Mody Pumps G 1002 T User Manual

MODEL: G 1002T

OPERATING INSTRUCTIONS, INSTALLATION & MAINTENANCE

MANUAL INCLUDING SPARE PARTS LIST

Mody Pumps Inc.

Bakersfield, CA 93308

Tel.: [phone] FAX.: [phone]

E-Mail: [e-mail]

http://www.modypump.com

2166 Zeus Court

ISO 9001 Certified

LLIIFFEE IISS PPRREECCIIOOUUSS -- TTHHIINNKK SSAAFFEETTYY

1. Most accidents can be avoided by using COMMON SENSE.

2. Please read the operation and maintenance instruction manual supplied with the
pump. If you did not receive one, please call your local distributor before pump
installation.

3. Do not wear loose apparel that may become entangled in the impeller or other
moving parts.

4. Always use appropriate safety equipment, such as safety glasses, when working on
the pump or piping.

5. Pumps build up heat and pressure during operation-allow time for pumps to cool
before handling or servicing.

6. Only qualified service personnel should install, operate and repair pump.

7. Keep clear of suction and discharge openings. DO NOT insert fingers in pump with
power connected.

8. Do not pump flammable or hazardous materials (gasoline, acids, alkalis, etc.)

9. Do not block or restrict discharge hose, as it may whip or burst catastrophically
under pressure.

10. Make sure lifting handles/hooks are securely fastened each time before lifting.

11. Do not lift pump by the power cord under any circumstances.

12. Do not exceed manufacturer's recommendation for optimum performance, as this
could cause the motor/pump to overheat and lead to premature wear or failure.

13. Secure the pump in its operating position so it does not tip over, fall or slide.

14. Keep away from impeller when power is connected.

15. Submersible Pumps are not approved for use in swimming pools, recreational water
installations, decorative fountains or any installation where human contact with the
pumped fluid is common.

16. Do not operate pump without adequate protection and safety devices in place.

17. Always replace safety devices that have been removed during service or repair.

18. To reduce risk of electrical shock, pump must be properly grounded in accordance
with the National Electric Code and all applicable state and local codes and
ordinances.

19. To reduce risk of electrical shock, always disconnect the pump from the power

source before handling or servicing.

20. Any wiring of pumps should be performed by a qualified electrician.

21. Never operate a pump with a power cord that has frayed or brittle insulation.

22. Cable should be protected at all times to avoid punctures, cuts, and

abrasions - inspect frequently.

23. Never handle connected - "hot" power cords with wet hands.

24. Never operate a pump with a plug-in type power cord without a ground fault circuit
interrupter, adequate overload and short circuit protection.

IMPORTANT !!! MODY Pumps Inc. is not responsible for losses, injury, or death resulting
from a failure to observe these safety precautions, misuse or abuse of pumps or
equipment.

Mody Pumps Inc.

:

2166 Zeus Court, Bakersfield, CA 93308 Tel.: [phone] Fax: [phone]

INTRODUCTION

THE

“mody” ELECTRIC DRIVEN PORTABLE SUBMERSIBLE PUMPS HAVE BEEN DEVELOPED DUE

TO A LONG FELT NEED OF HAVING A TRULY MAINTENANCE FREE PUMPSET FOR VARIOUS
APPLICATIONS. THE PUMP IS A LIGHTWEIGHT, COMPACT UNIT ENABLING IT TO BE USED IN
MOST SEA-CRAFT AND DIFFICULT LAND INSTALLATIONS. THE UNIT CONSISTS OF A
VERTICAL CENTRIFUGAL PUMP WITH AN IN-BUILT SQUIRREL CAGE, INDUCTION ELECTRIC
MOTOR WHICH IS AVAILABLE FOR VARIOUS ELECTRIC SUPPLY CONFIGURATIONS. THE PUMPED
WATER IS USED AS A COOLING MEDIUM WHICH COOLS THE ELECTRIC MOTOR. THE PUMPSET
CAN ALSO BE USED IN ANY POSITION THUS MAKING IT IDEAL FOR DEWATERING IN
DIFFICULT LOCATIONS.

THE SERVICE LIFE OF A SUBMERSIBLE PUMP DEPENDS MAINLY ON TWO THINGS: THE
DEPENDABILITY OF THE SEALING SYSTEM AND THE WEAR RESISTANCE OF THE PUMP WEAR
PARTS.

“mody” SUBMERSIBLE SUMP PUMPS INCORPORATE A UNIQUE SEALING SYSTEM. THE

ALL
CONSTRUCTION CONSISTS OF TWO MECHANICAL SEALS, ARRANGED IN TANDEM, IMMERSED IN
AN OIL BATH. THE COMPLETE PACKAGE IS A PRESSURE COMPENSATED SEALING DEVICE
WHICH ENSURES A MINIMAL PRESSURE DIFFERENTIAL ACROSS THE SEAL FACES,
IRRESPECTIVE OF THE DEPTH SETTING OF THE PUMP OR THE HEAD AGAINST WHICH THE
PUMP IS OPERATING.

“mody” SUBMERSIBLE SUMP PUMPS, ALL WEAR PARTS ARE RUBBER LINED/COVERED AND

IN
ARE READILY REPLACEABLE AS NEEDED. BOTH WEAR AND ELECTRICITY CONSUMPTION ARE
STILL FURTHER REDUCED WHEN THE PUMPS ARE FITTED WITH LEVEL CONTROLS FOR
AUTOMATIC STARTING AND STOPPING.

IT IS RECOMMENDED THAT IRRESPECTIVE OF TYPE OF PUMP, ADEQUATE MOTOR PROTECTION
SWITCHGEAR SHOULD BE USED AT THE INSTALLATION. WE STRONGLY RECOMMEND THE USE OF
SUITABLE CONTROL BOXES WHICH ARE AVAILABLE FROM US INCORPORATING ALL REQUIRED
PROTECTION.

IT IS IN THE INTEREST OF THE USER THAT HE GO THROUGH THIS MANUAL IN DETAIL
PRIOR TO USING THE PUMP. THE MANUAL WILL HELP HIM UNDERSTAND THE CONSTRUCTIONAL
FEATURES AND TO OBTAIN TROUBLE FREE SERVICE FROM THE PUMP.

PLEASE NOTE THAT ALL PART NOS. REFERRED TO IN DISMANTLING AND RE-ASSEMBLY ARE
PERTAINING TO MODEL G1002T.

PURPOSE:

THE PUMP HAS BASICALLY BEEN DESIGNED AS A DEWATERING UNIT TO PUMP OUT FLOODED
INSTALLATIONS OR ANY CONDITIONS THAT NEED DEWATERING OF UNWANTED FLUIDS. THE
PUMP HAS BEEN DESIGNED TO HANDLE WATER CONTAMINATED WITH OIL AS WELL AS
ABRASIVE PARTICLES NORMALLY ASSOCIATED WITH RAW WATER. THE MAXIMUM SIZE OF
PARTICLES THAT CAN BE HANDLED IS APPROX. 0.4”

OVERALL DIMENSIONS AND WEIGHT.

OVERALL HEIGHT 42”/1100MM (APPROX.)

MAX. DIAMETER 15.75”/400MM (APPROX.)

MAX. WEIGHT (EXCL. CABLE) 550 lbs.

MAINTENANCE SERVICES REQUIRED.

THE FOLLOWING CHECKS TO BE DONE AT INTERVALS INDICATED BELOW:

1. CONDITION OF SEALS TO BE CHECKED AT EVERY 2500 HOURS OF OPERATION BY
ASCERTAINING THE CONDITION OF OIL IN THE SEAL CHAMBER.

2. MONTHLY RUNNING OF PUMP FOR AT LEAST 5/10 MINUTES AND CHECKING OF AMPERES
DRAWN AND INSULATION RESISTANCE. (MIN. INSULATION RES. 1 MEG. OHM. AND MAX.
CURRENT DRAWN AS PER NAME PLATE)

SAFETY PRECAUTIONS.

1. ENSURE THAT THE INSULATION RESISTANCE OF THE MOTOR IS AT LEAST 1 MEG. OHM
BEFORE ENERGIZING THE UNIT.

2. CHECK THAT THE AVAILABLE POWER SUPPLY (VOLTAGE, PHASE, FREQUENCY) MATCHES
WITH THE DETAILS ON THE PUMP NAMEPLATE.

3. ENSURE THAT THE GROUND WIRE IN THE 4 CORE CABLE SUPPLIED WITH THE PUMP IS
SECURELY EARTHED.

4. ENSURE DISCHARGE CONNECTION IS CORRECTLY AND SECURELY FITTED

5. ENSURE DELIVERY HOSE IS FREE FROM KINKS AND SHARP BENDS.

6. DO NOT LIFT OR PULL THE PUMP UNDER ANY CIRCUMSTANCES BY MEANS OF THE CABLE.
THE PUMP MUST BE LOWERED/LIFTED FROM THE AREA TO BE PUMPED BY USING A LIFTING
ROPE ATTACHED TO THE EYEBOLTS PROVIDED ON THE TOP OF THE PUMP.

7. WHEN THE PUMP IS ENERGIZED IT WILL KICK WHICH IS OPPOSITE TO THE DIRECTION
OF ROTATION OF THE IMPELLER. ENSURE THE KICK IS IN THE CORRECT DIRECTION (SEE
THE ARROW MARKED ON THE PUMP). SHIFT ANY TWO PHASES IN POWER SUPPLY IF THE KICK
IS WRONG.

8. DRY RUNNING OF THE PUMP IS NOT DESIRABLE. HOWEVER THE PUMP WILL NOT BE
DAMAGED OR SUFFER ANY ILL EFFECTS IF IT IS RUN DRY FOR SHORT PERIODS (UPTO
APPROX. 10 MINUTES).

9. THE MAXIMUM PUMP SUBMERGENCE RECOMMENDED IS 50 FEET.

10. ENSURE CORRECT RATING H.R.C. BACK UP PROTECTION FUSES ARE INSTALLED IN
POWER CIRCUIT BEFORE STARTING THE PUMP. (REFER TABLE BELOW).

11. THE MAXIMUM SPECIFIC GRAVITY OF PUMPED FLUID SHOULD NOT EXCEED 1.1.
PUMP IS DESIGNED TO OPERATE IN FLUIDS WITH pH from 5 – 8.

12. IF PUMP IS NOT USED AND LYING IN STORAGE FOR MORE THAN 30 DAYS PLEASE
ENSURE THAT THE SEAL FACES ARE NOT GAUGE LOCKED – ROTATE THE IMPELLER/KICK
START THE UNIT ONCE A MONTH. REFER TO INSTRUCTIONS ON DISASSEMBLY/REASSEMBLY OF
MECH. SEALS IN THE EVENT THE FACES HAVE LOCKED.

13. 58HP @ 60HZ/460V, 63FLA; 50HP @ 50HZ/400V, 63FLA

MAINS VOLTAGE AT SITE HRC FUSE RECOMMENDED

380 VOLTS / 3 PHASE 115 AMPERES
415 VOLTS / 3 PHASE 110 AMPERES
460 VOLTS / 3 PHASE 103 AMPERES

FAULT FINDING IN THE UNIT.

TROUBLE GUIDE CAUSE REMEDY

1.FUSES BLOWN. 1.REPLACE FUSES

2.CABLE DAMAGED 2.SHORTEN/REPLACE CABLE

PUMP DOES NOT START.

4.BLOCKED IMPELLER. 4.CLEAN BOTTOM PARTS.

5.STATOR WINDING BURNT. 6.REPLACE STATOR/REWIND

1.BLOCKED IMPELLER. 1.CLEAN BOTTOM PARTS.

2.IMPELLER ROT.WRONG 2.SHIFT TWO PHASE CONN.

PUMP STARTS BUT STOPS

VOLTAGE.

4.VOLTAGE LOW/HIGH 4.CONTACT POWER CO.

5.CLOGGED STRAINER 5.CLEAN STRAINER

6.PUMP RUNNING DRY 6.SWITCH OFF POWER

7.WATER TOO WARM 7.SWITCH OFF POWER
(ABOVE 60 DEGREES C)

1.IMPELLER ROT.BACKWARD. 1.SHIFT TWO PHASE CONN.

2.PUMP WORN DOWN. 2.REPLACE WEAR PARTS

PUMP GIVES TOO LITTLE
OUTPUT

4.PRESSURE HEAD TOO HIGH 4.USE PUMPS IN TANDEM.

5.DISCHARGE HOSE TORN 5.USE NEW HOSE

6.LEAKING/CRACKED OUTLET 6.REPL.OUTLET/GASKET.

OPTIONAL FEATURES INCLUDE START/DELTA START, SEAL PROBE SENSOR OR THERMAL
OVERLOAD PROTECTION. EXTERNAL CONTROL BOXES ARE AVAILABLE FOR THE ABOVE
FEATURES. PLEASE CONTACT MODY.

TOO SMALL.

3.NO POWER. 3.CHECK POWER SUPPLY.

. 3.CONNECTED FOR WRONG 3.CHECK & RECONNECT.

3.LONG HOSE AND DIAMETER 3.CHECK PRESSURE LOSSES

TECHNICAL DESCRIPTION.

THE MODY SUBMERSIBLE PUMP IS IN ITSELF A COMPLETE PUMPING STATION. BESIDES A
POWER SUPPLY, CONTROL BOX AND A DISCHARGE HOSE NO EXTRA EQUIPMENT IS REQUIRED.
THE COMPLETE PUMPSET IS IN A MODULAR CONSTRUCTION ENSURING GOOD AND SIMPLE
SERVICEABILITY. MAJOR DESIGN FEATURES ARE AS UNDER:

THE MOTOR

A RUGGED ALUMINUM DIE CAST ROTOR DYNAMICALLY BALANCED TO GRADE 2.5 ACCURACY OF
ISO 942. A STAINLESS STEEL SHAFT RUNNING IN TWO BALL BEARINGS. INSULATION CLASS
"H" (180 DEGREES CELSIUS). END WINDINGS DULY EPOXY COATED TO PREVENT
DETERIORATION OF INSULATION EVEN IN EXTREMELY HUMID CONDITIONS. WINDING WIRE IS
DUAL COATED SUITABLE FOR "H" CLASS INSULATION.

THE SEAL CHAMBER

THE HEART OF THE MODY PUMP. TANDEM MECHANICAL, TUNGSTEN CARBIDE V/S TUNGSTEN
CARBIDE SEAL FACES (LOWER SEAL) AND TUNGSTEN CARBIDE V/S TUNGSTEN CARBIDE
(UPPER SEAL), SECONDARY SEALS OF HNBR RUBBER AND METAL PARTS IN STAINLESS
STEEL, RUNNING IN AN OIL BATH, ENCLOSED IN A PRESSURE COMPENSATING RUBBER OIL
BAG - CREATES THE ULTIMATE SEAL SOLUTION. THE DESIGN OPTIMIZES SEAL LIFE AND
ALLOWS FOR SIX MONTHLY (2500 HOURS) SERVICE INTERVALS.

BEARINGS.

TWO ANGULAR CONTACT BALL BEARINGS (IMPELLER SIDE), ARRANGED BACK TO BACK,
FILLED WITH A SPECIAL HIGH TEMPERATURE BEARING GREASE REQUIRING NO PERIODIC
MAINTENANCE WHATSOEVER. THE TOP BEARING IS A SINGLE ROW DEEP GROOVE BALL
BEARING, GREASE FILLED AND SEALED FOR LIFE.

THE HYDRAULIC ELEMENTS.

THE HARDENED STAINLESS STEEL IMPELLER RUNNING AGAINST A RUBBER LINED DIFFUSER
AND WEAR PLATE, CONSTITUTE THE HYDRAULIC ELEMENTS OF THE PUMP. THE
IMPELLER/DIFFUSER CAN BE ADJUSTED TO MAINTAIN MAXIMUM OUTPUT AFTER USAGE
WITHOUT PARTS REPLACEMENT. IT IS IMPORTANT, HOWEVER, TO MAINTAIN CLEARANCES
BETWEEN THE WEAR PARTS.

CABLE GLAND ASSEMBLY. (REFER DRG.)

THE PUMP IS SUPPLIED WITH 50 FEET CABLE AS STANDARD. THE CABLE IS A 4 CORE EPR
SHEATHED AND INSULATED CABLE CONFORMING TO INT’L STD. THE CABLE IS WATERPROOF
AND CAN BE COMPLETELY SUBMERGED IN WATER. THE CABLE IS TERMINATED IN THE PUMP
AT THE CABLE GLAND. THE GLAND ASSEMBLY SEALS THE CABLE ON THE OUTSIDE SHEATH AS
WELL AS A WATER DAM ARRANGEMENT IS PROVIDED WHICH SEALS THE INDIVIDUAL CORES OF
THE CABLE. THIS FEATURE IS UNIQUE AND IS ESSENTIAL TO PREVENT WATER SEEPING
THROUGH THE CORES OF THE CABLE INTO THE MOTOR CHAMBER IN THE EVENT OF A CUT
CABLE. THE CABLE IS ALSO SHEATHED FOR THE FIRST ONE METER BY MEANS OF A CABLE
GRIP MADE OF STAINLESS STEEL. THIS IS ESSENTIAL TO ENSURE THAT THERE IS NO
UNDUE STRAIN ON THE CABLE IF THE PUMP IS PULLED OR LOWERED INADVERTENTLY BY
MEANS OF THE CABLE. COMPLETE DETAILS OF THE CABLE GLAND ASSEMBLY ARE SHOWN IN
THE DRAWING.