Instruction Manual Installation Manual Submersible Mixed Flow/Axial Flow Pump Model SAM Model SPM Thank you for your purchase of the Submersible Mixed Flow/Axial Flow Pump. Teral s Submersible Mixed Flow/Axial Flow Pumps have a high-precision and rigid structure with outstanding performance and are manufactured based on our technologies gained through years of experience. Since our products are carefully inspected before delivery, we are confident that you can use them with your mind at ease. Furthermore, make use of this instruction manual to fully deliver the excellent performance of Teral s Submersible Mixed Flow/Axial Flow Pump. Upon receiving the pump, check the following points first: Check the nameplate to verify that the model name, pump head, discharge rate, revolution speed, motor output, voltage, frequency, and other information are exactly what you ordered. No part of the unit including cables is damaged during transportation. All bolts and nuts are firmly tightened. All the accessories that you ordered have been delivered. If you find any problems, contact the vendor from which you purchased the product. To the customers Instruct the vendor (installation contractor) to install the pump. Thoroughly read this manual and properly use the pump. Keep this manual carefully after use, and read it when needed. Note that we are not liable for any product failures or accidents caused by improper use. To the vendors (installation contractor) Properly install the pump according to this manual. On completion of the installation, be sure to submit this manual to the customer. Note that we are not liable for any product failures or accidents caused by improper installation or improper use. Contents Instruction Manual for the customer Safety precautions (Be sure to observe the following.)... 1 Instructions for proper use... 3 Troubleshooting... 4 After-sales service... 4 Installation Manual for the vendor (installation contractor) Safety precautions (Be sure to observe the following.)... 5 1. Instructions before installation (1) Cleaning the pit... 7 (2) Power voltage... 7 (3) Motor... 7 (4) Installation places to be avoided... 7 2. Instructions during installation (1) Checking the submersible cable... 8 (2) Installing the pump... 8 (3) Grounding... 8 (4) Role of the control panel... 8 (5) Installation places of the operation panel to be avoided... 8 3. Operation (1) What you need to know before operation... 9 (2) Operations before starting the pump... 9 (3) Starting the pump... 9 (4) Cautions during the operation... 9 (5) Caution when the pump is stopped... 10 (6) Trouble and the causes... 10 Teral Inc.
Instruction Manual Safety precautions Be sure to observe the following. The user must observe the following instructions in order to prevent personal injury and property damage. The following symbols and labels are used to indicate the severity of the injuries and damage that may result from improper use or work in defiance of the instructions. WARNING CAUTION indicates that incorrect handling may lead to death or severe injury. indicates that incorrect handling may lead to injuries or property damage. The following symbols indicate the types of instructions to be observed. (The following are only part of all the symbols.) This graphic symbol indicates prohibited actions that must NOT be done. This graphic symbol indicates mandatory actions that must be done. WARNING Never disassemble, repair, or modify the product. Do not operate the control panel, ground fault interrupter, or other electric devices with wet hands. Do not disassemble It may lead to ignition or malfunction, thus causing injuries. For repairs, contact the vendor (installation contractor). It may lead to an electric shock. Do not damage the submersible cable, apply an excessive force to it, or bundle it. If the submersible cable or above-ground wires are damaged, do not use the product. It may lead to a fire or electric shock. It may lead to a fire or electric shock. Instruct the vendor (installation contractor) to repair them. Do not put anything heavy on the submersible cable or above-ground wires, pinch them, or rework them. It may damage the submersible cable or above-ground wires, thus leading to a fire or electric shock. 1
WARNING Do not use the product with the door of the control panel open. Rainwater or dust gets into the control panel, and resulting insulation degradation or other problems may lead to an electric shock or fire. Do not perform zero-discharge operation for more than 10 minutes. Do not put anything inside the control panel. Resulting overheat may lead to ignition and a fire. Do not run the product in mud. It may lead to hot water, an electric shock, injury, or accident. It may lead to an electric shock or accident. Do not fix the position of the reset button of the motor protective relay with tape or other means. In the event of a failure, the motor or wires may be overheated, thus leading to ignition and a fire. If the motor protective relay is tripped, contact the vendor (installation contractor). Ensure to turn off the power before starting maintenance or inspection work. It may lead to an electric shock or injury. CAUTION Do not open the door of the control panel. Never run the pump dry (operation without any water being pumped out). It may lead to an electric shock or accident. It may lead to a fire, electric shock, or accident. If the product is not working properly, immediately turn off the power and contact the vendor (installation contractor). If no water flows out, immediately turn off the power and contact the vendor (installation contractor). 2
Instruction Manual Safety precautions Be sure to observe the following. CAUTION If you do not use the product for a long time, be sure to turn off the power. It may lead to insulation degradation, thus resulting in an electric shock; or it may lead to an electric leak, thus resulting in a fire. If the product does not run or if there is anything wrong with it, immediately turn off the power. It may lead to an electric shock, electric leak, or short circuit, thus resulting in a fire. Ensure to instruct the vendor (installation contractor) to inspect and repair the product. Instructions for proper use Pay attention to the discharge rate. The discharge rate may suddenly decrease if air is drawn from the strainer (suction port) or if the strainer is clogged with dirt. In such a case, contact the vendor (installation contractor). Pay attention to the needle of the ammeter. If the deflection of the meter needle is large or the operating current exceeds the rated value, contact the vendor (installation contractor). Close the cock of the compound pressure gauge. Leaving the cock open may damage the compound pressure gauge by a shock during startup or stop. If no water has been pumped out for over 3 or 4 days, open the water tap to run water for a while before use. In such a case, water inside the pump and piping may be cloudy. Even if you do not plan to use the pump for a long time, run it periodically (once a month or so). For maintenance and safety, it is recommended to check the insulation resistance and operating conditions (electric current, vibration, discharge rate, etc.) periodically (once a month or so). Contact the vendor (installation contractor). 3
Ensure to confirm the following installation points from the vendor (installation contractor). If the product is for indoor use, confirm that measures are taken against water leakage. If water flows out during repairs or inspection or in the event of a failure, it may drench surrounding areas or downstairs, thus leading to serious compensation issues. Check that no ground wire is connected to a gas pipe or water pipe. It may lead to an explosion or electric shock. Confirm that the product is securely grounded and that the dedicated ground fault interrupter is installed. It may lead to an electric shock in the event of a failure or electric leak. (You are required by law to connect a ground wire.) Check that measures are taken against freezing of the above-ground section and the pipe. Even in a warm region, an unexpected cold wave may freeze and damage the above-ground section and piping in winter. Troubleshooting If there is a problem, carry out troubleshooting according to the following table. If the problem still persists, contact the vendor (installation contractor). Problem Possible Cause Action No rotation of motor (The motor does not run.) The motor is running, but no water flows out, or the discharge rate is low. The power supply (ground fault interrupter) is shut off. The sluice valve of the above-ground section or a valve installed in the pipe is closed. Turn on the power (ground fault interrupter). Open the sluice valve and other closed valve(s) in the pipe. After-sales service For repair, handling, maintenance, and other work of the product, contact the vendor from which you purchased the product. Before instructing the vendor to repair the product, check the items shown in the Troubleshooting on this page. If the problem still persists, first turn off the power and the ground fault interrupter, and then contact the vendor (installation contractor) from which you purchased the product. 4
Installation manual Safety precautions Be sure to observe the following. The installation worker must observe the following instructions in order to prevent personal injury and property damage. The following symbols and labels are used to indicate the severity of the injuries and damage that may result from improper use or work in defiance of the instructions. WARNING CAUTION indicates that incorrect handling may lead to death or severe injury. indicates that incorrect handling may lead to injuries or property damage. The following symbols indicate the types of instructions to be observed. (The following are only part of all the symbols.) This graphic symbol indicates prohibited actions that must NOT be done. This graphic symbol indicates mandatory actions that must be done. WARNING Do not connect the ground wire to a gas pipe or water pipe. Do not operate the control panel, ground fault interrupter, or other electric devices with wet hands. It may lead to an explosion or electric shock. It may lead to an electric shock. Do not use the submersible cable for above-ground wiring. Use it for the connection of only up to the conduit, terminal box, etc. Do not damage the submersible cable, apply an excessive force to it, or bundle it on the ground. Resulting overheat may lead to ignition and a fire. It may lead to a fire or electric shock. Do not use the product at any voltage other than specified. It may lead to a fire or electric shock. Cut off any excess of the submersible cable above the ground, and connect the cable to the control panel or the terminal box. 5
WARNING Do not use the product for pumping any liquid other than clean water (salt water, oil, chemicals, etc.) or for pumping hot water above 40 C. It may lead to an explosion, fire, electric shock, or accident. Carry out installation work safely and securely. Problems such as the fall of the pump may occur, thus leading to an injury. Furthermore, improper work may cause water leakage, an electric shock, or a fire. Only specialist contractors are allowed to carry out the installation work. Carry out wiring work safely and securely according to the technical standards for electrical facilities, as well as the indoor wiring regulations. Improper wiring work may cause an electrical shock or a fire. Only licensed electrical engineers are allowed to carry out electrical wiring work. Ensure to install a ground fault interrupter. It may lead to an electric shock in the event of a failure or electric leak. (You are required by law to install a ground fault interrupter.) In the event of an electric leak, the interrupter immediately shuts off the power, thus preventing an electric shock. Ensure to turn off the power before grounding work. It may lead to an electric shock. Ensure to connect a ground wire (Class D grounding). Connect a ground wire It may lead to an electric shock in the event of a failure or electric leak. (You are required by law to connect a ground wire.) Connect a ground wire to the ground terminal of the well lid, and bury the ground rod in the ground. Only licensed electrical engineers are allowed to carry out the grounding work according to the technical standards for electrical facilities. 6
Installation manual 1. Instructions before installation (1) Cleaning the pit If the pit is not cleaned thoroughly, the suction port and strainer of the pump may get clogged with debris (such as wood pieces, bolts, nuts, iron pieces, gravel, concrete pieces, or rags) left in the pit, which significantly reduces the discharge rate and compromises its performance. Because running the pump in that condition may damage the pump, be sure to clean the inside of the pit before installation and take measures to prevent the entry of any debris or dirt into the pump, for example, by installing a screen on the suction port. (2) Power voltage a. Keep the voltage applied to the motor within ±10% of the rated voltage during the operation. b. If you need to connect an extra cable to the supplied cable for extension, use a cable thick enough to keep a voltage drop across the cable within 5% of the rated voltage during the operation. Do not allow the joint of the cables to be submerged in water. c. Keep the voltage imbalance between each phase within ±2.5%. (3) Motor a. Before shipment, antifreeze solution has been filled in the motor at our factory. Upon installing the pump, be sure to take the following steps to check whether the filled solution has leaked during the transportation: [1] Place the motor on its side. [2] Remove the plugs of the filler port and drain port located on the side in the upper section of the motor. [3] Check the level of the solution. [4] If the solution is insufficient, add clean water. Caution label Filler port plug, drain port plug (one for each) Pump strainer Submersible motor When you add clean water (you may use tap water), ensure that no air is trapped in the motor. Note that any residual air may cause the bearing or other parts of the motor to burn out. b. Never run the motor on the ground. Ensure to run the motor only after it is submerged in water. c. Handle both the motor section and the pump section with care. Pay special attention not to allow the unit to topple over or fall. d. If you need to lift the motor out of water and store it, remove the drain plug from the bottom of the motor and completely drain water before storage. Particularly when you store the motor at a place that could be exposed to the freezing temperature, be sure to drain water because otherwise the motor frame and other parts will be damaged. (4) Installation places to be avoided a. Places with a large amount of sand or debris b. Places exposed to corrosive substances c. Avoid pumping warm or hot water. d. Places exposed to sea water or salt 7
Installation manual 2. Instructions during installation (1) Checking the submersible cable Before and after installing the cable, be sure to measure its insulation resistance and continuity. Although this product including the submersible cable is strictly tested and inspected before shipment, check for any flaws or damage and measure the insulation resistance before installation, just in case. Be careful not to damage the submersible cable during the installation work, and measure the insulation resistance and continuity again after the installation. If the insulation resistance is 1MΩ or less, contact the vendor from which you purchased the product. (2) Installing the pump a. This product can be suspended or mounted for use. In either case, install supporting devices at necessary points. The supporting devices must be large and strong enough to support the weight of the pump, its accessories, lifting pipe, and pumping water as well as to absorb various vibrations and shocks to be generated during the operation. b. Ensure to install a check valve in the discharge piping. Otherwise, back flow occurs when the pump has stopped, which causes the pump to rotate in the reverse direction and significantly shortens the service life of the pump. Also install a sluice valve and a compound pressure gauge in order to control the water flow rate and for future inspection. Note: If you use a sluice valve together with the Axial Flow Pump, refer to the section 3.(2)-a. Operations before starting the pump on page 9. (3) Grounding Ground the product so that 100Ω or lower grounding resistance can be achieved (Class D grounding). For grounding, use copper wire with the diameter (thickness) specified in the following table. Capacity of motor Up to 2.2 kw Up to 3.7 kw Up to 7.5 kw Up to 15 kw Up to 37 kw Over 37 kw Wire thickness 1.6 mm (2.0 mm 2 ) or greater 2.0 mm (3.5 mm 2 ) or greater 2.6 mm (5.5 mm 2 ) or greater 14 mm 2 or greater 22 mm 2 or greater 38 mm 2 or greater (4) Role of the operation panel The most essential role of the operation panel is to prevent motor burnout. The submersible motor pump runs under water, and the only way to conduct a diagnosis on the ground is through the operation panel. Therefore, the operation panel must be highly reliable. The operation panel specified by Teral has been manufactured exclusively for use in the submersible motor pumps. It protects the pump and allows the user to start and stop the pump through simple operations. (5) Installation places of the operation panel to be avoided Avoid installing the operation panel at the following places: a. Places exposed to vibrations b. Hot or humid places c. Places exposed to water (rain, snow) (for indoor-type) d. Places with a possible ignition source e. Places with a possible generation of a corrosive gas f. Dusty or dirty places g. Places exposed to direct sunlight (for indoor-type) 8
Installation manual 3. Operation (1) What you need to know before operation a. Criteria for determining whether the rotation direction is normal or reverse If water is pumped up with the valve fully open, the motor is running in the normal direction. If the motor is running in the reverse direction, a significantly smaller amount of water will be pumped up, accompanied by a noise and vibration. Therefore, you can tell whether the motor is running in the normal or reverse direction. b. How to make the motor run from the reverse to normal direction Direct on-line starting Terminals on control panel Star-delta starting Terminals on control panel To main switch To motor To main switch To motor Swap V with W. Swap V1 with W1, and W2 with U2. (2) Operations before starting the pump a. Because of its characteristics, running the Mixed Flow/Axial Flow Pump with its sluice valve fully closed leads to overcurrent. Fully open the valve before turning ON the (start) switch. b. If the compound pressure gauge is used, keep the cock of the gauge closed. Otherwise, the shock applied during the startup may damage the gauge. (3) Starting the pump a. Turn ON the (start) switch. b. When water flows out, check the rotation direction of the pump (i.e., normal or reverse). If the pump produces a noise and vibration and the water pressure is significantly lower than the specified pressure, the motor is running in the reverse direction. Change the rotation to the normal direction in such a case, referring to the section 3.(1) What you need to know before operation on page 9. Be aware that running the pump in the reverse direction is not only highly inefficient, but may also cause damage to both the pump and motor. (4) Cautions during the operation a. Pay attention to the discharge rate. If the suction water level becomes abnormally low during the operation and that allows the entry of air from the suction port (the strainer), the pumping function may get compromised in terms of both efficiency and discharge rate and it may also cause the vibration of the pump. Furthermore, the strainer may get clogged with debris, leading to a sudden decrease in the discharge rate. Therefore, be sure to install a screen on the suction port to prevent the entry of debris. b. Pay attention to the needle of the ammeter. In the case described in the above caution (a.), the electric current decreases. If debris (such as sand) is caught in the sliding part of the impeller or in other parts, the needle shows a large deflection or the operating current exceeds the rated value. 9
(5) Caution when the pump is stopped In the event of a power failure during the operation, be sure to turn off the main switch. (6) Trouble and the causes Trouble with the pump and motor can result from a variety of causes and the actions are different accordingly; but in any case it is essential to identify the symptom and take actions at an early stage. The following table lists typical examples of symptoms and their causes. Refer to the table and take appropriate actions. If you have anything unclear, ask the vendor from which you purchased the product. Troubleshooting table Cause Symptom Difficulty in starting the pump Vibration Noise Overload Too little load Low discharge rate Low pump head Unable to pump up water Large deflection of ammeter needle Tripping of the auto stop protection device Reverse rotation Voltage drop The sluice valve is half-opened or closed. Wrong installation of the check valve Low water level Axial Flow Axial Flow Axial Flow Clogging at the strainer on the suction port The impeller eye is clogged with debris. Debris is caught in the impeller s sliding part. Wear of the impeller s sliding part Contact of a rotating part with another part, and its seizure Single-phase operation Insulation degradation (cable sheath, flaws, broken wire) 10
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