Technical Support

Submersible pumps are installed in the bores and are hardly accessible for visual inspection. However one can diagnose troubles by tuning ones ear to acoustical sound produced by discharge line. This can however be done by user rather than a trained mechanic as frequency of sound is typical to a tipical installation. It is advisable to touch one's ear to delivery line and observe the sound emitted by the pump. In a daily routine inspection following points should be noted:

  • Sound emitted by the pump.
  • Voltage supplied to the pump.
  • Current drawn by the pump.
  • Visual discharge at outlet of the pump.

The pump should not be operated for more than 2 Hrs. If the panel shows a voltage less than 01-180 V, 0 3-350 V. Any voltage less is likely to harm the motor. Current drawn at different available voltages for a particular installation should be recorded and checked on daily basis. Any abnormal current drawn by the pumpset can be a possible cause of trouble.

Visual discharges at outlet of the pump will depend on various factors like voltage available on the site, the depth of water available, and periodic yield of the borewell.


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Installation and Maintenance


General

  • The site safety regulations and statutory requirements if any, are to be taken care of and complied with, by the purchaser.
  • The motor and pump serial number, type and size, main operating data are stamped on the name plate of the pumpset. Please quote these details while ordering the spares.
  • STORAGE : The unit is preferably to be stored in vertical position. If the pumpset is in operation and required to be taken out for storage, after cleaning all external parts, the unit can be stored in a dry and dust free room. Thereafter whenever reinstallation is taken up, verify that the pump shaft and motor shaft rotate freely by hand. If pumpset is stored for long time, periodic inspection is advised.
  • SCOPE : Unless and otherwise contracted, our standard scope of supply is restricted to Motor unit, Pump unit & 3 mtr., long cable only. All other accessories are to be procured by puchaser separately.
  • SHUT DOWN PERIOD : The pumpset should not be allowed to remain stationary for more than 7 days, otherwise lime, iron and other substance tend to settle in bearings and impeller gaps. If the conditions demands that the pumpset has to remain shut down for a longer period, it is recommended that the pumpset should run daily at least 15 minutes to enable it to be in a healthy conditions.
  • MINIMUM FLOW RATE : If it is required to operate the pumpset at the reduced discharges by throtting the delivery valve, the munimum rate of flow, should not be less than 25% of rated flow to prevent over heating of the motor.
  • RECEIPT OF PACKAGES AT SITE VERIFICATION OF TRANSIT DAMAGES (IF ANY).
    After the goods are received at site, they are to be verified as per the dispatch documents. Transit damages, if any are to be reported immediately to the concern supplier. The pump and motor packed spearately, and they are packed in a corrugated tube. Great care needs to be taken, while unpacking the goods, in particular the motor. DO NOT PULL THE MOTOR BY ITS CABLE AT ANY TIME. After removing the equipment's from the respective packing varify that both pump and motor shaft rotate freely.

Recommended Accessories

  • CABLE : Every pumpset supplied with 3 mtr. of length since pumpsets are to be installed in borewell, an additional cable length is required to the Electric supply located at ground level.
    THE EXACT SIZE OF THE CABLE IS TO BE SELECTED WITH THE HELP CABLE SELECTION CHART
  • Most of the future complaints can be avoided by using proper make & size of the cable.
  • CONTROL PANEL: User is advised to use control panel with quality accessories to avoid future problems. Control panel should have following protective devices for trouble free operation of the pumpset :-
    • Thermal relay with suitable current relay setting.
    • Single phasing preventor (For 3 phase pumps only)
    • Provision for water level guard/ Auto switch connection to avoid dry running of the pumpset
    • Starting and running capacitors, (as per specification on motor nameplate)
    • Overload / under voltage protector.
  • WATER LEVEL GUARD / DRYRUN CONTROL :
    It is recommended to install the pumpset with water level guard / dryrun control of reputed make to protect the pumpset against dry running at lower water levels. The water level guard consists of a cable & probe. This probe is to be installed at about 0.5 mtr. above N. R. V. top. When the water level in the bore gets lowered below the probe level, starter will get switched off automatically by the level sensing device.
  • SUPPORTING CLAMPS : Two pairs of supporting clamps are required for installation of pumpset. One pair is required permanently to hold the pumpset in position. This clamp usually rests on girders or borewell casing pipe.
  • CABLE CLIPS : It is necessary to fix a cable at every 3 mtr. Length of delivery pipe to keep the cable in position. This minimizes the chances of damage to cable while lowering / taking out of pumpset in to / form borewell. Care is to be taken while fixing these clips so that damage to the cable is avoided.
  • BOREWELL CAP: It is necessary to cover the borewell opening with this cap to avoid entry of any foreign material like dirty water, stones etc. in to the borewell there by avoided damage to the pumpset. Sometimes if a larger size stone fails into the borewell and is sandwiched between delivery pipe & borewell wall it can damage the cable or may make it difficult to lift pumpset outside.
  • CHECK VALVE : The pumpset operating point can be adjusted using the valve, there by avoiding the pumpset operation at very low or high discharge flow.
  • NON- RETURN VALVE : It is recommended to protect the piping system in case of sudden power failures, causing water hammer by fitting N.R.V. in the delivary pipe.
  • PRESSURE GAUGE : It is recommended to fix a Bourdon tube type pressure gauge in order to indicate the pressure developed by the pumpset.
  • REQUIRED TOOLS FOR INSTALLATION :
    • A tripod stand of 20 feet length.
    • A chain- pully block of 1 Ton capacity for bore upto 100m. depth & 2 Ton for above 100m. depth installation.
    • Chain spanner - 2 No's.
    • A screw driver 8", 12", Insulating pliers, Spanners etc.
    • Megger 500 Mohm -1 No.
    • All plumbing material.

Check List Before Installation & Commissioning

  • Check the borewell for undersize, crokedness with the help of master size of pumpset before actually loading the pump in the borewell.
  • The yield of borewell should be more than the discharge of the pumpset.
  • Ensure that the N. R. V. top is at least 1 mtr. (3 feet) below maximum draw down level of water in the borewell. And also ensure that the pumpset is lowered min. 3-4 mtr. above the bottom of the borewell (check exact depth of borewell.)
  • Required electrical supply (1 phase or 3 phase) with appropriate voltage is available on sight.
  • Provide proper good earthing to reduce risk of electrical shock during operation of pumpset.
  • The voltage drop at motor connection on account of power fluctuation and/or length and size of supply cable, should not be more than minimum specified voltage. The recommended minimum voltage at motor connection should not be less than 300 V for 3 phase and 180 volts for single phase pumpset. The recommended maximum voltage at motor connection should not be more than 440 Volt for 3 phase and 250 Volt for single phase pumpset.
  • Motor & pump shaft rotate freely before coupling.
  • Motor is filled with cold, clear drinking water.

DO NOT FILL DISTILLED WATER IN MOTOR.

  • Check the motor protection relay is proper.
  • Keep the delivery valve slightly open if it is provided.
  • Cable joining has been made properly as per the procedure given in this manual.
  • Verify that suitable control panel with following protective devices are provided and are in working condition :
    • Thermal Relay with suitable relay current setting.
    • Single phasing preventor/Auto switch (for three phase pumpsets).
    • Provision for water level guard connection to avoid dry run of the pumpset / over load protector.
    • Starting & running capacitors as recommended on nameplate of moter.
    • Motor & Pump coupling face are clean. Remove rust preventor.

Cable Jointing Procedure

Good cable connection ensure a prefect water tight joint & at the same time gives reliable protection against mechanical damages to the joint.

Select Proper size ofthe cable with the help of Cable Selection Chart


  • Cut the motor & supply cable in a staggered manner.
  • Cut the outer black P.V.C. of both the cables.
  • Maintain projections of motor cable RED, YELLOW & BLUE conductors projecting outer black PVC by 50 mm. 75 mm. & 100 mm. respectively.
  • Remove insulation of all conductors to project copper wire approximate by 7.5 mm.
  • Coincide the copper wires of same colour conductor of both the cables. Insert copper wire of same colour conductor of both the cables in each crimping sleeve. Crimp each sleeve at three different points.
  • Clean the sleeve. Wrap two layers of approx. 6 mm. size MRF tape over each joint.
  • Wrap two layers of PVC adhesive tape over each sleeve.
  • Wrap each joint with two more layers of PVC Tape.
  • File both the outside Black PVC outer sheath of both the cables by rough file.
  • Wrap two layers of approx 8/10 mm size MRF tape and then wrap two layers of PVC. Adhesive tape.
  • Keep the joint deep in water for some time & test it by meggar if meggar value is 20 Mohm or more, then the joint is O.K.
  • CONTINUITY TEST : To check the continuity between the three possible combinations of the power leads, connect one lead from meggar to (R) phase and another lead from meggar to (Y) phase of motor cable. Rotate the handle of meggar and note down the reading. Repeat this for (Y) and (B) phase and also for (B) and (R) phase. In all cases, readings should be zero and infinity value will indicate break in winding wire, cable or joint or loosening of joint, which is to be corrected.
  • INSULATION TEST: Check the insulation resistance of winding coils and cable. Join all the leads, twist them together and connect them to the line lead from meggar, connect another lead from the meggar to a clean surface of delivery pipe on meggar dial. The rotation of meggar handle should be enough to produce 500 volts D.C. The reading on meggar dial should never be less than 5 megaohms. Reading of 2 Megaohms indicates that insulation has become weaker and (0) zero reading indicates shorting of windings/ cables or joints to the earth.
    In case of weaker insulation or Zero insulation, cut the cable at lead joint and again check the insulation of winding. If it is OK, then there is no fault in winding coils, the motor is to be sent to the works for repairs.

Installation & Commissioning of 'Lada' V4 96mm, V5 135mm, V6 Slim 135mm Submersible Pump

  • Hold motor in vertical position and remove both A & B water fillig plugs
  • Fill water from one of the water filling port A with cold, clean, fresh drinking water.
  • Hold motor carefully & shake it right & left to remove the air inside the motor.
  • Top up the water from one water filling port A till water comes out from other port B.
  • Check the insulation resistance of motor with 500 Volts. Megger should be minimum 100 Mega Ohms.
  • Connect the supply cable to motor cable strictly as per cable joining procedure
  • Remove the cable guard and strainer from the pump.
  • Couple the pump with motor. Check the play by lifting pump shaft with the help of screwdriver, it should be between 0.5-1 mm.
  • Adjust cable slot of suction piece of pump to fit suction sand protection provided on cable to prevent sand from going inside the motor.
  • After pump and motor surfaces are matched properly and perfectly tighten the opposite nuts equally.
  • Cover the cable running on pump by cable guard and suction intel by suction strainer.
  • Connect first delivery pipe to pump outlet (N.R.V.) and lower the pumpset in borewell by means of tripod chain - pulley block and supporting clamps.
  • Connect one by one delivery pipes likewise and lower the pumpset to desired depth. Cable running with delivery pipe should not be kept loose. It should be clipped with delivery pipe at an interval of min. 3 mtr. with cable clips.
  • Hold the last pipe on the borewell casing firmly by means of supporting clamps.
  • Connect bends, good quality of N.R.V. and check value on delivery pipe line.
  • Connect the cable leads to control panel.
  • Ensure that check valve is kept partially opened (1/3 of full open) before switching on the pumpset, to avoid entry of large amount of sand/ mud along with rapid flow of water.
  • Check direction of rotation after installation (for 3 phase pumpsets) Start the pumpset and check discharge. Confirm both the discharge flow and the correct electric connection that gives required discharge flow.
  • In case of single phase pumpsets the direction of rotation will show correct direction of rotation irrespective of the mode of connection of the supply.
  • Check supply voltage/ current is appropriate or not. Run the pumpset till clean and clear water is discharged continously.
  • Don't switch on / off for more than 15 times in an hour with minimum of one minute interval between two sucessive start and stops to avoid motor overheating.
  • Rest delivery pipe approximate min 1 Ft. above the ground level.
  • Use PVC pipe for under grounded supply cable.

CAUTION

  • Pumpset should not be run in dry condition in any case.
  • Before commissioning the pumpset, Meggar value should be checked & it should be 20 Mega Ohms minimum.

Installation & Commissioning of 'Lada' V6 100 mm Submersible Pump

  • Hold motor in vertical direction
  • Fill motor with fresh drinking water
  • Ensure that there is no water leakage from drain plug.
  • Hold motor carefully and shake it right and left to remove air inside the motor
  • Again fill the water
  • Check the insulation resistance of motor with 500 volts. Megger should be minimum 100 mega ohms.
  • Remove the cable guard and strainer from the pump
  • Clean the pump and motor coupling face. Couple the pump with motor by matching coupling slot. Match the stud hole and cable hole of motor and pump. Set the pump till it fits in the motor adaptor.
  • Check the play by lifting the pump shaft with the help of screw driver, it should be between 0.5mm to 1mm
  • Take out the cable from cable slot and fit the strainer.
  • Join the cables as per instruction in cable jointing.
  • Fit the cable guard carefully.
  • Connect first delivery pipe to pump outlet(NRV) and lower the pumpset in borewell by means of tripod stand, chain pully block and supporting clamps.
  • Connect one by one delivery pipes and lower the pump to desired depth. Cable running with delivery pipe should not be kept loose. It should be dipped with delivery pipe at an interval of minimum 3 Metres with cable clips.
  • Fit the bore cap on bore casing
  • Hold the last pipe on the borewell casing firmly by means of supporting Clamping.
  • Connect bends, gate valve and good quality NRV.
  • Connect the cable leads to control panel.
  • Control panel must have thermal relay of proper current setting range, single phasing preventer and facility to connect the water level guard.
  • Keep the gate valve slightly open to avoid the entry of mud and soil while starting pumpset.
  • Check the direction of rotation.
  • Check the supply voltage and current is appropriate or not. Run the pumpset till clean and clear water is discharged continuously.
  • Don’t switch ON/OFF for more than 15 times in an hour with minimum of one minute interval between two successive start and stops to avoid motor overheating.
  • Use PVC pipe for under grounded supply cable.
  • Rest delivery pipe approximate minimum 1 feet above the ground level.

CAUTION

  • Pumpset should not be run in dry condition in any case.
  • Before commissioning the pumpset, Meggar value should be checked & it should be 20 Mega Ohms minimum.

Periodic Inspection Chart

Name and Address of customer        Date of installation:

__________________________________________

__________________________________________

__________________________________________

__________________________________________


Average daily running time....................... Hours.


Sr. No Date of Inspection Shut off Pressure Insulation Resistance Meggar At Shut off On Full discharge
V 1 V 1
               
               
               
               
               
               

BREAKDOWN MAINTENANCE:

Laxmi Pumps Pvt. Ltd. can supply you all spares of your pump at reasonable price to carry out repairs at your local mechanics.However we insist that repairs to the pumps should be carried out by our authorised services stations or mechanics to save you from possible damage to your pump.


Please quote the type and serial number of pump while ordering spares of pumps. For the name of spare please refer cut section assembly.

WE ASSURE TO SERVE YOU BETTER

It is better to carry out periodic checks to determine the health of Submersible Pump and possibble troubles. This can be done in the following ways.

  • Install a Pressure guage (make provision while installation). Completely close the outlet of the pump by using a throttle valve. Record the pressure guage reading periodically. Any drop in pressure more than 15% of original value can suggest a problem in the pump. (Ref. Trouble shooting chart)
  • Periodic inspection should be carried out to determine the insulation resistance of winding.

Check the insulation resistance of winding coils and cable. Join all the leads, twist them together, connect them to the line lead from meggar and connect another lead from the meggar to a clean surface of delivery pipe on meggar dial. The rotation of meggar handle should be enough to produce 500 volts D.C. The reading on meggar dial should never be less than 5 Megaohms. Reading of 2 Megaohms indicates that insulation has become weaker and (0) zero reading indicates shorting of windings/ cables or joints to the earth.

In case of weaker insulation or Zero insulation, cut the cable at lead joint and again check the insulation of winding. If it is OK, then there is no fault in winding coils, the motor is to be sent to the works for repairs.

Do's

  • Ensure that the pump portion is kept resting on the N.R.V. and not on the coupling
  • Ensure that for prolonged storage, the motor is filled with cold dnnking water (NOT DISTILLED WATER)
  • Run the pump at least 1/2 an hour every week if the pump remains under shut down for a longer penod, to resume instant service at any time
  • Do suspend the pumpset 3-4 Mtr above the bottom in borewells.
  • Ensure that the pump is installed at least 1 Mtr below the lowest level of water.
  • Ensure proper coupling by lifting the shaft assembly with screw driver which should lift by 0.5 to 1.0 mm approx.
  • Run the motor for minimum 30 min after commissioning until clear water starts flowing
  • It is necessary to operate a submersible pumpset against a throttle discharge valve. Tho mm. rate of flow should be at least 25% of the rate of flow at an optimum efficiency point on the chart to avoid overheating of the pumpset
  • Use Overload Protection Relay
  • Ensure to fit water level guard for low yield borewells.
  • Use the 500 volt D.C meggar only.

Don'ts

  • Don't switch on/off for more than 15 times in an hour with minimum ol 1 min. interval between two successive start and stops to avoid damage to the motor.
  • Don't use the pump if the water is sandy or acidic.
  • Don't run the pump if any defect is observed.
  • Don't run the pumpset in dry condition
  • Don't run the pumpset against the closed discharge valve for more than 5 minutes to avoid over heating of the motor.
  • Don't use new pumpset for developing or surging well or to free it from sand when the bore is a new one.
  • Don't switch on the pumpset under any circumstances before filling the motor with drinking water.
  • Don't start the pump without fitting sluice valve and water level guard.
  • Don't operate the three phase pump in case of single phasing.
  • Don't Lift the Motor with the help of its Cable.
  • Don't bend the cable sharply
  • Don't use extra washer in motor and pump coupling for extra play.
Pump Does Not Start
Sr. No. Cause Suggested Remedy
1. Starting panel defective. Replace it by new starter and check for Continuity. Set relay properly
2. Overload protection out. Replace it with correct rating
3. Fuse blown off. Use adequate size cable.
4. Low line voltage Wait until the voltage recovers or contact electricity board people.

Fuse Blow Off Or Circuit Breaker Trips When Motor Is Started
Sr. No. Cause Suggested Remedy
1.
  • Defective control panel.
  • Defective wiring.
  • Incorrect fuse component.
Repair/ Replace as per instruction
2. Defective relay. Replace and reset the starter only for checking the current drawn. Make sure that abnormal current is not drawn.
3. Damaged motor winding or cable. Rewind motor / Replace cable.
4. Pump locked due to sand. Remove, dismantle and clean water passages inside the pump and reassemble.
5. Pumpset might have blocked in crossed well. Move the unit and put straight and then start. Otherwise shaft would have bend.
6. Pump and motor not coupled properly. Check and realign coupling and see the freeness.

Pump Does Not Deliver Any Water
Sr. No. Cause Suggested Remedy
1. Water level in borewell may have gone below level of pump. If possible lower the unit further.
Stop the unit until water level rises sufficiently.
Operate the pumpset with throttle valve.
2. Total head of the system is higher than designed head of pumpset Replace it with suitable pumpset for higher head.
Ensure that flow is not obstructed due to foreign bodies in valve or inferior quality of valve.
3. NRV sand blocked / wrongly connected NRV on delivery pipe Check the flow direction arrow on the NRV body and connect correctly.
Check for sand blockage. Clean and Replace.
4. Motor does not start. Check cable connection.
Check for correctness of incoming power supply.
Check for backup protection.
5. Motor starts but doesn't pickup the rated speed. Check voltage / frequency.
Replace cable with higher size if necessary.

Pump Operates But Delivers Less Water
Sr. No. Cause Suggested Remedy
1. Motor running lower than the rated speed. Check voltage/ frequency. Replace cable with higher size if necessary.
2. Strainer / Impeller / Stage Casing may be clogged. Dismantle the pump and clean strainer and water passage of impeller and stage casing if necessary Replace them.
3. Defective rising main delivery pipe (leakage) Check the piping joints for leakage / chock.
4. System, resistance of the pumpset is higher than estimated Replace pipes with higher size.
Replace the pumpset with higher capacity.
5. Yield of the bore is not sufficient. Lower the unit further if possible or throttle the sluice valve adjusting to suitable flow rate.
6. Damaged pump parts. Replace correct components e.g. Impeller / Diffuser / Bushes / Sleeves, Neckring etc.
Check slit / sand content of . water to avoid premature wear.

Fuse Blows When Motor Is Running
Sr. No. Cause Suggested Remedy
1. Incorrect voltage or inadequate power supply. Stabilise the voltage to rated & wait for adquate power supply.
2. Overheated Overload Protection box. Overload relay to be replaced or adjusted to a higher value.
Replace starter if trips repeatitively.
3. Defective control panel components. Defective electrical components to be replaced.
4. Damaged motor cable or winding. Check continuity in cable and wiring. Replace the cable. Rewind the motor if required.
5. Pump becomes sand locked Remove, dismantle and clean water passages inside the pump.

Pumpset Consumes Excessive Power
Sr. No. Cause Suggested Remedy
1. Motor may be running at a speed higher than rated. Check supply voltage and frequency.
2. Pumpset runs outside recommended range. Ensure that pumpset is operated nearer to best efficiency point.
3. Thurst plate of motor worn out. Replace / Relap it.

Excessive Noise And Vibration In System
Sr. No. Cause Suggested Remedy
1. Execessive air or gas insertion in the water pumped. Lower the unit further down in the borwell increasing the submergence.
2. Chances of water hammer in piping system especially in case of long piping. Install a suitable NRV to minimise the effect of water hammer on piping system. Ensure firm support to piping along the length and specially at the bends.
3. Improper piping system. Consult piping expert.
4. Worn out / defective bearing in motor. Replace the bearing bush.
Cable Selection Chart for 100 mm. 220 V olts, 1Ø Submersible Pump Sets
Sr. No. H.P. Max Current
in Amps.
Cable Sizes
in Sq.m.m.
1.5 2.5 4.0 6.0 10.0
1 0.35  3.50 Total
Cable
length*
in
Metre
105 180 300 450 800
2 0.50  4.50 90 140 230 350 625
3 0.70 6.00 60 105 175 260 460
4 0.85 6.50 55 95 160 240 430
5 1.00 7.00 50 90 150 225 400
6 1.258.00 45 80 135 200 250
7 1.50 9.00 40 60 105 155 275
8 2.00 12.00 30 55 85 130 230
9 2.50  14.00 26 45 75 110 200
10 3.00  18.50 26 45 75 no 200

Cable Selection Chart for 100 mm.415 Volts, 3Ø Submersible Pump Sets.
Sr.No. H.P.Max Current
in Amps.
Cable Sizes
inSq.m.m.
1.5 2.5 4.0 6.0 10.0
1 0.50 2.00 Total
Cable
length*
in
Metre
375 625 1000 - -
2 0.70 2.50 300 500 800 - -
3 0.85 2.75 275 450 725 1090 -
4 1.00 3.00 250 415 670 1000 -
5 1.25 3.50 215 355 575 880 1500
6 1.50 4.00 185 310 500 750 1310
7 2.00 4.50 165 275 440 660 1155
8 3.00 6.00 125 200 330 500 870
9 4.00 8.00 92 155 250 375 650
10 5.00 10.00 75 125 200 300 225

Cable Selection Chart for 150 mm. Submersible Pumpsets.
Sr. No. H.P. Max Current
in Amps. IS  9283/1995  
Cable Sizes
in Sq. m. m.
1.5 2.5 4.0 6.0 10.0
1 2.0 4.5 Total
Cable
length*
in
Metre
105 180 300 450 800
2 3.0 6.5 90 140 230 350 625
3 4.0 8.5 60 105 175 260 460
4 5.0 10.0 55 95 160 240 430
5 6.0 12.0 50 90 150 225 400
6 7.5 14.5 45 80 135 200 250
7 7.5 14.5 40 60 105 155 275
8 10.0 19.5 30 55 85 130 230
9 12.5 25.0 26 45 75 110 200
10 15.0 29.0 26 45 75 110 200
11 20.0 36.0 30 60 90 120 200
12 25.0 42.0 30 60 90 120 200

* Length of cable is Measured from Pole to Motor


Capacitor Rating Chart for Single Phase Motor.
Sr. No. H.P. Starting Capacitor
In MFD  
Running Capacitor
In MFD
1 0.35 120/150 25
2 0.50 120/150 25
3 0.70 120/150 36
4 0.85 120/150 36
5 1.00 120/150 36
6 1.25 150/200 36+25
7 1.50 150/200 36+25
8 2.00 200/250 36+36
9 2.50 200/250 36+36
10 3.00 250/300 50+50