Flowpap Operating Instructions
Contents
1. qualified fitters All work on the hydraulic connections may only be performed by 1 1 Unauthorized alteration and construction of replacement parts Alterations to the unit are only permitted after speaking with the manufacturer Safe operation is only guaranteed with original replacement parts and accessories authorized by the manufacturer The use of other parts releases liability 1 2 Prohibited modes of operation The operation safety of the delivered unit is only guaranteed for use according to the regulations in chapter 2 Technical data of the operating manual The limits given in the data sheet may in no case be exceeded 1 3 Statement of nonliability By not heeding this documentation product liability is rendered void PAPANTONATOS S A v 1 0 10 2004 Page 5 of 24 tl 2 PAPANTONATOS Operating instructions for FLOWPAP Pumps service amp engineering submersible pumps Technical data Each unit has been individually manufactured according to the special requirements of the customer The specific technical data regarding head delivery rate current requirement minimum permissible flow velocity on the external motor surfaces etc can be found in the data sheet delivered with the unit or in the order confirmation 2 1 Delivery contents e pump unit e these operating instructions e technical data sheet e instructions for filling submersible motors 2 2 General data 2 2 1 Normal operati2. values can be measured in the individual phases This is especially true for two pole motors These differences can be reinforced by unsymmetrical voltage between the phases from the line side power supply Due to the slender design of the submersible motors different current This effect can be reduced by transposing rotating all the 3 line side phases or all motor cable leads in the same direction For best motor performance current unbalance should not exceed 5 An unsymmetrical voltage between phases from the line side power supply may cause overcurrent in one motor phase and must be regulated On an unsymmetrical power supply network the motor current will be greatly unbalanced in the order 6 10 times the voltage unbalance As an example 6 Volts asymmetry on a 380 400V network 1 5 will cause 9 to 15 Ampere asymmetry on a 100A nominal motor current 9 15 According to IEC maximum permissible unsymmetrical voltage between phases is 1 which is still very high max 4 Volts for 400V network Details which concern the electrical switchgear must be taken from the operating instructions from the switch cupboard manufacturer For practical reasons the pressure pipe downstream of the slide valve 7 is first closed when the transported water is free of sand and or impurities 6 2 First switching on After the pump unit has finally been installed and all pipelines have been connected as far as the slide valv
3. PAPANTONATOS FLOWPAP Pumps service amp engineering Mi Operating instructions for Papantonatos submersible pumps Standard units 10 MA a i P i a i l Ir as EM B i P Ob j Es A iat i i J E 1 i l SS ji t f P 2 ia l nro TI Mu F wm q n 1 7 7 1 al A e l q PAPANTONATOS SA Roumelis amp Adelfon Ntouna 1 13671 Acharnes Attiki Greece Tel 30 210 2431111 Fax 30 210 2431601 Internet www papantonatos gr E mail sales papantonatos ar Pumps service amp engineering f PAPANTONATOS Operating instructions for FLOWPAP submersible pumps TABLE OF CONTENTS 0 General INTO MAatI N ista etnia Ut 61001 21 Ga cscs e 0 5 0 E E E E EE 0 2 Adaiional GO CMC NVA ON candidate A A nae te ene eta eee ee ee eee ee Mr Ce oem eer eee 1 o 1 1 Unauthorized alteration and construction of replacement parts ccccccccncccnnccnnnnnnnnnnnnnnnnnanannnnnnnnnnnnnnnnananns 1 2 Prolibitedimodes OL OPC AON rt dt LA Sateen or nonllablI idad a 2 ia AAA En E AE Zalla DELE COMES ene eee cen er eee eee re ee E daiciasss Dili CCT AIAN grt ROPERO RE vaccines ames setae e e o O So 2 2 1 Normal Operating CONAL ONS srt AR rro aa PP A A DT PE a 3 Hydraul Connec O ep EA meceacunman tenensenacnaenmeeuenenceniereusmeuscemecnuesaue 4 SANA nn Al Proced res upon receipt OL delivery anos os A MMM
4. ANE mtrs 5 10 2 Motors with two or more main feed lines ct 6 e aE e E o E AT A A A 6 1 ias Ge P aa e a Doradas rias 7 o A o E doussenucoumreumutecereneemnecuns 7 1 Starting frequency coccccccccccnncnnnnnnnnnnininnnnnnnnnnnnn nr 8 VU UIA CAIN GG APA PPP A nee Beeler Ei E sas eotoeaeo E E E ee ee ze CUM oasis Bo Elocmical iy e E AAA II e oo Ad REMO daa Sas Overhaul ofthe 0 tii ei 9 SOFIJE APN Ton O oA Srl il MM A e e OE gab naan Sasa A AET 9 2 Requirements for the storage areaQ oocccccccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nn 93s Slorape UNO QUE WES ratita OA storage between Land 24 MOROS dada dd 23 Noreo OPONE MOMIAS ee eee eee ee nen oe ne nn nice nn oe E en ee ee ee 1d ANS DOIG innatas 11 Operating problems and their eliminatiON ococccocccccnnnnonnnncccnnncncnnocnnanonnnaronnnnnonnnrnnannnnnnarenanans PAPANTONATOS S A v 1 0 10 2004 Page 3 of 24 fl PAPANTONATOS Operating instructions for FLOWPAP Pumps service amp engineering submersible pumps 0 General information 0 1 General description Standard submersible pumps serve to transport cold clean water under normal operating conditions Other uses or operating purposes must be agreed upon with the manufacturer Submersible pumps are subjected to a thorough inspection before leaving the factory and equipped with operating instructions for fitting starting care etc which conform to international safety regulations These instru
5. Labeling of conductor ends and rotation direction of motor The conductor ends of the power supply cables are labeled according to Fig 5 1 5 5 Counterclockwise rotation occurs if two phases of the main connection are transposed 5 2 1 Single phase motors The rotation direction of single phase motors is preset by the manufacturer and cannot be changed The rotation direction preset by the manufacturer can be seen in the data sheet Connection can only be made using the switching device accompanying the motor for which the labeling of the leads can be seen in Fig 5 6 5 3 Motors with one power supply cable If the current load values of the lines allow it a three or four lead power supply cable is connected to the motor for direct switching and switching via e g a starting autotransformer 5 4 Motors with two power supply cables parallel connection Motors whose rated current can no longer be conducted by one cable are equipped with two parallel cables The connection of a motor with two power supply cables with parallel connection as well as the color and letter labeling of the conductor ends follows Fig 5 2 5 5 Motors with two power supply cables open delta connection For motors with star delta switching Fig 5 3 motors whose star connection Fig 5 4 and or delta connection Fig 5 5 is in the switch board as well as for motors provided with two different voltages two three lead or one three and one four lead power supply
6. Short circuit protection To prevent short circuiting of the power supply cable and the motor safety measures must be taken according to local ordinances Guide values for the safety fuse sizes can be taken from the data sheet 5 10 Insulation test Before initial starting as well as after longer storage or idle time the insulation resistance of the drive must be measured During and after the measurement the connector ends of the motor line and or the connection terminals partly carry dangerous voltage and may not be touched AN Before the measurement ensure that there is no line voltage To measure the insulation disconnect all leads of the power supply cable of the motor All leads must carefully be cleaned of all dirt Heed the operating instructions of the insulation measuring device Insulation measurement is always performed with a measuring circuit voltage of 500 Volts DC output The measured value must be read after a minute of measurement duration Readings may vary using a lower voltage ohmmeter The motor windings or power supply cable charged up to the measuring PA circuit voltage must be discharged after measurement by means of the insulation measuring device The limits for minimum insulation resistance and critical insulation resistance for measurements at 20 C winding temperature are as follows New motor with its own power supply cable leads c ooocccoooc 200 MQ or m
7. cables are connected to the motor For motors with star delta starting method the maximum switching time from star to delta connection Y A t 3 sec PAPANTONATOS S A v 1 0 10 2004 Page 12 of 24 f PAPANTONATOS Operating instructions for FLOWPAP Pumps service amp engineering submersible pumps 5 6 Motor connection diagrams ae L2 L3 al PE an EE E PE U VW Fig 5 1 Fig 5 2 Fig 5 3 Motor for direct starting DOL Motor for direct starting DOL Motor for star delta starting Y A with one power supply cable with two power supply cables connected in parallel U U1 U2 V U V1 V2 W V W1 W2 PE W PE PE N L1 7 4 PE g f SE A PE V ZUN Fig 5 4 Fig 5 5 Fig 5 6 Motor for direct starting in Star Motor for direct starting in Delta Single phase motor Y connection in switch board A connection in switch board U1 U2 U1 U2 V V1 V2 V1 V2 UV W1 W2 W1 W2 Z PE PE PE PAPANTONATOS S A v 1 0 10 2004 Page 13 of 24 fl PAPANTONATOS Operating instructions for FLOWPAP Pumps service amp engineering submersible pumps 5 7 Protective measures against shock hazard voltages Protective measures against shock hazard voltages must be taken according to VDE regulations and the local electric supply company ordinances According to VDE 0100 the protective conductor must be connected directly to the motor on new systems This also applies when the unit is installed i
8. parts e g stator and rotor plates for functional reasons cannot be produced from corrosion resistant material and are therefore sensitive to any type of air humidity All units may basically be stored either in filled or unfilled condition however these two types of storage require different treatment of the unit AN All units should always be stored vertically Units must be secured by appropriate means in this storage position to prevent tipping over The leads of the power supply cables must be protected from moisture Also be careful that the power supply cables are not bent during storage 9 2 Requirements for the storage area The storage area should be well ventilated Air humidity should lie within a range of 40 60 Temperatures 50 C to 15 C for units with motors originally filled by the manufacturer For temperatures down to 25 C heed the guidelines in the accompanying instructions for filling submersible pump motors under the section Antifreezing compound 9 3 Storage up to four weeks No special arrangements are required for storage up to four weeks 9 4 Storage between 1 and 24 months For storage between 1 and 24 months we recommend turning the shaft of the unit approx every 6 to 8 weeks For this it may also be necessary to remove an already mounted pressure housing if needed including non return valve On pump units where this is not possible pump and motor must be separated from one anoth
9. 7 slowly so that the well is not overloaded by too great a flow and sand is also swept up Watch the current consumption of the motor on the ammeter during the opening Slowly open the slide valve 7 until the ammeter shows the operational current according to the data sheet PAPANTONATOS S A v 1 0 10 2004 Page 16 of 24 f PAPANTONATOS Operating instructions for FLOWPAP Pumps service amp engineering submersible pumps When the operating point has been reached for which the pump unit was designed current consumption must approx coincide with that given in the data sheet If this is not the case the fitting conditions and electrical connections must once again be checked If there are no abnormalities during and after the test run the pressure pipe can be connected if this has not yet been accomplished r lt B ZERE gt OO i zr Md T l iz kS DN RG ko L E TT X Z YN SASSI SUR O YOO O E E x N N PPP ELEH VA X w R NONANI ENANS AN SIENA A CE SESE TES IAS S mr Figure 6 1 Water supply system diagram PAPANTONATOS S A v 1 0 10 2004 o Pp AAA A RS MMMM Ud VIII SIRIOS SSI L y ae pet TT p f DIS E NS 5 ge la Submersible motor VR 1b Submersible pump LAG 2 Non return valve NA 3 Ascending pipeline 4 Fastening
10. anations and abbreviations Ds Well diameter Er Fitting depth La Unit length incl Non return valve US Lower operating point dry run protection OS Upper operating point only for automatic operation U Minimum water covering Wr Minimum Dynamic water level Vv To the consumers A Connection for 3 phase motor B Connection for single phase motor Page 7 of 24 fi PAPANTONATOS Operating instructions for FLOWPAP Pumps service amp engineering submersible pumps 4 Installation Every pump unit must only be operated with a completely filled motor and completely immersed The liquid level must be checked in every case before fitting and if necessary adjusted according to the FILLING INSTRUCTIONS FOR SUBMERSIBLE MOTORS 4 1 Procedures upon receipt of delivery The unit must be taken out of its packaging immediately upon receipt and checked for possible damage completeness and correctness If damage has been determined notify the carrier immediately Should the pump unit be stored or transported further please refer to the section on Transport or Storage The data on the rating plate must agree with that contained in the shipping documents 4 2 General remarks Units which are delivered or stored in several subassemblies due to the extreme length must be assembled during the fitting in the well Special fitting instructions must be requested from the manufacturer for this Due to the danger
11. ation instructions specific to that unit can be requested from the manufacturer We recommend however that the unit be examined by our technicians or that it be overhauled at one of our branch offices When taking the unit out of service and before starting removal work we recommend studying these operating instructions once again For special advice regarding additional information or the acquisition of replacement parts we need the following information 1 Type description of the unit according to the rating plate 2 Machine number according to the rating plate 3 For questions regarding replacement parts a ltem No according to the sectional drawing b Part description and part No according to parts list c Number of needed parts 4 For problems a Short description of the problem and or the effects B Description of the faulty parts according to the parts list Please refer all questions directly to the main factory or to a factory representative PAPANTONATOS S A v 1 0 10 2004 Page 20 of 24 f PAPANTONATOS Operating instructions for FLOWPAP Pumps service amp engineering Submersible pumps 9 Storage The pump unit must be stored vertically in a dry well ventilated room If upon receiving the unit it can not be foreseen at what time it will be put into service the following instructions should be heeded 9 1 General remarks Submersible pump units need special arrangements during storage because some inner
12. cessary the control lines and or instrument lead approx 0 5 m above the flange or the sleeve with a cable grip 4 Connect a second fitting bracket 5 beneath the upper flange or beneath the sleeve with screwed pipes Hang the unit onto the hoist with the upper fitting bracket rise a bit release the lower fitting bracket and sink the unit slowly into the well PAPANTONATOS S A v 1 0 10 2004 Page 9 of 24 fl PAPANTONATOS Operating instructions for FLOWPAP Pumps service amp engineering submersible pumps Do not let the pump slip through the bracket When lowering the unit proceed so that the power supply cable is neither squeezed nor scraped Ascending In order to protect the power supply cables we pipeline 3 recommend lining the well head at the entry point of the power supply cable into the well pipe with a NON Cable roller rubber sheet and feed it into the well shaft using a i cable roller see Fig 4 2 During the lowering the unit must always hang freely and must not become wedged in the well casing tube One control possibility the pump can be rotated freely Cable clamp 4 Attach a second cable clamp about 0 5 m beneath Figure 4 2 Fitting elements the upper flange sleeve Lower the unit far enough for the fitting bracket to sit on the well head and then screw on the next piece of the ascending pipeline If needed attach a cable clamp every 3 m of pipe length For especially
13. cient water cover A static water level at least 2m above the pump exit A dynamic water level above the suction housing taking into account the required NPSH value see pump characteristic for the pump Flow rate See pump characteristic Supply conditions of the pumping medium dependent upon the fitting conditions installed above the well filter If this must be changed direct suction within the filter line must be prevented by suitable measures e g blind tube in the filter Regardless of the above mentioned criteria the pump unit must definitely be outer pump mantle pump with sand protection jacket Other use and operating conditions must be checked with the manufacturer 2 2 3 Starting frequency The amount of regularly distributed starts per hour must be taken from the data sheet Higher starting frequencies are only permissible upon agreement with the manufacturer Amount of maximum permissible starts in sequence Cold motor Warm motor 3 starts 2 starts Rest interval after each cycle 5 minutes PAPANTONATOS S A v 1 0 10 2004 Page 6 of 24 fi PAPANTONATOS Operating instructions for FLOWPAP Pumps service amp engineering Submersible pumps 3 Hydraulic connection Exemplary construction of a water supply system is depicted in Fig 3 1 Since this shows a basic arrangement the actual layout must be suited to local and technical conditions The additional listed com
14. clamps for power supply and signal cables 5 Support clamp 6 Elbow with manometer connection 7 Control valve 8 Delivery pipe 9 Pressure tank or high level tank 10 Terminal box outlet for power supply cable 11 Switch cupboard with switching control and signal units 12 Pressure or float switch 13 System fuses 14 Centering device 15 Manometer 16 Well shaft vents 17 Double orifice air valve 18 Safety valve We also recommend for the safety of the pump unit or for automatic operation 19a Water level detector upper 19b Water level detector lower 20 Pressure sensor for water level measuring system 21 Flow rate meter Explanations and abbreviations Ds Well diameter Er Fitting depth La Unit length incl Non return valve US Lower operating point dry run protection OS Upper operating point only for automatic operation U Minimum water covering Wr Minimum Dynamic water level Vv To the consumers A Connection for 3 phase motor B Connection for single phase motor Page 17 of 24 fl PAPANTONATOS Operating instructions for FLOWPAP Pumps service amp engineering submersible pumps 7 Operation After the unit has operated for a longer period of time it is possible that a minimal readjustment of the motor circuit breaker be required due to changed operating conditions e g by the sinking of the water level In no case select a motor protection adjustment setting which is greater than the highest permissible value
15. ctions describe the procedures to be used for fitting operation and maintenance of standard submersible pumps This documentation is to be kept by the user so that it is available to the operating personnel at any time 0 2 Additional documentation This documentation describes the fitting operation and maintenance of standard submersible pumps You will find further information in the instructions for filling standard submersible motors in the data sheet in the order confirmation Should the information in these operating instructions differ from that in the order confirmation or in the data sheet follow the information in the order confirmation or the data sheet 0 3 Symbols The following symbols are used in this documentation in order to especially emphasize important information and call attention to dangers General information Not heeding this can lead to damage Live components Contact with these components can be deadly Caution Not heeding this can lead to severe damage or to injury health problems Warning Not heeding this can lead to destruction of the unit or to severe injury health problems gt Pp Information placed directly on the machine and or the unit as for example Rotation arrow Labeling of connections Rating plate must absolutely be heeded PAPANTONATOS S A v 1 0 10 2004 Page 4 of 24 f PAPANTONATOS Operating instructions for FLOWPAP Pumps s
16. e 7 the slide valve 7 is closed except for a small gap for venting the ascending pipeline The unit can be switched on after this Type series S pump units pumps with axial impellers must never be started against a closed slide valve Overloading with consequent destruction of the motor could then occur After switching on the pressure at the manometer must be greater than the head given in the data sheet minus the water depth w If this is not the case the drive is rotating in the wrong direction When the rotating direction is incorrect the pump has no or extremely reduced performance lf incorrect rotation should occur exchange 2 phases for one another on the line side input in the switch board Do not transpose anything on the star delta contactor combination Single phase motors are wired in such a way within the motor that they have the correct rotation on every supply system with the prescribed voltage AN The unit must not be driven longer than 3 minutes in the wrong direction A connected The rotation direction on these motors cannot be changed During the time that the still empty ascending pipeline 3 is being filled the ammeter may show a higher current than in the data sheet even after the switching on current has decayed during the initial switching on After this the operational current must be lower than the highest permissible current given in the data sheet Open the slide valve
17. e E O E A O A T 4 3 Work and checks before installation ooococcccnccnnnnnnnnnnnnononnnnnnnonnnnnonononononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnininininos 4 4 Installation of pre assembled pump unit coccccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnininss AD ASSembiy dunno MStalla OA eiei ia ONEROA EREEREER 4 6 Installation tips to ensure long life for the puMp UNlt occcccccccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnoninenininess 5 Elec mGal CONNEC AAPP E En ae as TE nee nner ene ee 5 2 Labeling of conductor ends and rotation direction Of IMOTOT ccccccccnnncncncnnnnnnnnnnnnnnnoninnnoninnnnnonnninonininininenes 5 2 1 EP ORS aR T OT S a E A A T E 5 3 Motors with one power supply cable cisciscssscnscosnsnesavenscasednnecs svanesksoansudsbranteadidowwcs bran sakadoentncbeapeeauodarwcsenss 5 4 Motors with two power supply cables parallel connection ccc cccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeees 5 5 Motors with two power supply cables open delta CONNECTION cccccccccccnnnncnocococoninnninnnnnnnnnnnnnnnnnnnnanananns 5 6 Motor connection AIAgramMS occcnncncnnnnnnnnnnnonininininin 5 7 Protective measures against shock hazard Voltages ccccccccsceeeeseeeeeeeeeeeeeeeeeeeeeseseeeeeeeeeeeeeeeeeeeeeeeeeeeeees Sis MOF DOCU ts My MOE CMC TIRE POCO anat 5 10 IIS AG iodo 0 esre ee e y O PU OO E TA 3104 Motors WIth OAC main feed
18. er If needed separate instructions must be requested from the manufacturer 9 5 Storage for over 24 months After storage of more than 24 months we recommend a complete visual inspection at our main factory or at your nearest factory representative PAPANTONATOS S A v 1 0 10 2004 Page 21 of 24 fl PAPANTONATOS Operating instructions for FLOWPAP Pumps service amp engineering submersible pumps 10 Transport For transport take care that the hoist has an adequate carrying force lt AN is expressly indicated that units less than 1000 kg carry no weight information Take special care when handling the pump unit Make certain that it is not hit against walls steel structures floors or the like Overlong pump units must be prepared for transport according to the section General remarks The motor must in no case be raised or moved by the power supply cables AN Check the motor filling before starting PAPANTONATOS S A v 1 0 10 2004 Page 22 of 24 PAPANTONATOS Pumps service amp engineering Operating instructions for FLOWPAP Submersible pumps 11 Operating problems and their elimination Failure effect Possible fault Possibility of damage repair Motor protection triggered Pump does not start Flow inadequate Motor circuit breaker adjusted too low Current consumption of motor too high Voltage failure Blocked pump Incorrect rotating direction Red
19. erating hours Insulation test Current consumption of the motor is the most important value for monitoring the unit For finding problems their cause and elimination see the chapter Operating problems and their elimination 8 2 Pump unit The pump unit can be operated without maintenance measures insofar as no irregularities in operation or pumping caused by sand or a corrosive pumping medium make premature removal necessary Fluctuating and or rapidly increasing current consumption points to mechanical problems in the pump or motor Strong oscillation of the pressure and at the same time of the ammeter can be caused by irregular water inflow 8 3 Electrical system All the work on the electrical system may only be performed by qualified electricians 8 4 Removal If the pump unit is equipped with a non return valve without load AN relieving holes the unit weight with ascending pipeline and the water column contained within it must be lifted during removal If the non return valve of the submersible pump is provided with load relieving holes the weight of the water column does not apply PAPANTONATOS S A v 1 0 10 2004 Page 19 of 24 fi PAPANTONATOS Operating instructions for FLOWPAP Pumps service amp engineering submersible pumps 8 5 Overhaul of the pump The structural design of a submersible pump unit makes assembly and disassembly possible with simple tools In case of removal install
20. ervice amp engineering submersible pumps 1 Safety instructions The unit may only be operated by trained personnel only in a completely assembled condition and with a completely filled and immersed pump unit This documentation is to be kept by the user so that it is available to operating personnel at any time Guards for movable parts e g coupling must not be removed from the machine while it is in operation Danger from electric energy must be eliminated for details see e g the regulations of the VDE and the local power supply companies Before maintenance and repair work the motor of the pump unit must first AN be completely separated from the power supply The user must be certain that all maintenance inspection and assembly work is completed by appropriately qualified technical personnel sufficiently informed by thorough study of the operating instructions Work on the machine must only ever be performed when it is stopped The procedures for stopping the machine in the operating instructions absolutely must be followed Pumps or units which convey health endangering substances must be decontaminated Immediately after finishing work all safety and protective systems must be replaced and or put back into operation Before restarting the points listed in the section First switching on must be heeded All work on the electrical system may only be performed by qualified electrician
21. given in the data sheet For monitoring the water level in the well and in the high level tank we recommend water level detectors or water level measuring units 7 1 Starting frequency The amount of regularly spaced starts per hour can be found in the data sheet Higher starting frequency levels are only permissible upon agreement with the manufacturer Amount of maximum permissible starts in sequence Cold MOtol cccccececeseceeeeeeeeserereeeeeer O Starts Warm Motol c ccccccsccecesecesenserersreree 2 Starts Resting time after each cycle 5 minutes It is suggested that the motor be protected against non permitted reconnection by a time delay relay PAPANTONATOS S A v 1 0 10 2004 Page 18 of 24 f PAPANTONATOS Operating instructions for FLOWPAP Pumps service amp engineering submersible pumps 8 Maintenance Submersible pump units normally run without maintenance If a pump unit should stand idle for a longer period of time perform a 10 minute test run every 2 3 months so that malfunctions can be recognized in time The pump unit must be completely submersed in pumping medium for AN this test run 8 1 General information Since the units are normally used at very great depths we recommend performing and recording the following listed checks at regular intervals in order to recognize malfunctions in time Current consumption Head A Flow System voltage Op
22. hat on the rating plate on the motor Ensure that the line voltage measured between two phases is equal to the motor voltage according to the rating plate The maximum permissible voltage fluctuation can be seen in the data sheet Greater voltage and frequency fluctuations must be given in the order and confirmed by the factory In case of doubt we recommend asking the manufacturer or the nearest factory representative before starting up the unit Before fitting the insulating resistance of the motor must be measured according to chapter 5 10 It must be ensured that the well diameter DB is large enough down to the fitting depth so that the pump unit can be fitted without difficulties If the ascending pipeline is made of flanged pipes the flanges must have recesses for the cable if the well diameter is narrowly proportioned 4 4 Installation of pre assembled pump unit Mount the first length of the ascending pipe which should not be longer than 0 5 m onto the assembled pump unit Fasten the power supply cables and if necessary the control lines and or instruments leads with clamps onto the ascending pipe Attach a fitting bracket beneath the ascending pipe flange or sleeve and hang the complete unit from a suitable hoist Lower the pump unit into the well until the fitting bracket is resting on the well pipe or well head Attach the next length of the ascending pipeline 3 Secure the power supply cables and if ne
23. iven value the switch must be adjusted lower so that there is effective protection and malfunctions can be indicated in time The motor protection adjustment must in no case be set higher than the highest permissible value given in the data sheet Testing the perfect functioning of a motor protection switch by intentional single phasing is not permitted PT100 Temperature sensor into the motor optional A PT100 temperature sensor 3 wire is recommended in order to allow monitoring of the internal motor temperature It can be used to detect insufficient motor cooling and thus contribute to motor protection Possible reasons for insufficient motor cooling are not sufficient cooling flow velocity along the motor surface deposits sedimentations on the motor surface that strangle heat transfer to ambient water high ambient water temperatures PT100 sensor has to be connected via a 3 wire cable to a PT100 control unit on the control panel PT100 sensor can only detect long term temperature reactions and thus does not replace the required electrical overload overcurrent protection Surge voltage protection Consider the installation of sufficient surge voltage protection lightning protection in the line side power supply according to IEC 60099 PAPANTONATOS S A v 1 0 10 2004 Page 14 of 24 f PAPANTONATOS Operating instructions for FLOWPAP Pumps service amp engineering Submersible pumps 5 9
24. n an inaccessible well If there is no protective conductor leading from the motor a separate protective conductor must be attached to the motor using the provided and labeled protective conductor screw This is labeled with an earth symbol 5 8 Motor protection To protect the motor against power overload an inverse time lag overload relay must be provided sensitive to phase failure and which compensates for temperature The overcurrent release for the switchgear and the safety fuses can be adjusted or selected according to the accompanying data sheet If the selection of the thermally delayed overcurrent release has not already been made by the supplier of the pump unit it must be chosen according to the data given in the table 5 1 For star delta contactors it is very important that the release is as a rule in the motor line see Fig 5 3 The adjusted current level is then only 58 of the operational current aan 1 05xXIl_ Ig Operational current rated current 1 20 x 16 t Delay time until release 5 00 x le 6 00 x e L Operational temperature before overload Table 5 1 Release ratings for submersible motors The adjustment of the motor protection switch thermally delayed overcurrent release must be done according to the value given in the data sheet The value given in the data sheet is a standard value for the operating point If the actual operational current in the operating point of the pump lies under this g
25. nance of PAPANTONATOS SA pumps Athens 15 3 2005 Papantonatos SA Panagiotis E Stavropoulos Quality Assurance Manager C EN ISO 9001 2000 certified
26. narrow and deep wells the insulating measurements according to chapter 5 10 should be repeated during installation process in order to be able to determine possible damage to the power supply cables in time 4 5 Assembly during installation Special fitting instructions from the manufacturer for assembling pump units during fitting on request PAPANTONATOS S A v 1 0 10 2004 Page 10 of 24 asraha arin hed Operating instructions for FLOWPAP a umps service amp engineering submersible pumps 4 6 Installation tips to ensure long life for the pump unit To allow proper motor cooling a minimum cooling flow velocity along the motor surface has to be granted for the minimum required flow refer to motor data sheet and motor name plate For best motor cooling the flow velocity along the motor surface must be 0 5 2 m sec Figure 4 3 Installing a pump unit in a well The pump unit must always be installed above the well filters so that all the pumped capacity will flow along the motor surface providing continuously the adequate cooling to the motor see Fig 4 3 In all cases the provided cooling flow velocity must be calculated During operation the actual cooling flow velocity along the motor surface is calculated by the following formula Motor cooling Q m h Pumped capacity Dw mm internal diameter of well casing or cooling jacket Dm mm external diameter of moto
27. ng conditions Pump unit pump motor must always be completely submerged Minimum cooling flow velocity along the motor surface as per motor data sheet Ambient temperature as per data sheet sand content approx 25mg lit no impurities which could lead to deposits and blockages within the pump or to deposits on the motor surface no occurrence of water hammer no operation against closed slide valve operation within prescribed voltage tolerance permissible operational range 50 to 120 of the optimal delivery rate correctly selected and adjusted motor protection observation of the max permissible starting frequency At higher surrounding temperatures and or lower flow velocities on the external motor surfaces or if there is risk of clogging special measures for heat AN dissipation are required This must be checked with the manufacturer by indicating the surrounding conditions In this case the suitability of the unit for its planned application must be confirmed by the manufacturer For units installed according to the instructions given in this documentation noise level produced by the motor working in his valid range shouldn t exceed 70 db A 2 2 2 Fitting position The following criteria must be taken into account in determining the fitting position and depth Vertical fitting in a well above the filter line so that a perfect flow is guaranteed along the motor Suffi
28. of sagging pump units which exceed the permissible length given in Table 4 1 must be supported by an auxiliary U or H carrier when mounting in the vertical fitting position The auxiliary carrier may only be removed after the pump unit is hanging vertically from the cranellifting block See Fig 4 1 When assessing the diameter of the unit use the smaller one from the pump and motor lt can be taken from the rating plate or the data sheet If a unit was shipped on a transport rail due to its extreme length it must be lifted into the vertical position on this transport rail auxiliary carrier before fitting into the well a pa Q Rated Permissible i diameter total length 1 3 3m H 6 3 5 m 44m Mm i 2 4 7 m Table 4 1 Fastening clamps WT AZZ auxiliary E carriers E x es WO MT Et A O a 4 __ _ i a e i a E lt TES nr ENCARTA ATACA pas cana ar DR SR RA ANAA e a TEEN A Aa AO EA AA AA a A as aries Tee Figure 4 1 Using an auxiliary carrier PAPANTONATOS S A v 1 0 10 2004 Page 8 of 24 f PAPANTONATOS Operating instructions for FLOWPAP Pumps service amp engineering submersible pumps 4 3 Work and checks before installation Before beginning installation check the dependability of auxiliary equipment particularly of hoists as well as comparing the information on the data sheet with t
29. ore New motor with power supply drop cable installed in the well 5 0 MQ or more Critical value after long operational time for a motor installed in the well 0 5 MQ Motor winding temperature higher than 20 C can substantially reduce the insulation resistance If the insulation value is near the minimum value possible causes could be increased air humidity or dirty and moist conductor ends A relatively low insulation resistance does not definitely show that the AN pump unit will break down due to insulation problems If however after regular measurements over a longer period of time an extreme drop in the insulation resistance occurs within a short time these must then be inspected If the insulation resistance falls below minimum value the cause or the malfunctioning part power supply cable line connection or windings must be determined and the insulation weakness removed 5 10 1 Motors with one main feed line Only one lead must be measured to chassis The remaining leads must be insulated from chassis during the measurement 5 10 2 Motors with two or more main feed lines Each lead from one powers supply cable must be measured to chassis while the remaining leads must be insulated from chassis PAPANTONATOS S A v 1 0 10 2004 Page 15 of 24 fl PAPANTONATOS Operating instructions for FLOWPAP Pumps service amp engineering submersible pumps 6 Starting 6 7 General instructions
30. peed too Undervoltage or wrong frequency Check system voltage and frequency low Motor running with one phase Check fuses Bearing damage Remove unit and repair Units run but Head too great Total system head does not Reduce head does not pump correspond to pump characteristic Unit not suspended Fitting depth inadequate Check well level and or suspend unit in pumping medium deeper Pressure pipe not Main slide valve closed Check blockage and control units free Motor runs but Coupling between pump and Remove unit and repair pump does not turn motor defective Suction sieve Foreign body in well Remove unit and clean suction sieve stopped up PAPANTONATOS S A v 1 0 10 2004 Page 24 of 24 tl 7 Roumelis amp Kapodistriou PAPANTONATOS FLOWPAP 361 Arames ati P O 46546 Pumps service amp engineering Tel 30210 2431111 Fax 30210 2431601 web site www papantonatos gr Declaration of Conformity complying with the Machinery Directive 98 37 EC Appendix IIA We herewith declare that the following submersible pump models R BF NE6 PN6 QN6 NB8 PN8 QN8 PN10 QN10 QN12 as completed with submersible electric motors comply with the provisions of the Machinery Directive 98 37 EC Appendix I The following harmonized standards are applicable EN 809 EN 292 Part 1 EN 292 Part 2 The User s Manual includes important safety recommendations for transportation storage installation operation and mainte
31. ponents are recommendations which serve the purpose of operational safety and the protection of the pump unit All work on the hydraulic connection may only be done by qualified fitters A E RUE gt O0 a an MA is SS ISI m M O YOM G x aN EN SPSS OSOS AR iB on l k w EN WM RY 7 ITOE P LLL 2 Hz Y B SERS Submersible motor Submersible pump Non return valve A We also recommend for the safety of the pump unit or for automatic operation E ALR ES MI KERR KK Ascending pipeline Q 4 Fastening clamps for power supply and signal cables S A 2 5 Support clamp S 2 6 Elbow with manometer connection K e 7 Control valve Riles A 8 Delivery pipe 53 ES i x 9 Pressure tank or high level tank SS E f um X 10 Terminal box outlet for power supply cable Z B X 11 Switch cupboard with switching control and signal units Y i X 12 Pressure or float switch Z m 13 System fuses Y A X 14 Centering device Y Le S 15 Manometer gt amp 16 Well shaft vents Sst 17 Double orifice air valve W e 18 Safety valve 2 X A S SAA ii Figure 3 1 Water supply system diagram PAPANTONATOS S A v 1 0 10 2004 19a Water level detector upper 19b Water level detector lower 20 Pressure sensor for water level measuring system 21 Flow rate meter Expl
32. r stator y _ Q mA x 353 68 m sec Dw mm Dy mm If the calculated cooling velocity is less than the minimum required a cooling jacket must be fitted which will force all the pumped capacity to flow along the motor surface and thus cooling the motor The internal diameter Dw of the cooling jacket must be chosen in order to give the adequate cooling flow to motor surface PAPANTONATOS S A v 1 0 10 2004 Page 11 of 24 fi PAPANTONATOS Operating instructions for FLOWPAP Pumps service amp engineering submersible pumps 5 Electrical connection 5 1 Connection of motor All work on the electrical system may only be performed by qualified electricians The connection diagrams Fig 5 1 to 5 6 shows the basic structure of the connection possibilities and the line arrangement of the mains cable and motor power supply cable Detailed information about the connection of motors and if necessary of control and monitoring devices can be taken from the appropriate circuit diagrams from the switch cupboard manufacturer So that a perfect connection with the least possible contact resistance can be established when connecting the power supply lines the conductor ends should not be tin plated Should the conductor ends be tin plated the tin plated ends must be removed The individual exposed fine strand wires must be connected to the electrical system by suitable terminal screws or with crimping or soldering cable lugs 5 2
33. uction of area in the pressure pipe Pressure pipe leak PAPANTONATOS S A v 1 0 10 2004 Motor circuit breaker incorrectly Readjust motor circuit breaker adjusted according to data sheet or rating plate Undervoltage or wrong frequency Check system voltage and frequency does the information on the type plate agree with the system voltage and frequency Phase failure Check fuses Examine power supply cables for damage Pump or motor sluggish Check the smooth running of the pump motor Blown fuse s Replace fuse s Defective power supply cable s Replace power supply cable s Motor protection triggered Find cause for triggering rectify and reset motor circuit breaker Impurities in the pump Disassemble pump section and clean Rotating direction was not Change rotating direction checked Isolator valves not completely Completely open isolator valves open Pressure pipe clogged Clean pressure pipe Foreign body in the pipe Clean pipework Wall filter stopped up Remove unit and regenerate well Pipework defective Check pipework Page 23 of 24 fl PAPANTONATOS Operating instructions for FLOWPAP Pumps service amp engineering submersible pumps Failure effect Possible fault Possibility of damage repair Flow Impellers worn out High sand content of the pumping Remove pump and repair check inadequate medium material selection in coordination with cont a water analysis Corrosive pumping medium Rotating s
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