KSB CORA 1C, CORA 7C, CORA 2C, CORA 12C, CORA 2AH Operating Instructions Manual
...
Operating Instructions
3300.810 / 06 - 85 G3
Submersible Motor Pumps (100 mm)
100 mm Submersible Motor Pumps
(50 Hz)
Contents
Submersible motor pumps (100 mm)
Sr. no. Description Page no.
1 General 1
1.1 Safety of pumping unit 1
1.1.1 Checks & Safety of pumping unit 1
1.1.2 Instructions on unit (Printed matter) 1
1.1.3 For unauthorized spare part and modifications 1
1.1.4 For unauthorized modes of operation 1
1.1.5 Water characteristics 1
1.2 Description of Product 1
1.2.1 Designation (example) of pump 1
1.2.2 Designation (example) of motor 1
2 Installation 1
2.1 Installation and operational accessories 1
2.2 Motor preparations 1
2.2.1 Motor fill 1
2.2.2 Insulation resistance (IR) 2
2.2.3 Extended Cable connection 2
2.2.3.1 Selection of Cable 2
2.2.4 Coupling of pump and motor 2
2.3 Typical installation at site 3
2.3.1 Vertical installation 3
2.3.2 Horizontal Installation (e.g. in tank or pit) 3
2.3.3 Plastic / Flexible Rubber riser piping instead
of normal GI riser piping 3
2.3.4 Installation of water level guard 4
2.3.5 Protection against electric shock 4
2.3.6 Fixing the power supply cable to the riser pipe 4
2.3.7 Verification of power line with respect to
motor design 4
2.3.8 Trip circuit for over current 4
2.4 Starting mode 4
2.4.1 For single-phase motor 4
2.4.2 For three-phase motor 5
Sr. no. Description Page no.
8 Trouble shooting 8
8.1 Motor 8
8.2 Pump 9
9 Schematic Cross-sectional Drawings 10
9.1 Pump - CORA 100 (Radial flow) 10
9.2 Pump - CORA 18C (Mix flow) 11
9.3 Pump - CORA 2AH, 3AH & 3A (Radial flow) 12
9.4 Motor - UMA 100 13
9.5 Motor - UMA I 100 & UMA I (S) 100 14
9.6 Motor - UMT (S) 100 15
9.7 Motor - XUMA (S) 100 16
Annexure I - Environment Protection Product Disposal after useful life 17
3 Commissioning and start up 5
3.1 Verification of rated current 5
3.2 Switching ON of mains 5
3.3 Checking the direction of rotation 5
3.4 Discharge valve position during initial start-up 5
3.5 Operation against a closed discharge valve 5
3.6 Operation against a throttled discharge valve 5
3.7 Operating limits of pump 5
3.8 Switching frequency 5
3.9 Interruptions / Shutdown periods 6
4 UMT (S) 100 motors 6
4.1 The motor is hermetically sealed induction motor 6
4.2 Connecting the motor 6
4.2.1 Starter panel 6
5 Maintenance 7
5.1 Storage 7
6 Services 7
7 Recommended stock of spare parts for
2 years of continuous operation 7
Submersible motor pumps (100 mm)
1 General
Submersible motor pumps by KSB have been developed in
accordance with state-of-the-art of design and manufacturing
technology with extreme care and rigid quality control. The manual
contains important information for reliable operation of pump.
The special feature of these submersible pumps is installation in
narrow deep wells to pump clean water for various applications
like water supply system, irrigation sprinkling systems, ground
water lowering, pressure boosting, fountains etc.
For any additional information or instructions please contact KSB’s
nearest office.
1.1 Safety of pumping unit
This operating manual contains fundamental installation,
operation and maintenance instructions. Hence this must be
clearly understood by concerned people, prior to installation. The
booklet must always be located for easy access at site.
1.1.1 Checks & Safety of pumping unit
Check for any transit damage. After unpacking inspect the pumpmotor for any signs of shaft deflection and for the damage of the
lead cable.
This operating manual does not take into account any safety
regulations those may apply. It’s a pump operator’s responsibility
that any such regulations are adhered to.
1.2 Description of Product
1.2.1 Designation (example) of pump
CORA 100 4 C / 7
Type series
Min. well diameter in mm
(100 mm ~ 4 inches)
Capacity for 50 Hz (in m3/hr.)
Design status
No. of stages
1.2.2 Designation (example) of motor
UMA / XUMA I (S) 100 - 0.8 / 2 1
Type series
Design variant
Single Phase
Min. well diameter in mm
(100 mm ~ 4 inches)
Electrical reference no.
No. of pair of poles
Winding wire insulation
1.1.2 Instructions on unit (Printed matter)
Follow the instructions attached on the motor / pump e.g.
- Arrow indicating the direction of rotation
- Various plugs for water connections viz. filling, venting, draining
etc. on motor
1.1.3 For unauthorized spare part and modifications
Modifications or alterations of the equipment supplied are strictly
not permitted. Original spare parts and accessories authorized
by the manufacturer ensure safety. The use of spurious parts
invalidates any liability of the manufacturer for consequential
damage.
1.1.4 For unauthorized modes of operation
The warranty related to the operation reliability and safety of the
unit supplied is valid only if the equipment is operated according
to designated parameters. The operating limits should not differ
from the limits specified on the nameplate.
1.1.5 Water characteristics
Submersible pumps are designed for handling clean or slightly
contaminated water with the following main characteristics : (As
per IS 8034 : 2002)
a) Turbidity : 50 ppm*, Max. (Silica scale)
b) Chlorides : 500 ppm*, Max.
c) Total Solids : 3000 ppm*, Max
d) pH value : 6.5 to 8.5
e) Temperature : 330 C, Max
f) Specific gravity : 1.004
g) Hardness : 300, Max (Drinking water)
* ppm – parts per million
2 Installation
2.1 Installation and operational accessories
The motor is supplied with a 3 meter long, 3 core waterproof
cable.
The following accessories are necessary for installation and
commissioning :
• A cable with vulcanizing rubber compound (which is normally
used for repairing the punctures in automobiles) and electric
insulation PVC tapes.
• Control panel
• 2 pairs of supporting or installation clamps for vertical
installation and 1 set of stands for horizontal installation.
• Overload trip unit, water level guard, single-phase preventor
(for 3 phase motor).
2.2 Motor preparations
2.2.1 Motor fill
For filling the motor with pure cold drinking water, follow the
procedure given below :
• Place the motor vertically up.
• Remove the two plugs provided at the top of the motor (Here
one plug is provided to escape the air and another for filling
the water).
• Fill the motor completely with pure water having no impurities
(Do not use distilled water).
• After filling the motor let it stand for 30 minutes and rotate the
rotor by hand to accelerate the escape of trapped air.
• At the same time pour more water to fill the loss of volume
caused by the escaped air bubbles.
• Refit the plugs.
• Check the motor completely for any leakages of water.
1
Submersible motor pumps (100 mm)
Now motor is ready for operation.
If a unit has been in storage for more than 2 months, check for
the motor filling and for rotor freeness.
2.2.2 Insulation resistance (IR)
The insulation resistance value of the new motor with 500 V DC
megger is generally 20 Mega Ohms. For older motors if the value
observed to be less than 2 Mega Ohms, please contact KSB or
Authorized Dealer before switching on the motor.
2.2.3 Extended Cable connection
Only the proper cable connector ensures a perfect watertight
joint and provides a protection against mechanical damage to
the cable jointing. While connecting extra cable beyond standard
length along with the pump set, it is necessary to have a water
tightened cable joint.
a. To connect the cables, cut off and strip the motor cable and
join it is staggered fashion where no 2 joints overlap each
other.
b. Colors of the leads, which are to be joined together must be
identical as per following sketch (Fig. 1).
c. Wrap vulcanizing rubber compound to each cable joint and
again wrap with electric insulation tape on the top of it.
d. To ensure proper insulation once again wrap with vulcanizing
rubber compound and electric insulation tape for each joint.
e. Finally wind the total cables with electric insulation tape.
f. Oil or grease should not have any contact with the tape.
g. Complete the taping over core insulation at each side.
Please see that each turn of the tape should have a 50% overlap
over the previous turn. The tape should be wound on to a
thickness at least equal to that of core insulation.
2.2.3.1 Selection of Cable
Voltage drop for extended cable should not be more than 3% of
rated voltage i.e.
Permissible voltage drop = Available voltage x 0.03
For Single phase :
Voltage drop = 2 x Cable Length in meters x Resistance / meter
for particular cable size x motor current
Allowed voltage drop is up to 7.0 volts (Considering available
voltage 230 volts).
e.g. For the cable length of 50 m and area of cross section 1.5
mm2, with rated current 3.5 A,
Voltage drop = 2 x 50 x 0.0121 x 3.5
= 4.24 volts (which is permissible)
For three phase :
Voltage drop = Cable Length in meters x Resistance / meter for
particular cable size x motor current
Allowed voltage drop is up to 12.5 volts (Considering available
voltage 415 volts).
e.g. For the cable length of 50 m and area of cross section 1.5
mm2, with rated current 2.4 A,
Voltage drop = 50 x 0.0121 x 2.4
= 1.45 volts (which is permissible)
Resistance / meter according to cross-section area :
Cross - section area Resistance in Ohm / m
(mm2) At 300C
1.5 0.0124
2.5 0.0075
4.0 0.0047
6.0 0.0031
Fig. no. 1
R = Red colored lead
Y = Yellow colored lead
B = Blue colored lead
2.2.4 Coupling of pump and motor
Couple the shaft to motor in vertical manner.
Before fitting the suction strainer the effortless rotation of the
coupled rotor should be checked at the sleeve coupling.
Please ensure that the top face of sand guard presses the bottom
face of the sleeve coupling to avoid the entry of sand inside the
coupling.
Fig. no. 2
2
Submersible motor pumps (100 mm)
2.3 Typical installation at site
Use lifting device of capability of carrying the weight of pump
unit as well as the weight of pipe filled with water for installation.
2.3.1 Vertical installation
Before installing the unit in narrow deep wells, the well should be
tested for trueness of size over its entire length (e.g. by running
a dummy cylinder of diameter 98 mm and length about 2 m inside
the well). A slight inclination of the well is immaterial, whereas
any twists or bends can make installation difficult.
Installation depth should be selected such that the motor would
never run dry even when the water level is at its lowest mark
(i.e. draw down of bore well capacity).
The minimum water level should be 0.5 m above the top of the
non-return valve.
The pump should always be installed with the suction strainer
above the slotted casing pipe. The effect is that the pump draws
in the water free from loose sand.
6
H geo
8
H h
3
1
H t
5
2
H e
7
T
2.3.2 Horizontal Installation (e.g. in tank or pit)
Fig. no. 4
1. Submersible pump unit
2. Water reservior for Motor
3. Support
4. Expansion joint
Note : Generally the horizontal installation of submersible pump
unit is equipped with two storage tanks to increase the water
capacity.
1. Referring to the above figure (Fig. 4) for horizontal installation
only two supports are needed. One is placed at the extreme
end of the NRV while other is placed at the center of motor.
2. Install adapter pipe to the pump with 2 Water reservior and
the motor with proper fittings.
3. Ensure that the cast RCC foundation is incorporated with
the recommended foundation bolts of proper height.
4. To make up the correct center height of aligned pump - motor,
provide sufficient metallic packing in the RCC foundation
itself. To attain precise alignment, minor shims up to 2 mm
thick made of M.S. sheet may be used below the pump or
motor stand.
5. Such installed pump shall be either perfectly horizontal or
maximum of 5 degree inclination with motor down and pump
lifted up from the ground. Precise tightening of foundation
bolts has to be done at the final stage.
6. Surface of the motor should be cleaned periodically for
8
effective cooling.
5. Non-return valve
6. Flange adapter
7. Discharge valve
8. Pressure gauge
4
Fig. no. 3
1. Discharge valve
2. Supporting clamp
3. Raiser pipe
4. Submersible motor-Pump set
5. Power supply cable
6. Starter
7. Slotted Casing pipe
(Length up to rock level)
8. Pressure Gauge
D
D = Well diameter
TB = Well depth
He = Installation depth
Hh = Stationary water level
Ht = Operation water level
H
= Geostatic head
geo
Ht - Hh = Drawdown
Notes for installation :
The motor pump unit must be immersed minimum 0.5 m more
below the lowest operation water level Ht.
Pump type Max. no. of stages allowed
for horizontal installation
CORA 1C & CORA 2C 30
CORA 4C 23
CORA 7C 19
CORA 12C 8
CORA 18C 8
CORA 2AH 17
CORA 3AH 12
CORA 3A 15
It is important to ensure that pump does not sit on the base of the
well and there is no risk of sand or sludge deposition around the
motor. This would disrupt heat dissipation from the motor.
2.3.3 Plastic / Flexible Rubber riser piping instead
of normal GI riser piping
Consult the HDPE / rubber pipe suppliers for the capability of
pipes for withstanding the pressure. If the pump is to be fitted
with HDPE raising piping, it is to be firmly tied up with stainless
steel wire ropes of dia. 2-3 mm to the eyelets on the non return
3
Submersible motor pumps (100 mm)
valve body and the vertical pipe line. This precaution will help
even in case of GI riser piping.
2.3.4 Installation of water level guard
Install a water level guard for dry running protection to avoid the
damage of pump unit in case of water level fluctuations.
2.3.5 Protection against electric shock
Submersible motors are provided with external earthing plug at
upper bearing body as a standard. A three-cored cable is led out
of the motor. The operator / user shall be responsible for proper
connection of the earthed conductor and of control unit at site.
2.3.6 Fixing the power supply cable to the riser pipe
During installation of pump into the bore well, power supply cable
should be fixed to the raiser pipe by means of cable clips at a
distance of approx. 3 m immediately after the flange or coupling
of the pipe.
2.3.7 Verification of power line with respect to
motor design
Verify the voltage and frequency of main supply with the data
given on the motor’s nameplate.
If it is not matching then consult with concerned electrical
authority.
Ensure that the main power supply is stable.
Typical examples of name plate :
Pump name plate :
KSB PUMPS LTD.
Type : CORA 100 1C/20
Sr. No. : -----
Q : 2.1 m3/hr Year : 2010
H : 48 mtrs kW : 0.75
N : 2800 rpm Ex. :
Motor name plate :
KSB PUMPS LTD.
Type : UMA I ( S ) 100 - 0.75 / 22
Sr. No. : ----
Voltage : 220 V Amp : 11.0
kW / HP : 0.75 / 1.0 Conn : ---
Speed : 2800 rpm Year : 2010
Run Capacitor : 36 uF 440 V Hz : 50 ± 3
Start Capacitor : 50 uF 230 V AC : 1 Ph
For operational values refer the nameplate attached to the pump
unit.
+ 6
- 15
2.3.8 Trip circuit for over current
A temperature compensated over current relay has to be provided
in the operational electrical circuit.
2.4 Starting mode
2.4.1 For single-phase motor
Single-phase motor connection diagram of starting method for
DOL is :
R : Red color wire C2 : Starting capacitor
B : Blue color wire C1 : Running capacitor
Y : Yellow color wire ORL 1 : Overload relay
S1 : On-off main switch P : Phase
S2 : Starting push button N : Neutral
Caution :
S2 - Starting push button should be pressed max. for 5 sec. In
case if the motor does not start, continuous operation of this
button may lead to burning the motor.
Capacitor details
C1 : Running capacitor : Polypropylene (440 V)
C2 : Starting capacitor : Electrolytic (230 V)
UMA I (S) 100
Motor capacity Run Capacitor Start Capacitor
kW
0.37 20 60
0.55 20 80-100
0.75 36 80-100
1.1 30 100-120
1.5 30 100-120
2.2 100 120-150
UMA (S) 100
Motor capacity Run Capacitor Start Capacitor
kW
0.5 25 100
0.8 25 100
1.25 36 120
1.5 50 120
2.2 50 200
XUMA (S) 100
Motor Run Start Run Start
Capacity Capacitor Capacitor Capacitor Capacitor
kW
0.37 20 60 - 80 30
0.55 30 80 - 100 30
0.75 36 80 - 100 50
1.1 50 100 - 120 50
1.5 50 100 - 120 100
2.2 100 120 - 150 120
µµ
µF
µµ
(> 180 Volt) (> 180 Volt) (< 180 Volt) (< 180 Volt)
µµ
µF
µµ
µµ
µF
µµ
µµ
µF
µµ
µµ
µF
µµ
µµ
µF
µµ
µµ
µF
µµ
µµ
µF
µµ
Value to be
enhance as
per actual
site
voltage
condition
4
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