 7½ to 15 HP models; and 10 times per hour on 20 to

40HPmodels.Rapidcyclingisamajorcauseofprematuremotorfailureduetoincreasedheat

buildup in the motor. If necessary, adjust controls to reduce the frequency of starts and stops.

Starting the Pump the First Time

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Frequency of

Type of Service Greasing Approved Types of Grease

Seasonal(motorisidle Yearly ShellDoliumR Orcompatibleequivalenttypeofgrease

formorethan6months)  ChevronSRI#2

Intermittently Semiannually TexacoSRI#2. Mobilith SHC100 is

Continuous Quarterly Texaco“PremiumPB” required for 30 & 40 HP motors

For severe duty or extreme conditions, special motor frames or conguration, or any questions regarding

greasing procedures, contact the motor manufacturer.

Maintenance

Motor Lubrication

Electric motors are pre-lubricated at the factory and do not require additional lubrication at start-up.

Motorswithoutexternalgreasettingsdonotrequireadditionallubricationduringtherst15,000

hoursofoperation.Motorswithgreasettingsshouldonlybelubricatedwithapprovedtypesof

grease.Donotovergreasethebearings.Overgreasingwillscauseincreasedbearingheatandcan

result in bearing/motor failure. DO not mix petroleum grease and silicon grease in motor bearings.

Operating Parameters

Procedure

IfmotorisequippedwithAlemitetting,cleantipofttingandapplygreasegun.Use1to2full

strokesonmotorsinNEMA215frameorsmaller.Use2to3strokesonNEMA254throughNEMA

365frame.FormotorswithdrainplugsontheoppositesideofAlemitegreasettingatthepul-

ley end: remove grease drain plug and operate motor for 20 minutes before replacing drain plug.

Motor Replacement

If the motor is damaged due to bearing failure or electrical failure, the following instructions detail

howtoremovethemotorforreplacement.ItmustbeemphasizedthatmotorsusedonLM/LPpumps

arespecicallyselectedtoourrigidspecications.REPLACEMENT MOTORS MUST BE OF THE

SAME NEMAC FRAME SIZE, AND MUST BE EQUIPPED WITH THE SAME FRAME BEARINGS

AND RATED TO HAVE THE SAME SERVICE FACTOR. Failure to follow these recommendations

may result in premature motor failure.

Disassembly

1. Removethecouplingguards;

2. Usingthepropersizemetricallenwrench,loosenthefourcapscrewsinthecouplingand

spread coupling apart;

3. With the correct size wrench, loosen and remove the four bolts which hold the motor to the

pump end;

4. Lift the motor straight up until the shaft is free from the coupling.

Assembly

TABLE B: SHAFT ADJUSTING FORKS

Shaft Diameter Part No.

 0.630”(16mm) 480176

 0.866”(22mm) 480177

 1.300”(33mm) 480178

1. Thoroughlycleanthesurfacesofthemotorandpumpendmountinganges.Themotorand

shaft must be clean of all oil/grease and other contaminants where the coupling attaches. Set

the motor on the pump end, guiding the motor shaft into the coupling.

2. Place the terminal box in the desired position by rotating the motor.

3. Insert the motor mounting bolts, then diagonally and evenly tighten.

4. Removethecouplingadjustingforkboltedtothepumpmotorstool.Therequiredadjusting

fork is determined by shaft diameter for both the

LMandLPpumptypes.SeeTableBforthecorrect

adjusting fork.

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5. Using a large screwdriver, raise the pump

shaft by placing the tip of the screwdriver

under the coupling and carefully elevating

the coupling to its highest point. Note: The

shaft can only be raised approximately 0.20

inches (5mm). See Figure 5.

6. InserttheGrundfos adjustingforkunderneath

the coupling and lower the coupling until it

touches the adjusting fork. See Figure 6.

7. IT IS EXTREMELY IMPORTANT TO

TIGHTEN THE COUPLING SCREWS

CORRECTLY. The four allen head fasten-

ers should be tightened as follows. Tighten,

but not completely, the bottom fasteners on

one side of the coupling. Then tighten, but

notcompletely, the top and bottom fasteners

on the other side of the of the coupling so

that the gaps between the coupling halves

are equal. Repeat this procedure, tighten-

ing each side of the coupling successively

until the fasteners are torqued to the values

listed in Table C. Check to ensure the gaps

between the coupling halves are equal.

Loosen and adjust if necessary. See Figure

Operating Parameters

TABLE C:

COUPLING BOLT TORQUE VALUES

Screw Size HP Ranges Torques

 M6x20 Upto5 10ft.-lbs.

M8 x 20 5 to 10 23 ft.-lbs.

M10 x 25 15 to 30 46 ft.-lbs.

8. Remove adjusting fork and be certain the

pump shaft can be rotated by hand. If the

shaft cannot be rotated or it binds, disas-

semble and check for misalignment.

9. Replaceadjustingforkandsecuretopump

housing.

10. Replacethetwocouplingguards.

Freeze Protection

If the pump is installed in an area where freezing

could occur, the pump and system should be

drained during freezing temperatures to avoid

damage. To drain the pump, close the isolation

valves, loosen the air vent screw and remove the

drain plug at the base of the pump. See Figure

8. Do not replace the drain plug or tighten the air

vent screw until the pump is to be used again.

Figure 5

Figure 6

Figure 7

Figure 8

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Regular Check-Ups

Atregularintervals,dependingontheconditionsandtimeofoperation,thefollowingchecks

should be made:

1. Pump meets required performance and is operating smoothly and quietly;

2. There are no leaks, particularly at the shaft seal;

3. The motor is not overheating;

4. Removeandcleanallstrainersorltersinthesystem;

5. Verifythetrippingofthemotoroverloadprotection;

6. Check the operation of all controls. Check until control cycling twice and adjust if necessary;

7. If the pump is not operated for unusually long periods, the unit should be maintained in ac-

cordance with these instructions. In addition, if the pump is not drained, the pump should be

manually rotated or run for short periods of time at monthly intervals.

If the pump fails to operate or there is a loss of performance, refer to the Troubleshooting

Section. Troubleshooting

WHEN WORKING WITH ELECTRICAL CIRCUITS, USE CAUTION TO AVOID

ELECTRICAL SHOCK. IT IS RECOMMENDED THAT RUBBER GLOVES AND BOOTS

BE WORN, AND METAL TERMINAL BOXES AND MOTORS ARE GROUNDED

BEFORE ANY WORK IS DONE.FOR YOUR PROTECTION, ALWAYS DISCONNECT

THE PUMP FROM ITS POWER SOURCE BEFORE HANDLING.

Preliminary Tests

Supply

Voltage

Operating Parameters

How to Measure

By means of a volt meter, which

has been set to the proper scale,

measure the voltage at the pump

terminal box or starter.

On three-phase units, measure

between the legs (phases).

What it Means

Whenthemotorisunderload,thevoltage

should be within ±10% of the nameplate

voltage. Larger voltage variation may

cause winding damage.

Large variations in the voltage indicate

a poor electrical supply and the pump

should not be operated until these varia-

tions have been corrected.

If the voltage constantly remains high or

low, the motor should be changed to cor-

rect the power supply.

Current

Measure How to Measure

By use of an ammeter, set on the

proper scale, measure the current

oneachpowerleadattheterminal

box or starter. See motor name-

plate for amp draw information.

Currentshouldbemeasuredwhen

the pump operating at constant

discharge when the motor is fully

loaded.

What it Means

Iftheampdrawexceedsthelisted service

factoramps(SFA)orifthecurrentunbal-

anceisgreaterthan5% between each leg

of three-phase units, check the following:

1. Burned contacts on motor starter;

2. Loose terminals in starter or terminal box or

possible wire defect. Check winding and in

sulation resistances;

3. Too high or low supply voltage;

4. Motor windings are shorted;

5. Pump is damaged causing a motor overload.

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Insulation

Resistance

Troubleshooting

Diagnosing Specic Problems

Problem Possible Cause Remedy

The pump does

not run Check for voltage at motor terminal box. If

no voltage at motor, check feeder panel for

tripped circuits and reset circuit.

Turn off power and remove fuses. Check for

continuity with ohmmeter.  Replace blown

fuses or reset circuit breaker. If new fuses

blow or circuit breaker trips, the electrical in-

stallation,motorandwiresmustbechecked.

Check for voltage on line and load side of

starter. Replace burned heaters or reset.

Inspect starter for other damage. If heater

trips again, check the supply voltage and

starter holding coil.

Energizecontrolcircuitandcheckforvoltage

attheholdingcoil.If no voltage,checkcontrol

circuitfuses.Ifvoltage,check holding coil for

shorts.Replacebadcoil.

Check all safety and pressure switches

for operation. Inspect contacts in control

devices. Replace worn or defective parts

or controls.

Turn off power and disconnect wiring.

Measure the lead to lead resistances with

ohmmeter(RX-1).Measureleadtoground

valueswithohmmeter(RX-100K).Record

measured values. If an open or grounded

winding is found, remove motor and repair

or replace.

1. No power at motor.

2. Fuses are blown or

circuit breakers are

tripped.

3. Motorstarteroverloads

are burned or have

tripped out.

4. Starter does not ener-

gize.

5. Defective controls.

6. Motor is defective.

How to Measure

Turnoffpoweranddisconnectthesup-

ply power leads in the pump terminal

box.Usinganohmormegaohmmeter,

setthescaleselectortoRx100Kand

zero adjust the meter.

Measure and record the resistance

between each of the terminals and

ground.

What it Means

Motors of all HP, voltage, phase

and cycle duties have the same

value of insulation resistance.

Resistance values for new mo-

tors must exceed 1,000,000 ohm.

If they do not, motor should be

repaired or replaced.

L-LM-TL-001_LM,LP I&O_0611.indd 10 6/8/2011 8:50:38 AM

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