sqflex_SI_US_WG.book Page 1 Thursday, October 1, 2009 3:27 PM GRUNDFOS SERVICE INSTRUCTIONS SQFlex pumping system The SQFlex is a reliable water supply system especially suitable for remote locations not connected to the electricity supply grid. The SQFlex system is equipped with the SQFlex submersible pump. The SQFlex system is powered by renewable energy sources.
sqflex_SI_US_WG.book Page 2 Thursday, October 1, 2009 3:27 PM Mission - to successfully develop, produce, and sell high quality pumps and pumping systems worldwide, contributing to a better quality of life and healthier environment.
sqflex_SI_US_WG.book Page 4 Thursday, October 1, 2009 3:27 PM Service instructions SQFlex water supply systems Table of contents 1. SQFlex components ........................................................................................................................ 4 1.1 Pumps................................................................................................................................................ 4 1.2 Motor...................................................................
sqflex_SI_US_WG.book Page 4 Thursday, October 1, 2009 3:27 PM 1. SQFlex components 1.1 Pumps Two pump types are used, the helical rotor pump type and the centrifugal pump type. Nameplate, helical rotor pump The nameplate is engraved into the pump sleeve. 1 2 TM02 6973 2103 3 4 Fig. 1 Nameplate, helical rotor pump Key to nameplate, helical rotor pump Pos. 1 Code Description PROD. NO.
sqflex_SI_US_WG.book Page 5 Thursday, October 1, 2009 3:27 PM Nameplate, centrifugal pump The nameplate is attached to the suction interconnector. TM02 6974 984457 60 SQF 3 Fig. 2 Nameplate, centrifugal pump Key to nameplate, centrifugal pump Pos. Code Description 1 Type 60 SQF -3 Type designation, see section Type key on page 6 2 MODEL A Pump generation 3 96078070 Product number 4 Q m³ Rated flow rate (not indicated) 5 Weight 4.
sqflex_SI_US_WG.book Page 6 Thursday, October 1, 2009 3:27 PM Type key The type key is common for helical rotor pump and centrifugal pump. X Rated flow rate in US GPM at 3000 min-1 SQF - X (approximate value) • 3 = helical rotor pump • 6 = helical rotor pump • 11 = helical rotor pump • 25 = centrifugal pump • 40 = centrifugal pump • 60 = centrifugal pump Type range Number of stages Centrifugal pumps come in two main types: with splined pump shaft and with cylindrical pump shaft.
sqflex_SI_US_WG.book Page 7 Thursday, October 1, 2009 3:27 PM 1.2 Motor The MSF 3 motor is a sealed construction made of stainless steel. It is a brushles, electronically commutated DC-motor with a permanent-magnet rotor. Nameplate, motor The nameplate is engraved into the stator sleeve. MSF 3 TM02 2452 0202 500-3600 Fig. 3. Nameplate, motor Key to nameplate, motor Pos. 1 2 Code MSF 3 Type designation PROD. NO.
sqflex_SI_US_WG.book Page 8 Thursday, October 1, 2009 3:27 PM 1.3 Control and switch boxes 1.3.1 CU 200 SQFlex control unit The CU 200 SQFlex control unit offers: • system monitoring on the basis of sensor signals • system control on the basis of sensor signals • monitoring of pump operation and alarm indication. Technical data • 30-300 VDC, PE. • 1 x 90-240 V –10%/+6%, 50/60 Hz, PE. Maximum load: 100 mA.
sqflex_SI_US_WG.book Page 9 Thursday, October 1, 2009 3:27 PM CU 200 SQFlex display and indicator lights The front cover of CU 200 features a button and various indications: ON/OFF button Full water reservoir Pump operation A running green light indicates that the pump is operating at more than 500 rpm. The yellow light indicates that the water reservoir is full. • Green light on: The system has been switched on. • Red light on: The system has been switched off.
sqflex_SI_US_WG.book Page 10 Thursday, October 1, 2009 3:27 PM Trouble-shooting by means of CU 200 Indication/Fault 1. No light in front cover. Pump does not deliver water. Possible cause Remedy No voltage supply. • Reestablish the voltage supply. Position of ribbon cable connector is wrong or cable is defective. CU 200 is defective. • Correct the position of the cable or replace it. 2. No light in front • Replace the CU 200. cover, and pump does not deliver water.
sqflex_SI_US_WG.book Page 11 Thursday, October 1, 2009 3:27 PM Indication/Fault Possible cause 8. CU 200 indicates ‘F4 = overload’. Too low input voltage. Remedy • Increase the supply voltage, to 30 VDC or higher. • Repair or replace the pump. Pump is defective. • Clean the liquid and replace the pump. Only helical rotor pumps. Pumped liquid is contaminated with oil or similar substance. Motor liquid low / Missing. • Check or refill motor liquid. 9. Green indicator light Insufficient power supply.
sqflex_SI_US_WG.book Page 12 Thursday, October 1, 2009 3:27 PM 1.3.2 IO 50 SQFlex switch box The IO 50 enables manual starting and stopping of the pump in a solar-powered SQFlex system. In addition, the IO 50 functions as a connection point for all necessary cables. Internal (and external) wiring of IO 50 SQFlex switch box Technical data: DC: Max. 225 V, PE. AC: Max. 265 V, 50/60 Hz, PE.
sqflex_SI_US_WG.book Page 13 Thursday, October 1, 2009 3:27 PM 1.3.3 IO 101 SQFlex switch box The IO 101 SQFlex switch box makes it possible to • switch off the voltage supply to the pump and • connect a back-up generator. A back-up generator is useful in periods of insufficient solar energy or in case of an immediate requirement for water supply or a need for water at night. Internal (and external) wiring of IO 101 SQFlex switch box Technical data: • DC: Max. 225 V, PE. • AC: Max. 265 V, 50/60 Hz, PE.
sqflex_SI_US_WG.book Page 14 Thursday, October 1, 2009 3:27 PM 1.3.4 IO 102 SQFlex breaker box The IO 102 is applicable in SQFlex systems powered exclusively by a wind turbine The IO 102 SQFlex breaker box makes it possible to • switch off the voltage supply to the pump, and • Stop the wind turbine blades • connect solar modules as well as a wind turbine. The IO 102 is applicable in SQFlex systems provided the system voltages mentioned below are not exceeded. Technical data: • DC: Max.
sqflex_SI_US_WG.book Page 15 Thursday, October 1, 2009 3:27 PM 1.4 Solar modules Positioning Solar modules located in the northern hemisphere should face south. Use a compass to position the modules as precisely as possible. Due to the magnetic declination it may be necessary to turn the modules some degrees away from the direction of the compass. In case of positive declination, turn the modules some degrees to the west, in case of negative declination, turn the modules some degrees to the east. See Fig.
sqflex_SI_US_WG.book Page 16 Thursday, October 1, 2009 3:27 PM 1.4.1 GF 80 solar modules The GF 80 solar modules are equipped with plugs and sockets for easy connection of several modules in parallel or series. The solar modules must be mounted on a support structure, tilted at an angle ensuring optimum utilization of the solar energy. This module is UL, Tüv, CE and IEC 61215 approved. TM04 5085 2609 GF 80 Peak power (PMax) 80 W Voltage (Vmp) 33.3 V Current (Imp) 2.
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sqflex_SI_US_WG.book Page 18 Thursday, October 1, 2009 3:27 PM 1.5 Wind turbine VAC 160 Breaker Box IO 102 mV mA A A V V OFF A mA A COM V VDC 220 160 mV V V mA A A OFF A mA A COM V mV V V mA A A OFF A mA A COM V 160 mV V V mA A A OFF TM04 5087 2609 A mA A COM V Wind turbine voltage [VAC] Measurement of VAC and VDC IO 102 voltage [VDC] m/s mph m/s mph Values measured between the three phases must be identical.
sqflex_SI_US_WG.book Page 19 Thursday, October 1, 2009 3:27 PM 1.5.1 Trouble-shooting 1. Find out if the problem is mechanical or electrical. • Propeller cannot turn = Mechanical problem, see Mechanical problems on page 20. • Propeller turns slowly = Electrical problem, see Electrical problems on page 21. Electrical problems may be in the wind turbine or the IO 102 breaker box. Determine which as follows: 2. Disconnect the three wires from the wind turbine one at a time at the IO 102 breaker box.
sqflex_SI_US_WG.book Page 20 Thursday, October 1, 2009 3:27 PM Mechanical problems Fault 1. Propeller is stationary, even in high winds. 2. a) Propeller will not turn at all except in high wind b) Scraping or rubbing sound at low rpm c) Propeller always stops in the same position. Cause Remedy • Ice in wind turbine, or uneven ice on propeller. • Remove ice, or wait for warm weather. • Debris between rotor and stator. • Turn propeller gently by hand and blow or use piece of paper to dislodge debris.
sqflex_SI_US_WG.book Page 21 Thursday, October 1, 2009 3:27 PM Electrical problems Note: Always be aware of the danger of high voltage. Do not directly touch the wires. Fault 1. Pump does not operate and propeller do not turn or turns slowly even in high winds. Possible cause Remedy • The wind speed is too slow. • Wait for the wind speed to increase. • The IO 102 ON/OFF switch is set to OFF. • Set the IO 102 ON/OFF switch to ON.
sqflex_SI_US_WG.book Page 22 Thursday, October 1, 2009 3:27 PM 2. Start-up The starting sequence has three steps: 1. Charging the capacitor 2. positioning of the rotor 3. start. Consequently, during start-up the motor will make small rotations in order to bring the rotor into the correct starting position. These rotations also ensure that there is water in the pump and that the pump parts are lubricated.
sqflex_SI_US_WG.book Page 23 Thursday, October 1, 2009 3:27 PM 3. Maintenance This section describes how to maintain solar modules and wind turbines. Under normal operating conditions the pumps and the controls are maintenance-free. 3.1 Solar modules Routine maintenance Cleaning • The solar modules must be cleaned when they are dirty. Use only clean water without soap and a soft brush or cloth. Make sure there is no sand or other abrasive particles in the water.
sqflex_SI_US_WG.book Page 24 Thursday, October 1, 2009 3:27 PM 3.2 Wind turbine Monthly maintenance Test brake (This checks electrical wiring.) Stop the wind turbine in a moderate wind (charging but not furling). No unusual difficulty or noise should be experienced in stopping the propeller. A noise during braking can indicate a disconnected wire. Check mechanical condition Watch and listen from the tower base. Use binoculars. The propeller and tail must not wobble.
sqflex_SI_US_WG.book Page 25 Thursday, October 1, 2009 3:27 PM 4. Trouble-shooting Visual/general inspection of main components Before starting specific Trouble-shooting, go through these simple visual inspections first. Visual inspection of solar modules • Check that the solar modules are intact. • Make sure that trees, grass, bushes, buildings, etc. do not cast a shadow on the solar modules.
sqflex_SI_US_WG.book Page 26 Thursday, October 1, 2009 3:27 PM Overview of possible system combinations 1. In the table below find the system corresponding to your system. 2. Follow the Trouble-shooting instructions for your system. In systems with solar modules Trouble-shooting must be carried out in the middle of an unclouded day. In systems with wind turbine Trouble-shooting must be carried out at a wind speed of minimum 3.5 m/s (8 mph).
sqflex_SI_US_WG.book Page 27 Thursday, October 1, 2009 3:27 PM 4.1 Solar-powered system Pos. 1. 12 7 6 5 2 Component SQF pump 2. Submersible drop cable 3. Cable clips 4. Straining wire 5. Wire clamps 6. Solar modules 7. Support structure 12. IO 50 SQFlex switch box 3 4 5 TM02 2304 4101 1 Fig. 5. Solar-powered system and its main components IO 50 Fig. 6. Internal (and external) wiring of IO 50 SQFlex switch box.
sqflex_SI_US_WG.book Page 28 Thursday, October 1, 2009 3:27 PM 4.1.1 Trouble-shooting of a solar-powered system 1. Disconnect the pump • Set the IO 50 switch to off. • Disconnect the pump cable from the terminals (6T3, N, 8T4). 2. Check the solar modules • Measure the voltage and short-circuit current across the terminals (2T1, 4T2). See electrical connection in Section 1.4. If the DC voltage or DC current is outside the range, one or more of the solar modules is faulty. Replace the faulty solar module/s.
sqflex_SI_US_WG.book Page 29 Thursday, October 1, 2009 3:27 PM 4.2 Solar-powered system with CU 200 control unit and level switch 14 Pos. 1. 15 11 7 5 6 2 Component SQF pump 2. Submersible drop cable 3. Cable clips 4. Straining wire 5. Wire clamps 6. Solar modules 7. Support structure 11. CU 200 control unit 14. Water reservoir 15. Level switch (optional) 3 4 5 TM02 2305 4101 1 Fig. 7.
sqflex_SI_US_WG.book Page 30 Thursday, October 1, 2009 3:27 PM 4.2.1 Trouble-shooting of a solar-powered system with CU 200 control unit and level switch All measuring points/terminal designations in the following refer to the CU 200 control unit. 1. Check the system by means of the CU 200 If the CU 200 indicates fault, proceed according to section Trouble-shooting by means of CU 200 on page 10. 2. Disconnect the pump • Switch off the pump by pressing the ON/OFF button at the CU 200.
sqflex_SI_US_WG.book Page 31 Thursday, October 1, 2009 3:27 PM 4.3 Solar-powered system with generator back-up 13 10 7 6 5 Pos. Component 1 SQF pump 2 Submersible drop cable 3 Cable clips 4 Straining wire 5 Wire clamps 6 Solar modules 7 Support structure 10 Diesel or petrol powered generator 13 IO 101 switch box 2 3 4 5 TM02 2309 4101 1 Fig. 9. Solar-powered system with IO 101 and generator 4T2 L Solar modules N 2T1 X1.3 X1.4 Generator TM02 4373 0702 IO 101 Fig. 10.
sqflex_SI_US_WG.book Page 32 Thursday, October 1, 2009 3:27 PM 4.3.1 Trouble-shooting of a solar-powered system with generator back-up All measuring points/terminal designations in the following refer to the IO 101 switch box 1. Disconnect the pump • Make sure that the generator has been turned off. • Set the IO 101 switch to Off. • Disconnect the pump cable from the terminals (X1.3, X1.4). 2. Check the solar modules • Measure the DC voltage and short-circuit DC current across the terminals (2T1, 4T2).
sqflex_SI_US_WG.book Page 33 Thursday, October 1, 2009 3:27 PM 4.4 Wind-powered system Pos. 1. 8 9 Component SQF pump 2. Submersible drop cable 3. Cable clips 4. Straining wire 5. Wire clamps 8. Wind turbine 9. IO 102 breaker box 5 2 3 4 5 TM02 2306 4101 1 Fig. 11. The wind-powered system main components. TM02 4374 0702 IO 102 Fig. 12. Internal (and external) wiring of IO 102 SQFlex breaker box If the system does not work properly, follow the instructions in section 4.4.
sqflex_SI_US_WG.book Page 34 Thursday, October 1, 2009 3:27 PM 4.4.1 Trouble-shooting of a wind-powered system All measuring points/terminal designations in the following refer to the IO 102 breaker box. 1. Disconnect the pump • Stop the wind turbine and turn off the pump, by turning the ON/OFF switch to off. • Disconnect the pump cable from the terminals in the IO 102 breaker box. • Release the wind turbine by turning the ON/OFF switch to on. 2.
sqflex_SI_US_WG.book Page 35 Thursday, October 1, 2009 3:27 PM 4.5 Wind-powered system with CU 200 control unit and level switch Pos. 1. 8 14 15 11 9 5 2 Component SQF pump 2. Submersible drop cable 3. Cable clips 4. Straining wire 5. Wire clamps 8. Wind turbine 9. IO 102 breaker box 11. CU 200 control unit 14. Water reservoir 15. Level switch 3 4 5 TM02 2308 4101 1 Fig. 13. Wind-powered system with CU 200 and level switch CU 200 IO 102 J5 Contact closed: Tank full.
sqflex_SI_US_WG.book Page 36 Thursday, October 1, 2009 3:27 PM 4.5.1 Trouble-shooting of a wind-powered system with CU 200 control unit and level switch 1. Check the system by means of the CU 200 If the CU 200 indicates fault, proceed according to section Trouble-shooting by means of CU 200 on page 10. 2. Disconnect the pump • Switch off the pump by pressing the ON/OFF button at the CU 200. The OFF light must be on. • Disconnect the pump cable from the terminal J2. 3.
sqflex_SI_US_WG.book Page 37 Thursday, October 1, 2009 3:27 PM 4.6 Combined system 9 Pos. 1. 6 8 7 5 2 Component SQF pump 2. Submersible drop cable 3. Cable clips 4. Straining wire 5. Wire clamps 6. Solar modules 7. Support structure 8. Wind turbine 9. IO 102 breaker box 3 4 5 TM02 2307 4101 1 Fig. 15. Combined system main components Solar modules TM02 4375 0702 IO 102 Fig. 16.
sqflex_SI_US_WG.book Page 38 Thursday, October 1, 2009 3:27 PM 4.6.1 Trouble-shooting of a combined system All measuring points/terminal designations in the following refer to the IO 102 breaker box. 1. Disconnect the pump • Set the IO 102 switch to off. • Disconnect the pump cable from the terminals. • Disconnect plus or minus from the solar modules. WARNING: Do not touch the wire due to high voltage. Release the wind turbine by setting the IO 102 switch to on. 2.
sqflex_SI_US_WG.book Page 39 Thursday, October 1, 2009 3:27 PM 4.7 Combined system with CU 200 control unit and level switch 8 14 15 6 Pos. Component 1. SQF pump 2. Submersible drop cable 3. Cable clips 4. Straining wire 5. Wire clamps 6. Solar modules 7. Support structure 8. Wind turbine 9. IO 102 breaker box 11. CU 200 control unit 14. Water reservoir 15. Level switch 7 9 11 5 2 3 4 5 TM02 2310 4101 1 Fig. 17.
sqflex_SI_US_WG.book Page 40 Thursday, October 1, 2009 3:27 PM 4.7.1 Trouble-shooting of a combined system with CU 200 control unit and level switch Measuring points/terminal designations in the following refer to the IO 102 breaker box or the CU 200. 1. Disconnect the pump • Set the IO 102 switch to off. • Disconnect plus or minus from the solar modules. WARNING: Do not touch the wire due to high voltage. • Disconnect the pump cable from the terminal J2.
sqflex_SI_US_WG.book Page 41 Thursday, October 1, 2009 3:27 PM 4.8 Options with generator as back-up source Below are wiring diagrams for options with generator as a power supply back-up source. For Trouble-shooting of the individual components see sections 3.1 to 3.7. For application overview see section Overview of possible system combinations on page 26. Solar-powered system with CU 200 control unit and level switch IO 101 CU 200 4T2 X1.3 L N 2T1 J1 X1.
sqflex_SI_US_WG.book Page 42 Thursday, October 1, 2009 3:27 PM Wind-powered system with CU 200 control unit and level switch IO 101 IO 102 CU 200 4T2 X1.3 X1.4 2T1 L N J1 J2 J5 Combined system IO 101 IO 102 4T2 X1.3 X1.4 2T1 L N Combined system with CU 200 control unit and level switch IO 101 IO 102 L N 4T2 2T1 42 / 60 CU 200 X1.3 X1.
sqflex_SI_US_WG.book Page 43 Thursday, October 1, 2009 3:27 PM 5. Service of pump and motor 5.1 General information 30 TM02 5769 3902 37 Helical rotor pumps cannot be separated from the motor as a unit. If the motor or the pump has to be replaced, the pump must be dismantled, see section 5.4 Helical pump type on page 47. Fig. 19. When fixing the motor in a vice, tighten only on the 30 mm wide area starting 37 mm from the upper edge of the motor sleeve.
sqflex_SI_US_WG.book Page 44 Thursday, October 1, 2009 3:27 PM 5.2 Service tools A B C D E F G H I J K L M N O P Q R S T Special tools Designation A Mounting plate B Spline pin with screw C Spacing pipe To be used for Supplementary information Helical pump 25 SQF 40 SQF 75 SQF SV0049 SV0226 ∅ 13 / ∅ 8.5 x 39.5 SV0006a ∅ 13 / ∅ 8.5 x 39.
sqflex_SI_US_WG.book Page 45 Thursday, October 1, 2009 3:27 PM Standard tools Pos. Designation J Hexagon key K Ring/open-end spanner L Nut driver with socket M Pipe wrench N Screwdriver (torx) O Socket for hexagon head screws To be used for D Supplementary information 25 SQF 6 mm 40 SQF 75 SQF SV1204 16-24 10 mm (two pcs. needed for pos.
sqflex_SI_US_WG.book Page 46 Thursday, October 1, 2009 3:27 PM 5.3 Torques and lubricants This section shows the screws and nuts that must be tightened to a certain torque and the lubricants to be used. Pos.
sqflex_SI_US_WG.book Page 47 Thursday, October 1, 2009 3:27 PM 5.4 Helical pump type Helical pumps cannot be separated from the motor as a unit. If the motor or the pump must be replaced, the pump must be dismantled. 5.4.1 Dismantling 1. Fix the motor in a vice. Note: Tighten only on the area shown in fig. 19. 2. Refer to section 5.9.1 Drawings on page 55. Unscrew the screws pos. 18a and 18b and remove them together with the cable guard pos. 18. 3. If the motor is intact, the cable need not to be removed.
sqflex_SI_US_WG.book Page 48 Thursday, October 1, 2009 3:27 PM 5.5 Centrifugal pump and motor 5.5.1 Detaching pump from motor 1. Fix the motor in a vice. Note: Tighten only on the area shown in fig. 19. 2. Unscrew the screws pos. 18a and remove them together with the cable guard pos. 18c. 3. Unscrew the screws pos. 18b and remove them (if any) together with the cable guard pos. 18. 4. If the motor is intact, the cable need not be removed.
sqflex_SI_US_WG.book Page 49 Thursday, October 1, 2009 3:27 PM 5.6 Centrifugal pump type with splined shaft 5.6.1 Dismantling 1. Fit the and tighten the spline pin with screw B on the mounting plate A. Note: Make sure that the mounting plate is positioned correctly so that the recess of the mounting plate and the suction interconnector pos. 14 fit into each other. 2. Place the pump on the mounting plate A. 3. Unscrew and remove the screws pos. 19 together with the washers pos. 71. Remove the strap pos. 17.
sqflex_SI_US_WG.book Page 50 Thursday, October 1, 2009 3:27 PM 5.7 Centrifugal pump type with cylindrical shaft 5.7.1 Dismantling 1. Fit the mounting plate A to the suction interconnector pos. 14 by means of the spacing pipe C and the hexagon socket head screw with washer D. Note: Make sure that the mounting plate is positioned correctly so that the recess of the mounting plate and the projection of the suction interconnector pos. 14 fit into each other. Fix the mounting plate in a vice. 2.
sqflex_SI_US_WG.book Page 51 Thursday, October 1, 2009 3:27 PM 5.8 Checking and replacing wear parts of centrifugal pumps Bearing pos. 8 Check Replace • Check whether the bearings are defective due to sand or dry running. • Remove the bearing pos. 8 by pressing it out of the chamber pos. 9. • Press a new bearing into the chamber from the bottom side with the largest bearing diameter against the bottom side of the chamber. Top bearing pos. 6 Check Replace • Check whether the bearing is defective.
sqflex_SI_US_WG.book Page 52 Thursday, October 1, 2009 3:27 PM 5.9 Testing the pump by means of CU 200 SQFlex control unit The pump must deliver a flow rate (m³/h) at a given power consumption and head. The “Test value curves ‘ on page 61 apply to the head stated for each pump. The curve values are minimum values. SERVICE SERVICE Test jumper NORMAL NORMAL AC MAIN SWITCH W H Q Head Flow TM02 5908 4002 90-240 VAC +6%/-10% 50/60 Hz 1.
sqflex_SI_US_WG.book Page 53 Thursday, October 1, 2009 3:27 PM 5.9.1 Test value curves The curve shown in the curve charts below is the minimum performance curve for the pump. Service test, 6 SQF-2 Service test, 6 SQF-2 H=200 H = 200ftft. 3,00 6 2,50 5 2,00 4 US gal/m US gal/m Service Service test,test, 3 SQF-2 3 SQF-2 H = 200 H=200 ft ft.
sqflex_SI_US_WG.book Page 54 Thursday, October 1, 2009 3:27 PM 5.9.
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sqflex_SI_US_WG.book Page 59 Thursday, October 1, 2009 3:27 PM Being responsible is our foundation Thinking ahead makes it possible Innovation is the essence L-SQ-TL-031 1009 US Repl. Rev. 09/04 © 2004, 2009 Grundfos Pumps Corp. Subject to alterations. GRUNDFOS Pumps Corporation 17100 West 118th Terrace Olathe, Kansas 66061 Phone: +1-913-227-3400 Telefax: +1-913-227-3500 www.grundfos.com GRUNDFOS Canada Inc.
