Foras PTR 12 Water Pumps Instruction Manual

USE AND MAINTENANCE MANUAL
Submersible motors
PTR 12 – PTR 14
Traduzione delle istruzioni originali

FOREWORD

The purpose of this instructions manual is to ease as much as possible the installation. We strongly recommend to read it attentively and to consult it whenever work is done on the motor. Unobservahce of the instructions here reported or improper use of the motor by unskilled personnel may compromise motor Iife and proper operation.
Our sales office is at your complete disposal: for any doubt or any problem you can also contact us.
1.1 DELIVERY NOTE CHECK
The motors are carefully inspected and tested before dispachment.
Check however the equipment at delivery against the accompanying documents. Check box integrity before removing the motor.
Parts and accessories can be packed alone or fastened to the box.
lf something is missing or damaged, please contact immediately your local forwarding agent.
1.2 WARRANTY
The warranty does not include possible damages or failure caused by mishandling, wrong electrical connections and uncorrect assembling. The warranty also excludes in all cases the issuing of pass certificates and remboursements for the equipment or for consequential damage. We decline any responsability tor damages to persons and things due to improper use of the machinery here described.
Normal wear parts are not subjected to warranty.
1.3 SAFETY WARNING
The equipment must be used only and exclusively after having read and understood the instructions given in the following document.
The PTR series motors may be used by children 8 years of age or older and by persons with reduced physical, sensory or mental capabilities, or lack of appropriate experience and knowledge, provided they are supervised or have received instructions on the safe use of the equipment and understand the potential hazards.
Children should not play with the equipments.
Water extraction, cleaning, and maintenance of the machine should only be performed by adults and only after the machine has been disconnected from the electrical power supply and cannot be accidentally reconnected.
The machine must be powered by an electrical supply system protected by a differential switch with an intervention current of less than 30 mA.
The machine should be used only and exclusively for the purpose for which it was designed.
If the power cord is damaged, it must be replaced by qualified personnel in order to prevent any risk.
The power cord should never be used to carry or move the motor and pump. Never remove the plug from the outlet by pulling on the cord.
Do not use the unit with people swimming in pools or ponds.
The writer reserves the right to make any changes it deems appropriate to the machines described without prior notice.

PRODUCT DESCRIPTION

2.1 MOTOR

Winding| Wire of pure electrolytic coppersheated with special non-Hydroscopic thermoplastic materiai of high dielectric strenght characteristics.
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Stator| Casing in stainless steel.
Rotor| Squirrel cage. Rotor is dynamically balanced for smooth and vibrationfree operation.
Thrust bearing| Self equalizing and sel-aligning Michell or Kingsbury type assembly, water lubricated
Shaft bearing| Anti-wear bush bearing in rnetallized graphite. Water lubrication
Shaft| Stainless steel shaft of oversized design minimized deflection, lengthening service life.
Seal:| Rubber lip-type shaft seal or mechanical seal.
Diaphragm| Equilizing diaphragm compensates for submergence pressure.
Motor| Is filled with water.
Cable| Rubber single-core or triple-core, depending on the of motor.

2.2 CONSTRUCTION FEATURES
Our submersible motors are designed and tested according to IEC 60034-2021 Standards.
Motor nameplate shows the following operating data:

• Manufacturer
• Motor type
• Part Number
• Production date
• Voltage (V)
• Ampere (A)
• Power (kW)
• Reference standard IEC 34
• Frequency (Hz)
• Rotational velocity (rpm)
• Power factor (cos @)
• CE marking
• Weight
• Operating condition

2.3 APPLICATIONS
Submersible motors are coupled to submersible pumps and installed in a vertical position for use in the following applications:

• Industriai and civil applications
• Irrigation systems
• Water supply systems
• Mining
• Offshore
• Nuclear and steam power stations
• Fire-fighting equipments

3.1 TRANSPORT
Before transportation, please checks:

• Motor weight
• Motor overall dimensions
• Suitability ot lifting points.

The submersible motors and their accessories (if included) are packed in boxes suited far transportation to avoid any damage on the way. However, we reccomend to inspect caretully the motor at delivery.
The motor should be handled with equipment suited to its weight and to the shape ot its crate to avoid possible damages due to mishandling.Lifting by hand is allowed only for weights lower than 25 kilograms. For higher weights, we suggest to lift the motor.
3.2 STORAGE
During storage, please observe the following precautions:

• Stare the motor in a closed, dry and airy environment.
• All motors are filled with a water-antifreeze mixture to prevent internal freezing below -10° C.
• Motors should not be stored or installed with lower temperatures or for periods longer than 12 months; however, it this is unavoidable turn the shaft by hand once a month.
• Motors stored for more than 12 months must be checked by an authorized shop betore installation.
• Protect cable ends against humidity.
• To avoid any damage to the electric cables, never bend them with a curving radius lower than 6 times their diameter.
• Protect against direct sunlight the electric cables and, in case the motor will be stored partially dismantled, the rubber parts and the thrust bearings.

INSTALLATION

4.1 MOTOR FILLING
Before proceeding with motor installation, it is necessary to fill up the motor . The motor is delivered filled up with a special mixture assuring bearings lubrication and cooling.
Before you install the motor, fill the motor with liquid. Follow this procedure:

• Piace the motor at a 45° angle with the top of the motor upwards.
• Unscrew the plug A and piace a tunnel in the hole.
• Pour tap water into the motor until the motor liquid inside the motor begins to flow out the motor at A.
• Remove the tunnel and refit the plug A.

Attention:
Before you fit the motor to a pump after a long period of storage, lubricate the shaft seal by adding a few drops of water and turning the shaft.
Note: Motor liquid contains glycerol.
For proper motor operation. never neglect to perform motor filling.
4.2 INSULATION CHECKING
Check motor insulation before coupling the motor to the pump.
Join one megahometer end to motor case and the other end to the cables coming out of the motor.
The megahometer reading should not be lower than 30 MΩ. 4.3 ELECTRICAL CONNECTION
Electrical connection must be performed by specialized personnel only, strictly following the instructions of motor and electrical equipment manufacturers.
lf the motor is supplied without cable, the cable must be selected following the prescriptions of Technical Service.
For supply cable selection it is necessary to consider the following factors:

• Mains voltage
• Allowable voltage drop along the line
• Motor BHP
• Cable max. output (Ampere)
• Ambient temperature

Motor cable connection should be performed with extreme care. lf two cables have to be connected in parallel, pay extreme attention to join together cables of the same colours or showing the same symbols. We suggest to leave 2 or 3 meters of cable more in case terminal connections should be changed.
4.4 ELECTRICAL EQUIPMENT
The motor is connected by the supply cable to the control panel, which contains the necessary control and protection devices.
4.5 ELECTRICAL PROTECTIONS
The following protections are always necessary:

• Overload pratection
• Short-circuit protection

These protections must trip on all three-phases. We suggest besides to install pratections against

• Phase drop
• Voltage drop

lf the overload thermal pratection relay has to be set, remember that with cold motor the protection operating time should be less than 10 sec. with 5 times the motor rated voltage. Therefore, for an optimal result, set the thermal relay as follows:

• Set the thermal relay at motor rated voltage.
• Start the motor and keep it working tor halt an hour in normal operating conditions.
• Slowly lower thermal setting until tripping the protection.
• Raise tripping value by 5%

For Star/Delta starters with stator impendences and with autotranformers, we suggest a protection operating period lower than 5 – 7 sec.
4.6 ROTATION DIRECTION
Check motor rotation direction betore coupling the motor to the pump, so to avoid any damage to motor thrust bearing. Find and mark by means of a cyclic phase indicator, whose pointer is turning counterclockwise mains terminals L 1, L2 and L3 and connect them to contrai panel terminals. L 1, L2 and L3.
DOL, stator and autotransformer starting
Motor cables are marked with letters U1, V1, W1 and have to be connected to control panel terminals, respectively: U1, V1, W1 tor clockwise ratation (seen from motor/pump coupling). Far clockwise rotation, reverse two of the cables.
4.7 FURTHER INSTRUCTIONS FOR SIX-CABLES MOTORS TERMINALS CONNECTION
Six cables motors can be started with a Star/Delta starter only if main voltage is at least equivalent to the motor minimum rated voltage.
To obtain the correct ratation direction, find main terminals L 1, L2 and L3 as previously described. Star/delta starting
Motor cables are marked with letters U1-V1-W1 e U2-V2-W2.
They have to be connected to control panel terminals, respectively: U1-V1-W1 and U2-V2-W2 for counterclockwise rotation (seen from motor/pump coupling).
In case of clockwise rotation, reverse terminals U1-V1 and U2- W2.
4.8 OPERATION
The max. number of startups/hour depends from starter type and motor power.

• Up to 75 kW 10 starts/hour
• Up to 150kW 8 starts/hour
• Over 150kW 5 starts/hour

All motors can accept a supply voltage tollerance of +6% – 10% about nameplate value and ±2% about nameplate frequency.

MOTOR CHECKING AND FAULT FINDING

In case of motor checking or mistfunctioning during motor operation, operate as follows:
5.1 SUPPLY VOLTAGE

Operation:
Check voltage between the phases with a
voltmeter| Checking
Running motor voltage has to be as reported at point 4.8.
Higher variations might damage motor windings: in this case, stop the motor and check supply voltage.
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5.2 VOLTAGE ABSORPTION

Operation
Measure voltage on each phase.
Max. voltage value is reported on motor nameplate| Checking
Voltage difference between the phases should not exceed 5%. Excessive BHP can take piace in the following cases:
• Weakening connections in the joinings
• Supply voltage too low or too high
• Short-circuiting motor windings
• Damaged pump overloading the motor
• Resistance value between the phases are too different
• Asymmetrical supply voltage
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5.3 WINDINGS RESISTANCE

Operation
Disconnect output cable from control panel.
Measure resistance to leads.| Checking
The difference between resistance values should not exceed 5%.
For higher differences, check separately motor and cable and replace detective parts.
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5.4 INSULATION RESISTANCE

Operation
Disconnect output cable correct from control
panel.
Measure insulation between each phase and
ground.| Checking
Make sure grounding connection is and in good conditions.
lnsulation with cold motor should be at least 30
megahoms or higher.
lt this is not the case, check separately motor and cable and replace detective parts.
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MAINTENANCE AND REPARATION

6.1 DISASSEMBLING THE MOTOR
Thanks to its construction features, the motor can be disassembled andreassembled quite easily by using standard shop metric tools. Motor disassembling, reassembling and reparation must be carried out by qualified personnel only or by an authorized shop.
6.2 REASSEMBLING THE MOTOR
Once reassembled, the motor cannot operate without being completely filled up as explained “Motor filling” pag.17.
Before starting, test the motor as explained in “WIndings resistance” pag.20 and “Insulation resistance” pag.20
6.3 TESTING
In case of motor windings replacement, perform the tollowing operation before coupling the motor to the pump.

• Check motor ground insulation by joining one megahometer end to motorcase and the other end to the cables coming out of the motor. The megahometer reading should not be lower than 30 MΩ.
• Connect motor to the mains through motor control panel and give a voltage pulse at voltage rated value. Check phase absorption for each phase: the values should be even, with a max. allowable difference of +/- 5%. Detected voltage value should be between 30% and 40% of In.
• Dielectric strenght test: place the motor on an insulating support and apply with a suited equipment a 1000V + 2Vn voltage for 30 seconds. Once performed the voltage test, check insulation to the ground as “Insulation resistance” pag.20

SPARE PARTS

7.1 SPARE PARTS ORDERING
For a faster processing of your order, when ordering spare parts please specify:

• Motor type
• Motor serial number
• Part name and number as listed on sectional drawings

The first two intormations are easily found on motor nameplate.

DECOMMISSIONING AND DISMANTLEMENT

8.1 DISMANTLEMENT
**** When the motor will be permanently stopped and dismantled, the various construction materials should be properly disposed of.
lt is important to make sure that no residuai polluting liquids are trapped within the motor.
The materials used tor motor construction are:

• Steel and cast iron.
• Aluminium.
• Rubber and plastic.
• Copper.

The disposal of polluting liquids and materials should follow current environmental rules.
PTR12
12″ SUBMERSIBLE MOTOR
MATERIALS

N.| PARTS| STD VERSION| VERSION 316 SS| VERSION 904 SS
---|---|---|---|---
1| SHAFT| STAINLESS STEEL| STAINLESS STEEL| STAINLESS STEEL
2| SHAFT TERINAL| AIS1 316 STAINLESS STEEL| AISI 316 STAINLESS STEEL| ALSI 904 STAINLESS STEEL
3| MECHANICAL SEAL| CERAMIIC/ARBON| SIC/SIC| SIC/SIC
4| BUSHES| STEEL/NBR| STEEL/NBR| STEEL/NBR
5| CABLE| EPDM| EPDM| EPDM
6| STRUCTURAL PARTS| CAST IRON| AISI 316 STAINLESS STET| AISI 904 STAINLESS STEEL
7| JACKET| AISI 316 STANLESTEEL| AISI 316 STAINLESS STEEL| A 904 STAINLESS STEEL
8| CLEARANCE RING| STEEL| STEEL| STEEL
9| THRUST| STEEL/NBR| STEEL/NBR| STEEL/NBR
10| DIAPHRAGM| EPDM| EPDM| EPDM
11| SCREWS| AISI 314 STAINLESS STEEL| AISI 316 STAINLESS STEEL| AISI 904 STAINLESS STEEL

DIMENSIONS – THREE-PHASE MOTORS – 2 poles

DIMENSIONS – THREE-PHASE MOTORS – 4 poles

PTR12
14″ SUBMERSIBLE MOTOR
MATERIALS

DIMENSIONS – THREE-PHASE MOTORS – 2 poles

DIMENSIONS – THREE-PHASE MOTORS – 4 poles

Translation of the original language
MOTORI SOMMERSI PTR 12-14
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
Mod. 051F rev.0

References

• Domain Default page
• Homepage

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