Instruction Manual Installation Manual Submersible Turbine Pump (Volute) STM type (T, TU, and TU3) SSTM type (TUA) Thank you for your purchase of Teral (Volute) Submersible Turbine Pump. To the customers Instruct the dealer (installation contractor) to install the pump. Thoroughly read this manual to properly use the pump. Keep this manual carefully after use, and read it when needed. Note that we are not liable for any product trouble or accidents caused by improper use. To the dealers (installation contractor) Properly install the pump according to the installation manual. After the completion of installation, be sure to submit this manual to the customer. Note that we are not liable for any product trouble 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 Name and function of each part...4 Troubleshooting...5 After-sales service...5 Standard specifications...6 Installation manual for the dealer (installation contractor) Safety precautions (Be sure to observe the following.)...7 Installed pump system and names...9 Instructions for installation...10 Control panel...12 Wiring work...13 Anti-freeze measures...14 Test operation...14 Teral Inc.
Instruction Manual Safety precautions Be sure to observe the following. The following symbols and labels indicate the instructions that the user must observe in order to prevent personal injury and property damage. Levels of possible injuries and damage as a result of improper use in defiance of the instructions are classified by the following symbols and labels. 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 symbols.) This symbol indicates "prohibition" that you must NOT do. This symbol indicates "mandatory" actions that you must do. WARNING Never disassemble, repair, or modify the product. Do not operate the control panel or 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 dealer (installation contractor). An electric shock may occur. 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. A fire or electric shock may occur. A fire or electric shock may occur. Instruct the dealer (installation contractor) to repair them. Do not put anything heavy on the submersible cable or the above-ground wires, pinch them, or modify them. It may damage the submersible cable or above-ground wires, thus causing a fire or electric shock. 1
WARNING Do not use the product while the door of the control panel is open. Do not put anything inside the control panel. It may cause rainwater or dust to enter the control panel. As a result, insulation degradation or other problems may occur, thus resulting in an electric shock or fire. It may cause overheating, thus resulting in ignition and fire. Do not perform Zero discharge operation for over 10 minutes. Do not run the product in mud. It may make the water hot, thus resulting in an electric shock, injury, or accident. An electric shock or accident may occur. Do not fix the position of the reset button of the motor protective relay with tape etc. It may overheat the motor or the wires in the event of trouble, thus resulting in ignition and a fire. If the motor protective relay is tripped, contact the dealer (installation contractor). Be sure to turn off the power before maintenance or inspection. An electric shock or injury may occur. CAUTION Do not open the door of the control panel. Never run the pump dry (when it is not submerged in water). An electric shock or accident may occur. A fire, electric shock, or accident may occur. If the product is not running properly, immediately turn off the power and contact the dealer (installation contractor). If water does not flow out, immediately turn off the power and contact the dealer (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 cause an electric shock through insulation degradation or a fire through electric leak. If the product does not run or there is anything wrong, immediately turn off the power. It may cause an electric shock, or electric leak or short circuit, thus resulting in a fire. For repairs or inspection, be sure to instruct the dealer (installation contractor) from which you purchased the product. Instructions for proper use Pay attention to the discharge rate. The discharge rate may suddenly decrease when air is drawn from the strainer (suction opening) or the strainer is clogged with dirt. In such a case, contact the dealer (installation contractor). Pay attention to the needle of the ammeter. If the deflection of the meter needle is large or the current exceeds the rated value, contact the dealer (installation contractor). Shut the cock of the compound pressure gauge. Keeping 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. Water in the pump or in the 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 inspect the insulation resistance and operating conditions (electric current, vibration, discharge rate, etc.) periodically (once a month or so). Contact the dealer (installation contractor). 3
Instruction Manual Safety precautions Be sure to observe the following. Be sure to confirm the following installation points from the dealer (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 trouble, it may drench surrounding areas and downstairs, thus resulting in serious compensation issues. Check that no ground wire is connected to a gas pipe or water pipe. An explosion or electric shock may occur. Confirm that the product is securely grounded and that the dedicated ground fault interrupter is installed. An electric shock may occur in the event of trouble 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 in winter may freeze and damage the above-ground section and piping. Name and function of each part Refer to page 9 for the installed system of the pump and the above-ground section. Refer to the separate Instruction Manual for the control panel. 4
Instruction Manual Troubleshooting If there is a problem, carry out troubleshooting according to the following table. If the problem still persists, contact the dealer (installation contractor). Problem Possible Cause Action No rotation of motor (The motor does not run.) The power (ground fault interrupter) is turned off. Turn on the power (ground fault interrupter). The motor is running, but no water flows out, or the discharge rate is low. The sluice valve of the above-ground section or a valve installed on the pipe is shut. Open the sluice valve and the valve on the pipe. Instructions If the light comes on at any alarm indicator of the motor protective relay, such as the overcurrent indicator or open-phase indicator, be sure to instruct the dealer (installation contractor) to inspect the unit. After-sales service For repairs, handling, maintenance, and other work for the product, contact the dealer from which you purchased the product. Before instructing the dealer to repair the unit, check the items shown in the "Troubleshooting" on this page. If the problem still persists, turn off the power and the ground fault interrupter, and then contact the dealer (installation contractor) from which you purchased the product. 5
Instruction Manual Standard specifications SSTM type (all liquid contact parts are made of stainless steel) Bore (mm) 32 40 50 65 Item Liquid to be pumped Pump Submersible motor Structure Material Starter type Material STM type Item Liquid to be pumped Pump Submersible motor Structure Material Starter type Material Liquid quality Fresh water Liquid temperature 0 to 40 C Chlorine content Contained sand quantity PH 5.8 to 8.6 Max. allowable chlorine content: 200 mg/l Max. allowable sand quantity: 50 mg/l (Max. allowable grain size: 0.1 to 0.25 mm) Motor output (kw) 0.4 to 3.7 0.75 to 7.5 0.75 to 11 1.5 to 15 Suction opening Type Impeller Bottom Sectional type Closed Casing SUS 304 Impeller SUS 304 Type Number of poles, phase, voltage Shaft SUS 420J2 or SUS 431 0.4kW to 7.5kW 11kW, 15kW Canned type 2-pole, 3-phase 200V Full voltage starting (Direct on line starting) Star-delta starting Insulation class Up to 3.7kW output: Class B 5.5kW or higher: Class F Class F Flange Frame Up to 3.7kW output: SUS316 5.5kW or higher: SUS304 SUS304 Shaft Up to 3.7kW output: SUS630 5.5kW or higher: SUS431 SUS431 Lead wire Liquid quality Bore (mm) 2PNCT Special threaded flange 32 40 50 65 80 100 125 Fresh water Liquid temperature 0 to 40 C Chlorine content Contained sand quantity PH 5.8 to 8.6 Max. allowable chlorine content: 200 mg/l Max. allowable sand quantity: 50 mg/l (Max. allowable grain size: 0.1 to 0.25 mm) Motor output (kw) 0.4 to 7.5 0.75 to 7.5 0.75 to 11 1.5 to 30 1.5 to 37 3.7 to 55 5.5 to 75 Suction opening Type Impeller Casing Impeller Type Number of poles, phase, voltage Middle or bottom Sectional type Closed FC200 CAC406 (BC6) Shaft SUS 420J2 or SUS 403 0.4kW to 7.5kW 11kW or higher Insulation class Flange Frame Shaft Lead wire Canned type (up to 3.7kW output), PE winding type (3.7kW or higher) 2-pole, 3-phase 200V Full voltage starting (Direct on line starting) Star-delta starting Class B (Canned type) or polyethylene (PE winding type) SUS316 (Canned type) or FC150 (PE winding type) SUS630 (Canned type) or SUS403 (PE winding type) 2PNCT JIS10K type or JIS20K type 6
Installation Manual Safety precautions Be sure to observe the following. The following symbols and labels indicate the instructions that the installation worker must observe in order to prevent personal injury and property damage. Levels of possible injuries and damage as a result of improper use in defiance of the instructions are classified by the following symbols and labels. 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 symbols.) This symbol indicates "prohibited" actions that you must NOT do. This symbol indicates "mandatory" actions that you must do. 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. An explosion or electric shock may occur. An electric shock may occur. Do not use the submersible cable for above-ground wiring. Use it for the connection of only up to the conduit and terminal box. It may cause overheating, thus resulting in ignition and fire. Do not use the product at any voltage other than specified. Do not damage the submersible cable. Do not apply excessive force to the cable or bundle the cable on the ground. A fire or electric shock may occur. Cut off any excess of the submersible cable exposed on the ground, and connect the cable to the control panel or the terminal box. A fire or electric shock may occur. 7
WARNING Do not use the pump for any liquids other than fresh water (such as salt water, oil, and chemicals) or for hot water exceeding 40 C. An explosion, fire, electric shock, or accident may occur. Carry out installation work safely and securely. Otherwise, there may be a danger; for example, the pump falls down, thus resulting in injury. Furthermore, improper work may cause water leak, electric shock, or fire. Only specialist contractors are allowed to carry out the installation work. Carry out wiring work safely and securely in accordance with the Technical Standards for Electrical Equipment and the indoor wiring regulations. Improper wiring work may cause an electrical shock or fire. Only electricians are allowed to carry out the electrical wiring work. Be sure to install the ground fault interrupter. An electric shock may occur in the event of trouble or electric leak. (You are required by law to install the ground fault interrupter.) If electric leak occurs, immediately turn off the power to prevent an electric shock. Be sure to turn off the power before grounding work. An electric shock may occur. Be sure to connect a ground wire (Class D grounding). Connect a ground wire An electric shock may occur in the event of trouble or electric leak. (You are required by law to connect a ground wire.) Connect a ground wire to the grounding terminal of the well lid; and bury the ground rod in the ground. Only electricians are allowed to carry out the grounding work in accordance with the Technical Standards for Electrical Equipment. 8
Installation manual Installed pump system and names Compound pressure gauge (Pressure gauge) Air valve Check valve Sluice valve Discharge bend Bedplate Submersible cable Ground wire Terminal box Lifting pipe Anchor bolts Cable tie Submersible turbine pump (volute) Suction opening (Strainer) 9
Installation manual Instructions for installation Clean the water tank If the water tank is not cleaned enough, remaining foreign matter (such as wood chips, bolts, nuts, iron chips, gravel, concrete chips, or shreds of rags) may clog the strainer (suction opening) and cause the sudden drop of discharge rate, which not only hinder the full performance of the pump, but also may damage the pump. Therefore, before installing the pump, be sure to clean the inside of the tank and take measures to prevent the entry of foreign matter and dirt into the tank, for example, by installing a screen at the inlet. Placement of the pump Due consideration must be given to the position where the pump is installed in the tank. Installation of the pump at an improper place may cause swirls on the water surface, thus resulting in irregular/unstable water flow, air drawing, significant decrease in pumping performance, as well as vibration and noise. Particularly when two or more pumps are installed, some measures should be taken to allow water to evenly flow into each pump. Minimum water level for operation The minimum water levels required for starting and running the pump differ depending on the pump orientation (horizontal or vertical) and the strainer position (bottom or middle) for vertical installation. Refer to the catalogue for details. When an automatic operation unit is installed, determine the water levels of turning ON (start running) and OFF (stop) the pump, referring to the following diagram. OFF (minimum level for operation) Minimum level for startup Strainer OFF (minimum level for operation) Strainer Strainer OFF (minimum level for operation) Horizontal mount rack 10
Installation manual Instructions for installation Check the motor sealing water Before shipping, the motor is filled with sealing water in the factory. Remove the plug and check that the sealing water is full without any leakage. For a horizontally mounted pump, perform the same check when the water is drained from the tank. * There is no need to check the amount of motor sealing water for SSTM type motors and for STM bottom suction (TU) type motors of up to 18.5 kw. STM type -- Middle suction (T type) STM type -- Bottom suction (TU type) Filler/Vent port * Use a screw driver with wide blade. Filler/Vent port The figure shows a horizontally installed pump. Even if you use a pump of this type without the horizontal mount racks, place the pump horizontally in the same way when checking the sealing water. Remove the plug of the filler/vent port and check that water is full. If it is insufficient, add fresh water (drinking water). Reinstall the plug back in place and securely tighten it. When you install the pump in a horizontal position, be sure to use the specially supplied horizontal mount rack(s) and install the pump on a level foundation. SSTM type STM type -- Bottom suction (TU type) Horizontal mount rack Horizontal mount rack CAUTION Never run the pump in the air (above water). It may cause overheating, which leads to accidents such as a fire or electric shock. Submersible cable Before and after installing the cable, be sure to measure the insulation resistance and continuity. Although this product including the submersible cable is strictly tested and inspected in the factory before shipping, 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, and measure the insulation resistance and continuity again after the installation. If the insulation resistance is 10MΩ or less, contact the vendor from which you purchased the product. Instructions Be sure to measure the insulation resistance of the submersible cable. If the measured value is 10MΩ or less, contact the vendor. 11
Installation manual Instructions for installation Installation of the pump The pump can be used in a suspended, vertical, or horizontal position (horizontal position is only supported by the pumps of STM T type [middle suction], SSTM type, and STM TU canned type of up to 3.7kW). In any case, install sufficient supports at necessary points to support the weight of the pump, its accessories, lifting pipe, and water to be lifted as well as to absorb various vibrations and impacts generated during the operation of the pump. Be sure to install a check valve on the piping. Otherwise, back flow occurs when the pump is stopped, which causes the pump to rotate in the reverse direction and significantly shortens the life of the pump. In addition, install a sluice valve and a pressure gauge for the regulation of water flow rate and for future inspection. Instructions Only electricians are allowed to carry out the installation work. Be sure to check the voltage of supplied power. The control panel must be installed almost vertically at a place as close to the pump as possible or where you can easily carry out the operation and maintenance. Control panel Use the Teral s control panel for submersible pumps. Its 2E relay (or 3E relay) trips to protect the motor in the event of overload, open phase, or reverse phase during operation. If it is unavoidable to use a control device other than Teral s, use a protection relay equivalent to the 2E (or 3E) relay. In that case, set the tripping conditions shown in the following table. Current Tripping condition 105% No trip 150% Trip within 25 sec 500% Trip within 3 sec WARNING Do not install the control panel at a place with a risk of ignition, generation of corrosive gas, or exposure to vibrations, dust, high temperatures (40 C or higher) or high humidity (90% or higher). If the panel is of an indoor type, do not install it at a place possibly exposed to rainwater. An explosion, fire, or electric shock may occur. 12
Installation manual Wiring work Be sure to connect a ground wire to prevent an electric shock. Only electricians are allowed to carry out the grounding work in accordance with the Technical Standards for Electrical Equipment (Class D grounding). Connect a ground wire to the grounding terminals on the bedplate and control panel; and bury the grounding rod in the ground. Perform wiring work safely and securely in accordance with the Technical Standards for Electrical Equipment and the indoor wiring regulations. For the wiring work between the power supply and the control panel as well as between the control panel and the terminal box, the users must provide wiring materials on their own and perform wiring work in accordance with the Technical Standards for Electrical Equipment and the indoor wiring regulations. The voltage applied to the motor must be within ±10% of the rated voltage during operation. Use wires thick enough to keep a voltage drop at the terminal box within 5% of the rated voltage during operation. If you need to connect an extra cable to the supplied cable for extension, use a cable thick enough to keep a voltage drop along the cable within 5% of the rated voltage during operation. WARNING Do not submerge any connected points of the extended cable in water. An electric shock may occur. Keep the voltage imbalance of each phase within ±2.5%. For the connection of the control panel, refer to the Instruction Manual for the control panel. Check the rotation direction normal or reverse. Open the sluice valve about a half-turn to one turn. Shut the cock of the compound pressure gauge. Turn on the switch of the control panel. Shut the sluice valve, read the compound pressure gauge, and then open the sluice valve about one turn. Total shutoff head (m) Reading of the compound pressure gauge (m) + Minimum water level for operation (m) If both sides of the above equation are roughly equal, the motor rotates in the normal direction. If the rotation is reverse, change the connection according to the following diagram to switch to the normal direction. Direct on line starting Terminals at operation panel Star-delta starting Terminals at operation panel To main switch To motor To main switch To motor Swap V with W. Swap V1 with W1, and W2 with U2. Instructions Only electricians are allowed to carry out the wiring work. Be sure to check the voltage of supplied power. 13
Installation manual Anti-freeze measures (Be sure to read the following instructions even if the product is used in a warm region.) Even in a warm region, an unexpected cold wave in winter may freeze and damage the above-ground piping. Therefore, be sure to take the following measures against freezing. Heat insulation with heat insulating materials Wrap felt or other material around the following above-ground section to keep them warm: discharge bend, check valve, sluice valve, and the exposed area of piping. Bury any horizontal piping in the ground. (Determine the depth of piping to be buried depending on the temperature and the nature of the soil in the region.) In a region where the outside air temperature is especially low, construct a concrete pit or shed; and wrap a heat insulating material around the exposed areas of the above-ground section and piping. If a concrete pit has been constructed, provide a heat insulating material to the inside of the pit. Instructions For the pits and shed, provide space to allow for repairs, inspection, and lifting. In addition, construct them to allow for draining. Test operation WARNING Do not run the product if the insulation resistance between the control panel and the submersible motor is not higher than 1 MΩ. A fire or electric shock may occur. Open the sluice valve a half-turn to one turn. Shut the cock of the compound pressure gauge or the pressure gauge. Turn on the switch of the control panel. When water flows out, shut the sluice valve, open the cock of the compound pressure gauge or the pressure gauge, determine whether the rotation direction is normal or reverse, and ensure that the motor rotates in the normal direction. (To determine the rotation direction, refer to "Check the rotation direction -- normal or reverse" on page 13.) Open the sluice valve gradually to regulate the water flow until the water discharge rate reaches the specified value. Instructions Be sure to check the water level in the tank before starting the operation. If the pump is operated without water or without being submerged in water, the ammeter indicates light load but the pump runs dry, thus leading to an accident or trouble. 14
Head Office 230, Moriwake, Miyuki-cho, Fukuyama-city, Hiroshima, 720-0003, Japan Tel.+81-84-955-1111 Fax.+81-84-955-5777 www.teral.net