Mody Pumps MS 482 User Manual

MODELS: MS 480, 481 & 482

OPERATING INSTRUCTIONS, INSTALLATION & MAINTENANCE

MANUAL INCLUDING SPARE PARTS LIST

Mody Pumps Inc.

2166 Zeus Court

Bakersfield, CA 93308

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

E-Mail: [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]

GENERAL INFORMATION.

“MS” SERIES OF MODY'S SUBMERSIBLE SEWAGE PUMPS ARE PRIMARILY DESIGNED FOR

THE
HANDLING SEWAGE, SLUDGE, SLURRIES, WASTEWATER AND LIQUID MANURE. THEY CAN ALSO
BE USED FOR HANDLING STORMWATER DRAINAGE WITH HIGH SOLIDS CONTENT.

THE SERVICE LIFE OF A SUBMERSIBLE PUMP PRIMARILY HINGES ON TWO ASPECTS: THE
DEPENDABILITY OF THE SEALING SYSTEM AND THE WEAR RESISTANCE OF THE PUMP ITSELF.

THE “MS” SERIES OF PUMPS ARE AVAILABLE WITH A WIDE RANGE OF IMPELLERS TO SUIT
PRACTICALLY EVERY PUMPING DUTY WITH HIGH EFFICIENCES. THE MS 480

MODELS AS UNDER :

1. MS 481 SINGLE CHANNEL IMPELLER WITH 75MM/3” SOLID HANDLING CAPACITY.

2. MS 482 SINGLE CHANNEL IMPELLER WITH 100MM/4” SOLID HANDLING CAPACITY.

THE SINGLE CHANNEL IMPELLERS ARE IN CAST IRON CONSTRUCTION. THE PUMP VOLUTES
ARE ALSO IN CAST IRON WITH SMOOTH PROFILED GEOMETRY FOR CLOG FREE OPERATION AND
HIGH EFFICIENCES. ALL VOLUTES ARE FITTED WITH REPLACEABLE WEAR RINGS.

IT IS IN THE INTEREST OF THE USER THAT HE/SHE GO THROUGH THIS MANUAL IN DETAIL
PRIOR TO USING THE PUMP.

TECHNICAL DESCRIPTION.

THE PUMPSET IS IN A MODULAR CONSTRUCTION ENSURING EASY AND SIMPLE
SERVICEABILITY. THE MAJOR DESIGN FEATURES ARE AS UNDER:

A] THERMAL PROTECTION : SEE UNDER "MOTOR PROTECTION" .

B] 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 DEEP GROOVE

BALL BEARINGS. INSULATION CLASS "F" (155 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.

C] THE SEAL CHAMBER: THE HEART OF THE "MODY" PUMP. DUAL MECHANICAL SEALS,
TUNGSTEN CARBIDE V/S TUNGSTEN CARBIDE SEAL FACES. SECONDARY SEALS OF NITRILE
RUBBER AND METAL PARTS IN STAINLESS STEEL, RUNNING IN AN OIL BATH. THE SEALS
HAVE BEEN SPECIFICALLY DESIGNED WITH EXTREMELY SHORT WORKING LENGTHS KEEPING
IMPELLER OVERHANG TO THE MINIMUM. THIS ENSURES EXTENDED SEAL AND BEARING LIFE.

D] BEARINGS: DOUBLE ROW ANGULAR CONTACT LOWER BEARING, WITH SINGLE ROW DEEP
GROOVE UPPER BALL BEARING GREASED FOR LIFE WITH A SPECIAL HIGH TEMPERATURE
BEARING GREASE REQUIRING NO PERIODIC MAINTENANCE WHATSOEVER.

E] THE HYDRAULIC ELEMENTS: SINGLE CHANNEL IMPELLERS WITH LARGE SOLID HANDLING
CAPACITY. SMOOTH PROFILED VOLUTES FOR HIGH EFFICIENCES.

SERIES HAS TWO

F] CABLE GLAND ASSEMBLY: THE PUMP IS SUPPLIED WITH 50’ CABLE AS STANDARD. THE
CABLE IS AWG #10 SOOW 4 CORE WITH AN OPTION AVAILABLE FOR 7 CORE WHEN THERMAL
OVERLOADS AND SEAL PROBE SENSOR ARE REQUIRED. (MODYCAB 8-4/16-3) THE CABLE IS
TERMINATED IN THE PUMP AT THE CABLE GLAND. THE GLAND ASSEMBLY SEALS THE CABLE
ON THE OUTSIDE SHEATH. A WATER DAM ARRANGEMENT IS ALSO 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 TERMINAL CHAMBER
IN THE EVENT OF A CUT CABLE. THE CABLE IS ALSO SHEATHED FOR THE 1ST ONE METRE
LENGTH 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. AN OPTIONAL TRAILING CABLE CAN ALSO BE
PROVIDED FOR SEAL PROBE AND THERMALS.

G] ELECTRICAL INFORMATION : MOTORS ARE DESIGNED TO OPERATE ON SINGLE VOLTAGE
AND FREQUENCY. MAXIMUM DEVIATION IN VOLTAGE ALLOWED IS -/+ 6% AND FREQUENCY -/+
3%. CHECK NAME PLATE FOR OPERATING VOLTAGE AND FREQUENCY. 230/460V DUAL WIRED
MOTORS STANDARD IN NORTH AMERICA.

DESIGN PARAMETERS :

• LOWEST LIQUID LEVEL SHOULD BE 0.2 MTRS (8”) ABOVE PUMP CASING.

• THE MAXIMUM SUBMERGENCE RECCOMENDED IS 15 METRES.(50’)

• THE SPECIFIC GRAVITY OF THE PUMPED FLUID SHOULD NOT EXCEED 1.1.

• MAXIMUM FLUID TEMPERATURE IS 40 DEG. CELSUIS.

• pH OF THE PUMPED FLUID : 6 - 11

INSTALLATION

PUMPS ARE AVAIABLE FOR THREE TYPES OF INSTALLATION:

P TYPE INSTALLATION: SEMI PERMANENT/WET. PUMPS ARE LOWERED DOWN GUIDE BARS TO

AUTOMATICALLY CONNECT TO DISCHARGE PIPING. PLEASE SEE ILLUSTRATION AT END OF
MANUAL FOR DETAIL DIMENSIONS AND INSTALLATION.

S TYPE INSTALLATION: PORTABLE/WET. VERSATILE, MULTIPURPOSE, EASY TO INSTALL AND
MOVE FROM SUMP TO SUMP. PUMP IS AVAILABLE WITH HOSE/FLANGE TYPE OUTLET
CONNECTION AND INDEPENDENT BASE STAND. SEE ILLUSTRATION AT END OF MANUAL.

D TYPE INSTALLATION: THIS IS A DRY WELL INSTALLATION OR IN LINE PUMPING
SYSTEMS. FLANGED CONNECTION TO FIXED SUCTION AND DELIVERY PIPELINES. SUITABLE
FOR HORIZONTAL OR VERTICAL MOUNTING FOR DRY INSTALLATIONS. POWER LIMITATIONS
EXIST FOR CERTAIN MODELS AND EXTERNAL COOLING MAY BE NECESSARY. PLEASE CONTACT
FACTORY/SALES IF PUMP IS TO BE USED WITH THIS TYPE OF INSTALLATION.

• CHECK THAT THE SITE VOLTAGE CORRESPONDS WITH THAT OF THE PUMP.

• CHECK THAT FUSES ARE INTACT.

• USE SHORTEST POSSIBLE HOSE OF RECOMMENDED DIMENSION. AVOID SHARP BENDS,

CREASES AND CONTRACTIONS. FOR P TYPE AND D TYPE INSTALLATIONS ENSURE ALL
ACCESSORIES ARE AVAILABLE BEFORE STARTING INSTALLATION.

• NEVER LIFT OR PULL THE PUMP BY MEANS OF THE CABLE. SUSPEND THE PUMP BY A

ROPE/CHAIN OR PREFERABLY PLACE IT ON A SOLID BASE. FOR P TYPE INSTALLATIONS
THE REQUISITE CHAIN & TACKLE EQUIPMENT MUST BE AVAILABLE. PLEASE READ OUR
PUBLICATION REGARDING “P” TYPE INSTALLATION.

• WIRE THE PUMP TO THE MAINS CORRECTLY. ALWAYS USE A STARTER OR A PANEL BOARD.

SEE INSTRUCTIONS UNDER "MOTOR PROTECTION" BELOW.

• WHEN THE PUMP IS ENERGIZED IT WILL KICK, WHICH IS OPPOSITE TO THE DIRECTION

OF ROTATION OF THE IMPELLER. SHIFT TWO PHASES IN THE POWER CONNECTION IF THE
KICK IS IN THE WRONG DIRECTION. THE CORRECT DIRECTION IS INDICATED ON THE
PUMP COVER AT THE TOP OF THE PUMP.

• CHECK LEVEL AND CONDITION OF THE OIL AT SERVICE EVERY SIX MONTHS. IF THE OIL

IS EMULSIFIED BY WATER THE SEALS MUST BE REMOVED FROM THE ROTOR SHAFT FOR
FURTHER ACTION. THE SHAFT SEAL SHOULD BE CHECKED FOR WEAR EVERY 2500 HRS. OF
OPERATION. IF SEAL FACES SHOW ANY SIGNS OF WEAR, THEY SHOULD BE REPLACED.

.

HRC FUSE RECOMMENDED

MAINS VOLTAGE AT SITE MS 480 MS 481 MS 482

220 VOLTS 3 PHASE 35 AMPS 40 AMPS 40 AMPS
380 VOLTS 3 PHASE 20 AMPS 25 AMPS 25 AMPS
415 VOLTS 3 PHASE 20 AMPS 25 AMPS 25 AMPS
460 VOLTS 3 PHASE 20 AMPS 25 AMPS 25 AMPS
575 VOLTS 3 PHASE 15 AMPS 20 AMPS 20 AMPS

TROUBLE GUIDE CAUSE REMEDY

1.FUSES BLOWN. 1.REPLACE FUSES

2.CABLE DAMAGED 2.SHORTEN/REPLACE CABLE

PUMP DOES NOT START 3.NO POWER. 3.CHECK POWER SUPPLY

4.BLOCKED IMPELLER. 4.CLEAN BOTTOM PARTS.

5.STATOR WINDING BURNT. 5.REPLACE STATOR.

1.BLOCKED IMPELLER. 1.CLEAN BOTTOM PARTS.

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

PUMP STARTS BUT STOPS. 3.CONNECTED FOR WRONG 3.CHECK & RECONNECT.

VOLTAGE.

4.VOLTAGE TOO LOW/HIGH. 4.APPROACH POWER CO.

5.LIQUID DENSITY HIGH 5.HIGHER HP REQUIRED.

6.BI-METAL TRIPS. 6.CHECK CURRENT.

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

2.PUMP WORN DOWN. 2.REPLACE IMPELLER.

PUMP GIVES TOO LITTLE 3.LONG HOSE AND DIAMETER 3.CHECK PRESSURE LOSSES
WATER. TOO SMALL.

4.PRESSURE HEAD TOO HIGH 4.INSTALL BIGGER PUMP.

5.WEARING RING WORN OUT. 5.REPLACE WEAR RING.

MOTOR PROTECTION

IT IS ESSENTIAL THAT THE PUMP BE USED WITH A STARTER AND PREFERABLY A CONTROL
PANEL. PANEL BOARDS INCORPORATING ALL PROTECTIVE DEVICES ARE READILY AVAILABLE,
CONTACT SALES. THE FULL LOAD AMPERE RATINGS OF THE TWO MODELS ARE AS PER TABLE
BELOW. THE OVERLOAD RELAY IN THE STARTER SHOULD CHOSEN ACCORDINGLY AND AMPERES
SET AT THE FULL LOAD SETTING FOR THE PARTICULAR MODEL OF THE PUMP. (DETAILS
BELOW ARE FOR 230/460 VOLT PUMPS. CHECK FULL LOAD AMPERES FOR DIFFERENT
VOLTAGES ON PUMP NAME PLATE)

MODEL FULL LOAD AMPERES.

MS 480 11.5 AMPS @ 460V, 23 AMPS 2 220V, 9.2 AMPS @ 575 VOLTS
MS 481 14 AMPS @ 460V, 28 AMPS @ 230V, 11.2 AMPS @ 575 VOLTS
MS 482 14 AMPS @ 460V, 28 AMPS @ 230V, 11.2 AMPS @ 575 VOLTS

POWER CABLE OPTIONS

A) FOUR CORE CABLE

THE PUMP IS SUPPLIED WITH A FOUR CORE CABLE AND THE FUNCTION OF THE SAME IS AS
UNDER:

• RED/YELLOW(WHITE)/BLUE(BLACK) ARE THE POWER CORES.

• GREEN CORE IS FOR EARTHING.

B) SIX CORE CABLE

THE PUMP IS SUPPLIED WITH A SIX CORE CABLE AND THE FUNCTION OF THE SAME IS AS
UNDER:

• RED/YELLOW(WHITE)/BLUE(BLACK) ARE THE POWER CORES.

• GREEN CORE IS FOR EARTHING.

• ORANGE AND BLUE ARE FOR THERMALS

THREE THERMAL SWITCHES ARE EMBEDDED IN THE MOTOR WINDING OF WHICH TWO ARE
CONNECTED IN SERIES. THESE ARE CONNECTED TO THE WHITE CORES OF THE CABLE. THE
WHITE CORES OF THE CABLE ARE TO BE CONNECTED IN SERIES WITH THE CONTACTOR COIL
OF THE STARTER. THIS IS MOST IMPORTANT.
IN THE EVENT OF OVERHEATING OF THE STATOR WINDING FOR ANY REASON, THE
EMBEDDED THERMAL SWITCHES WILL OPEN, CAUSING THE STARTER COIL TO DROP OUT AND
ISOLATE THE PUMP UNIT FROM THE MAINS. THESE SWITCHES DO NOT PROVIDE ANY
PROTECTION IN THE CASE OF A SHORT CIRCUIT, AND ADEQUATE H.R.C. FUSES SHOULD BE
USED FOR SHORT CIRCUIT PROTECTION.

C) MODYCAB SEVEN CORE CABLE

THE PUMP IS SUPPLIED WITH A SEVEN CORE CABLE AND THE FUNCTION OF THE SAME IS AS
UNDER:

• RED/WHITE/BLACK ARE THE POWER CORES.

• GREEN CORE IS FOR EARTHING.

• TWO # 16 AWG WHITE CORES ARE FOR THERMALS

• ONE # 16 AWG BLACK CORE IS THE SEAL PROBE SENSOR

THE SEAL PROBE SENSOR NEEDS TO BE WIRED TO AN ABB LLC4 LIQUID LEVEL PROBE
SENSOR THAT DETECTS MINUTE AMOUNTS OF FLUID IN THE OIL CHAMBER INSIDE THE
CONTROL PANEL. SEE FOLLOWING DIAGRAM.

GENERAL OVERHAUL AND OIL CHECK. (THIS APPLIES TO BOTH
MODELS)

TO CARRY OUT A GENERAL OVERHAUL, IT IS ESSENTIAL THAT A COMPLETE
SET OF TOOLS BE AVAILABLE AS PER TOOL KIT LIST. (LIST IS AVAILABLE
AT THE END OF THE MANUAL). IT IS NOT POSSIBLE TO CONDUCT THE
OVERHAUL WITHOUT THE REQUISITE TOOLS.

DIS-ASSEMBLY (REFER DRG.NO.MS/801/803 SHEET 1 & 2) AT END OF
MANUAL)

• IT IS MANDATORY THAT ALL "O" RINGS BE REPLACED WHENEVER A PUMP IS OVERHAULED

OR DISMANTLED. UNDER NO CIRCUMSTANCES SHOULD OLD "O" RINGS BE USED, EVEN IF
THEY SEEM O.K. BE CAREFUL NOT TO SCRATCH SEALING SURFACES. ALWAYS GREASE NEW
“O” RINGS BEFORE INSTALLATION.

• ALWAYS ISOLATE THE UNIT FROM ELECTRICAL POWER BEFORE ATTEMPTING ANY

OVERHAUL.

• THE TRANSPORTABLE VERSION IS SUPPLIED WITH A PUMP BASE. REMOVE BASE BEFORE

ANY FURTHER DIS – ASSEMBLY. THE PERMANENT INSTALLATION VERSION IS SUPPLIED
WITH A SLIDING BRACKET FIXED ON THE VOLUTE OF THE PUMP.

• LAY THE PUMP ON ITS SIDE ON A BENCH OR OVER TWO SUPPORTS. TURN THE PUMP SO

THAT THE OIL ORIFICE FACES DOWNWARDS. USING AN ALLEN KEY UNSCREW OIL PLUG
(36) TO DRAIN OIL FROM THE SEAL CHAMBER. IT IS EASIER TO DRAIN THE OIL IF
THE OTHER OIL HOLE CAP SCREW IS ALSO REMOVED. BE CAREFUL. IF THE SEAL HAS
LEAKED, THE OIL CASING MAY BE UNDER PRESSURE. HOLD A RAG OVER THE OIL PLUG
TO PREVENT SPLATTER.

• UNSCREW NUTS (33) AND REMOVE PUMP VOLUTE (19) FROM SEAL HOUSING (17). REMOVE

CAP SCREW (25) AND SPRING WASHER (24). REMOVE LOCK WASHER (23) AND SLIDE
IMPELLER OF THE MOTOR SHAFT. IF THE IMPELLER IS SLIGHTLY TIGHT USE A WOODEN
MALLET TO TAP THE SAME OFF THE SHAFT. REMOVE KEY (28) AND KEEP ASIDE
CAREFULLY.

• THE LOWER MECHANICAL SEAL IS LOCKED ON THE SHAFT BY MEANS OF A LOCKING RING

(30). THIS RING CAN ONLY BE REMOVED/INSTALLED BY MEANS OF A SPECIAL TOOL
SUPPLIED ON REQUEST. (A PICTORIAL REPRESENTATION OF THE INSTALLATION /
REMOVAL METHOD IS APPENDED AT THE END OF THE MANUAL.SEE FIG. 1.) READ THE
INSTRUCTIONS SUPPLIED WITH THE TOOL CAREFULLY AND REMOVE THE LOCKING RING
FROM THE SHAFT. THE MECH. SEAL ASSEMBLY CAN NOW BE REMOVED FROM THE SHAFT BY
HAND. BE VERY CAREFUL WITH THE SEALING SURFACES SO THAT THEY DO NOT SUFFER
DAMAGE OR GET SCRATCHED IN ANY WAY. LEAVE THE SEAL SEAT IN THE SEAL HOUSING.

• UNSCREW NUTS (4) HOLDING THE SEAL HOUSING AGAINST THE STATOR CASING AND

REMOVE SEAL HOUSING. USE A WOODEN MALLET TO TAP OFF THE SAME. THE UPPER
MECH. SEAL IS NOW IN VIEW. REMOVE THE SEAL IN EXACTLY THE SAME MANNER AS THE
LOWER MECH. SEAL.

• UNSCREW HEX HD BOLTS (38) HOLDING THE LOWER BEARING BRACKET AGAINST THE

STATOR CASING. THE COMPLETE ROTOR ASSEMBLY WITH LOWER BEARING BRACKET AND
LOWER BEARINGS CAN BE PULLED OUT FROM THE STATOR ASSEMBLY. THE LOWER BEARING
BRACKET CAN BE REMOVED FROM THE ROTOR BY REMOVING THE BEARING COVER. THE
BEARING CAN NOW BE EXAMINED.