KSB Monosub R Manual de usuario

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.

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.

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.

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.

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

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.

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

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.

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

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

384.02

59-47

Exploded View - Single Phase

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

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