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    Grundfos Submersible Pump Installation and Operating Instructions

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    Taj Deluria
    Installation and Operating Manual for Grundfos Type SP Stainless Steel Submersible Pump

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    Grundfos Submersible Pump Installation and Operating Instructions

    Uploaded by

    Taj Deluria
    626 views8 pages
    Installation and Operating Manual for Grundfos Type SP Stainless Steel Submersible Pump

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    © © All Rights Reserved

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    Installation and Operating Manual for Grundfos Type SP Stainless Steel Submersible Pump

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    Download as pdf
    626 views8 pages

    Grundfos Submersible Pump Installation and Operating Instructions

    Uploaded by

    Taj Deluria
    Installation and Operating Manual for Grundfos Type SP Stainless Steel Submersible Pump

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    Download as pdf
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    _GRUNDFos £1 Installation and Operating Instructions for Submersible Pumps of Stainless Steel DELIVERY GRUNDFOS SUBMERSIBLE PUMPS are delivered from the factory packing in which they should remain Until they are to be installed. During unpacking and) ‘must be taken when handling the pump to ensure that misalignment does not occur due to bending. The motors are fitted with a motor cable somewhat lon- than the pump, to which the submersible drop cable is to be connected. ach pump is supalied with a set ot loose data plates which should be fied at the borehole head or near the motor starter, PREPARATION Before installation, the following checks should be made: 1. Liquid in Motor ‘The submersible motors are factory-filled with a special anti-freeze liquid and are ready for operation, See »Checking of Liquid in Motor« before the submersible pump is installed. 2. Eloctiity Supply ‘The motor voltage. phase, and frequency details given on the motor nameplate should be compared with the actual electricity supply available. 3. Cable ‘The insulation sheaths of the motor cable and the submersible drop cable should be checked for damage. Instructions in joining the submersible drop cable and the motor cable are supplied with each cable termination kit 4, Pump/Borehole The iside diameter ofthe borehole shouldbe checked to ensure that itis not smaller than the minimum borehole onthe: nical data sheets foreach pump type ‘ameter ofthe borehole should also b ‘ad to ensure that the riser pipe plus twice the dlameter of the cable joint is larger than the outside diameter of 9 tests, a check should be made that Byojected instalation depth ensures that the water Tevel is always at least 1:metre above the pump inlet dung operation. If the pump is installed close to the bottom of the borehole or the filter and there is no water flow past the motor, measures should be taken to ensure a flow of water past the motor, which cools the motor and pre- Vents the deposit of sand and mud around the motor. CHECKING OF LIQUID IN MOTOR | la 4°, 6" and 8” submersible motors are factory-filed with a special anti-freeze liquid (down to - 20° C). If there are visible signs, eg. leaking out into the packing, whi show that the motor may have lost a considerable amount of liquid, the liquid in the ‘motor should be checked and, ifnecessary, the motor must be refilled If the motor is insufficiently filled, there may be problems with the starting of the if the installed depth is more than 30 metres below water level TOA ‘carried out as described below. or if the motor has been totally drained, then special anti- 023 iquid must be used to refill the motor. Otherwise clean water may be Used for refiling ee GRUNDFOS Submersible Motors 4” Place the submersible pump in Such a postion that the stud fitted wit the filing screw (is at the same level as the top point of the motor (2) fg. A. The the fling plug should be removed. With a filing syringe ha fu le"mocted into the mator fvough te fig Boy untdf stas running out around the motor state Ter the diaphragm built into the motor will force liquid back into the filing syringe. If the liquid is free of air, t correctly filed with hquid If there are air bubbles in the liquid, continue fo inject igud unt itis free of air bubbles. Replace the screw in the filing plug and tighten securely before changing the position of the pump, which is now ready for installation. GRUNDFOS Submersible Motors 6” and 8 Checking of iquid in motor and possible refiling Check the uid eve by retiling the motor. Use clean water for reiling {never use dated water) Refi fhe motor through one of fe priming pug holes by means ofa filing syringe ora similar device, see fig. Refilingis carried out as follows 1" Stand the submersible motor upright shaft end uppermost) wit the Bottom of the motor on the ground ‘ake care not to dirty the bottom of the motor. as the dlaphragm opening may be blocked. 2. Remove ane of the two priming plugs. 3 Fill the syringe with clean water. Inject water into the motor unt it Stars running out of the hole. Gently hammer on the side of the motor with rubber mallet to remove possible air Continue to inject water, 4 Cover the plug witha sealing compound. Replace the plug and tighten Securely, Filling an empty motor with liquid Fine etor es been totaly drained fil the motor with special GRUNDFOS ant Filing is carried out as follows 1. Stand the submersible motor upright (shaft end uppermost), withthe bottom of the motor on the ground. Take are not fo dirty tre bottom ofthe motor, as the claphragm opening may be blocked. Remove one ofthe priming plugs inthe top of the motor. fig. C Remove the box nut from th filing valve inthe bottom of the motor, fig. C, and fit the hose from the hand pump or the lke to the filing Valve, 3/8" extemal thread Pump liquid into the motor until the liquid ‘motor witha rubber mallet to remove poss Cover the plug witha sealing compound. Replace the plug and tighten securely Remove the hose of the hand pump and eft the box nut. No sealing compound s required. asthe filing valve has Suit non aun valve. Pe hand pump fo ling can be replaced bya hone of 3m ited up over he motor ‘he liquid can then be pouredinto the motor through the hose. Priming/vent plug Filing valve 1g out of the hole is free of air. Gently hammer on the side of the oo 2 oN INSTALLATION The pump is now ready and the installation may begin. Ifthe diameter of the riser pipe is different to that of the pump outl pump or the compression coupling/steel pipe to avoid corrosion ‘The pump should only be gripped by means of the four flats on the valve casing at the top of the pump when pipes or nipples are being fitted and under no circumstances must the body of the pump or motor be clamped. This is also ‘applicable during installation when the pipe clamps must be used on the riser pipe and not on the pump body. Due to its slim design, the pump must not be exposed to bending stress whilst being raised from the horizontal to the verti cal position or whilst itis being lowered into the borehole. I pumps with 6” or 8° motors are installed in a horizontal position, the motor cable entry must be uppermost. RISER PIPE For the smaller pumps, pel (polythene) pipes may be used, and the pump should be partially supported by means of a stainless steel straining wire. For the larger pumps, threaded or flanged steel pipes should be used. Where the flanged pipes are used, the flanges should be slotted to take the submersible drop cable, the water level gauge hose, and the borehole electrode ca- bles. The threaded joints must be well cut and fit together tightly so ensure that they do not work loose when sub- Jected to the torque reaction caused by the stopping and starting of the electric motor, It is recommended that a Jointing compound, such as Hermetite is used The thread on the first section of the riser pipe, which is to be screwed into the pump, should not be longer than the threads in the valve casing at the top of the pump. Whenever a connection is made between threaded pipes and pel pipes, a compression coupling with a cone should be used. It a stainless steel straining wire is required for lowering and lifting the pump, it should on all 4 pumps (#100 mm) be fastened to the discharge chamber as shown on fig. 0. Maximum wire dia. meter @ mm. On the rest of the pump types, the wire should be fastened to a fitting between the pump and the ‘compression coupling When the last section of the riser pipe has been installed, the wire should be slackened so much that it becomes unloaded to ensure that the pump is in vertical position, Care must be taken when lfting the pump and drawing in the wire that the pump remains vertical {At the borehole head the wire should be fastened to a suitable support and sufficient length should be left so that the pump can be removed easily at a later date ‘The submersible drop cable from the starter, the water level electrode cables, and the water level gauge hose, it fitted should be strapped to the riser pipe by means of rubber cable clips. The first ones just above and just below the cable joint, and then at 3 metre intervals, see »Cable Fitting When flanged pipes are used, cable clips should be fitted above and below each flange joint. When pel pipes are used, some slackness must be left in the cables and the hose to the water level gauge. This, should equal 2% of the total length of the riser pipe, which is equivalent to 6 cm ifthe cable clips are positioned at 3 ‘metre intervals, This slackness is very important as pel pipes expand when loaded. Use only new elastic cable clips as damage to the cable can be caused if old clips which have lost their are used. Make sure that the submersible drop cable and the hose to the water level gau way damaged when the pipe is being lowered into the borehole. ‘When the pump has been installed to the required depth, the installation should be finished by means of the borehole seal or pipe clamps supported by the foundation, ‘The stainless steel straining wire should be locked by means of the wire locks to the foundation or the borehole seal For pumps fitted with pel pipes without a straining wire, the expansion of the pipes must be taken into consi- ‘eration when deciding on the installation depth of the pump. ‘The water level gauge and the water level electrodes should be fitted in accordance with the separate instructions ‘accompanying these accessories. ‘The riser pipe can now be connected to the delivery pipe and the submersible drop cable can be connected to the motor starter. See »Electrical Connections. CABLE FITTING ‘The GRUNDFOS set of cable clips can be supplied with any pump and should be used for fitting the submersible drop cable and the plastic hose for the water level gauge, if fitted. ‘The set, part No. 1150 16, consists of 7.5 metres of rubber band and 16 buttons. The number of sets required is proportional to the size and length of the riser pipe. Cable clips should normally be fitted every 3 metres. the bush should be of the same material as the asticity re not cut or in any other ‘Submersible drop cable to and including 19 mm diameter, fig. E. ‘Cut off the rubber band so that the piece at the end with no slit becomes as long as possible, then in- sert a button in the first slit. Position the hose to the water level gauge, if fitted along side the sub- mersible drop cable and directly against the riser pipe. Keep the end of the rubber band free of the hose, so that itis not kinked or restricted, and wind the band tightly twice around the riser pipe and the cable. Push the nearest slit over the button and then cut off the band. ‘Submersible drop cable with a diameter greater than 19 mm, fig. F. Cut off the rubber band so that the piece at the end with no slit becomes as long as possible, then insert a button in the first slit Position the end of the band against the cable and put the water level hose on top of the rubber band. Wind the band tightly twice around the riser pipe and submersible drop cable, taking care not to crush the water level hose. Push the nearest slit over the button and then cut off the band, ELECTRICAL CONNECTION The electrical connection should be carried out by an authorized electrician in accordance with local regulations and the diagrams for the motor protection, starter and control components used. The GRUNDFOS 4”, 6° and 8° submersible motors are wound for direct-on-line starting (DOL), and the starting Current is up to 5 times the full load current, see appropriate data sheet, Due to the low moment of inertia of both pump and motor, and the loading characteristics of the pump, the run-up time is approx. 0.1 sec. Direct-on-line starting is therefore normally approved by the electricity supply authorities, butifa reduction of the starting current is required, autotransformer starters can be used, The voltage, phase, and frequency details, together with the full load current of the motor appear on the motor nameplate. Both motor and pump details are given on the plates supplied with the pump, one of which should be fitted at the top of the borehole or next to the motor starter. Direction of Rotation ‘GRUNDFOS 4° of rotation for SP 5, SP 10 and SP 25 pumps is shown in fig. A. 3 of rotation for all other submersible pumps is given in fig. B (GRUNDFOS 4”, 6” and 8” SUBMERSIBLE MOTORS three-phase For three-phase motors, connection. R-S-T to1-2-3 will produce direction B and RS 2 will produce direction A. The colours of the four leads in the motor cable (flat cable) are as follows: lack, 2= blue, 3=brown, 4 =yellow/green. The colours of the three single leads in the motor cable (possibly with a separate earth lead) are as follows: 4” submersible motor 1 = black, 2 =red, 3=yellow. 6” submersible motor. 1 =black,2=yellow, 3 =red, GRUNDFOS submersible motors, type MS 400 and type MS 401, stamped single-phase should be connected in accord- ance with the diagram shown in the instructions for the ‘motor type in question B Control box, type SA-SPM 1, is used for motor, type MS 400, Control box, type SA-SPM 2, is used for motor, type MS 401 ‘Submersible motor, type MS 401, has a fixed direction of rota- tion B, Therefore, it cannot be used for SP 5, SP 10.and SP 25, ‘SUBMERSIBLE MOTORS stamped three-phase cannot be altered for single-phase operation, ‘The pump must only be started to check the direction of rotation when itis completely submerged. ‘Severe damage will be caused if the pump/motor is run dry. MOTOR PROTECTION ‘Three-phase submersible motors must be connected to an effective quick-tripping motor starter which must protect. \d the cable against damage from voltage drop, phase failure, overload, and a locked rotor. ‘Single-phase GRUNDFOS submersible motors require no motor starter, but should be connected to a GRUNDFOS. control box or GRUNDFOS capacitor box The ampere scale of the overload unit should cover the range from 0.8 to 12 times the motor full load current. The overload unit fitted to the starter must trip out in less than 10 seconds at a locked rotor (starting current), from cold. If the overload characteristic does not meet this requirement, the motor guarantee will be invalidated. Manually Operated Motor Starters should always be preferred and must be used where variations in voltage are larger than + 10%. For automatic start/stop, by a remote control, etc, a separate contactor should be used in conjunction with the manually operated motor starter. If there is a defect in the separate contactor, such as burnt or welded contacts, the tripping effect of the overload unit is not affected. Thus it affords the motor far better protection Magnetic Motor Starters can be used where the voltage is constant, or where short variations in voltage, if any, are smaller than = 10%. Itis advisable to protect the motor by means of a phase failure/undervoltage relay. If the contactor fails to trip, due to welded contacts, the magnetic motor starter does not afford the motor any protection Lightning ‘Three-phase GRUNDFOS submersible motor In addition to the motor starter and overload unit, the installation may be fitted with a special overvoltage protection device, which protects the ‘motor against voltage surges which may be caused by lightning. However, the overvoltage protection device does not protect against direct stroke of lightning, but it does afford protection against voltage surges caused in the power lines when lightning strikes somewhere in the area. The overvoltage protection device should be connected on the supply side of the motor starter. The overvoltage protection device must be connected in accordance with local regulations, and the voltage stamped on it should correspond to the voltage between phase and earth For GRUNDFOS 4” SUBMERSIBLE MOTORS, a special cable termination kit with a built in overvoltage protection device is available. (See separate instructions on cable jointing). For 6” and 8” submersible motors, the protection is built into the motor starter. 3 eo eo SETTING OF MOTOR STARTER To ensure the best possible protection of the submersible motor, the setting of the motor starter should be carried out as follows: The overtoad unit should first be set to 0.9 times the motor full load current Ifthe overload unit does not trip out af half an hour's operation, it should be set down until the tripping point is reached. From this point the unit should adjusted up by 5%. If the starter trips out at the setting of 0.9 times the full load current, check voltage and current if the voltage is Correct and the current consumption is less than the stated full load Current, set the overload up unti the tripping point is reached and then it should be adjusted up by 54. thigh ambient temperatures (over 50° C), a new adjustment might be necessary. START-UP \Wherrthe pump has been installed, the following check of the direction of rotation should be carried out. 1. Shut off the discharge valve until the pump is giving approximately 1/3 of its maximum volume of water. 2. Start the pump and take @ reading of the head and water quantity, 3. Stop the pump and interchange two of the phases to the motor at a convenient point. 4. Start the pump and take a reading ofthe head and water quantity 5. Stop the pump. Compare the results taken under points 2 and 4, and the connection which gives the larger head or quantity of water is the correct direction of rotation, ‘The single-phase units should automatically oper in the starters or control boxes. ‘The check for the direction of rotation for three-phase units should last for the shortest possible time. When the motor has been connected correctly, the pump should be started with the discharge valve still closed off to approximately 1/3 of maximum output. nth impurities in the water, the valve should be opened gradually as the water becomes clearer. The pump should not be stopped until the waters clean. It the water is clean when the pump is started, the valve should be opened slowly until its fully open. As the valve is being opened, the draw down should be checked to ensure that the pump always remains submerged ‘The dynamic water level should always be at least 1 m above the inlet strainer of the pumps. IMPORTANT: Exact setting of the motor starter should be carried out as described abov. the correct direction, provided they are connected as shown OPERATION AND INSPECTION ‘The pump must not be operated when the delivery vaive Is shut off, otherwise the motor will overheat. Depending on the number of hours of operation of the pump, the following should be checked at suitable intervals: Quantity of water - delivery pressure - draw down - starting frequency - control and protective devices. If any of the above checks reveal any abnormal operating details, with the fault finding chart ispection should be carried out in accordance FAULT FINDING CHART ‘A. No electricity supply Contact the electricity supply authorties about the power failure, 1. The fuses are blown, ‘Replace the blown fuses. Ifthe new ones blow 100, the @ectn netala: tion, the motor and the cable shouldbe checked C. The motor starter overload has tripped out 1D. The magnetic coll nthe motor star terfeontactoris shor eveuted [Not eutting For singlephase ‘motors poms DLE. F. see sepa = The contactsin the motor sarter/ ‘contactor are detective. ‘Rese he sarer overload Wi ips out aga the valage should be check edit tetis ot For three-phase motors - see item 1 0.6 Forsingle-phase motors see separate instruction for GRUNDFOS Control box or GRUNDFOS capacitor box ‘Replace the col, Check the col votage. Replace the contacts FF. The contol circuit has cut out or selective G. The water level electrodes lifted may nave stopped the pump, due to ow water love H, Motor/submersibe cable are Select [A. Nowater or t0 low water level inborehole '. The non-setun valves blocked is its shut postion . The strainers choked vp ‘Check the contol cvcut and the contact Sute switch level siteh ete) Check the water level. See 38 and 48 (Check motor and cable Check that the water level during operation is t least 1m above the suction iterconnector ofthe pump. 1150, the wate’ Suppy i ok ull ou the pump and replace or repar the valve Pull ov the pump and clean the strainer inthe suction inerconnector 1D. The pumps defective ‘A. Wrong direction of rotation 'B The draw down i larger than anvoppotes Pullout, dismante, clean and check the pump Any defective parts should be replaced ‘See sEectical Connection. direction of rotation ‘Check the draw down during operation and compare with the borehole tnd pump data Increase the wstalanon depth ofthe pure. Throte the pump of replace ‘twat a smaller modelo obtan & males capacity The valves in the diacharge pipe ate party shut blocked 1. The discharge pipe is party choked by mpuries (ochre) ‘Overhaul the valves ‘Measure the aischarge head and compare wah the calculated data Clean o replace the ascharge pipe, or replace the pump by one with 3 larger discharge head , The non-return valve ofthe pump 'spanty blocked, The pump and the riser pipe are party choked by impurities (octe) Pullout the pump, and replace or repair the valve, Pall out, diamante, lean, and check the pump. Any detective parts should be replaced Clean ihe pipes G.The pump is defective A. The itferentia of the pressure Sitch between the start a too pressures i 00 small Pall oun, Gamante, Gean, and check the pump. Any defective part should be replaced Increase the efferent However, the top pressure must not exceed the The electrodes to the aviomatc ‘water level gauge oF the level ‘utchos nthe reservow ate otinstalled correctly The non retumn valve leaking or stuck hal open The volume of arin the pressure eis 00 smal “Adjust the intervals of the eectrodes/the level switches to ensure @ Sable me Between the cutting sn and euting out ofthe pump, ‘See the installation and operating isttuctions forthe avtomatc devices It the intervals between st0p/stat cannot be changed atthe automatic Sevces, the pump capacity may be reduced by throttling the dacharge Pullout the pump, and replace or repair the non-return vane. Pump in av uni the volume of ar a at pressure approx 2/3 ofthe total volume ofthe pressure tank Pressure tank’ diaphragm tank 10 small [A Leakagein the pipework The capacity by replacing or ‘he pressure tank’ daphragm tank should be increased ing with an adtonal tank. Chock and repair the pipework 8. The rise pipe is defective Pall out the pump, repair or eplace the rise pipe. The non-return valve defective, Seoae CHECKING OF MOTOR AND CABLE 1. Supply voltage ‘On three-phase systems measure by means ofa voltmeter, the votage be tween tho phases. For single-phase ‘motors between phase and neutral Connect the voltmeter tothe terminals inthe motor starter The voltage should, when the motor is loaded, be within + 10% ofthe declared voltage. The motor may burn if there are large variations in volage. I the voltage is constantly t00 high oF too low, the motor must be re- placed by one comtesponding tothe supply voltage Large varatons in votage indicate poor electricity supply, and the pump should be stopped unt the defect has been found Re-settng ofthe motor starter may be necessary Measure the current of each phase ile te pump is operating at 3 con tant decharge Mead possible atthe capacty whee fe meta most Rea lyloaded) For normal operating cent se data ‘The variation n current in all vee phases should not exceed I0¥ ofthe ow. fost valuo. Ii does, ol the current exceeds the ful load Curent there the folowing possible faults “me contacts ofthe motor starter ara burt (Replace the contacts or the

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