Marelli AQUAFIT User manual

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A
AQ QU UA AF FI IT T
M
MO ON NO OB BL LO OC C E EL LE EC CT TR RI IC C P PU UM MP PS S
O
OP PE ER RA AT TI IN NG G I IN NS ST TR RU UC CT TI IO ON N
20060 Gessate (MILANO), ITALY / Piazza Aturia, 9
Tel. [phone] /Fax [phone]
www.gruppoaturia.com
Gruppo Aturia S.p.A.

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CHAP./ Par. TITLE PAG.
1 GENERAL DESCRIPTION 4
1.1 Construction Features 4
1.2 Applications 4
1.3 Noise levels 5
2 TRANSPORT AND STORAGE 5
2.1 Transport 5
2.2 Storage 5
3 GENERAL SAFETY INSTRUCTION 6
3.1 General Instructions 6
3.2 Precautions during Operation 6
3.3 Residual Risks 6
4 INSTALLATION 7
4.1 Installation 7
4.2 Electrical Connections 7
5 COMMISSIONING AND STARTUP 8
5.1 Startup 8
6 MAINTENANCE 9
6.1 Ordinary Maintenance 9
7 FAULT FINDING 10-11
8 REPARATION 12
9 SPARE PARTS 13
9.1 Ordering Procedures 13
10 DECOMMISSIONING AND DISMANTLING 13
10.1 Dismantling 13
11 SECTION VIEWS 14-15
CONTENTS

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1) FOREWORD
The purpose of this instruction manual s to ease as much as
possible the installation, operation and servicing of AQUAFIT
monobloc centrifugal pumps. We strongly recommend to
read it attentively and to consult it whenever work is done on
the pump. Inobservance of the instructions here reposted or
improper use of the pump by unskilled personnel may result
in heavy damage to things and/or injuries to the person due
to the presence of moving parts, pressurized fluids and
electrical connections.
MARELLI technical assistance is readily available: for
any doubt or possible problem, please contact us also
by phone.
2) VERIFICATION OF SHIPMENT.
Check the equipment at delivery against the accompanying
documents, paying particular attention to its completeness
and to possible damages occurred during transportation.
The same should be done for any ancillary equipment.
3) WARRANTY AND LIMITATIONS.
The warranty does not include possible damages or failure
caused by mishandling, wrong electrical connections and
incorrect assembling; the warranty also excludes in all
cases remboursements for the equipment or for “major
damage”.
We declines any responsibility for damages to persons
and things due to improper use of the machinery here
described.
Consumables are not subject to warranty.
FOREWORD, WARRANTIES AND LIMITATIONS

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GENERAL DESCRIPTION
1.1 Construction Features
AQUAFIT pumps are centrifugal horizontal pumps coupled by
means of a spindle to a three-phase totally enclosed
asynchronous motor with external ventilation for motor cooling.
Pump casing is provided with fastening feet for pumps with
motor up to size 132; for bigger motor sizes B3/B5, the pump
is without feet.
Sealing in ensured by a mechanical shaft seal.
Typical performances refer to continuous duty with clear water
(specific weight: 1,000 kg/m3) with a manometric suction head
of 2 meters if not otherwise specified.
For higher heads, please contact MARELLI to check for the
pump best suited to the service.
Pump nameplate reports the following data:
- Manufacturer - Head (meters)
- Pump type - Month/year of construction
- Serial number - Break power (in kW)
- Delivery (litres per minute) - Rounds per minute (min-1)
1.2 Applications
AQUAFIT pumps are mainly employed in the following
applications:
- Heating and air conditioning systems.
- Water lifting from lakes, rivers, wells, etc.
- Irrigation system on ground surface or by sprinkling.
- Water supply for small communities or isolated houses.
- Pressure systems.
AQUAFIT pumps should always operate within the following
operating limits:
- Max operating pressure: 10 bar.
- Max liquid temperature: +130˚C
- Min liquid temperature: - 10˚C
- Max ambient temperature: +40˚C
- Max liquid viscosity: 5˚E
- Max n˚of startups/hour: 20 (at regular intervals)
ATTENTION: Condensate may develop inside the motor.
CHAPTER 1

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1.3 Noise levels
The following table reports the noise level produced by
AQUAFIT pumps running within their operating limits and
installed according to the instructions given in this manual.
(Average values measured at 1 meter from the pump and
elaborated according to ISO curve A – standard R1680.
MOTOR
POWER
(kW) POLES NOISE LEVELS dB(A)
0,25 – 2 2 < 70
3 2 72
4 – 6,3 2 78
7,5 – 15 2 80
18,5 – 22 2 81
30 – 37 2 83
0,25 - 9 4 < 70
TRANSPORT AND STOTAGE
2.1 Transport
Before transportation, please perform the following checks:
Weight of pumps/motor unit
Overall dimensions of pump/motor unit
Suitability of lifting points.
The electric pump can be dispatched in the following ways:
A) Box
B) Single pallet
C) Pallet with other pumps
The pump should be transported in horizontal position and
handled with equipment suited to its weight and to the shape
of its packing (see side pictures).
Lifting by hand is allowed only for weights lower than 20
kilograms.
2.2 Storage
During storage, please observe the following precautions:
Store the pump in a dry, sheltered environment.
Check that ambient temperature never falls lower than 5 C.
Restore the motor after long storage (more than 6
months).
CHAPTER 2

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GENERAL SAFETY INSTRUCTIONS
3.1 General Instructions
The pump(s) should be used only for the applications specified
in par. 1.2. Recommended operational limits must be strictly
observed. In case of applications not specified on this
manual, please contact MARELLI to check for pump suitability,
installation safety and pump life.
We recommended to install the pump in a safe place.
ATTENTION
In case of emergency, switch off line voltage and warn service
personnel.
3.2 Precautions during Operation
Never put your hands or any kind of object into pump
openings where the shaft rotates (see side picture).
Protect motor and electric parts in general according to
current regulations.
If warm is pumped, do not touch the pump.
3.3 Residual Risks
Take care not to:
Kick the pump.
Pressurize the pump beyond recommended limits.
Use the pump unproperly.
Damage the pump by wrong handling.
CHAPTER 3

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INSTALLATION
4.1 Installation
For what concerns handling and installation, please refer to
section 2.1.
the pump can be bolted in position through the openings in
its feet or in motor feet, or fastened straight to piping (see
pictures).
Pipes should always be connected so to avoid any kind of
stress to the pumps. Suction pipe should be absolutely
airtight, with a diameter larger or (at most) equal to the pump
suction nozzle diameter.
Fluid velocity inside the piping should never exceed 2 mt./sec
At suction and 3 mt./sec. at delivery.
In suction pipes, absolutely avoid slopes toward the pump as
that could from harmful air bubbles; if necessary, use wider
bends. In case of suction from basins, install a foot valve with
strainer. We recommended the use of gate valves upstream
and downstream the pump. Leave enough space for motor
ventilation.
4.2 Electrical Connections
Electrical connections should be made only by specialized
personnel, strictly following the instructions of pump and
electrical equipment manufacturers.
Remove terminal board cover by unscrewing its screws.
connect electrical lines as shown in the picture aside and
inside the terminal board.
NOTE
We recommended to install upstream the motor a safety
switch to protect the motor against voltage drop or overload.
Please refer to voltage data on motor nameplate for its correct
sizing.
CHAPTER 4

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COMMISSIONING AND START-UP
5.1 Start-up
Before starting the pump it is necessary to prime it, i.e. to fill
with liquid pump and suction pipe through the suited filing
hole.
In case of double-impeller pumps, bleed trapped air by means of
the suited bleeding valve (see picture).
Check rotation direction against the arrow on pump/motor
casing (see picture); if motor rotation does not match the one
show by the arrow, reverse motor phases (in case of a
three-phases motors).
Once the pump has been primed, close delivery gate valve,
start the pump and open slowly delivery gate valve (startup
with gate valve closed reduces starting voltage peak).
ATTENTION
Never leave delivery gate valve closed for more
Than a minute as the pump can dangerously overheat. Avoid
dry running.
During operation, check shaft seal: it is a mechanical seal,
and therefore there should be no leaks.
Check also that the pump runs within its operating limits and
that voltage values reported on control panel do not exceed
motor nameplate rated values. If necessary, partially close
gate valve or adjust pressure switches intervention.
A slight dripping from the mechanical seal is quite normal
and should not be of concern.
However, if some misfunctioning is detected during startup,
stop immediately the pump and investigate the problem
starting with the Fault Finding chart (chapter 7).
ATTENTION
The system should be fully completed before
starting the pump, especially for what concerns electrical,
mechanical and hydraulic component. All safety system
must be correctly operating.
Junction box cover must always be fixed on motor.
CHAPTER 5

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MAINTENANCE
6.1 Ordinary Maintenance
Once started the pump, check it as frequently as possible
by means of system instrumental like pressure
gauges, vacuum meters and ammeters. The pump
needs normally no maintenance, except a periodical
check for:
Absorbed power, suction head and final pressure.
Mechanical seal operation (there should be no leaks).
Bearing operation.
If a danger of frost exists, drain the pump completely
during idle periods in winter.
Before starting the unit again, make sure the rotor is not
jammed or clogged by scales or similar. If so, turn the
motor fan with a screwdriver till the rotor can freely turn.
As far as the cooling system are concerned, make sure
that no condensate has developed inside the motor,
otherwise place the motor in vertical position and make
exhaust holes shields to release condensate. This
operation must be carried out by skilled personnel only.
Pumps and system can now be primed again as described
In chapter 5.1.
CHAPTER 6

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FAULT FINDING
PROBLEM PROBABLE CAUSE REMEDY
1.
THE PUMP GIVEN NO
WATER
1.1 PUMP AND SUCTION PIPE NOT
WELL PRIMED, WITH AIR TRAPPED
IN THE SYSTEM.
PRIME AGAIN PUMP AND
SUCTION PIPE.
1.2 AIR ENTER THE SYSTEM
THROUGH SUCTION PIPE OPEN
TAPS.
CORRECT INSTALLATION.
1.3 SUCTION HEAD TOO HIGH. CORRECT INSTALLATION.
1.4 WRONG ROTATION DIRECTION. SEE PAR. 5.1
1.5 THE TOTAL HEAD REQUIRED BY
THE SYSTEM IS HIGHER THAN
RATED PUMP HEAD.
THE PUMP IS NOT SUITED TO
THE DUTY REQUIRED.
2.
UNSUFFICIENT
DELIVERY
2.1 FOREIGN BODIES AT IMPELLER
CHANNELS OR THE SAME CAUSES
AS POINTS 1.1, 1.3, 1.4, 1.5.
REMOVE THE CAUSES.
2.2 UNDERSIZED SUCTION PIPE
VALVE, OR WRONG POSITIONING
OF SUCTION PIPE.
CORRECT INSTALLATION.
2.3 WORN IMPELLER AND/OR PUMP
CASING. SEE CHAP.8.
3.
UNSUFFICIENT
PRESSURE
3.1 LIQUID VISCOSITY HIGHER THAN
SPECIFIED AND/OR THE SAME
CAUSES AS POINT 1.4, 1.5, 2.3.
PUMP NOR SUITED TO THE
VISCOSITY AND/OR REMOVE
THE CAUSES.
CHAPTER 7

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PROBLEM PROBABLE CAUSE REMEDY
4.
EXCESSIVE BREAK
POWER
4.1 PUMP PERFORMANCES ARE
DIFFERENT THAN RATED.
DELIVERY GATE VALVE
PARTIALLY CLOSED..
4.2 LIQUID SG HIGHER THAN
SPECIFIED.
PUMP NOT SUITED TO THE
SERVICE OR DELIVERY GATE
VALVE PATIALLY CLOSED.
4.3 ABNORMAL INTERNAL RUBBING
(ROTATING PARTS RUB AGAINST
FIXED PATRS).
REPAIR THE PUMP, SEE CHAP.
8.
5.
THE SEAL LEAKS
EXCESSIVELY
5.1 WORN MECHANICAL SEAL. SEE CHAP. 8.
5.2 WORN SHAFT AT MECH SEAL
POSITION.
REPAIR THE PUMP, SEE CHAP.
8.
6.
THE PUMP VIBRATES
AND IT IS NOISY
6.1 UNBALANCED ROTATING
ASSEMBLY.
REPAIR THE PUMP, SEE CHAP.
8.
6.2 MOTOR BEARINGS FAILURE. SEE CHAP. 8.
6.3 THE PUMP RUNS WITH TOO LOW
OR TOO HIGH CAPACIT; ALSO THE
SAME CAUSES AS POINTS 1.3, 2.1,
2.2.
OPERATE THE PUMPS
DIFFERENTLY; REMOVE THE
CAUSES OF THE
MISFUNCTIONING.
6.4 PUMP AND/OR PIPING NOT
FIRMLY FASTENED. CORRECT INSTALLATION.

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REPAIRING THE PUMP
Before disassembling the pump
Switch off line voltage.
Close suction and delivery gate valves.
Leave the pump cool off line in case warm liquid has been
pumped.
Drain the pump through the suited draining hole (see picture).
Removing the pump from installation
A) Full remove from the installation:
Remove bolts from suction and delivery flanges.
Remove all screws fastening the pump to the ground and lift
it with a suited hoist (see section 2). For repairing, please
send the pump to the manufacturer or to an authorized shop.
B) Partial remove from the installation
Unscrew the screw between pump casing and lantern and
remove assembly motor/lantern cover/impeller without
removing the pipes to which pump casing remains connected.
For double impellers pumps, however, it is necessary to
remove also the delivery casing.
Use a suited hoist when moving/lifting the pump;
see section 2.
C) Mechanical seal replacement
When replacing the mechanical seal, ensure the complete
cleaning of each part and use all necessary care to avoid
damaging the seal by knocks, jolts, cutting edges, etc. Take
care not foul sealing faces, especially with grease or oil.
To re-install the pump, please refer to section 4 and 5.
CHAPTER 8

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SPARE PARTS
9.1 Spare parts ordering
For a faster processing of your order, when ordering spare
parts please specify:
- Pump type
- Pump serial number
- Part name and number as listed on sectional drawing
- Pump type and serial number are ar easily found on pump
nameplate.
DECOMMISIONING AND DISMANTLING
10.1 Dismantling
When the pump will be stopped and dismantled,
the various materials composing it should be properly disposed
of. It is important to make sure that no residual polluting liquids
are trapped within the pump.
The materials used in pump construction are:
- Steel and cast iron
- Aluminum
- Rubber and plastic
- Copper and brass
The disposal of polluting liquids and materials should follow
current environment regulations. Environment protection is an
increasingly pressing problem.
CHAPTER 9
CHAPTER 10

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SECTIONAL VIEWS

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DICHIARAZIONE DI CONFORMITA'
( secondo allegato II A - Direttiva Macchine 2006/42/CE )
DECLARATION OF CONFORMITY
( according to enclosure II A - Machinery Directive 2006/42/EC )
S Se ez zi io on ne e 1 1 D DE ES SC CR RI IZ ZI IO ON NE E M MA AC CC CH HI IN NA A
Section 1 Machinery Description
Costruttore
GRUPPO ATURIA S.p.A.
Manufacturer
Tipo A
AQ QU UA AF FI IT T
Type
Descrizione Elettropompa centrifuga MONOBLOCCO
Description Monobloc centrifugal electric pump
S Se ez zi io on ne e 2 2 N NO OR RM ME E / / D DI IR RE ET TT TI IV VE E A AP PP PL LI IC CA AB BI IL LI I
Section 2 Applicable Directives / Standards
Direttiva Macchine 2006/42/CE
Machinery Directive 2006/42/EC
Norma Armonizzata UNI EN 809
Harmonised Standard UNI EN 809
S Se ez zi io on ne e 3 3 D DI IC CH HI IA AR RA AZ ZI IO ON NE E
Section 3 Declaration
Noi, Gruppo Aturia S.p.a. /Piazza Aturia,9 /Gessate/ Mi/, dichiariamo che é garantita
la conformità ai requisiti essenziali di sicurezza e di tutela della salute della Direttiva
Macchine 2006/42/CE.
We, Gruppo Aturia S.p.a. /Piazza Aturia,9/Gessate/ Mi/, declare that is in conformity
with all the essential health and safety requirements of the Machinery Directive
2006/42/CE.
RESPONSABILE
Authorized/Responsible Officer
Firma data/date: 04/2011
Signed Gallieni Ing. Stefano
Qualifica Direttore Generale
Title General Manager
Persona Giurudica Responsabile del Fascicolo Tecnico
Legal Person Responsible of Technical File
Gruppo Aturia S.p,A.
P.zza Aturia, 9 – 20060 Gessate (MI) - Italy
GRUPPO ATURIA s.p.a. - 20060 - Piazza Aturia, 9 Gessate, Mi (Italy) Tel.[phone] - Fax. [phone]
Gruppo Aturia
AUDOLI &
BERTOLA
ARIS
CHIAPPA

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REGULATION (EU) N. 547/2012 of 25-06-2012 implementing Directive 2009/125/CE
We, GRUPPO ATURIA S.p.a. – P.za Aturia, 9 – Gessate (MI) – Italy, declare under our exclusive
responsibility that the following directive integrates the EC Declaration of Conformity contained in
the present manual of instructions.
Minimum efficiency index: MEI ≥0,40
The benchmark for most efficient water pumps is MEI ≥0.70
The efficiency of a pump with a trimmed impeller is usually lower than that of a pump with the full
impeller diameter. The trimming of the impeller will adapt the pump to a fixed duty point, leading to
reduced energy consumption. The minimum efficiency index (MEI) is based on the full impeller
diameter.
The operation of this water pump with variable duty points may be more efficient and economic
when controlled, for example, by the use of a variable speed drive that matches the pump duty to
the system.
information on benchmark efficiency is available at :
[www.europump.org].
Benchmark efficiency graph for MEI = 0.7 and MEI = 0,4 for this pump can be found at :
[www.europump.org/efficiencycharts]
Gessate (MI), 01/01/2015
Stefano Gallieni
CEOGruppoAturia