Mody Pumps G 556 T User Manual

MODELS: G 506T, 536T, 556T

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

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” 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.

“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 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 506T G 536 T G 556 T

OVERALL HEIGHT

(APPROXIMATE)

MAX DIAMETER 10.75”/ 276MM 10.75”/ 276MM 10.75”/276MM

25”/640MM 28.5”/725MM 29.5”/750MM

MAX WEIGHT

(EXCLUDING CABLE)

115LBS/50KG 135LBS/61KG 147LBS/67KG

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 100 FEET.

10. THE MAXIMUM SPECIFIC GRAVITY OF PUMPED FLUID SHOULD NOT EXCEED 1.1.
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. ENSURE CORRECT OVERLOAD BREAKERS ARE INSTALLED IN POWER CIRCUIT BEFORE
STARTING THE PUMP. (REFER TO AMP RATING ON NAMEPLATE).

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.

6.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.

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 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. DUAL 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 SPECIAL HIGH
TEMPERATURE BEARING GREASE REQUIRING NO PERIODIC MAINTENANCE WHATSOEVER.

THE HYDRAULIC ELEMENTS:

TWO STAINLESS STEEL IMPELLERS IN TANDEM RUNNING AGAINST A RUBBER LINED
DIFFUSERS AND A GUIDE PLATE, CONSTITUTE THE HYDRAULIC ELEMENTS OF THE PUMP. THE
IMPELLERS/DIFFUSERS 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 CONTACTOR 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 SEA- WATER
ARE PRIMARILY OF STAINLESS STEEL AND ALUMINUM. AS SEAWATER IS AN ELECTROLYTE
THE PROBLEM OF GALVANIC CORROSION EXISTS DUE TO THE DIFFERENT ELECTRIC
POTENTIALS OF THE MATERIALS IN FLOWING SEAWATER. 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.

ELECTRICAL INFORMATION:

MOTORS ARE DESIGNED TO OPERATE ON SINGLE VOLTAGE AND FREQUENCY. MAX. DEVIATION
IN VOLTAGE ALLOWED IS + - 6 % AND FREQUENCY +- 3%. CHECK NAMEPLATE FOR
OPERATING VOLTAGE AND FREQUENCY.

LINE TO LINE RESISTANCE VALUES FOR NINE LEAD STATORS

230V 460
G 506 T 0.63 Ω 2.5 Ω
G 536 T 0.45 Ω 1.80 Ω
G 556 T 0.31 Ω 1.23 Ω

DISMANTLING AND OVERHAULING.

GENERAL OVERHAUL AND OIL CHECK. (REF.DRGS.NO.DW/131//00 SHEET 1&2)

1. ALWAYS REPLACE O-RINGS WITH NEW ONES WHENEVER DISMANTLING AND RE-ASSEMBLING
A PUMP. NEVER RE-USE OLD O-RINGS.

2. REMOVE BASE PLATE (76), STRAINER (75), NUT (18) AND DIFFUSER (74). THE
DRAWING SHOWS THESE DETAILS. CHECK BY HAND THAT THE ROTOR SHAFT IS NOT BLOCKED.

3. UNSCREW IMPELLER NUT (73), REMOVE LOCK WASHER (72), AND REMOVE 1ST IMPELLER
(65). SLIDE OFF IMPELLER FROM SHAFT. REMOVE KEY (71) AND KEEP ASIDE. UNSCREW
NUT HOLDING GUIDE PLATE (70) AND PRY OFF GUIDE PLATE. SLIDE OFF SHAFT SLEEVE
(66) FROM ROTOR SHAFT. UNSCREW NUTS HOLDING DIFFUSER 2(18) AND PRY OFF
DIFFUSER. REMOVE SECOND IMPELLER FROM SHAFT AND REMOVE KEY UPPER (64).

4. PLACE THE PUMP ON THE BOTTOM STUDS (62). TAP THE OUTER CASING (68) WITH
NYLON TIPPED HAMMERS TILL IT LOOSENS FROM THE TOP BRACKET (22). SEPARATE THE
OUTER CASING FROM THE TOP BRACKET BY EMPLOYING TWO SCREWDRIVERS AS LEVERS AND
PUSH THE OUTER CASING DOWNWARDS TILL IT STANDS ON THE FLOOR. LIFT THE UNIT BY
THE TIE BOLTS (3) CLEAR OFF THE OUTER CASING.

4. THE SEAL CHAMBER CONTAINS APPROX. 1.5 LITRES OF OIL. THE LEVEL AND CONDITION
OF THE OIL SHOULD BE CHECKED EVERY SIX MONTHS. UNSCREW THE OIL PLUGS (66) AND
POUR OUT SOME OIL. NOTE THAT THE OIL GETS A SLIGHTLY DARKER SHADE, BUT THIS IS
NORMAL AND IS NO CAUSE FOR WORRY. IF THE OIL IS EMULSIFIED BY WATER, THE SEALS
HAVE WORN OUT AND MUST BE REMOVED FROM THE ROTOR FOR FURTHER ACTION.

6. UNSCREW NUTS (18) AND FOUR STUDS (17) AND REMOVE WEAR PLATE (31). THIS CAN
BE EASILY DONE BY INSERTING TWO SCREWDRIVERS BETWEEN WEAR PLATE AND LOWER
BRACKET (15) AND PRYING THE WEAR PLATE LOOSE. ALL THE PUMP PARTS HAVE BEEN
DISMANTLED. REPLACE WORN PARTS. REMOVE SAND GUARD (59) BY UNSCREWING FOUR
CHEESE HEAD SCREWS (74) FROM THE SEAL HOUSING (28).

7. THE OIL DIAPHRAGM (56) IS NOW IN VIEW. UNSCREW BOTH THE OIL PLUGS (66) AND
DRAIN OUT THE OIL FROM THE OIL CHAMBER. LOOSEN SCREWS AND NUTS (35/54) FROM THE
BIG OIL CLAMP (55) AND REMOVE CLAMP. TURN OIL DIAPHRAGM INSIDE OUT AND REMOVE
SMALL OIL CLAMP IN THE SAME FASHION. REMOVE OIL DIAPHRAGM. SLIDE OFF OUTER
RETAINING SPRING (61) FROM ROTOR SHAFT AND REMOVE LOWER MECHANICAL SEAL FROM
ROTOR SHAFT. BE VERY CAREFUL IN HANDLING THE TUNGSTEN CARBIDE SEAL FACE. LEAVE
TUNGSTEN CARBIDE SEAT IN THE SEAL HOUSING (38). UNSCREW FOUR NUTS (65) AND PULL
OUT SEAL HOUSING (38). THE TUNGSTEN CARBIDE SEAL FACE WILL COME OUT WITH THE
SEAL HOUSING. HANDLE THE FACE CAREFULLY. THE UPPER MECHANICAL SEAL IS NOW IN
VIEW. REMOVE THE UPPER SEAL IN THE SAME WAY AS THE LOWER SEAL.

8. REMOVE THE FOUR NOS DEEP SEATED CAP SCREWS (16) THAT HOLD THE LOWER BEARING
BRACKET AGAINST THE INNER CASING. BY MEANS OF TWO NOS SCREWDRIVERS REMOVE THE
LOWER BEARING BRACKET FROM THE INNER CASING (12). THE COMPLETE ROTOR (11) WITH
BEARING (68), BEARING COVER AND TUNGSTEN CARBIDE SEAT WILL COME OUT WITH THE
LOWER BEARING BRACKET. REMOVE BOLTS (70) AND REMOVE BEARING COVER. PULL OUT
ROTOR WITH BEARING FROM LOWER BEARING BRACKET. (IF THIS IS DIFFICULT USE A HAND
PRESS TO REMOVE ROTOR FROM BEARING BRACKET. ENSURE NO DAMAGE TO THE TUNGSTEN
CARBIDE SEAT IN BEARING BRACKET). THE TC SEAT WITH CUP SEAL HOLDER CAN NOW BE
PUSHED OUT FROM THE BEARING SIDE BY GENTLY TAPPING THE SAME. (USE FINGERS OR A
NYLON TIPPED LIGHT HAMMER ONLY).