SERVICE AND ASSEMBLY INSTRUCTIONSFOR SUBMERSIBLE PUMP SETS

1“ - EVGU - 16 - 8 - GU - 080

1 1/4“ - EVGU - 25 - 6 - GU - 080

oriGinal dirEctions for UsE

2

RECOMMENDATIONS FOR INSTALLATION OF THE PUMP SET:

A. It is necessary to keep the minimum required inside diameter of delivery pipeline leading from the pump to a pressure vessel, respectively:

25mmforthepumps1”-EVGU-16-8,asaminimum 32mmforthepumps1¼”–EVGU-25-6

BE PARTICULAR IN fulfilment of this requirement even in case of using any plastic pipeline!

B. Size of a pressure vessel shall be chosen with respect to water requirement and pressure demand, according to thedesigner’srecommendations.

Forexample,forafamilyoffour,andwhileusingapressurevesselwitharubberbag,thevesselvolumeof80litresatleastcanberecommended.

c. non-return flap valve being installed between the pump and a pressure vessel (if it is not a part of the pressure vessel)

shallbe installedabovethewatermaximumlevel inawatersource.Installationonthepumpdischargecasingorbelow water level cannot be recommended!

Right installation, suitable accessories and regular maintenance of the whole system guarantee pump reliability and long service life.

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CONTENTS:

1. BASICPROVISIONS

2. APPLICATION

3. SAFETY

4. TECHNICALDATA

5. DESCRIPTIONOFPUMPSETMAINPARTS

6. PUMPSETFUNCTIONING

7. MAINPARTSOFPUMPSET

8. ASSEMBLY

9. ELECTRICEQUIPMENT

10. DISMANTLING

11. SCOPEOFDELIVERY

12. STORAGE

13. WARRANTY

14. APPENDIX

15. LISTOFAUTHORIZEDSERVICECENTRES

16. NOTESPREPAREDTOHELPYOUPREVENTPROBLEMS

ASWELLASDEALWITHTHEM

17. GUIDELINESONDISPOSALOFWASTE

18. SPAREPARTS

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2. aPPlicationPumpsetisdestinedforpumpingpotableandserv-ice water without mechanical impurities out of deep and narrow bore holes and wells up to temperature 35°CandpHrangingfrom6.5to12.Thisproductisdestinedforcontinuouscontactwithpotablewater.This appliance is not destined for using by people (including children) whose physical, sensual or mental inabilities or lack of experience and knowl-edge inhibit from the appliance safe using without supervision and/or instructing in respect of this ap-pliance using by a person who is responsible for theirsafety.It is inevitable to watch the children in order to pre-venttheircontactwiththisappliance.Unacceptable methods of application

Pumpmustnotconveyotherliquidsthanwater-Pumpmustnotbeusedinexplosionhazard-environments Pumpmustnotconveywatercontainingacids,-lyes, carbon, sea water, chemicals, and so onPumpmustnotworkdryorwiththeopposite-sense of rotationPumphasgotclearpurposeofusingspecified-by its name, design and application defined in this section and other purpose of its using cannot be supposed either advisedly, accidentallyordue-toignorance

Noise levelEquivalent levelofacousticpressureA in thedis-tance 1m from the pump set surface (using the weightingfilterA)doesnotexceedthevalueLPA= 70dBa.

3. SAFETYThese Service and Assembly Instructions containbasic instructions that shall be observed within installation, operation and maintenance of these pumps. That iswhy it is inevitable for competentand responsible workers and service staff learn these Instructions carefully even before the pump installation and putting into operation. Keep thisManualhandyforfuturereferenceatsite.

Not only all above mentioned general safety rules as given in this Clause devoted to safety, but also all specific safety rules given in other Clauses shall beobserved.SafetyrulesincludedintheseServiceandAssemblyInstructions, breach of which could be a menace to people, are marked with the symbol

Or in cases covering electric safety they are marked with the symbol

Safetyrulesthatshallbeconsideredduetosafetyin working of the pump or the pump set and/or pro-tection of the pump itself or the pump set shall be provided with the advice

Safetyrules,breachofwhichcouldendangerqual-ity of human living environment, are marked with the symbol

Analysis of residual risksDesign of this pump is slim, with a small-base, that is why there is a serious risk of its overturning from its vertical positionWhen handling the pump it is necessary to-recheck its disconnecting from the mains and simultaneouslypreventitsaccidentalswitching-on.There isariskof injury fromrotatingpartsandelectricpowerdue-tounskilledhandling.This pump shall be transported in its horizontal or-a secured position

1. BASIC PROVISIONS

- Before starting-up fill the motor with clean water- Pump set may be neither starte dup nor run “dry”- during operation it is necessary to keep right sense of rotation- install a safety valve in delivery pipeline - Provide the motor with overcurrent protection

-Submersiblepumpset1”-EVGU-16-8-GU-080-Submersiblepumpset1¼”-EVGU-25-6-GU-080

ATTENTION!

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4.2Informativecharacteristicsofpumps

Diagramshavebeendrawnupfordensityof1,000kg.m-3

4.1PumpRatingPlate

4. TECHNICAL DATA

1 Producer’sBusinessname andHeadquarters 2 Type designation 3 Rateofflow 4 Serialnumber 5 Deliverypressure 6 Powerdemand 7 Max.deliveryhead 8 Speed 9 Max.depthofsubmersion10 Temperatureofpumpedliquid11 Yearofproduction12 Domicileoforigin13 Markofconformity

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1310 Dischargecasing1200 Suctioncasing1130 Stator2500 Helix2180 Connectionrod6544.1 Retainingring4510.1 Washer7000 Coupling6570 BoltM8x256570.1 BoltM6x84510 Washer88100 Electricmotor

Type L D

1“-EVGU3ph 680 1“

1“-EVGU1ph 640 1“

11/4“-EVGU 748 1 ¼“

4.3Pumpsetmainparts

D

5

Startprotectionbox(1”-EVGU-16_-GU-172) R1PJ6090Breakingcurrent***) Ijist A 9Runcapacitor Voltagecapacity μF/V 60/450Motorstartingcapacitor Voltagecapacity μF/V 120/250Size(widthxheightxdepth) L mm 250x195x95Spacingofmountingholes L mm 190x135Cable entries 2xPg13,5

***)Recommendedprefixedprotection–fuses16gG,circuitbreakerB16A.

Pump 1"-EVGU-16-8-GU-080 1“-EVGU-16-8-GU-172 11/4"-EVGU-25-6-GU-080

Electricmotor Type 1P60-112-01 1PJ60900-01 1P60-112-06

Poweroutput kW 1.1 1.1 2.2

Pumpsetcable Type HO7RN-F*) HO7RN-F*) HO7RN-F*)

Length m 25**) 25**) 25**)

Corecross-section mm2 1 (15, 25m)1.5(35,50m)

1.5 1.5

Volumerateofflow Q I.s-1

0.67 0.66 1.33

Deliverypressure pdo MPa 0.8 0.8 0.6

Electricmotorspeed n min-1

2810 2900 2820

Ratedvoltage U V 400 230 400

Frequency f Hz 50 50 50

Ratedcurrentofmotor l A 3.4 8.3 6.4

Circuit-breaker ESM12,5÷4A ESM14÷6,3A

Protectionstartingbox R1PJ6090

Max.dailywaterinlet hl 50 50 100

Max.submersionunderwaterlevel m 30 30 30

Pumpsetoutsidediameter mm 142 142 142

Boreholesmallestdiameter mm 150 150 150

Diameterofdeliveryconnection D G1" G1“ G11/4"

Pumpsetweightwithacable G kg 24 24 31

5. dEscriPtion of PUMP sEt

MAIN PARTS1. ElectricmotorofEVGUpumpsisasynchronous,

squirrel-cage and its design is adapted forworksunderwaterlevel.Stator winding of a three-phase motor isconstructedfromPVCinsulatedcopperwire.Asforasingle-phasemotor,itsstatorwindingis constructed from copper enamelled wire anditisfilledupwithinsulationmixture.Rotorstampingisforcedontheshaftthatiscarriedinballbearings.Bearingsaregrease-lubricatedandsealedwiththeshaftlockrings.Thereisagrooveattheshaftend-faceservingfor the rotor protection from rotating during acouplingmountinganddismounting.The motor rear shield is provided with a flange with four threaded holes securing connectionwiththepump.Intheshieldthereis even a threaded hole for the cable entry.The funnelled cable entry protects the cable

from pulling-out. In the shield there is alsoa hole sealed with a plug being provided with a sieve. This is destined for filling themotor with water and can be also used as a “breathing hole”.

ATTENTION!

the three-phase motor interior must be filled with clean water before its putting into operation.

Senseofthemotorrotationistotheright(clock-wise)whenviewingfromthepumpside.

2.Pumpisofprogressivecavitytypeconsistingofthe following main parts:

- Stator (1130) consists of steel pipe withscorched rubber lining with a cavity shaped as

a double start thread; -Helix(2500)screw-shaped; -Connectionrod(2180)withrubberjoints; -Suctioncasing(1200)withholesdestinedfor

supply of a pumped liquid and with two ring lugs for the pump set suspension;

-Dischargecasing (1310)withan inner threadforscrewingonthedeliverypipeline.

4.4PerformanceData Table 1

*)Itispossibletouseanothercable,ifallparametersareconvenient.**)Thepumpcanbedeliveredalsowithcablelengths15,35or50m

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Determinationofdeliverypressurepdo (Fig.2).This pressure with the pump set 1”-EVGU-16-8cannot exceed the value 0.8 MPA (80m of watercolumn), and with the pump set 1 ¼”-EVGU-25-6it cannot exceed the value0.6MPA (60mofwatercolumn).Deliverypressurepdo facilitates overcoming:a)Verticaldistancezvg (total static head of the pump equipment on the discharge side of water level at the lowestwater-levelstage inawellup to thehighestspot where water is transported);b) Resistances pzv generating within water flowing through the straight pipeline, elbows, bends, pipe fittings and fixtures built in the delivery pipeline;c) Overpressure ppforjetting-up(A)orinthepres-surevessel(B).

Whendeterminingthepipelinelengthduetocalcu-lation of losses to the pump discharge branch (not onlytowaterlevelinawatersource).

Table 2

pdo=pp+pzv+zvg

6. PUMP sEt fUnctioninG Turningmotionofthemotorshaft(8100)istrans-mittedbymeansoftheclutch(7000)andthecon-nection rod (2180) with rubber joints onto thepump helix (2500). When the helix is rotatingsome closed spaces are created in the stator cav-ity thanks to which a liquid can be delivered from thesuctioncasing (1200) to thedischargecasing(1310).On principle, the volume delivered depends only on thestatorhelixdimensions,andspeed.Liquid pressure generated by the pump is adaptedimmediatelytoback-pressureinthedeliverypipelineand it can attain to a high-risk pressure value re-sulting in a failure of the pump, an electric motor or otherequipment.

CAUTION!

That is why it is forbidden to:1. Use a throttle valve for controlling flow rate,

because flow rate throttling may increase back pressure and cause the electric motor over-pressure.

2. Put the pump into operation with the delivery pipeline being closed. Even during operation it is not permitted to close the delivery pipeline or increase pressure in any way above allo-wable values, that is: 0.8 MPa for 1”-EVGU and 0.6 MPa for 1 ¼” – EVGU.

It is inevitable to protect the pump set from the pressure excessive rise by means of suitable prote-ctionoftheelectricmotorandasafetyvalve.

Fig 2

EXAMPLE:(for11/4”-EVGU)Vertical distance zvg is 25 m, the pp measured byapressuregauge is0.15MPA.Overall lengthof pipeline 1 1/4” (from the pump branch to thejetting-up)is65mandithasgot5bends.Resist-ancesareobtainedfromtheTable2.

pzv=(6.5.0.022)+(5.0.00026)=0.143+0.0013=0.1443MPA

pdo=pd+pzv+zvg=0.15+0.1443+0.25=0.5443MPA

If the detected pressure is lower than the allowed pressure0.6MPA, the resultingstate is satisfac-tory. If thecalculatedpressureexceeds thevalue0.6MPA,itisnecessarytoreduceitwithusingapipelineoflargerinsidediameter.

Deliverypipelinediameter

MPA

Forevery10mofstraight pipeline there are losses pzv

1“ 0.08

11/4“ 0.022

11/2“ 0.0062

Resistanceof1pcofthebend90°inthelength of straight pipeline

1“ 0.00056

11/4“ 0.00026

11/2“ 0.001

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perhapseventhewaterleveldepthintheborehole.Minimumdiameterofaboreholeforthepumpsetshallbe150mm.

2.Lengthofpipelineandacableshallbepreparedaccording to the borehole or a water well depth andtheminimumwaterleveldepth.Itisnecessarytochoosesufficientlyrobustpipeline,withrigidjo-ints in view of weight of pipeline, the pump set and water.Itisrecommendedtousenewpipelinewithwell-screwed thread jointsor reinforced flanges.Pipelineshallbecleanedproperlybeforedismant-ling and remains of scale and other impurities are to be removed too. Burrs caused by cutting orthreading are to be removed by a file, as well as metal chips and fillings.Pipeline shall be rinsedwithwater.

3.Tosuspendthepumpsettogetherwithpipelineintoa dug well it is necessary to prepare and wall in ste-eltransversegirders(Fig.4)soastheyareabletoacceptloadsafely.Itisrecommendedtoplacethegirders so as they do not prevent access into the well.Asfordugwells,itisnecessarytoleantheas-sembly clip against the casing upper edge that must beinthesamedepthaspipelineoutsidethewell.Insuch a case it is useful to extend the borehole in its diameter up to the required depth and make well casing with the aid of big centres, as with dug wells (Fig.5).

CAUTION!

Pipeline of smooth surface and uniform cross-section between the pump and a safety valve shall be without stop valves.

1-Safetyvalve2-Cable3-Drain

4-Clip5-Girder6-Self-grippingstrip7-Casing

8. assEMBlY

Beforethepumpsetassemblyandinstallationitisnecessary:

1.When installing the pump set into a borehole itisnecessary to re-inspect theboreholealong itswhole length with lowering a check cylinder or

a check pipe of diameter 145 mm and of leng-th750mm.Thiscylinderor thepipemustpassthrough the whole borehole without any resistan-ce.Inthiswaywecandetermineaboreholedepth, Fig.5

1-PUMP2-POWERCABLE3-PLUGS,SOCKETS4-PROTECTIONANDCONTROLCABINET*)5-DISTRIBUTIONBOX6-PROBEOFWATERUPPERLEVEL7-PROBESOFWATERLOWERLEVEL8-CABLESOFWATERLEVELCONTROLLER9-CARRYINGCLIP10-SAFETYVALVE11-DELIVERYPIPELINE12-CLAMPINGSTRIP13-FLANGE14-NON-RETURNFLAPVALVE,VALVE

Fig.3

Positions3,4,5,6,7,8,9,10,11,12,13,14arenot included in the scope of standard deliveries!

*)Asforthepumpoftheworkmanshipversion“172”(single-phase)thereisastartprotectionbox, that is a part of standard deliveries

7. MAIN PARTS OF PUMP SET

Fig. 4

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PreparationofpumpsetoperationRemove the self-adhesive label “For continuouscontactwithpotablewater!”

CAUTION!While handling the pump (carrying, helix turnin-g-over, dismantling) it is necessary to disconnect it from mains to prevent mains connection by mi-stake! Fill the motor with clean /fresh water! For this purpose the pump set shall be placed in the vertical position with its discharge branch upwards, the sealing screw of filling hole in the motor flange, as well as the filter cartridge are to be removed, then the motor can be filled with fresh water through a suitable funnel.Waituntilwatergets toallplaces then incli-nethemotorof15°soasthefillingholewouldbeinthehighestpointandre-fillthemotor.Beforerefillingshake up the pump set gently so as air can leak more easily.Afterrefillinginsertthefiltercartridgeintotheholeanddrivethesealingscrew.

CAUTION!

After finishing electrical installation re-check theright sense of the pump set rotation. Pourwaterintothedischargecasing(Fig.6).

CAUTION!Before inserting a tool into the helix cavity and manual turning-over for several times it is inevi-table to re-check the pump set disconnecting from mains. There is a real risk of accident due to the tool shooting up at unexpected starting-up! Insert a suitable (flat, square or triangular) tool into the helix cavity(Fig.7)andturnitperhapsforfourtimestotheleft,thenremovethetool.Thehelixis“severed”fromthestator(namelyafterlong-lastingstorage).Re-fillwaterintothedischargecasingandputintoope-rationforashorttime.If the sense of rotation is not correct no water is flowing out of the pump discharge branch, so there is a real risk of the pump damage. If the sense of the pump set rotation is correct (that is according to the rotation arrow being placed on the pump set) water is flowing out of the discharge branch (fig. 8).Electricmotoristobe disconnected from mains and phase connections are tobedesignedduetonextconnection.

- interventions into electrical systems, as well as ex-change of any of two phases may be carried out solely by a person properly qualified in electrical enginee-ring!

CAUTION!

- due to testing sense of rotation the pump set can-not run for more than 2 seconds!

PUMP SET INSTALLATION INTO WATERSOURCE

Afterpreparingeverythingaccordingtothepreviousparagraphs the assembly can be commenced:

1.Connect the pipe to the pump set dischargebranch; an assembly clip serving for catching the pulley block rope is to be attached to the pipe another end and it can be lowered to the boreho-leedgeortothewellgirders.Anothertubewithsecondassemblyclipcanbeattachedtoitsend.Aftercatchingpulleyblockbysecondclipthefirst clip can be unlocked and the pump can be lowered into thewell togetherwith both pipes.This procedure of connecting other pipes is to be repeated until the pump set is located in the re-quireddepth.Insuchacasethatthesinglesecti-ons of pipes are longer than 3m, it is necessary to carry out assembly of the pipe single sections in two steps (assembly clip is to be placed in the middleofthepipe).

CAUTION!

Seal all joints thoroughly! Vertical pipeline from the pump set is to be provided with right-hand threads! For lowering the pump set into a well it is possible to use a suspension eye / holding tackle on the suc-tioncasing.Thissuspensioneye /holdingtacklecanbe used even for the pump set protection when using someplasticdeliverypiping.2.Ifthepumpshallbeloweredtothewellbottom

it is necessary to suspend it in such a manner toreachthemotorloweredgepositioning30cmfrom thebottom,at least.Duringoperation the

Fig.6 Fig.7

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5.Attachmentofverticalpipelineinawelltodelive-ry pipeline outside the well is recommended to be realizedwith theaidofa flangeorscrewedfitting.Itbringsadvantageofeasymountinganddismounting.

6.Outsidethewellitisnecessarytoputthepipinginfreezesafedepth(perhapsfrom110to130cm).Itis advantageous to place the piping into a channel builtfromburntbricks,accordingtotheFig.10.The channel is to be covered with soil to prevent itsdeformationorshift.Airgapofsuchachannelis very good insulation, so the pipeline can be put eveninasmallerdepth.Anotheradvantageisaneasy access to piping for repair, dismantling, and soon.Outsidethewellthedeliverypipingisputwith a flat gradient from the well and in the straight line, without useless bends

9.ELECTRIC EQUIPMENT9.1InGeneralAsapartofelectricequipmentofthepumps1“-EVGU-16-8-GU-080and1¼“-ECGU-25-6-GU-080thereisathree-phaseelectricmotorwithalead-in(service)cableAs a part of electric equipment of the pump1“-EVGU-16-8-GU-172 there is a single-phaseelectricmotorwithalead-in(service)cableandastartprotectionbox.TheboxconnectionisillustratedintheFig.12.

CAUTION!

Minimuminnerdiameterofwell=900mm–1”-EVGU-16 1000mm–1¼”-EVGU-25

1–Self-grippingstrip2–Pipe3–Screw4–Clamp5–Vent Fig.9

Fig.10

Fig.8

pump shall be wholly submerged under water level.Ifthereislittlewaterinawell,itispossibletomount the pump horizontally, “lying down”(Fig.9),howeveritisinevitableto:

a)Primethemotorthoroughlywithwaterwithfil-ling hole in its highest position;

b)Guaranteesufficientinsidediameterofthewell;c)Protect the cable fromdamagewhen lowe-

ringintoawell.

3.Ifthereisariskofwaterlackorinsufficiencyinawellitisnecessarytoprotectthepumpsete.g.byanelectrodeinterlockingdevice.

4.Cable can be attached to the vertical deliverypiping in successive steps, using self-grippingstrips.Ifthepipelineisconnectedwithflanges,itisfastenedineithersideofaflangedjointandwith longer sections of single delivery pipeline also in themiddle of it. It is recommended toprovide every flange by a groove for cable that is protected from damage during assembly in this manner.Duringassemblyitisnecessarytopreventstriking the pump set against girders or other ob-staclesinthewell.

CAUTION!

During assembly it is not allowed to pull at the cable or use it for the pump set carrying or tugging; the cable cannot be damaged due to im-pact or jamming!Cable upper end cannot get into touch with water!

WATER LEVEL

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systems, namely:- measurement of insulation resistance (it must be greater than 20MΩ)- recheck of correct set-up of overcurrent prote-ction- recheck of security of protection from hazardous touch voltageSingle-phasepumpstarting-upcanberealizedwiththe aid of a rocker switch located on the cabinet face boardwithpositionsOandI.Aftergettingthepumpelectric motor under voltage – the position I, the switchgreenbacklightisturnedon.Theposition0isdestinedforitsswitching-off.Withthepumpfirstputtingintooperationit isre-commendedtore-checksupplypressure,ampereload and keep thepump inoperation for10min.at least, in order to remove all impurities out of the pipelineorawatersource.

Pump can be put into operation solely with the pipeline being fully open!

If power supply has been damaged it must be replaced by the producer, a service engineer or other responsible and qualified person to prevent any dangerous conditions.

9.6MaintenanceIt is recommended to inspect and re-check theelectrical installation regularly, every six months, atleast.Inparticular it isnecessarytocheckterminalsre-tightening, including a protective earth conductor, protection from hazardous touch voltage and theequipment insulation characteristics – it must

9.2Pumpconnection

Pumpcanbeconnectedonlytomainswhosevaluesofvoltage and frequency conform with the data in the elect-ricmotorrateplate.Electricalequipmentassemblycanbe carried out only by people qualified in electrical engi-neering.Beforeloweringthepumpintoaboreholeitisnecessary to recheck the pump set and a cable whether theywerenotdamagedduringtransportation.The pump set must be disconnectable from the mains with the aid of a device that is provided with opening contacts at all poles, so the complete dis-connection is secured in terms of overvoltage of the CategoryIII.Thisequipmentmustbeinstalledintoa stationary line in accordance with all regulations validforlinesanditmustbeaccessible.This pump is to be always protected from over-current and cut-off. Over-current protection mustbe set to rated (breaking) current of the electric mo-tor(thepump).For three-phasepumpsthebestprotectioncanbeachievedbysettingtheover-currentprotectionele-ment to the value of the actually measured current consumption at the working place, but no more than to the value given in the table 1 or on the electric motor ratingplate. Examplesof connection are il-lustratedintheFigure11.Forthesingle-phasepump1“-EVGU-16-8-GU-172,itsover-currentprotectionissecuredinastartpro-tectionboxtothefixedvalue.Thecontrolandpro-tection cabinet is to be installed on a vertical surface withtheaidoftwoorfourboltswithspacingM4,according to the table in the section “Performancedata”.ExamplesofconnectionareillustratedintheFigure12.If it is not possible to guarantee enough water in a well,itisnecessarytoinstalle.g.electrodelockingdevicetoavoidrunningthepumpdry.ExamplesofwiringareillustratedintheFigure13.

9.3Protectionfromhazardoustouch voltage PumpprotectionfromhazardoustouchvoltageshallbeprovidedaccordingtothestandardCSN332000-4-41and associated standards (as for an installation site), namely it is a protection by automatic, self-actuateddisconnectionfromasource.Inparticularlyhazardousspacesitispossibletorealizeprotectionbyprotectivebondingorbyanearth-leakagecircuitbreaker.Itisne-cessarytouseanearth-leakagecircuitbreakerwithtimedelay/lagof10ms,atleast(withthe“G”and/or“S”designation).

9.4PuttingintooperationBefore putting the pump into operation it is neces-sary to carry out a check (a revision) of electrical

9.5OperationandServicingWith regard to themotor service life it is recom-mended not to exceed the number of switching operations18-times / hour – divided equally.Mi-nimumtimeofstand-still afterswitching-offshallbe90seconds.Ifthesingle-phasepumpisdisconnectedfromthemainsdue-tooverload,thereistheresetpushbut-ton of the thermal circuit breaker for unlocking the off-state,butonlyafterthecircuitbreakercooling-down(ca.1min.)andafterremovingthecauseofoverload.Pumpsetcanbeoperatedevenbypeoplewithoutanyqualificationinelectricalengineering.

If any failures or defects were found either in electrical installation or in

the pump, it is necessary to switch the pump off and inform a specialist in electrical engineering about these failures or defects

11

be greater than 2MΏ.Iftheinsulationresistanceis lower, it is necessary to dismantle the pump set andsenditforrepair.

Manipulation and repairs on the pump set and accessories can be carried out solely when the pump set is switched-

off and when operating conditions are safe.

Pumpset is tobecheckedcontinuously,whetherthere is any noise, vibration and current take-off.After the lapse of 6,000 operating hours it is re-commended to:-re-filltheelectricmotor,orreplaceradiallipsea-lingrings“gufero”andbearings;- re-check condition of components and ele-ments of the hydraulic part due to their wear, re-place them, if necessary

Fig.11

MOTOROVERCURRENTCIRCUITBREAKER,e.g.:

JUNCTION

BOXPLUG

ELECTRICMOTOR

GREE

N/YE

LLOW

BROWN

GREY

BLAC

K

GREE

N/YE

LLOW

BROWN

GREY

BLAC

K

Exampleofwiringdiagramforconnectingthecircuitbreakertothepump.

ELECTRICMOTOR1PJ6090-01,1.1kW,230V,50Hz

Fig.12Exampleoftheschematicwiringdiagramofthesingle-phasepumpwith a start protection cabinet

Příklad schema zapojení jednofázového čerpadla s rozběhovou skříňkou

Obr. 12.

BROWN–AUXILIAR

Y

GREY

(BLU

E)–M

AIN

BLAC

K–CO

MMON

GREEN/YELLO

W

S1– CIRCUITBREAKERF1 – THERMALCIRCUITBREAKERK1– STARTINGRELAYC1 – STARTPROTECTIONCAPACITORC2 – RUNCAPACITORX1– TERMINALBOARDZ1,Z2– INTERFERENCEELIMINATIONMEMBER

ESM1-4(2.5-4A)(ESM1-6(4-6.3A))

..

12

10. disMantlinG

Disconnect the pump from mains and secu-re it from mains connection by mistake!

Afterpullingoutofawellthepumpsetistobedis-connectedfromdeliverypipeline.Removethestator(1130),unscrewbolts (6570)and force thesuctioncasing (1200) off themotor (8100).Push the retai-ningrings(6544)accordingtotheFig.16outof theclutch(7000)andoutofthehelix(2500)andpulltheconnectionrod(2180)withflexiblecouplingsoutofthehelix(2500)andtheclutch(7000).Unscrewthebolt(6570.1)anddismantletheclutch(7000)–ithasgotleft-handthread.AssemblyFollow the reverse procedure outlined under disas-sembly.Onlywhenputtingtheconnectionrod(2180)onitisnecessarytoadaptcouplingsbygrinding-off/brushingaccordingtotheFig.18(usingemerypaper,fine-cutfile),becauseafteralongertimeofoperationthereisaraisededgeontheflexiblecouplings–seetheFig.17–obstruct theclutchengagement.Befo-re engagement of a flexible coupling into the clutch (7000)itisnecessarytoinsertthewasher(4510.1).

Fig.16

It is necessary to insert a file into a spot designated byanarrow(aslitring)andthrowtheringup.

Fig.17

Fig.18

Fig.13

MOTOROVERCURRENTCIRCUITBREAKER,e.g.:

JUNCTIONBOXPLUG

ELECTRICMOTOR

GREEN/YE

LLOW

BROWN

GREY

BLAC

K

GREEN/YE

LLOW

BROWN

GREY

BLAC

K

LIQUIDLEVELCONTROLLER

Exampleofwiringdiagramforconnectingthecircuitbreakerandtheliquidlevelcontrollertothepump.

13

11. SCOPE OF DELIVERY Standardscope-Pumpinfully-assembledstate,withacable-asforthesingle-phasepump,thestartprotectioncabinet is an integral part of standard deliveriesOn request:-ClipDN25for1”-EVGUorDN32for1¼”EVGU-Self-grippingstrips

12. storaGEThis pump set is to be protected from direct sunlight and solar radiation, frost, sudden changes of tempe-rature, excessive humidity, impurities and various chemicalimpacts.Asforstorageandservicingandmaintenanceofrub-berproductsthereistheStandardCSN630001.

13. WARRANTYTime duration of the warranty is given in the con-tractofpurchaseandinthecertificateofwarranty.However,theproducerdoesnotanswerfordamagescaused by incorrect and unprofessional servicing, the pump set overload or due to non-observanceorbreachofinstructionsgivenintheseServiceandassemblyinstructions.Duringwarrantyperioditispossibletocarryoutthepump dismantling solely with the agreement with theproducer.The warranty does not cover defects and failures incur-red due to wear and tear, external failure causes or du-ringtransportation.

14. APPENDIXCAUTION!

a) When removing troubles of power supply sys-tem the phase sequence changeover may hap-pen (even for a short time). thereby the op-posite sense of rotation may happen with the three-phase pump and there is a real danger of the pump failure

b) the most frequent defect is the pump rubber stator rubbing-out. the main cause of it is the pump running dry even for a short time (for se-veral seconds). Prevent from water dropping below the pump (lower than under minimum liquid level – fig. 3). if there is a small wa-ter supply/inflow in a well it is recommended to protect the pump from running dry with the aid of an interlocking device.

c)Allpartsofthispumpsetarereplaceable.Spareparts are available in factory outlets or in speci-ality-linestores.Mountingandservicingcanbecarriedoutintheproducer’sservicedepartmentsorinservicecentres.

d) In serious and complicated cases it is necessary to furnish information about the pump set pla-cing and positioning, as well as about its assem-bly, because the pump set reliable operation de-pendsnotonlyonwell-doneassemblybutalsoon correct placing and positioning, as well as on design.

e) Installation, checks and reviews, as well as the pump set repairs are to be given in charge of specialists/professionals – authorized servicecentres.

f) Pipelinetothepumpsetisnotanintegralpartofdeliveries.Electrodeinterlockingdeviceisnotalso included into the delivery scope (pump set protection from running dry in case of water de-ficiencyinawell).

15. list of aUtHoriZEd SERVICE CENTRESListofauthorizedservicecentresisgiveninthecertificateofwarranty.

14

16. notEs PrEParEd to HElP YoU PrEVEnt ProBlEMs as WEll AS DEAL WITH THEM

PROBLEM CAUSE OF PROBLEM MEASURES

1.Pumpisrunningbutnowaterand/orlittlewaterisdelivered.

a) Water shortage in a well orthe pump is not submerged sufficiently under the water level, soairleakagecanhappen.

a) Lower down the pump ordeepen the well. Pump cannotoperate dry –statorrubberwillbeburntout.

b)Damaged rubber cartridgeofstator.

b) Send for repair, replace thestatorbyanewone.

c) Pump opposite direction ofrotation.

c) Inspection and repair of the pump is inevitable. Carry outinterchanginganyoftwophases.This can be realized solely bya person properly qualified in electricalengineering.

d) Partial or total clogging ofsuctioninlets/holes.

d) It is necessary to pull the pump outofthesourceandcleanit.

e) Leakage of delivery pipeline(either joints leakage or it hasbecome leaky due to corroding processes and water flows through it back to a well or to soil).

e) Mend the pipeline jointssealing, replace leaky pipes (that is even the line placed underground).

f) Excessive wear of the pumpfunctionalparts.

f)Send thepumpset for repairor replace damaged parts by new ones.

g)Excessivesupplypressure(higherthan0.6MPswith1¼-EVGUand0.8MPawith1“-EVGU

Re-checkentiresupplypressureof the pump and reduce resistan-ces in pipeline, if possible (e.g.by choice of greater diameter ofpipeline). If it isnotpossibleto reduce supply pressure, it is nesessery to choose other pump withhighersupplypressure.

2.Pumpcannotbestartedup. a)Absenceofcurrentinelectricalpowernetwork,itisdead.

a) Notify the nearest distribution plantofthisfailure.

b) Fault in power supply from mains.

b)Inspectandre-check,repair.

c) Fault in the pump electric motor.

c)Sendforrepair.

15

d)Pumphelixgotstuck(however,this fault may happen only with thefirststarting-up,orafterlongoperationalshutdown).

d) It stands to reason that instructions relating to the pump installation into a well given in thisManualwere not observed.So it is necessary to pull thepump and pipeline out of the well. (Moredetailed informationcan be found in the Clause 8“Assembly”).

e) Broken connection rod ordamagedrubberjoints.

e) Send the pump for repair orreplace the connection rod by a newone.

f) Pumphas been cloggedwithsettle sludge originating from waterandfromdeliverypipeline.

f)Removeimpuritiesandensurefree rotation of the helix in the stator.

g) Opened contact of a thermal circuitbreakerdue-tooverloadofthepump(theelectricmotor).

g) After the circuit breakercooling-down and after removalcause of the pump overload it is necessary to depress the reset push button on the front board ofthestartprotectionbox.

h) Fault of the start protection capacitor or a relay

h)Startprotectionboxmustbesentforrepair.

3. Pump is running noisily(buzzing)andpowerconsumptionisexcessive.

a)Someof thephasesofstatorwinding have been short-circuitedorbrokenup.

a) Recheck in turn all motorphases,usinganamperemeter.If the motor is in good condition the current values in all phases areapproximatelyequal.

b)Winding insulation has beendamaged and fault current is passing through the protective bonding/guardcircuit.

b) Re-check insulation with theaid of an inductor. Insulationvalue shall be always higher than 0.5MΩ in hot conditions, and 2 MΩincoldconditions.

c)Bearingshavebeenworn-outordamaged.

c) It is recommended to send the pumpforrepair.

d) Clamping bolts of the pump or of themotorhavebeenloosened.

d) Re-tighten the screws andboltsuniformly.

16

17. GUidElinEs on disPosal of WastEDirectionstodisposalofwastegeneratingduringlifecycleofthepump(bycourseof§10,Cl.3oftheLawofWastesNo.185/2001oftheCodeofLaw,asamended).

Sort of waste Code1) Category Method of disposal

Paperandcardboardpackages

150101 OOtherwaste-Utilizablewaste–throughsortedrefusecollection in communities it is necessary to hand it overtoapersonauthorizedtowastedisposal.

200136 O

Entirelyworn-outelectricdevicesshallbepassed(freeofcharge)inaplacedestinedforit(collectionspot).Inno case it may be disposed together with normal mixed municipal waste! 3)

Sort of waste Code1) Category Method of disposal

Wasteofelectricalandelectronicdevices-scrapped/disabled parts

160214 O

Otherwaste–Utilizablewaste–aftersortingitisnecessarytohanditovertoapersonauthorizedforpurchaseofwasteorsecondaryrawmaterial.

Paperand/orcardboardpackages

150101 O

Otherscrapeddevices–metallic components of pumps (without any oil remains

170407 O

Otherscrapeddevices–non-metallic components of pumps (e.g.ofcarbon,carbide,ceramics)

160216 OOtherwaste–itisnecessarytocollectandhanditovertoawastedumpoperator.

Otherscrappedmaterials–rubber elements of pumps

160216 O

Otherwaste–itisnecessarytocollectandhanditovertodisposalinawasteincinerationplant.

Woodpacking 150103 O

Plasticpackages–foilofPE 150102 O

Smallplasticthings2) 160216 O

Other motor, gearbox and/or lubrication oils

130208 N

Hazardouswaste–itisnecessarytocollectandhanditovertodisposalbyanauthorizedperson.

Solventsandtheirmixtureswith preservative products (exceptoforganic-decomposable)

140601140602140603

N

1. Household appliances

2. součásti čerpadel pro průmysl

1) see the Public notice no. 381/2001 of the code of law, in which the catalogue of waste was published0–OtherwasteN–Hazardouswaste2) ATTENTION!Polytetrafluoroethylene(Teflon,PTFE)shallnotbeincineratedelsewherethaninawasteincinerationplantdue to their toxicity!

3) Thisdevicecannotbehandledashouseholdrefuse.Theproductshallbedisposedbyhandingitovertoacolle-ctionspotdestinedforrecyclingofelectricalandelectrotechnicaldevicesandequipment.Inordertogainmoredetailed information on this product recycling it is necessary to contact staff of a collection facility, or the staff of thestorewhereyouhaveboughtthisproduct.

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Pos. Name Drawing.No. Pcs

1130 Stator V737606 1

1200 Suctioncasing V745423 1

1310 Socket1½”x1 CSN138237.1 1

2180 Connection rod V402884 1

2500 Helix V724521 1

4510 Washer8 CSN021740 4

4510.1 Washer V114510 1

6544 Retainingring 3152385857670 2

6570 BoltM8x25 CSN021103 4

6570.1 BoltM6x8 CSN021185 1

7000 Clutch V535700 1

8100 Electricmotor 1P60-112-01 1

*1PJ6090-01

Pos. Name Drawing.No. Pcs

1130 Stator V723076 1

1200 Suctioncasing V739907 1

1310 Dischargecasing V587168 1

2180 Connection rod V4022582731111077340

1

2500 Helix V746475 1

4510 Washer8 CSN021740 4

4510.1 Washer V400945 1

6544 Retainingring 3152382000220 2

6570 BoltM8x25 CSN021103 4

6570.1 BoltM6x8 CSN021185 1

7000 Clutch V402257 1

8100 Electricmotor 1P60-112-01 1

Whenorderingsparepartsitisnecessarytogive the serial number of the pump marked in the rating plate, the pump type, positions and componentnumber.

18. sParE Parts

1“-EVGU-16-8-GU-080,-172* Table 3

11/4“-EVGU-25-6-GU-080 Table4

Wereservetherighttoalterdata,textandillustrationswithoutpriornotification.

TD51502 0511

SIGMA 1868 spol. s r.o.JanaSigmunda79

78350LutínCzechRepublic

Tel.:+420585651302Fax:+420585651339www.sigma1868.cz