Mody Pumps G 554 T User Manual

MODELS: G 530 T, G 554 T

OPERATING INSTRUCTIONS, INSTALLATION & MAINTENANCE

MANUAL INCLUDING SPARE PARTS LIST

Mody Pumps Inc.

2166 Zeus Court

Bakersfield, CA 93308

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

EMAIL: [e-mail]

http://www.modypump.com

ISO 9001 Certified

LIFE IS PRECIOUS - THINK SAFETY

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” MOTOR 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.

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

IN “mody” SUBMERSIBLE SUMP PUMPS, ALL WEAR PARTS ARE RUBBER LINED/COVERED AND ARE READILY REPLACEABLE AS NEEDED. BOTH WEAR AND ELECTRICITY CONSUMPTION ARE STILL FURTHER REDUCED WHEN THE PUMPS ARE FITTED WITH BUILT-IN LEVEL CONTROLS FOR AUTOMATIC STARTING AND STOPPING. IT IS HOWEVER 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 PANELS WHICH ARE AVAILABLE FROM US INCORPORATING ALL REQUIRED PROTECTION DEVICES.

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 G 554T. NUMBERS FOR MODEL G 530T ARE INDICATED IN THE DRAWINGS. THE CONSTRUCTION IS IDENTICAL.

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”. THE MAXIMUM SPECIFIC GRAVITY OF

THE PUMPED FLUID SHOULD NOT EXCEED 1.1.

OVERALL DIMENSIONS AND WEIGHT.

	G 530T	G 554T
OVERALL HEIGHT	28”(APPROX.)/711MM	31”(APPROX.)/790MM
MAX. DIAMETER	10.75”/275MM	10.75”/275MM
MAX. WEIGHT(EXCL. CABLE)	121 lbs./55KG	135 lbs./61KG

MAINTENANCE SERVICES REQUIRED.

THE FOLLOWING CHECKS TO BE DONE AT INTERVALS INDICATED BELOW:

1.CONDITION OF SEALS TO BE CHECKED AT EVERY 2500 HRS. 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 RESISTANCE 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 HOSE 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 SPACE TO BE PUMPED BY USING A LIFTING ROPE ATTACHED TO THE HANDLE/EYEBOLT PROVIDED IN THE PUMP.

7.AT THE STARTING MOMENT THE PUMP SHALL MAKE A KICK WHICH IS OPPOSITE TO THE DIRECTION OF ROTATION OF THE IMPELLER. ENSURE THE KICK IS IN THE CORRECT DIRECTION (SEE THE ARROW CAST ON THE CONTACTOR COVER OF THE PUMP).SHIFT ANY TWO PHASES IN THE MALE PLUG 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. 30 MINUTES).

9.THE MAXIMUM PUMP SUBMERGENCE RECOMMENDED IS 50 FEET.

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

11.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.

12. FULL LOAD AMPS AT 460V IS 14AMPS (G554), 11.5AMPS (G530) & AT 400V IS 16 AMPS (G554), 12.5AMPS (G530)

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

MAINS VOLTAGE AT SITE			HRC FUSE RECOMMENDED
220	VOLTS / 3	PHASE	40	AMPERES
380	VOLTS / 3	PHASE	25	AMPERES
415	VOLTS / 3	PHASE	22	AMPERES
460	VOLTS / 3	PHASE	20	AMPERES

FAULT FINDING IN THE UNIT.

TROUBLE GUIDE	CAUSE	REMEDY
	1.FUSES BLOWN.		1.REPLACE FUSES
PUMP DOES NOT START.	2.CABLE DAMAGED		2.SHORTEN/REPLACE CABLE
	3.NO POWER.		3.CHECK POWER SUPPLY.
	4.BLOCKED IMPELLER.		4.CLEAN BOTTOM PARTS.
	6.STATOR WINDING BURNT.		6.REPLACE STATOR/REWIND
	1.BLOCKED IMPELLER.		1.CLEAN BOTTOM PARTS.
PUMP STARTS BUT STOPS.	2.IMPELLER ROT.WRONG		2.SHIFT TWO PHASE CONN.
	3.CONNECTED FOR WRONG		3.CHECK & RECONNECT.
	VOLTAGE.		4.CONTACT POWER CO.
	4.VOLTAGE LOW/HIGH
	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.
PUMP GIVES TOO LITTLE	2.PUMP WORN DOWN.		2.REPLACE WEAR PARTS
	3.LONG HOSE AND DIAMETER 3.CHECK PRESSURE LOSSES
OUTPUT	TOO SMALL.
	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.

TECHNICAL DESCRIPTION.

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

THE MOTOR

A RUGGED ALUMINUM DIE CAST/COPPER 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.

SINGLE ROW DEEP GROOVE BALL BEARINGS SEALED FOR LIFE WITH A SPECIAL HIGH TEMPERATURE BEARING GREASE REQUIRING NO PERIODIC MAINTENANCE WHATSOEVER.

THE HYDRAULIC ELEMENTS.

THE 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 INTERNATIONAL STANDARDS. 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.

GALVANIC CORROSION PROTECTION (FOR SEA-WATER DUTY PUMPS ONLY)

THE PARTS OF THE "MODY" SUBMERSIBLE PUMP THAT ARE IN CONTACT WITH SEAWATER ARE PRIMARILY OF STAINLESS STEEL AND ALUMINUM. AS SEA-WATER IS AN ELECTROLYTE THE PROBLEM OF GALVANIC CORROSION EXISTS DUE TO THE DIFFERENT ELECTRIC POTENTIALS OF THE MATERIALS IN FLOWING SEA-WATER. TO PREVENT THIS, THE PUMPS ARE EQUIPPED WITH ZINC ANODES FIXED ON THE OUTER CASING AND DIFFUSER. ZINC, BEING THIS LESS "NOBLE" METAL (MORE NEGATIVE POTENTIAL) GETS CORRODED THUS PREVENTING CORROSION OF ALUMINUM AND STEEL. IT IS HOWEVER NECESSARY TO INSPECT THE CONDITION OF THE REPLACEABLE ANODES PERIODICALLY AND REPLACE WHENEVER NECESSARY. (INSPECTION ONCE IN A YEAR IS ENOUGH.)

NON REPAIRABLE ITEMS

1.ALL "O" RINGS TO BE REPLACED WHENEVER PARTS ARE DISMANTLED.

2.SEAL ELASTOMER PARTS SHOULD NEVER BE RE-USED AFTER DIS-ASSEMBLY.

3.DO NOT REFILL BEARING GREASE. ALWAYS REPLACE COMPLETE NEW BEARING WITH SPECIAL HIGH TEMPERATURE GREASE.