advertisement
OPERATION MANUAL
MODEL ST4125G/ST6125G
SUBMERSIBLE PUMP
Revision #0 (11/18/10)
To fi nd the latest revision of this publication, visit our website at: www.multiquip.com
THIS MANUAL MUST ACCOMPANY THE EQUIPMENT AT ALL TIMES.
ST4125G/ST6125G
Submersible Pump
Table Of Contents .................................................... 2
Parts Ordering Procedures ...................................... 3
Safety Information ................................................ 4-7
Specifi cations ............................................................ 8
Dimensions .............................................................. 9
General Information .............................................. 10
Components ......................................................... 11
Float Switches .................................................. 12-14
Control Box Installation .................................... 15-16
230/460 Vac Voltage Selection ............................. 17
Control Box Power Connections ........................... 18
Control Box Wiring Layout .................................... 19
Operation ......................................................... 20-21
Maintenance .................................................... 22-25
Control Box Wiring Diagram ................................. 26
TABLE OF CONTENTS
PAGE 2 — ST4125G/ST6125G SUBMERSIBLE PUMP • OPERATION MANUAL — REV. #0 (11/18/10)
NOTES
ST4125G/ST6125G SUBMERSIBLE PUMP• OPERATION MANUAL — REV. #0 (11/18/10) — PAGE 3
Do not operate or service the equipment before reading the entire manual. Safety precautions should be followed at all times when operating this equipment.
Failure to read and understand the safety messages and operating instructions could result in injury to yourself and others.
SAFETY MESSAGES
The four safety messages shown below will inform you about potential hazards that could injure you or others. The safety messages specifi cally address the level of exposure to the operator and are preceded by one of four words:
DANGER, WARNING, CAUTION or NOTICE.
SAFETY SYMBOLS
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in DEATH or SERIOUS INJURY.
WARNING
Indicates a hazardous situation which, if not avoided,
COULD result in DEATH or SERIOUS INJURY.
CAUTION
Indicates a hazardous situation which, if not avoided,
COULD result in MINOR or MODERATE INJURY.
NOTICE
Addresses practices not related to personal injury.
SAFETY INFORMATION
Potential hazards associated with the operation of this equipment will be referenced with hazard symbols which may appear throughout this manual in conjunction with safety messages.
Symbol Safety Hazard
Burn hazards
Electric shock hazards
Rotating parts hazards
Pressurized fluid hazards
PAGE 4 — ST4125G/ST6125G SUBMERSIBLE PUMP • OPERATION MANUAL — REV. #0 (11/18/10)
GENERAL SAFETY
CAUTION
NEVER operate this equipment without proper protective clothing, shatterproof glasses, respiratory protection, hearing protection, steel-toed boots and other protective devices required by the job or city and state regulations.
Avoid wearing jewelry or loose fi tting clothes that may snag on the controls or moving parts as this can cause serious injury.
NEVER operate this equipment when not feeling well due to fatigue, illness or when under medication.
NEVER operate this equipment under the infl uence of drugs or alcohol.
SAFETY INFORMATION
NOTICE
This equipment should only be operated by trained and qualifi ed personnel 18 years of age and older.
Whenever necessary, replace nameplate, operation and safety decals when they become diffi cult read.
Manufacturer does not assume responsibility for any accident due to equipment modifi cations. Unauthorized equipment modifi cation will void all warranties.
NEVER use accessories or attachments that are not recommended by Multiquip for this equipment. Damage to the equipment and/or injury to user may result.
ALWAYS know the location of the nearest fi re extinguisher.
ALWAYS know the location of the nearest fi rst aid kit.
ALWAYS know the location of the nearest phone or keep
a phone on the job site. Also, know the phone numbers of the nearest ambulance, doctor and fi re department.
This information will be invaluable in the case of an emergency.
ALWAYS clear the work area of any debris, tools, etc. that would constitute a hazard while the equipment is in operation.
No one other than the operator is to be in the working area when the equipment is in operation.
DO NOT use the equipment for any purpose other than its intended purposes or applications.
ST4125G/ST6125G SUBMERSIBLE PUMP• OPERATION MANUAL — REV. #0 (11/18/10) — PAGE 5
PUMP SAFETY
DANGER
NEVER operate the equipment in an explosive atmosphere or near combustible materials. An explosion or fi re could result causing severe bodily harm or even death.
WARNING
Accidental starting can cause severe injury or death. ALWAYS place the ON/OFF switch in the OFF position.
DO NOT place hands or fingers inside pump when pump is running.
NEVER disconnect any emergency or
safety devices. These devices are intended for operator safety. Disconnection of these devices can cause severe injury, bodily harm or even death. Disconnection of any of these devices will void all warranties.
Risk of Electric Shock - This pump has not been investigated for use in swimming pool or marine areas.
CAUTION
DO NOT restrict the fl ow of the discharge hose as it may cause the pump to overheat.
Be careful of discharge hose whipping under pressure.
ALWAYS check pump oil level only when pump is cool.
Expansion due to heat may cause hot oil to spray from the oil plug when the oil plug is removed. The possibility of severe scalding may exist.
NOTICE
ALWAYS place the pump in an upright position on a platform before using. The platform will prevent the pump from burrowing itself on soft sand or mud.
NEVER operate pump on its side.
DO NOT allow the pump to freeze in water.
NEVER leave an open pump chamber unattended.
ALWAYS keep the machine in proper running condition.
DO NOT attempt to thaw out a frozen pump by using
SAFETY INFORMATION
a torch or other source of fl ame. Application of heat in this manner may heat the oil in the seal cavity above the critical point, causing pump damage.
DO NOT pump water with a temperature greater than
104°F.
DO NOT pump liquids containing acid or alkali.
ALWAYS check strainer before pumping. Make sure strainer is not clogged. Remove any large objects, dirt or debris from the strainer to prevent clogging.
ALWAYS use a large basket strainer when pumping water that contains large debris.
ALWAYS fl ush pump (clean) after use when pumping water concentrated with heavy debris. It is very important to always fl ush the pump before turning it off to prevent clogging.
Fix damage to machine and replace any broken parts immediately.
ALWAYS store equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children and unauthorized personnel.
NEVER lubricate components or attempt service on a running machine.
NEVER run pump dry.
ALWAYS allow the machine a proper amount of time to cool before servicing.
Keep machine in proper running condition.
ELECTRICAL SAFETY
DANGER
The electrical voltage required to operate pump can cause severe injury or even death through physical contact with live circuits.
ALWAYS disconnect electrical power from pump before performing maintenance on pump.
WARNING
To reduce the risk of electric shock, connect only to a circuit protected by a Ground-Fault Circuit-Interrupter
(GFCI).
PAGE 6 — ST4125G/ST6125G SUBMERSIBLE PUMP • OPERATION MANUAL — REV. #0 (11/18/10)
NOTICE
ALWAYS make certain that the voltage supplied to the pump is correct. Always read the pump’s nameplate to determine what the power requirements are.
Power Cord/Cable Safety
DANGER
NEVER let power cords or cables lay in water.
NEVER stand in water while AC power cord is connected to a live power source.
NEVER use damaged or worn cables or cords. Inspect for cuts in the insulation.
NEVER grab or touch a live power cord or cable with wet hands. The possibility exists of electrical shock, electrocution or death.
Make sure power cables are securely connected to the motor's output receptacles. Incorrect connections may cause electrical shock and damage to the motor.
WARNING
NEVER attempt to use the power cord as a lifting or lowering device for the pump.
NOTICE
ALWAYS make certain that proper power or extension cord has been selected for the job. See Cable Selection
Chart in this manual.
Grounding Safety
DANGER
ALWAYS make sure pump is grounded.
NEVER use gas piping as an electrical ground.
ALWAYS make sure that electrical circuits are properly grounded to a suitable earth ground (ground rod) per the National Electrical Code (NEC) and local codes before operating generator. Severe injury or death by
electrocution can result from operating an ungrounded motor.
SAFETY INFORMATION
Control Box Safety
DANGER
ALWAYS have a qualifi ed electrician perform the control box installation. The possibility exists of electrical shock or electrocution.
NOTICE
ALWAYS mount control box in a vertical position protected from harsh environmental elements.
LIFTING SAFETY
CAUTION
When raising or lowering of the pump is required, always attach an adequate rope or lifting device to the correct lifting point (handle) on the pump.
NOTICE
DO NOT lift machine to unnecessary heights.
NEVER lift the equipment while the electric motor is running.
TRANSPORTING SAFETY
NOTICE
ALWAYS shut down pump before transporting.
ALWAYS tie down equipment during transport by securing the equipment with rope.
ENVIRONMENTAL SAFETY/DECOMMISSIONING
CE
DO NOT pour waste or oil directly onto the ground, down a drain or into any water source.
Contact your country's Department of Public
Works or recycling agency in your area and arrange for proper disposal of any electrical components, waste or oil associated with this equipment.
When the life cycle of this equipment is over it is recommended that the pump casing and all other metal parts be sent to a recycling center
Metal recycling involves the collection of metal from discarded products and its transformation into raw materials to use in manufacturing a new product.
Recyclers and manufacturers alike promote the process of recycling metal. Using a metal recycling center promotes energy cost savings.
ST4125G/ST6125G SUBMERSIBLE PUMP• OPERATION MANUAL — REV. #0 (11/18/10) — PAGE 7
ST4125G/ST6125G SUBMERSIBLE PUMP — SPECIFICATIONS
Model
Type
Impeller
Discharge Size
Max Solids
Maximum Pumping Capacity
Max Head
Power
Voltage/Phase
Starting Amps
Running Amps
Max Starts/Hr.
Enclosure Type
Insulation Class
Max Temperature
Control Box Required
Power Cable Length
Dry Weight
Max Height
Max Diameter
Table 1. Specifi cations
ST4125G
Centrifugal Submersible Pump
Cast Ductile Iron
4.00 in. (101 mm)
.078 in (2 mm)
380 gallons/minute
(1,438 liters/minute)
111 ft. (33.8 meters)
10 HP (7.5 kw)
230/460 3Ø
180 (230V)
90 (460V)
24 (230V)
12 (460V)
30
68
F
104° F (40° C)
See Note 3
50 ft. (15.2 m)
344 lb (156 kg)
33.5 in (85.09 cm)
14.0 in (35.56 cm)
ST6125G
Centrifugal Submersible Pump
Cast Ductile Iron
6.00 in. (152 mm)
.078 in (2 mm)
TBD
TBD
15 HP (11 kw)
230/460 3Ø
TBD
TBD
30
68
F
104° F (40° C)
See Note 3
50 ft. (15.2 m)
TBD)
TBD
TBD
1. Motor Rotation – Let pump hang freely from a lifting device. Start and stop pump while observing movement
(kick) of pump. If connected correctly the impeller will rotate clockwise (CW) as viewed from above. If pump rotates counterclockwise interchange any two phases from the power source.
2. Mechanical Seal Oil – Use ISO VG32 lubrication oil, Mobile DTE 24 turbine oil 90 or equivalent. Fill oil chamber 75% to 85% full (allow air space for expansion).
3. Control Box - For unattended operation, CB12 or CB14 Control Box (Table 3) is required. Control boxes will provide thermal overload protection.
PAGE 8 — ST4125G/ST6125G SUBMERSIBLE PUMP • OPERATION MANUAL — REV. #0 (11/18/10)
ST4125G/ST6125G SUBMERSIBLE PUMP — DIMENSIONS
15.47 in.
(393 mm)
3.94 in.
(100 mm)
12.72 in.
(323 mm)
6.97 in.
(177 mm)
16.89 in.
(429 mm)
5.90 in.
(150 mm)
12.72 in.
(323 mm)
6.97 in.
(177 mm)
34.21 in.
(869 mm)
ST4125G
28.9 in.
(734 mm)
35.67 in.
(906 mm)
ST6125G
30.67 in.
(779 mm)
4.57 in.
(116 mm)
4.57 in.
(116 mm)
11.89 in.
(302 mm)
11.89 in.
(302 mm)
Figure 1. ST4125G/ST6125G Pump Dimensions
ST4125G/ST6125G SUBMERSIBLE PUMP• OPERATION MANUAL — REV. #0 (11/18/10) — PAGE 9
ST4125G/ST6125G — GENERAL INFORMATION
The Multiquip Model ST4125G and ST6125G submersible pumps are designed to pump water. These pumps work best when faced with high head applications where you need an appreciable fl ow.
Each pump has dual voltage capability, easily switched between 230 and 460 volts.
These pumps have a heavy-duty cast iron body that is very durable and able to withstand rough handling. The
ST4125G comes with a 4-inch NPT threads for standard hose connections while the ST6125G is equipped with
6-inch fl ange fi tting.
The mechanical seal of these pumps operates within an oil-fi lled chamber that provides positive lubrication. This helps prevent damage in the event the pump is run dry for short periods of time.
PAGE 10 — ST4125G/ST6125G SUBMERSIBLE PUMP • OPERATION MANUAL — REV. #0 (11/18/10)
5
6
ST4125G/ST6125G — COMPONENTS
4
4
5
6
3 3
2 2
1
7
8
1
7
8
Figure 2. Submersible Pump Components
Figure 2 shows the location of the basic components, for the ST4125G and ST6125G submersible pumps. Listed below is a brief explanation of each component.
1. Strainer Base – This strainer base is made of stainless steel which is resistant to hardware corrosion. For dewatering purposes, always place the strainer base on a platform.
2. Volute/Impeller – Impellers are constructed of cast ductile iron to minimize wear and prolong service life.
3. Electric Motor – The ST4125G pump utilizes a 60
Hz, three-phase, 230/460 VAC, 10 HP electric motor and the ST6125G pump utilizes a 60 Hz, three-phase,
230/460 VAC, 15 HP electric motor. Consult with a licensed electrician before connecting motor to a power source. Observe all city and local safety codes.
4. Discharge Port – Connect a 4-inch hose (ST4125G) or 6-inch hose (ST6125G) to this port. Remember to adequately support the discharge hose to avoid stress on the pump.
5. AC Power Cable – These pumps are supplied with a
50 ft. (15.2 meters) AC power cable. Always check the cable for signs of wear. NEVER use a defective power cable. Replace the cable immediately if the cable is worn or defective.
6. Eye Bolts – Always lift the submersible pump by the eye bolts using a chain and lifting device capable of lifting about 400 lbs. NEVER lift the pump by its power cord! Lifting the pump by the power cord will cause undue stress on the cord and ultimately the cord will become dislodged from the pump.
7. Mechanical Seal Oil – This oil-fi lled seal provides lubrication when running the pump dry. NEVER run the pump dry! Running the pump dry will cause severe damage to the pump.
8. Mechanical Seal Oil Plug – Remove this plug to check and add ISO VG32 lubrication oil, Mobile DTE
24, turbine oil 90 or equivalent to the oil chamber. This oil protects the mechanical seal. Oil chamber should be full enough to cover seal spring.
ST4125G/ST6125G SUBMERSIBLE PUMP• OPERATION MANUAL — REV. #0 (11/18/10) — PAGE 11
Mechanical Float Switch
Mechanically activated fl oat switches offer a reliable low current control for dewatering applications.
How It Works
The mechanical fl oat switch control will turn ON (close) when the fl oat tips 45° above -horizontal, indicating a high level, and turns OFF (opens) when the fl oat switch drops
45° below horizontal. Reference Figure 4 and Figure 5.
Maximum pumping range is 120 degrees. See Figure 3 below.
FLOAT SWITCHES
Design Features
Float switch housings are constructed of high-impact, corrosion resistant polypropylene with mechanically activated, snap action contacts.
Suitable for most liquid environments.
Hermetically sealed.
Thick-walled non-corrosive PVC plastic enclosure.
Pressure tested to 30 ft. (9 meters).
Standard SJO, 16-gauge, 2 conductor cord (20 ft./6.09 m).
CONTACTS
CLOSED
PUMP
ON
60
120
ON/OFF
RAMP
STEEL
BALL
PUMP
OFF
60
Figure 4. Float Switch (Closed)
SUBMERSIBLE
PUMP
CONTACTS
OPEN
Figure 3. Pumping Range (Float Switch)
Pumping Range
The pumping range of the pump is determined by the fl oat switch tether cord. Use Table 2 as guide line to determine your required pumping range. Pumping ranges are based on non-turbulent conditions. Range may vary due to water temperature and cord shape. Please note as the tether length increases, so does the variance of the pumping range.
Tether Length
Pumping Range
2 in.
5.08 cm.
6 in.
15.24 cm.
4 in.
10.16 cm.
10 in.
25.4 cm.
STEEL
BALL
Figure 5. Float Switch (Open)
Table 2. Pumping Range
6 in.
15.24 cm.
8 in.
20.32 cm.
10 in.
25.4 cm.
14 in.
35.56 cm.
18 in.
45.72 cm.
22 in.
55.88 cm.
12 in.
30.48 cm.
27 in.
68.58 cm.
ON/OFF
RAMP
14 in.
35.56 cm.
31 in.
78.74 cm.
16 in.
40.46 cm.
35 in.
88.9 cm.
PAGE 12 — ST4125G/ST6125G SUBMERSIBLE PUMP • OPERATION MANUAL — REV. #0 (11/18/10)
Float Switches
For unattended operation of the submersible pump two single fl oat switches (Model SW-1WOPA) will be required.
These fl oat switches can be connected directly to a control box (bare wires) and will allow the pump to turn on and off depending on the length of the tether.
FLOAT SWITCHES
Mounting The Float Switches
1. Determine the required cord tether length as shown in Figure 3 and Table 2.
2. Place the cord into the clamp as shown in Figure 6.
3. Secure the clamp to the discharge hose as shown in
Figure 6. DO NOT install cord under hose clamp.
4. Using a screwdriver, tighten the hose clamp. DO NOT over- tighten. Make sure the fl oat cord is not allowed to touch the excess hose clamp band during operation.
EXTERNAL 3-PHASE
(230 OR 460 VOLT)
POWER SOURCE
L1
CIRCUIT
BREAKER
L2
L3
RED
WHITE
BLACK
INPUT POWER
TO CONTROL BOX
CAUTION!
HIGH
VOLTAGE!
CONTROL
BOX
RESET
CB12/14
PUMP POWER
CABLE
GND.
FLOAT SWITCH
CABLES (2)
DISCHARGE
HOSE
3.5 in. (9 cm.)
MINIMUM
TETHER
LENGTH
PUMP
ON
MODEL SW-1WOPA
FLOAT SWITCH (2)
PUMPING
RANGE
PUMP
OFF
SUBMERSIBLE
PUMP
Figure 6. Float Switch Application
ST4125G/ST6125G SUBMERSIBLE PUMP• OPERATION MANUAL — REV. #0 (11/18/10) — PAGE 13
FLOAT SWITCHES
CB12/CB14 Control Boxes
For remote pumping applications, both submersible pumps, require a control box (Figure 7).
The CB12 control box requires 230VAC, 3-phase input voltage for normal operation, while the CB14 control box requires 460VAC, 3-phase input voltage. Reference Table 3 for the desired heater. The heater size is determined by the the full load amps the pump will draw.
These water-resistant control boxes provide electronic overload protection a watertight enclosure and glands to prevent water from leaking into the box, and a fl oat switch interface.
Each control box will require the use of two SW-1WOPA fl oat switches, no plug, bare wires for direct connection to the control box. Reference Figure 21 for a schematic reprensentation of the control box.
NOTICE
Contact Multiquip sales department to order control boxes as listed in Table 3.
CB12/14
CAUTION!
HIGH
VOLTAGE!
RESET
MAN
OFF
AUTO
Figure 7. Electrical Control Box
(Model CB12/14)
Control Box
Model No.
CB12
CB12
CB14
CB14
Used With
Pump Model
ST-4125G
ST-6125G
ST-4125G
ST-6125G
Table 3. Control Box Specifi cations
VoltageType
Heater
Size
Full Load
Amps
UL/CSA
Listed
Thermal
Overload
Protection
Float
Switch
Capability
230 VAC
Three-Phase
230 VAC
Three-Phase
460 VAC
Three-Phase
460 VAC
Three-Phase
K67
K73
K56
K62
27
39
14
19.7
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
PAGE 14 — ST4125G/ST6125G SUBMERSIBLE PUMP • OPERATION MANUAL — REV. #0 (11/18/10)
Control Box Installation
The following procedure outlines the steps for connecting the pump to a control box.
DANGER
The ST4125G and ST6125G submersible pumps are designed to work with a control box.This control box contains the necessary electronics (fl oat switch connections) to operate the pump. Remember this control box contains hazardous voltages. Disconnect all sources of power before installing or servicing. There exists the possibility of electrocution, electric shock or burn, which can cause severe bodily harm or even death!
DANGER electrocution and possibly death! NEVER have untrained personnel perform the installation. ALWAYS have qualified service personnel (licensed electrician) perform the installation.
When installing the control box, the possibility exists of electrical shock,
WARNING
Explosion or Fire Hazard exists if this pump is used with fl ammable liquids. DO NOT use this pump with fl ammable liquids. DO NOT install this pump in hazardous locations as defi ned by the National Electrical Code,
ANSI/NFPA 70.
CONTROL BOX INSTALLATION
CONTROL BOX MOUNTING
Mount the control box in an upright vertical position. Make sure the control box is securely fastened to a fl at surface, that is free of dust, dirt, moisture or any elements that may contaminate or erode the electronic components of the control box.
3-Phase Power Installation (Input)
The ST-4125G/ST6125G submersible pumps require 230 or 460V 3-phase power for normal operation. Each pump is shipped from the factory in the 230 VAC confi guration. To change the voltage setting from 230 VAC to 460 VAC refer to the 230/460 VAC voltage selection section (Figure 8).
If you cannot determine what your pump's power requirements are, look at the vendor supplied identifi cation name tag attached to the pump or please contact Multiquip's
Service/Technical Assistance department.
CAUTION
Applying incorrect power (voltage phasing) to the submersible pump can cause severe damage to the pump. Please make sure that the correct voltage and phase are applied to the pump at all times.
Power Cord Requirements
When routing the 230/460 VAC, 60 Hz., 3-phase power via a power cord to the control box, ALWAYS use the correct wire size. Please refer to Table 4 to determine the correct wire size. Incorrect wire size can adversely affect the performance of the pump and may ultimately burn out the pump motor.
AMPS
15
20
25
30
40
10 FT.
(3.0 m)
Table 4. Power Cord Length and Wire Size
20 FT.
(6.0 m)
30 FT.
(9.1 m)
12 AWG
10 AWG
10 AWG
10 AWG
8 AWG
10 AWG
8 AWG
6 AWG
6 AWG
6 AWG
8 AWG
6 AWG
6 AWG
4 AWG
4 AWG
50 FT.
(15.2 m)
6 AWG
4 AWG
4 AWG
2 AWG
2 AWG
ST4125G/ST6125G SUBMERSIBLE PUMP• OPERATION MANUAL — REV. #0 (11/18/10) — PAGE 15
Connecting SW-1WOPA Float Switches to Control
Box
1. Remove the fl oat switch input connector housing, then route the fl oat switch wires through the cable gland on the control box. Attach the wires of the fl oat switch to the terminal block as indicated by Table 5 and Figure 9.
Table 5. Dual Float switch Connections
Float
Switch
Terminal
Block No.
Wire
Color
Start
Stop
TB1-A1
TB1-A2
TB1-A3
TB1-A4
Black
White
Black
White
2. Tighten the connector housing to ensure a tight fi t between the cord and the connector body. This will prevent the cable from pulling out of the terminal block and also prevent moisture from entering the control box.
3. Determine the tether length of the fl oat switch wires then secure fl oat switch wires to pump discharge hose.
See Figure 3 and Table 2 to determine the pumping range.
CONTROL BOX INSTALLATION
PAGE 16 — ST4125G/ST6125G SUBMERSIBLE PUMP • OPERATION MANUAL — REV. #0 (11/18/10)
230/460 VAC VOLTAGE SELECTION
230/460 VAC Voltage Selection
The ST4125G/ST6125G submersible pumps are factory set at 230 VAC. To change the voltage from 230 VAC to 460
VAC, reference Figure 8:
230 VAC
REMOVE
SLEEVING
BLACK
T9
T9
T8
T3
T2
T1
T8
T7
T7
RED
WHITE
BLACK
GROUND
GREEN
BLACK
T4
T5
T6
T5
T6
T1
T2
T3
T4
460 VAC
T1
T2
BLACK
T9
T3
T8
T7
T3
T2
T5
T4
T6
T1
T4
T5
T6
T8
T7
RED
WHITE
BLACK
T9
GROUND
GREEN
BLACK
MOTOR WINDING CONFIGURATION
W
230 VAC
(LOW VOLTAGE)
U 9 7
460 VAC
(HIGH VOLTAGE)
U
X
7
Z
Y
X
V
MOTOR
WINDING
STAR WITH
NEUTRAL
8
W
Z
9
MOTOR
WINDING
STAR WITH
NEUTRAL
8
Y
Figure 8. 230/460 VAC Electric Motor Windings
V
ST4125G/ST6125G SUBMERSIBLE PUMP• OPERATION MANUAL — REV. #0 (11/18/10) — PAGE 17
CB12/CB14 CONTROL BOX POWER CONNECTIONS
3-Phase Power Installation (Input to Control Box)
1. The 3-phase input power cord should have four wires.
Each wire is color coded. The colors are RED, WHITE,
BLACK and GREEN.
2. Remove the 3-phase AC input connector housing from the control box, then route the three phase input power cable through the cable gland on the control box. Attach the wires to the AC terminal block inside the control box as indicated by Table 7 and Figure 9.
Table 6. 3Ø-230/460 VAC
Input Power Connections
Wire Color
RED
Input Power
Terminal Block
L1
WHITE
BLACK
GREEN
L2
L3
GROUND
3-Phase Power Installation (Output To Pump)
1. The 3-phase output power cord should have four wires.
Each wire is color coded. The colors are RED, WHITE,
BLACK and GREEN.
2. Remove the 3-phase AC output power connector housing on the control box, then route the output power cable through the cable gland on the control box.
Attach the wires to the AC terminals on the overload relay module as indicated by Table 7 and Figure 9.
Table 7. 3Ø-230/460 VAC
Output Power Connections
Wire Color
RED
Output Power
Overload Relay
T1
WHITE
BLACK
GREEN
T2
T3
GROUND
3. Tighten the connector housing to ensure a tight fi t between the power cord and the connector body. This will prevent the cable from pulling out of the terminal block and also prevent moisture from entering the control box.
4. Connect the other end of the 3-phase input power cord to the voltage source. Remember to provide a means of disconnecting the power from the control box (circuit breaker or quick disconnect switch). Also make sure to provide a good earth ground to the control box.
NOTICE
It is recommended that the power being supplied to the control box ALWAYS be connected to a circuit breaker or a quick disconnect switch. This safety feature allows for quick removal of power from the control box in the event of an emergency.
PAGE 18 — ST4125G/ST6125G SUBMERSIBLE PUMP • OPERATION MANUAL — REV. #0 (11/18/10)
MOUNT CONTROL
BOX IN AN UP-LEFT
VERTICAL POSITION
AS SHOWN.
CB12/CB14 CONTROL BOX WIRING LAYOUT
CONTROLLER
AC POWER
TERMINAL BLOCK
FLOAT SWITCH
TERMINAL BLOCK
EXTERNAL 3-PHASE
(230 OR 460 VOLT)
POWER SOURCE
L1
CIRCUIT
BREAKER
RED
WHITE
BLACK
L2
L3
1-
1 L1
3 L2
23-
5 L3
4-
-3
1-
-4
23-
4 T2
AEG
6 T3
4-
T
8/10
M
SE FU
DUEL-ELE
FUSE
RED
L1 L2
WHT
L3
4 3 2 1
BLK
GRN
BLACK
L
1
R
E
S
E
T
T
1
L
2 2
L
3
T
2
M
A
I
N
T
R
I
P
T
3
RED WHT BLK
GRN
GROUND
FLOAT
SWITCH
INPUTS
3 PHASE
AC INPUT
POWER CABLE 1.SECURE FLOAT SWITCH
WIRES TO PUMP
DISCHARGE HOSE
2. START FLOAT
SWITCH. CONNECT
TO TERMINALS 1 AND 2
TRANSFORMER
OFF/ON
LAMP
1
3
6
MANUAL/AUTO
SWITCH
OVERLOAD
RELAY
HEATER
SEE TABLE 2
3 PHASE
AC OUTPUT
POWER CABLE
WARNING
CONTROL BOX INSTALLATION IS TO BE
PERFORMED BY A LICENSED ELECTRICIAN
OR QUALIFIED PERSONNEL.
THE POSSIBILITY OF ELECTRICAL SHOCK
OR ELECTROCUTION EXISTS, WHICH COULD
CAUSE SEVERE BODILY HARM EVEN DEATH!.
3. STOP FLOAT
SWITCH. CONNECT
TO TERMINALS 3 AND 4
PUMPING
RANGE
Figure 9. Three Phase
Control Box/Pump System Diagram
ST4125G/ST6125G SUBMERSIBLE PUMP• OPERATION MANUAL — REV. #0 (11/18/10) — PAGE 19
Pump Placement
1. Attach a suitable lifting chain to the eye bolts (Figure 10) on the pump. Use a crane, or similar lifting device and lower the pump into place. For applications where there is an excessive amount of mud, grit or silt, the use of a support platform is desirable.
OPERATION
2. Make sure the pump is always placed in an upright position, not tilted (Figure 11). Never position the pump directly on a soft, loose bottom. To attain maximum pumping capacity and prevent excessive wear, position the pump so it will not burrow itself into sand or clay.
4 or 6-INCH
DISCHARGE
HOSE
LIFTING
CHAIN
CONNECT
TO CONTROL
BOX
POWER
CORD
SUPPORT
PLATFORM
Figure 10. Placing the Submersible Pump
(Correct Upright Position)
Figure 11. Tilted Position (Incorrect)
Control Box Operation (Manual Mode)
PAGE 20 — ST4125G/ST6125G SUBMERSIBLE PUMP • OPERATION MANUAL — REV. #0 (11/18/10)
1. From the voltage source, set the circuit breaker or quick disconnect switch to the ON position.
2. For manual operation of the pump, place the 3-position operation switch (Figure 12) on the control box in the
MANUAL position.
OPERATION
1. When the electronic overload module detects an overload condition, the pump will shut down. Check the pump and correct the cause of ther overload.
2. Let the pump cool down, then press the RESET button
(see Figure 15) on the front of the control box to restore power.
Figure 12. Manual-Off-Auto SW.
(Manual Position)
3. Verify that the ON indicator (Figure 13) on the control box is LIT. This means that power is being supplied to the control box.
Figure 15. RESET Button
Shut-Down
1. Place the 3-position operation switch on the control box to the OFF position (Figure 16).
Figure 13. Control Box Power ON Indicator
4. In the manual mode the pump will run continuously. Pay close attention when running the pump in this mode.
DAMAGE to the pump may occur if pump is not fully immersed in water.
Control Box Operation (Auto Mode)
1. To operate the pump automatically (fl oat switches), place the 3-position operation switch in the AUTO position (Figure 14).
Figure 14. Manual-Off-Auto SW.
(Auto Position) is a suffi cient amount of water. This amount of water is determined by the setting of the fl oat switches. The
stop fl oat switch contacts will open when the water level is low and power will be removed from the pump's electric motor.
Once the water level has risen back to the appropriate level the start fl oat switch contacts will close and power will be restored to the pump's motor.
Reset Button
Figure 16. Manual-Off-Auto SW.
(OFF Position)
2. Verify that the control box power ON light is OFF.
3. Turn the circuit breaker or quick disconnect switch to the OFF position.
4. Using a suitable lifting device, lift the pump up from its current position and place on a secure fl at surface.
5. Remove the discharge hose from the discharge port on the pump.
6. Remove all power cables and fl oat switches from the control box. Place cables and fl oat switches in a suitable container where they will not get damaged.
7. If the pump was used to pump mud, grit or silt, fl ush vigorously with clean water.
8. Wipe off any mud or debris that might have attached itself to the pump.
9. Store pump in a clean dry place away from dirt and debris.
ST4125G/ST6125G SUBMERSIBLE PUMP• OPERATION MANUAL — REV. #0 (11/18/10) — PAGE 21
Lubrication
To check the lubrication oil level of the mechanical seal perform the following:
Checking Lubrication Oil Level
1. Lay the pump (Figure 17) on its side with the oil plug facing upwards.
2. Remove oil fi ll plug.
3. Visually inspect oil plug hole to verify that oil chamber is full enough to cover seal spring.
4. When reinstalling oil fi ll plug, apply tefl on tape to prevent leaking.
WARNING
When removing oil fi ll plug, please note that pressure may have built up in the oil chamber. DO NOT fully remove plug until pressure has been relieved. Turn oil fi ll plug slowly to relieve pressure.
MAINTENANCE
Inspecting Lubrication Oil (Mechanical Seal)
1. Block the oil fi ll opening with a fi nger and roll pump to one side to drain (Figure 18) oil into a small transparent container.
2. If oil is cloudy (milky) or has water in it, indicates that mechanical seal is defective or worn. Replace
mechanical seal.
Changing Lubrication Oil
1. If lubrication oil level is low, block the oil fi ll opening with a fi nger and roll pump to one side to drain oil into a small container.
2. Use a funnel (Figure 17) and fi ll oil chamber with ISO
VG32 lubrication oil or equivalent. Oil chamber capacity is 74.4 oz. (2.2 liters). Fill to 75-80% capacity to allow for expansion. Replace lubrication oil once a year or 3,000 hours.
Figure 18. Lubrication Oil Inspection
NOTICE
When replacing the oil in the oil chamber, shaft seal
MUST be changed at the same time.
LAY PUMP FLAT
ON ITS SIDE
REMOVE FILL PLUG, AND
VISUALLY INSPECT THAT
OIL CHAMBER IS FULL ENOUGH
TO COVER SEAL SPRING.
FILL TO 75-80% CAPACITY
(APPROXIMATELY 74.4 OZ. (2.2 LITERS)
FILL WITH ISO VG32 LUBRICATION
OIL OR EQUIVALENT.
CHECK HYDRAULIC OIL ONCE
A YEAR OR EVERY 3000 HOURS.
Figure 17. Adding Lubrication Oil
PAGE 22 — ST4125G/ST6125G SUBMERSIBLE PUMP • OPERATION MANUAL — REV. #0 (11/18/10)
Impeller Removal
Refer to the the following procedure and Figure 19 for the removal of the impeller.
1. Remove oil plug (item 193) and o-ring (item 194). Drain oil from oil chamber as referenced in Figure 18.
2. Remove suction strainer/ring stand (item 84A).
3. Remove the six suction cover bolts and washers (items
188A/188B) that secure the suction cover (item 189) to the pump housing (item 50). Remove suction cover
(item 189).
4. Remove impeller cap nut (item 188) and washer (item
66) from motor shaft.
5. Remove impeller (item 49), gap washer (item 49A) and impeller key (item 9A) from motor shaft.
6. Reassemble in reverse order.
MAINTENANCE
NOTICE
Clearance between impeller and wear plate should be between .011~.019 in. (0.3~0.5 mm). If impeller is defective or badly worn, replace immediately.
Long Term Storage
1. Area must be free from excessive humidity, corrosive gases, vapors or vibrations which might damage the pump.
2. Store pump in a vertical position on a pallet or stand.
3. Coil up the cable, and seal the open end (control box wires) with waterproof tape or a cable cap. This will prevent moisture from penetrating into the motor which could cause severe damage to the windings.
4. Give all unpainted surfaces a light coat of oil or grease to prevent corrosion.
5. If new pumps are stored for more than two months, turn the impeller by hand every two months to prevent the mechanical seal faces from seizing up. Failure to do this may result in seal damage when the pump is started.
Water Tank Storage
1. If an installed pump (immersed in water) has not been in operation for a long period of time, check the insulation resistance and run the pump for 30 minutes every month.
If the pump cannot be run due to lack of water in the tank inspect the pump and turn the impeller by hand each month and prior to putting the pump back into service. If insulation drops below 10 megohms, contact an authorized Multiquip service center.
Figure 19. Impeller Removal
ST4125G/ST6125G SUBMERSIBLE PUMP• OPERATION MANUAL — REV. #0 (11/18/10) — PAGE 23
Electrical Insulation Testing
Why perform electrical insulation testing?
Electrical insulation starts to age as soon as it is made.
Harsh environments, especially those with extreme temperature changes and/or chemical contamination, cause further deterioration of the insulation (power cord).
As a result, personnel safety (electrocution/shock) and power reliability can suffer resulting in higher operating cost and maintenance.
What is Insulation Resistance Testing
Insulation resistance testing applies a regulated stabilized high voltage (Figure 20), typically 500 VDC or greater across a dielectric (power cord). Measuring the amount of
leakage current fl owing through the dielectric will yield a resistive measurement in megohms.
Insulating Material Testing
To verify the integrity of the pump's insulating material
(power cable) it will be necessary to perform an electrical insulation test. Any electrical insulation must have the opposite characteristic as the conductor: it should resist the fl ow of current, keeping it within the conductor.
To measure the IR (current x resistance), the use of an IR tester must be employed. This IR tester is a portable device that is a resistance meter (ohmmeter) with a built in DC generator that develops a high DC voltage.
The high DC voltage from the IR tester is usually 500 VDC or more. This voltage, when applied causes a small current to fl ow through and over the insulation's surfaces. The tester provides a direct reading of IR in megohms.
A high resistance reading would indicate a "good" insulation, meaning very little current is escaping through the insulation. While a relatively low resistance reading would indicate a poor insulation, meaning a signifi cant amount of current may be leaking through and along the insulation.
MAINTENANCE
NOTICE
Insulation resistance is moisture and temperature sensitive. When temperature increases, insulation resistance decreases, and vice versa.
When performing this test measurement, perform the test using the same test parameters as used in the initial testing. Contact an authorized Multiquip service center if the measured cable insulation is 10 megohms
or less.
20M W
POWER CABLE
INSULATION
MW
V
OFF
W
W
KW
SET
UP
MEGGER™
500 VDC INSULATION
TEST METER
GROUND WIRE
(GREEN)
SUBMERSIBLE
PUMP
Figure 20. Insulation Tester Application
DANGER
Read and follow the manufacturer's user's manual prior to operating insulation tester
(megaohm meter). This meter generates a test voltage of 500 volts or greater. Only qualifi ed and trained personnel should use this equipment. The possibility exists of severe
electrical shock, electrocution even death, when using insulation tester.
PAGE 24 — ST4125G/ST6125G SUBMERSIBLE PUMP • OPERATION MANUAL — REV. #0 (11/18/10)
TROUBLESHOOTING
Water in Mechanical
Seal Oil
SYMPTOM
Pump Fails To Start
Pump Fails to Deliver Full
Output
Table 8. Pump Troubleshooting
POSSIBLE PROBLEM
Incorrect voltage/amps?
SOLUTION
Check that the proper voltage, 230 or 460 VAC, 60
Hz, 3-phase is being supplied to the pump. Also check that there is an adequate amount of current
(amps) to run the pump. Check power source circuit breaker.
If using fl oat switches check wiring, inspect power cord.
Check electrical connections?
Blown power fuse or tripped circuit breaker?
Impeller locked?
Replace fuse check circuit breaker, check cause of blown fuse or tripped breaker.
Disconnect power cord and check for clogging. Unclog pump. Check overload protection device.
Wet motor windings?
Use multimeter to check motor insulation. Insulation resistance must be approximately 15 megaohms. If resistance is low, disassemble pump motor and bake windings to dry them.
Check for excessive bearing wear, if worn replace bearings. Replace motor if defective.
Defective motor and pump bearings?
Twisted or restricted discharge hose?
Clogged pump strainer?
Lay hose fl at un-kinked. Remove clog from hose line.
Low voltage?
Clean strainer.
Use a voltmeter to check voltage while pump is energized. Voltage must be within ±10%. Check power source (no load and load). If an extension cord is used, make sure it has adequate current-carrying capacity for the required length.See Table 4.
Impeller worn?
Replace impeller.
Defective mechanical seal?
Replace mechanical seal.
Loose Oil Fill Plug?
Tighten securely. Apply tefl on tape.
ST4125G/ST6125G SUBMERSIBLE PUMP• OPERATION MANUAL — REV. #0 (11/18/10) — PAGE 25
CB12/CB14 CONTROL BOX WIRING DIAGRAM
EXTERNAL 3-PHASE
(230 OR 460 VOLT)
POWER SOURCE
L1
CIRCUIT
BREAKER
L2
L3
RED
WHITE
BLACK
CB-12/CB-14
POWER
INPUT
L1 L1
L2 L2
L3 L3
H1
GROUND
F1
XF
FUSE
1/2 AMP
X1
THREE PHASE WIRING
CONNECTIONS
M O/L
RED AWG 8
RED AWG 8
RED AWG 8
H3 H2
GRN
H4
CONTROL
TRANSFORMER
50VA CPT
WHT
X2
RED
WHT
BLK
T1
T2
T3
PUMP
MOTOR
SEE TABLE 2
FOR CORRECT
HEATER SELECTION
GRN
2
MAN
BLK 1
4
OFF
AUTO
4
RED
AWG 10
3
NO
4
RED
AWG 10
3 2 1
OVERLOAD
RELAY
RED
AWG 10
O/L
NC
ON
LAMP
X2
INDICATOR
G
WHT
AWG 10
CONTACTOR
5 HP
M
A2 A1
TERMINAL
BLOCK
WHT AWG 10
SELECTABLE 230 OR 460 VAC
VOLTAGE INPUTS
FUSE
X1
X1
120
115
110
XF
H4 H2 H3 H1
X2
TRANSFORMER
JUMPER
TAB
L1
STOP
FLOAT
SWITCH
230V INPUT
START
FLOAT
SWITCH
L2
H1 H3 H2 H4
CB-12
L1
460V INPUT
L2
H1 H3 H2 H4
CB-14
Figure 21. CB12/CB14 Control Box Wiring Diagram
PAGE 26 — ST4125G/ST6125G SUBMERSIBLE PUMP • OPERATION MANUAL — REV. #0 (11/18/10)
NOTES
ST4125G/ST6125G SUBMERSIBLE PUMP• OPERATION MANUAL — REV. #0 (11/18/10) — PAGE 27
OPERATION AND PARTS MANUAL
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
UNITED STATES
Multiquip Corporate Offi ce
18910 Wilmington Ave.
Carson, CA 90746
Contact: [email protected]
Service Department
800-421-1244
310-537-3700
Technical Assistance
800-478-1244
Tel. (800) 421-1244
Fax (800) 537-3927
Fax: 310-537-4259
Fax: 310-943-2238
MEXICO
MQ Cipsa
Carr. Fed. Mexico-Puebla KM 126.5
Momoxpan, Cholula, Puebla 72760 Mexico
Contact: [email protected]
Tel: (52) 222-225-9900
Fax: (52) 222-285-0420
MQ Parts Department
800-427-1244
310-537-3700
Warranty Department
800-421-1244
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Fax: 310-537-1173
UNITED KINGDOM
Multiquip (UK) Limited Head Offi ce
Unit 2, Northpoint Industrial Estate,
Globe Lane,
Dukinfi eld, Cheshire SK16 4UJ
Contact: [email protected]
Tel: 0161 339 2223
Fax: 0161 339 3226
CANADA
Multiquip
4110 Industriel Boul.
Laval, Quebec, Canada H7L 6V3
Contact: [email protected]
Tel: (450) 625-2244
Tel: (877) 963-4411
Fax: (450) 625-8664
© COPYRIGHT 2010, MULTIQUIP INC.
Multiquip Inc and the MQ logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property of their respective owners and used with permission.
This manual MUST accompany the equipment at all times. This manual is considered a permanent part of the equipment and should remain with the unit if resold.
The information and specifi cations included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in this manual are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifi cations, design or the information published in this publication at any time without notice and without incurring any obligations.
Your Local Dealer is:
advertisement
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project