AQUASUB ENGINEERINGTUDIYALUR POST, COIMBATORE - 641034

TEL : 0422 - 2642484, E-mail : marketing@aquagroup.in

Website : www.aquagroup.in

VERTICAL MULTISTAGE HIGH PRESSURE PUMPSAV, AVI, AVN SERIES

OPERATION MANUAL

CONGRATULATIONS

Thank you for your purchase of 'AQUATEX' Vertical multistage high pressure pump. You are proud owner of new generation high pressure pump. It is designed and manufactured with stringent quality control to give trouble free service for years. Please follow the instructions given in this manual to install and maintain 'AQUATEX' high pressure pump to get the best possible and highly reliable operation. Utilise the services of a qualified technician for installation.

Please inform the name plate details i.e. serial number of the pump, type of pump etc. when you order for spare parts in the future.

After reading this operation manual, keep it safe and easily accessible, so that it can be referred to whenever information is needed while operating the equipment.

DESIGN'AQUATEX' Vertical multistage high pressure centrifugal In-Line pumps

(AV,AVI & AVN Series) are non self priming pumps of In-Line design. Flange or with Victaulic coupling with equally sized suction and discharge ports.

Stage construction with Stainless Steel impellers, diffusers and outer tube, pump shaft and motor shaft are of IEC Standards. All wetted parts of pump are made of high grade corrosion resistant Stainless Steel SS304/SS316 and highly suitable to use in R.O systems for drinking water. All pumps are equipped with cartridge type mechanical seal for easy maintenance and minimum down time in case of replacement.

'AQUATEX' Vertical multistage high pressure centrifugal In-Line pumps are driven by Totally Enclosed Fan Cooled (TEFC) high efficiency AC Induction motors.

APPLICATIONSPRESSURE BOOSTING AND WATER SUPPLY : Pressure Boosting in residential apartments, Commercial high rise buildings, IT Parks, Hotels, Hospital and Colleges. Pressurized water supply in Process and Food industry and for Fire fighting and HVAC System.

WATER TREATMENT : Pumping water in Reverse Osmosis Systems (RO), Water Softeners and Ultra-filtration systems.

IRRIGATOIN : Sprinkler Irrigation for Golf Courses, Sports Stadiums and Agricultural fields.

INDUSTRY : Boiler feeding and Industrial Washing / Cleaning System.

CUT SECTION VIEW AND SPARE PARTS LIST

AV-1,3,5,10,15,20 AVI, AVN-1,3,5,10,15,20

AV-32,45,64,90 AVI, AVN-32,45,64,90

44

57

4882

36

37

18

12

24

59

36

37

56

18

12

24

59

44

57

3882

62

53

36

48

14

37

57

1812

248242

59

53

36

48

14

62

37

57

1812

2482

42

59

CUT SECTION VIEW AND SPARE PARTS LIST

AV-120,150 AVI, AVN-120,150

P.No. AV, AVI, AVN - 1,3,5,10,15,20

AV, AVI, AVN - 32,45,64,90

AV, AVI, AVN -120,150

12

Diffuser Assembly

Bowl

14

-

Bearing ring

-

17

-

-

Bearing ring

18

Impeller

24

Neck ring

36

Motor bracket

Top casing

37

Shaft

42

-

Bottom bearing ring

48

Outer tube

53

-

Motor bracket

56 Top casing* - -

57 Mechanical seal

59 Inline casing

62 Base Inline casing

62A - - Base

82 O ring for outer tube

*Only for AVI and AVN models

57

12

17

1842

82

62A62

59

24

48

37

36

53

57

12

17

1842

82

62A

53

36

37

48

24

59

INSTALLATION PRECAUTIONS

PRODUCT INSPECTION

Inspect the purchased pump for damage or leakage during

transportation. And make sure all bolts and nuts are tightened

properly.

TYPICAL INSTALLATIONA typical installation diagram is shown below. Please

follow the given installation precautions before and during installation.

Pump should be positioned as shown in figure-A. Pump should be installed in a protected environment, not exposed to weather. Provide sufficient space around the pump for motor cooling and accessibility, refer figure-B.

A B

No. Description 1

Pipe support: Support piping system properly to avoid stresses on connections.

2

Isolating valves: Install isolating

valves for easy access- before the pump intake and after the pump discharge.

3

Use flexible piping on both input and output sides of the pump to reduce vibration and transmission of noise.

4

Check valves will prevent return flow of pumped liquid when pump is stopped, reducing the danger of pump damage.

5Control Panel: Use high quality components. Make sure that the panel conforms to local standards and regulations.

6 Do not place elbows next to the pump intake and discharge.

7If pump needs to be operated with isolating valve closed, install a by-pass line to avoid damaging the pumping system.

16

7

2 3 3 4 2 1

5

GENERAL INSTALLATION PRECAUTIONS

Do not use this pump for sandy water, oil, toxic, acetic, corrosive and inflammable liquids. Pumping inflammable liquids could cause explosion. Warranty is void, if pump is used for other than clear cold water.

The pump must be fixed firmly by bolts through the holes in the flange or base plate.

Use good quality pump accessories (Non Return Valve, nipple, pipe,

ball valve, etc..) for better performance and trouble free operation.

If you find damage or discrepancy in the product, contact the dealer where the pump was purchased or the "AQUASUB ENGINEERING's" sales office in your area.

No. Description 8

If it is necessary to increase the diameter of the suction pipe, place an eccentric reducer between the isolating

valve and the flexible pipe section.

9

Using elbows will increase the flow resistance.

Wide bends will result in lesser flow resistance.

10

The piping must have a level or positive gradient to prevent the formation of air pockets.

11

The diameter of the drop pipe must be bigger than the diameter of the pump’s suction port.

12

Use a foot valve in case of negative suction head.

13

Size pump for correct head.

14

Place the intake of the suction pipe so that the intake is always submerged to prevent entry of air.

15

Install a compound gauge at the pump suction and a pressure gauge at the pump discharge.

89

9

10

10

11

12

13

1314

14

15 15

ELECTRICAL PRECAUTIONS

OPERATION PRECAUTIONS

MAINTENANCE

Use good quality electrical accessories for safe operation and electrical accessories must be sufficient rated. Consider local regulation before commencing electrical installation.

Provide proper earthing. Do not connect the earthing wire to water pipe, lightening rod or telephone earth wire. Improper earthing could cause electrical shock.

Overload protection should be provided and to avoid the possibility of dry running, it is strongly recommended to install dry running protection device.

Warranty is void for coil failure and capacitor failure, if pumpset is not operated in the prescribed Voltage range..

Start the pump in discharge valve closed condition, slowly open the discharge valve and ensure the smooth and noiseless working. If there any disturbance in operation re-prime the pump.

Check the current drawn by the motor. If necessary, adjust the setting of the thermal relay. (Thermal relay is provided in single phase 0.5HP and 1.5HP only).

Switch off the power supply and ensure the motor fully stopped, before changing rotation or making any other adjustments.

Do not run the pump dry, it could lead to mechanical seal damage and product damage. Warranty is void if pump is not operated in the prescribed operating range.

Disconnect the power supply before starting maintenance or inspection of the pump to avoid electrical shock.

For uninterrupted performance, planned maintenance and

inspection are indispensable. Please follow below guidelines while

maintaining or inspecting the pump.

Priming : Pump should be filled by clear cold water before start-up. Ensure that the pump is fully filled by water without air pockets. If air pockets trapped in the pump, adjust the air screw to release trapped air.

COUPLING ADJUSTMENT

If the motor is fitted with grease nipples, then the motor should be lubricated with high temperature lithium-based grease.

If the pump and motor are not used frequently with long intervals of non-operation, then it is recommended that the motor to be greased. Follow the steps shown in figure for coupling adjustments

AV, AVI, AVN – 1, 3, 5 SERIES

COUPLING ADJUSTMENT

AV, AVI, AVN - 10,15,20 SERIES

COUPLING ADJUSTMENT

AV, AVI, AVN - 34, 45, 62, 90, 120, 150 SERIES

TROUBLE SHOOTING

If you find any trouble during operation of the pump,

please follow the guidelines to overcome some of the

troubles given below.

Fault Probable cause Possible Solution

Pump does not run when the motor

starter is activated.

a. Supply failure or no power supply.

Check connections or restart the power supply.

b. Main contacts in motor starter are not making contact or the motor coils are defective

Reconnect or replace contacts or magnetic coil.

c. Pump or auxiliary circuits

protection fuses blown.

Replace fuses.

d. Pump or piping system may be obstructed causing a jam.

Clean the obstruction and restart pump.

e. Motor may have failed.

Replace the motor.

f. Motor protector or thermal relay has tripped out.

Reset the motor or thermal protector.

g. Tripping of

anti-dry running protection.

Check the water level in the tank or the water system pressure. If everything is in order, check the protection device and its connection cables.

Starter overload trips immediately when the power is

switched on.

a. Overload setting is too low.

Set the motor starter correctly.

b. The cable connection is loose or faulty. Fasten or replace the cable connection.

c. One fuse is blown.

Replace fuse and try starting again.

d. Pump is jammed by an obstruction

Check and clean obstruction from system.

e. Contacts in overload are faulty. Replace motor starter contacts.

f. The motor winding is defective. Replace the motor.

g. Low voltage(Especially at peak time) Check the power supply.

The pump startsbut, after a short time, the thermal protector trips out or the fuses blow.

a. The voltage is not within the motor’s operating limits.

Check the operating conditions of the pump.

b. The control panel is situated in an excessively heated area or is exposed to direct sunlight.

Protect the control panel from heat sources and from the sun.

c. A phase in the power supply is missing. Check the power supply.

The pump starts up but, after a

period of time, the thermal protector

trips.

a. Worn out motor bearings causing motor to overheat.

Replace motor bearings.

b. The pump’s delivery rate is higher than the specified rate on the pump nameplate.

Partially close the isolating valve located discharge side until the delivery rate returns to within the specified limits.

c. There are obstructions inside the pump or pumping system.

Disassemble and clean the pump and piping.

d. Less viscous liquids may cause the motor to work too hard and overload the motor, causing the motor to overheat.

Check the actual power requirements based on the characteristics of the liquid being pumped, and replace the motor accordingly.

TROUBLE SHOOTING

Conduct trial operation after maintenance or inspection.

Dispose replaced components with appropriate care, to save environment.

For unsolvable troubles in the pump, contact the dealer where this pump was purchased or the "AQUASUB ENGINEERING's" sales office in your area for specialized service.Do not try to solve unspecified troubles of pump, as it may lead to severe damage to the pump or personal injuries.

Fault

Probable cause

Possible Solution

Pump runs but no water delivered.

a. Pump is not primed with liquid.

Fill the pump with the liquid to be pumped.

b. The pump, suction or discharge pipes are blocked by solids in the liquid being pumped.

Clean the pump, suction or discharge pipe.

c. The foot or check valve is blocked or has failed.

Replace the foot or check valve.

d. The suction pipe leaks.

Repair or replace the suction pipe.

e. The air is in the suction pipe or pump. Remove trapped air from system.

f. Motor operating in wrong direction (three-phase motor).

Change the direction of rotation of the motor by reversing motor connections.

The pump capacity is not constant.

a. The pump draws in air or the inlet pressure is too low.

Improve the suction conditions.

b. The pump or the suction side of the piping system partly blocked by foreign bodies.

Clean the pump or suction pipe.

The system's general protection cuts in

Short circuit.

Check electrical system.

The pump rotates

in the wrong direction when switched off.

a.

The foot or the check valve has failed.Check and replace check valve or foot valve.

b. Leakage in the suction pipe. Repair or replace the suction pipe.

The frequency ofPump start-up is

too high.

a. Leakage in the foot valve, check valve or system.

Repair or replace the components.

b. Ruptured membrane or no air pre-charge in surge tank.

See relevant instructions in surge tank’s manual.

Vibration and noise

a. Cavitation

Reduce the required flow or improve the operating conditions of the pump (suction conditions, head, flow resistance, liquid temperature, viscosity,…etc.).

b. Make sure that pump and motor shafts are properly aligned.

Adjust the pump and/or motor shafts.

c. Worn motor bearings. Replace the bearings or the motor.

d. Operation with frequency converter.Consult a qualified engineer form the supplier of the frequency converter.

e. Check vibration and noise damping devices

Replace vibration & noise dampers, if worn.

WARRANTY DECLARATION

WARRANTY CARD(Please retain this for your personal record)

Authorised Dealer's seal Name & Signature of Authorised Dealer

Product Name & Model No. ....................... Serial No............................................

Name and Address of dealer ………...............……....................................................

Bill No. ........................................... Date of Purchase............................................

WARRANTY FOR VERTICAL MULTISTAGE HIGH PRESSURE PUMP

AQUASUB ENGINEERING warrants to the purchaser of this AQUATEX product, that for a period of

12 months commencing from the date of purchase of the product. Aquasub Engineering will

repair or replace free of charge any part or parts of the product, should AQUASUB ENGINEERING

be fully satisfied in its sole discretion, that the defect/s is / are due to faulty material or

workmanship only. The warranty will be governed by the following clauses:

1. Only AQUASUB ENGINEERING or their Authorised Service Agent / Dealer will repair / replace

all parts that are failing due to faulty material or defective workmanship pertaining to the above

product.

2. Only Aquasub Engineering or its Authorised Service Agent / Dealer can service / repair or

attend to install / reinstall the above product.

3. All expenses incurred in collecting the units or parts thereof from the Authorised Service

Centre or the Dealer of Aquasub Engineering as well as expenses incurred in connection with

deputing of service personnel / technicians towards to and fro travel conveyance and other

incidentals etc., will be borne by the customer.

4. The warranty extended therein is in lieu of all implied conditions and warranties under the law

and is confined to the repair or replacement of defective parts and does not cover any

consequential or resulting liability, damage or loss arising from such defects. Furthermore, the

warranty in no case, shall extend to the payment or any monetary consideration whatsoever, of

the replacement or return of the product as a whole.

5. The warranty is issued subject to jurisdiction of Coimbatore Court of Law.

6. The warranty is covered by Force Majeure clause. In the event if the above product

is struck by any natural calamity, this warranty stands null and void.

This Warranty is not valid in case of any of the following events.

a. This Pump is not used according to the instructions given in this Operation manual.

b. If the electrical power supply voltage is not within the stipulated norms. Coil burning due to

low voltage or overload.

c. Any repair work / alteration / installation carried out by a person other than Aquasub

Engineering Service Centre / Service Agent / Dealer.

d. The serial Number is deleted, defaced or altered.

e. Mechanical seal failure and other failures due to dry running of the pump.

f. Failure of accessories other than supplied pump.

AQUASUB ENGINEERINGTUDIYALUR POST, COIMBATORE - 641034

TEL : 0422 - 2642484, E-mail : marketing@aquagroup.in

Website : www.aquagroup.in

OTHER BUILDING SERVICES PRODUCTS

Hydropneumatic Pumping System

Domestic Booster System, Water Transfer, Sewage, Drainage, Construction Dewatering and

Vertical Inline High Pressure Pumpsets.

AV

-118/0

0 0

6-2

016