Teral LP User manual

Instruction Manual
Model: LP / SLP2
Line Pum
p
Do not operate, service or inspect this pump until you have
read and understood this manual.
Keep this manual in a safe place where it can be consulted
at any time.
To: All mechanical Contractor
Make sure to supply copies of this manual to the
customer’s operator maintenance and inspection
personnel.

Limit of Liability
1. Warranty period is for period of 18 months after date of the bill of lading or 12 months after installation
whichever earlier.
2. During warranty period, equipment sold is warranted to the Buyer to be free from defective material
and workmanship. If Buyer notifies Seller in writing of any claimed defect in the equipment and if,
after appropriate reasonable opportunity to inspect and remedy any defect by Seller, the equipment is
found not be in conformity with this warranty, the Seller will, at its option and expenses either repair
the same or provided a replacement of defective parts, on condition of F.O.B. Japan.
3. The warranties set forth herein are exclusive and in lieu of all the warranties, express or implied by
law or trade usage.
Seller shall not be liable for any special, indirect, or consequential damages, including but not limited
to loss of use for lost of anticipated profits, arising out of this contract or a breach thereof. Seller
does not warrant any auxiliary equipment.
4. The foregoing warranty does not cover, and the Seller makes no warranty with respect to:
(1) Defect is caused by other equipment which not supplied by Seller or use of improper parts not
specified by Seller.
(2) Failures not reported the Seller within the warranty period above specified.
(3) Force Majeure:
The Seller shall not be liable in any manner for failures, damages, directly or indirectly owing to
any causes or circumstances beyond Seller’s control, including Acts of God, Governmental
orders or restriction, war, war like conditions, hostilities, sanctions, riot, looting, strike, lockout,
plague or other epidemics, fire and flood.
(4) Failures or damages due to negligence, accident, abuse, improper operation or maintenance or
abnormal conditions of temperature, moisture, dirt, or corrosion, and repaired works by others
without Seller’s consent.
(5) Improper storage before installation.
(6) The cost of dismantling and installation of the equipment.
(7) Dispatching an engineer for repair.
I

Purpose of this Manual
The purpose of this manual is to provide the detailed information that the user needs to know in
order to correctly operate, service and inspect the Coolant Pump.
This manual is intended for persons experienced in the operation of coolant pumps, or for persons
who have received instruction from such experienced persons.
Wiring and electrical work must be performed by qualified persons only.
CONTENTS
Limit of Liability I
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Purpose of this Manual II
1. Safety
1.1 Warnings 1-1
1.2 Safety instructions 1-1
1.2.1 Safety instructions for operation 1-1
1.2.2 Safety instruction for installation, maintenance and inspection 1-1
2. Structure and overview of the pump
2.1 Names of parts 2-1
2.2 Specifications 2-1
3. Installation
3.1 Before using the pump 3-1
3.2 Instructions for installation 3-1
3.3 Cautions for piping work 3-3
3.4 Instructions for wiring work 3-4
4. Preparation for operation
4.1 Checks prior to test operation 4-1
4.1.1 Electrical system checks 4-1
4.1.2 Pump system checks 4-1
4.2 Test operation 4-2
5. Maintenance and inspection
5.1 Instructions for maintenance and inspection 5-1
5.1.1 Precautions for daily inspection 5-1
5.1.2 Precautions for when the pump is out of use for prolonged periods 5-2
5.2 Periodic inspection table 5-2
6. Troubleshooting 6-1
II

1. Safety
1.1 Warnings
The warnings used in this manual are graded into 4 types, according to the degree of danger (or
seriousness of potential accident) that they signify. DANGER indicates the highest degree of
danger, followed by WARNING and CAUTION, in that order. There are also NOTES, which draw
attention to important information.
Be sure to know the degree of danger signified by the various types of warning, and follow all the
instructions that they give.
Grade Meaning
Imminent danger. Failure to follow the instructions given will
result in death or serious injury.
Potential danger. Failure to follow the instructions given could
result in death or serious injury.
Potential danger. Failure to follow the instructions given could
result in medium or light injury, or in damage to the equipment.
Draws attention to or stresses important information.
1.2 Safety instructions
1.2.1 Safety instructions for operation
(1) Use the pump with a power supply of the rated voltage only.
Do not use any other power supply voltages.
(2) Make sure that the pump turns in the correct (regular) direction.
(3) If the pump sucks in air, it must not be operated.
If the pump starts sucking in air during operation, stop operation.
(4) Do not run the pump for prolonged periods with the discharge sluice valve closed
(that is, at shut-off pressure).
If you do, the motor will be damaged and electric shock could result.
(5) Do not run the pump in dry operation.
If you do, the water inside the pump will boil, and could cause burn injury.
(6) Do not put fingers or objects into the motor’s openings.
If you do, you could get an electric shock.
1.2.2 Safety instructions for installation, maintenance and inspection
(1) Installation, maintenance and inspection of the pump should be performed by personnel who
have been trained in its operation and use. Electrical wiring work should be performed only
by suitably qualified personnel or electricians.
1-1

(2) When carrying out maintenance or inspection of the pump, stop the pump and turn off the
main power supply to the operation panel.
If you do, electric shock could result.
(3) Remodelling and repair of the pump should be performed by the manufacturer or a specialist
company ONLY.
(4) If any trouble or abnormality occurs while the pump is running, stop operation, shut off the
power supply and contact the dealer that you bought the pump from, or else a service agent
approved by the manufacturer.
If you continue operation despite the occurrence of trouble or abnormality, electric shock or fire
could result.
(5) Install the pump correctly, in accordance with the instructions in this manual.
Incorrect installation could result in electric shock, fire, or injury caused by the pump falling
over.
(6) Ground the pump. Do not connect the pump’s ground cable to gas or water pipes, lightning
conductors or telephone ground cables.
Ground the pump properly. Otherwise, electric shock could result.
(7) Do not install the pump in places with high temperatures or where there are high levels of
moisture in the air, such as bath rooms. If you do, the pump could generate heat or catch fire,
or electrical leakage could occur.
1-2

2. Structure and overview of the pump
2.1 Names of parts
〔Ｍｏｄｅｌ ＬＰ〕
Ａｉｒ ｒｅｌｅａｓｅ ｐｌｕｇ
Ｃａｓｉｎｇ
Ｍｏｔｏｒ
〔Ｍｏｄｅｌ ＳＬＰ２〕
Ｍｏｔｏｒ
Ｃａｓｉｎｇ
Ａｉｒ ｒｅｌｅａｓｅ ｐｌｕｇ
2.2 Specifications
The specifications of the standard pump are given in the table below. If optional or special
specifications have been ordered, details of them will be found in the outside dimension drawings
and other specification documents.
Do not use the pump in conditions out of its specification operating of
ranges.
If the pump is used out these ranges, electric shock, fire, or
breakdown could result.
*Qualities Fresh water
Pumped
medium Temperature Model: SLP2…0～100℃Model: LP…0～80℃(Above 5.5kw)
0～100℃(0.25～3.7kw)
0～90℃(Max. 0.15kw)
Total suction head -6m (20℃)
Allowable positive suction pressure See spec. table in catalog.
Installation location Indoors (ambient temperature 0-40℃)
But can be installed outdoors (ambient temperature 0-40℃) if motor
is totally enclosed, fan-cooled outdoor type (not any other type).
Power supply Single phase 200V (less than 0.4kw)
Three phase 400/440Vtalog.
Motor Type Totally Enclosed, fan-cooled, type (0.25-0.75kw)
O.D.P. type (1.5kw and over)
*The pump cannot be used for pumping seawater or special liquids.
2-1

3. Installation
3.1 Before using the pump
When your line pump is delivered, check the following:
If any defects, contact the dealer that you ordered the pump from.
(1) Is it the product that was ordered? – Check the data on the name plate.
(2) Has any damage occurred during transportation?
(3) Are any nuts or bolts (or other parts that should be tight) loose?
(4) Have all the accessories that were ordered been delivered?
3.2 Instructions for installation
(1) Install the pump in a place with a well-ventilated, little humidity or dust in the air.
Do not install the pump in places with high temperatures or where
there are high levels of moisture in the air, such as bath rooms. If
you do, the pump could generate heat or catch fire, or electrical
leakage could occur.
(2) The total suction head close to the intake water source should not exceed –6m. However,
sometimes the temperature of the pumped water may necessitate an even smaller value for
total suction head. Generally speaking, if the water temperature is over 70°C, positive suction
pressure will be necessary.
(3) If the pump is used for circulating hot water and the piping is hermetically sealed, provide an
expansion tank and safety valves.
Do not install the pump at a point in the piping where there is a
projection (portion where air will accumulate). If you do, dry
operation could occur, resulting in seizing of the sliding faces inside
the pump.
(4) If the pump is used as a circulation pump, fit sluice valves to the discharge and suction piping.
The sluice valves will make it unnecessary for the piping to be drained of water prior to
inspection or repair.
(5) To lift the pump, attach the ropes or wires to the casing.
(if eye-bolts are provided, use them)
Before lifting the pump, check its weight (given in catalog and
outside dimension drawings), and make sure that the weight of the
pump does not exceed the rated load of the ropes and lifting
equipment.
3-1

Do not install the pump the wrong way up, and do not install it
inclined at an angle to the vertical. If you do, water is liable to enter
the pump interior, causing faults in insulation resistance.
3-2

3.3 Cautions for piping work
(1) Provide pipe supports (pipe support stands) for the piping, so that the weight of the piping is
not imposed on the pump.
(2) Bent portions of the piping should be located as far as possible from the pump’s suction port,
and the radius of the bends should be as large as possible.
(3) Install the piping joints very carefully, so that no air gets into the piping.
(4) The suction piping should be of the same size as the pump, or larger.
If it is smaller than the pump size, cavitation may occur.
(5) If the pump is used for lift pumping:
 Make the suction piping as short as possible, with as few bends as possible.
Do not install a sluice valve to the discharge piping.
 To prevent accumulation of air in the suction piping, make the piping slope gently upwards
towards the pump (at a gradient of at least 1/100).
 Fit a foot valve with strainer to the end of the suction piping, to prevent intake of foreign
matter.
 The foot valve must be installed perfectly vertically. If it is
inclined at an angle to the vertical, it will not open and close
properly and will not be able to perform its intended function.
 The foot valve should be submerged below the water surface at
a distance of at least two times the pipe diameter, in order to
prevent air being sucked in. Also, there should be a clearance
of at least 500 mm from the foot valve to the bottom of the
water.
3-3

(6) Provide a sluice valve and a check valve in the discharge piping.
If there is danger of water hammer occurring, use a hammerless type check valve.
(7) If there are any projection portions along the discharge piping, make sure that air can be
purged from them.
3.4 Instructions for wiring work
 Wire the pump safely, in accordance with technical standards
for electrical equipment and with local regulations. Wire the
pump correctly. Otherwise, electrical leakage or fire could
result.
 Ground the pump. Do not connect the pump’s ground cable to
gas or water pipes, lightning conductors or telephone ground
cables.
Ground the pump properly. Otherwise, electric shock could
result.
 Depending on the installation site, installation of an electrical
leakage breaker may be necessary.
If an electrical leakage breaker is not installed, there will be
danger of electric shock.
 The pump must be wired by a qualified electrician or other
suitably qualified person. It is illegal, and very dangerous, for
unqualified people to perform wiring work.
(1) Provide an electrical leakage breaker and overload protection device for the pump’s main
power supply cable.
(2) Pass the main power supply cable through a metal pipe or metal duct to shield it, and ground
the outer surface of the pipe/duct.
Fluctuation in the power supply voltage should not exceed ±10% of
the rated voltage, and fluctuation in the power supply frequency
should not exceed ±5%.
If fluctuation exceeds these limits, breakdown may result.
3-4

4. Preparation for operation
4.1 Checks prior to test operation
4.1.1 Electrical system checks
(1) Check that the wiring has been connected correctly or terminal connections are secure.
Use the pump with a power supply of the rated voltage ONLY.
If other power supply voltages are used, fire or electric shock could
result.
(2) Check that grounding has been carried out properly.
(3) Check that the setting on the overload protection device is the motor’s rated current.
4.1.2 Pump system checks
(1) Turn the pump by hand, and check that it rotates easily.
If the pump is difficult to turn (stiff), or if it does not turn smoothly, inspect the pump interior.
Remove the cap in the center of
the motor’s protective cover.
There is a slot beneath the cap.
Insert a screwdriver into the slot
and turn it. The pump will
rotate.
ALWAYS turn off the main power
supply before turning the pump by
hand.
(2) If there is a sluice valve in the suction piping, fully open it.
4-1

(3) Prime the pump.
Turn the pump by hand to completely expel the air from inside it.
If the pump circulates hot water for a heating system, be sure to
wear protective gloves when performing the above operation.
Hot water could spurt out through the air purge cock and scald bare
skin.
NEVER run the pump in dry operation (that is, without
priming it).
Running the pump in dry operation will make the sliding
faces inside it seize.
4.2 Test operation
Be sure to fit the cover over the motor terminal box.
There is danger of electric shock.
(1) Turn the power switch on and off again 1 or 2 times, and check that the pump rotates in the
correct direction.
The regular direction is clockwise, viewed from the motor end of the pump.
If the pump rotates in the reverse direction, change round 2 of the main power cable’s 3 wires.
Do not run the pump in the reverse direction, or it could
break down.
(2) Turn on the power switch, and run the pump.
Do not run the pump for prolonged periods with the discharge sluice
valve closed (that is, at closed valve operation).
If you do, the motor will be damaged and electric shock could result.
(3) Gradually open the sluice valve on the discharge side, until the specified discharge pressure is
reached.
4-2

(4) Check for abnormal pressure, abnormal current, abnormal noise or abnormal vibration.
Do not put fingers or objects into the motor’s openings.
If you do, you could get an electric shock.
(5) Close the discharge side sluice valve, and stop the pump.
4-3

5. Maintenance and inspection
Before maintaining and inspecting the pump, always stop
the pump and shut off the power supply. There is danger
of electric shocks if the power is not shut off.
5.1 Instructions for maintenance and inspection
5.1.1 Precautions for daily inspection
(1) If pump discharge pressure, current, noise or vibration are markedly different from normal, it
means that breakdown is probably going to occur. In such a case, take prompt corrective
action.
You are advised to post a Log Book, in which details of pressure, current, noise, etc., are
entered daily. This will facilitate detection of abnormality in the above conditions.
Keep the cocks of the pressure gauge, compound gauge and other
instruments closed at all times, except when they are being used for
gauging.
If these cocks are left open, breakdown is likely to occur.
(2) If the mechanical seal (for the shaft) is functioning normally, there should be practically no
leakage from it. If the mechanical seal leaks significantly, replace it.
(3) Do not run the pump at closed valve operation for longer than 5 minutes.
If the pump is run for long periods at closed valve
operation, the water inside it will heat up, resulting in
trouble or accident.
(4) Starting and stopping the pump repeatedly at short intervals will shorten the pump’s
operational life. As a rule, do not start up and stop the pump more than 6 times in one hour.
(5) If a power failure, shut off the power supply without fail. Otherwise the pump could suddenly
start up when the power supply is resumed, and an accident could result.
5-1

5.1.2 Precautions for when the pump is out of use for prolonged periods
(1) In the wintertime, there is danger that water inside the pump may freeze, so be sure to drain
all the water from the pump if it is to be left unused for a long time
If the pump is to be out of use for a prolonged period, turn off its
power supply. This is a safety precaution.
If the power is left on, accumulations of dust could lead to the pump
heating up or catching fire.
(2) If you have a reserve pump, run it from time to time to keep it in good operating condition.
5.2 Periodic inspection table
Replacement of parts or repair should be performed by
personnel from a specialist company or by a service agent
approved by the manufacturer.
Incorrect replacement or repair can cause breakdown or
malfunction.
Inspection interval Consumable
Item
Part for
inspection/
adjustment
What to
inspect Method Criterion
Daily 1
month 6 months 1 year Item Quantity When to replace
Temperature Measure
0 – 40°C ○
Humidity Measure
Max. relative
humidity 85% ○
Ambient
conditions
Dust, etc.
Conditions
within
spec.
ranges? Observe
visually Should be no dust ○
Voltage Should be rated
voltage
○
Voltage
variation
Measure Should be in
allowable variation
range
○
Power
Power supply
terminal board
Screws
loose? Tighten Should be no
looseness
○
Clogging? Disassemble
and inspect Should be no clogging
○
Impellers Wear Disassemble
and inspect Should be normal
○
Shaft &
surroundings Rotation smooth? Rotate by hand Should rotate
easily
○
Bearings Overheating Feel by
hand Heat should be
normal
○Bearings 2 Every
3
years
Mechanical seal Leaking
condition Observe visually Should be none ○
Mechanical
seal 1 Every
1
year
Appearance Abnormal
noise &
vibration Listen Should be none ○
Pump & motor
Insulation
resistance
Between
ground
and each
lead wire
Megger
tester Should be at least
1 MΩ
○
5-2

6. Troubleshooting
If some trouble occurs in the pump, investigate the cause very thoroughly. If parts need to be
repaired or replaced, have the repair or replacement performed by a specialist company or a
service agent appointed by the manufacturer.
Symptom Cause Action
Power supply fuse blown Replace with correct fuse
Disconnected or broken power source wires Check with tester
Replace faulty items.
Power supply voltage too low Contact electric company
Foreign matter clogging impeller and casing
Motor broken down
Pump does not start
Bearing rusted up
Pump must be disassembled &
inspected, so contact specialist
company
Insufficient priming water inside casing Prime thoroughly
Air has got into suction piping Check suction piping joints
Pump rotating in wrong direction Re-wire to obtain correct direction
Suction head is too high Take vacuum gauge reading. If reading too high, contact
specialist company.
Pump starts up, but no
water is pumped
Sluice valve(s) closed Open valve(s)
6-1

Head Office
230, Moriwake, Miyuki-cho, Fukuyama-city, Hiroshima, 720-0003, Japan
Tel.[phone] Fax.[phone]
www.teral.net
2016 06
TP‑067‑02