Thank you for having selected a Tsurumi submersible pump. For full benefit of this equipment, you should read, before use, the following points which are necessary for safety and reliability anyway. The table of contents guides you to the respective warnings and instructions.
Applications.........................................................
2
Product Description.............................................
2
Handling and Storage.........................................
2
Installation...........................................................
2
Electrical Connections.........................................
3
Operation.............................................................
3
Contents
Service and Maintenance...................................
4
Trouble Shooting.................................................
5
Technical Data.......................................see appendix
Applications
These instructions apply to the submersible pumps specified on the cover. They are intended for use with periodic maintenance, under conditions approved by a competent installation technician, in water of up to 40°C, with solids or nonflammable liquids compatible with cast iron, nitrile rubber and the other materials, without the mixture exceeding a viscosity of 10 cp (m pa•s) . During use, discharge conduit and cabling should be touched only if need be, and the water absolutely not. The area should be accessible to competent maintenance technicians only, to the absolute exclusion of children and the general public. The pumps conform to the relevant directives of the EU.
CAUTION!
The pump must not be permanently installed in swimming pools or fountains if the installation area can be flooded.
DANGER!
The pump must not be used in an explosive or flammable environment or for pumping flammable liquids.
CAUTION!
The pump must not be run if it has been partially dismantled
=Speed of rotation
=Oil volume
=Immersion depth
(maximum)
Product Description
See table for technical data; see definitions of the icons used, below. Individual performance graphs, dimension diagrams and any other data wanted for proper selection and installation will be gladly provided upon request by the local Tsurumi agent.
The significance of the text in the table (appendix) is as follows:
=Electric cable
=Mechanical seal
=Dry weight
(without cable)
I
ø
=Dimensions
=Rated current
I
max
=Starting current
P
2
=Rated power
P
1
=Power input
Q
max
=max. flow rate
H
max
=max. head
=connection to terminal board
(diagramm in appendix)
The pumps should not be used in an atmosphere that could become explosive nor in water that might contain traces of flammable liquid.
Handling and Storage
The pump can be transported and stored either vertically or horizontally. Make sure that it is securely lashed and cannot roll.
CAUTION!
Always lift the pump by the lifting handle - never by the motor cable or hose.
The time between delivery and the first hour of pumping is extremely hazardous. Care need be taken not to crush, kink or pull the fragile cable and not to break the hard but brittle cast iron or endanger a bystander. No water should enter the open end of the cable during handling.
CAUTION!
The pump must always rest on a firm surface so that it will not overturn. This applies to all handling, transport, testing and installation.
Store in a dry place to avoid corrosion by damp air inside the pump. The pump should first be rinsed if a corrosive mixture has been pumped. Rinsing with water mixed with cutting oil can be of some help if no dry storage is available.
Installation
CAUTION!
The lifting tackle must always be designed to suit the pump weight. See under the heading “Product description”.
Safety measures
In order to reduce the risk of accidents during service and installation work, take extreme care and bear in mind the risk of electrical accidents.
Only a competent electrician should be allowed to work on the electrical circuit, since only he knows the dangers involved and the regulations.
Do not connect the power supply if any part of the pump or its installation has not been completed and inspected, or if anyone is touching the water.
Installation:
If the pressure at the pump outlet is very low, say less than 1 bar, 1kg/cm² or 10 m H
2
O (water column), layflat hose is used nearly exclusively. Folds in the hose can reduce or stop the flow from the pump. Using spiral reinforced hose at least for the first 5m or so and to go over a possible wall or edge, is an improvement, even for higher pressures. Better to use layflat hose only in straight lengths.
If the pressure at the pump outlet is high and/or hose diameter large, loosening or rupture of a hose can result in violent movement or flooding. With large hoses
(8” to 12”), the weight of water, stiffening when (even under slight) pressure and axial force of the water combine to make for unreliability unless expert attention is given to selection and erection. Rigid lightweight quick-couple piping and bends, available on the market up to 12 “, lessen the risk.
2
Lifting:
Every pump needs a stout lifting rope. Its end must remain accessible under all circumstances.
Cable:
The cable and its possible watertight connection and extension cable must reach to a level beyond reach of flooding. An electrician can extend a cable and make the splice waterproof, if he is experienced and has the proper 3M or equivalent kit. Replacement of the cable, in a workshop only, is always preferable.
Voltage loss due to underrated cabling between power source and pump, is by far the most common cause of motor overload.
Only a competent electrician should be allowed to work on the electrical circuit, since only he knows the dangers involved and the regulations to be followed.
Before switching on:
Do not connect the power supply if any part of the pump or its installation has not been completed and inspected, or if anyone is touching the water.
Two additional hazards for the cable are snagging whilst the pump is being lowered, and crushing by vehicle tires or tracks. Transport is also a potential source of change.
Electrical Connections
The pump must be connected to terminals or starting equipment installed at a level at which it cannot be flooded.
All electrical work must be carried out by an authorized electrician.
Only open a motor at a workshop. All measurements must be made at the free end of the cable.
NOTE!
If a plug and socket are used, the grounding lead should be longer than the phases to ensure that the other leads will, in case of a strong pull, be torn first.
CAUTION!
All electrical equipment must always be earthed (grounded).
this applies both to the pump and to any monitoring equipment.
CAUTION!
Before connecting the cabtyre cable to the terminal board, make sure that the power supply (i.e. circuit breaker) is properly disconnected. Failure to do so may lead to electrical shock, short, or injury caused by the unintended starting of the pump.
Improper wiring can lead to current leakage, electrical shock or fire.
Be sure to use a ground leakage breaker and an overcurrent protector (or breaker) to prevent damage to the pump that may lead to electrical shock.
Imperfect grounding can cause the pump to be put out of operation by electro-galvanic corrosion very quickly.
CAUTION!
If a cable is damaged, it must always be replaced.
CAUTION!
The electrical installations must conform to national and local regulations.
For connecting the cables correctly to the terminal board please keep to the diagramme indicated in the table in the appendix
Check that the nameplate of the pump to verify that its voltage and frequency are correct.
Power supply variation must be within ±1Hz (frequency) and ±5% (voltage) of rated values. Check that the thermal overload relays has been set to the pump’s rated ampere draw.
Connection of starter and motor conductors
If electrical connection of the pump is found to be difficult, contact your
Tsurumi dealer. To enable the correct connections, the number of conductors, any monitoring equipment and the method of starting must be known.
Cabtyre cable
If one or more extension cables are used, they may need to be of larger section than the pump cable, according to length and possible other loads. A cable of insufficient section results in loss of voltage and hence overheating of motor and cable, which may lead to repeated motor stoppage, unreliability, shortcircuit, fire, current leakage and electric shock. So does a damaged or unsecurely wired cable, the more so if it is submerged. No attempt should be made to replace or splice the pump cable, or open the motor, outside of a suitably manned workshop.
Always protect the cable against pulling, crushing, grazing and kinking, as the copper conductors are fragile and must remain insulated to avoid lack of voltage, shortcircuiting or electric shock. Apply no load to a cable that is lying in a roll, as a peak voltage can result, high enough to burn through the insulation.
Operation
CAUTION!
Reversal of the direction of rotation on a plug that has no phase transposing device may be done only by an authorized person.
Before Starting:
Check that all persons concerned agree that all verifications have been completed. Check that all bolts are tight and the pump´s weight is supported, the discharge conduit has been connected up, nobody is touching the water nor is unnecessarily near the conduit or switchgear. Be prepared to stop at once.
CAUTION!
checking the direction of rotation.
Make sure that the pump is firmly supported and cannot rotate.
The starting jerk may be violent.
Don´t hold the pump handle when
The pump will jerk anti-clockwise when viewed from above, indicating that it is running clockwise. If not, two of the three phases U, V, W should be transposed with care by an electrician at the point of connection of pump cable to starter.
In the case of star delta please ask your Tsurumi dealer.
CAUTION!
If the built-in motor protection has tripped, the pump will stop but will restart automatically when it has cooled down.
NEVER open the motor to make measurements, this can be done at the free end of the cable.
WARNING!
Never insert your hand or any other object into the inlet opening on the underside of the pump casing when the pump is connected to the power supply.
Before inspecting the pump casing, check that the pump has been isolated from the power supply and cannot be energized.
3
Service and Maintenance
CAUTION!
Before any work is started, check that the pump is isolated from the power supply and cannot be energized.
Note:
In the appendix is the sectional drawimg of a model of the KTZ-series that is representative for the majority of our pumps.
Due to the large number of different models we have to ask you to contact your
Tsurumi dealer if you need a parts list or a drawing of a certain model.
If the pump will not be operated for a long period of time, pull the pump up, allow it to dry, and store it indoors.
If the pump remains immersed in water, operate the pump on a regular basis (i.e.
once a week) to prevent the impeller from seizing due to rust.
Remove any debris attached to the pump´s outer surface, and wash the pump with tap water. Pay particular attention to the impeller area, and completely remove any debris from the impeller.
Verify that the paint is not peeled, that there is no damage, and that the bolts and nuts have not loosened. If the paint has peeled, allow the pump to dry and apply touch-up paint.
WARNING!
Never insert your hand or any other object into the inlet opening on the underside of the pump casing when the pump is connected to the power supply.
Before inspecting the pump casing, check that the pump has been isolated from the power supply and cannot be energized.
Make sure that the pump is completely reassembled before putting into operation again. Take care that bystanders keep a safe distance to the conduit or switch gear and avoid contact with the water.
In one application, a pump can be under constant risk, and even with frequent attention may have a short life. In another application a pump can run for years without any maintenance at all. Recommendations as to intervals, need interpretation, with the most hazardous characteristic in mind. At least superficial periodic inspection is needed in order to maintain a certain level of reliability and safety.
Interval
Monthly
Once every 2 to 5 years
Periodical inspection and replacement of lubricant
Inspection Item
1. Measuring insulation resistance
2. Measuring the loaded current
3. Measuring the power supply voltage
4. Inspecting the impeller
Overhaul
Insulation resistance reference value = 20M Ohm
NOTE:
The motor must be inspected if the insulation resistance is considerably lower than that obtained during the last inspection
To be within the rated current
Power supply voltage tolerance=±5% of rated voltage
If the performance level has decreased considerably, the impeller may be worn.
The pump must be overhauled even if the pump appears normal during operation. The pump may need to be overhauled earlier if it is used continuously or repeatedly.
NOTE:
Contact your Tsurumi-dealer to overhaul the pump.
KTV2-50, KRS2-50/80/100:
Inspection: Every 2000 hours of running time or every 6 months, whichever comes first
Changing interval: Every 4000 hours of running time or every 12 months , whichever comes first.
Other models:
Inspection: Every 3000 hours of running time or every 6 months, whichever comes first.
Changing Interval: Every 4000 hours of running time or every 12 months, whichever comes first
Choking:
Access of the water to the pump and apparent discharge capacity obviously need to be checked as often as experience dictates. Suspending the pump at the ideal level, if need be from a raft, is the main thing. Basically, the strainer should be free and if the pump is meant to remove water it should not carry more sand and pebbles than necessary.
The inlet should be protected from solids, if occurring in sufficient quantity to block the holes of the strainer, preventing flow. A cage, pierced drum or mesh can help.
Flow can in rare cases also be stopped by quantities of small stringy vegetal matter wrapping itself around the impeller blades.
Sand wears out the suction cover (wear plate) and shaft seal of any pump. This wear is roughly proportional to the square of the pressure, so it can be worth while using an extra large diameter delivery hose or pipe; very rarely will this lead to settling of sand or pebbles unless high concentration, an obstructed strainer, worn impeller, increased head or a constricted delivery conduit have resulted in diminished flow. If the pump is to remove water, often it can be placed on a raised object or suspended from masonry, piles or an improvised raft. If a pump buries itself in earth, or is buried by a landslide, it can be ruined in minutes.
Generating Set:
Hz to be within ±1 Hz, and voltage within ±5%, may also need to be checked frequently, if power is provided by a generating set. The lighter the generating set, the higher the risk of erratic voltage and wrong frequency.
Insulation Check:
Less obvious than oil inspection but equally valuable, is a periodic check of insulation value between the pump cable´s earth lead and the other leads, and between the other leads, by means of an insulation tester. This value, well over 20 M Ohm when the pump is new or reconditioned, should be at least 1 M Ohm when the pump and its cable have been in the water for a long time. If it is down to 1M Ohm, repair in a workshop is urgently needed. It is useful to keep a record of measurements of this insulation value, and of ampere draw if possible, over the years, so as to notice a steep decline of the ohm value before a short occurs in the motor winding. Decreased ampere draw indicates impeller wear.
On workshop inspection, if it is found that the cable is at fault, it should not be re-used, even if 30 M Ohm insulation can be restored. If the motor is at fault, the winding specialist can opt for ovendrying and revarnishing under vacuum, or in a favourable case drying only. In the latter case, dry at no more than 60°C with motor protector still fitted or at not more than 105°C with motor protector removed. In case of oven drying, insulation should be higher than 5 M Ohm when hot or 20 M
Ohm when cooled down.
Oil:
Replace the oil also if it is slightly greyish or contains a droplet of water. Ensure that electric power cannot be accidentally applied to the pump. Lay the pump on its side, remove the plug, holding a piece of cloth over it to prevent possible spraying. If the oil is greyish or contains water drops or dust, or if there is less than 80% of the recommended quantity left, then measure carefully at the cable´s end (never open the motor outside a workshop) the ohm resistance between the leads and replace shaft seal to avoid humidity getting into the motor and shorting the windings. Use turbine oil (ISO VG32).
Use the quantity specified in the specification table. Dispose of old oil in accordance with local regulations. Carefully check the packing (gasket) of the filling plug and replace.
4
CAUTION!
In the event of inward leakage, the oil housing may be pressurized. When removing the oil plug, hold a piece of cloth over it to prevent oil from splashing.
NOTE!
Old oil should be entrusted to an oil disposal company in accordance with local regulations.
The gasket and the O-ring for the oil filler plug must be replaced with a new part at each oil inspection and change.
Bearing Grease (only LH with more than 55kW):
Refilling bearing grease (only LH with more than 55kW): Refilling of bearing grease should be done with upright standing position of the pump in accordance as below.
Remove a cover on center of motor bracket (fixed with two M6 hexagonal bolts) and grease plug {55-75kW (M25)}, {90-110kW (M12)} on the bearing housing side for an upper and lower bearing respectively, and pour in grease from the grease nipple in accordance with the table as below and the drawing as shown on right figure.
Note:
Replenishment period is every 3,000 hours, however it may vary due to operating condition.
Hexagonal Bolt (M6)
Model kind of grease Initial quantity Replenishment
Cover
LH855
LH675
LH875
LH690
LH890
LH4110W
LH6110
LH8110 e.g. ENS GREASE
(Nippon Oil Co.) e.g. Multinoc Delux 2
(Nippon Oil Co.) e.g. RAREMAX SUPER
(Kyodo Yushi Co.,Ltd)
Lower
Upper
Lower
Upper
Lower
360g
100g
200g
370g
320g
60g
30g
60g
30g
60g
Gasket
Grease Nipple
Motor Bracket
Bearing
Grease Plug
O-Ring
Oil Plug
Bearing
Bearing Housing
Grease Inlet
Replacing the impeller
CAUTION!
Before disassembling and reassembling the pump, be sure that the power supply is disconnected, and remove the cabtyre cable from the terminal board. To prevent serious accidents, do not perform a conduction test during disassembly and reassembly.
CAUTION!
A worn impeller often has sharp edges. Take care not to cut yourself on them.
WARNING!
Never insert your hand or any other object into the inlet opening on the underside of the pump casing when the pump is connected to the power supply.
Before inspecting the pump casing, check that the pump has been isolated from the power supply and cannot be energized.
Make sure that the pump is completely reassembled before putting into operation again. Take care that bystanders keep a safe distance and avoid contact with the water.
CAUTION!
Be sure to perform a trial operation when starting the pump after a reassembly. If the pump was assembled improperly, it may lead to abnormal operation, electrical shock, or water damage.
Removal of the suction cover (wear plate) and especially removal of the impeller, and even more so the shaft sealing, must be left to a mechanic. Show him the sectional view.
If the pump has a strange smell or appearance, have it cleaned professionally before the mechanic touches it.
When reassembling, the mechanic will turn the impeller by hand to check that it turns freely and that there is no ticking or grating noise from a bearing. Impellers that are not of the vortex type, have a clearance with respect to the suction cover
(wear plate) of about 0,3 to 0,5 mm when new or repaired.
Trouble shooting
CAUTION!
To prevent serious accidents, disconnect the power supply before inspecting the pump.
Read this Operation Manual carefully before requesting repair. After re-inspecting the pump, if it does not operate normally, contact your Tsurumi-dealer.
Pump fails to start
Pump starts but stops immediately, causing the motor protector to actuate
The pump´s head and pumping volume is lower
The pump generates noise or vibration
Pump is new or has been repaired and tested
• Check that voltage applied agree with rating plate.
• Check at pump cable free end (never open motor) insulation value of earth lead (over 20M
Ohm), and continuity of winding. On three phase motor check whether ohm values of three windings are within ±10%.
Pump has been satisfactorily in use
• Same as above except that also impeller needs to be checked (stone, debris, rust between impeller blades and suction cover after long disuse).
• Motor windings or cable damaged. Do not open motor. Check as above.
• Impeller blocked or choked.
• If pump is new, wrong voltage or frequency.
• Voltage too low (most common cause); check supply voltage under load.
• If voltage is from diesel generator, inexact frequency.
• Wrong direction of rotation.
• Liquid of too high viscosity or density.
• Wrong setting of thermal overload unit.
• Wrong direction of rotation.
• Piping resistance too high.
• Impeller worn, partially choked or severely narrowed by hard deposits.
• Strainer or inlet blocked.
• Pump draws air, or liquid is partly volatile or contains high level of gas in solution.
• Wrong direction or rotation.
• Solid object (stone, etc.) in volute.
• Impeller severely damaged, or bearing damaged. Repair at once.
• Pump lying on its side and drawing a little air. High wear rate likely.
Description of parts:
(see exploded view in appendix)
No.
7
8
9
10
11
3
4
5
6
1
2
Part Name
Hexagonal bolt
Spring washer
Mechanical seal
Oil ring
Rounded head screw
O-ring
Packing (Gasket)
Oil casing
Packing (Gasket)
Oil plug
Spring washer
5
No.
18
19
20
21
22
12
13
14
15
16
17
Part Name
Hexagonal bolt
Shaft sleeve
Pump casing
Spring washer
Hexagonal bolt
O-ring
Labyrinth ring
Impeller adjusting washer
Impeller
Impeller thread protective cover
Hexagonal nut
No.
29
30
31
32
33
23
24
25
26
27
28
Part Name
Impeller nut
Suction cover packing (gasket)
Suction cover
Spring washer
Hexagonal bolt
Spring washer
Stud bolt
Strainer
Bottom plate
Spring washer
Hexagonal nut
