Foras 2 Water Domestic Drainage Pump Instruction Manual

Foras 2 Water Domestic Drainage Pump Instruction Manual

DECLARA EN – DECLARATION OF CONFORMITY TION OF CONFORMITY
The listed products (models 1 and 2) comply with the requirements of the Directives [D-CE] and are built in accordance with the updated, current regulations [N-A].

INSTALLATION AND OPERATION MANUAL – FORAS ELECTRIC SUBMERSIBLE

General safety instructions

• The equipment should only be used after having read and understood the instructions provided in the following document.
• Model FM, FV, FC and FTR pumps are intended exclusively for industrial use and should not be used for domestic applications.
• Models SP, SPV, DS, FC, DR, DB, DTR101 can be used by children over the age of 8 and by persons with reduced physical, sensory or mental capabilities or who lack experience and knowledge in their use as long as they are supervised or have been instructed on how to use the equipment safely and understand the potential hazards involved.
• Children must not be allowed to play with the equipment.
• The machine must only be removed from the water, cleaned and maintained by adults and only after it has been disconnected from the electrical power supply, ensuring that it cannot be switched on accidentally.
• The machine must be powered by an electrical power supply that is protected by a differential current circuit breaker that has a tripping current of less than 30 mA.
• The machine must only be used for the purpose for which it was designed.
• If the power cable is damaged, it must be replaced by qualified personnel in order to prevent hazards.
• The power cable and/or the float switch must not be used to transport or move the pump.
• (SP, SPV, DS, FC, DR, DB, DTR101) Do not remove the plug from the socket by pulling the power cable.
• Do not use the equipment if there are people in the swimming pool or the body of water.
• The manufacturer reserves the right to make any changes it considers appropriate to the machines without prior notice.

Description

The assembly referred to in this manual consists of a pumping unit complete with a submersible electric motor that is cooled by the pumped liquid.

Intended use

The FORAS submersible electric pumps are monoblock, single-impeller, vertical, axial-flow pumps designed for submersible operation in fixed or mobile installations. They are suitable for pumping:

Pump type| Water type| Suspended solids| Minimum Suction Depth (mm) in manual mode
---|---|---|---
Quantity (%)| Dimension (mm)
SP 40 and 60| Clean| <5| <4| 15
SP 80 and 100| Clean| <5| <7| 20
SPV 80 and 100| Clean| <5| <15| 55
DS 80 and 100| Clean/dirty| <15| <28| 110
FC 80 and 100| Clean/dirty| <15| <35| 110
DR 80 and 100| Clean/dirty| <5| <10| 15
DB 100 and 150| Clean/dirty| <15| <50| 110
Pump type| Permitted clearance (mm)| Water type| Impeller type
---|---|---|---
FVT 400/550| 45| With a high solids content and long fibre solids, liquids con- taining a high concentration of gas and sewage.|

Open-back Vortex type

FV(T)160/210, FVT310/750/1000| 50
FVT250-4/300-4/400-4, FVT550-4/750-4
FM(T) 160/210| 50| Clear, liquids containing solids and short fiber solids, sewage, sludge| Single channel Closed
FMT 310/410/560| 45| Single channel Open
FMT 1000| 50
FMT250-4/300-4/400-4| 60
FMT550-4/750-4| 90
FC(T)160/210 FCT 310/ 410/560 ,FCT 750/1000| 10| Clean or slightly dirty, free fromfibres and filamentous com- pounds| High-head open mulita- channel
FTR(T)1WW01/150/200 FTRT310/400/550 FTRT750/1000|

/

| Waste water containing filament- tous or fibrous solids, which need to be broken up. It must not contain abrasive particles or materials (e.g. sand, gravel)|

Open multichannel and suction grinding system.

The maximum immersion depth and the number of permissible starts / hour is shown in the following

Reasonably foreseeable misuse

• It is strictly forbidden to use the equipment for uses other than those described in the “Intended use” section and for pumping liquids that:
• at temperatures above 40° C, density greater than 1100 kg / m3
• with pH less than 5 or greater than 8
• flammable and explosive
• chemically aggressive, toxic and harmful
• It is strictly forbidden to use the equipment:
• in a configuration other than the one intended by the manufacturer
•  in wells, tanks or other environments in which there is the presence of gas and / or an explosion hazard
• in a zone classified according to the 2014/34/EU ATEX directive
• if it is integrated into other systems and / or equipment not considered by the Manufacturer in the final design
• if it is connected to mains electricity supplies with characteristics other than those intended by the manufacturer (indicated on the data plate).
• dry and/or when not entirely submerged in the liquid to be pumped
• if it is not submerged in the liquid to be pumped, never remove the pump from the water when it is still in operation
• in combination with commercial devices for purposes other than that specified by the manufacturer.

Transport

The machines referred to will be supplied in suitable packaging to ensure that they are adequately protected during transport. If the packaging appears to be damaged when the goods are received, make sure that the equipment has not been damaged and/or tampered with. If the equipment appears to be damaged or if any parts are missing, the carrier and the manufacturer must be notified immediately, and photographic documentation provided. The materials used to protect the equipment during transport must be recycled or disposed of according to applicable procedures in the country of use.

Lifting and Handing

When carrying out lifting and handling operations, the operator must wear at least the minimum personal protective equipment required for the work to be carried out (safety shoes, gloves and hard hat).
Machines weighing more than 25 kg must be moved using suitable handling systems, the capacity of which is greater than the weight of the machine to be handled. (See the weight indicated on the packaging). If slings are needed to move the machine, they must be in good condition and their capacity must be adequate for the weight of the machine to be handled. (Fig. 1)
Electric pumps weighting <25 kg can be lifted manually by the operator without having to use lifting equipment.

Storage

The equipment must always be kept in a covered area that is not excessively damp, protected from atmospheric agents and at a temperature of between -10°C and +40°C. Avoid direct exposure to sunlight. If the machine is to be stored for long periods, it is recommended not to remove it from its packaging.
During storage, place the pump on its suction base, in a vertical position and with the power cable wrapped around the body of the motor.

Installation

The internal diameter of the pipes depends on their length and the flow rate required. To prevent obstructions and blockages, the speed of the liquid in the delivery pipe should be greater than 0.8-1 m/s. If the liquid contains sand or suspended particles, the speed should be at least 1.6 m/s in horizontal pipes and 2.5 m/s in vertical pipes: the speed should, in any case, not exceed of 3.5-4 m/s.
The diameter of the delivery pipe must never be less than the diameter of the pump outlet.
To prevent sedimentation when the pump stops, it is good practice to limit the vertical sections of the pressure piping to a minimum and install the horizontal sections slightly inclined in the direction of flow.
Rest the pump, with vertical axis, on the bottom of the collection chamber or the place of installation. Make sure that the pumped liquid does not contain or cannot generate explosive gas mixtures: always make sure that the collection tank (pit) is well ventilated and does not allow gas to stagnate.

• The collection chamber should always be sized so that:
• the usable volume (consider the amount of water in arrival and the flow rate of the pump) limits the number of pump starts / hour: see maximum permissible number of starts (section 3 intended use)
• the time in which the pump is not running should not allow hard sediments to form.

Install a non-return valve on the delivery pipe, preferably on horizontal sections that are easily accessible.
Always fasten a safety rope or chain made of a non-perishable material to the eyebolt (FM, FV, FC and FTR) or to the handle (SP, SPV, DS, FC, DR, DB, DTR101) of the pump. Always use a safety rope to lift or lower the pump, especially if the delivery piping is made of plastic or of a flexible material. Always remember to secure the safety rope that is used to lower the pump to the edge of the collection chamber or the collection chamber cover.
Fasten the power cable to the safety rope using suitable cable ties, making sure that you leave the cable loose so that it is not under tension (Fig. 4)

Never use the power cable and/or the float to support the pump. (Fig. 1)

It is always preferable, even in the case of transportable installations, for the pump to rest on a solid base and not be suspended when it is in operation.
(FM, FV, FC and FTR) Fixed installation (Fig. 2)

In order to be able to remove the pump without having to drain the system, install a gate valve and opening downstream of the non-return valve to allow the non-return valve to undergo maintenance and cleaning. In order not to amplify the vibrations that are typical of all rotating machines, it is best for the support base of the pump to be securely fastened to the bottom of the pit; also provide clamps and supports for the delivery pipe. If the pump has to operate in sandy and/or muddy areas, mount it on a solid base and keep it at a certain distance from the bottom.
(FM, FV, FC and FTR) Fixed installation with coupling foot (Fig. 3)

For electric pumps that use this option, proceed as follows:

• fix the coupling foot to the bottom of the collection chamber using expansion bolts

• install the delivery pipe with the relative check valve and gate valve: in order to perform cleaning and maintenance on the valve,
  it is best to install the gate valve and check valve in horizontal sections that are easily accessible, with the gate valve downstream from the.
  check valve

• engage the two guide tubes with the coupling foot, fastening the upper part using the special pipe guide bracket, relative seals and threaded washers (to ensure that the two guide pipes are parallel)

• fasten the pump to the coupling shoe and lower the pump using the chain: the two guide pipes will ensure that the pump engages perfectly with the foot.

This is the easiest solution for fixed installations because it allows the electric pump to be removed and repositioned easily and quickly in the pit. This means that the pump can be cleaned and maintained without having to empty the collection chamber or remove any bolts.

Electrical connection

The SP, SPV, DS, FC, DR, DB, DTR101 electric pumps are supplied with a power cable and plug, so they are ready to be installed and used. The user must provide a device in the fixed wiring for disconnecting the power supply for the FM, FV, FC and
FTR pumps.
The electrical connection must always be carried out by qualified personnel in compliance with electrical code in the country of use.
Make sure that the voltage / frequency of the mains power supply is the same as that indicated on the data plate of the electric pump. Make sure that the mains power supply is properly earthed and that therefore the electric pump is earthed.
The power cable and / or float switch cable must never be subjected to stress, pulled or bent to a tight radius.
During use, make sure that the free end of the power cable is never immersed in water and that it is well protected against the possible infiltration of water or moisture. Pay particular attention to the integrity of the cables; even small cuts could allow water to get into the electric motor.
If the cables are damaged, it is preferable to replace them rather than repairing them. If extension cables are used, the join must remain dry and the conductors must be of a suitable cross section.
Some models of single-phase electric pumps, fitted with motor protectors, could restart without warning if the motor protector were to trip due to overheating: disconnect the power supply before carrying out any work on the electric pump.
The cooling time for the motor protector will be approximately 15 minutes, after which the pump will switch on automatically. In any case, you should try to find and eliminate the cause for the tripping of the thermal protector (impeller blocked due to foreign matter in the pump, temperature of the liquid too high).

In order to work, the single-phase electric pumps require a capacitor, the characteristics of which are shown in the table below:

Series| Operating capacitor characteristics| Starting capacitor characteristics
---|---|---
FV160/FM160/FTR150/FC160| C=35 µF / 450 V|
FV210/FM210/FTR200/FC210| C=50 µF / 450 V|
FTR150 (equipped with grinder)| C=35 µF / 450 V| C=85 µF / 480 V on time / restarttime: 1.5” / 6”
FTR200 (equipped with grinder)| C=50 µF / 450 V| C=85 µF / 480 V on time / restarttime: 1.5” / 6”

The purpose of the auxiliary (starting) capacitor is to increase the torque during the start-up stage, and it should be connected in parallel with the operating capacitor.
The capacitor(s) must be installed by qualified personnel following the diagram given on the sticker on the power cable.
Both three-phase and single-phase electric pumps must anyway be permanently connected to the mains power supply and a suitable protection device installed (suitably rated thermal magnetic circuit breaker incorporated in the fixed wiring) that ensures an all pole disconnection of the mains power supply.
The maximum permissible tolerance between the actual electrical supply voltage and the nominal value indicated on the data plate of the electric pump is ± 10% for three-phase electric pumps and ± 6% for single-phase electric pumps. Start-up and operation (Fig. 5) **

Before installing the eclectic pump, and with the machine disconnected from the power supply, make sure that the shaft rotates freely: to do this you can use a tool to turn the impeller (or, for model FTR pumps, the rotating part of the grinding system) through the suction inlet: make sure to wear suitable personal protective equipment.
For three-phas e electric pumps, you should make sure that the direction of rotation is correct, i.e. clockwise as seen from
the top of the machine (the arrow can be seen next to the delivery outlet on the pump). In order to do this before installing the pump, lift the pump using a suitable lifting device and start the motor for a few seconds (on and off): if the direction of rotation is correct the electric pump will kick back in an anticlockwise direction.
When carrying out this procedure, make sure that the machine is a safe distance from people, animals or personal property. If the direction of rotation is incorrect, you should invert two phase wires of the power cable.
The single-phase electric pumps can only rotate in one direction, which is factory pre-set.
Operation with a float switch: the float switch connected directly to the electric pump will control the starting and stopping of the pump. If necessary, adjust the length of the float switch cable, but making sure that an excessive length does not cause the pump to operate uncovered and cause the motor to overheat. Make sure that the float switch can move freely by providing collection chambers of suitable dimensions (see   ction 8 Installation). Make sure that the electric pump operates within its nominal performance range indicated on the data plate; otherwise regulate the gate valve on the delivery pipe.

Operation without a float switch: only start the pump if it is immersed in the liquid to be pumped; check the minimum suction
depth of the machine that has been installed.
N.B. in both cases, with or without the float switch, the electric motor must be completely submerged in the liquid for continuous operation of the electric pump.**

Maintenance

Disconnect the power supply before carrying out maintenance and/or repairs. For SP, SPV, DS, FC, DR, DB, DTR101 pumps, disconnect the power supply cable that is supplied with them, while for all the other types of electric pumps, disconnect the power supply using the isolating device (installed by the user). Pay particular attention to the cutting elements of the grinder (FTR models). Do not, for any reason, remove the pump from the liquid whilst the grinder is still in operation.
Any work to be carried out on the electric pumps must be performed by specialized personnel that have been adequately trained and using appropriate equipment.

Series SP, SPV, DS, FC, DR, DB, DTR101
Under normal conditions of use, these pumps do not require any special maintenance; it is recommended not to remove even individual parts, as tampering can affect the operation of the machine. If there is a risk of freezing, in the case of prolonged machine stoppages, the pump body and all the pipes should be completely drained. Then take the machine out of the water and store it in a dry place. Models DS, FC, DR, DB, DTR101 will be fitted with an electric motor and a mechanical seal immersed in biodegradable hydraulic oil (Fina Biohydran RS 38 or similar): be careful because the pressure and / or temperature of this oil could be higher than that of the external environment. In addition to this, the oil used will not pose any particular risks and will not contain substances that are hazardous to health: in the event of contact with the skin, thoroughly wash the areas affected with water.
Series FV, FM, FC, FTR
To ensure a long service life of the electric pumps they should undergo regular maintenance. It is recommended to carry out the following inspections every 250-300 hours of operation or at least twice a year:

• make sure that the current draw between the three phases is balanced and not higher than that shown on the rating plate
• make sure that the noise and vibration levels are the same as when the machine was put into service.

The electric pumps will be fitted with an electric motor and the mechanical seal on the motor side immersed in biodegradable hydraulic oil (Fina Biohydran RS 38 or similar): be careful because the pressure and / or temperature of this oil could be higher than that of the external environment. Under normal conditions of operation, the oil should be changed once a year, and every six months for more intensive use. To drain and fill the oil via the upper seal (motor side), use the plugs located on the flange of
the motor (Fig. 6).

If the oil that is drained out is emulsified, it should be changed for new oil and the mechanical seal on the pump side should be checked. If water drains out together with the oil, the pump side mechanical seal should be replaced. After filling the chamber with new oil, make sure that the plugs are tight and fitted with a new aluminum or copper seal.
To drain oil from the motor chamber and to fill it with oil, use the motor cover and/or, for more powerful machines, the plug on the motor casing (Fig. 7).

The motor side mechanical seal should only be replaced if it is damaged or if the pumped liquid is found in the chamber. After filling the motor chamber with fresh oil, make sure that the plug is tight and fitted with a new aluminum or copper seal. Replace the rubber sealing ring between the cover and the motor casing as well. In order for the electric pump to operate correctly, it is very important that Fina Biohy dran RS38 or equivalent oil is used , in the quantity indicated in the following table:

If the pump is used with muddy liquids or very dirty water, it is recommended to wash it thoroughly by rinsing briefly with clean water immediately after use or before prolonged periods of inactivity. This will remove any solid residues that may dry and block the impeller and obstruct the internal passages. Before restarting the electric pump, make sure that the shaft rotates freely, i.e. that it is not seized due to incrustations or other causes, that the electrical insulation of the motor and the electric power cable are  intact, that the oil level is correct and that the oil is in good condition.

Decommissioning

No special procedures are required. The machine is made of materials that when disposed of do not present particular risks for human health. For recycling or disposing of the materials that make up the equipment, please refer to the National and Regional Laws regarding the disposal of solid industrial waste and hazardous substances. Electrical and electronic equipment (WEEE with the symbol shown opposite) must be collected separately. For any questions or doubts you may have regarding the demolition and disposal of the machine or about aspects not covered in this document, please contact the manufacturer.Manufacturer and depositary of technical documentation:
PENTAX S.p.A.
Viale dell’Industria, 1
37040 Veronella (VR) – Italy
Gianluigi Pedrollo (President)
              Veronella (VR), 23/04/2018
Gianluigi Pedrollo

Sede amministrativa e stabilimento: Viale dell’Industria, 1 – 37040 Veronella (VR) Italy
Tel. +39 0442 489500 – Fax : +39 0442 489510 – www.foras- pumps.com– E-mail: com@foras- pumps.it

References

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