KSB Amacan P 1200-870, Amacan P series, Amacan P 1500-1060, Amacan P 1600-1060, Amacan P 900-540 Installation & Operating Manual

...

Submersible Pump in Discharge Tube

Amacan P

50 Hz Amacan P 700 - 470 Amacan P 800/900 - 540 Amacan P 1000 - 700 Amacan P 1200 - 870 Amacan P 1500/1600 - 1060

Installation/Operating Manual

Mat. No.: 01137299

Legal information/Copyright

Installation/Operating Manual Amacan P

Original operating manual

All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited or processed for any other purpose, nor otherwise transmitted, published or made available to a third party without the manufacturer's express written consent.

Subject to technical modification without prior notice.

Contents

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Contents

1 General.................................................................................................................................................... 7

1.1 Principles ...........................................................................................................................................................7

1.2 Installation of partly completed machinery....................................................................................................7

1.3 Target group.....................................................................................................................................................7

1.4 Other applicable documents............................................................................................................................7

1.5 Symbols .............................................................................................................................................................7

2 Safety...................................................................................................................................................... 8

2.1 Key to safety symbols/markings.......................................................................................................................8

2.2 General..............................................................................................................................................................8

2.3 Intended use .....................................................................................................................................................9

2.4 Personnel qualification and training...............................................................................................................9

2.5 Consequences and risks caused by non-compliance with this manual .........................................................9

2.6 Safety awareness ..............................................................................................................................................9

2.7 Safety information for the operator/user.......................................................................................................9

2.8 Safety information for maintenance, inspection and installation ..............................................................10

2.9 Unauthorised modes of operation................................................................................................................10

2.10 Explosion protection ......................................................................................................................................10

2.10.1 Repair..................................................................................................................................................11

3 Transport/Temporary Storage/Disposal............................................................................................. 12

3.1 Checking the condition upon delivery..........................................................................................................12

3.2 Transport.........................................................................................................................................................12

3.2.1 Transporting the delivered pump to the place of installation .......................................................12

3.2.2 Placing the pump set in a vertical or horizontal position ...............................................................12

3.2.3 Transporting the pump set................................................................................................................14

3.2.4 Transport lock ....................................................................................................................................15

3.3 Storage/preservation......................................................................................................................................15

3.4 Return to supplier...........................................................................................................................................16

3.5 Disposal ...........................................................................................................................................................17

4 Description of the Pump (Set)............................................................................................................. 18

4.1 General description ........................................................................................................................................18

4.2 Designation.....................................................................................................................................................18

4.3 Name plate......................................................................................................................................................18

4.4 Design details..................................................................................................................................................19

4.5 Installation types ............................................................................................................................................19

4.6 Configuration and function...........................................................................................................................20

4.7 Scope of supply...............................................................................................................................................21

4.8 Dimensions and weights ................................................................................................................................21

5 Installation at Site................................................................................................................................ 22

5.1 Safety regulations...........................................................................................................................................22

5.2 Checks to be carried out prior to installation...............................................................................................22

5.2.1 Checking the structural requirements ..............................................................................................22

5.2.2 Checking the operating data ............................................................................................................22

5.2.3 Checking the lubricant of the mechanical seal ................................................................................22

5.2.4 Checking the direction of rotation ...................................................................................................23

5.3 Lowering the pump set into the discharge tube..........................................................................................25

5.3.1 Information for correct installation..................................................................................................26

5.3.2 Installation without support rope ....................................................................................................26

5.3.3 Installation with a support rope .......................................................................................................27

5.3.4 Installation with a support rope and support spacer ......................................................................30

5.4 Electrical system..............................................................................................................................................35

5.4.1 Information for planning the control system ..................................................................................35

5.4.2 Electrical connection..........................................................................................................................41

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6 Commissioning/Start-up/Shutdown................................................................................................... 43

6.1 Commissioning/Start-up.................................................................................................................................43

6.1.1 Prerequisites for commissioning/start-up .........................................................................................43

6.1.2 Start-up...............................................................................................................................................44

6.2 Operating limits..............................................................................................................................................44

6.2.1 Operation on the power supply mains.............................................................................................44

6.2.2 Frequency of starts.............................................................................................................................45

6.2.3 Operation on a frequency inverter...................................................................................................45

6.2.4 Fluid handled .....................................................................................................................................45

6.3 Shutdown/storage/preservation ....................................................................................................................47

6.3.1 Shutdown ...........................................................................................................................................47

6.3.2 Measures to be taken for shutdown ................................................................................................47

6.4 Returning to service .......................................................................................................................................48

7 Servicing/Maintenance........................................................................................................................ 49

7.1 Safety regulations...........................................................................................................................................49

7.2 Maintenance/inspection.................................................................................................................................51

7.2.1 Inspection work..................................................................................................................................51

7.3 Removing the pump set.................................................................................................................................53

7.3.1 Removing the pump set ....................................................................................................................53

7.3.2 Drainage/cleaning..............................................................................................................................54

7.3.3 Checking the cable bundle................................................................................................................54

7.3.4 Checking the earth conductor ..........................................................................................................55

7.3.5 Checking the mechanical seal for leakage .......................................................................................55

7.4 Lubrication and lubricant change .................................................................................................................56

7.4.1 Lubricating the mechanical seal........................................................................................................56

7.4.2 Lubricating the rolling element bearings.........................................................................................59

7.5 Dismantling the pump set..............................................................................................................................60

7.5.1 General information/Safety regulations...........................................................................................60

7.5.2 Preparing the pump set.....................................................................................................................61

7.5.3 Removing the bellmouth...................................................................................................................61

7.5.4 Removing the impeller ......................................................................................................................62

7.5.5 Removing the mechanical seal..........................................................................................................62

7.5.6 Dismantling the motor section .........................................................................................................64

7.6 Reassembling the pump set...........................................................................................................................66

7.6.1 General information/Safety regulations...........................................................................................66

7.6.2 Installing the replacement cable gland ............................................................................................68

7.6.3 Fitting the motor housing cover .......................................................................................................69

7.6.4 Installing the mechanical seal ...........................................................................................................71

7.6.5 Fitting the impeller............................................................................................................................75

7.6.6 Fitting the bellmouth ........................................................................................................................76

7.6.7 Leak testing........................................................................................................................................77

7.7 Checking the electrical connection and motor.............................................................................................79

7.8 Tightening torques.........................................................................................................................................79

7.9 Spare parts stock.............................................................................................................................................80

7.9.1 Ordering spare parts..........................................................................................................................80

7.9.2 Recommended spare parts stock for 2 years' operation to DIN24296 ..........................................80

8 Trouble-shooting.................................................................................................................................. 82

9 Related Documents.............................................................................................................................. 84

9.1 General assembly drawing.............................................................................................................................84

9.1.1 Special features..................................................................................................................................93

9.2 Cable bundle...................................................................................................................................................94

9.3 Wiring diagrams .............................................................................................................................................96

9.3.1 Wiring diagram for the power cable 700-470…1500-1060.............................................................96

9.3.2 Wiring diagram for the power cable 1600-1060..............................................................................97

9.3.3 Wiring diagrams for the sensors .......................................................................................................98

9.4 Flamepaths on explosion-proof motors......................................................................................................102

9.5 Dimensions....................................................................................................................................................103

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9.6 Wiring diagrams ...........................................................................................................................................107

9.6.1 Installation type BU .........................................................................................................................107

9.6.2 Installation type BG .........................................................................................................................110

9.6.3 Installation type CU .........................................................................................................................112

9.6.4 Installation type CG .........................................................................................................................115

9.6.5 Installation type DU.........................................................................................................................118

9.6.6 Installation type DG.........................................................................................................................121

9.6.7 Dimensions of the flow-straightening vane...................................................................................124

10 EU Declaration of Conformity........................................................................................................... 126

11 Certificate of Decontamination......................................................................................................... 127

Index ................................................................................................................................................... 128

Glossary

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Glossary

Certificate of decontamination

A certificate of decontamination is enclosed by the customer when returning the product to the manufacturer to certify that the product has been properly drained to eliminate any environmental and health hazards arising from components in contact with the fluid handled.

Close-coupled design

Motor directly fitted to the pump via a flange or a drive lantern

ECB (ever clean blade) design

Self-cleaning vane profile

Submersible pump in discharge tube

A submersible motor pump which is completely submerged and suspended in a discharge tube

1 General

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1 General

1.1 Principles

This operating manual is supplied as an integral part of the type series and variants indicated on the front cover.

The manual describes the proper and safe use of this equipment in all phases of operation.

The name plate indicates the type series and size, the main operating data, the order number and the order item number. The order number and order item number clearly identify the pump set and serve as identification for all further business processes.

In the event of damage, immediately contact your nearest KSB Service centre to maintain the right to claim under warranty.

1.2 Installation of partly completed machinery

To install partly completed machinery supplied by KSB refer to the sub-sections under Servicing/Maintenance.

1.3 Target group

This operating manual is aimed at the target group of trained and qualified specialist technical personnel. (ðSection2.4,Page9)

1.4 Other applicable documents

Table1: Overview of other applicable documents

Document Contents

Data sheet Description of the technical data of the pump (set) Hydraulic characteristic curve Characteristic curves showing head, NPSH

required, efficiency and power input

General assembly drawing

Sectional drawing of the pump set

Sub-supplier product literature1)Operating manuals and other product literature

describing accessories and integrated machinery components

Spare parts lists

Description of spare parts

For accessories and/or integrated machinery components observe the relevant manufacturer's product literature.

1.5 Symbols

Table2: Symbols used in this manual

Symbol Description

✓ Conditions which need to be fulfilled before proceeding with the

step-by-step instructions

⊳ Safety instructions

⇨

Result of an action

⇨ Cross-references

Step-by-step instructions

Note Recommendations and important information on how to handle the product

1) If agreed to be included in the scope of supply

2 Safety

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2 Safety

DANGER

All the information contained in this section refers to hazardous situations. In addition to the present general safety information the action-related safety

information given in the other sections must be observed.

2.1 Key to safety symbols/markings

Table3: Definition of safety symbols/markings

Symbol Description

DANGER

DANGER This signal word indicates a high-risk hazard which, if not avoided, will result in death or serious injury.

WARNING

WARNING This signal word indicates a medium-risk hazard which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION This signal word indicates a hazard which, if not avoided, could result in damage to the machine and its functions.

Explosion protection This symbol identifies information about avoiding explosions in potentially explosive atmospheres in accordance with EU Directive 2014/34/EU (ATEX).

General hazard In conjunction with one of the signal words this symbol indicates a hazard which will or could result in death or serious injury.

Electrical hazard In conjunction with one of the signal words this symbol indicates a hazard involving electrical voltage and identifies information about protection against electrical voltage.

Machine damage In conjunction with the signal word CAUTION this symbol indicates a hazard for the machine and its functions.

2.2 General

This operating manual contains general installation, operating and maintenance instructions that must be observed to ensure safe operation of the system and prevent personal injury and damage to property.

The safety information in all sections of this manual must be complied with. The operating manual must be read and understood by the responsible specialist

personnel/operators prior to installation and commissioning. The contents of this operating manual must be available to the specialist personnel

at the site at all times. Information attached directly to the product must always be complied with and kept

in a perfectly legible condition at all times. This applies to, for example:

▪ Arrow indicating the direction of rotation ▪ Markings for connections ▪ Name plate

The operator is responsible for ensuring compliance with all local regulations not taken into account in this operating manual.

2 Safety

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2.3 Intended use

▪ The pump (set) must only be operated in the fields of application and within the

use limits specified in the other applicable documents.

▪ Only operate pumps/pump sets which are in perfect technical condition. ▪ Do not operate the pump (set) in partially assembled condition. ▪ Only use the pump to handle the fluids described in the data sheet or product

literature of the pump model or variant.

▪ Never operate the pump without the fluid to be handled. ▪ Observe the limits for continuous duty specified in the data sheet or product

literature (Q

min

and Q

max

) (to prevent damage such as shaft fracture, bearing

failure, mechanical seal damage, etc).

▪ Observe the minimum flow rate and maximum flow rate indicated in the data

sheet or product literature (to prevent overheating, mechanical seal damage, cavitation damage, bearing damage, etc).

▪ Always operate the pump (set) in the direction of rotation it is intended for.

2.4 Personnel qualification and training

All personnel involved must be fully qualified to transport, install, operate, maintain and inspect the machinery this manual refers to.

The responsibilities, competence and supervision of all personnel involved in transport, installation, operation, maintenance and inspection must be clearly defined by the operator.

Deficits in knowledge must be rectified by means of training and instruction provided by sufficiently trained specialist personnel. If required, the operator can commission the manufacturer/supplier to train the personnel.

Training on the pump (set) must always be supervised by technical specialist personnel.

2.5 Consequences and risks caused by non-compliance with this manual

▪ Non-compliance with these operating instructions will lead to forfeiture of

warranty cover and of any and all rights to claims for damages.

▪ Non-compliance can, for example, have the following consequences:

– Hazards to persons due to electrical, thermal, mechanical and chemical

effects and explosions – Failure of important product functions – Failure of prescribed maintenance and servicing practices – Hazard to the environment due to leakage of hazardous substances

2.6 Safety awareness

In addition to the safety information contained in this manual and the intended use, the following safety regulations shall be complied with:

▪ Accident prevention, health regulations and safety regulations ▪ Explosion protection regulations ▪ Safety regulations for handling hazardous substances ▪ Applicable standards, directives and laws

2.7 Safety information for the operator/user

▪ Fit protective equipment (e.g. contact guards) supplied by the operator for hot,

cold or moving parts, and check that the equipment functions properly.

▪ Do not remove any protective equipment (e.g. contact guards) during operation. ▪ Provide the personnel with protective equipment and make sure it is used.

2 Safety

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▪ Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g.

explosive, toxic, hot) so as to avoid any danger to persons and the environment. Adhere to all relevant laws.

▪ Eliminate all electrical hazards. (In this respect refer to the applicable national

safety regulations and/or regulations issued by the local energy supply companies.)

▪ If shutting down the pump does not increase potential risk, fit an emergency-

stop control device in the immediate vicinity of the pump (set) during pump set installation.

2.8 Safety information for maintenance, inspection and installation

▪ Modifications or alterations of the pump (set) are only permitted with the

manufacturer's prior consent.

▪ Use only original spare parts or parts/components authorised by the

manufacturer. The use of other parts/components can invalidate any liability of the manufacturer for resulting damage.

▪ The operator ensures that maintenance, inspection and installation is performed

by authorised, qualified specialist personnel who are thoroughly familiar with the manual.

▪ Only carry out work on the pump (set) during standstill of the pump. ▪ Only perform work on the pump set when it has been disconnected from the

power supply (de-energised).

▪ The pump (set) must have cooled down to ambient temperature. ▪ Pump pressure must have been released and the pump must have been drained. ▪ When taking the pump set out of service always adhere to the procedure

described in the manual. (ðSection6.3,Page47)

▪ Decontaminate pumps which handle fluids posing a health hazard. ▪ As soon as the work has been completed, re-install and re-activate any safety-

relevant devices and protective devices. Before returning the product to service, observe all instructions on commissioning. (ðSection6.1,Page43)

2.9 Unauthorised modes of operation

Never operate the pump (set) outside the limits stated in the data sheet and in this manual.

The warranty relating to the operating reliability and safety of the supplied pump (set) is only valid if the equipment is used in accordance with its intended use.

2.10 Explosion protection

DANGER

Always observe the information on explosion protection given in this section when operating an explosion-proof pump set.

Sections of the manual marked by the symbol opposite apply to explosion-proof pump sets also when temporarily operated outside of potentially explosive atmospheres. Only pumps/pump sets marked as explosion-proof and identified as such in the data sheet may be used in potentially explosive atmospheres.

Special conditions apply to the operation of an explosion-proof pump set to EUDirective 2014/34/EU (ATEX). Especially adhere to the sections in this manual marked with the symbol opposite. The explosion-proof status of the pump set is only assured if the pump set is used in accordance with its intended use. Never operate the pump set outside the limits stated in the data sheet and on the name plate. Prevent impermissible modes of operation.

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2.10.1 Repair

Special regulations apply to repair work on explosion-proof pumps. Modifications or alterations of the pump set can affect explosion protection and are only permitted after consultation with the manufacturer.

Repair work at the flameproof joints must only be performed in accordance with the manufacturer's instructions. Repair to the values in tables 1 and 2 of EN60079-1 is not permitted.

3 Transport/Temporary Storage/Disposal

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3 Transport/Temporary Storage/Disposal

3.1 Checking the condition upon delivery

1. On transfer of goods, check each packaging unit for damage.

2. In the event of in-transit damage, assess the exact damage, document it and notify KSB or the supplying dealer and the insurer about the damage in writing immediately.

3.2 Transport

DANGER

Improper transport

Danger to life from falling parts! Damage to the pump set!

▷ Use the attachment point provided for attaching the lifting accessory. ▷ Never suspend the pump set by its power cable. ▷ Use the lifting chain/rope included in the scope of supply exclusively for

lowering or lifting the pump set into/out of the pump sump.

▷ Securely attach the lifting chain/rope to the pump and crane. ▷ Use tested, marked and approved lifting accessories only. ▷ Observe the regional transport regulations. ▷ Observe the product literature supplied by the lifting accessory manufacturer. ▷ The load-carrying capacity of the lifting accessory must be higher than the

weight indicated on the name plate of the pump set to be lifted. Take into account any additional system components to be lifted.

3.2.1 Transporting the delivered pump to the place of installation

Fig.1: Transporting the pump set in its original packaging

▪ The pump set is supplied in a horizontal position on a suitable transport support. ▪ Use suitable lifting equipment to transport the pump set in its original packaging

to its place of installation. Observe the marked centres of gravity and/or attachment points on the transport boxes! For the weight refer to the name plate or data sheet. (ðSection4.3,Page18)

3.2.2 Placing the pump set in a vertical or horizontal position

WARNING

Pump set tilting

Risk of squashing hands and feet!

▷ Suspend or support the pump set.

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WARNING

Placing the pump set down on unsecured and uneven surfaces

Personal injury and damage to property!

▷ Always place down the pump set on a solid and level surface with the pump set

in a vertical position and the motor on top.

▷ Only place the pump set on a surface of sufficient load-carrying capacity. ▷ Use appropriate means to secure the pump set against tilting or tipping over. ▷ Refer to the weights given in the data sheet/on the name plate.

WARNING

Incorrect handling of the power cable

Personal injury and damage to property!

▷ Secure the power cables against falling down. ▷ Avoid power cables being laid on surfaces without fastening. ▷ When moving the pump set keep at a safe distance from the power cables.

WARNING

Improper handling when placing the pump set in a vertical/horizontal position

Personal injury and damage to property!

▷ Use one or two pieces of lifting equipment, depending on the pump size. ▷ Use appropriate means to secure the pump set against tilting, tipping over or

rolling off.

▷ Maintain a safe distance during lifting operations (load may swing when being

lifted).

▷ Use additional supports for the transport holder to secure it against tilting.

WARNING

Improper lifting/moving of heavy assemblies or components

Personal injury and damage to property!

▷ Use suitable transport devices, lifting equipment and lifting tackle to move

heavy assemblies or components.

CAUTION

Improper storage

Damage to the power cables!

▷ Support the power cables at the cable entry to prevent permanent

deformation.

▷ Only remove the protective caps from the power cables at the time of

installation.

3 Transport/Temporary Storage/Disposal

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Pulling the pump set upright with one crane

Pulling the pump set upright with two cranes

ü Suitable lifting equipment has been selected (e.g. crane).

1. a) For one piece of lifting equipment: Attach the eyehook to the bail of the pump set. b) For two pieces of lifting equipment: Attach one eyehook to the bail of the pump set. Then suitably loop a rope around the pump set and attach this loop to the second crane hook.

2. Lift the pump set with the lifting equipment. ð Guiding the pump set over the edge of the bellmouth or pump casing is only

permissible on a wooden base!

ð Protect the power cable against kinking!

3. Place the pump set on a level, clean surface and protect it against tilting, tipping over or rolling off.

3.2.3 Transporting the pump set

WARNING

Incorrect positioning/placing down

Personal injury and damage to property!

▷ Position the pump set vertically with the motor on top. ▷ Use appropriate means to secure the pump set against tilting and tipping over. ▷ Refer to the weights given in the data sheet/on the name plate.

WARNING

Incorrect handling of the power cable

Personal injury and damage to property!

▷ Secure the power cables against falling down. ▷ Avoid power cables being laid on surfaces without fastening. ▷ When moving the pump set keep at a safe distance from the power cables.

WARNING

Improper lifting/moving of heavy assemblies or components

Personal injury and damage to property!

▷ Use suitable transport devices, lifting equipment and lifting tackle to move

heavy assemblies or components.

3 Transport/Temporary Storage/Disposal

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WARNING

Improper handling when placing the pump set in a vertical/horizontal position

Personal injury and damage to property!

▷ Use one or two pieces of lifting equipment, depending on the pump size. ▷ Use appropriate means to secure the pump set against tilting, tipping over or

rolling off.

▷ Maintain a safe distance during lifting operations (load may swing when being

lifted).

▷ Use additional supports for the transport holder to secure it against tilting.

Fig.2: Transporting the pump set in a vertical position Use suitable lifting equipment to transport the pump set in the illustrated position.

3.2.4 Transport lock

Pump sets from size Amacan P 1000 - 700 are supplied with a transport lock. Prior to checking the direction of rotation, lowering the pump into the discharge tube and commissioning, remove the transport lock, which is a metal plate between impeller and bellmouth.

3.3 Storage/preservation

If commissioning is to take place some time after delivery, we recommend that the following measures be taken:

Store the pump set as follows:

▪ In its original packaging: in a horizontal position ▪ Without packaging: in a vertical position with the motor on top

WARNING

Pump set tilting

Risk of squashing hands and feet!

▷ Suspend or support the pump set.

3 Transport/Temporary Storage/Disposal

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CAUTION

Improper storage

Damage to the power cables!

▷ Support the power cables at the cable entry to prevent permanent

deformation.

▷ Only remove the protective caps from the power cables at the time of

installation.

CAUTION

Damage during storage due to humidity, dirt or vermin

Corrosion/contamination of the pump (set)!

▷ For outdoor storage cover the pump (set) or the packaged pump (set) and

accessories with waterproof material.

CAUTION

Wet, contaminated or damaged openings and connections

Leakage or damage to the pump!

▷ Clean and cover pump openings and connections as required prior to putting

the pump into storage.

Table4: Ambient conditions for storage

Ambient condition Value

Relative humidity 5% to 85% (non-condensing) Ambient temperature -20°C to +70°C

▪ Store the pump set under dry and vibration-free conditions, if possible in its

original packaging.

1. Rotate the impeller by hand once every three months.

3.4 Return to supplier

1. Drain the pump as per operating instructions. (ðSection7.3.2,Page54)

2. Flush and clean the pump, particularly if it has been used for handling noxious, explosive, hot or other hazardous fluids.

3. If the pump has handled fluids whose residues could lead to corrosion damage in the presence of atmospheric humidity or could ignite upon contact with oxygen also neutralise the pump and blow through with anhydrous inert gas to ensure drying.

4. Always complete and enclose a certificate of decontamination when returning the pump. Indicate any safety measures and decontamination measures taken. (ðSection11,Page127)

NOTE

If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination

3 Transport/Temporary Storage/Disposal

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3.5 Disposal

WARNING

Fluids handled, consumables and supplies which are hot and/or pose a health hazard

Hazard to persons and the environment!

▷ Collect and properly dispose of flushing fluid and any fluid residues. ▷ Wear safety clothing and a protective mask if required. ▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

1. Dismantle the pump (set). Collect greases and other lubricants during dismantling.

2. Separate and sort the pump materials, e.g. by:

- Metals

- Plastics

- Electronic waste

- Greases and other lubricants

3. Dispose of materials in accordance with local regulations or in another controlled manner.

4 Description of the Pump (Set)

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4 Description of the Pump (Set)

4.1 General description

▪ Submersible pump in discharge tube

Pump set for handling river water and stormwater, pre-screened domestic and industrial waste water as well as activated sludge

4.2 Designation

Example: Amacan PA4 800-540 / 120 6UTG1

Table5: Designation key

Code Description

Amacan Type series P Impeller type

P Propeller

A Pressure class

B 4 Number of vanes 800 Nominal diameter of the discharge tube [mm] 540 Nominal impeller diameter [mm] 120 Motor size 6 Number of motor poles UT Motor version

UT Without explosion protection, standard

Explosion protection II 2G Ex db h IIB T3 Gb

G1 Material variant

G1 Grey cast iron, standard material variant

G3 Grey cast iron with Zn anodes, shaft made of 1.4057 stainless steel

4.3 Name plate

TYPE No. Q TEMP. MAX. °C kg

WARNING - DO NOT OPEN WHEN ENERGIZED AVERTISSEMENT - NE PAS OUVRIR SOUS TENSION

MOTOR IP 68 SUBM. MAX. 30 m CLASS H

3 ~ M.-No. V Hz cosφ

A IA/IN

kWP

WARNUNG - NICHT UNTER SPANNUNG ÖFFNEN

min

-1

5 m

1165

2018

970

149/86

4,7

0,87

400/690

123456

1 2 3 4

11 12 13

7 8

15 16

18 19 20

TYPE No. Q TEMP. MAX. °C kg

WARNING - DO NOT OPEN WHEN ENERGIZED AVERTISSEMENT - NE PAS OUVRIR SOUS TENSION

MOTOR IP 68 SUBM. MAX. 30 m CLASS H

3 ~ M.-No. V Hz cosφ

A IA/IN

kWP

WARNUNG - NICHT UNTER SPANNUNG ÖFFNEN

min

-1

II 2G Ex db h IIB T3 Gb

0035 II 2G Ex db IIB T3 Gb

2018

9970918352/001010

4000 m3/h

R22L06-80

Amacan PA4 800-540/806 UTG1

Amacan PA4 800-540/806 XTG1

5 m 1165

970

149/86

4,7

0,87

400/690

123456

9970918352/001010

1600 m3/h

R22L06-80

IBExU08 ATEX 1064X

Johann-Klein-Straße 9

Deutschland

67227 Frankenthal

KSB SE & Co. KGaA

Johann-Klein-Straße 9

Deutschland

67227 Frankenthal

KSB SE & Co. KGaA

Fig.3: Name plate (example) a) Standard pump set b) Explosion-proof pump set

1 Designation 2 KSB order number 3 Flow rate 4 Maximum fluid temperature and ambient

temperature 5 Enclosure 6 Motor type 7 Rated power 8 Rated speed 9 Rated voltage 10 Rated current 11 Head 12 Year of construction 13 Total weight 14 Maximum submergence 15 Thermal class of winding insulation 16 Motor number

4 Description of the Pump (Set)

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17 Power factor at rated operating point 18 Rated frequency 19 Duty cycle 20 Starting current ratio 21 ATEX marking for the submersible motor 22 ATEX marking for the pump set

4.4 Design details

Design

▪ Fully floodable submersible pump in discharge tube (submersible motor pump) ▪ Not self-priming ▪ Close-coupled design ▪ Single-stage ▪ Vertical installation

Drive

▪ Three-phase asynchronous squirrel-cage motor ▪ Type of protection Ex db IIB (motor integrated in explosion-proof pump set) ▪ Enclosure: IP68 to EN60529/IEC529

Shaft seal

▪ Two bi-directional mechanical seals in tandem arrangement, with liquid reservoir ▪ Leakage chamber

Impeller type

▪ Axial propeller in ECB design

Bearings

▪ Grease-lubricated rolling element bearings

4.5 Installation types

Six different types are available for selection2):

Table6: Overview of installation types

BU discharge tube

Overflow design for installation in

open intake chamber

CU discharge tube

Design with underfloor discharge

for installation in open intake

chamber

DU discharge tube

Design with above floor discharge

nozzle for installation in open intake

chamber

2) For information on the various designs (foundation measurements, intake chamber, etc.) refer to the general arrangement drawings.

4 Description of the Pump (Set)

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BG discharge tube

Overflow design for installation in

covered intake chamber with low

suction-side water levels

CG discharge tube

Design with underfloor discharge

for installation in covered intake

chamber with low suction-side

water levels

DG discharge tube

Design with above-floor discharge

nozzle for installation in covered intake

chamber with low suction-side water

levels

4.6 Configuration and function

Fig.4: Amacan with axial propeller

1 Suction nozzle (bellmouth) 2 Impeller 3 Pump bowl 4 Electric motor 5 Shaft 6 Bearing, motor end 7 Bearing bracket 8 Bearing, pump end 9 Bearing housing, pump end 10 Shaft seal

Design The pump is designed with an axial fluid inlet and an axial outlet. The hydraulic

system sits on the extended motor shaft. The shaft runs in common bearings.

Function The fluid enters the pump axially via a suction nozzle (bellmouth) (1) and is

accelerated outward in a rotating flow by the rotating impeller (2). The required energy is transmitted from the electric motor (4) to the impeller (2) via the shaft (5). In the pump bowl (3) the kinetic energy of the fluid is converted into pressure energy

4 Description of the Pump (Set)

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Amacan P

and the rotational movement of the fluid flow is diverted in axial direction. The shaft passage through the casing is sealed towards the fluid with a shaft seal (10). The shaft (5) runs in two rolling element bearings (6 and 8), which are supported by the bearing housing (9) and the bearing bracket (7).

Sealing The pump is sealed by two bi-directional mechanical seals in tandem arrangement.

A lubricant reservoir in-between the seals ensures cooling and lubrication of the mechanical seals.

Monitoring

equipment

The pump sets are equipped with various sensors.

Standard

▪ Temperature monitoring of the motor ▪ Temperature monitoring at the lower bearing ▪ Leakage monitoring of mechanical seals ▪ Leakage sensors in the motor chamber and connection space

Option

▪ Temperature monitoring at the upper bearing

▪ Vibration sensor ▪ Additional winding temperature monitoring with Pt100 resistance thermometer

4.7 Scope of supply

Depending on the model, the following items are included in the scope of supply:

▪ Pump set complete with power cables ▪ O-ring ▪ Back-up name plate

Optional accessories:

▪ Support rope ▪ Accessories for installing the cable guide:

– Fitting – Turnbuckle – Support – Shackle – Cable clamps

▪ Cable support sleeves ▪ Discharge tube ▪ Flow-straightening vane to prevent floor vortices

NOTE

A separate name plate is included in KSB's scope of supply. This name plate must be attached in a clearly visible position outside the place of installation, e.g. at the control panel, pipeline or mounting bracket.

4.8 Dimensions and weights

For dimensions and weights refer to the name plate or data sheet of the pump set.

3) Included in the standard design for size 1600-1060

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5 Installation at Site

5.1 Safety regulations

DANGER

Improper installation in potentially explosive atmospheres

Explosion hazard! Damage to the pump set!

▷ Comply with the applicable local explosion protection regulations. ▷ Observe the information in the data sheet and on the name plates of pump and

motor.

DANGER

Persons in the intake chamber during pump set operation

Electric shock! Risk of injury!

▷ Never start up the pump set when there are persons in the intake chamber.

WARNING

Impermissible solid objects (tools, screws/bolts or similar) in the pump sump/inlet tank during pump start-up

Personal injury and damage to property!

▷ Check the pump sump/inlet tank for impermissible solid objects before

flooding, and remove, if necessary.

5.2 Checks to be carried out prior to installation

5.2.1 Checking the structural requirements

All structural work required must have been prepared in accordance with the dimensions stated in the outline drawing/general arrangement drawing.

5.2.2 Checking the operating data

Before inserting the pump set into the discharge tube, verify the data on the name plate against the data given in the purchase order and the system data.

Back-up name plate KSB’s scope of supply includes a separate name plate attached to the end of the

pump cable which indicates the pump and motor data.

1. Attach this name plate in a clearly visible position outside the discharge tube, e.g. at the control cabinet, pipeline or mounting bracket.

5.2.3 Checking the lubricant of the mechanical seal

The lubricant reservoir is filled at the factory with an environmentally-friendly, nontoxic lubricant.

The pump set is supplied in a horizontal position on a suitable transport support.

Visual inspection for signs

of oil leakage

1. If no oil leakage is visible in the area of pump bowl, impeller or transport support, the lubricant reservoir is filled properly.

2. If oil leakage is visible in the area of pump bowl, impeller or transport support, top up the lubricant.

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903.03

903.01

411.01

Fig.5: Checking the lubricant level

Table7: Key to the symbols and codes

Symbol Description

Always apply a liquid sealant (e.g. Hylomar SQ32M) to sealing surfaces marked with this symbol.

1. Place the pump set down in a horizontal position and make sure it cannot roll off. (ðSection3.2.2,Page12)

2. When placing the pump set down, make sure that screw plug 903.03 is on top.

3. Remove screw plug 903.03.

4. Remove screw plug 903.01 and joint ring 411.01.

5. Shine a torch through the hole in the pump bowl to see the opening of the lubricant reservoir.

ð If the lubricant level reaches the opening, fit screw plug 903.01 together with

a new joint ring 411.01, and screw plug 903.03.

ð If the lubricant level is below the opening, top up the lubricant.

(ðSection7.4.1.4.2,Page58)

6. Re-insert and tighten screw plug 903.01 with joint ring.

7. Re-insert and tighten screw plug 903.03.

NOTE

If more than 1.5 litres of lubricant are required for topping up, this suggests a defect of the mechanical seals.

5.2.4 Checking the direction of rotation

DANGER

Pump set running dry

Explosion hazard!

▷ Check the direction of rotation of explosion-proof pump sets outside

potentially explosive atmospheres.

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WARNING

Improper handling when placing the pump set in a vertical/horizontal position

Personal injury and damage to property!

▷ Use one or two pieces of lifting equipment, depending on the pump size. ▷ Use appropriate means to secure the pump set against tilting, tipping over or

rolling off.

▷ Maintain a safe distance during lifting operations (load may swing when being

lifted).

▷ Use additional supports for the transport holder to secure it against tilting.

WARNING

Improper positioning of pump set when checking the direction of rotation

Personal injury and damage to property!

▷ Use appropriate means to secure the pump set against tilting or tipping over.

WARNING

Hands and/or foreign objects in the pump casing

Risk of injuries, damage to the pump!

▷ Never insert your hands or any other objects into the pump. ▷ Check that the inside of the pump is free from any foreign objects. ▷ Verify that the transport lock has been removed. ▷ Take suitable precautions (e.g. wear safety goggles).

CAUTION

Pump set running dry

Increased vibrations! Damage to mechanical seals and bearings!

▷ Never operate the pump set for more than 60seconds outside the fluid to be

handled.

Check the direction of rotation before installing the pump set, i.e. in dry condition.

1. Place the pump set in a vertical position on a level surface and secure it sufficiently against tipping over. (ðSection3.2.2,Page12)

2. Connect the pump set to the power supply and start it up.

3. Use one of the following options to check the direction of rotation: ð 1. Look down into the pump bowl and check that the impeller is turning

clockwise.

ð 2. Verify the direction of rotation of the impeller against the arrow

indicating the direction of rotation on the pump bowl.

4. If the impeller rotates in the wrong direction of rotation, check and correct the electrical connection and the control system if applicable. Then check the direction of rotation again.

5. If the direction of rotation is correct, mark which core ends match which of the terminals in the control cabinet.

6. Disconnect the pump set from the power supply and secure it against unintentional start-up.

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WARNING

Unintentional starting of the pump set

Risk of injury by moving components and shock currents!

▷ Ensure that the pump set cannot be started unintentionally. ▷ Always make sure the electrical connections are disconnected before carrying

out work on the pump set.

5.3 Lowering the pump set into the discharge tube

DANGER

Improper transport

Danger to life from falling parts! Damage to the pump set!

lowering or lifting the pump set into/out of the pump sump.

weight indicated on the name plate of the pump set to be lifted. Take into account any additional system components to be lifted.

DANGER

Improper installation in potentially explosive atmospheres

Explosion hazard! Damage to the pump set!

▷ Comply with the applicable local explosion protection regulations. ▷ Observe the information in the data sheet and on the name plates of pump and

motor.

WARNING

Incorrect handling of the power cable

Personal injury and damage to property!

▷ Secure the power cables against falling down. ▷ Avoid power cables being laid on surfaces without fastening. ▷ When moving the pump set keep at a safe distance from the power cables.

WARNING

People falling into the unsecured discharge tube

Risk of personal injury!

▷ Take suitable precautions during the entire installation/removal process to

protect people from falling into the open discharge tube.

▷ Fence off the work area appropriately.

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5.3.1 Information for correct installation

The flow-straightening vane is indispensable for the inlet conditions of the pump set. It prevents the development of a submerged vortex (floor vortex) which could cause a drop in performance, for example. To provide optimum inlet conditions, observe the following information:

1. Observe the structural requirements! Install the flow-straightening vane concentrically below the discharge tube, see general arrangement drawing.

Fig.6: Installation position of the flow-straightening vane

1 Flow-straightening vane 2 Discharge tube 3 Intake chamber

2. Observe the installation position of the pump set! Lower the pump set into the discharge tube with the anti-swirl baffles (2) in the bellmouth aligned with the flow-straightening vane (3). Use the bail alignment of the pump set for orientation. The bail (1) is aligned with the anti-swirl baffles (2).

Fig.7: Installation position of the pump set

1 Bail 2 Anti-swirl baffles 3 Flow-straightening vane

5.3.2 Installation without support rope

CAUTION

Incorrect installation

Damage to the pump set!

▷ Verify that the pump set is correctly seated in the discharge tube.

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412.05

112

Fig.8: Inserting the O-ring

Refer to and comply with the general arrangement drawing/outline drawing when installing the pump set.

1. If not already fitted, insert the supplied O-ring 412.05 into pump bowl 112.

2. Attach the crane hook to the bail of the pump set.

3. Centre the pump set above the discharge tube. Slowly lower the pump set into the discharge tube until it is seated in the recommended position. (ðSection5.3.1,Page26)

4. Pull the electric cables up by hand. Fasten them to the sump construction with a cable support sleeve if required. Do not lift the pump set out of its seat.

Fig.9: Fastening the cable support sleeve

5.3.3 Installation with a support rope

Refer to and comply with the general arrangement drawing/outline drawing when installing the pump set.

Prior to installing the pump set, visually inspect the support rope. Do not exceed the permissible load-carrying capacity.

X 59-24

X 59-17.01

Fig.10: X = indication of load-carrying capacity

59-24 Support rope 59-17.01 Shackle

CAUTION

Incorrect installation

Damage to the pump set!

▷ Verify that the pump set is correctly seated in the discharge tube.

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WARNING

Pump set drops during the installation or removal process

Personal injury and damage to property!

▷ Never use the turnbuckle , shackle or discharge tube cover to lift the pump set. ▷ Always use lifting lug 59-47.

NOTE

Prior to fitting the turnbuckle, check that the corresponding split pin has not been cracked and/or chipped. If damaged, always use a new split pin.

ü Suitably sized lifting equipment is available. ü The support rope has been visually inspected. ü The split pin of the turnbuckle has been checked for any damage.

412.05

112

Fig.11: Inserting the O-ring

1. If not already fitted, insert the supplied O-ring 412.05 into pump bowl 112.

Fig.12: Lifting and positioning the pump set

2. Secure the lifting chain or lifting rope (1) to the trolley (4) of the lifting equipment (2).

3. Attach the support rope (5) to the bail by its shackle. (ðSection9.2,Page94) For a galvanised shackle, secure the pin at the shackle with Loctite243. For a stainless steel shackle, undo and tighten the pin twice and secure it with Loctite243.

4. Check that the support rope is arranged correctly. ð The free lifting lug (6) has to point away from the pump set

5. Partially unwind the support rope and electric cables.

6. Lower the pump set into the discharge tube until the bail is in an accessible position, protruding from the discharge tube.

7. Securely cover the discharge tube except for a gap which allows work to continue.

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8. Attach the first lifting lug of the support rope (5) to the lifting rope (1) to securely position the pump set above the discharge tube.

9. Unclip the hook of the lifting equipment from the lifting lug of the support rope and run the lifting equipment to a higher level.

Fig.13: Securing the control cable and power cable

10. Secure the control cable (7) and power cables (8) to the crane hook (3) of the lifting equipment with a manila rope (9).

11. Trim spacer (a) to fit between the two ferrules.

Fig.14: Cross-section of the cable guide

12. Insert the support rope (f) and the control cable (c) into the spacer (a) and make sure that they are in their respective ducts.

13. Tighten the electric cables with the manila rope running over the crane hook.

14. Insert the power cables (b) into the hollows of the spacer (a) and, starting from the bottom, firmly clamp the power cables with cable clamps (d) covered by a plastic sheath (e).

15. In the area of the lifting lug between the rope sections, lay all electric cables in loops and fasten them to the rope section above.

16. Progressively lower the pump set into the discharge tube while securing the cable bundle with evenly spaced sheathed cable clamps.

17. Fit a heat shrink tube on any protruding sharp-edged rope ends (e.g. at the ferrule) to prevent any damage to the power cable and control cable.

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Fig.15: Lowering the pump set

18. Finally, attach the support rope with shackle and turnbuckle to a suspension loop (provided in the discharge tube or structure). Secure the turnbuckle with a split pin. After inserting the split pin, bend over its two legs.

19. Tighten the turnbuckle until the cable bundle is tight without lifting the pump off its seat.

20. Unclip the hook of the lifting equipment from the lifting lug, free the electric cables from the manila rope and route them to the control cabinet.

21. Make sure that the top loose lifting lug is attached to the cable bundle to prevent noise and wear caused by chafing.

22. Remove the safety cover from the discharge tube and mount the discharge tube cover. Seal the cable entries if any!

5.3.4 Installation with a support rope and support spacer

Always refer to and comply with the general arrangement drawing/ outline drawing when installing the pump set.

Prior to installing the pump set, visually inspect the support rope. Do not exceed the permissible load-carrying capacity.

X 59-24

X 59-17.01

Fig.16: X = indication of load-carrying capacity

59-24 Support rope 59-17.01 Shackle

+ 102 hidden pages

KSB Amacan P 1200-870, Amacan P series, Amacan P 1500-1060, Amacan P 1600-1060, Amacan P 900-540 Installation & Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual