Grindex Proline Tubo User manual

No: 90 056 01 Revision 0 2006.06
Operator’s manual for
submersible drainage
and sludge pumps
PROLINE
www.grindex.com
TUBO
This manual is intended for the following pump types:
• Pumps with single-phase and three-phase motors
• Pumps with and without built-in starter and SMART motor protection system
• Pumps for direct on line (DOL) and star/delta (Y/D) starting of motor

2
2
Pumps with three-phase motor, equipped with motor starter and SMART
(electronic motor surveillance system)
ROTASENSE™
• Ensures that the motor runs with correct rotation only.
PHASE GUARD™
• Stops the pump immediately if one of the three phases in the power supply fails.
TEMPERATURE GUARD
• Protects the motor from overloading, undervoltage, unbalanced loading and overheating.
After cooling down, the pump can be restarted manually by disconnecting and connecting
the power.
Pumps with single-phase motor
A pump with single-phase motor has a built in start relay and capacitors that govern the start
and operation of the motor. The temperature contacts in the auxiliary and main windings of
motor will protect from overheating. If the start relay has tripped because of overheating or start
malfunction, the pump can be restarted manually by disconnecting and connecting the power,
after the pump has cooled down.
Midi, Matador, Semi and Senator pumps
Pumps with built-in starter and SMART protection combined with overload relay that protects
motor from harmful over current situations. Over load relay should be set at 1,1 x rated current
(line current) for DOL start and 0,58 x rated current (phase current) for Y/D start. The over load
relay should be set at automatic mode.
Congratulations on a sound choice!
Your choice of an electrical submersible pump from Grindex has given you a pump that
will serve you well for a long time to come. Grindex pumps are designed and built for
continuous use in demanding working conditions.
The service life of your Grindex pump will depend to some extent on you. If you want
optimal service for the longest possible time, it’s important that you familiarise yourself
with the advice and directions given in these instructions.
With cordial greetings
GRINDEX
Technical Manager
PS If you wish to do your own servicing and repairs, we recommend that you attend one of our service courses and
that you order the workshop manual that has been prepared for use by our service and repair workshops. Ask your
salesman for further information.
Pumps with built-in motor protector . . . . 2
Pumps without built-in motor protector. . 3
How to read the data plate . . . . . . . . . . . 4
Installation and use . . . . . . . . . . . . . 4 - 9
Cable and power supply. . . . . . . . . . . . . 9
Permanent installation . . . . . . . . . . . . . 10
Respect limitations . . . . . . . . . . . . . . . . 10
Trouble shooting. . . . . . . . . . . . . . . . . . 11
Service . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance. . . . . . . . . . . . . . . . . . . . . 12
Storage. . . . . . . . . . . . . . . . . . . . . . . . . 12
Accessories . . . . . . . . . . . . . . . . . . . . . 12
Warm water pumps . . . . . . . . . . . . . . . 12
Conversion of a pump . . . . . . . . . . . . . 12
TABLE OF CONTENTS Page TABLE OF CONTENTS Page

3
3
Tubo 8” and Tubo 12”
Pumps should be equipped with an On/Off
phase shifter switch with an overload relay
and thermal monitoring system.
Midi, Semi, Matador, Senator
Pumps can be supplied with GRINDEX
external starter for DOL or Y/D start. Starter
units feature SMART and overload protection
system.
Maxi
Pumps can be supplied with GRINDEX
external starter for DOL or Y/D start. Starter
units feature phase guard and phase
sequence relay.
Magnum
Pumps can be supplied with GRINDEX
external starter with leakage sensor float
switch in stator housing. Leakage sensor
will stop operation of pump if water leakage
occurs into stator housing. For proper
operation of the leakage sensor, the pump
must stand secured in vertical position.
Following motor starters can be used:
• On/Off switch, thermal overload magnetic circuit breaker/relay and integrated thermal
monitoring system. (For connection of motor thermal contacts circuit T1/T2)
• On/Off switch and thermal overload circuit breaker/relay.
The thermal overload circuit breaker must conform to the rated current and motor input power of
actual pump.
After connection to power, always check that direction of rotation of motor is correct!
The following pumps do not have a built-in starter with motor protector:
(The pumps are equipped with an additional data plate, see page 4)
IMPORTANT
The thermal overload circuit breaker/relay must conform to the rated current and motor power
input of the actual pump. Over load relay should be set at 1,1 x rated current (line current) for
DOL start and 0,58 x rated current (phase current) for Y/D start.
After connection to power, always check that direction of rotation of motor is correct.
Each pump listed above must be equipped with an external motor starter
with protection system.

www.grindex.com S-136 25 Haninge
c/s
Box 538 Sweden
Before use see operator’s manual
4
4
Direction of start reaction
Direction of impeller rotation
Number of phases and
frequency
Rated current
Rated voltage
Pump type No.
Pump model MAJOR N 168111
G 3103
380-415 Y
13,0-12,0
503
7,6
25
40
Maximum submersion depth
Weight
Maximum capacity
Maximum head
Maximum power consumption
Serial No.
45
20m
If you need further technical data, please refer to the relevant product data sheets.
How to read the data plate
Read the manual before
installing the pump
Installation and use
Read this before installing the pump
Check that you have received the right type of pump and that the pump data corresponds with
what you ordered. The simplest way to do this is to check the particulars on the data plate,
which you will find on the main cover.
The rated voltage, rated current and maximum power consumption are particularly important.
On the bases of these data you can check that you have the right power supply and the right
fuse.
Extra data plate for pumps without built-in motor protection

5
5
Insert the plug
The pump
doesn’t start
START
Pull out the plug
and shift two phases
NOTE!
Three-phase pumps equipped with SMART ROTASENSE™ (rotation control). Note the
following at start:
1. 2. 3. 4. 5.
Switch on Shift phases
If the pump still
doesn’t start, call a
qualified electrician
CEE plug
Phase shifter
On/Off switch
Connect the pump to power. If the pump fails to start and the fuses are correct, shift two
phases in the CEE plug or turn the knob on phase shifter to start the pump.
NOTE! Do not reverse phase sequence while pump motor is running. Doing so may cause
temporary incorrect rotation, resulting in damage to motor electronics and rotating parts.
If the pump still doesn’t start, call a qualified electrician and ask him to check the mains
and the junctions.
Advice for trouble free operation of the pump
Connection of a pump to the right outlet of power supply is very important. The short-circuit
protection should be in accordance with the rated data shown on the data plate of the
pump. It is recommended to use time delay fuses rated 1,5 x rated current for the actual
pump.
If the pump is connected to a local power source, the performance of generator set must
be sufficient for start and running of the actual pump. As a thumb rule the max. power kVA
for generator should be 3 x max. power consumption for a DOL direct-on –line started
pump. For a Y/D started pump recommended kVA value for a DOL started pump can be
reduced by 25%. When two pumps are to be driven by the same generator, the actual kVA
value can be multiplied by 1.5. Generator sets can have different characteristics, internal
or external controls, therefore it is always recommended to consult the manufacturer of
generator to find out if the selected generator is capable of operating the pump.
Requirements of the power supply
The variations of voltage must no exceed 5%, the balance between the phases must not
exceed 2%, and the variation of the frequency must not exceed 3Hz.
For trouble free operation of a pump, the above values are measured at the terminal board
of the pump.

6
6
Safety precautions
Study all safety rules and safety requirements. Continue study all other health and safety
rules, local codes and ordinances before moving the equipment.
Transportation
The pumps can be transported in vertical or horizontal positions. Make sure that the pump
can not fall over or come loose.
Installation
Always lift the pump by its carrying handle or lifting eyes, never by the pump cables or the
discharge hose. Use proper lifting equipment when lifting and lower pump down in the pump
station. The heavier pumps must be lifted and lowered down by crane with ropes/chains/
wires suspended in lifting handle or the two lifting eyes of the pump.
Do not let the pump hit hard at the bottom! Make sure that the cables have no sharp bends
and are not stretched or pinched. Pump is frost proof as long as it is operating or immersed
in the liquid.
Storage
For longer periods of storage, flush pump with clean water and leave it in a dry place,
protected from heat. For longer periods it is recommended to turn the impeller every other
months to prevent the shaft seals from sticking together.
Start reaction
Start reaction is counter clock-wise and rotation of
motor is clock-wise when the pump is viewed from top.
Beware!
The start reaction on large pumps can be powerful.
WARNING!
Before attempting any work or handling of the pump, switch off and lock out the power source.
Make sure that eye bolts, carrying handle and their means of attachment are undamaged.
How to install the pump
Begin with a test start
For pumps with built-in motorprotection:
Connect the pump to power. If the pump fails to start and the fuses are correct, shift two phases in the
CEE plug or turn the knob on phase shifter to start the pump. This is also described at page 5.
For pumps with external starter or without built-in motor protection:
Connect the pump to power and check the start reaction. If it’s wrong, the phases need to be shifted on
the output terminal of the starter. (See operator’s manual for the starter)

7
7
How to place the pump in the sump
To obtain maximum capacity and to prevent excessive wear, the pump should be positioned in
one of the following ways so that it doesn’t burrow itself into sand or clay:
Never let the pump
burrow itself into
sand or clay
WARNING!
Never use the cable
for lifting or lowering
the pump.
Hang the pump freely
by a rope or chain
Put the pump into
a cut-down and
perforated oil drum
Place the pump on a
plank, or make a bed
of coarse gravel
Before installing the pump you should attach a rope to the handle and use it for
lowering and lifting the pump. Use lifting chains or wires connected to the eye bolts on
the bigger pumps.

8
8
Avoiding sedimentation
In order to avoid sedimentation when the pumped medium contains solid particles, the velocity of the
medium in the discharge line should be:
Mixture Min. velocity in discharge line
1. Water + coarse gravel 4 m/s (13.1ft/s)
2. Water + gravel 3 m/s (11.5 ft/s)
3. Water + sand
Sand particles < 0.1 mm (0.004 in) 1.5 m/s (4.9 ft/s)
Sand particles < 0.6 mm (0.024 in) 2.5 m/s (8.2 ft/s)
Automatic operation
The pump motor controller system can be equipped with a level regulation system with float
switches. This will prevent unnecessary operation and wear on the hydraulic components.
Cleaning
If the pump has been running in very dirty water, let it run for a while in clean water, or flush it
through the discharge connection. If clay, cement or other similar dirt is left in the pump it may
clog the impeller and sealing, preventing the pump from working.
Hose
The discharge hose connection on the pump can be fitted vertical or horizontal. Fit it so that
there is no sharp bend on the hose. Kinks, sharp bends and pinching of the hose will reduce the
pump capacity.
Pump sump with sedimentation partitions
If you are planning a more permanent installation and the medium that is to be pumped out is
heavily contaminated, it may be a good idea to build a settling pump sump.

9
9
Cable and power supply
Using the right cable and handling it properly will save you from many malfunctions. Treat the
electrical equipment with care. This will prevent both malfunctions and accidents.
• If you use an extension cable, see that it is correctly dimensioned. The longer the cable, the
greater the conductor cross-section you will need in order to avoid voltage drop.
• If you’re drawing your power from your own generator it’s important that it is correctly
dimensioned.
Do not use the Generator set Auto idle function.
WARNING!
If the cable sheath is damaged and the cable is lowered into the water, water may enter into the
junction chamber of the pump. If the cable is damaged it has to be replaced.
WARNING!
If persons are likely to come into physical contact with the pump or pumped media (liquid),
for example on construction sites or farms etc, the earthed (grounded) socket must have an
additional earth-(ground-) fault protection device (GFI) connected.
When pumping near a lake (beaches, ponds and fountains etc) a safety-distance of at least
20 m (65 ft) between the person and the pump is applicable. The pump must never be placed
directly into a swimming pool. If used in connection with swimming pools, special safety
regulations apply.
Strong sunlight may heat up
the cable and cause voltage
drops.
Don’t lay the starting equipment
directly on the ground.
Make sure that junctions
don’t get into the water.
If your cable is too long, don’t
coil it up, since this could
cause cable overheating and
voltage drop.
Connecting pumps in series
In order to achieve higher pumping
heads, you can connect two or more
Grindex drainage pumps in series.

10
10
15 12
Permanent installation Respect limitations
• The pump must not be submerged to more than
20 metres/65 feet. IP-68.
• The temperature of the medium must not
exceed 40°C/103°F
• The pH-value should be between 5 and 8.
When the pump is used in saline or brackish
water where galvanic corrosion may occur, the
pump should be equipped with zinc-anodes.
• The voltage drop in operation must not exceed
5 %.
• Maximum number of starts per hour:
Minex-Major Master-Magnum
Salvador-Super Semi-Senator
• Maximum cable lengths. Excessively long
cables cause voltage drops that can result
in malfunctions. By using a cable of greater
conductor cross section, you reduce the voltage
drop and can therefore increase the cable
length
• Pressure losses. Long or unnecessarily small-
bore hoses give substantial pressure losses.
• The pump may be transported and stored in
vertical or horizontal positions.
Make sure that it can not roll or fall over.
• On certain installations, the sound level of 70
dB may be exceeded.
WARNING!
The pump must not be used in explosive
or fire-risk conditions or for pumping
inflammable liquids.
1. Submersible drainage
or sludge pump
2. Lifting tackle
3. Shut-off valve
4. Non-return valve
5. Hose
6. Base plate / foundation
7. Float switches
8. Alarm high level
9. Level control unit
In order to decide what pump would be best
for a permanent installation, you need to
know the following:
• Type of medium (sludge, abrasive, corrosive, etc.)
• Inflow of liquid
• Delivery head
• Desired pump capacity
• Size of the pump sump
• Size and length of discharge pipe, number of
bends and valves, etc, for calculation of pressure
losses.
WARNING!
Never enter the hand
into the pump housing!

11
11
Trouble shooting
If the pump fails to start, it may be due to
incorrect phase sequence. Proceed as follows:
• Pull out the plug.
• Shift two phases. This is done by turning two
contact pins with a screwdriver
NOTE: Do not take the plug apart.
Other reasons why the
pump won’t run
WARNING!
Always disconnect and lock the power out before
trouble shooting!
Malfunction
Broken cable
Impeller jammed
Motor overheated
Motor breakdown
WARNING!
The pump will restart automatically after a
corrected phase fault or power cut.
NOTE!
Do not reverse phase sequence while pump motor
is running. To do so may cause temporay incorrect
rotation with resulting damages to motor electronics
and rotating parts. Respect the 8 s delay.
CEE plug
Or turn the knob to the opposite position 1, with
an 8 s. delay
Phase shifter On/Off switch
If the pump stops during operation.
The SMART electronic motor protection
(optional) might have tripped.
Try resetting by pulling
and inserting the power
plug, or disconnect and
reconnect the power.
Remedy
The pump is equipped with a
cable of special design which, if
it is damaged, has to be replaced
with a cable of the same type.
This cable can be obtained from
Grindex or our representatives.
NOTE: The rubber seal must
always be replaced when the cable
is changed. Make sure it is of the
right size (see the spare parts list)
to suit the cable you are using.
The cable has to be fitted by an
authorized electrician.
Contact the appropriate
serviceman.
Deal with the cause of the
overheating. Leave the pump to
cool for a few minutes. To start the
pump, again disconnect and then
reconnect the power.
Hand the pump in to an authorised
workshop
The pump starts but the motor protector
trips after a while.
Too low voltage
Strainer or air
valves blocked
Water temperature
exceeds 40°C/103°F
Density or viscosity
too high
Contact a qualified electrician.
Flush the pump clean.
The pump should not be used in
this application.
Consult the distributor or Grindex.
The pump runs but delivers too little water.
Discharge hose
pinched or kinked
Heavy pressure
losses caused by
hose that is too long
or is undersized
Pump has too small
capacity
Worn hydraulic parts
Arrange the hose as straight as
possible.
See that the right hose size is
being used. Shorten the hose if
possible. Change to a larger pump.
Check that the lifting head of the
pump corresponds with the given
data. The easiest way to do this is
to use a pressure gauge.
Choose a pump with a larger
head or connect several pumps in
series.
Hand the pump in for repair and
fine adjustment.

Service
To get the maximum service life out of your
Grindex pump, we recommend that you have it
serviced after every 2.000 running hours.
You can get good and guaranteed service by
handing the pump to your nearest Grindex
workshop. If you prefer to do the servicing
yourself, we refer you to the Grindex Workshop
manual.
Maintenance
Maintenance should be carried out after each
time the pump is used and should cover the
following points:
• Flush the pump clean outside and in. The inside
of the pump is flushed by way of the hose
connection or through the inspection cover (in
the case of sludge pumps).
• Inspect the cable.
Storage
Before the pump is returned to store it should be
put through maintenance as above.
Accessories
For all Grindex pumps there are accessories that
will expand their serviceability.
Level regulator
For automatic operation of pump between preset
water levels, there are special regulators with float
switches available.
Zinc anodes
To protect the aluminium parts of pump from
galvanic corrosion there are sets of zinc anodes
available.
Low suction collar
Fits some of the drainage pumps, enables
pumping to continue down to the floor level.
Conversion kits
Tubo conversion kits are available for some
drainage pumps.
Tandem connection flanges
To increase pumping head, two or more drainage
pumps can be connected in series. For this
purpose, special connecting flanges are available.
Warm water pumps
For pumping warm liquids (70-90° C / 158-149° F)
there are special warm water pumps available.
Conversion of a pump
Some of the drainage pumps come in the
following executions:
(N) normal head, (H) high head and (L) high
flow. The pumps can be converted to another
execution when the pump motor is same. The
various parts are specified in the spare parts list.
WARNING!
If the cable sheath is damaged and the cable is
lowered into the water, water may enter into the
junction chamber of the pump. If the cable is
damaged it must be replaced.
IMPORTANT
Regular inspection and maintenance of the
pump will prolong its service life and ensure
more reliable operation.
The oil in the pump and the discharge head
of the pump should be checked after 2000
hours of operation. A major service of the pump
should be done after about one year under
normal operating conditions.
In severe abbrasive applications,
inspections should be carried out more
frequently.