ÁLrkouk INTRODUCTION lkekU; fooj.

k GENERAL DESCRIPTION
These pumps are used on Indian iEi ,oa eksVj Motor and Pump
Railways coaching stock for lifting
Motor body, pump casing, rear cover and front
water from under frame mounted main
end bracket are molded out of high quality cast
tank to auxiliary tank located at the
iron. Pump casing is hydrostatic pressure tested
ceiling of the coaches to supply water in at 1.5 times the maximum discharge pressure.
toilets & wash basins. The stator is constructed with electrical grade
These are horizontal centrifugal self silicon steel laminated stampings. The rotor is
priming mono set pumps which are made of high conductivity aluminium by
driven by 3- phase, 50 Hz. 415 V ac pressure die casting.
supply.
iEi 'kk¶
kk¶V Pump Shaft
rduhdh vk¡dM+
dM+s TECHNICAL DATA The shaft for rotating rotor is dynamically
(Ref: Amendment no. 1 to RDSO/PE/SPEC/AC/0022-(Rev.0)-2002 dated 13.01.2004) balanced, (with impeller) to minimize vibration at
eksVj Motor the highest allowed speed and to ensure smooth
Type Squirrel cage induction motor TEFC running and increased life of the bearings. It is
Rated Output 0.5 HP/0.37 kW made of stainless steel of AISI 410 Grade or as per
IS: 6603.
Rated Voltage 415 V ± 6 %, 3 Phase AC
Rated Frequency 50 Hz ± 3 %.
Load Current 1.1 Amps bEisyj Impeller
Speed 2800 RPM Impeller is the rotary element of the pump and is
Insulation Class F secured on a shaft mounted on suitable bearings. It
Winding Connection Y (Star) is made of brass and properly balanced.
Duty Continuous (S1 duty a per IS: 325)
The entry of water from pump to motor is
Type of mounting Foot mounted
jcj lhy Rubber Seal prevented by providing high quality Nitrile
iEi Pump rubber seal.
Type Self Priming, Centrifugal Only sealed low function RZ type bearing of SKF/
Total Head 8 Mtrs fc;fjax Bearing FAG makes are used The minimum life of bearing
Suction Head 3 mtrs. is 1,00,000 Hrs.
Discharge Head 5 mtrs vfFkZax Earthing
Discharge in LPH 2520 (0.7 liters/second) Motor casing is provided with two
Suction Flange Size 1” BSP (25 mm) independent earthing terminals which are
Delivery Flange Size 1” BSP (25 mm) connected to the coach body.
1 2

ikuh VSad Water Tank
Four cylindrical water tanks are fitted under
frame of the coach body which are inter
connected to each other with a pipe.
ukWu fjVuZokYo Non Return Valve (NRV)
Non return valve is provided on each pump at out
let pipe to avoid back flow of water while pump
is not working
buysV ,oa vksoj ¶yksj okYo
In let & Over flow pipe
Inlet pipe is connected to the
top of the tank & an over flow
pipe is also provided to allow
the flow of extra water from
main tank while refilling.
Áos’k vkoj.k Ingress Protection
The entire motor portion have ingress protection IP 55 as per IS 4691.
iEi fu;a=d
=d Pump Controller
Pump controller is provided in AC coach
power panel. It has a selector switch to
operate the pump either in auto or manual
mode. Pump 1 or 2 may be selected in manual
mode. In auto mode pump change over takes
place automatically after 4-6 hrs. It also
displays running time of pump-motor and
LED displays are provided for working
status/faulty condition for individual pump.
fØ;k WORKING
Water is pumped in the coach from under slung water tanks through Mono-
block pump. Either pump works continuously and water is pumped in
auxiliary tanks mounted over the each toilets. The extra water overflows
from auxiliary tanks to the main tank through a recycle pipe.

VehZuy ckDl ,oa mlds dusD’ku Terminal Box & Connections lapkyu funsZ’k OPERATIONAL INSTRUCTIONS
The terminal connection for supply are brought out in The following points shall be checked:
a terminal box on the motor and clearly marked RYB i. Ensure that the main tanks are filled with water.
(embossed) on the terminal plate to obtain correct
ii. Ensure that pump selector switch of pump controller is on ‘Auto’
direction of rotation. The terminal plate is made of
mode.
epoxy reinforced glass fiber material conforming to
BS-3815 and it is also anti- moisture absorbent and iii. Ensure that the outlet valve of main tank to pump is in open
free from porosity. condition.
iv. Ensure that motor rotates in the correct direction as
Cable entry to the terminal box is made in the bottom at right angle along with painted/embossed.
the suitable size of cable gland. Silver brazed joints/ fused for connecting v. Ensure that the pump set runs quickly and smoothly.
terminals leads and wires are used. Soldered joints are not acceptable. The
terminal box cover and lid is made of die-cast aluminium.. vii. Check the availability of the water in toilets and wash basins.

3 4
[kksyuk ,oa iqu% yxkus dh fØ;k fof/k S PROBLEM CAUSE REMEDIAL ACTION
DISMANTLING AND RE-
RE-ASSEMBLY PROCEDURE N

Isolate supply connections and dismantle the pump from the Impeller stuck due Rotate the shaft by hand/with the
pipe lines and foundation. to keeping idle for help of screwdriver to ensure free
a longer time. rotation.

Remove the bolts, which are holding the casing to remove
casing from the assembly and slide out the impeller. Motor winding Check winding for open
defective circuit etc.

Remove the screw on end cowl then remove fan, remove bolts
2 Pump does not Priming not Fill water till it flows
on end cover and pull out the end cover. The shaft with stuffing lift water sufficient continuously without air lock
box can be taken out from the frame. Air leak in suction Use proper sealing to arrest leak

All parts are to be checked and replace if damaged and worn pipe or use teflon tape at joints.
out. Blocked suction Clean the suction pipe
pipe

Check bearing condition and replace if necessary.
Leaking seal Replace the seal

Replace rubber seals and gaskets before re-assembly.
Air cock side Tighten the air cock, renew if

While re-assembly, follow the reverse procedure of dis- leaking required.
assembly, if the impeller is tight, tap the shaft at the non-driving Mono block pump By changing any one phase of
end. running in the electrical connection the
opposite direction direction can be changed.

Shaft rotates freely after assembly.
3 Leaking Running face is Lap the running face or replace

Ensure that the non return valve (NRV) is kept at right position mechanical seal damaged it.
while installation.
4 Insufficient Strainer clogged. Clean the strainer.
leL;k] dkj.k ,oa muds mik; discharge/
Capacity decrease Wrong direction Interchange any two phase to
PROBLEMS, CUASES & THEIR REMEDIES of rotation. correct the direction.
6 Pump set draws Defective bearing Replace defective bearing.
SN PROBLEM CAUSES REMEDIAL ACTION more current
impure water Ensure clean water
1 Motor does No power Ensure 3 phase power supply
7 Pump set making Wrong direction Interchange any two phase to
not supply at different locations. noise of rotation. correct the direction.
rotate/fails Defective Replace defective bearings.
Over heating Remove fan cover and check
to start bearings
for free rotation of motor
shaft along with fan and 8 Motor starts with Pump jammed Switch off the supply and rotate
allow the motor to cool & a humming the shaft with the help of screw
sound, does not driver/by hand.
switch on. rotate and then
trip
5 6
js[kk fp= SCHEMATIC DIAGRAM ¼dsoy dk;kZy;hu mi;ksx gsrq½
(For Official Use Only)

Hkkjr ljdkj GOVERNMENT OF INDIA

jsy ea=ky;
ky; MINISTRY OF RAILWAYS

vkj ,e ih ;w okrkuwdwfyr fMCcksa esa

ikuh p<+kus
kus okys eksuks lsV iEi
vuqj{k.k xfrfof/k;k¡ MAINTENANCE ACTIVITIES

Sr. Activities TI M HY IOH POH

ij iEQysV
(D1) (D2) (D3) (SS-1) (SS-2)
PAMPHLET ON
1. Check functioning of water     
pumping arrangement in auto WATER RAISING MONO SET PUMP FOR
mode/ manual mode through
pump controller. RMPU AC COACHES
2. Visually check the mounting     
arrangement for any abnormality.
CAMTECH/E/2013-
CAMTECH/E/2013-14/WRA/1.0
3. Check running of pump-motor --     April 2013
for any abnormal sound, water
leakage from pipe lines, joints
etc.
4. Check cable connections on -- --   
terminal box for tightness and for
sign of overheating etc.
5. Check rubber seal/ gasket for any -- --   
damages/ water leakage.

fMLDysej Disclaimer:
;g Li"V fd;k tkrk gS fd ;g iSEQsysV vkjMh,lvks] jsyos cksMZ ;k ewy midj.k
fuekZrk }kjk fofuZfn"V fdlh Hkh fo/kku dks foLFkkfir ugha djrh A ;g iSEQsysV dsoy
ekxZn’kZu gsrq gS ,oa ;g ,d LVsP;wVjh MkWD;wesaV ugha gSA
It is clarified that this pamphlet does not supersede any existing provisions laid
down by RDSO, Railway Board or Zonal Railways. The pamphlet is for guidance only
and it is not a statutory document.
If you have any suggestion or comment, please write to:
Director (Electrical), CAMTECH, Maharajpur,Gwalior (M.P.) – 474 005 egkjktiqj, Xokfy;j & 474 005
Ph.0751-2470740, Fax 0751-2470841 7 Maharajpur, GWALIOR - 474 005
Email : direlcamtech@gmail.com