Ultraflow UMDZ7500/80/30 Datasheet

IMPORTANT
Installation Operating
Maintenance Instructions
& Warranty Conditions
SUBMERSIBLE
SUMP PUMP RANGE
This instruction
manual must be
read and adhered
to prior to
installating and/or
operating the
pump/s.
For safety
reasons, persons
who have not read
these instructions
should not be
authorised to use
the pump.
The Installer must
provide a copy of
this manual to the
Operator of the
pump/s.
While this booklet
is comprehensive,
it is not exhaustive.
Therefore, if you
need clarification
of any of the
information
contained herein,
please contact us.

PRIOR TO INSTALLATION & OPERATION
The Installer must consult a WHS supervisor
and/or adhere to all relevant criteria and
regulations. The installer should consult an
engineer for site assessment and correct
installation methods.
When the pump is delivered, first perform the
following checks.
INSPECTION
While unpacking, inspect the product for
damage during shipment, and make sure all
the fasteners, clamps, etc. are tightened
properly.
SPECIFICATION CHECK
Check the model number to make sure it is
the product that was ordered. Be certain it is
the correct voltage and frequency.
PRODUCT SPECIFICATIONS
CAUTION:
• Do not operate this product under any
conditions other than those for which it
is specified.
• Failure to observe this precaution can
lead to electrical shock, electrical
leakage, fire, water leakage, damage to
property, injury and death.
1. Cable
2. Protector
3. Motor Cover
4. Motor
5. Shaft
6. Motor Frame
7. Oil Chamber
8. Mechanical Seal
9. Casing
10. Impeller
11. Stand/Strainer
12. Discharge
13. Wear Plate
2

CAUTION:
• Do not use pump in liquids other than
water, sewage, or chemically stable
wastewater. Do not use pump in oil,
salt water, flammable liquids, or
organic solvents.
• Use with a power supply voltage within
±5% of the rated voltage.
• Do not use in water temperatures
outside the range of 0-35°C. This can
lead to failure, electrical leakage, shock
or fire.
• Do not use in the vicinity of explosive or
flammable materials, or areas
classified as hazardous.
• Use only in fully assembled state.
NOTE: Consult your dealer or representative
before using with any liquids others than
those indicated in this document.
PREPARING FOR
INSTALLATION
Before installing the pump at a work site, you
will need to have the following tools and
instruments ready.
• Insulation resistance tester
• AC Voltmeter
• AC ammeter (clamp on type)
• Bolt and nut tighteners
• Power supply connection tools
• Ensure adequate power supply is
available
NOTE: Please read also the instructions that
come with each of the test instruments.
CHECKS TO MAKE BEFORE
INSTALLATION
When a three pin plug is used:
Use the megohmeter to measure the insulation
resistance between the cabtyre cable plug tips
and ground.
When connection leads are used:
With the megohmeter, measure the insulation
resistance between each core lead and the
ground lead (Green/Yellow).
Reference insulation resistance:
20 Ω or greater.
NOTE: The reference insulation resistance
(20
Ω or greater) is the value when the pump
is new or has been repaired.
3
INSTALLATION

WARNING:
• When installing the pump, pay close
attention to its centre of gravity and
weight. If it is not lowered into place
correctly, it may fall and be damaged or
cause injury.
• When transporting the pump by hand,
be sure to employ manpower
commensurate with the weight of the
pump. To avoid back injury when lifting
the pump, bend the knees to pick it up
rather than bending your back.
CAUTION:
• Do not under any circumstances install
or move the pump by suspending it
from the power cable. The cable may
be damaged, causing electrical
leakage, shock, fire, injury or death.
1Attach the hose to the hose coupling
as far as it will go, then fasten it
securely with the hose band.
2Avoid dropping the pump or other
strong impact. Lift the pump by holding
it firmly with both hands or by
attaching a rope or chain to the handle.
3Install the pump in an upright position
on a secure base. Ensure that the inlet
to the pump is not blocked by sludge,
mud, solids, plastic bags, rubbish.
4Where a float switch is attached to the
pump, ensure the float switch is free to
operate without interfering with tank
walls, pipe work etc.
5A swing check non-return valve and
isolating valve should be fitted to
discharge pipe close to the pump but
accessable so that it can be replaced.
6The pump must not be used in or at
swimming pools, garden ponds or
where there are people in the water.
CAUTION:
• Avoid dry operation, which will not only
lower performance but can cause the
pump to malfunction, leading to
electrical leakage and shock.
7Install the pump in a location with
sufficient water level, where water
collects readily.
NOTE: Please refer to “Operating Water Level”
(page 10) for the water level necessary for
operation.
NOTE: The discharge end should be located
higher than the water surface. If the end of the
hose or pipe is submerged, water may flow
back to the pump when the pump is stopped;
and if the hose end is lower than the water
surface, water may overflow when the pump
is turned off.
4

CAUTION:
• If large quantities of earth are sucked
up, damage resulting from erosion in
the pump can lead to electrical leakage
and shock.
8To prevent the pump strainer stand
from becoming submerged in mud,
causing it to suck in debris, mount it on
a block or firm base.
PERFORMING ELECTRICAL
WIRING
WARNING:
• Electrical Wiring should be perfromed
by a qualified/licenced person in
accord with all applicable regulations.
Failure to observe this precaution not
only risks breaking the law but is
extremely dangerous.
• Incorrect wiring can lead to electrical
leakage, electrical shock, fire, property
damage, injury or death.
• Always make sure the pump is
equipped with the specified overload
protectors and fuses or breakers, as
required by law, so as to prevent
electrical shock from an electrical leak
or pump malfunction.
• The voltage, frequency and current
rating are displayed on the name plate,
please ensure that the power supply
meets the requirements.
GROUNDING
WARNING:
• Do not use the pump without first
earthing it properly. Failure to earth it
can lead to electrical shock from an
electrical leak or pump malfunction.
CAUTION:
• Do not attach the earth wire to a gas
pipe, water pipe, lightening arrestor or
telephone earth wire. Improper earthing
can result in electrical shock.
CONNECTING THE POWER
SUPPLY
WARNING:
• Before connecting leads to the
terminal, make certain the power
supply is turned off (circuit breaker,
etc), to avoid electrical shock, shorting,
5
ELECTRICAL WIRING

or unexpected starting of the pump,
leading to injury or death.
WARNING:
• Before inserting the power supply plug
make certain the power supply is
turned off (circuit breaker etc), to avoid
electrical shock, shorting, or
unexpected starting of the pump,
leading to injury or death.
CAUTION:
• Do not use the pump with the power
cable or plug connected loosely, which
can result in electric shock, shorting,
fire, injury or death.
CAUTION:
• Draw power from a dedicated power
outlet. Sharing the outlet with other
equipment may overheat the branch
outlet and could result in a fire.
- When using a three pin plug,
connect as described in the
manufacturer’s instructions.
- When a single-phase power source
is used, connect the leads to the
control panel terminals as shown in
the diagram, making sure they do
not become twisted together.
CAUTION:
• Be sure to use a dedicated power
supply with a ground/earth leakage
circuit breaker.
CAUTION:
• If it is necessary to extend the power
cable, use a core size equal to or larger
than the original. This is necessary not
only for avoiding a voltage drop, but to
prevent cable overheating which can
result in fire, electrical leakage,
electrical shock, injury and death. Refer
to AS3000
• If a cable with cut insulation or other
damage is submerged in the water,
there is a danger of water seeping into
the motor causing a short. This may
result in damage to pump, electrical
leakage, electrical shock, fire, injury or
death.
• Be careful not to let the power cable be
cut or become twisted. This may result
in damage to the pump, electrical
leakage, electrical shock, fire, injury or
death.
6
POWER CABLE

• If it is necessary to submerse the
connection leads of the power cable in
water, first seal the leads completely in
a molded sleeve, to prevent electrical
leakage, electrical shock, fire, injury or
death.
• Do not allow power cable leads or
power supply plug to become wet.
• Make sure that the cable does not
become excessively bent or twisted,
and does not rub against a structure in
a way that might damage it.
7
ELECTRICAL CIRCUIT DIAGRAMS
• THREE PHASE PUMPS must be connected to a external motor starter fitted with a
contactor and overload. The nominal current of the motor starter must correspond to the
electrical data marked on the pump nameplate.
CHECKING OF DIRECTION
OF ROTATION (THREE
PHASE PUMPS ONLY)
The direction of rotation should be checked
every time the pump is connected to a new
installation.
Check the direction of rotation as follows:
At all times keep fingers and hands away from
impeller.
1Position the pump so that the impeller
can be observed.
2Start the pump momentarily, pump will
jerk – be careful.
3Observe the rotation of the impeller.
The correct direction of the rotation is
indicated by an arrow on the top of the
motor (anticlockwise when seen from
the bottom). If the impeller rotates in
the wrong direction, reverse the
direction of rotation by interchanging
two phases of the motor.

8
If the pump is connected to a piping system,
the direction of rotation can be checked as
follows:
1Start the pump and check the quantity
of water or the discharge pressure.
2Stop the pump and interchange two of
the phases to the motor.
3Start the pump and check the quantity
of water or the discharge pressure.
4Stop the pump.
5Compare the results taken under point
1 and 3. The connection which gives
the larger quantity of water or the
higher pressure is the correct direction
of rotation.
BEFORE STARTING
1Make sure once again that the product
is of the correct voltage and frequency
rating.
CAUTION:
• Using the product with a voltage and
frequency other than the rated voltage
frequency will not only lower its
performance but damage the product.
NOTE: Confirm the rated voltage and
frequency on the model name plate.
2Confirm the wiring, supply voltage,
circuit breaker capacity, and motor
insulation resistance.
Reference insulation resistance: 20 Ω or
greater.
NOTE: The reference insulation resistance
(20
Ω or greater) is the value when the pump
is new or has been repaired.
3The setting on the circuit breaker or
other overload protector should be
made in accord with the rated currency
of the pump.
NOTE: See the model name plate on the
pump for its rated current.
TEST OPERATION
WARNING:
• Never operate the pump while it is
suspended in the air. The recoil will
result in injury, property damage or
death.
1Run the pump for a short time (3–10
minutes) and confirm the following:
• Using an ammeter (clamp-on type),
measure the operating current at the
L1, and L2 phase leads on the
terminal.
OPERATION

9
Countermeasure: If the operating current
exceeds the rated value, pump motor overload
may be a cause, or there may be insufficient
back pressure. Make sure the pump has been
installed under proper conditions as described
in Installation (page 5).
• Using an AC voltmeter (tester),
measure voltage at the terminals.
Supply voltage tolerance: within ±5% of rated
voltage.
Countermeasure: If the supply voltage is
outside the tolerance, possible causes are the
power supply capacity or an inadequate
extension cable. Look again at Electrical Wiring
(page 8) and make sure the conditions are
proper.
CAUTION:
• In case of very excessive vibration,
unusual noise or odour, turn off the
power immediately and consult with
your nearest dealer or representative.
Continuing to operate the pump under
abnormal conditions may result in
electrical shock, fire, property damage,
injury or death.
2If the test operation reveals no problems,
continue operating the pump.
OPERATION
WARNING:
• Do not operate the pump in dry pit,
well, trench etc.
• The pump may become very hot during
operation. To avoid being burned, be
careful not to contact the pump
accidentally.
• Make sure no extraneous objects such
as pins, nails or other metal objects,
cloth, wipes, rocks, wood, napkins or
sanitary items or products of this
nature are sucked into the pump.
These can damage the pump or cause
it to malfunction, and can result in
electrical shock or electrical leakage.
• In case of a power outage, turn off the
power to the pump to avoid having it
start unexpectedly when the power is
restored, presenting serious danger to
people in the vicinity.
• Pay careful attention to the water level
while the pump is operating. Dry
operation may cause the pump to
malfunction.
NOTE: See page 10, “Operating water
level” for the water level necessary for
operation.
• Sharp bends in the hose, especially
near its base, may cause air pockets to
form resulting in idle operation. Lessen
the degree of bending while continuing
to operate the pump.

10
OPERATING WATER LEVEL
CAUTION:
• Do not operate the pump below the
C.W.L. (continuous running water
level). Failure to observe this condition
may result in damage to pump,
electrical leakage or electrical shock.
MOTOR PROTECTION
SYSTEM (Autocut Protector)
Some single phase pumps have a built-in
motor protection system (Autocut Protector). If
an excessive current is detected or the motor
overheats, for reasons such as the following,
the pump will automatically, stop operating
regardless of the water level, to protect the
motor.
• Change in supply voltage polarity
• Overload
• Open-phase operation or operation under
constraint
NOTE: Always determine the cause of the
problem and resolve it before resuming
operation. Simply repeating cycles of stopping
and restarting will result in damage to the
pump. Do not continue operation at a very low
lift, low water level, or while the strainer stand
is clogged with debris. Not only will
performance suffer, but such conditions may
cause noise, heavy vibration, and
malfunctioning.
MAINTENANCE AND
INSPECTION
Regular maintenance and inspections are
necessary for continued efficient functioning of
the pump. If any abnormal conditions are
noticed, refer to the section on Troubleshooting
(pages 12-13) and take corrective measures
immediately.
It is highly recommended that a spare pump
be kept ready in case of any problems.
PRIOR TO INSPECTION
WARNING:
• Consult WHS supervisor for correct
proceedures.
WARNING:
• Detach the power cable from the
receptacle or terminals, after making
certain the power supply (circuit
breaker, etc) is turned off. Failure to
follow this precaution will result in a
serious accident or death from
electrical shock or unexpected starting
of the pump motor.
C.W.L.

11
1Washing the Pump: Remove
accumulated matter from the surface
of the pump and wash it with clean
water. Take special care to remove any
debris from the impeller.
2When inspecting the pump exterior
look for any peeling or chipped paint,
and make sure the nuts and bolts are
fastened tightly. Any cracks in the
surface should be repaired by cleaning
up that area, drying it and then
applying touchup coating.
NOTE: touchup is not supplied. Note that
some kinds of damage or looseness may
require that the unit be dismantled for repairs.
Please consult with your nearest dealer.
Frequency
MONTHLY
BI-ANNUALLY
ANNUALLY
2 TO 5 YEARS
Inspection Items
Measure insulation resistance – Reference resistance 1Ωor greater
NOTE: if the insulation resistance has become notably lower than previous
inspection, an inspection of the motor will be necessary.
• Measure operating current - Compare with rated current.
• Measure supply voltage - Compare with allowable range (within ±5% of
rated voltage)
• Pump inspection.
• A noticable drop in performance may indicate wear in the impeller, etc., or
else clogging of the strainer stand, etc. Remove clogged debris, and replace
any worn parts.
• Oil inspection.
• Check the oil every six months or after 1,000 hours of use, whichever comes
first.
• Change Oil.
• Change oil every 12 months or after 2,000 hours of use, whichever comes
first.
• Designated Oil: Turbine oil VG32 - Caltex – or similar.
• Change mechanical seal.
NOTE: Trained personnel are required for inspecting and replacing the mechanical
seal. Consult with your nearest dealer or representative.
• Overhaul – This should be carried out even if there are no problems with the
pump. The frequency depends on how continuously the pump is in use.
NOTE: Consult with your nearest dealer

12
STORAGE
When the pump is out of use for an extended
period, wash it and dry it thoroughly, then store
it indoors.
NOTE: Always run a test operation before
putting the pump back into service.
When the pump is left installed in the water, it
should be run at regular intervals (about once
a week).
OIL INSPECTION & CHANGE
•Inspecting Oil
Remove the Oil Plug (Hex. Bolt) and tilt the
pump to drain a small amount of oil. If the
oil is milk white or has water mixed with it,
the Mechanical seal maybe faulty. In this
case the pump will need to be dismantled
and repaired.
•Replacing the Oil
Remove the Oil Plug and drain all the oil,
then replace it with the specified amount.
NOTE: Used oil and other waste products
should be disposed of by a qualified agent, in
accord with applicable laws. The Oil Plug
packing and O-Ring should be replaced each
time the oil is inspected or changed.
Trouble
Does not start. Starts, but
immediatly stops.
Cause
1. Power Failure
2. Large discrepancy between power
source and voltage
3. Significant drop in voltage
4. Motor phase malfunction
5. Electric circuit connection faulty
6. Faulty connection of control circuit
7. Fuse blown
8. Faulty magnetic switch
9. Water is not at level indicated by float
10. Float is not at appropriate level
11. Float defective
12. Short circuit breaker is functioning
13. Foreign matter clogging pump
14. Motor burned out
15. Motor bearing failure
Remedy
1.- 3. Contact electric power company
and devise counter measures
4. Inspect connections and magnetic
switch
5. Inspect electric circuit
6. Correct wiring
7. Replace with correct type of fuse
8. Replace correct type of magnetic
switch
9. Raise water level
10. Move float to appropriate starting level
11. Repair or replace
12. Repair location of short circuit
13. Remove Foreign matter
14. Repair or replace
15. Repair or replace
TROUBLESHOOTING

13
Trouble
Operates, but stops after a while.
Cause
1. Prolonged dry operation has
activated motor protector and
caused the pump to stop
2. High liquid temperature has
activated motor protector and
caused the pump to stop.
Remedy
1. Raise stop water level
2. Lower liquid temperature
Does not pump.
Inadequate volume.
1. Reverse rotation
2. Significant drop in voltage
3. Operating a 60Hz pump on 50Hz
4. Discharge head is high
5. Large piping loss
6. Low operating water level causes
air suction
7. Leaking from discharge piping
8. Clogging of discharge piping
9. Foreign matter in suction inlet
10. Foreign matter clogging pump
11. Worn impeller
1. Correct rotation (operation 2, 3)
2. Contact electric power company
and devise counter measures
3. Check nameplate
4. Recalculate and adjust
5. Recalculate and adjust
6. Raise water level or lower pump.
7. Inspect, repair
8. Remove foreign matter
9. Remove foreign matter
10. Disassemble and remove foreign
matter
11. Replace impeller
Over current. 1. Unbalanced current and voltage
2. Significant voltage drop
3. Motor phase malfunction
4. Operating 50Hz pump on 60Hz
5. Reverse rotation
6. Low head, Excessive volume of
water
7. Foreign matter clogging pump
8. Motor bearing is worn or
damaged
1. Contact electric power company
and devise counter measure
2. Contact electric power company
and devise counter measure
3. Inspect connections and magnetic
switch
4. Check nameplate
5. Correct rotation (see page 7)
6. Replace pump with low head pump
7. Disassemble and remove foreign
matter
8. Replace bearing
Pump vibrates; excessive
operating noise.
1. SHut off valve closed too far
2. Piping resonates
3. Reverse rotation
1. Open shut off (valve)
2. Improve pipe mounting
3. Correct rotation (see page 7)
TROUBLESHOOTING

14
GENERAL PUMP COMPANY warrants to the original
user that its products are free from defects in
materials and workmanship at the time of shipment
and will make good, by repair or at its option by
replacement, faults and/or defects which appear
during the warranty period of twelve (12) months
after the purchase date, provided that:
1. the equipment was correctly installed and
under proper use in accordance with the
‘Installation, Operation and Maintenance
Instructions’ issued by GENERAL PUMP
COMPANY and also accepted codes of good
practice, relevant Australian Standards and
Government regulations.
2. the claim for goods under warranty arises
solely from alleged faulty and/or defective
materials and/or workmanship.
3. the company is notified in writing within
twenty four (24) hours, after the discovery of
any alleged faults and/or defects stating the
date, place of purchase and invoice number.
4. the repair is carried out by GENERAL PUMP
COMPANY or its agent who has been
specifically authorised in writing to carry out
the repair under warranty.
5. the faulty and/or defective goods are
returned freight paid and at the purchaser’s
risk to the company or its authorised agent
as required.
6. pumps returned for service/warranty which
have been used for other than clean water
must be clearly marked with details of the
pumped liquid or application involved.
7. it is the customers responsibility to advise
the company when any product returned for
service/warranty has been in contact or
used with hazardous liquids.
8. goods are maintained and serviced
according to instructions set by GENERAL
PUMP COMPANY.
GENERAL PUMP COMPANY’S warranty does not
cover the failure or defect of any product, process,
system, part or component:-
• due to advice, directions or instructions
provided by GENERAL PUMP COMPANY, it’s
Staff and/or contractors.
• that is determined by GENERAL PUMP
COMPANY to be fair, normal wear and tear,
misuse and abuse
• the Supplier shall not be under any liability
for any injury, including loss of life, damage,
loss including consequential damage or loss
including physical, financial, mental damage
or loss, disease resulting from the use of its
products or resulting from any faults and/or
defects therein. This includes the cost of
taking up and reinstalling the equipment and
the tradesperson’s time and material costs.
• damage caused by abnormal operating
conditions, tampering, war, violence, storm,
cataclysm or any other force majeure.
• damage caused by pumps jamming on
metal objects, wood, wet wipes, sanitary
napkins, cloth, non-degradable toweling.
• damage caused by the equipment being
used for an application for which it is not
manufactured or recommended for.
• damage caused by sand or abrasive
materials, corrosion due to saline water,
WARRANTY CONDITIONS

15
WARRANTY CONDITIONS
hazardous liquids, electrolytic action, liqiud
temperature beyond the recommended
range, cavitation, improper supply voltage, or
insufficient liquid to enable the pump to
perform to specification.
• damage caused by inadequate power
supply, under voltage, power surge or spike,
and generator power supply.
• damage caused by the lack of maintenance
of installation including but not limited to
regular cleaning of pits, pumpwells and float
switches
• damage caused by incorrect installation
including, but not limited to, incorrect valves,
incorrect installation of valves and incorrect
electrical termination
• unless an appropriate consulting engineer
and WHS officer has agreed to and given
written consent to the installation and
operating instructions, guidelines,
operations, maintenance, service and
repairs.
• if the alleged fault or defect would have
been detectable prior to installation.
This warranty does not exclude any condition or
warranty implied by the Trade Practices Act or
seperate state laws and is in additon to any right
that the original purchaser or any subsequent
purchase may have at law.
In the case of equipment or components which are
not manufactured, repaired or installed by GENERAL
PUMP COMPANY but are supplied by the company,
the warranty is limited to that extended by the
manufacturer, supplier, repairer or installer of such
equipment or components.
GENERAL PUMP COMPANY has made a diligent
effort to accurately illustrate and describe it
products in all its literature and quotations.
However, such illustrations and descriptions are not
a warranty.
The above express warranty is in lieu of and
excludes all other warranties, express or implied
including without limitation, merchantability or
fitness for a particular purpose.