Grundfos SQE-NE Series Installation And Operating Instructions Manual

Page 1
English (GB) Installation and operating instructions
Caution
Note
English (GB)
Original installation and operating instructions.
CONTENTS
Page
1. Symbols used in this document
2. General
2.1 Applications
3. Technical data
3.1 Storage
3.2 Sound pressure level
4. Preparation
4.1 Refilling of motor liquid
4.2 Positional requirements
4.3 Liquid temperatures/cooling
5. Electrical connection
5.1 General
5.2 Motor protection
5.3 Connection of motor
6. Installation
6.1 General
6.2 Assembly of pump part and motor
6.3 Removal of non-return valve
6.4 Fitting the cable plug to the motor
6.5 Fitting the cable guard
6.6 Cable sizing
6.7 Fitting the submersible drop cable
6.8 Pipework connection
7. Start-up
8. Operation
8.1 Minimum flow rate
8.2 Selection of diaphragm tank and setting of precharge pressure and pressure switch
8.3 Built-in protection
9. Maintenance and service
9.1 Contaminated pumps
10. Fault finding chart
10.1 Megging
11. Checking the power supply
12. Environment
13. Disposal
Warning Prior to installation, read these
installation and operating instructions. Installation and operation must comply with local regulations and accepted codes of good practice.
8 8
8
9
9 9
10
10
1. Symbols used in this document
10 10
11
11 12 12
12
12 12 12 13 13
2. General
14 14
15
instructions, you will find copies of the pump and motor nameplates.
16
Before the SQ/SQE pump is lowered into the
16
borehole, this page should be filled in with the
16
relevant nameplate data. These installation and operating instructions must be
kept in a dry place near the installation site for
16
reference purposes.
17
17
2.1 Applications
17
The SQ and SQE pumps are designed for pumping thin, clean, non-aggressive, non-explosive liquids,
18
not containing solid particles or fibres.
19
Typical applications:
20
• Groundwater supply for
20 20
• Liquid transfer in tanks.
• Pressure boosting.
Warning The use of this product requires
experience with and knowledge of the product. Persons with reduced physical, sensory or mental capabilities must not use this product, unless they are under supervision or have been instructed in the use of the product by a person responsible for their safety. Children must not use or play with this product.
Warning If these safety instructions are not
observed, it may result in personal injury!
If these safety instructions are not observed, it may result in malfunction or damage to the equipment!
Notes or instructions that make the job easier and ensure safe operation.
– private housing – small waterworks – irrigation systems in for instance green houses.
8
Page 2
The SQE-NE pumps are designed for pumping thin,
Note
clean, non-explosive liquids, not containing solid particles or fibres.
These pumps are suitable for pumping contaminated or hydrogen-carbonate containing groundwater, e.g. from
• dumps
• chemical depots
• industrial areas
• oil and petrol filling stations
• environmental applications. The SQE-NE pumps can also be used for sampling
and monitoring and to some extent for incorporation in water treatment systems.
Information applying to all pump types
The maximum sand content of the water must not exceed 50 g/m the life of the pump and increase the risk of blocking.
pH values
SQ and SQE: 5 to 9. SQE-NE: Please contact Grundfos.
Liquid temperature
The temperature of the pumped liquid must not exceed 35 °C.
3
. A larger sand content will reduce
If liquids with a viscosity higher than that of water are to be pumped, please contact Grundfos.
3. Technical data
Supply voltage
1 x 200-240 V - 10 %/+ 6 %, 50/60 Hz, PE. Operation via generator: As a minimum, the generator output must be equal to the motor P + 10 %.
Starting current
The motor starting current is equal to the highest value stated on the motor nameplate.
Power factor
PF = 1.
Motor liquid
Type SML 2.
Motor cable
1.5 m, 3 x 1.5 mm
Liquid temperature
Maximum 35 °C.
Pump outlet size
SQ 1, SQ 2, SQ 3: Rp 1 1/4. SQ 5, SQ 7: Rp 1 1/2.
Pump diameter
74 mm.
Borehole diameter
Minimum 76 mm.
Installation depth
Maximum 150 m below static water level. See also section 6.8.2 Installation depths.
Net weight
Maximum 6.5 kg.
2
, PE.
3.1 Storage
Storage temperature: -20 °C to +60 °C.
3.1.1 Frost protection
If the pump has to be stored after use, it must be stored on a frost-free location or it must be ensured that the motor liquid is frost-proof.
The motor must not be stored without being filled with motor liquid.
3.2 Sound pressure level
The sound pressure level of the pump is lower than the limiting values stated in the EC Council Directive 2006/42/EC relating to machinery.
[kW]
1
English (GB)
9
Page 3
4. Preparation
10
Allowed
Not allowed
English (GB)
Grundfos MS 3 and MSE 3 submersible motors have water-lubricated slide bearings. No additional lubrication is required.
The submersible motors are factory-filled with a special Grundfos motor liquid (type SML 2), which is frost-proof down to - 20 °C and preserved to prevent the growth of bacteria. The level of motor liquid is decisive for the operating life of the bearings and consequently the life of the motor.
4.1 Refilling of motor liquid
If for any reason the motor liquid has been drained or lost, the motor must be refilled with Grundfos motor liquid SML 2.
To refill the motor, proceed as follows:
1. Remove the cable guard and separate the pump part from the motor.
Fig. 1
2. Place the motor in vertical position with an inclination of approx. 10 °.
3. Remove the filling plug using a screwdriver or a similar tool.
4. Inject motor liquid into the motor with a filling syringe or the like.
5. To allow possible air to escape, move the motor from side to side.
6. Refit the filling plug and make sure it is tight.
7. Assemble pump part and motor.
8. Refit the cable guard.
The pump is now ready for installation.
4.2 Positional requirements
The pump is suitable for vertical as well as horizontal installation, however, the pump shaft must never fall below the horizontal plane. See fig. 2.
Fig. 2
If the pump is to be installed horizontally, e.g. in a tank, and there is a risk that the pump might be covered by mud, it must be fitted in a flow sleeve.
For installation depths, see section 6.8.2.
4.3 Liquid temperatures/cooling
Figure 3 shows an SQ/SQE pump installed in a borehole. The pump is operating.
Figure 3 illustrates the following:
• borehole diameter
• pump diameter
• temperature of pumped liquid
• flow past the motor to the pump suction strainer.
TM02 9606 3504
TM01 1375 4397
10
Page 4
Fig. 3
Caution
Caution
Liquid
temperature
Borehole diameter
Pump diameter
Caution
To ensure sufficient cooling of the motor, it is important to observe the maximum liquid temperature of 35 °C under all conditions.
The borehole diameter must be at least 76 mm (approx. 3").
The motor should always be installed above the well screen. If a flow sleeve is used, the pump may be installed freely in the borehole.
Do not let the pump run against a closed discharge pipe for more than 5 minutes. When the discharge pipe is closed, there is no cooling flow and there is a risk of overtemperature in motor and pump.
If the actual temperature of the pumped liquid exceeds the specified value or the operating conditions otherwise fall outside the specified conditions, the pump may stop. Please contact Grundfos.
5. Electrical connection
5.1 General
The electrical connection should be carried out by an authorised electrician in accordance with local regulations.
Warning Before starting work on the pump,
make sure that the power supply has been switched off and that it cannot be accidentally switched on.
The pump must be earthed. The pump must be connected to an
external mains switch with a minimum contact gap of 3 mm in all poles.
If the motor cable is damaged, it must be replaced by Grundfos, an authorised Grundfos service workshop or similarly qualified persons to avoid a hazard.
The supply voltage, rated maximum current and power factor (PF) appear from the motor nameplate.
The required voltage for Grundfos submersible motors, measured at the motor terminals, is - 10 %/ + 6 % of the nominal voltage during continuous operation (including variation in the supply voltage and losses in cables).
TM01 0518 1297
If the pump is connected to an electric installation where an earth-leakage circuit breaker (ELCB) is used as an additional protection, this circuit breaker must trip out when earth fault currents with DC content (pulsating DC) occur.
The earth leakage circuit breaker must be marked with the following symbol: .
Supply voltage
1 x 200-240 V - 10 %/+ 6 %, 50/60 Hz, PE. The current consumption can only be measured by
means of a true RMS instrument. If other instruments are used, the value measured will differ from the actual value.
On SQ/SQE pumps, a leakage current of 2.5 mA at 230 V, 50 Hz, can typically be measured. The leakage current is proportional to the supply voltage.
The SQE and SQE-NE pumps can be connected to a control box, type CU 300 or CU 301.
The pump must never be connected to a capacitor or to another type of control box than CU 300 or CU 301. The pump must never be connected to an external frequency converter.
English (GB)
11
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5.2 Motor protection
Caution
Caution
NL
P
Pressure switch
Note
L
156 mm
English (GB)
The motor incorporates thermal overload protection and requires no additional motor protection.
5.3 Connection of motor
The motor incorporates a starter device and can therefore be connected directly to the mains.
Start/stop of the pump will typically be done via a pressure switch. See fig. 4.
The pressure switch must be rated for the maximum amps of the specific pump size.
Fig. 5
3. Grease the motor shaft end with the grease supplied with the motor.
4. Screw the pump part on the motor (55 Nm). Caution: The pump shaft must engage with the motor shaft. A spanner may be used on the clamping faces of the pump part. See fig. 6.
Fig. 6
TM02 8425 5203TM01 2854 3804
Fig. 4
6. Installation
6.1 General
Warning Before starting any work on the pump/
motor, make sure that the power supply has been switched off and that it cannot be accidentally switched on.
Do not lower or lift the pump by means of the motor cable.
The loose data plate supplied with the pump should be fixed close to the installation site.
6.2 Assembly of pump part and motor
To assemble pump part and motor, proceed as follows:
1. Place the motor horizontally in a vice and tighten it. See fig. 6.
2. Pull the pump shaft out to the position shown in fig. 5.
12
Motor (P2)
[kW]
[mm]
0.70 120
TM01 1480 4697
1.15 102
1.68 66
1.85 66
When pump part and motor have been assembled correctly, there must not be a clearance between pump part and motor.
6.3 Removal of non-return valve
If a pump without non-return valve is required, the valve can be removed as follows:
1. Cut off the legs of the valve guide using side­cutting pliers or a similar tool. See fig. 7.
2. Turn the pump upside down.
3. Check that all loose parts fall out of the pump.
TM01 4337 0199
Fig. 7
SQE-NE is supplied without non-return valve.
The non-return valve can be fitted in a Grundfos service workshop.
L
TM01 4338 0199
Page 6
6.4 Fitting the cable plug to the motor
Warning The motor plug must under no
circumstances be removed by the user. The following description is exclusively
intended for service personnel. If the motor cable is to be replaced, see
section 5.1 General. The cable with plug must be fitted or
removed by an authorised Grundfos service workshop or a similarly qualified person.
The cable plug supplied with the motor is factory­greased. Check that the plug is greased correctly.
To fit the cable plug, proceed as follows:
1. Check that the cable is of the correct type, cross­section and length.
2. Check that the mains on the location has correct connection to earth.
3. Check that the motor socket is clean and dry. Make sure that the loose gasket has been fitted.
4. Press the cable plug onto the motor socket. The plug cannot be fitted wrongly. See fig. 8.
6.5 Fitting the cable guard
To fit the cable guard, proceed as follows:
1. Make sure that the submersible drop cable lies flat in the cable guard.
2. Place the cable guard in the groove in the cable plug. The two flaps of the cable guard must engage with the upper edge of the pump sleeve. See fig. 9.
Fig. 9
3. Fasten the cable guard to the pump suction strainer with the two self-tapping screws supplied. See fig. 10.
English (GB)
TM02 9613 3504TM01 4427 0299
Fig. 8
5. Fit and tighten the four screws (1 - 1.5 Nm). See fig. 8.
When the plug has been fitted, there must not be a clearance between the motor and the cable plug.
TM02 9605 3504
Fig. 10
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6.6 Cable sizing
Caution
English (GB)
Grundfos can supply submersible drop cables for any type of installation.
The cross-section of the submersible drop cable must be large enough to meet the voltage requirements specified in section 5.1 General.
The table values below are calculated from the following formula:
I x 2 x 100 x PF x L x ρ
q=
U x ΔU
where q = Cross-section of submersible drop cable
[mm
2
]. I = Rated maximum current of the motor [A]. PF = 1.0. L = Length of submersible drop cable [m]. ρ = Specific resistance: 0.02 [Ωmm U = Nominal voltage [V]. ΔU = Voltage drop [%] = 4 %. The 4 % voltage drop is according to IEC 3-64,
HD-384 Series. The calculation gives the following maximum cable
lengths at a supply voltage of 240 V:
Motor
(P2)
[kW] [A]
I
N
1.5 mm
0.7 5.2 80 112 133 176 213 320
1.15 8.4 50 69 83 109 132 198
1.68 11.2 37 52 62 82 99 149
1.85 12 35 49 58 76 92 139
2
/m].
Max. cable length [m]
2.1 mm2/
2
14 AWG
2.5 mm
Cable size
3.3 mm2/
2
12 AWG
4 mm
2
6 mm
2
6.7 Fitting the submersible drop cable
It is recommended to join the submersible drop cable and the motor cable by means of a Grundfos cable termination kit, type KM.
Cable termination kit, type KM
Cross-sectional area Product number
1.5 to 2.5 mm
4.0 to 6.0 mm
For larger cross-sections, please contact Grundfos.
14
2 2
96021462 96021473
Page 8
6.8 Pipework connecti on
Note
3 metres
Max. 150 metres
1
2
Caution
Caution
If a tool, e.g. a chain pipe wrench, is used when the riser pipe is fitted to the pump, the pump must only be gripped by the pump discharge chamber.
When connecting plastic pipes, a compression coupling should be used between the pump and the first pipe section.
For pumps fitted with plastic pipes, the expansion of the pipes when loaded should be taken into consideration, when deciding on the in st al lat io n d ept h of the pump.
Where flanged pipes are used, the flanges should be slotted to take the submersible drop cable.
Figure 11 shows a pump installat ion with indication of:
• position of cable clips, pos. 1, and distance
between the clips.
• fitting of straining wire, pos. 2.
• maximum installation depth below the static
water level.
6.8.1 Cable clips
Cable clips must be fitted every 3 metres. See fig. 11.
When connecting plastic pipes, some slackness must be left between each cable clip as plastic pipes expand when loaded.
Where flanged pipes are used, the cable clips should be fitted above and below each joint.
6.8.2 Installation depths Maximum installation depth below the static water
level: 150 metres. See fig. 11. Minimum installation depths below the dynamic
water level:
Vertical installation: During start-up and operation, the pump must always be completely submerged in water.
Horizontal installation: The pump must be installed and run at least
0.5 metres below the dynamic water level. If there is a risk that the pump might be covered by mud, the pump must always be fitted in a flow sleeve.
6.8.3 When lowering the pump into the borehole
It is recommended to secure the pump by an unloaded straining wire. See fig. 11, pos. 2.
Slacken the straining wire so that it becomes unloaded and lock it to the borehole seal by means of wire locks.
The straining wire must not be used for pulling the pump with riser pipe out of the borehole.
English (GB)
Fig. 11
Do not lower or lift the pump by means of the motor cable.
TM01 0480 4397
15
Page 9
7. Start-up
Caution
Caution
C
B
A
Q
p
pre
p
min
p
cut-in
p
cut-out
Q
max
Diaphragm tank
Pressure switch
English (GB)
Make sure that the well is capable of yielding a minimum quantity of water corresponding to the pump capacity.
Do not start the pump until it is completely submerged in the liquid.
Start the pump and do not stop it until the pumped liquid is completely clean, as otherwise the pump parts and the non-return valve may choke up.
8. Operation
8.1 Minimum flow rate
To ensure the necessary cooling of the motor, the pump flow rate should never be set to a value lower than 50 l/h.
If the flow rate suddenly falls, the reason might be that the pump is pumping more water than the borehole can yield. The pump must be stopped and the fault corrected.
The pump dry-running protection is effective only within the recommended duty range of the pump.
8.2 Selection of diaphragm tank and setting of precharge pressure and pressure switch
Warning The installation must be designed for
the maximum pump pressure.
As the pump has a built-in soft starter giving a run-up time of 2 seconds, the pressure at the pressure switch and diaphragm tank during starting will be lower than the pump cut-in pressure set on the pressure switch (p called minimum pressure (p
). This lower pressure is
cut-in
min
).
is equal to the desired minimum pressure at the
p
min
highest tap + head and head loss in the pipe from the pressure switch and diaphragm tank to the highest
= B + C). See fig. 12.
tap (p
min
Fig. 12
A: Head + head loss from dynamic water level
to diaphragm tank.
B: Head + head loss from diaphragm tank to
highest tap.
C: Minimum pressure at highest tap.
Make sure that the selected pump can deliver a pressure higher than p +A.
p
: Precharge pressure of diaphragm tank.
pre
: Desired minimum pressure.
p
min
p
: Cut-in pressure set on pr essure switch.
cut-in
: Cut-out pressure set on pressure switch.
p
cut-out
: Maximum flow at p
Q
max
min
.
cut-out
TM00 6445 3795
16
Page 10
min
Note
Note
and Q
Using p can be found in the guideline table below:
, the minimum diaphragm tank size, precharge pressure and pressure switch settings
max
Example
= 35 m head, Q
p
min
= 2.5 m3/h.
max
On the basis of this information, the following values can be found in the table: Minimum diaphragm tank size = 33 litres.
= 31.5 m head.
p
pre
= 36 m head.
p
cut-in
p
= 50 m head.
cut-out
[m3/h]
Q
max
p
p
min
0.6 0.8 1 1.2 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8
[m]
[m]
pre
p
cut-in
[m]
Diaphragm tank size [litres]
25 8 8 18 18 18 18 24 33 33 50 50 50 50 80 80 80 80 80 22.5 26 40 30 8 8 18 18 18 24 33 33 50 50 50 50 80 80 80 80 80 27 31 45 35 8 181818182433335050508080808080 31.5 36 50 40 8 1818181824335050508080808080 36 41 55 45 8 18181824333350505080808080 40.5 46 60 50 8 181818243350505080808080 45 51 65 55 18 18 18 18 24 33 50 50 50 80 80 80 49.5 56 70 60 18 18 18 18 24 33 50 50 80 80 80 80 54 61 75 65 18 18 18 24 24 33 50 50 80 80 80 80 58.5 66 80
1 m head = 0.098 bar.
8.3 Built-in protection
The motor incorporates an electronic unit which protects the motor in various situations.
In case of overload, the built-in overload protection will stop the pump for 5 minutes. After that period, the pump will attempt to restart.
If the pump has been stopped as a result of dry running, it will start automatically after 5 minutes.
If the pump is restarted and the borehole is empty, the pump will stop after 30 seconds.
Resetting of the pump: Switch off the power supply for 1 minute.
The motor is protected in case of:
• dry running
• voltage surges (up to 6000 V)
In areas with high lightning intensity, external lightning protection is required.
• overvoltage
• undervoltage
• overload
• overtemperature.
SQE pumps/MSE 3 motors
9. Maintenance and service
The pumps are normally maintenance-free. Deposits and wear may occur. For that purpose,
service kits and service tools are available from Grundfos. The Grundfos Service Manual is available on request.
The pumps can be serviced at a Grundfos service centre.
9.1 Contaminated pumps
If a pump has been used for a liquid which is injurious to health or toxic, the pump will be classified as contaminated.
If Grundfos is requested to service the pump, Grundfos must be contacted with details about the pumped liquid, etc. before the pump is returned for service. Otherwise Grundfos can refuse to accept the pump for service.
However, any application for service (no matter to whom it may be made) must include details about the pumped liquid if the pump has been used for liquids which are injurious to health or toxic.
Via the CU 300 or CU 301, the dry­running stop limit of the MSE 3 motors can be adjusted to match the actual application.
p
cut-out
[m]
English (GB)
17
Page 11
SQE-NE: Only pumps that can be certified as
English (GB)
uncontaminated, i.e. pumps containing no hazardous and/or toxic material, may be returned to Grundfos for servicing.
To prevent injury to the health of persons involved and to the environment, a document certifying that the pump is clean is required.
Grundfos must receive this certificate before the product. Otherwise, Grundfos will refuse to accept the product for servicing.
Possible costs of returning the pump are paid by the customer.
10. Fault finding chart
Warning Before starting any work on the pump/motor, make sure that the power supply has been
switched off and that it cannot be accidentally switched on.
Fault Cause Remedy
1. The pump does not run.
2. The pump runs but gives no water.
a) The fuses in the electric
installation are blown.
b) The ELCB or the voltage-operated
ELCB has tripped out. c) No power supply. Contact the power supply authorities. d) The motor protection has cut off
the power supply due to overload. e) The pump/submersible drop cable
is defective. f) Overvoltage or undervoltage has
occurred. a) The discharge valve is closed. Open the valve. b) No water or too low water level in
borehole. c) The non-return valve is stuck in its
closed position. d) The suction strainer is choked up. Pull out the pump and clean the strainer. e) The pump is defective. Repair/replace the pump.
Replace the blown fuses. If the new ones blow too, the electric installation and the submersible drop cable should be checked.
Cut in the circuit breaker.
Check whether the motor/pump is blocked.
Repair/replace the pump/cable.
Check the power supply.
See item 3 a).
Pull out the pump and clean or replace the valve.
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Page 12
Fault Cause Remedy
CC
U
U
U
PE
N
L
C
C
3. The pump runs at reduced capacity.
a) The drawdown is larger than
anticipated.
b) The valves in the discharge pipe
are partly closed/blocked.
c) The discharge pipe is partly
Increase the installation depth of the pump, throttle the pump or replace it by a smaller model to obtain a smaller capacity.
Check and clean/replace the valves, if necessary.
Clean/replace the discharge pipe.
choked by impurities (ochre).
d) The non-return valve of the pump
is partly blocked.
e) The pump and the riser pipe are
partly choked by impurities (ochre).
Pull out the pump and check/replace the valve.
Pull out the pump. Check and clean or replace the pump, if necessary. Clean the
pipes. f) The pump is defective. Repair/replace the pump. g) Leakage in the pipework. Check and repair the pipework. h) The riser pipe is defective. Replace the riser pipe. i) Undervoltage has occurred. Check the power supply.
4. Frequent starts and stops.
a) The differential of the pressure
switch between the start and stop pressures is too small.
b) The water level electrodes or level
switches in the reservoir have not been installed correctly.
Increase the differential. However, the stop pressure must not exceed the operating pressure of the pressure tank, and the start pressure should be high enough to ensure sufficient water supply.
Adjust the intervals of the electrodes/level switches to ensure suitable time between the cutting-in and cutting-out of the pump. See installation and operating instructions for the automatic devices used. If the intervals between stop/start cannot be changed via the automatics, the pump capacity may be reduced by throttling the discharge valve.
c) The non-return valve is leaking or
stuck half-open.
Pull out the pump and clean/replace the
non-return valve. d) The supply voltage is unstable. Check the power supply. e) The motor temperature gets too
high.
Check the water temperature.
English (GB)
10.1 Megging
Megging of an installation incorporating SQ/SQE pumps is not allowed, as the built-in electronics may be damaged. See fig. 13.
Fig. 13
TM02 0689 5000
19
Page 13
11. Checking the power supply
L N PE
Subject to alterations.
English (GB)
Warning Before starting any work on the pump/motor, make sure that the power supply has been
switched off and that it cannot be accidentally switched on.
1. Supply voltage
2. Current consumption
Measure the voltage (RMS) between phase and neutral. Connect the voltmeter to the terminals at the connection.
TM00 1371 4904
Measure the current (RMS) while the pump is operating at a constant discharge head (if possible, at the capacity where the motor is most heavily loaded).
For maximum current, see nameplate.
TM00 1372 5082
12. Environment
During handling, operation, storage and transport, all environment regulations dealing with the handling of hazardous materials must be observed.
Warning When the pump is taken out of
operation, it must be ensured that no hazardous material is left in the pump/ motor and the riser pipe, which can be injurious to persons and the environment.
In case of doubt, please contact Grundfos or the local authorities.
The voltage should, when the motor is loaded, be within the range specified in section 5. Electrical connection. Large variations in supply voltage indicate poor power supply, and the pump should be stopped until the defect has been remedied.
If the current exceeds the full load current, there are the following possible faults:
• Poor connection in leads, possibly in the cable joint.
• Too low supply voltage, see item 1.
13. Disposal
This product or parts of it must be disposed of in an environmentally sound way:
1. Use the public or private waste collection service.
2. If this is not possible, contact the nearest Grundfos company or service workshop.
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