evak Hippo DN65 E-Series Submersible Sewage Pump Instruction Manual

evak Hippo DN65 E-Series Submersible Sewage Pump

Introduction

Check the following points upon receipt of your pump:

•  Is the pump exactly what you ordered? Check nameplate. It is especially important that you check whether the pump is to be used with 50 or 60 Hz.
• Has any damage occurred during shipment? Are any bolts or nuts loose?
•  Have all necessary accessories been supplied? (For a list of standard accessories see Construction.) We recommend that you keep a spare pump on hand in case of emergencies.

Keep this instruction manual in a place for future reference.

Specifications

Check the nameplate for your pump’s head, discharge volume, speed (R.P.M), motor voltage  and current.

Other specifications are noted in the chart below.

Liquid handled

| Type| Sewage, waste water, miscellaneous drain water
Temperature| Non-Automation| 1.5~5.5 HP| 0~40 °C (32~104°F)
Automation| 1.5~2 HP| 0~40 °C (32~104°F)

Materials

| Pump Casing| EN-GJL-200
Impeller| EN-GJL-200
Shaft| AISI 410 stainless steel
Motor type| Dry type submersible motor
Shaft seal lubrication oil| Turbine No.32 ISO VG-32
Maximum water depth| 10m (33ft)

Installation

Check the follo wing before beginning installation.
Insulation resistance measurement:
With the motor and cable (excluding the power supply cable) immersed in water, use a Megger to measure the insulation resistance between ground and each phase of the motor, and again between each phase of the motor. The Megger should indicate an insulation resistance of not less than 20mega ohms. While making the measurement, keep the power supply ca-ble off the ground.
We recommend that an auxiliary pump be kept on hand in case of emergency.

Installation

1. WARNING : Under no circumstances should cable be pulled while the pump is being transported or installed.
   Attach a chain or rope to the grip and install the pump.

2. This pump must not be installed on its side or operated a dry condition. Ensure that it is installed upright on a secure base.

3. Install the pump at a location in the tank where there is the least turbulence.

4.  If there is a flow of liquid inside the tank, support the piping where appropriate.

5. Install piping so that air will not be entrapped. If piping must be installed in such a way that air pockets are unavoidable, install an air release valve wherever such air pockets are most likely to develop.

6. Do not permit end of discharge piping to be submerged, as backflow will result when the pump is shut down.

7. .! WARNING : Non-automatic pumps do not have an automatic operating system. Do not operate the pump for a long time with the water level near the lowest water level(H1) as shown in Fig.1, as the automatic cut-off switch incorporated inside the motor will be activated.

8. To avoid dry operation, install an automatic operating system so that this will not happen, as shown in Fig.2 and maintain a safe operating water level.

Electrical wiring

1. Wiring
   A) Wire as indicated for the appropriate start system as shown in Fig-3 & 4 for single phase version and Fig-5 for three phase.
   B) Loose connections will stop the pump. Make sure all electrical connections secure.
   C) For three phase motors – Operate the pump for a short time (1 or 2 seconds) to verify the rotation of direction of the impeller, if its recoil is in counterclockwise direction, the direction of its rotation is correct. If not please switch two of the three power cords to correct the rotation of direction of the impeller.
   D) Make sure to check the pump’s direction of rotation with the pump exposed to the atmosphere. Operating the pump with reversed rota-tion while in submerged condition under water will most likely to damage the pump, which may lead to leakage and electrical shock.

2. Cable
   WARNING : Never let the end of the cable contact water.
   A) If the cable is extended, do not immerse the splice in water.
   B) Do not pull the cable.
   C) Install the cable so that it will not overheat. Overheating is caused by coiling the cable and exposing it to direct sunlight.

3.  Grounding
   To ground the green (yellow/green) wire. Under no circumstances should the green (yellow/green) wire be connected to the power sup-ply directly.
   4. WARNING : Use short circuit breakers to prevent danger of electrical shock.
   5. WARNING : Never start the pump while it is suspended, as the pump may jerk and cause serious accident involving injury.

Operation

1. Before starting the pump
   a. After completing installation, measure the insulation resistance again as described in Installation.
   b. Check water level.
   If the pump is operated continuously for an extended period of time in a dry condition or at the lowest water level, the motor protector will be activated. Constant repetition of this action will shorten pump service life. Do not start the pump again in such a situation until after the motor has completely cooled.

2. Test operation….
   Non-automatic pump Automatic pump
   a. Turn the operating switch on and off a couple of times to check for normal pump start.
   Floating switch must be raised for the pump to start.
   b. Next, check direction of rotation. If discharge volume is low or unusual sounds are heard when the pump is op-erating, rotation has been reversed. When this happens, reverse two of the wires.

Maintenance

Check pressure, output, voltage, current and other specifications. Unusual readings may indicate. Refer to Troubleshooting and correct as soon as possible.

Daily inspections
Check current and ammeter fluctuation daily. If ammeter fluctuation is great, even though within the limits of pump rating, foreign matter may be clogging the pump. If the quantity of liquid discharged falls suddenly, foreign matter may be blocking the suction inlet.

Regular inspections

Monthly inspections
Measure the insulation resistance. The value should be more than 1M ohm. If resistance starts to fall rapidly even with an initial indication of over 1M ohm, this nay be an indication of trouble and repair work is required.

Annual inspections
To prolong the service life of the mechanical seal by replacing the oil in the mechanical seal chamber once a year. Wa-ter mixed the oil or cloudy textures are indications of a defective mechanical seal requiring replacement. When replac-ing the oil, lay the pump on its side with filler plug on top. Inject suitable amount turbine oil No.32 (ISO VG-32) .

Inspections at 3-5year intervals
Conduct an overhaul of the pump. These intervals will preclude the possibility of future trouble.

Parts that will need to be replaced

Replace the appropriate part when the following conditions are apparent.

Replaceable part| Mechanical seal| Oil filler plug O-ring| Lubricating oil| O-ring
---|---|---|---|---

Replacement guide

| Whenever oil in mechanical seal

chamber is clouded

| Whenever oil is replaced or inspected|

Whenever clouded or dirty

| Whenever pump is overhauled
Frequency| Annually| A half yearly| A half yearly| Annually

Note: above replacement schedule is based on normal operating conditions.

= 7.52Øx14.5Øx3.53 t
Lubricating oil

(turbine oil #32)

| 280 cc| 500 cc

Construction

NO| Part| Material| Photo| NO| Part| Material| Photo
---|---|---|---|---|---|---|---

2

| ****

Handle

| ****

ASTM A36

| |

12

| Pump Casing (DN65)| ****

EN-GJL-200

| ****

3

| ****

Motor Cover

| ****

EN-GJL-200

| | ****

12

| ****

Pump Casing (DN80)

| ****

EN-GJL-200

| ****

4

| ****

Bracket

| ****

EN-GJL-200

| | 15-1

15-2

| Upper Bearing Lower Bearing| ****

NTN/TPI

| ****

5

| ****

Motor Housing

+Stator

| ****

AISI 304

| |

17-1

17-2

| ****

O-rings

| ****

NBR

| ****

6

| ****

Shaft with Rotor

| ****

AISI 410

| |

18

| ****

Gasket

| ****

NBR

| ****

7

| ****

Oil Chamber

| ****

EN-GJL-200

| |

18-1

| Elbow Gasket (DN65)| ****

NBR

| ****

8

| ****

Mechanical Seal

| CA/CE

+    SIC/SIC

| |

18-1

| ****

Elbow Gasket (DN80)

| ****

NBR

| ****

9

| ****

Seal Housing

| ****

EN-GJL-200

| |

18-2

| ****

Flange Packing

| ****

NBR

| ****

10

| ****

Lip Seal

| ****

NBR

| |

27

| ****

Flange (DN65)

| ****

EN-GJL-200

| ****

11

| ****

Impeller

| ****

EN-GJL-200

| |

28

| ****

Elbow

| ****

EN-GJL-200

| **
NO| Part| Material| NO| Part| Material**
1| Cable| H07RN-F/ SJTOW/STOW| 20-5| Washer| AISI 304
13| Protector (3 Phase)| KLIXON| 20-7| Washer| AISI 304
14| Capacitor (1 Phase)| –| 21-1| Spring Washer| AISI 304
19| Screw| AISI 304| 21-4| Washer with O-ring| AISI 304+NBR
19-1| Screw| AISI 304| 21-6| Spring Washer| AISI 304
19-2| Long Screw of motor| Steel| 21-9| Spring Washer| AISI 304
19-3| Screw| AISI 304| 22| Oil Filler Plug| AISI 304
19-4| Screw| AISI 304| 22-1| O-ring of Oil Filler Plug| NBR
19-6| Screw| AISI 304| 24| Wire and Screw| AISI 304
19-7| Screw| AISI 304| 31| Nut of impeller| AISI 304
19-8| Screw| AISI 304| 31-1| Nut of Elbow| AISI 304
19-9| Screw| AISI 304| 35| Key| AISI 304

Disassembly and Assembly

1. Disassembly-

When disassembling pump, have a piece of cardboard or wooden board ready to place the different parts on as you work. Do not pile parts on top of each other. They should be laid out neatly in rows. The “O” ring and gasket cannot be used again once they are removed. Have replacement parts ready. Disassemble in the following order, referring to the sectional view.

Be sure to cut off power source before disassembly.

• Remove pump casing bolts, raise the motor section and remove pump
• Remove shaft head bolt and
• Remove oil filler plug and drain lubricating
• Remove intermediate casing bolts and oil

(Remember that any lubricating oil remaining in the mechanical seal chamber will flow out.)

• Carefully remove mechanical seal, beware of not to scratch sliding surface of motor

2. Assembly-

Re-assemble in reverse order of disassembly.

Be careful of the following points.

• During re-assembly, rotate the impeller by hand and check for smooth If rotation is not smooth, perform steps-(3) through -(5) again.
• Upon completion of re-assembly step -(1) rotate the impeller by hand from the suction inlet and check that it rotates smoothly without touching the suction cover before operating the

Please order “O” rings, packing, shaft seals and other parts from your dealer.

Troubleshooting

(1)~(3) Contact electric power company and devise counter-measures
(2) Large discrepancy between power source and voltage
(3) Significant drop in voltage
(4) Motor phase malfunction| (4) Inspect electric circuit
(5) Electric circuit connection faulty| (5) Correct wiring
(6) Faulty connection of control circuit| (6) Inspect connections and magnetic coil
(7) Fuses is blown| (7) Check circuit then replace fuse
(8) Faulty magnetic switch| (8) Replace with correct one
(9) Water is not at level indicated by Float| (9) Raise water level
(10) Float is not in appropriate level| (10) Adjust the position of float
(11) Float is not effective| (11) Repair or replace
(12) Short circuit breaker is functioning| (12) Repair location of short circuit
(13) Foreign matter clogging pump| (13) Remove foreign matter
(14) Motor burned out| (14) Repair or replace
(15) Motor bearing broken| (15) Repair or replace
Operates, but stops after a while.| (1) Prolonged dry operation has activated motor pro- tector and caused pump to stop| (1) Raise water level to C.W.L
(2) High liquid temperature has activated motor pro- tector and caused pump to stop| (2) Lower liquid temperature
(3) Reverse rotation| (3) Correct rotation
Does not pump. Inadequate vol- ume.| (1) Reverse rotation| (1) Correct rotation (see Operation)
(2) Significant drop in voltage| (2) Contact electric power company
(3) Operating a 60Hz pump with 50Hz| (3) Check nameplate
(4) Discharge head is high| (4) Recalculate and adjust
(5) Large piping loss| (5) Recalculate and adjust
(6) Low operating water level causes air suction| (6) Raise water level or lower pump
(7) Leaking from discharge piping| (7) Inspect, repair
(8) Clogging of discharge piping| (8) Remove foreign matter
(9) Foreign matter in suction inlet| (9) Remove foreign matter
(10) Foreign matter clogging pump| (10) Remove foreign matter
(11) Worn impeller| (11) Replace impeller
Over current| (1) Unbalanced current and voltage| (1) Contact electric power company
(2) Significant voltage drop| (2) Contact electric power company and de- vise counter-measure
(3) Motor phase malfunction| (3) Inspect connections and magnetic switch
(4) Operating 50Hz pump on 60Hz| (4) Check nameplate
(5) Reverse rotation| (5) Correct rotation
(6) Low head. Excessive volume of water| (6) Replace pump with high head pump
(7) Foreign matter clogging pump| (7) Remove foreign matter
(8) Motor bearing is worn out or damaged| (8) Replace bearing
Pump vibrates; excessive oper- ating noise.| (1) Reverse rotation| (1) Correct rotation
(2) Pump clogged with foreign matter| (2) Disassemble and remove foreign matter
(3) Piping resonates| (3) Improve piping
(4) Strainer is closed too far| (4) Open strainer

Unit 1, 1 Wimbledon Avenue, Brandon, Suffolk, IP27 0NZ 01842 819130

sales@automatedenvironmentalsystems.co.uk

Evak Pump Technology Corp. No. 551, Zhongshan R,d. Oingshui Dist, Taichung City 436, Taiwan.

Tel : +886-4-26233556

Fax: +886-4-26235559

www.evak1-p6umps.com

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