Aquasub engineering AQUA GROUP AQUATEX AV Series User manual

AQUASUB ENGINEERING
TUDIYALUR POST, COIMBATORE - 641034
TEL : 0422 - 2642484, E-mail : [email protected]
Website : www.aquagroup.in
VERTICAL MULTISTAGE HIGH PRESSURE PUMPS
AV, AVI, AVN SERIES
OPERATION MANUAL

CONGRATULATIONS
Thank you for your purchase of 'AQUATEX' Vertical multistage high
pressure pump. You are proud owner of new generation high pressure pump. It
is designed and manufactured with stringent quality control to give trouble free
service for years. Please follow the instructions given in this manual to install
and maintain 'AQUATEX' high pressure pump to get the best possible and highly
reliable operation. Utilise the services of a qualified technician for installation.
Please inform the name plate details i.e. serial number of the pump,
type of pump etc. when you order for spare parts in the future.
After reading this operation manual, keep it safe and easily accessible,
so that it can be referred to whenever information is needed while operating
the equipment.
DESIGN
'AQUATEX' Vertical multistage high pressure centrifugal In-Line pumps
(AV,AVI & AVN Series) are non self priming pumps of In-Line design. Flange or
with Victaulic coupling with equally sized suction and discharge ports.
Stage construction with Stainless Steel impellers, diffusers and outer
tube, pump shaft and motor shaft are of IEC Standards. All wetted parts of
pump are made of high grade corrosion resistant Stainless Steel SS304/SS316
and highly suitable to use in R.O systems for drinking water. All pumps are
equipped with cartridge type mechanical seal for easy maintenance and
minimum down time in case of replacement.
'AQUATEX' Vertical multistage high pressure centrifugal In-Line pumps
are driven by Totally Enclosed Fan Cooled (TEFC) high efficiency AC Induction
motors.
APPLICATIONS
PRESSURE BOOSTING AND WATER SUPPLY : Pressure Boosting in residential
apartments, Commercial high rise buildings, IT Parks, Hotels, Hospital and
Colleges. Pressurized water supply in Process and Food industry and for Fire
fighting and HVAC System.
WATER TREATMENT : Pumping water in Reverse Osmosis Systems (RO), Water
Softeners and Ultra-filtration systems.
IRRIGATOIN : Sprinkler Irrigation for Golf Courses, Sports Stadiums and
Agricultural fields.
INDUSTRY : Boiler feeding and Industrial Washing / Cleaning System.

CUT SECTION VIEW AND SPARE PARTS LIST
AV-1,3,5,10,15,20 AVI, AVN-1,3,5,10,15,20
AV-32,45,64,90 AVI, AVN-32,45,64,90
44
57
48
82
36
37
18
12
24
59
36
37
56
18
12
24
59
44
57
38
82
62
53
36
48
14
37
57
18
12
24
82
42
59
53
36
48
14
62
37
57
18
12
24
82
42
59

CUT SECTION VIEW AND SPARE PARTS LIST
AV-120,150
AVI, AVN-120,150
P.No.
AV, AVI, AVN -
1,3,5,10,15,20
AV, AVI, AVN -
32,45,64,90
AV, AVI, AVN -
120,150
12 Diffuser Assembly Bowl
14 - Bearing ring -
17 - - Bearing ring
18 Impeller
24 Neck ring
36 Motor bracket Top casing
37 Shaft
42 - Bottom bearing ring
48 Outer tube
53 - Motor bracket
56 Top casing* - -
57 Mechanical seal
59 Inline casing
62 Base Inline casing
62A - - Base
82 O ring for outer tube
*Only for AVI and AVN models
57
12
17
18
42
82
62A
62
59
24
48
37
36
53
57
12
17
18
42
82
62A
53
36
37
48
24
59

INSTALLATION PRECAUTIONS
PRODUCT INSPECTION
Inspect the purchased pump for damage or leakage during
transportation. And make sure all bolts and nuts are tightened
properly.
TYPICAL INSTALLATION
A typical installation diagram is shown below. Please
follow the given installation precautions before and during
installation.
Pump should be positioned as shown in figure-A. Pump
should be installed in a protected environment, not
exposed to weather. Provide sufficient space around the
pump for motor cooling and accessibility, refer figure-B.
AB
No. Description
1 Pipe support: Support piping system properly to avoid stresses on connections.
2
Isolating valves: Install isolating valves for easy access- before the pump intake and after
the pump discharge.
3
Use flexible piping on both input and output sides of the pump to reduce vibration and
transmission of noise.
4
Check valves will prevent return flow of pumped liquid when pump is stopped, reducing
the danger of pump damage.
5Control Panel: Use high quality components. Make sure that the panel conforms to local
standards and regulations.
6Do not place elbows next to the pump intake and discharge.
7If pump needs to be operated with isolating valve closed, install a by-pass line to avoid
damaging the pumping system.
1
6
7
233421
5

GENERAL INSTALLATION PRECAUTIONS
Do not use this pump for sandy water, oil, toxic, acetic, corrosive and
inflammable liquids. Pumping inflammable liquids could cause
explosion. Warranty is void, if pump is used for other than clear cold
water.
The pump must be fixed firmly by bolts through the holes in the flange
or base plate.
Use good quality pump accessories (Non Return Valve, nipple, pipe,
ball valve, etc..) for better performance and trouble free operation.
If you find damage or discrepancy in the product, contact the dealer
where the pump was purchased or the "AQUASUB ENGINEERING's"
sales office in your area.
No. Description
8
If it is necessary to increase the diameter of the suction pipe, place an eccentric reducer
between the isolating valve and the flexible pipe section.
9
Using elbows will increase the flow resistance. Wide bends will result in lesser flow
resistance.
10 The piping must have a level or positive gradient to prevent the formation of air pockets.
11
The diameter of the drop pipe must be bigger than the diameter of the pump’s suction
port.
12 Use a foot valve in case of negative suction head.
13 Size pump for correct head.
14
Place the intake of the suction pipe so that the intake is always submerged to prevent
entry of air.
15
Install a compound gauge at the pump suction and a pressure gauge at the pump
discharge.
8
9
9
10
10
11
12
13
13
14
14
15 15

ELECTRICAL PRECAUTIONS
OPERATION PRECAUTIONS
MAINTENANCE
Use good quality electrical accessories for safe operation and
electrical accessories must be sufficient rated. Consider local
regulation before commencing electrical installation.
Provide proper earthing. Do not connect the earthing wire to water
pipe, lightening rod or telephone earth wire. Improper earthing could
cause electrical shock.
Overload protection should be provided and to avoid the possibility of
dry running, it is strongly recommended to install dry running
protection device.
Warranty is void for coil failure and capacitor failure, if pumpset is
not operated in the prescribed Voltage range..
Start the pump in discharge valve closed condition, slowly open the
discharge valve and ensure the smooth and noiseless working. If
there any disturbance in operation re-prime the pump.
Check the current drawn by the motor. If necessary, adjust the
setting of the thermal relay. (Thermal relay is provided in single
phase 0.5HP and 1.5HP only).
Switch off the power supply and ensure the motor fully stopped,
before changing rotation or making any other adjustments.
Do not run the pump dry, it could lead to mechanical seal damage
and product damage. Warranty is void if pump is not operated in
the prescribed operating range.
Disconnect the power supply before starting maintenance or
inspection of the pump to avoid electrical shock.
For uninterrupted performance, planned maintenance and
inspection are indispensable. Please follow below guidelines while
maintaining or inspecting the pump.
Priming : Pump should be filled by clear cold water before start-up.
Ensure that the pump is fully filled by water without air pockets. If air
pockets trapped in the pump, adjust the air screw to release trapped
air.

COUPLING ADJUSTMENT
If the motor is fitted with grease nipples, then the motor should be
lubricated with high temperature lithium-based grease.
If the pump and motor are not used frequently with long intervals of
non-operation, then it is recommended that the motor to be greased.
Follow the steps shown in figure for coupling adjustments
AV, AVI, AVN – 1, 3, 5 SERIES

COUPLING ADJUSTMENT
AV, AVI, AVN - 10,15,20 SERIES

COUPLING ADJUSTMENT
AV, AVI, AVN - 34, 45, 62, 90, 120, 150 SERIES

TROUBLE SHOOTING
If you find any trouble during operation of the pump,
please follow the guidelines to overcome some of the
troubles given below.
Fault Probable cause Possible Solution
Pump does not run
when the motor
starter is activated.
a. Supply failure or no power supply.
Check connections or restart the power
supply.
b. Main contacts in motor starter are not
making contact or the motor coils are
defective
Reconnect or replace contacts or magnetic
coil.
c. Pump or auxiliary circuits protection
fuses blown.
Replace fuses.
d. Pump or piping system may be
obstructed causing a jam.
Clean the obstruction and restart pump.
e. Motor may have failed. Replace the motor.
f. Motor protector or thermal relay has
tripped out.
Reset the motor or thermal protector.
g. Tripping of anti-dry running protection.
Check the water level in the tank or the
water system pressure. If everything is in
order, check the protection device and its
connection cables.
Starter overload
trips immediately
when the power is
switched on.
a. Overload setting is too low. Set the motor starter correctly.
b. The cable connection is loose or faulty. Fasten or replace the cable connection.
c. One fuse is blown. Replace fuse and try starting again.
d. Pump is jammed by an obstruction Check and clean obstruction from system.
e. Contacts in overload are faulty. Replace motor starter contacts.
f. The motor winding is defective. Replace the motor.
g. Low voltage(Especially at peak time) Check the power supply.
The pump starts
but, after a short
time, the thermal
protector trips out
or the fuses blow.
a. The voltage is not within the motor’s
operating limits.
Check the operating conditions of the
pump.
b. The control panel is situated in an
excessively heated area or is exposed to
direct sunlight.
Protect the control panel from heat sources
and from the sun.
c. A phase in the power supply is missing. Check the power supply.
The pump starts up
but, after a
period of time, the
thermal protector
trips.
a. Worn out motor bearings causing motor
to overheat. Replace motor bearings.
b. The pump’s delivery rate is higher than
the specified rate on the pump nameplate.
Partially close the isolating valve located
discharge side until the delivery rate
returns to within the specified limits.
c. There are obstructions inside the pump
or pumping system.
Disassemble and clean the pump and
piping.
d. Less viscous liquids may cause the motor
to work too hard and overload the motor,
causing the motor to overheat.
Check the actual power requirements
based on the characteristics of the liquid
being pumped, and replace the motor
accordingly.

TROUBLE SHOOTING
Conduct trial operation after maintenance or inspection.
Dispose replaced components with appropriate care, to save
environment.
For unsolvable troubles in the pump, contact the dealer where this
pump was purchased or the "AQUASUB ENGINEERING's" sales
office in your area for specialized service.
Do not try to solve unspecified troubles of pump, as it may lead to
severe damage to the pump or personal injuries.
Fault Probable cause Possible Solution
Pump runs but no
water delivered.
a. Pump is not primed with liquid. Fill the pump with the liquid to be pumped.
b. The pump, suction or discharge pipes are
blocked by solids in the liquid being pumped. Clean the pump, suction or discharge pipe.
c. The foot or check valve is blocked or has
failed.
Replace the foot or check valve.
d. The suction pipe leaks. Repair or replace the suction pipe.
e. The air is in the suction pipe or pump. Remove trapped air from system.
f. Motor operating in wrong direction (three-
phase motor).
Change the direction of rotation of the
motor by reversing motor connections.
The pump capacity
is not constant.
a. The pump draws in air or the inlet
pressure is too low.
Improve the suction conditions.
b. The pump or the suction side of the piping
system partly blocked by foreign bodies. Clean the pump or suction pipe.
The system's general
protection cuts in
Short circuit. Check electrical system.
The pump rotates
in the wrong
direction when
switched off.
a. The foot or the check valve has failed. Check and replace check valve or foot
valve.
b. Leakage in the suction pipe. Repair or replace the suction pipe.
The frequency of
Pump start-up is
too high.
a. Leakage in the foot valve, check valve or
system.
Repair or replace the components.
b. Ruptured membrane or no air pre-charge
in surge tank.
See relevant instructions in surge tank’s
manual.
Vibration and noise
a. Cavitation
Reduce the required flow or improve the
operating conditions of the pump (suction
conditions, head, flow resistance, liquid
temperature, viscosity,…etc.).
b. Make sure that pump and motor shafts
are properly aligned. Adjust the pump and/or motor shafts.
c. Worn motor bearings. Replace the bearings or the motor.
d. Operation with frequency converter. Consult a qualified engineer form the
supplier of the frequency converter.
e. Check vibration and noise damping
devices Replace vibration & noise dampers, if worn.

WARRANTY DECLARATION
WARRANTY CARD
(Please retain this for your personal record)
Authorised Dealer's seal Name & Signature of Authorised Dealer
Product Name & Model No. ....................... Serial No............................................
Name and Address of dealer ………...............……....................................................
Bill No. ........................................... Date of Purchase............................................
WARRANTY FOR VERTICAL MULTISTAGE HIGH PRESSURE PUMP
AQUASUB ENGINEERING warrants to the purchaser of this AQUATEX product, that for a period of
12 months commencing from the date of purchase of the product. Aquasub Engineering will
repair or replace free of charge any part or parts of the product, should AQUASUB ENGINEERING
be fully satisfied in its sole discretion, that the defect/s is / are due to faulty material or
workmanship only. The warranty will be governed by the following clauses:
1. Only AQUASUB ENGINEERING or their Authorised Service Agent / Dealer will repair / replace
all parts that are failing due to faulty material or defective workmanship pertaining to the above
product.
2. Only Aquasub Engineering or its Authorised Service Agent / Dealer can service / repair or
attend to install / reinstall the above product.
3. All expenses incurred in collecting the units or parts thereof from the Authorised Service
Centre or the Dealer of Aquasub Engineering as well as expenses incurred in connection with
deputing of service personnel / technicians towards to and fro travel conveyance and other
incidentals etc., will be borne by the customer.
4. The warranty extended therein is in lieu of all implied conditions and warranties under the law
and is confined to the repair or replacement of defective parts and does not cover any
consequential or resulting liability, damage or loss arising from such defects. Furthermore, the
warranty in no case, shall extend to the payment or any monetary consideration whatsoever, of
the replacement or return of the product as a whole.
5. The warranty is issued subject to jurisdiction of Coimbatore Court of Law.
6. The warranty is covered by Force Majeure clause. In the event if the above product
is struck by any natural calamity, this warranty stands null and void.
This Warranty is not valid in case of any of the following events.
a. This Pump is not used according to the instructions given in this Operation manual.
b. If the electrical power supply voltage is not within the stipulated norms. Coil burning due to
low voltage or overload.
c. Any repair work / alteration / installation carried out by a person other than Aquasub
Engineering Service Centre / Service Agent / Dealer.
d. The serial Number is deleted, defaced or altered.
e. Mechanical seal failure and other failures due to dry running of the pump.
f. Failure of accessories other than supplied pump.

AQUASUB ENGINEERING
TUDIYALUR POST, COIMBATORE - 641034
TEL : 0422 - 2642484, E-mail : [email protected]
Website : www.aquagroup.in
OTHER BUILDING SERVICES PRODUCTS
Hydropneumatic Pumping System
Domestic Booster System, Water Transfer, Sewage, Drainage,
Construction Dewatering and
Vertical Inline High Pressure Pumpsets.
AV-118/00 06-2016