English
Installation, Operation and Maintenance Instructions Subrotor Pump
MPA555/14
Contents
Warranty Warranty Statement Declaration Manufacturer’s Declaration Declaration of Conformity
4 4
Introduction Intended Use System Overview Requirements for Installation
5 5 5
Specifications Motor Specifications Motor Cable Specifications Single Phase Controller Specifications Pump Specifications
6 7 8 9
3
Installation Pre-Installation Checks 10 Generator Recommendations 11 Splicing the Motor Cable 12 Splicing and Insulating Connection: 12 Electrical Connection 13 Installation of the Subrotor Controller 13 Recommended Installation of a Single Phase Subrotor System 14 Three Phase Motors 15 Submersible Motor Cooling 15 Lightning 16 Pressure Systems 16 Installing the Pump 16-18 Operations Operating the Subrotor Controller Dip Switches Subrotor Controller Indicator Lights and Their Meaning
19 20 21
Maintenance Subrotor Pump Wet End - Disassembly Subrotor Pump Wet End - Assembly Spare Parts
22 23-24 25
Fault Finding Fault Finding
26-27
Contents – Page 3 Issued – July 2010 Reference – MPA555/14
Warranty
1. The Subrotor Pump manufactured by Mono Pumps is covered by warranty for a period not exceeding twelve months from purchase. 2. Mono Pumps will make good by repair, or at their option, the replacement of faulty parts under warranty, providing always that: (a) The equipment was correctly installed and properly used in accordance with Mono Pumps Installation, Operation and Maintenance Instruction and accepted codes of good engineering practice. (b) The claim for goods under warranty arises solely from faulty design, material or workmanship. (c) The repair is carried out in the Mono factory or by an authorised agent or distributor appointed by Mono Pumps. (d) All freight costs to and from the factory or repair agent are to be paid by the purchaser. 3. In the case of equipment or components which are not of Mono manufacture, but supplied by them, the warranty is limited to that extended by the suppliers or manufacturers of such equipment. 4. Mono Pumps warranty does not cover any of the following: (a) Claims for third party liability of damage caused by failure of any of the company’s products. (b) Damage caused by abnormal operating conditions, war, violence, storm cataclysm or any other force. (c) Damage caused by the equipment being used for an application for which it is not recommended. (d) Damage caused by sand or abrasive materials, corrosion due to salt water or electrolytic action. (e) Damage to the motor if the motor is found to have been disassembled before being returned to Mono Pumps. (f) Damage caused by running the pump dry.
Warranty – Page 5 Issued – July 2010 Reference – MPA555/14
5. The decision of Mono Pumps in relation to any claims or disputes over warranty is final. 6. The warranty is in lieu of all other warranties and conditions expressed or implied, written or oral, statutory or otherwise, which are hereby negated and excluded. 7. This express warranty does not exclude any conditions or warranty implied by the Trade Practices Act 1974 or separate State laws and in addition to any other right, that the original purchasers or any subsequent purchaser may have at law. In case of claim please contact your Authorised Mono Dealer or contact Mono Pumps (Australia) Pty. Ltd.
Declaration Manufacturer’s Declaration Mono Manufacturer’s Declaration as required by the EEC Machine Directive 98/37/EC, Annex ll B: The Mono machines delivered in accordance with our design are intended to be fitted in one machine or assembled together with other machines to form one machine/plant. The machinery must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of the Directive.
Declaration of Conformity
Mono machines that do not possess any safety accessories do not fulfil the requirements of the EEC Machine Directive 98/37/EC. For this reason, no Declaration of Conformity as required by the EEC Machine Directive 98/37/EC Annex ll A can be issued before appropriate safety devices have been installed/mounted on the machine and/or plant with due regard to the information given in these operating instructions. The following harmonised standards are particularly applicable: EN292T1, EN292T2
Signed: G D Thomas Chief Engineer
Applicable national standards and specifications must be taken into consideration. Following assessment of the conformity of the machine/ plant with the EEC Machine Directive, customers may on their own initiative place on the full machine/plant the EEC symbol ‘CE’ as defined in Identification Directive 93/68/EEC.
Declaration – Page 6 Issued – July 2010 Reference – MPA555/14
Introduction Intended Use
Requirements for Installation
The Subrotor system is designed for pumping potable water from boreholes using either 240 volt or 415 volt power. Do not use the system for any other purpose.
(1)
A Mono Subrotor pump and electro sub motor suited to the electrical supply and borehole conditions.
System Overview
(2)
Electrical protection controls for the motor:
This manual will provide the user with essential information on the installation, operation and maintenance of the Mono Subrotor System.
(a) FOR SINGLE PHASE MOTORS i. A control box matched to the electrical supply voltage and the motor power. ii. The line and control box must be protected (fuse/breaker).
The pumping of sand or other abrasives may damage the pump and should be avoided. Bores should be screened and properly developed before installing your Mono Subrotor pump.
(b) FOR THREE PHASE MOTORS An approved contactor and motor protection relay (magnetic starter), with overloads and approved surge arrestors which must be earthed to the motor.
If excessive sand is present in the bore, then a Mono borehole pump with column and shafting is recommended for trouble free service. Typical Subrotor Pump Installation It is recommended that the pump be mounted vertically. If the pump installation is horizontal, the pump must be supported by 50x50 angle over the full length of the pump (including motor).
(c) An isolator or circuit breaker for both single and three phase motors in accordance with local electrical regulations. (3)
Sufficient length of underwater cable correctly sized to the pump motor.
(4)
Suitable earth cable.
(5)
Riser pipe in steel, PVC or polyethylene.
(6)
Bore cap.
(7)
If required: Pressure gauge, pipe bends, non-return valve, union or flange, cable clips and underwater jointing kit (termination kit).
Subrotor pump should never be throttled using a gate valve. 8)
Stainless steel safety rope (to be fitted when delivery pipe is installed.
All electrical connections must be performed by a qualified electrician.
Introduction – Page 7 Issued – July 2010 Reference – MPA555/14
Specifications Motor Specifications Part Number
Power
voltage
Run Current Locked Rotor Current phases
RPM
(kW)
(V)
(Amps)
(Amps)
ESM-103
0.75
415
2.2
8.5
3
2800
ESM-153
1.1
415
3.2
16
3
2800
ESM-203
1.5
415
3.95
19.7
3
2800
ESM-303
2.2
415
5.3
26.5
3
2800
ESM-101
0.75
240
6.1
22
1
2820
ESM-151
1.1
240
7.9
28
1
2820
ESM-201
1.5
240
10
34
1
2820
ESM-301
2.2
240
15
52.5
1
2820
Mechanical Specifications Part Number Motor Casing Length Outside Diameter Weight Minimum Bore Diameter ESM-103
340mm
94mm
7.7 kg
100mm (4”)
ESM-153
370mm
94mm
9 kg
100mm (4”)
ESM-203
400mm
94mm
10.5 kg
100mm (4”)
ESM-303
480mm
94mm
13.5 kg
100mm (4”)
ESM-101
370mm
94mm
9 kg
100mm (4”)
ESM-151
400mm
94mm
10.5 kg
100mm (4”)
ESM-201
440mm
94mm
12 kg
100mm (4”)
ESM-301
480mm
94mm
12.5 kg
100mm (4”)
Resistance Between Phases Resistance between Phases (Ohms)
Pump Size
Black/ Blue
Blue/ Brown
Black/ Brown
0.75kw/ 1.0 hp 415 volts
19.8
19.8
20.1
0.75kw/ 1.0 hp 240 volts
3.7
13.3
9.6
1.1kw/ 1.5 hp 415 volts
12.5
12.6
12.5
1.1kw/ 1.5 hp 240 volts
3.1
7.4
4.7
1.5kw/ 2.0 hp 415 volts
10.8
10.7
10.6
1.5kw/ 2.0 hp 240 volts
3.2
6.8
4.5
2.2kw/ 3.0 hp 415 volts
7.2
7.0
7.1
2.2kw/ 3.0 hp 240 volts
2.2
5.0
3.6
Specifications – Page 8 Issued – July 2010 Reference – MPA555/14
Specifications Motor Cable Specifications Single Phase 240v 50Hz
Three Phase 415v 50Hz
Motor (kw)
Current (Amps)
1.5mm
2.5mm
4.0mm
6.0mm 10.00mm
Current (Amps)
1.5mm
2.5mm
4.0mm
0.75
6.1
50m
84m
134m
201m
N.A.
2
308m
N.A.
N.A.
1.1
8.0
38m
64m
102m
154m
256m
2.9
212m
354m
N.A.
1.5
10.0
30m
51m
82m
123m
184m
3.8
162m
270m
432m
2.2
14.9
N.A.
34m
55m
82m
137m
5.3
116m
193m
309m
Notes: 1. The lengths shown are the maximum permissible run in metres from the motor to the control box. 2. The calculations are based on using Mono supplied cables stranded with 0.20mm copper conductors.
Specifications – Page 9 Issued – July 2010 Reference – MPA555/14
Specifications Single Phase Controller Specifications Electrical
Environmental
Voltage
240V +/-6%
Frequency Model No.
50Hz
Storage Temperature
-10 to 60oC
Operating Temperature
-10 to 50oC
IP Rating
IP66
Humidity
95% Max.
Power (Hp)
Power (kW)
Current (Amps)
SUB CTRL0750
1.0
0.7
6.1
SUB CTRL1100
1.5
1.1
8.0
SUB CTRL1500
2.0
1.5
10.0
Dimensions (in carton)
270 x 390 x 310mm
SUB CTRL2200
3.0
2.2
14.9
Weight (in carton)
2.7kg
Dimensions & Weight
Dimensions 190
4
156
8
328
308
254
287
86
33
50
50 148
50
MOUNTING M5 X 4 PLACES
Ø 16
Specifications – Page 10 Issued – July 2010 Reference – MPA555/14
Ø 25
Ø 20
Specifications Pump Specifications Model Numbers
SM022 SM041 SM042 SM061 SM062 SM101 SM102 SM151
Power [kW]
0.75
0.75
1.5
1.1
2.2
1.5
2.2
2.3
Maximum Speed [RPM]
2800
2800
2800
2800
2800
2800
2800
2800
Flow at Maximum Speed [lpm]
14.4
28.2
31.8
48.6
45.6
78.0
85.2
90.6
Maximum Discharge Pressure [kPa]*
1500
750
1500
750
1500
750
1200
750
Length of Pump (without motor) [mm]
860
850
940
850
940
890
1010
900
* Discharge pressures are maximum for the pump only. Pressure limitations due to motor current will result in lower maximum pressures for some system. Mechanical Specifications Typical Weight Without Motor
7.9 kg
Outlet
1½ inch BSP threaded
Maximum Starts Per Hour
6
Max. Depth of Immersion (water level above pump)
150m
Min. Depth of Immersion (water level above pump)
2m
Mounting arrangement To NEMA standard 17/5/72 motors “Submersible Motors for Deep Well Pumps 4 inch” The pump can be mounted on a NEMA shaft if an adaptor is used. Materials (All models) Motor Adaptor
316 cast stainless steel
Pump Barrel
304 stainless steel
Socket Adaptor
304 stainless steel
Stator
304 stainless steel tube with natural rubber lining
Flexishaft
431 stainless steel coated with Halar
Rotor
316 stainless steel with Hard Chrome Plating
Non Return Valve
Bronze with nitrile seat and anti-rotating pin
O Rings
Nitrile
Water Quality Maximum Water Temperature
35 deg C
pH Range
6.0 to 8.5
Hardness Range Salt Concentration
Specifications – Page 11 Issued – July 2010 Reference – MPA555/14
2000 mg/L 500 ppm
Installation Pre-Installation Checks 1. Unpack the unit carefully to avoid damage to motor, pump and motor cable. 2. Compare motor, pump and control equipment to ensure that they are matched.
1. In all cases an adequately sized earth cable must be connected to the arrestor/earth terminal in the controller/starter and the upper cable guard screw on the pump. 2. Check underwater cable size to ensure adequate voltage at the motor. Refer to table in Motor Cable Specification for cable size and maximum length.
3. Check the power source with a voltmeter and compare with the motor and controller or starter. 4. If a three phase motor, check that the contactor and motor protection relay is approved, and check the overloads to ensure that they are sized for the full load motor current. 5. If a single phase motor, check that the circuit breaker is rated at the full load motor current and is available as back-up protection.
CAUTION: Be sure to maintain the colour sequence at the cable joint, particularly with single phase motors. 9. Determine the borehole depth and standing water level.
6. If a three phase motor, check that surge arrestors (Heineman surge arrestors models LAS 1, LAS 2, or LAS 3 are also approved) are available for each phase. 7. Check the direction of rotation with three phase motors before installation, as pump components may unscrew when operated in the wrong rotation.
CAUTION: Ideally, the motor should be set just above the level at which water enters the borehole. If this level is uncertain or cannot be established, then a “flow inducer” tube must be fitted over the motor and pump inlet to ensure adequate cooling. General
Correct Rotation Direction
The warranty does not cover damage due to running the pump dry. If there is a possibility that the pump will pump more water than the borehole can supply, Mono Pumps recommend that a water level controller is fitted to the system (available from Mono). The warranty does not cover damage to the motor or pump caused by water quality outside the limits specified in the Pump Specification section of this manual.
Installation – Page 12 Issued – July 2010 Reference – MPA555/14
Installation Generator Recommendations Minimum Sizes For Single Phase Subrotor Systems Motor Size (kW)
Run Current (A)
Run (kVA)
Start Current (A)
Start (kVA)
Min
Min
0.75
6.1
1.5
15.5
3.7
1.1 1.5
8.0
2.0
20.5
4.9
10.0
2.4
25.0
6.0
2.2
14.9
3.6
37.5
9.0
Notes: 1.
Generator must supply the run kVA continuously (even for small loads).
2.
The surge start current/kVA that a generator can supply, must meet the minimum requirements above. Start kVA is required for
