DT OOKLET Hz Pumps Motors ISO ompany Pumping Solution
ontents Product data Introduction pplications Features and benefits Type key Operating conditions Other versions on request Function LE ontroller for to pumps LE V ontroller for to pumps Pump Motor Shaft seal Performance range onstruction onstruction Dimensions and weights Flange dimensions System components Materials LR, LRI, LRN,,,, and Materials LR, LRN,, and Installation Mechanical installation Electrical installation Performance curves LR LR LR LR LR LR LR LR LR LR Dimensions and weights ooster set with pump ooster set with pump ooster set with pump Diaphragm tank Diaphragm tank selection
Product data Introduction Lubi booster sets consist of to identical vertical multistage (LR) pumps mounted in parallel on a common base frame, control cabinet with motor protection and integrated LE series controller. These pumps are automatically operated according to system requirement by means of pressure switches (one for each pump). The setting of the pressure switches have to be within the optimal performance area of each pump model. utomatic operation of one or more pumps with VFD control is optional. booster sets are supplied as complete, preassembled and tested systems including suction and discharge manifolds, isolating valves, nonreturn valves, pressure gauge and pressure switches. To ensure stable operation the booster set must be fitted with a suitable diaphragm tank. To select the size of the diaphragm tank see section Diaphragm tank selection at page. pplications Lubi booster sets are designed for the transfer and pressure boosting of clean water for community water supply, apartment complex, hotels, hospitals, industries, commercial buildings, schools, etc. Features and benefits The stateoftheart features introduced into this new vertical multistage pump generation offer the following benefits: High efficiency Low NPSH ir handling Spacer coupling Sleeve sealing Minimized energy cost Improves suction capability Reduces risk of dryrunning llows easy disassembly of motor from pump (for kw motor onwards) Provides high resistance to pressure pulses and withstands temperature fluctuations as well as external forces nd/or Tungsten carbide bearings Reinforced shaft lock ring Wear resistance, improved dryrunning capability and handling of thermal shocks enable longer operating time Strong axial locking force and high torque lock system enable robust and reliable operation of rotating assembly LE Type key Example Type G SS LR x V /G : See System components /L : See System components /N : See System components Pump Pressure switch NonReturn valve Pressure gauge Isolating valve SS: Onoff control VF : VFD control for pump VF : VFD control for pumps VF : VFD control for pumps VF : VFD control for pumps Number of pumps Pump type Fig. pressure boosting system Voltage/frequency Nonreturn valves can be fitted on the suction side on request.
Product data Operating conditions The maximum suction lift (H) can be calculated as follows: H =. m NPSH of the pump other suction losses a safety margin of. metres. Maximum inlet pressure Power range DOL starting SD starting Power supply : : : : Flow range Operating pressure Liquid temperature mbient temperature Maximum suction lift (H): Other versions on request The following versions are available on request: ooster set with jokey pump ooster set with LRI,,,,, pumps Different material combination see chapter System components Singlephase power supply: x V, Hz Threephase power supply: x V, Hz Starting configuration other than standard Hz. Function When a tap is opened, water is taken from the diaphragm tank. Then the pressure drops to the first cutin pressure, and the first pump is cut in. s the consumption rises, more pumps will be cut in until the performance of the pumps in operation corresponds to the requirement. When the water consumption falls, the discharge pressure rises to the cutout pressure and the LE ontroller cuts out one pump. s the consumption falls, more pumps will be cut out. Please see fig. which explains how the pumps will operate based on consumption of water. Example: with pumps utin utout H Pr Pr Pr Pr Pr Pr One pump in operation : : : : : Up to m³/h max. bar to + to +. bar Up to kw per pump Up to. kw to kw x V, Hz. Two pumps in operation Three pumps in operation Fig. Operation with cutin and cutout ascade Step ΔPressure Q LE ontroller for to pumps The Lubi LE ontroller supervises a given number of mainsoperated pumps. The LE ontroller offers the following features/functions: ttractive control box with a dust proof & water proof IP protection & lockable key. ascade control, only the required number of pumps are in operation at any time. Highly reliable magnetic motor contactors. Single phase prevention & overload motor protection. Dry run protection & low pressure protection. Delay & minimum run timers to eliminate unnecessary pump cycle. Manual operation. Pump ON & pump Fault indication. utomatic alternation (changeover) of lead pump to ensure equal run time of all pumps. t the heart of the controller is a PL controller with. olour Touch Screen Display (HMI) to programme the system as per the customer site requirement. LE V ontroller for to pumps LE V ontroller is a premium series state of the art controller which offers all the features mentioned above of LE ontroller. This controller is additionally equipped with a Variable Frequency Drive (VFD) for customer required quantity of pumps. Following are the additional features with VFD ontroller. pressure transducer connected on the discharge manifold, provides a continuous feedback to the VFD to either increase or decrease the speed of the pump, to provide constant pressure during varying flow condition. These means that when demand for water reduces, the pump speed reduces which in turn reduces energy consumption. These feature provides the benefit of lower energy consumption to the customer. The Variable Frequency Drive also provides a smooth, ramp up of speed when the pump motor is started. These drastically reduces the starting current requirement for the pump motor. It also reduces wear and tear on motor bearings & pump rotating components. LE V ontroller also provides a special feature which is called Zero Flow/Demand to avoid unnecessary running of pump motor at very low speeds. Whenever there is no demand of water there is a small leakage loss thru faucets which is detected by the controller and it shuts down the pump motor to save energy. When the pump motor is shut down the leakage losses as mentioned above are supplied by the water from the hydro pneumatic tank. Once the pressure in hydro pneumatic tank falls below a preset condition, the controller will start one of the pump shortly to boost up the pressure in the hydro pneumatic tank. When the usage of water increases, again the controller will detect this and will start operating in a normal condition.
Product data Motor Pump head Outer sleeve Tiebolts ase Impellers Fig. LE V ontroller display for to pumps Protection pressure switch or a level switch at the suction side can be used as dryrunning protection. When the water level or pressure has been restored, automatic or manual resetting is possible. Time control To adapt the booster set operation to the actual conditions, the following settings can be made with the touch screen display: Startup delay : Prevents simultaneous startup of all pumps. Stop delay : Prevents simultaneous stop of all pumps. fterrun delay: Keeps pumps in operation for few seconds, after cutout pressure is reached. Time control is particularly convenient to reduce the number of starts and stops per hour, to prevent water hammer and negative pressure in the suction manifold as well as other problems that can arise under certain conditions. Pump The LR pumps are nonselfpriming, vertical multistage centrifugal pumps. The pump consists of a base and a pump head. The chamber stack and the outer sleeve are secured between the pump head and the base by means of tiebolts. The base has suction and discharge connections on the same level (inline). ll pumps are equipped with a maintenancefree mechanical shaft seal. Fig. LR pump Motor These pumps are fitted with a totally enclosed, fancooled, pole motor with principal dimensions in accordance with the EN/IE and DIN standards. Electrical tolerances according to EN /IE. Electrical data Mounting designation Insulation class Efficiency class Enclosure class Supply voltage (Tolerance: ±%) Supply frequency Up to kw: V From. kw: V F EFF IP For P :. to kw x / V For P : to kw x V Hz Motor protection ll motors are protected by the control panel of the booster set. Threephase motors from kw upwards have a builtin thermistor (PT) according to DIN. Singlephase motors have a built in thermal overload switch. Shaft seal s standard the LR pump is fitted with a QV shaft seal (ellow type). Shaft seal QV Description Oring (ellow), arbon/si, FKM Max. Temperature range [ ] to +
Product data Performance range Q (USgpm) Hz ISO nnex LR LR LR LR LR LR LR LR LR LR Q (m /h) Q (l/sec) Q (l/min)
DELT onstruction onstruction is built up on a common base frame. The pumps are fixed to the base frame by means of bolts. The control cabinets are divided into three groups based on construction. Systems with the control cabinet mounted on the pump base frame. Systems with the control cabinet mounted on a separate base frame. Systems with the control cabinet without a base frame, therefore suitable for floor mounting. For further information, see the paragraph Dimensions. discharge manifold is mounted on the discharge side of the pumps. n isolating valve and nonreturn valve are mounted between the discharge manifold and the individual pumps. The nonreturn valve may be mounted on the suction side on request. suction manifold is mounted on the suction side of the pumps. n isolating valve is mounted between the suction manifold and the individual pumps. Dimensions and weights Dimensions and weights for are stated on pages to. Please note that the dimensions stated may very ± mm and that all systems are supplied without vibration dampers. The dimensions may vary according to the technological improvements of the components and/or materials used. Flange dimensions PN flanges D D D S Standard: EN PN (. Mpa) Nominal diameter (DN) DN D D D S x x x x xx System components Fig. System components Pos. Description Qty. Versions G L N ontrol panel Metal, painted Metal, painted Metal, painted Panel stand Galvanized steel Galvanized steel. (ISI ) Suction manifold Galvanized steel. (ISI ). (ISI ) Isolating valve per rass Nir plated rass Nir plated. (ISI ) pump or cast iron or cast iron and cast iron ase frame Galvanized steel/painted Galvanized steel/painted. (ISI ) Nonreturn valve per rass Nir plated rass Nir plated. (ISI ) pump or cast iron or cast iron Discharge manifold Galvanized steel. (ISI ). (ISI ) Pump LR LRI LRN Diaphragm tank s per customer requirement
onstruction Materials LR, LRI, LRN,,,, and LR LRI, LRN Designation Materials EN/DIN ISI/STM EN/DIN ISI/STM Pump head ast iron ENGJL ENJL STM ENJL STM Pump head cover Stainless steel. F M eq. to ISI Shaft Stainless steel. ISI ISI.. ISI ISI Impeller Stainless steel. ISI. (LRI). (LRN) ISI (LRI) ISI (LRN) hamber Stainless steel. ISI. (LRI). (LRN) ISI (LRI) ISI (LRN) Outer sleeve Stainless steel. ISI. (LRI). (LRN) ISI (LRI) ISI (LRN) Oring for outer sleeve EPDM or FKM ase ast iron ENGJL (LR)/ Stainless steel (LRI/LRN) ENJL STM. F M eq. to ISI Neck ring PTFE Rubber parts EPDM or FKM Materials LR, LRN,, and Designation Materials EN/DIN LR ISI/STM EN/DIN LRN ISI/STM Pump head ast iron ENGJS (LR)/ Stainless steel (LRN) ENJS STM. F M eq. to ISI Motor stool ast iron ENGJL ENJL STM ENJL STM Shaft Stainless steel. ISI. Impeller Stainless steel. ISI. ISI hamber Stainless steel. ISI. ISI Outer sleeve Stainless steel. ISI. ISI Oring for outer sleeve EPDM or FKM ase ast iron ENGJS (LR)/ Stainless steel (LRN) ENJS STM. F M eq. to ISI Neck ring arbongraphite filled PTFE earing ring ronze ottom bearing ring T/T Rubber parts EPDM or FKM
Installation Mechanical installation Location The booster system must be installed in a wellventilated room to ensure sufficient cooling of the control cabinet and pumps. Note: is not designed for outdoor installation and must not be exposed to direct sunlight. The booster system should be placed with a metre clearance in front and on the two sides for inspection and removal. Pipework rrows on the pump base show the direction of flow of water through the pump. The pipework connected to the booster system must be of adequate size. The pipes are connected to the manifolds of the booster system. To optimize operation and minimize noise and vibration, it may be necessary to consider vibration dampening of the booster system. Noise and vibration are generated by the rotations in the motor and pump and by the flow in pipework and fittings. The effect on the environment is subjective and depends on correct installation and the state of the remaining system. If booster systems are installed in blocks of flats or the first consumer on the line is close to the booster system, it is advisable to fit expansion joints on the suction and discharge pipes to prevent vibration being transmitted through the pipework. Pos. Description Expansion joint Pipe support Vibration damper Note: Expansion joints, pipe supports and vibration dampers shown in the fig. are not supplied with a standard booster system. ll nuts should be tightened prior to startup. The pipes must be fastened to parts of the building to ensure that they cannot move or be twisted. Foundation The booster system should be positioned on an even and solid surface, such as a concrete floor or foundation. If the booster system is not fitted with vibration dampers, it must be bolted to the floor or foundation. Note: s a rule of thumb, the weight of a concrete foundation should be. x the weight of the booster system. Dampening To prevent the transmission of vibrations to building, it is advisable to isolate the booster system foundation from building parts by mean of vibration dampers. Which is the right damper varies from installation to installation, and a wrong damper may increase the vibration level. Vibration dampers should therefore be sized by the supplier. If the booster system is installed on a base frame with vibration dampers, expansion joints should always be fitted on the manifolds. This is important to prevent the booster system from hanging in the pipework. Electrical installation The electrical installation should be carried out by an authorized person in accordance with local regulations. The electrical installation of the booster set must be carried out in accordance with enclosure class IP. Make sure that the booster set is suitable for the electricity supply to which it is connected. Make sure that the wire crosssection corresponds to the specifications in the wiring diagram. Note: The mains connection should be carried out as shown in the wiring diagram. Fig. Schematic view of hydraulic installation
Performance curves with LR Q (USgpm) LR Hz ISO nnex LR LR LR LR LR LR Q (m /h) Q (l/sec) Q (l/min)
Performance curves with LR Q (USgpm) LR Hz ISO nnex LR LR LR LR LR LR Q (m /h) Q (l/sec) Q (l/min)
Performance curves with LR Q (USgpm) LR Hz ISO nnex LR LR LR LR LR LR Q (m /h) Q (l/sec) Q (l/min)
Performance curves with LR Q (USgpm) LR Hz ISO nnex LR LR LR LR LR LR LR Q (m /h) Q (l/sec) Q (l/min)
Performance curves with LR Q (USgpm) LR Hz ISO nnex LR LR LR LR LR LR Q (m /h) Q (l/sec) Q (l/min)
Performance curves with LR Q (USgpm) LR Hz ISO nnex LR LR LR LR LR Q (m /h) Q (l/sec) Q ( l/min )
Performance curves with LR Q (USgpm) LR Hz ISO nnex LR LR LR LR LR Q (m /h) Q (l/sec) Q (l/min)
Performance curves with LR Q (USgpm) LR Hz ISO nnex LR LR LR LR Q (m /h) Q (l/sec) Q (l/min)
Performance curves Q (USgpm) with LR LR Hz ISO nnex LR LR LR LR Q (m /h) Q (l/sec) Q (l/min)
Performance curves with LR Q (USgpm) LR Hz ISO nnex LR LR LR LR LR Q (m /h) Q (l/sec) Q (l/min)
Dimensions & weights pumps ooster set with pump H HQ DELT L Fig. Dimensional sketch of a booster set with a control cabinet centred the base plate H HQ DELT L Fig. booster set with a control cabinet mounted on the same base plate as the pumps H HQ DELT L LQ Fig. booster set with a control cabinet mounted on a separate base plate
Dimensions & weights ooster set with pump Pump type LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR Supply voltage [V] xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv Motor [kw]................................................................ Manifold connection R R R R R R R R R R R R R R R R R R R R R R ½" R ½" R ½" R ½" R ½" R ½" R ½" R ½" DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN L LQ Design : booster set with a control cabinet mounted on the same base plate as the pumps. Design : booster set with a control cabinet centred on the base plate. Design : booster set with a floormounted control cabinet. Design D: booster set with a control cabinet mounted on a separate base plate. Dimensions may vary by ± mm. pumps H HQ Weight [kg] Design
Dimensions & weights pumps ooster set with pump H HQ DELT L Fig. booster set with a control cabinet mounted on the same base plate as the pumps H HQ DELT L Fig. booster set with a control cabinet mounted on the same base plate as the pumps H HQ DELT L LQ Fig. booster set with a control cabinet mounted on a separate base plate
Dimensions & weights pumps ooster set with pump Pump type Supply voltage [V] Motor [kw] Manifold connection L LQ H HQ Weight [kg] Design LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv................................................................ R R R R R R R R R R R R R R R R R R R R R R ½" R ½" R ½" R ½" R ½" R ½" R ½" R ½" DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN Design : booster set with a control cabinet mounted on the same base plate as the pumps. Design : booster set with a control cabinet centred on the base plate. Design : booster set with a floormounted control cabinet. Design D: booster set with a control cabinet mounted on a separate base plate. Dimensions may vary by ± mm.
Dimensions & weights pumps ooster set with pump H HQ DELT L Fig. booster set with a control cabinet mounted on the same base plate as the pumps H HQ DELT L LQ Fig. booster set with a control cabinet mounted on a separate base plate H HQ DELT L LQ Fig. booster set with a floormounted control cabinet
Dimensions & weights ooster set with pump Pump type LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR LR Supply voltage [V] xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv xv Motor [kw]................................................................ Manifold connection R ½" R ½" R ½" R ½" R ½" R ½" R ½" R ½" R ½" R ½" R ½" R ½" R ½" R ½" R ½" R ½" R ½" R ½" R ½" R ½" R ½" DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN DN L LQ Design : booster set with a control cabinet mounted on the same base plate as the pumps. Design : booster set with a control cabinet centred on the base plate. Design : booster set with a floormounted control cabinet. Design D: booster set with a control cabinet mounted on a separate base plate. Dimensions may vary by ± mm. pumps H HQ Weight [kg] Design
Diaphragm tank Diaphragm tank selection To ensure stable operation, the booster set must be installed in combination with an adequate diaphragm tank. The size of the obligatory diaphragm tank can be calculated by means of the following formula: Q x x ( + (utin) + Δp) V = x x n max x Δp V = Tank volume [litres] Q = Mean flow [m³/h] Δp = Difference between cutin and cutout pressure utin = utin pressure (lowest) [bar] k = onstant for diaphragm tank precharge pressure: k =. nmax = Max. numbers of starts/stops per hour The diaphragm tank precharge pressure is set to. times the lowest cutin pressure. k The diaphragm tank may also be selected on the basis of the below tables in which the following values have been used: Motors up to and including. kw: Motors above. kw: Diff. between cutin and cutout: n = to n = to Δp =. [bar] Lubi pumps and motors are not subject to any particular limitations as they are tested up to start/stops per hour. However when dimensioning the diaphragm tank volume the following parameters may also be considered: Maximum number of start/stops per hour allowed by local regulations Maximum number of start/stops per hour described by the system designer Temperature and ventilation conditions vailable space for diaphragm tank installation. Minimum diaphragm tank volume [litres] at Δp =. [bar] and n max = : Pump type utin [bar] utin [bar] Minimum diaphragm tank volume [litres] utin [bar] utin [bar] utin [bar] utin [bar] utin [bar] utin [bar] LR LR LR LR LR LR LR LR LR LR Minimum diaphragm tank volume [litres] at Δp =. [bar] and n max = : Pump type utin [bar] utin [bar] Minimum diaphragm tank volume [litres] utin [bar] utin [bar] utin [bar] utin [bar] utin [bar] utin [bar] LR LR LR LR LR LR LR LR LR LR Note: Refer to the cutin pressure closest to the lowest setting of the selected booster set.
NOTE
Lubi Submersibles Limited. +, +, + Joppa House next to lma Hotel, Kitengela along NamangaNairobi Sales Enquiries: info@damwotechengineering.com, sales@damwotechengineering.com www.lubipumps.com Product Improvement is a continuous process at LUI. The data given in this publication is therefore subject to revision.