KSB Monosub R User manual

Submersible openwell monobloc pumpsets - MONOSUB R

MONOSUB R
Index
Sr.No. Contents Page No.
1. Introduction 1
2. General 1
3. Erection and commissioning 1
3.1 Water filling of motor 1
3.2 Safety Instructions 2
3.3 Electrical checks 2
3.3.1 Insulation Resistance Test 2
3.3.2 Earthing 2
3.3.3 Cable and cable jointing 2
3.4 Non Return Valve : 3
3.5 Lowering the pumpset 3
3.6 Pump set installation and
delivery pipe connection 4
3.7 Starters/Control Panel 5
4. Starting the pump set 5
5. Trouble Shooting 6

MONOSUB R
Index
Sr.No. Contents Page No.
1. Introduction 1
2. General 1
3. Erection and commissioning 1
3.1 Water filling of motor 1
3.2 Safety Instructions 2
3.3 Electrical checks 2
3.3.1 Insulation Resistance Test 2
3.3.2 Earthing 2
3.3.3 Cable and cable jointing 2
3.4 Non Return Valve : 3
3.5 Lowering the pumpset 3
3.6 Pump set installation and
delivery pipe connection 4
3.7 Starters/Control Panel 5
4. Starting the pump set 5
5. Trouble Shooting 6

1. Introduction
This pumpset must be operated within the limit values specified for
the medium handled, capacity, speed, density, pressure,
temperature and the motor rating. The name plate on pump
indicates the type of pump size, main operating data and Works
Order No. as Sr. No. Please quote this information in all queries,
repeat orders and when ordering spare parts
2. General
These maintenance free open well submersible mono-bloc
pumpsets are noise less in operation, environmental friendly and
have high operating efficiency resulting in lower power
consumption. No foundation or pump house arrangements are
required.
For trouble-free, satisfactory operation, installation should be
properly done and maintained.
3. Erection and commissioning
3.1 Water filling of motor
The motor is to be filled with potable water just before
installation. For this remove the two eyebolts fitted on the
top of the motor. Fill sufficient quantity of water inside the
motor and wait for a few minutes till all the air trapped
inside comes out. Top up further till water overflows and
then fit the two eyebolts. Do not operate the Pump set
under any circumstances without water, as this will cause
extensive damage to the parts of the pump.
1
3.2 Safety Instructions
3.2.1 Do not use the motor cable to lift or lower the pump set.
3.2.2 Do not run the pump set in dry condition. The pump set
must always be fully submerged in water during operation.
3.3 Electrical checks
3.3.1 Insulation Resistance Test
Once the motor is filled with water, check insulation
resistance with a 500 volts megger. A minimum of 50
megaohms insulation resistance should be shown w.r.t.
motor casing.
3.3.2 Earthing
Earthing of the motor should be done properly. i.e., body of
motor shall be earthed by two separate and distinct
connections to earth.
3.3.3 Cable and cable jointing
A proper size cable should be used, additional cable should
be connected as per the procedure given below and that the
cable joint should be water tight.
a. To connect the cables, cut off and strip the pump cable
and joining cable in a staggered form at regular intervals.
b. The colors of the leads which are to be joined together
must be identical.
c. Wrap insulation tape to each cable joint and again wrap
with rubber tape on the top of it.
2
MONOSUB RMONOSUB R

1. Introduction
This pumpset must be operated within the limit values specified for
the medium handled, capacity, speed, density, pressure,
temperature and the motor rating. The name plate on pump
indicates the type of pump size, main operating data and Works
Order No. as Sr. No. Please quote this information in all queries,
repeat orders and when ordering spare parts
2. General
These maintenance free open well submersible mono-bloc
pumpsets are noise less in operation, environmental friendly and
have high operating efficiency resulting in lower power
consumption. No foundation or pump house arrangements are
required.
For trouble-free, satisfactory operation, installation should be
properly done and maintained.
3. Erection and commissioning
3.1 Water filling of motor
The motor is to be filled with potable water just before
installation. For this remove the two eyebolts fitted on the
top of the motor. Fill sufficient quantity of water inside the
motor and wait for a few minutes till all the air trapped
inside comes out. Top up further till water overflows and
then fit the two eyebolts. Do not operate the Pump set
under any circumstances without water, as this will cause
extensive damage to the parts of the pump.
1
3.2 Safety Instructions
3.2.1 Do not use the motor cable to lift or lower the pump set.
3.2.2 Do not run the pump set in dry condition. The pump set
must always be fully submerged in water during operation.
3.3 Electrical checks
3.3.1 Insulation Resistance Test
Once the motor is filled with water, check insulation
resistance with a 500 volts megger. A minimum of 50
megaohms insulation resistance should be shown w.r.t.
motor casing.
3.3.2 Earthing
Earthing of the motor should be done properly. i.e., body of
motor shall be earthed by two separate and distinct
connections to earth.
3.3.3 Cable and cable jointing
A proper size cable should be used, additional cable should
be connected as per the procedure given below and that the
cable joint should be water tight.
a. To connect the cables, cut off and strip the pump cable
and joining cable in a staggered form at regular intervals.
b. The colors of the leads which are to be joined together
must be identical.
c. Wrap insulation tape to each cable joint and again wrap
with rubber tape on the top of it.
2
MONOSUB RMONOSUB R

d. To ensure proper insulation once again wrap with tape
and rubber tape for each joint. Finally wrap the total
cable with insulation tape.
3.4 Non Return Valve
Non Return valve is mandatory for high head pumpset at
delivery side to protect from water hammering problem.
3.5 Lowering the pumpset
Lower the pumpset using suitable chains / ropes. For this
make use of two eye bolts provided for horizontal
installation/suspension The pumpset can also be suspended if
the bottom of well is likely to be clogged ( clearance for the
pump suction due to slush in the well).Delivery pipe should
be properly supported so that weight of pipe is not
3
GL GL
Control Panel Delivery Pipe
Rod For Hanging
Rope
(Optional)
anchored on the pump. To prevent damage to the cable
during handling and operation see that it is properly
anchored and fastened to the delivery pipe.
3.6 Pump set installation and delivery pipe connection
a. Connect the bend to the suction flange of the pump so
that it should be in vertical position.
b. Fit the strainer at the inlet of bend to prevent the entry of
foreign particles.
c. Connect the delivery pipe to the delivery flange.
d. Tie steel or nylon rope to the two Eyebolts provided on
the body and lower the pump set along with the delivery
pipe.
e. Clamp the 3 core cable to the delivery pipe with cable
clips at regular intervals.
f. Allow the pump to rest on the bottom or it can be kept
hanging in horizontal condition.
4
MONOSUB RMONOSUB R
Insulation Tape Rubber Component
Insulation TapeRubber Component
Red Yellow Blue

d. To ensure proper insulation once again wrap with tape
and rubber tape for each joint. Finally wrap the total
cable with insulation tape.
3.4 Non Return Valve
Non Return valve is mandatory for high head pumpset at
delivery side to protect from water hammering problem.
3.5 Lowering the pumpset
Lower the pumpset using suitable chains / ropes. For this
make use of two eye bolts provided for horizontal
installation/suspension The pumpset can also be suspended if
the bottom of well is likely to be clogged ( clearance for the
pump suction due to slush in the well).Delivery pipe should
be properly supported so that weight of pipe is not
3
GL GL
Control Panel Delivery Pipe
Rod For Hanging
Rope
(Optional)
anchored on the pump. To prevent damage to the cable
during handling and operation see that it is properly
anchored and fastened to the delivery pipe.
3.6 Pump set installation and delivery pipe connection
a. Connect the bend to the suction flange of the pump so
that it should be in vertical position.
b. Fit the strainer at the inlet of bend to prevent the entry of
foreign particles.
c. Connect the delivery pipe to the delivery flange.
d. Tie steel or nylon rope to the two Eyebolts provided on
the body and lower the pump set along with the delivery
pipe.
e. Clamp the 3 core cable to the delivery pipe with cable
clips at regular intervals.
f. Allow the pump to rest on the bottom or it can be kept
hanging in horizontal condition.
4
MONOSUB RMONOSUB R
Insulation Tape Rubber Component
Insulation TapeRubber Component
Red Yellow Blue

3.7 Starters/Control Panel
Connect supply leads, pump set leads to the panel board
according to the connection diagram. Keep panel board in a
waterproof shelter. For all the 3 Phase pumpsets we
recommend the use of starters with built in thermal overload
and single phasing preventors. For pumps upto 5.5 Kw Direct
On Line (DOL) starters are recommended Above 7.5Kw
star/delta starters are recommended.
All Single Phase pumpsets are to be used with control panels
supplied along with pumps.
4. Starting the pump set
4.1 Single phase pumpsets
Press green button on panel board and hold only for 3
seconds. Continuous pressing of ON push button will damage
motor windings due to overheating. Minimum time interval
between “ON – OFF “ should be 5 minutes.
4.2 Three phase pumpsets
3-phase pumps sets can be started in the normal mode.
Check that motor current, flow and head are within the Name
plate values
The pump set is to be run at least once a week to prevent
possibility of jamming of the moving parts Thus pump is ready
for operation at all times.
5 6
5. Trouble Shooting
Problem Probable cause Possible remedy
Motor does
not Rotate
The clearances between
impeller and casing are
clogged with foreign
particles.
No power supply
Low voltage or single
phasing conditions
Control panel not
functioning because
protective devices inside
panel are activated. For
single phase panels the
capacitor could be faulty
Low voltage / speed low
Dismantle and remove
obstructions
Check power supply, and
panelBoard connections
as per Connection
diagram
Operate only within
voltages range specified
on Name plate and
ensure balanced 3-phase
supply.
For single phase panel
Replace capacitors, if
found defective.
Check supply voltage
and operate only if
supply conditions are
healthy
MONOSUB RMONOSUB R

3.7 Starters/Control Panel
Connect supply leads, pump set leads to the panel board
according to the connection diagram. Keep panel board in a
waterproof shelter. For all the 3 Phase pumpsets we
recommend the use of starters with built in thermal overload
and single phasing preventors. For pumps upto 5.5 Kw Direct
On Line (DOL) starters are recommended Above 7.5Kw
star/delta starters are recommended.
All Single Phase pumpsets are to be used with control panels
supplied along with pumps.
4. Starting the pump set
4.1 Single phase pumpsets
Press green button on panel board and hold only for 3
seconds. Continuous pressing of ON push button will damage
motor windings due to overheating. Minimum time interval
between “ON – OFF “ should be 5 minutes.
4.2 Three phase pumpsets
3-phase pumps sets can be started in the normal mode.
Check that motor current, flow and head are within the Name
plate values
The pump set is to be run at least once a week to prevent
possibility of jamming of the moving parts Thus pump is ready
for operation at all times.
5 6
5. Trouble Shooting
Problem Probable cause Possible remedy
Motor does
not Rotate
The clearances between
impeller and casing are
clogged with foreign
particles.
No power supply
Low voltage or single
phasing conditions
Control panel not
functioning because
protective devices inside
panel are activated. For
single phase panels the
capacitor could be faulty
Low voltage / speed low
Dismantle and remove
obstructions
Check power supply, and
panelBoard connections
as per Connection
diagram
Operate only within
voltages range specified
on Name plate and
ensure balanced 3-phase
supply.
For single phase panel
Replace capacitors, if
found defective.
Check supply voltage
and operate only if
supply conditions are
healthy
MONOSUB RMONOSUB R

Problem Probable cause Possible remedy
Pump Does
not Deliver
Water
Pump
vibrates is
noisy and
drawing
excessive
current
Wrong direction of
rotation
Wrong selection of
Pump
Obstruction in piping
system
Foreign particles lodged
in impeller
Inappropriate pipe
fitting
Motor axial or radial
bearing are damaged or
shaft is bent
Sand inside or
corrosiveness
Rotating parts rubbing
against Stationary parts
because radial bearing
bush is worn out or shaft
is bent.
Check the connection:
For 3-phase pumpsets
interchange any 2 phases
Select proper pumpset
Clean the pipes
Clear the impeller and
casing
Fit the pipes properly
Replace defective
components.
Clean the pump impeller
and bearing components,
replace if needed.
Replace the defective
components
7
MONOSUB R
902
901.01
156
107
920
230
59-47350.01
920.01
421 545.01
81-59
940
384.01 818
350.02
59-1281-60
901.02
905
819
824
545.02
932
400.1
902
920.01
905
920.02
920.02
384.02
59-47
Exploded View - Single Phase
8
MONOSUB R
Part No. Part Name
350.01 Bearing housing
230 Impeller
156 Discharge nozzle
107 Discharge Casing
81-60 Diaphragm Casing
81-59 Stator
59-47 Eye Bolt
59-12 Diaphragm
Part No. Part Name
824 Cable
819 Shaft
818 Rotor
545.01/.02 Bearing Bush
421 Oil Seal
400.1 Washer
384.01/.02 Thrust Plate
350.02 Bearing housing
Part No. Part Name
940 Key
932 Circlip
920.01/.02 Hex Nut
920 Hex lock Nut
905 Tie bolt
902 Stud
901.02 Hex bolt
901.01 Hex bolt