KSB Amacan S, Amacan S 650-365, Amacan S 650-364, Amacan S 800-505, Amacan S 650-404 Installation And Operating Manual

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Page 1

Submersible Pump in Discharge Tube

Amacan S

Amacan S 650 - 364 Amacan S 650 - 365 Amacan S 650 - 404 Amacan S 650 - 405 Amacan S 800 - 505

Installation/Operating Manual

Mat. No.: 01350210

Page 2

Legal information/Copyright

Installation/Operating Manual Amacan S

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.

Page 3

Contents

1 General ..................................................................................................6

1.1 Principles ...........................................................................................................6

1.2 Installation of partly completed machinery .................................................... 6

1.3 Target group ..................................................................................................... 6

1.4 Other applicable documents ............................................................................ 6

1.5 Symbols .............................................................................................................6

2 Safety .....................................................................................................7

2.1 Key to safety symbols/markings ....................................................................... 7

2.2 General .............................................................................................................. 7

2.3 Intended use .....................................................................................................7

2.4 Personnel qualification and training ............................................................... 8

2.5 Consequences and risks caused by non-compliance with this manual ......... 8

2.6 Safety awareness ..............................................................................................8

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

2.8 Safety information for maintenance, inspection and installation work ....... 9

2.9 Unauthorised modes of operation .................................................................. 9

3 Transport/Temporary Storage/Disposal .............................................10

3.1 Checking the condition upon delivery .......................................................... 10

3.2 Transport ......................................................................................................... 10

3.3 Storage/preservation ...................................................................................... 14

3.4 Return to supplier ........................................................................................... 14

3.5 Disposal ...........................................................................................................15

4 Description of the Pump (Set) ............................................................16

4.1 General description ........................................................................................ 16

4.2 Designation ..................................................................................................... 16

4.3 Name plate ...................................................................................................... 16

4.4 Design details .................................................................................................. 17

4.5 Installation types ............................................................................................17

4.6 Configuration and function ........................................................................... 19

4.7 Scope of supply ............................................................................................... 20

4.8 Dimensions and weights ................................................................................20

5 Installation at Site ...............................................................................21

5.1 Safety regulations ........................................................................................... 21

5.2 Checks to be carried out prior to installation ............................................... 21

5.3 Lowering the pump set into the discharge tube .......................................... 23

5.4 Electrical system .............................................................................................. 29

6 Commissioning/Start-up/Shutdown ...................................................35

6.1 Commissioning/start-up ................................................................................. 35

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Contents

6.2 Operating limits .............................................................................................. 36

6.3 Shutdown/storage/preservation .................................................................... 37

6.4 Returning to service .......................................................................................38

7 Servicing/Maintenance .......................................................................40

7.1 Safety regulations ........................................................................................... 40

7.2 Maintenance/inspection ................................................................................. 40

7.3 Removing the pump set ................................................................................. 43

7.4 Lubrication and lubricant change ................................................................. 46

7.5 Dismantling the pump set .............................................................................. 51

7.6 Reassembling the pump set ........................................................................... 56

7.7 Checking the electrical connection and motor ............................................. 65

7.8 Tightening torques ......................................................................................... 65

7.9 Spare parts stock ............................................................................................. 66

8 Trouble-shooting ................................................................................67

9 Related Documents ............................................................................68

9.1 General assembly drawing of pump sets with UAG motors (DKA motor) .. 68

9.2 Cable guide ..................................................................................................... 71

9.3 Wiring diagrams ............................................................................................. 72

9.4 Dimensions ...................................................................................................... 75

9.5 General arrangement drawings .................................................................... 77

10 EC Declaration of Conformity ............................................................97

11 Certificate of Decontamination .........................................................98

Index ....................................................................................................99

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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

Submersible pump in discharge tube

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

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1 General

1.1 Principles

This manual is supplied as an integral part of the type series and variants indicated on the front cover. It 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 uniquely identify the pump (set) and serve as identification for all further business processes.

In the event of damage, contact your nearest KSB service centre immediately 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. (⇨ Section 2.4 Page 8)

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

Sub-supplier product literature

Sectional drawing of the pump set

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

If agreed to be included in the scope of supply

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DANGER

WARNING

CAUTION

DANGER

2 Safety

All the information contained in this section refers to hazardous situations.

2.1 Key to safety symbols/markings

Table 3: Definition of safety symbols/markings

Symbol Description

DANGER This signal word indicates a high-risk hazard which, if not avoided, will result in death or serious injury. WARNING This signal word indicates a medium-risk hazard which, if not avoided, could result in death or serious injury. CAUTION This signal word indicates a hazard which, if not avoided, could result in damage to the machine and its functions. 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 manual contains general installation, operating and maintenance instructions that must be observed to ensure safe pump operation and prevent personal injury and damage to property.

The safety information in all sections of this manual must be complied with. This manual must be read and completely understood by the specialist personnel/

operators responsible prior to installation and commissioning. The contents of this manual must be available to the specialist personnel at the site

at all times. Information attached directly to the pump must always be complied with and be

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 manual.

2.3 Intended use

The pump (set) must only be operated within the operating limits described in the other applicable documents.

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

literature of the respective design variant.

▪ Never operate the pump without the fluid to be handled.

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2 Safety

▪ Observe the limits for continuous operation specified in the data sheet or

product literature (Q

min

and Q

) (to prevent damage such as shaft fracture,

max

bearing failure, damaged mechanical seal, etc).

▪ Observe the information on the maximum flow rates provided in the data sheet

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

▪ Consult the manufacturer about any use or mode of operation not described in

the data sheet or product literature.

Prevention of foreseeable misuse

▪ Observe the minimum flow velocities required to fully open the swing check

valves to prevent the reduction of pressure and risk of clogging. (Contact the manufacturer for the required minimum flow velocities/loss coefficients.)

▪ Never exceed the permissible operating limits specified in the data sheet and in

the product literature regarding pressure, temperature, etc.

▪ Observe all safety information and instructions in this manual.

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 this operating manual 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 and safety regulations ▪ Explosion protection regulations ▪ Safety regulations for handling hazardous substances ▪ Applicable standards and laws

Minimum permissible flow rate

Maximum permissible flow rate

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2 Safety

2.7 Safety information for the operator/user

▪ The operator shall fit contact guards for hot, cold and moving parts and check

that the guards function properly.

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

▪ Modifications or alterations of the pump are only permitted with the

manufacturer's prior consent.

▪ Use only original spare parts or parts authorised by the manufacturer. The use of

other parts can invalidate any liability of the manufacturer for resulting damage.

▪ The operator ensures that all maintenance, inspection and installation work 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. ▪ The pump casing 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. (⇨ Section 6.3 Page 37) ▪ Decontaminate pumps which handle fluids posing a health hazard. ▪ As soon as the work has been completed, re-install and/or re-activate any safety-

relevant and protective devices. Before returning the product to service, observe

all instructions on commissioning. (⇨ Section 6.1 Page 35)

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.

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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.

In the event of in-transit damage, assess the exact damage, document it and notify KSB or the supplying dealer (as applicable) 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 (eyebolt, lifting lug or bail) for attaching

lifting accessories.

▷ Never suspend the pump set by its power cable. ▷ Never use the lifting ropes included in KSB's scope of supply for lifting loads

other than the KSB product supplied.

▷ Securely attach the lifting ropes to the pump and crane.

3.2.1 Transporting the delivered pump set to the place of installation

Fig. 1: Transporting the delivered pump set to the place of installation

▪ The pump set is supplied in horizontal position in a suitable saddle-shaped

holder. ▪ Use suitable hoisting tackle to transport the pump set in its original packaging to

its place of installation.

Note the marked centres of gravity and/or attachment points on the transport

boxes!

For the weight refer to the name plate or data sheet.

3.2.2 Placing the pump set in vertical or horizontal position

WARNING

Pump set tipping over Risk of squashing hands and feet!

▷ Suspend or support the pump set.

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3 Transport/Temporary Storage/Disposal

WARNING

Setting the pump set down on unsecured and uneven surfaces Personal injury and damage to property!

▷ Always set 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 overturning or tipping

over.

▷ Refer to the weights given in the data sheet/on the name plate.

WARNING

Improper handling of the power cable when placing the pump set in a vertical position or transporting it Personal injury and damage to property!

▷ Secure power cables against falling down.

WARNING

Improper handling when placing the pump set in a vertical/horizontal position Personal injury and damage to property!

▷ Depending on the size of the pump (set) use either one or two pieces of lifting

equipment.

▷ Use appropriate means to secure the pump set against overturning, tipping

over or rolling off.

▷ Maintain adequate safety distance during lifting operations (load may swing

when being lifted).

▷ Use additional supports for the transport holder to secure the pump set against

overturning.

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.

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3 Transport/Temporary Storage/Disposal

Fig. 2: Placing the pump set in a vertical or horizontal position

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

a) For one piece of lifting equipment: Attach the eyehook to the bail of the

1. 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 eye hook.

2. Lift the pump set with the lifting equipment.

⇨ Guiding the pump set over the edge of the bellmouth or pump casing is only

permissible on a wooden base!

⇨ Protect the power cable against kinking!

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

overturning or rolling off.

3.2.3 Transporting the pump set

WARNING

Incorrect positioning Personal injury and damage to property!

▷ Set the pump set down in a vertical position with the motor on top. ▷ Use appropriate means to secure the pump set against overturning and tipping

over.

▷ Refer to the weights given in the data sheet/on the name plate.

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3 Transport/Temporary Storage/Disposal

WARNING

Improper handling when placing the pump set in a vertical/horizontal position Personal injury and damage to property!

▷ Depending on the size of the pump (set) use either one or two pieces of lifting

equipment.

▷ Use appropriate means to secure the pump set against overturning, tipping

over or rolling off.

▷ Maintain adequate safety distance during lifting operations (load may swing

when being lifted).

▷ Use additional supports for the transport holder to secure the pump set against

overturning.

WARNING

Improper handling of the power cable when placing the pump set in a vertical position or transporting it Personal injury and damage to property!

▷ Secure power cables against falling down.

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.

Fig. 3: Transporting the pump set Use suitable lifting equipment to transport the pump set in the illustrated position.

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3 Transport/Temporary Storage/Disposal

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 tipping over Risk of squashing hands and feet!

▷ Suspend or support the pump set.

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 by humidity, dirt, or vermin Corrosion/contamination of the pump (set)!

▷ For outdoor storage cover the packed or unpacked pump (set) and accessories

with waterproof material.

CAUTION

Wet, contaminated or damaged openings and connections Leakage or damage to the pump set!

▷ Only remove caps/covers from the openings of the pump set at the time of

installation.

Table 4: Ambient conditions for storage

Ambient conditions Value

Relative humidity 5 % to 85 %

(non-condensing)

Ambient temperature - 20 ℃ to + 70°C

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

original packaging.

Rotate the impeller by hand once every three months.

3.4 Return to supplier

1. Drain the pump as per operating instructions. (⇨ Section 7.3.2 Page 44)

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

3. If the fluids handled by the pump set leave residues which might lead to

corrosion damage when coming into contact with atmospheric humidity, or which might ignite when coming into contact with oxygen, the pump set must also be neutralised, and anhydrous inert gas must be blown through the pump for drying purposes.

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3 Transport/Temporary Storage/Disposal

4. Always complete and enclose a certificate of decontamination when returning

the pump (set). Always indicate any safety and decontamination measures taken. (⇨ Section 11 Page 98)

NOTE

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

3.5 Disposal

WARNING

Fluids, 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 residues of the fluid

handled.

▷ 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.

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.

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Mat. No. 01097374

ZN 3826 - M 24

TYPE No. Q

TEMP. MAX.

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

MOTOR IP 68 SUBM. MAX. 30 m CLASS H

3 ~ M.-No.

cosφ

0,82

IA/IN 5,3

67227 Frankenthal

KSB Aktiengesell s chaft

WARNUNG - NICHT UNTER SPANNUNG ÖFFNEN

1 2 3

11 12

7 8 9

15 16

18 19 20

Amacan S 650 - 365 / 80 4 UAG2

99719100010/000100

1700 m³/h

12 m

40 °C 1070 kg

2011

DKA 225.4-80

75 kW

1470 min

-1

145 A

400 V 50

123456

4 Description of the Pump (Set)

4.1 General description

Pump set for handling clean water, pre-screened river water and stormwater, waste water without any long fibres or large solid particles, and activated sludge

4.2 Designation

Example: Amacan S 650-365 / 80 4 UAG2 Table 5: Key to the designation

Code Description

Amacan Type series S Impeller type, e.g. S = mixed flow impeller 650 Nominal diameter of the discharge tube [mm] 365 Nominal impeller diameter [mm] 80 Motor size 4 Number of motor poles

4 4-pole 6 6-pole

UA Motor version

UA Non-explosionproof

G2 Material variant

G2 Grey cast iron, standard material variant G3 Grey cast iron with Zn anodes, shaft made of 1.4057

stainless steel

4.3 Name plate

Fig. 4: Name plate: standard pump set (example)

1 Designation 2 KSB order number 3 Flow rate 4 Maximum fluid 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 17 Power factor at design point 18 Rated frequency 19 Mode of operation 20 Starting current ratio

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4 Description of 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

Impeller type

▪ Open mixed flow impeller

Shaft seal

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

Bearings

▪ Grease-packed rolling element bearings

Drive

▪ Three-phase asynchronous squirrel-cage motor

4.5 Installation types

Six design variants4) are available for the following installation types:

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

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Table 6: Installation types

4 Description of the Pump (Set)

Overflow design with open intake chamber

Underfloor discharge with open intake chamber

BU discharge tube

CU discharge tube

Overflow design for installation in covered intake chamber with low suction-side

Design with underfloor discharge for installation in covered intake chamber with low

BG discharge tube

water levels

CG discharge tube

suction-side water levels

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Above-floor discharge nozzle with open intake chamber

DU discharge tube

Amacan S

Design with above-floor discharge nozzle for installation in covered intake chamber

DG discharge tube

with low suction-side water levels

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4 Description of the Pump (Set)

4.6 Configuration and function

Fig. 5: Amacan with mixed flow impeller

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

Design

Function

Sealing

Monitoring

equipment

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.

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 casing (3) the kinetic energy of the fluid is converted into pressure energy. The rotational movement diverts the fluid flow into a mixed flow. 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 (7 and 8), which are supported by the lower bearing housing (9) and the upper bearing housing (6).

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.

The pump sets are equipped with various sensors.

▪ Temperature monitoring of the motor ▪ Temperature monitoring at the lower bearing ▪ Temperature monitoring at the upper bearing ▪ Leakage monitoring of the mechanical seal system

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4 Description of the Pump (Set)

▪ Leakage sensors in the motor space

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:

▪ Support rope ▪ Accessories for mounting the cable guide

- Spacer

- Turnbuckle

- Support

- Shackle

- Clamps

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

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.

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230

101

5 Installation at Site

5.1 Safety regulations

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

Improper installation in potentially explosive atmospheres Damage to the pump set!

▷ Comply with the applicable local explosion protection regulations. ▷ Observe the information given in the data sheet and on the pump/motor name

plates.

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

Back-up name plate

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. 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.

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 level of the mechanical seal The lubricant reservoir is filled at the factory with an environmentally-friendly, non-

toxic lubricant.

Fig. 6: Visual inspection for signs of oil leakage

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5 Installation at Site

1. Set the pump set down in a horizontal position and make sure it cannot roll off.

Perform a visual inspection.

⇨ If no oil leakage is visible between impeller 230 and pump casing 101, the

lubricant reservoir is filled properly.

⇨ If signs of oil leakage are visible between impeller 230 and pump casing 101,

top up the lubricant reservoir.

For topping up the lubricant reservoir the pump set needs to be partly dismantled. Observe the following steps and sequence:

Table 7: Step-by-step instructions

Sequence Steps See the following section.

1 Placing the pump in vertical

position 2 Removing the bellmouth (⇨ Section 7.5.3 Page 52) 3 Removing the impeller (⇨ Section 7.5.4 Page 53) 4 Filling in the lubricant (⇨ Section 7.4.1.4.2 Page 49) 5 Fitting the impeller (⇨ Section 7.6.5 Page 61) 6 Fitting the bellmouth (⇨ Section 7.6.6 Page 62) 7 Adjusting the clearance (⇨ Section 7.6.7 Page 63)

(⇨ Section 3.2.2 Page 10)

NOTE

Always observe the safety instructions given in the individual sections.

5.2.4 Checking the direction of rotation

WARNING

Hands or objects inside 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. ▷ Take suitable precautions (e.g. wear safety goggles, etc).

WARNING

Improper handling when placing the pump set in a vertical/horizontal position Personal injury and damage to property!

▷ Depending on the size of the pump (set) use either one or two pieces of lifting

equipment.

▷ Use appropriate means to secure the pump set against overturning, tipping

over or rolling off.

▷ Maintain adequate safety distance during lifting operations (load may swing

when being lifted).

▷ Use additional supports for the transport holder to secure the pump set against

overturning.

WARNING

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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 overturning or tipping

over.

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5 Installation at Site

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.

Place the pump set in a vertical position on a level surface and secure it

1. sufficiently against tipping over.

2. Connect the pump set to the power supply and switch it on.

3. Use one of the two following options to check the direction of rotation: ⇨ 1. Look down into the pump casing and check that the impeller rotates

clockwise.

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

indicating the direction of rotation on the pump casing.

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.

WARNING

Unintentional starting of pump set Risk of injury by moving parts!

▷ Make sure that the pump set cannot be started up 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

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.

5.3.1 Notes on correct installation The flow-straightening vane is indispensable for the inlet conditions of the pump set.

as this device prevents the occurrence of a submerged vortex (floor vortex) which could cause a drop in performance, among other things. For optimum inlet conditions, observe the following information:

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

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Fig. 7: 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. 8: Installation position of the pump set

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

5.3.2 Installing the pump set without support rope

CAUTION

Incorrect installation Damage to the pump set!

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

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

If not already fitted, fit the supplied O-ring 412.05 into pump casing 101.

Fig. 9: Inserting the O-ring

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2. Attach the eye hook of the crane 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. (⇨ Section

5.3.1 Page 23)

4. Pull the 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.

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Fig. 10: Fastening the cable support sleeve

5.3.3 Installing the pump set with a support rope Always refer to and comply with the general arrangement drawing/outline drawing

when installing the pump set.

CAUTION

Incorrect installation Damage to the pump set!

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

CAUTION

Pump set dropping during the installation or removal process Damage to the machinery and system!

▷ Never use the turnbuckle or shackle to lift the pump set. ▷ Always use lifting lug 59-47. (⇨ Section 9.2 Page 71)

1. If not already fitted, fit the supplied O-ring 412.05 into pump casing 101.

Hoisting and positioning the pump set

Fig. 11: Inserting the O-ring

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

2. (2).

3. Attach the support rope (5) to the bail by its shackle. Check that the support rope is arranged with the lifting lug (6) pointing away from the pump set.

4. Partially unwind the support rope and cables.

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

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

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

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

Secure the control cable (7) and power cables (8) to the eye hook (3) of the

9. lifting equipment with a manila rope (9).

10. Trim the spacer to fit between the two rope eyes.

Securing the control and power cables

Lowering the pump set

Fig. 12: Cross-section of the cable guide

11.

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

12. Tighten the power cables with the manila rope running over the eye hook.

13. 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).

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

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

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

17. Finally, attach the support rope with shackle and turnbuckle to a suspension eye (provided in the discharge tube or structure). Caution: Never use the turnbuckle or shackle to lift the pump set.

18. Tighten the turnbuckle until the cable strands are tight but do not lift the pump off its seat.

19. Unclip the hook of the hoisting tackle from the lifting lug, free the cables from the manila rope and route them to the control cabinet.

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

21. Remove the safety cover from the discharge tube and mount the discharge tube cover. Seal the cable glands, if any!

5.3.4 Installing the pump set with a support rope and support spacer

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

CAUTION

Incorrect installation Damage to the pump set!

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

CAUTION

Pump set dropping during the installation or removal process Damage to the machinery and system!

▷ Never use the turnbuckle or shackle to lift the pump set.

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▷ Always use lifting lug 59-47. (⇨ Section 9.2 Page 71)

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Hoisting and positioning

the pump set

Securing the control and power cables

5 Installation at Site

1. If not already fitted, fit the supplied O-ring 412.05 into pump casing 101.

Fig. 13: Inserting the O-ring

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

3. Attach the support rope (5) to the bail by its shackle. Check that the support rope is arranged with the lifting lug (6) pointing away from the pump set.

4. Partially unwind the support rope and cables.

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

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

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

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

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

10. Trim the spacer to fit between the two rope eyes.

Fig. 14: Cross-section of the cable guide

Insert the support rope (f) and the control cable (c) into the spacer (a) and make

11. sure that they are in their respective ducts.

12. Tighten the power cables with the manila rope running over the eye hook.

13. 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).

Lowering the pump set

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5 Installation at Site

Fig. 15: Example of a support rope with support spacer

14.

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

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

16. Attach support 59-7 between the two ropes with shackles. Guide the power and control cables along the support to the next cable clamp. Pull them taught and secure them with the clamp.

17. Progressively lower the pump set into the discharge tube. Secure the cable strand with cable clamps.

18. Finally, attach the support rope with shackle and turnbuckle to a suspension eye (provided in the discharge tube or structure). Caution: Never use the turnbuckle or shackle to lift the pump set.

19. Tighten the turnbuckle until the cable strands are tight but do not lift the pump off its seat.

20. Unclip the hook of the hoisting tackle from the lifting lug, free the 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 strand 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 glands, if any!

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5.4 Electrical system

5.4.1 Information for planning the control system

For the electrical connection of the pump set observe the "Wiring diagrams" section. (⇨ Section 9.3 Page 72) The pump set is supplied with power cables; it is wired for DOL starting.

NOTE

When laying a cable between the control system and the pump set's connection point, make sure that the number of cores is sufficient for the sensors. A minimum cross-section of 1.5 mm² is required.

The motors can be connected to electrical low-voltage grids with rated voltages and voltage tolerances to IEC 38 or other grids or power supply facilities with maximum rated voltage tolerances of ± 10 %.

5.4.1.1 Overload protection

1. Protect the pump set against overloading by using a thermal time-lag overload protection device in accordance with IEC 947 and local regulations.

Set the overload protection device to the rated current specified on the name

2. plate.

5.4.1.2 Level control

Electromagnetic

compatibility

Interference immunity

Selection

Start-up

Operation

CAUTION

Fluid level below the specified minimum Damage to the pump set by cavitation!

▷ Never allow the fluid level to drop below the specified minimum.

Automatic operation of the pump set in a tank requires the use of level control equipment. Observe the minimum fluid level. (⇨ Section 6.2.4.3 Page 37)

5.4.1.3 Frequency inverter operation The pump set is suitable for frequency inverter operation as per IEC 60034-17. When selecting a frequency inverter, check the following details:

▪ Data provided by the manufacturer ▪ Electrical data of the pump set, particularly the rated current ▪ Ensure short start ramps (max. 5 s) ▪ Only start speed-controlled operation after 2 minutes at the earliest.

Pump start-up with long start ramps and low frequency may cause clogging.

Observe the following limits when operating the pump set via frequency inverter:

▪ Only utilise up to 95 % of the motor power rating P2 indicated on the name

plate.

▪ Frequency range 25-50 Hz

Frequency inverter operation produces RFI emissions whose level varies, depending on the inverter used (type, interference suppression, make). To prevent the drive system, consisting of a submersible motor and a frequency inverter, from exceeding the limits stipulated in EN 50081 always observe the EMC information provided by the inverter manufacturer. If the inverter manufacturer recommends a shielded power cable, make sure to use a pump set with a shielded power cable.

The pump set generally meets the interference immunity requirements to EN 50082. For monitoring the sensors installed the operator must ensure sufficient interference immunity by appropriately selecting and laying the cables in the plant. No

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modifications are required on the power/control cable of the pump set. Suitable analysing devices must be selected. To monitor the leakage sensor inside the motor, it is recommended to use a special relay available from KSB.

5.4.1.4 Sensors

DANGER

Operating an incompletely connected pump set Damage to the pump set!

▷ Never start up a pump set with incompletely connected power cables or non-

operational monitoring devices.

CAUTION

Incorrect wiring Damage to the sensors!

▷ Observe the limits stated in the following sections of this manual when

connecting the sensors.

The pump set is equipped with sensors designed to prevent hazards and damage to the pump set.

Measuring transducers are required for analysing the sensor signals supplied. Suitable devices for 230 V~ can be supplied by KSB.

NOTE

Reliable and safe operation of the pump within the scope of our warranty is only possible if the sensor signals are properly analysed as stipulated in this manual.

All sensors are located inside the pump set and are connected to the power cable. For information on wiring and core identification please refer to the "Wiring diagrams" section. (⇨ Section 9.3 Page 72) The individual sensors and the limit values to be set are described in the following sections.

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Fig. 16: Sensor positions

PositionSensor Standard Optional

1 Bearing temperature (lower bearings) ✘ 2 Motor temperature (PT100) - ✘ 3 Motor temperature (PTC) ✘ 4 Bearing temperature (upper bearing) ✘ 5 Leakage inside the motor ✘ 6 Mechanical seal leakage ✘ -

5.4.1.4.1 Motor temperature

CAUTION

Insufficient cooling Damage to the pump (set)!

▷ Never operate a pump (set) without operational temperature monitoring.

Three series-connected thermistors (PTC) at terminals 10 and 11 monitor the winding temperature. Use a thermistor tripping unit with manual reset.

Resistance thermometer (PT100) As an option, in addition to the above, the motor can be fitted with (PT100)

resistance thermometers in the winding. These can be used to display the motor temperature (sensor circuit maximum 6 V/2 mA).

CAUTION

Temperature monitoring devices not properly connected Winding damage!

▷ Never use the resistance thermometers as the only means of monitoring the

motor temperature.

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5.4.1.4.2 Leakage inside the motor

Position of the electrode

Connecting the electrode relay

An electrode fitted inside the motor monitors the winding for leakage. This electrode must be connected to an electrode relay (core marked 9). Tripping of the electrode relay must result in the pump set cutting out.

The electrode relay (K1) must meet the following requirements:

▪ Sensor circuit 10 to 30 V ~ ▪ Tripping current 0.5 to 3 mA

(equivalent to a tripping resistance of 3 to 60 kΩ)

5.4.1.4.3 Mechanical seal leakage The chamber for mechanical seal leakage is equipped with a float switch (core

identification 3 and 4). The contact (maximum 250 V~/2 A) opens when leakage is detected in the leakage chamber. Opening of the contact shall trigger an alarm signal.

Fig. 17: Float switch

5.4.1.4.4 Bearing temperature The bearings of the pump set are equipped with bearing temperature sensors. The

two sensors are PT100 resistance thermometers (core identification 15 and 16). They have to be connected to a temperature control device with a PT100 input and 2 separate outputs for two different switching points (sensor circuit maximum 6 V/2 mA).

Set the following limits:

▪ Alert at 110 °C ▪ Cut-out of the pump set at 130 °C

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5.4.2 Electrical connection

DANGER

Work on the pump set by unqualified personnel Danger of death from electric shock!

▷ Always have the electrical connections installed by a trained and qualified

electrician.

▷ Observe regulations IEC 60364 and, for explosion-proof models, EN 60079.

WARNING

Incorrect connection to the mains Damage to the mains network, short circuit!

▷ Observe the technical specifications of the local energy supply companies.

CAUTION

Improper routing of power cable Damage to the power cables!

▷ Never move the power cables at temperatures below - 25 ℃. ▷ Never kink or crush the power cables. ▷ Never lift the pump set by the power cables. ▷ Adjust the length of the power cables to the site requirements.

CAUTION

Motor overload Damage to the motor!

▷ Protect the motor by a thermal time-lag overload protection device in

accordance with IEC 947 and local regulations.

For electrical connection observe the wiring diagrams in the Annex and the information on planning the control system.

The pump set is supplied complete with power cables. Always use all cables provided and connect all marked cores of the control cable.

DANGER

Operating an incompletely connected pump set Damage to the pump set!

▷ Never start up a pump set with incompletely connected power cables or non-

operational monitoring devices.

DANGER

Connection of damaged power cables Danger of death from electric shock!

▷ Check the power cables for damage before connecting them to the power

supply.

▷ Never connect damaged power cables.

CAUTION

Flow-induced motion Damage to the power cable!

▷ Run the power cable upwards without slack.

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5 Installation at Site

Fig. 18: Fastening the power cable

Run the power cables upwards without slack and fasten them.

2. Only remove the protective caps from the power cables immediately before connecting the cables.

3. If necessary, adjust the length of the power cables to the site requirements.

4. After shortening the cable, correctly re-affix the markings on the individual cores at the cable ends.

The pump set does not have an external PE connection (risk of corrosion).

DANGER

Touching the pump set during operation Electric shock!

▷ Make sure that the pump set cannot be touched during operation.

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6.1 Commissioning/start-up

6.1.1 Prerequisites for commissioning/start-up

DANGER

Persons in the tank during pump operation Electric shock!

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

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.

Before starting up the pump set make sure that the following requirements are met:

▪ The lubricant has been checked. ▪ The direction of rotation has been checked. ▪ The pump set has been properly connected to the electric power supply and is

equipped with all protection devices.

▪ The pump set has been installed in the discharge tube as described in this

manual.

▪ The minimum fluid level has been reached. ▪ After prolonged shutdown of the pump (set), the activities described in the

section Returning to service have been carried out. (⇨ Section 6.4 Page 38)

6.1.2 Start-up

DANGER

Persons in the tank during pump operation Electric shock!

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

CAUTION

Re-starting while motor is still running down Damage to the pump set!

▷ Do not re-start the pump set before it has come to a standstill. ▷ Never start up the pump set while the pump is running in reverse.

✓ The fluid level is sufficiently high.

CAUTION

Pump start-up against a closed shut-off element Increased vibrations! Damage to mechanical seals and bearings!

▷ Never operate the pump set against a closed shut-off element.

1. Fully open the discharge line shut-off element, if any.

Start up the pump set.

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6.2 Operating limits

DANGER

Non-compliance with operating limits Damage to the pump set!

▷ Comply with the operating data indicated in the data sheet. ▷ Avoid operation below Q

min

▷ Never operate the pump set outside the limits specified below.

6.2.1 Supply voltage The maximum permissible deviation in supply voltage is ±10% of the rated voltage.

The voltage difference between the individual phases must not exceed 1 %.

6.2.2 Frequency of starts

CAUTION

Excessive frequency of starts Risk of damage to the motor!

▷ Never exceed the specified frequency of starts.

To prevent high temperature increases in the motor and excessive loads on the motor, seal elements and bearings, the switching frequency shall not exceed 10 startups per hour.

These values apply to mains start-up (direct or with autotransformer, soft starter). This limitation does not apply to operation on a frequency converter.

CAUTION

Re-starting while motor is still running down Damage to the pump set!

▷ Do not re-start the pump set before it has come to a standstill. ▷ Never start up the pump set while the pump is running in reverse.

6.2.3 Frequency inverter operation Frequency inverter operation of the pump set is permitted in the frequency range

from 25 to 50 Hz.

6.2.4 Fluid handled

6.2.4.1 Temperature of the fluid handled The pump set is designed for transporting liquids. The pump set is not operational

under freezing conditions.

CAUTION

Danger of frost/freezing Damage to the pump set!

▷ Drain the pump set or protect it against freezing.

Refer to the maximum permissible fluid and ambient temperature on the name plate and in the data sheet.

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6.2.4.2 Density of the fluid handled The pump input power changes in proportion to the density of the fluid handled.

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6 Commissioning/Start-up/Shutdown

CAUTION

Impermissibly high density of the fluid handled Motor overload!

▷ Observe the information on fluid density indicated in the data sheet. ▷ Make sure the motor has sufficient power reserves.

6.2.4.3 Minimum level of fluid handled

CAUTION

Fluid level below the specified minimum Damage to the pump set by cavitation and air-entraining vortices!

▷ Never allow the fluid level to drop below the specified minimum.

The pump set is ready for operation when the fluid level has reached dimension "t1" as a minimum (see the corresponding general arrangement drawing).

Fig. 19: Example: minimum level of fluid handled

6.2.4.4 Abrasive fluids Do not exceed the maximum permissible solids content specified in the data sheet.

When the pump handles fluids containing abrasive substances, increased wear of the hydraulic system and shaft seal are to be expected. In this case, reduce the commonly recommended inspection intervals.

6.3 Shutdown/storage/preservation

6.3.1 Shutdown

CAUTION

Uncontrolled backflow of the fluid from the riser Damage to the pump set!

▷ Prevent any uncontrolled backflow of the fluid handled with suitable means. ▷ Control the fluid backflow, e.g. by throttling the gate valve in the discharge

line.

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6.3.2 Measures to be taken for shutdown

DANGER

Work on the pump set by unqualified personnel Danger of death from electric shock!

▷ Always have the electrical connections installed by a trained and qualified

electrician.

▷ Observe the IEC 60079 (DIN VDE 0100) regulation.

WARNING

Unintentional starting of pump set Risk of injury by moving parts!

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

out work on the pump set.

WARNING

Fluids and supplies posing a health hazard and/or hot fluids or supplies Risk of injury!

▷ Observe all relevant laws. ▷ When draining the fluid take appropriate measures to protect persons and the

environment.

▷ Decontaminate pumps which handle fluids posing a health hazard.

CAUTION

Danger of frost/freezing Damage to the pump set!

▷ If there is any danger of frost/freezing, remove the pump set from the fluid

handled and clean, preserve and store it.

The pump set remains installed

✓ Make sure sufficient fluid is available for the operation check run of the pump

set. For prolonged shutdown periods, start up the pump set regularly once every

1. three months for approximately one minute. This will prevent the formation of deposits within the pump and the pump intake area.

The pump (set) is removed from the pipe and stored

✓ All safety regulations are observed.

1. Clean the pump set.

2. Preserve the pump set.

3. Observe the instructions given. (⇨ Section 3.3 Page 14)

6.4 Returning to service

For returning the pump set to service observe the sections on commissioning/start-up (⇨ Section 6 Page 35) and operating limits .

For returning the pump set to service after storage also follow the instructions for maintenance/inspection.

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WARNING

Failure to re-install or re-activate protective devices Risk of personal injury from moving parts or escaping fluid!

▷ As soon as the work is complete, re-install and/or re-activate any safety-relevant

and protective devices.

NOTE

On pumps/pump sets older than 5 years we recommend replacing all elastomer seals.

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7.1 Safety regulations

The operator ensures that all maintenance, inspection and installation work is performed by authorised, qualified specialist personnel who are thoroughly familiar with the manual.

WARNING

Unintentional starting of pump set Risk of injury by moving parts!

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

out work on the pump set.

WARNING

Fluids and supplies posing a health hazard and/or hot fluids or supplies Risk of injury!

▷ Observe all relevant laws. ▷ When draining the fluid take appropriate measures to protect persons and the

environment.

▷ Decontaminate pumps which handle fluids posing a health hazard.

WARNING

Hot surface Risk of injury!

▷ Allow the pump set to cool down to ambient temperature.

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.

WARNING

Insufficient stability Risk of crushing hands and feet!

▷ During assembly/dismantling, secure the pump (set)/pump parts to prevent

tipping or falling over.

A regular maintenance schedule will help avoid expensive repairs and contribute to trouble-free, reliable operation of the pump, pump set and pump parts with a minimum of servicing/maintenance expenditure and work.

NOTE

All maintenance, service and installation work can be carried out by KSB Service or authorised workshops. Find your contact in the attached "Addresses" booklet or on the Internet at "www.ksb.com/contact".

Never use force when dismantling and reassembling the pump set.

7.2 Maintenance/inspection

KSB recommends the following regular maintenance schedule:

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Table 8: Overview of maintenance work

Maintenance interval Servicing/maintenance work For details see ...

Every 4,000 hours but at least once a year

Every 8,000 hours but at least every 3 years

Check the earth conductor. (⇨ Section 7.2.1.1 Page 41) Measure the insulation

(⇨ Section 7.2.1.2 Page 41) resistance. Check the cable strand. (⇨ Section 7.3.3 Page 44) Check the sensors. (⇨ Section 5.4.1.4 Page 30) Check the mechanical seal

(⇨ Section 5.2.3 Page 21) leakage. Change the lubricant. (⇨ Section 7.4.1 Page 46)

Every 16,000 hours but at least every 5 years

General overhaul (Re-lubricate the rolling element bearings (⇨ Section

7.4.2 Page 50) )

On G3 seawater variants the cathodic protection (anodes) must initially be checked after 6 months. Replace the anodes, if necessary. If the anode shows little wear the maintenance interval can be extended to 12 months.

7.2.1 Inspection work

7.2.1.1 Checking the earth conductor

1. Measure the resistance between earth conductor and earth. The resistance must be below 1 Ω.

Replace any damaged components by original spare parts.

DANGER

Defective earth conductor Electric shock!

▷ Never switch on a pump set with a defective earth conductor.

7.2.1.2 Measuring the insulation resistance Measure the insulation resistance of the motor winding during annual maintenance

work.

✓ The pump set has been disconnected in the control cabinet. ✓ Use an insulation resistance measuring device. ✓ The recommended measuring voltage equals 500 V (maximum permissible

1000 V). Measure the winding against earth.

1. To do so, connect all winding ends together.

2. Measure the winding temperature sensors against earth. To do so, connect all core ends of the winding temperature sensors together and connect all winding ends to earth.

⇨ The insulation resistance of the core ends against earth must not be lower than

1 MΩ. If the resistance measured is lower, power cable and motor resistance must be measured separately. Disconnect the power cable from the motor for this purpose.

NOTE

If the insulation resistance for one of the power cables is below 1 MΩ, the cable is defective and must be replaced.

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NOTE

If the insulation resistance values measured on the motor are too low, the winding insulation is defective. The pump set must not be returned to service in this case.

Temperature sensors in

the motor winding

Leakage sensors in the

Float switch (mechanical

leakage)

Bearing temperature

motor

seal

sensor

7.2.1.3 Checking the sensors

CAUTION

Excessive test voltage Damage to the sensors!

▷ Use a commercially available ohmmeter to measure the resistance.

The tests described below measure the resistance at the core ends of the control cable. The actual sensor function is not tested.

Table 9: Resistance measurement

Measurement between terminals ... Resistance

[Ω]

10 and 11 200 - 1000 31 and 32

If the specified tolerances are exceeded, disconnect the power cable at the pump set and repeat the check inside the motor. If the tolerances are exceeded here, too, the motor section has to be opened and overhauled. The temperature sensors are fitted in the stator winding and cannot be replaced.

If the sensors are defective, use the back-up sensors provided at the same place in the stator winding.

Table 10: Resistance measurement of the leakage sensor in the motor

Measurement between terminals ... Resistance

9 and earth conductor (PE) > 60

Lower resistance values suggest water ingress into the motor. In this case the motor section must be opened and overhauled.

Table 11: Resistance measurement of the float switch

Measurement between terminals ... Resistance

3 and 4 < 1 If the readings suggest an open switch, check for mechanical seal leakage. Table 12: Resistance measurement of the bearing temperature sensors

Measurement between terminals ... Resistance

15 and 16

16 and 17

100 - 120

[kΩ]

[Ω]

100 - 120

Optional

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7.3 Removing the pump set

7.3.1 Removing the pump set

DANGER

Insufficient preparation of work on the pump (set) Risk of injury!

▷ Properly shut down the pump set. ▷ Close the shut-off elements in suction and discharge line. ▷ Drain the pump and release the pump pressure. ▷ Close any auxiliary connections. ▷ Allow the pump set to cool down to ambient temperature.

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.

WARNING

Turnbuckle and shackle are not suitable for lifting the pump set Risk of injury! Damage to the pump set!

▷ Always use the lifting lugs of the support rope to lift the pump set.

✓ The power cables have been disconnected and secured against unitentional

start-up.

✓ The discharge tube is open; its opening is securely covered except for a gap

allowing work to continue.

✓ Suitable lifting equipment is provided.

Attach the hoisting chain or rope to the trolley.

2. Free the uppermost lifting lug from the cables, attach it to the eye hook and run the lifting equipment to a higher level.

3. Open and disconnect the turnbuckle.

NOTE

Prevent any loose parts from falling into the pump sump!

4. Pull the pump set up until it reaches the second lifting lug of the cables. Attach the hoisting chain or rope with the shackle to the first lifting lug

5. (together with the eye hook).

6. Unclip the eye hook and attach it to the second lifting lug.

7. Pull the pump set up until it reaches the third lifting lug. Free the hoisting chain or rope from the first lifting lug and attach it to the third lifting lug.

8. Pull the pump set up until it reaches the fourth lifting lug. Unclip the eye hook and attach it to the fourth lifting lug.

9. Repeat this procedure until the pump bail is located above the discharge tube, then attach it to the eye hook.

10. Remove the safety cover from the discharge tube.

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7 Servicing/Maintenance

11. Extract the pump set from the discharge tube, move it sideways and set it down.

WARNING

Pump set tipping over Risk of squashing hands and feet!

▷ Suspend or support the pump set.

CAUTION

Improper storage Damage to the power cables!

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

deformation.

▷ Protect the core ends against moisture.

12. To prevent the pump set from tipping over, do not disconnect it from the hook of the lifting equipment.

Clean the pump set (e.g. with water).

13.

14. Collect and properly dispose of any cleaning liquid.

7.3.2 Drainage/cleaning

WARNING

Fluids, 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 residues of the fluid

handled.

▷ Wear safety clothing and a protective mask, if required. ▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

1. Always flush the pump if it has been used for handling noxious, explosive, hot or other hazardous fluids.

Always flush and clean the pump before sending it to the workshop.

2. Make sure to add a certificate of decontamination. (⇨ Section 11 Page 98)

7.3.3 Checking the cables When removing the pump set from the discharge tube, check the hoisting rope and

the power cables for any damage. Replace any damaged components by original spare parts.

Longer sections of combined cables must be dismantled:

Remove the cables from the cable clamps.

2. Remove the spacer.

3. Roll up the power cables and place them next to the pump set.

4. Undo the shackle to separate the support rope from the pump set.

44 of 100

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(1)

903.02

411.02

7 Servicing/Maintenance

7.3.4 Checking the mechanical seal leakage

WARNING

Fluids, 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 residues of the fluid

handled.

▷ Wear safety clothing and a protective mask, if required. ▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

WARNING

Excess pressure inside the pump set Risk of injury when opening the pump set!

▷ Take care when opening the inner chambers. Equalise the pressure.

NOTE

Slight wear of the mechanical seal is unavoidable. This will be aggravated by abrasive substances contained in the fluid handled.

Checking the leakage chamber serves to assess the function of the drive-end mechanical seal.

Fig. 20: Checking the mechanical seal leakage

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

✓ A suitable container for the leakage is on hand. ✓ The pump is positioned horizontally on a level surface and is protected against

rolling off. (⇨ Section 3.2 Page 10)

Place the container underneath screw plug 903.02.

2. Remove screw plug 903.02 and joint ring 411.02. Observe the plate "Leakage drain".

3. Screw in a sufficiently long tube (1) with G 1/2 thread.

4. Carefully rotate the pump set until the tube points downwards.

5. Drain the leakage fluid into a container positioned underneath the tube. ⇨ If there is no leakage or, after several years of operation, only a small

amount, the mechanical seals are working properly. If the leakage exceeds 1 litre, the mechanical seals are defective and must be replaced.

6. Unscrew the tube (1).

7. Fit screw plug 903.02 together with a new joint ring 411.02.

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7 Servicing/Maintenance

Recommended lubricants:

7.4 Lubrication and lubricant change

7.4.1 Lubricating the mechanical seal The mechanical seal is supplied with lubricant from the lubricant reservoir.

7.4.1.1 Intervals Replace the lubricant every 8,000 operating hours but at least every 3 years.

7.4.1.2 Lubricant quality The lubricant reservoir is filled at the factory with an environmentally friendly, non-

toxic lubricant of medical quality (unless otherwise specified by the customer). The following lubricants can be used to lubricate the mechanical seals:

Table 13: Lubricant quality

Code Properties

Paraffin oil

white oil.

Alternative: motor oil

grades SAE 10W to

SAE 20W

▪ Merkur WOP 40 PB, made by SASOL ▪ Merkur white oil Pharma 40, made by DEA ▪ Thin-bodied paraffin oil No. 7174, made by Merck ▪ Equivalent brands of medical quality, non-toxic ▪ Water-glycol mixture

Kinematic viscosity at 40 °C < 20 mm2/s

Flash point (to Cleveland) > 160 °C

Solidification point (pour point) < -15 °C

WARNING

Lubricant contaminating fluid handled Hazard to persons and the environment!

▷ Using machine oil is only permitted if the oil is disposed of properly.

7.4.1.3 Lubricant quantity Table 14: Lubricant quantity

Pump size Lubricant quantity

[l]

650 - 364 1.6 650 - 365 1.6 650 - 404 1.6 650 - 405 1.6 800 - 505 1.8

46 of 100

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7 Servicing/Maintenance

7.4.1.4 Changing the lubricant

WARNING

Lubricants posing a health hazard and/or hot lubricants Hazard to persons and the environment!

▷ When draining the lubricant take appropriate measures to protect persons and

the environment.

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

WARNING

Excess pressure inside the pump set Risk of injury when opening the pump set!

▷ Take care when opening the inner chambers. Equalise the pressure.

WARNING

Improper handling when placing the pump set in a vertical/horizontal position Personal injury and damage to property!

▷ Depending on the size of the pump (set) use either one or two pieces of lifting

equipment.

▷ Use appropriate means to secure the pump set against overturning, tipping

over or rolling off.

▷ Maintain adequate safety distance during lifting operations (load may swing

when being lifted).

▷ Use additional supports for the transport holder to secure the pump set against

overturning.

7.4.1.4.1 Draining the lubricant

WARNING

Incorrect positioning Personal injury and damage to property!

▷ Set the pump set down in a vertical position with the motor on top. ▷ Use appropriate means to secure the pump set against overturning and tipping

over.

▷ Refer to the weights given in the data sheet/on the name plate.

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138

920.01

502

914.07 922

210

940.02

230

7 Servicing/Maintenance

Fig. 21: Removing the bellmouth

✓ The pump has been placed in vertical position with the bellmouth on wooden

supports and secured against tipping over.

✓ A suitable drain pan for collecting the lubricant is on hand.

Undo nuts 920.01.

2. Attach the eye hook to the bail and lift the pump set off the bellmouth with the casing wear ring.

3. Place the pump set in horizontal position on wooden supports and make sure it cannot roll off.

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Fig. 22: Removing the impeller

Undo socket head cap screws 914.07 and impeller nut 922.

5. Pull impeller 230 off shaft 210.

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903.01

411.01

(M)

7 Servicing/Maintenance

Fig. 23: Draining the lubricant

a Oil drain b Tube

The screw plug for the oil drain is positioned on the front face of pump casing 101.

Remove screw plug 903.01 and joint ring 411.01.

2. Screw in a sufficiently long tube (2) with G 1/2" thread.

3. Carefully rotate the pump set until the tube points downwards.

4. Collect the lubricant in a suitable container. To do so, slowly lift the pump a little. Properly dispose of the drained lubricant.

5. Remove the tube. Fit screw plug 903.01 (oil drain) and a new joint ring with liquid sealant.

7.4.1.4.2 Filling in the lubricant

Fig. 24: Filling in the lubricant Table 15: Key to the symbols and codes

Symbol Description

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

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7 Servicing/Maintenance

✓ The pump set has been placed in horizontal position and protected against

rolling off.

✓ Screw plug 903.01 and joint ring 411.01 have been removed from the filler

opening. Screw a sufficiently long tube with G 1/2" thread into the filler opening.

2. Fill the lubricant in through the tube until it overflows.

3. Remove the tube. Fit screw plug 903.01 and a new joint ring 411.01 with liquid sealant.

NOTE

For commissioning: If more than 1.0 litre of lubricant is required for topping up, this suggests a defect of the mechanical seal.

7.4.2 Lubricating the rolling element bearings The pump set is equipped with grease-lubricated, maintenance-free rolling element

bearings.

7.4.2.1 Intervals Change the grease when carrying out a general overhaul but at least every 5 years.

7.4.2.2 Grease quality

CAUTION

Mix of different grease types Damage to the pump set!

▷ Make sure to use the right type of grease. ▷ Never mix different types of grease.

Table 16: Lubricant characteristics

Base oil Type Thickener NLGI grade

Ester oil A Polyurea 2 265 to 295 > 250 -40 to +180 100 11

The following greases can be used to lubricate the rolling element bearings:

(ISO 2137)

Worked

penetration

at 25 °C, 0.1 mm

(ISO 2137)

Drop point

(ISO 2176)

[°C]

Application

temperature

range

[°C]

Viscosity

(DIN 51562)

[mm2/s]

at 40 °C at 100

The re-lubrication and maintenance intervals apply to the grease type originally used by the manufacturer:

▪ Type A: Klüberquiet BQH 72-102, made by Klüber Lubrication KG, München

(⇨ Section 7.4.2.1 Page 50)

℃

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7.4.2.3 Grease quantity Table 17: Grease quantity

Size Grease type Grease quantity

[cm3]

Drive end Pump end

650 - 364 Type A 30 600 650 - 365 Type A 30 600 650 - 404 Type A 30 600 650 - 405 Type A 30 600 800 - 505 Type A 30 600

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7 Servicing/Maintenance

7.5 Dismantling the pump set

7.5.1 General information/Safety regulations

DANGER

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

▷ Use the attachment point provided (eyebolt, lifting lug or bail) for attaching

lifting accessories.

▷ Never suspend the pump set by its power cable. ▷ Never use the lifting ropes included in KSB's scope of supply for lifting loads

other than the KSB product supplied.

▷ Securely attach the lifting ropes to the pump and crane.

WARNING

Unqualified personnel performing work on the pump (set) Risk of injury!

▷ Always have repair and maintenance work performed by specially trained,

qualified personnel.

WARNING

Hot surface Risk of injury!

▷ Allow the pump set to cool down to ambient temperature.

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.

WARNING

Excess pressure inside the pump set Risk of injury when opening the pump set!

▷ Take care when opening the inner chambers. Equalise the pressure.

WARNING

Components with sharp edges Risk of cutting or shearing injuries!

▷ Always use appropriate caution for installation and dismantling work. ▷ Wear work gloves.

WARNING

Pump set tipping over or rolling off Risk of personal injury!

▷ Make sure the pump set is secured against tipping over during the entire

dismantling process.

▷ For dismantling the pump set in horizontal position, secure it against rolling

off.

Observe the general safety instructions and information.

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138

920.01

502

7 Servicing/Maintenance

For dismantling and reassembly observe the general assembly drawing. In the event of damage you can always contact our service staff.

7.5.2 Preparing the pump set

1. De-energise the pump set and secure it against unintentional start-up. Remove the pump set from the discharge tube. (⇨ Section 7.3.1 Page 43)

3. Clean the pump set. (⇨ Section 7.3.2 Page 44)

4. Drain the lubricant. (⇨ Section 7.4.1.4.1 Page 47)

5. Drain the leakage chamber and leave it open for the duration of the disassembly.

7.5.3 Removing the bellmouth

Fig. 25: Removing the bellmouth

✓ The pump set has been disconnected from the power supply and secured

against unintentional start-up.

✓ The pump set has been placed in vertical position with the bellmouth on

wooden supports and secured against tipping over.

Undo nuts 920.01.

2. Attach the eye hook to the bail and lift the pump set off bellmouth 138. Casing wear ring 502 remains in bellmouth 138.

3. Place the pump set in horizontal position on wooden supports and make sure it cannot roll off.

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914.07 922

210

940.02

230

932.01

550.05 433.01

7 Servicing/Maintenance

7.5.4 Removing the impeller

Fig. 26: Removing the impeller

✓ The pump has been placed in horizontal position on wooden supports and is

protected against rolling off.

✓ The leakage has been drained.

Undo socket head cap screw 914.07 and impeller nut 922.

2. Pull impeller 230 off shaft 210.

3. Remove keys 940.02 from shaft 210.

4. Protect the shaft thread against damage.

7.5.5 Removing the mechanical seal

7.5.5.1 Removing the impeller-end mechanical seal

Fig. 27: Removing the mechanical seal

✓ The pump has been securely placed in horizontal position on wooden supports. ✓ The impeller has been removed.

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80-1

818

571

914.02

350

101

932.01

550.05

433.02

7 Servicing/Maintenance

✓ The lubricant has been drained.

Remove circlip 932.01 and disc 550.05.

2. Pull mechanical seal 433.01 off the shaft.

NOTE

To protect the mechanical seal against damage when pulling it off the shaft it is recommended to place a foil (no thicker than 0.3 mm) around the free shaft stub.

7.5.5.2 Removing the drive-end mechanical seal

Fig. 28: Removing the mechanical seal

✓ The impeller-end mechanical seal has been removed.

Suspend the pump set from the hoisting tackle and pull it upright. Sit the pump set on the bellmouth with pump casing 101 down.

2. Undo socket head cap screws 914.02.

3. Attach the lifting tackle to bail 571 and lift the pump set out of pump casing

101.

4. Place motor unit 80-1 including rotor 818 with bearing and bearing housing 350 on a wooden support and protect it against rolling off.

5. Remove circlip 932.01 and disc 550.05.

6. Carefully pull mechanical seal 433.02 and the mating ring of the mechanical seal off the shaft.

54 of 100

7.5.6 Dismantling the motor section When dismantling the motor section and the power cables make sure that the cores/

terminals are clearly marked for future reassembly.

7.5.6.1 Removing the motor housing cover

NOTE

The motor housing cover must only be removed to replace the power cable.

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812

571

914.03

835

350

7 Servicing/Maintenance

Fig. 29: Removing the motor housing cover

✓ Suitable lifting equipment is provided. ✓ The pump set has been disconnected from the power supply. It has been

securely placed on a level surface in vertical position.

Attach bail 571 to the lifting equipment.

2. Undo hexagon socket head cap screws 914.03.

3. Carefully lift off motor housing cover 812.

4. Remove the cable ties.

5. Lift the motor housing cover up further until the power and control cables can be disconnected.

6. Disconnect the cores of the control cable from the corresponding connector.

7. Disconnect the cores of the power cable from terminal board 835. Disconnect the earth conductor and the shield of shielded cables from bearing housing 350.

8. Set motor housing cover 812 down and secure it against rolling off.

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571

68-3.02 (82-11)

914.05

834.02

914.04

834.01

812

7 Servicing/Maintenance

Removing the power cable

Removing the control

cable

7.5.6.2 Dismantling the cable gland and power cable

Fig. 30: Dismantling the cable gland and power cable

✓ The motor housing cover has been removed, set down and protected against

rolling off.

Remove cover plate 82-11 or 68-3.02 from bail 571. Remove cable gland

834.01/02 as required for the replacement.

2. Undo screws 914.04 at cable gland 834.01.

3. Pull cable gland 834.01 out of the centring seat in motor housing cover 812.

✓ The motor housing cover has been removed, set down and protected against

rolling off. Disconnect the cores of the control cable from the connector.

2. Undo screws 914.05 at cable gland 834.02.

3. Pull cable gland 834.02 out of the centring seat in motor housing cover 812.

NOTE

It is recommended to keep a record of the core identification and lengths. This will facilitate installing the replacement cable gland.

7.6 Reassembling the pump set

7.6.1 General information/Safety regulations

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.

WARNING

Components with sharp edges Risk of cutting or shearing injuries!

▷ Always use appropriate caution for installation and dismantling work. ▷ Wear work gloves.

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412.08

914.05

834.01

412.07

914.04

834.03

812

243

7 Servicing/Maintenance

WARNING

Insufficient stability Risk of crushing hands and feet!

▷ During assembly/dismantling, secure the pump (set)/pump parts to prevent

tipping or falling over.

CAUTION

Improper reassembly Damage to the pump!

▷ Reassemble the pump (set) in accordance with the general rules of sound

engineering practice.

▷ Use original spare parts only.

NOTE

Apply liquid sealant to all screw plugs. Apply liquid sealant to all wetted clearances (e.g. Hylomar SQ 32M).

Sequence

Always reassemble the pump set in accordance with the corresponding general assembly drawing.

Sealing elements

▪ O-rings

– Check O-rings for any damage and replace by new O-rings, if required. – Never use O-rings that have been glued together from material sold by the

metre.

▪ Assembly adhesives

– Avoid the use of assembly adhesives, if possible.

Tightening torques

For reassembly, tighten all screws and bolts as specified in this manual. (⇨ Section 7.8 Page 65)

7.6.2 Installing the replacement cable gland

Connecting the power

cable

Fig. 31: Installing the cable gland Table 18: Key to the symbols and codes

Symbol Description

Always secure screwed connections marked with this symbol with Loctite 243.

✓ The motor housing cover has been removed, set down and protected against

rolling off.

1. Adjust the lengths of the cable cores to those of the original cable gland.

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571

901.02

812

350.02

914.03

80-1

571

903.04

411.04

550.23

932.23 835

82-11

68-3.02

901.20

932.20

243

Connecting the control

cable

7 Servicing/Maintenance

2. Attach the core identification to match the original cable gland. Slide O-ring 412.08 onto the core ends of the power cable and into the groove

3. of the centring seat.

4. Insert cable gland 834.01 with the power cable and O-ring 412.08 into the opening provided.

5. Fasten cable gland 834.01 with hexagon socket head cap screws 914.05 and secure the screwed connection with Loctite 243.

6. Fasten cable terminals to the core ends.

✓ The motor housing cover has been removed, set down and protected against

rolling off. Adjust the lengths of the cable cores to those of the original cable gland.

2. Attach the core identification to match the original cable gland.

3. Guide O-ring 412.07 onto the short core ends of the control cable and into the groove of the centring seat.

4. Insert cable gland 834.03 with the control cable and O-ring 412.07 into the opening provided.

5. Fasten cable gland 834.03 with hexagon socket head cap screws 914.04 and secure the screwed connection with Loctite 243.

7.6.3 Fitting the motor housing cover

DANGER

Work on the pump set by unqualified personnel Danger of death from electric shock!

▷ Always have the electrical connections installed by a trained and qualified

electrician.

▷ Observe regulations IEC 60364 and, for explosion-proof models, EN 60079.

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Fig. 32: Fitting the motor housing cover

a Anti-rotation device of the

bearing housing

✓ A new O-ring has been inserted into the groove of bearing housing 350.02.

Attach lifting tackle to bail 571, lift up motor housing cover 812 and lower it

b Recess for anti-rotation device in

the motor housing cover

down onto bearing housing 350.02 until only a gap remains which allows work to continue.

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932.01

550.05

433.02

914.02 80-1 571350.01

818

243

7 Servicing/Maintenance

2. Connect the control cable to the terminal strip as indicated. Connect the power cable cores to terminal board 835 with disc 550.23, circlip

932.23 and nuts in accordance with the wiring diagram.

4. Fasten the earth conductor (conductor marking green/yellow) of the power cable to bearing housing 350.02 with bolt 901.20 and spring washer 932.20.

5. Tie the control and power cables together with cable ties.

6. Slowly lower motor housing cover 812 onto motor housing 811. Align the antirotation device of the bearing housing with the recess in the motor housing cover.

7. Fasten motor housing cover 812 to motor housing 811 or motor unit 80-1 with hexagon socket head cap screws 914.03. Secure the screwed connection with Loctite 243. Observe the tightening torque! (⇨ Section 7.8 Page 65)

8. Perform a leak test on the motor.

9. Fasten bail 571 with hexagon head bolts 901.02. Observe the tightening torque! (⇨ Section 7.8 Page 65)

10. Insert the power and control cables with cable protectors 81-97 into cover plate 82-11 or 68-3.02.

11. Fasten the cover plate to the bail.

7.6.4 Installing the mechanical seal Observe the following to ensure trouble-free operation of the mechanical seal:

▪ Only remove the protective wrapping of the contact faces immediately before

assembly takes place.

▪ The shaft surface must be absolutely clean and undamaged. ▪ Immediately before installing the mechanical seal, wet the contact faces with a

drop of oil.

▪ For easier installation of bellows-type mechanical seals, wet the inside diameter

of the bellows or the O-rings with soapy water (not oil).

▪ Cover any grooves in the shaft into which the O-rings could slide with suitable

means or assembly aids.

▪ To prevent any damage to the rubber bellows, place a thin foil (of approximately

0.1 to 0.3 mm thickness) around the free shaft stub. Slide the rotating assembly over the foil into its installation position. Then remove the foil.

7.6.4.1 Installing the drive-end mechanical seal

Fig. 33: Installing the drive-end mechanical seal

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7 Servicing/Maintenance

Table 19: Key to the symbols and codes

Symbol Description

Always secure screwed connections marked with this symbol with Loctite 243.

✓ The pump set has been positioned horizontally on suitable wooden supports

and is protected against rolling off. Press the mating ring of mechanical seal 433.02 including an O-ring into the

1. indicated drilled seat of bearing housing 350.01.

2. Slide the bellows part of mechanical seal 433.02 onto the shaft until it rests against the mating ring.

3. Slide disc 550.05 and circlip 932.01 onto the shaft. Press the circlip in with an assembly sleeve until it is axially fastened in the shaft groove.

4. Screw the testing device into the leakage drain hole (X) of bearing housing

350.01 and perform a leak test. (⇨ Section 7.6.4.1.1 Page 60)

5. Attach the eye hook to the bail and pull upright motor unit 80-1 including rotor 818 with bearing and bearing housing 350.01.

6. Place the pump set on the pump casing and bellmouth. Fasten it with hexagon socket head cap screws 914.02. Secure the screwed connection with a threadlocking agent (Loctite 243).

7.6.4.1.1 Leak test when installing the mechanical seal Observe the following values for leak testing:

▪ Test medium: compressed air ▪ Test pressure: 1 bar max. ▪ Test period: 5 minutes

The pressure must not drop during the test period.

1. If the pressure does drop, check the seals and screwed connections. Then perform another leak test.

2. If the test has been successful, remove the testing device. Do not close the leakage drain hole to allow drainage of any water ingress.

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932.01

550.05 433.01

914.07 922

210

940.02

230

7 Servicing/Maintenance

7.6.4.2 Installing the impeller-end mechanical seal

Fig. 34: Installing the impeller-end mechanical seal

✓ The pump casing has been fastened to the motor. ✓ The pump has been positioned horizontally on a wooden support and is

protected against rolling off.

Use an assembly sleeve of a suitable diameter to push the mating ring of mechanical seal 433.01 together with the O-ring into the drilled recess in the pump casing.

2. Carefully push in the bellows part of the mechanical seal until it rests against the mating ring.

3. Guide disc 550.05 and circlip 932.01 onto the shaft and push the circlip in with an assembly sleeve until it is axially fastened to the shaft groove.

4. Test the lubricant reservoir for leakage.

5. Fill the lubricant reservoir with lubricant. Then close the lubricant reservoir.

7.6.5 Fitting the impeller

Fig. 35: Fitting the impeller

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920.01

571

502

138

243

7 Servicing/Maintenance

✓ The pump has been placed in horizontal position on a wooden support and is

protected against rolling off.

✓ The impeller-end mechanical seal 433.02 has been installed.

Insert and fit two keys 940.02 into the keyway.

2. Coat all sides of the shaft seat and shaft thread with an assembly paste which prevents seizure of the chrome steel parts.

3. Guide impeller 230 onto shaft 210 until it abuts against the shaft collar. ⇨ This is as far as the impeller can move along the shaft. This position results in

the maximum possible clearance between bellmouth with casing wear ring and impeller vanes.

4. Screw impeller nut 922 onto the shaft thread.

5. Align the holes of impeller 230 and impeller nut 922 and fasten them with hexagon socket head cap screws 914.07.

7.6.6 Fitting the bellmouth

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Fig. 36: Aligning and fitting the bellmouth

a Bail b Baffles in the bellmouth

Table 20: Key to the symbols and codes

Symbol Description

Always secure screwed connections marked with this symbol with Loctite 243.

✓ Bellmouth 138 has been positioned on wooden supports on a level and solid

surface.

✓ Suitable lifting equipment is provided. ✓ The pump set has been completely pre-assembled. ✓ Casing wear ring 502 has been fitted in bellmouth 138.

Attach the lifting tackle to bail 571 and carefully pull the pump set upright.

2. Centre the pump set above bellmouth 138. Note: Make sure that the pin of bail 571 for attaching the lifting tackle and the baffles in bellmouth 138 are aligned in the same direction.

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914.07

922

230

502

243

7 Servicing/Maintenance

3. Slowly lower the pump set. While lowering the pump set, make sure that studs

920.01 are aligned with the drilled holes. Then lower the pump set until it sits on bellmouth 138.

5. Fasten all studs 902.01 with corresponding nuts 920.01. Observe the tightening torque! (⇨ Section 7.8 Page 65)

7.6.7 Adjusting the clearance

Fig. 37: Adjusting the clearance Table 21: Key to the symbols and codes

Symbol Description

Always secure screwed connections marked with this symbol with Loctite 243.

✓ The pump has been placed in horizontal position on wooden supports and is

protected against rolling off.

✓ The pump set has been completely assembled.

Undo socket head cap screw 914.07 and impeller nut 922.

2. Screw bolts and/or threaded rods into the tapped holes on the face of impeller 230 to pull the impeller forward until the impeller vanes abut the bellmouth/ casing wear ring 502.

⇨ This is the maximum front position of the impeller (clearance = 0).

3. Screw on impeller nut 922 until it abuts the front face of the impeller hub.

4. Screw the impeller nut on further (by dimension "B") to move the impeller along the shaft until the specified clearance "A" is established.

5. Use a feeler gauge to measure and verify the adjusted clearance between the impeller vanes and casing wear ring 502. Perform this measurement at several points spaced around the circumference.

6. Align two tapped holes in the impeller hub with two holes in the impeller nut.

⇨ Screw the impeller nut on slightly further until the holes match. ⇨ If avoidable, do not loosen the nut to match the holes.

7. Secure the impeller nut with socket head cap screws 914.07 and a threadlocking agent. Rotate the pump rotor by hand to check the clearance. During rotation the impeller must not touch any part of the casing.

Table 22: Clearances "A" and "B"

Size

Amacan S ....

650 - 364 0.45 650 - 365 0.45

Clearance "A"

[mm]

+0.2

-0.1

+0.2

-0.1

Clearance "B"

[mm]

+0.6

1.5

-0.3

+0.6

1.5

-0.3

Amacan S

63 of 100

Page 64

P 1,0 bar

7 Servicing/Maintenance

Size

Amacan S ....

650 - 404 0.55 650 - 405 0.55 800 - 505 0.55

7.6.8 Leak testing

7.6.8.1 Checking the lubricant reservoir for leakage

Clearance "A"

[mm]

+0.2

-0.1

+0.2

-0.1

+0.2

-0.1

Clearance "B"

[mm]

+0.6

1.7

-0.3

+0.6

1.6

-0.3

After reassembly the mechanical seal area/lubricant reservoir must be tested for leakage. The leak test is performed at the lubricant filler opening.

Observe the following values for leak testing:

▪ Test medium: compressed air ▪ Test pressure: 1 bar max. ▪ Test period: 5 minutes

Fig. 38: Screwing in the testing device

✓ The impeller-end mechanical seal has been installed.

Screw the testing device tightly into the G 1/2 lubricant filler opening.

2. Carry out the leak test with the values specified above. The pressure must not drop during the test period. If the pressure does drop, check the seals and screwed connections.

3. Repeat the leak test, if required.

4. If the leak test has been successful, fill in the lubricant. (⇨ Section 7.4.1.4.2 Page

49)

5. Close screw plug 903.01 with new joint ring 411.01 and liquid sealant.

7.6.8.2 Testing the motor for leakage

CAUTION

Screw plug leaking or missing Damage to the motor!

▷ Never start up a pump set without screw plug 903.04. ▷ Apply a thread-locking agent (Loctite 243) to screw plug 903.04.

Observe the following values for leak testing:

▪ Test medium: nitrogen ▪ Test pressure: 0.8 bar maximum ▪ Test duration: 2 minutes

64 of 100

Amacan S

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0 , 8 b a r

243

7 Servicing/Maintenance

Fig. 39: Leak test of motor space

Remove screw plug 903.04 and joint ring 411.04 at the motor housing cover.

2. Screw the testing device tightly into the hole.

3. Carry out the leak test with the values specified above. The pressure must not drop during the test period. If the pressure does drop, check the seals and screwed connections. Repeat the leak test.

4. Remove the testing device.

5. Apply a thread-locking agent (Loctite 243) and liquid sealant to screw plug

903.04.

6. Re-insert screw plug 903.04 with new joint ring 411.04.

Table 23: Key to the symbols and codes

Symbol Description

Always secure screwed connections marked with this symbol with Loctite 243. Always apply a liquid sealing agent (e.g. Hylomar SQ32M) to sealing surfaces marked with this symbol.

7.7 Checking the electrical connection and motor

Once reassembly has been completed, carry out the steps described in (⇨ Section

7.2.1 Page 41) .

7.8 Tightening torques

Table 24: Bolt tightening torques [Nm] depending on thread, type of steel and property class

Type of steel

Property class 8.8 -50 -70 R

Thread Mini-

M4 3,0 3,4 1,0 1,1 2,1 2,4 2,5 2,8 2,1 2,4 M5 6,1 6,8 2,0 2,2 4,3 4,8 5,0 5,6 4,3 4,8 M6 10,3 11 3,4 3,7 7,2 8,0 8,5 9,5 7,2 8,0

M8 25 28 8,2 9,1 18 19 21 23 18 19 M10 49 55 16 18 35 38 41 45 35 38 M12 85 94 28 31 59 66 70 78 59 66 M14 134 149 44 49 94 105 111 124 94 105 M16 209 232 69 76 147 163 173 192 147 163 M20 408 453 134 149 287 319 338 375 287 319 M24 704 782 231 257 495 550 583 648 495 550 M27 1025 1139 36 374 721 801 849 944 721 801 M30 1403 1559 460 511 986 1096 1162 1291 986 1096 M33 1888 2098 619 688 1327 1475 1563 1737 1327 1475 M36 2445 2717 802 891 1719 1910 2025 2250 1719 1910 M42 3904 4338 1281 1423 2745 3050 3233 3592 2745 3050 M48 5880 6534 1929 2144 4135 4594 4870 5411 4135 4594

mum

Rated

torque

A2, A4 A2, A4 1.4410 1.4462

Minimum

Tightening torque MA [Nm]

Rated

torque

Mini-

mum

Rated

torque

≥ 530 N/mm

p0.2

Minimum

Rated

torque

Mini-

≥ 450 N/mm

p0.2

mum

Rated

torque

Amacan S

65 of 100

Page 66

7 Servicing/Maintenance

NOTE

If using an adjustable torque wrench or screwdriver, adjust it to a value within the indicated range between the minimum and the rated torque.

7.9 Spare parts stock

Table 25: Quantity of spare parts for recommended spare parts stock

Part No. Description Number of pumps (including stand-by pumps)

230 Impeller 1 1 1 2 2 3 30 % 320 / 321

Rolling element bearing, pump end

322 Rolling element bearing,

drive end

412.05 O-ring, for discharge tube cover

433.01 Mechanical seal, pump end 2 3 4 5 6 7 90 %

433.02 Mechanical seal, drive end 2 3 4 5 6 7 90 %

502 Casing wear ring 2 2 2 3 3 4 50 % 80-1 Motor unit - - - - 1 2 30 % 818 Rotor - - - - 1 2 30 % 834 Cable gland 1 1 2 2 2 3 40 % 99-9 Set of sealing elements,

motor

99-9 Set of sealing elements,

hydraulic system

7.9.1 Ordering spare parts Always quote the following data when ordering replacement or spare parts:

▪ Pump type ▪ KSB order number ▪ Motor number

Refer to the name plate for all data. Also supply the following data:

▪ Description ▪ Part No. ▪ Quantity of spare parts ▪ Shipping address ▪ Mode of dispatch (freight, mail, express freight, air freight)

Refer to the general assembly drawing for part numbers and descriptions.

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

2 3 4 5 6 8 10 and

1 1 2 2 3 4 50 %

2 3 4 5 6 8 100 %

4 6 8 8 9 10 100 %

66 of 100

Amacan S

Page 67

8 Trouble-shooting

WARNING

Improper work to remedy faults at the pump (set) Risk of injury!

▷ For any work to remedy faults at the pump (set) observe the relevant

information in this manual or in the relevant accessory manufacturer's documentation.

Pump is running but does not deliver

Pump delivers insufficient flow rate

Excessive current/power consumption

Insufficient discharge head

Vibrations and noise during pump operation

Table 26: Trouble-shooting

A B C D E Possible cause Remedy

The pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure. Disconnect the pump set from the power supply!

✘

✘ ✘

✘ ✘ ✘

✘ ✘

✘ ✘ ✘ ✘ Wear Replace worn components by new ones. ✘

✘

✘ Water level lowered too much during

operation

✘ Total pressure corresponding to NPSH

high Total pressure corresponding to NPSH

low

✘ Penetration of air into the pump due to

formation of an air pocket

- Suction-side water level too low

✘ Unfavourable flow to the pump inlet Improve the flow to the intake chamber

✘ Pump running in off-design conditions

- low flow/overload

✘ ✘ Pump clogged by deposits Clean intake and pump components.

✘ ✘ Impermissible air or gas content in the fluid

handled

✘ System-induced vibrations Contact KSB.

✘

✘ Wrong direction of rotation Check the connection of the motor and

No voltage Check the electrical installation.

Motor winding or electric cable are defective. Replace with original KSB cable or contact

✘

✘ Worn or defective rolling element bearings Contact KSB.

The thermistor tripping unit with manual reset for temperature limiter has tripped the pump as a result of the permissible winding temperature being exceeded. Motor has been tripped by leakage monitor. Have cause determined and eliminated by

Mechanical seal monitor has tripped. Have cause determined and eliminated by

Bearing temperature monitor has tripped. Have cause determined and eliminated by

pump

system

Check supply and capacity of system (sump floor area).

Check level control equipment.

too

Increase fluid level on the suction side. Clean screening equipment, if required.

too

Increase the suction-side water level. If this is not possible or unsuccessful, contact KSB.

(contact KSB). Check the pump's operating data.

Contact KSB.

switchgear, if any.

Contact the energy supplier.

KSB.

Have cause determined and eliminated by qualified and trained personnel.

qualified and trained personnel.

Amacan S

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Page 68

834.03

412.08

914.04

901.02

812

932.03

758

69-6.01

520.01

322

932.04

421.02

80-1

360

914.01

836.01

914.02

99-17

421.01

350.01

412.01

502

903.01

411.01

230

922

138

914.07

940.02

433.01

902.01

920.01

412.05

433.02

101

81-45

321

320

903.02

411.02

412.02

411.26

81-56

69-6.01

818

500.02

563

350.02

412.03

914.03

835

885

412.07

914.05

903.04

411.04

834.01

571

QNB50

243

932.02

500.01

9 Related Documents

9.1 General assembly drawing of pump sets with UAG motors (DKA motor)

Fig. 40: General assembly drawing

68 of 100

Amacan S

Page 69

920.25

550.25

68-3.02

81-97.01

81-97.02

59-7.01

550.25

901.25

A -- A

932.01

550.05 433.01

433.02

836.02

914.19

901.20

99-17

932.20

B - B

970.04

970.03

970.05

970.01

970.02

243

Q NB 50

9 Related Documents

Table 27: Detailed views

Detailed view: bracket Detailed view: mechanical seal

Detailed view: connection space Pump signage

Table 29: List of components

Part No. Description Part No. Description

101 Pump casing 758 Strainer insert 138 Bellmouth 80-1 Motor unit 230 Impeller 81-45 Float switch 320 Angular contact ball

321 Deep groove ball bearing 81-97.01/.02 Cable protector 322 Cylindrical roller bearing 812 Motor housing cover

350.01/.02 Bearing housing 818 Rotor

970.01 - factory name plate

970.02 - name plate

970.03 - oil drain

970.04 - oil filler plug

970.05 - leakage drain

Table 28: Key to the symbols and codes

Symbol Description

Always secure screwed connections marked with this symbol with Loctite 243. Always apply a liquid sealing agent (e.g. Hylomar SQ32M) to sealing surfaces marked with this symbol. Use a lubricant paste (e.g. Altemp Q NB 50).

81-56 Moisture protection (motor)

bearing

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9 Related Documents

Part No. Description Part No. Description

360 Bearing cover 834.01/.03 Cable gland

411.01/.02/.04/.26 Joint ring 835 Terminal board

412.01/.02/.03/.05/.07/.08 O-ring 836.01/.02 Terminal strip

421.01/.02 Lip seal 885 Chain

433.01/.02/.03 Mechanical seal 99-17 Desiccant

59-7.01 Support spacer 901.02/.20/.25 Hexagon head bolt

500.01/.02 Ring 902.01 Stud

502 Casing wear ring 903.01/.02/.04 Screw plug

520.01 Sleeve 914.01/.02/.03/.04/.05/.07/.19 Hexagon socket head cap

screw

550.05/.25 Disc 920.01/.25 Nut

563 Pin 922 Impeller nut 571 Bail 932.01/.02/.03/.04/.20 Circlip 68-3.02 Cover plate 940.02 Key 69-6.01 Temperature sensor 970.01/.02/.03/.04/.05 Label/plate

70 of 100

Amacan S

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A A

M M

59-8

59-17.2

733.5

720

59-24

59-17.1

59-47.99

59-8

59-17.2

720

59-24

733.5

59-17.3

59-7

59-17.3

59-24

59-17.1

59-47

A - A

720

733.5

719.5

59-24

9 Related Documents

9.2 Cable guide

Fig. 41: Cable guide a) basic design b) with intermediate ring c) with support

Fig. 42: Cross-section A - A, position of power cable, control cable and rope

c Power cable d Control cable

Table 30: List of components cable guide

Part No. Description Part No. Description

59-7 Support 59-47 Lifting lug 59-8 Turnbuckle 719 Sheathing 59-17 Shackle 720 Spacer 59-24 Rope 733 Clamp

NOTE

Dimension M = 50 mm to 100 mm

Amacan S

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Page 72

(black)

(brown)

(grey)

(geen/yellow)

L1 L2 L3

9 Related Documents

9.3 Wiring diagrams

9.3.1 Wiring diagram

Fig. 43: Drawing of auxiliary connections * Shielded cable optional

Up to 6 parallel cable pairs possible

72 of 100

Amacan S

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(green/yellow)

9 Related Documents

9.3.2 Wiring diagrams for the sensors

Standard

pump sets

Fig. 44: Wiring diagram for sensors of standard pump sets

* Shielded cables optional

Ⓐ Motor temperature (PTC) Ⓑ Mechanical seal leakage Ⓒ Bearing temperature (lower bearings) Ⓓ Bearing temperature (upper bearing) Ⓕ Leakage inside the motor

Amacan S

73 of 100

Page 74

(green/yellow)

Pump sets

with additional PT100

motor temperature

monitoring

9 Related Documents

Fig. 45: Wiring diagram with PT100

Ⓐ Motor temperature (PTC) Ⓑ Mechanical seal leakage Ⓒ Bearing temperature (lower bearings) Ⓓ Bearing temperature (upper bearing) Ⓕ Leakage inside the motor Ⓗ Motor temperature (PT100)

74 of 100

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9 Related Documents

9.4 Dimensions

Fig. 46: Dimensions of the pump set

Table 31: Dimensions of the pump set [mm]

Size Motor

size

Num

ber

[kg]

pole

650 - 364 45 4 2090 2042 260 1605 625 500 510 390 35 651 70 970 650 - 364 65 4 2090 2042 260 1605 625 500 510 390 35 651 70 970 650 - 364 80 4 2290 2242 260 1805 625 500 510 390 35 651 70 1080 650 - 365 65 4 2090 2042 260 1605 625 500 510 390 35 651 70 960 650 - 365 80 4 2290 2242 260 1805 625 500 510 390 35 651 70 1070 650 - 365 100 4 2290 2242 260 1805 625 500 510 390 35 651 70 1100 650 - 365 120 4 2290 2242 260 1805 625 500 510 390 35 651 70 1150 650 - 404 80 4 2305 2258 290 1820 620 – 500 390 35 665 70 1080 650 - 404 100 4 2305 2258 290 1820 620 – 500 390 35 665 70 1120 650 - 404 120 4 2305 2258 290 1820 620 – 500 390 35 665 70 1170 650 - 404 140 4 2505 2458 290 2020 620 – 500 390 35 665 70 1300 650 - 405 120 4 2305 2258 290 1820 620 – 500 390 35 665 70 1160 650 - 405 140 4 2505 2458 290 2020 620 – 500 390 35 665 70 1290 650 - 405 160 4 2585 2528 290 2100 620 – 500 480 45 665 90 1550 650 - 405 180 4 2585 2528 290 2100 620 – 500 480 45 665 90 1610 650 - 405 200 4 2665 2608 290 2180 620 – 500 480 45 665 90 1690 650 - 405 220 4 2665 2608 290 2180 620 – 500 480 45 665 90 1730 800 - 505 100 6 2375 2328 370 1890 775 665 645 390 35 795 70 1340 800 - 505 120 6 2375 2328 370 1890 775 665 645 390 35 795 70 1380 800 - 505 140 6 2575 2528 370 2090 775 665 645 390 35 795 70 1480 800 - 505 150 6 2520 2463 370 2035 775 665 645 480 45 795 90 1790 800 - 505 175 6 2600 2543 370 2115 775 665 645 480 45 795 90 1890

Pump set complete with 10 m power cable and 5 m support rope

Amacan S

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Page 76

45°

9 Related Documents

Fig. 47: Dimensions of the discharge tube

A Suction umbrella; option for reducing the minimum water level

1) This dimension depends on the type of installation, see general arrangement drawings

Table 32: Dimensions of the discharge tube [mm]

Size Motor size Number of

D d

poles

650 - 364 45 4 660 530 900 225 7,1 650 - 364 65 4 660 530 900 225 7,1 650 - 364 80 4 660 530 900 225 7,1 650 - 365 65 4 660 530 900 225 7,1 650 - 365 80 4 660 530 900 225 7,1 650 - 365 100 4 660 530 900 225 7,1 650 - 365 120 4 660 530 900 225 7,1 650 - 404 80 4 660 530 900 265 7,1 650 - 404 100 4 660 530 900 265 7,1 650 - 404 120 4 660 530 900 265 7,1 650 - 404 140 4 660 530 900 265 7,1 650 - 405 120 4 660 530 900 265 7,1 650 - 405 140 4 660 530 900 265 7,1 650 - 405 160 4 660 530 900 265 7,1 650 - 405 180 4 660 530 900 265 7,1 650 - 405 200 4 660 530 900 265 7,1 650 - 405 220 4 660 530 900 265 7,1 800 - 505 100 6 813 680 1050 335 8 800 - 505 120 6 813 680 1050 335 8 800 - 505 140 6 813 680 1050 335 8 800 - 505 150 6 813 680 1050 335 8 800 - 505 175 6 813 680 1050 335 8

76 of 100

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①

geo

100

②

③

0 - 10° v

max

= 1 m/s

B - B

100

350

A-A

45°

9 Related Documents

9.5 General arrangement drawings

9.5.1 Example of installation type BU

Foundation recesses

Detail X:

support plate of the discharge tube

Drawing: without pump

Detail Y:

①: Minimum water level (values see diagram on the next page),

seating ring

②: Approach flow, ③: Flow-straightening vane (⇨ Section 9.5.7 Page 95)

Table 33: Dimensions [mm]

Size D b b

650 - 364 660 1000 200 – 200 – 530 660 900 700 650 - 365 660 1000 200 – 200 – 530 660 900 700 650 - 404 660 1000 200 – 200 – 530 660 900 700

without

suction

umbrella d

with

suction

umbrella d

without

suction

umbrella d

suction

umbrella d

with

All dimensions for foundation recesses apply to discharge tube design without intermediate flange.

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Page 78

7°

0,1 0,2 0,3 0,4 0,5 0,6 0,8 1 2 3 4 5 6

0,1

0,2

0,3

0,4

0,5

0,6

0,8

[m]

Q [m

/s]

DA = 400 mm

DA = 600 mm D

= 800 mm

= 1000 mm

= 1200 mm

= 1400 mm

= 1600 mm

= 1800 mm

= 2000 mm

= 2200 mm

9 Related Documents

Size D b b

without

suction

umbrella d

with

suction

umbrella d

without

suction

umbrella d

suction

umbrella d

with

650 - 405 660 1250 250 – 250 – 530 660 900 700 800 - 505 813 1250 250 – 250 – 680 810 1050 850

Table 34: Dimensions [mm]

Size

without suction

umbrella d

with suction

umbrella d

min.

m p

4 min.

650 - 364 420 540 225 580 750 850 590 260 2350 650 - 365 420 540 225 580 750 850 590 260 2350 650 - 404 420 540 265 580 750 850 590 260 2560 650 - 405 420 540 265 830 750 850 590 320 2720 800 - 505 500 620 335 750 910 1000 740 320 2660

t2 = 1.1 x water level; max. 2 x t1 (depending on head H and structure) Height of corner lining (b1 and b2) equals t

Permissible tolerances:

▪ Tolerances in building construction to DIN 18202, Part 4, Group B ▪ Welded constructions: B/F to DIN EN ISO 13920 ▪ Tolerances for conical seat (detail Y): ISO 2768-mH

Loss diagram

Overflow head h

Loss diagram

Calculation formulas: H = H

∆ H

+ ∆ H

geo

▪ Overflow head hü (see diagram)

▪ Loss in the riser (pipe friction) ▪ Outlet loss v2/2 g (v refers to DA)

Overflow head hü depends on Q and the discharge diameter DA. The characteristic

Always observe this dimension.

Value for maximum motor length

78 of 100

curve values only apply to unimpeded outlet in all directions; otherwise they are approximate values only.

Amacan S

Page 79

4000

3000

1600

1200 1000

500 400

2000

[mm]

0,1 0,2 0,5 1 1,5 2 3 4 5 6 8

Q [m

/s]

9 Related Documents

Minimum water level diagram

Open chamber

Minimum water level d8 = Design: without suction umbrella (standard)

d9 = Design: with suction umbrella

Amacan S

79 of 100

Page 80

③

0 - 90° v

max

= 1 m/s

②

B - B

geo

①

45°

100

350

A-A

45°

9 Related Documents

9.5.2 Example of installation type BG

Foundation recesses

10)

Detail X:

support plate of the discharge tube

Drawing: without pump

Detail Y:

seating ring

①: Minimum water level (values see diagram on the next page), ②: Approach flow, ③: Flow-straightening vane (⇨ Section 9.5.7 Page 95)

Table 35: Dimensions [mm]

Size D b b

650 - 364 660 1000 200 400 530 550 600 700 300

11)

650 - 365 660 1000 200 400 530 550 600 700 300 650 - 404 660 1000 200 400 530 550 600 700 300 650 - 405 660 1250 250 500 530 660 690 700 375 800 - 505 813 1250 250 500 680 700 735 850 375

10)

11)

80 of 100

All dimensions for foundation recesses apply to discharge tube design without intermediate flange. Always observe this dimension.

Amacan S

Page 81

7°

0,1 0,2 0,3 0,4 0,5 0,6 0,8 1 2 3 4 5 6

0,1

0,2

0,3

0,4

0,5

0,6

0,8

[m]

Q [m

/s]

DA = 400 mm

DA = 600 mm D

= 800 mm

= 1000 mm

= 1200 mm

= 1400 mm

= 1600 mm

= 1800 mm

= 2000 mm

= 2200 mm

9 Related Documents

Table 36: Dimensions [mm]

Size e

min

m p

11)

4 min

12)

650 - 364 500 225 1000 750 850 590 260 2350 375 650 - 365 500 225 1000 750 850 590 260 2350 375 650 - 404 500 265 1000 750 850 590 260 2560 375 650 - 405 625 265 1250 750 850 590 320 2720 470 800 - 505 625 335 1250 910 1000 740 320 2660 470

Permissible tolerances:

▪ Tolerances in building construction to DIN 18202, Part 4, Group B ▪ Welded constructions: B/F to DIN EN ISO 13920 ▪ Tolerances for conical seat (detail Y): ISO 2768-mH

Loss diagram

Overflow head h

Loss diagram

Calculation formulas: H = H

∆ H

+ ∆ H

geo

▪ Overflow head hü (see diagram)

▪ Loss in the riser (pipe friction) ▪ Outlet loss v2/2 g (v refers to DA)

Overflow head hü depends on Q and the discharge diameter DA. The characteristic curve values only apply to unimpeded outlet in all directions; otherwise they are

approximate values only.

12)

Value for maximum motor length

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81 of 100

Page 82

4000

3000 2500

1600

1200 1000

900 800 700 600

500

400

0,1 0,2 0,3 0,4 0,5 0,6 0,8 1 1,5 2,5 3 4 5 6 7 82

2000

t1[mm]

Q [m3/s]

9 Related Documents

Minimum water level diagram

Covered chamber

Minimum water level

82 of 100

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Page 83

①

0 - 10° v

max

= 1 m/s

②

③

④

B - B

geo

⑤

200

A -- A

250

300

200

45°

9 Related Documents

9.5.3 Example of installation type CU

Foundation recesses

13)

①: Vent line, ②: Minimum water level (values see diagram on the next page), ③: Approach flow, ④: Flow-straightening vane (⇨ Section 9.5.7 Page 95) ⑤: Connect the discharge pipe to the discharge tube without transmitting any stresses or strains.

Detail X:

support plate of the discharge tube

Drawing: without pump

Detail Y:

seating ring

13)

All dimensions for foundation recesses apply to discharge tube design without intermediate flange.

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Page 84

9 Related Documents

Table 37: Dimensions [mm]

Size D DN

min

14)

max

14)

b b

witho

suctio

umbr

ella d

with

suctio

umbr

ella d

witho

suctio

umbr

ella d

with

suctio

umbr

ella d

650 - 364 660 400 600 610 1050 800 405 1000 200 – 200 – 530 650 - 365 660 400 600 610 1050 800 405 1000 200 – 200 – 530 650 - 404 660 400 600 610 1050 800 405 1000 200 – 200 – 530 650 - 405 660 400 600 610 1050 800 405 1250 250 – 250 – 530 800 - 505 813 500 800 700 1220 970 480 1250 250 – 250 – 680

Table 38: Dimensions [mm]

Size d

witho

suctio

umbr

ella

15)

with

suctio

umbr

ella

min

16)

15)

min

17)

650 - 364 660 900 420 540 225 580 1100 430 1160 860 960 260 2350 720 650 - 365 660 900 420 540 225 580 1100 430 1160 860 960 260 2350 720 650 - 404 660 900 420 540 265 580 1100 430 1160 860 960 260 2600 720 650 - 405 660 900 420 540 265 830 1100 430 1160 860 960 320 2750 720 800 - 505 810 1050 500 620 335 750 1270 505 1375 1075 1175 320 2700 835

t2 = 1.1 x water level; maximum 2 x t1 (depending on head H and structure) Height of corner lining (b1 and b2) like t

Permissible tolerances:

▪ Tolerances in building construction to DIN 18202, Part 4, Group B ▪ Welded design: B/F to DIN EN ISO 13920 ▪ Tolerances for conical seat (detailed view Y): ISO 2768-mH ▪ Discharge flanges to DIN EN 1092-1 PN6, DIN EN 1092-2 PN6

16)

14)

Designed for DN 2 max.

15)

Always observe these dimensions.

16)

Designed for DN 2 max.

17)

Value for maximum motor length

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0,1 0,2 0,3 0,4 0,5 0,6 0,8 1 2 3 4 5 6

Q [m

/s]

0,1

0,2

0,3

0,4

0,5

0,6

0,8

1,0

2,0

V ges

[m]

2,5

1 2

4000

3000

1600

1200 1000

500 400

2000

[mm]

0,1 0,2 0,5 1 1,5 2 3 4 5 6 8

Q [m

/s]

Calculation formulas: H = H

∆ H

+ ∆ H

geo

comprises: ▪ Elbow

V ges.

9 Related Documents

Loss diagram

- Loss in the riser (pipe friction)

- H

(see diagram)

v ges.

▪ Discharge pipe length = 5 x DN

▪ Swing check valve ▪ Outlet losses v2/2g

Minimum water level diagram

Open chamber

① - DN2 = 200 mm ② - DN2 = 250 mm ③ - DN2 = 300 mm ④ - DN2 = 350 mm ⑤ - DN2 = 400 mm ⑥ - DN2 = 500 mm ⑦ - DN2 = 600 mm ⑧ - DN2 = 700 mm ⑨ - DN2 = 800 mm ⑩ - DN2 = 900 mm ⑪ - DN2 = 1000 mm ⑫ - DN2 = 1100 mm ⑬ - DN2 = 1200 mm ⑭ - DN2 = 1300 mm ⑮ - DN2 = 1400 mm ⑯ - DN2 = 1500 mm ⑰ - DN2 = 1600 mm

Minimum water level d8 = Design: without suction umbrella (standard)

d9 = Design: with suction umbrella

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①

②

geo

45°

0 - 90° v

max

= 1 m/s

③

④

B - B

⑤

200

A -- A

250

300

200

45°

9 Related Documents

9.5.4 Example of installation type CG

Foundation recesses

18)

Detail X:

support plate of the discharge tube

Drawing: without pump

Detail Y:

seating ring

18)

All dimensions for foundation recesses apply to discharge tube design without intermediate flange.

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0,1 0,2 0,3 0,4 0,5 0,6 0,8 1 2 3 4 5 6

Q [m

/s]

0,1

0,2

0,3

0,4

0,5

0,6

0,8

1,0

2,0

V ges

[m]

2,5

1 2

9 Related Documents

Table 39: Dimensions [mm]

Size D DN

min

19)

max

19)

b b

650 - 364 660 400 600 610 1050 800 405 1000 200 400 530 550 600 650 - 365 660 400 600 610 1050 800 405 1000 200 400 530 550 600 650 - 404 660 400 600 610 1050 800 405 1000 200 400 530 550 600 650 - 405 660 400 600 610 1050 800 405 1250 250 500 530 660 690 800 - 505 813 500 800 700 1220 970 480 1250 250 500 680 700 735

Table 40: Dimensions [mm]

Size

20)

min

19)

20)

21)

min

19)

min

650 - 364 300 500 225 1000 1100 430 1160 860 960 260 2350 720 375 650 - 365 300 500 225 1000 1100 430 1160 860 960 260 2350 720 375 650 - 404 300 500 265 1000 1100 430 1160 860 960 260 2600 720 375 650 - 405 375 625 265 1250 1100 430 1160 860 960 320 2750 720 470 800 - 505 375 625 335 1250 1270 505 1375 1075 1175 320 2700 835 470

Permissible tolerances:

Loss diagram

Calculation formulas: H = H

∆ H

19)

20)

21)

+ ∆ H

geo

- Loss in the riser (pipe friction)

- H

comprises: ▪ Elbow

V ges.

Designed for DN 2 max. Always observe this dimension. Value for maximum motor length

(see diagram)

v ges.

▪ Discharge pipe length = 5 x DN

▪ Swing check valve ▪ Outlet losses v2/2g

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4000

3000 2500

1600

1200 1000

900 800 700 600

500

400

0,1 0,2 0,3 0,4 0,5 0,6 0,8 1 1,5 2,5 3 4 5 6 7 82

2000

t1[mm]

Q [m3/s]

9 Related Documents

Minimum water level diagram

Covered chamber

Minimum water level

88 of 100

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0 - 10° v

max

= 1 m/s

①

③

④

B - B

②

⑥

⑤

200

A -- A

250

300

200

45°

9 Related Documents

9.5.5 Example of installation type DU

Foundation recesses

22)

support plate of the discharge tube

Drawing: without pump

①: Vent line, ②: Minimum water level (values see diagram on the next page), ③: Approach flow, ④: Flow-straightening vane (⇨ Section 9.5.7 Page 95) , ⑤: Not pressure-proof ⑥: Connect the discharge pipe to the discharge tube without transmitting any stresses or strains.

Detail X:

Detail Y:

seating ring

22)

All dimensions for foundation recesses apply to discharge tube design without intermediate flange.

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Table 41: Dimensions [mm]

9 Related Documents

Size D DN2 min DN2 max a a

b b

without

suction

umbrella

with

suction

umbrella

without

suction

umbrella

with

suction

umbrella

650 - 364 660 400 600 610 810 560 1000 200 – 200 – 530 650 - 365 660 400 600 610 810 560 1000 200 – 200 – 530 650 - 404 660 400 600 610 810 560 1000 200 – 200 – 530 650 - 405 660 400 600 610 810 560 1250 250 – 250 – 530 800 - 505 813 500 800 700 960 710 1250 250 – 250 – 680

Table 42: Dimensions [mm]

Size d

la d

23)

with suction umbrel

la d

min

m n p

withou

suction umbrel

23)

4 min

650 - 364 660 900 420 540 225 580 860 1110 810 910 260 2350 650 - 365 660 900 420 540 225 580 860 1110 810 910 260 2350 650 - 404 660 900 420 540 265 580 860 1110 810 910 260 2600 650 - 405 660 900 420 540 265 830 860 1110 810 910 320 2750 800 - 505 810 1050 500 620 335 750 1030 1260 960 1060 320 2700

t2 = 1.1 x water level; maximum 2 x t1 (depending on head H and structure) Height of corner lining (b1 and b2) like t

Permissible tolerances:

24)

23)

Always observe this dimension.

24)

Value for maximum motor length

90 of 100

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V Kr

[m]

0,1 0,2 0,3 0,4 0,5 0,6 0,8 1 2 3 4 5 6

Q [m

/s]

0,04

0,05

0,06

0,08

1,0

0,8

0,6

0,5

0,4

0,3

0,2

0,1

1 2

12 13

4000

3000

1600

1200 1000

500 400

2000

[mm]

0,1 0,2 0,5 1 1,5 2 3 4 5 6 8

Q [m

/s]

9 Related Documents

Loss diagram

Calculation formulas: H = H

∆ H

+ ∆ H

geo

▪ Loss in the elbow h

▪ Loss in the riser (pipe friction) ▪ H

must be determined for the specific system.

V System

Minimum water level diagram

Open chamber

Minimum water level d8 = Design: without suction umbrella (standard)

d9 = Design: with suction umbrella

(valves, etc. )

(see diagram)

V Kr

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0 - 90° v

max

= 1 m/s

③

④

45°

①

②

⑥

200

A -- A

250

300

200

45°

9 Related Documents

9.5.6 Example of installation type DG

Foundation recesses

25)

support plate of the discharge tube

Detail X:

Drawing: without pump

Detail Y:

①: Vent line, ②: Minimum water level (values see diagram on the next page), ③: Approach flow,

seating ring

④: Flow-straightening vane (⇨ Section 9.5.7 Page 95) , ⑤: Not pressure-proof ⑥: Connect the discharge pipe to the discharge tube without transmitting any stresses or strains.

25)

92 of 100

All dimensions for foundation recesses apply to discharge tube design without intermediate flange.

Amacan S

Page 93

Table 43: Dimensions [mm]

V Kr

[m]

0,1 0,2 0,3 0,4 0,5 0,6 0,8 1 2 3 4 5 6

Q [m

/s]

0,04

0,05

0,06

0,08

1,0

0,8

0,6

0,5

0,4

0,3

0,2

0,1

1 2

12 13

9 Related Documents

Size D DN2 min DN2 max a a

b b

650 - 364 660 400 600 610 810 560 1000 200 400 530 550 600 650 - 365 660 400 600 610 810 560 1000 200 400 530 550 600 650 - 404 660 400 600 610 810 560 1000 200 400 530 550 600 650 - 405 660 400 600 610 810 560 1250 250 500 530 660 690 800 - 505 813 500 800 700 960 710 1250 250 500 680 700 735

Table 44: Dimensions [mm]

Size

26)

min

m n p

26)

min

27)

650 - 364 300 500 225 1000 860 1110 810 910 260 2350 375 650 - 365 300 500 225 1000 860 1110 810 910 260 2350 375 650 - 404 300 500 265 1000 860 1110 810 910 260 2600 375 650 - 405 375 625 265 1250 860 1110 810 910 320 2750 470 800 - 505 375 625 335 1250 1030 1260 960 1060 320 2700 470

Permissible tolerances:

Loss diagram

Calculation formulas: H = H

∆ H

26)

27)

+ ∆ H

geo

must be determined for the specific system.

V System

Always observe this dimension. Value for maximum motor length

▪ Loss in the elbow h

(see diagram)

V Kr

▪ Loss in the riser (pipe friction) ▪ H

(valves, etc. )

V System

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Page 94

4000

3000 2500

1600

1200 1000

900 800 700 600

500

400

0,1 0,2 0,3 0,4 0,5 0,6 0,8 1 1,5 2,5 3 4 5 6 7 82

2000

t1[mm]

Q [m3/s]

9 Related Documents

Minimum water level diagram

Covered chamber

Minimum water level

94 of 100

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Page 95

(e1)

9 Related Documents

9.5.7 Outline drawing of the flow-straightening vane Design of the intake chamber wall surfaces (to prevent vortex formation)

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. In addition, the floor and wall surfaces of the intake chamber should be designed as a rough concrete surface. Rough surfaces minimise the separation of boundary layers that may cause wall and floor vortices.

Flow-straightening vane and intake chamber

▪ The anti-vortex vanes in the bellmouth must be aligned with the flow-

straightening vane.

▪ The bail of the pump is oriented in the same direction as the anti-swirl baffles in

the bellmouth.

Fig. 48: Installation position of the pump set

1 Bail 2 Anti-vortex vanes 3 Flow-straightening vane

Variant 1

Flow-straightening vane cast from

Variant 2

Steel section

concrete

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9 Related Documents

A Bolted to the floor of the intake chamber B Flow-straightening vane centred beneath the discharge tube C Discharge tube D Intake chamber

Dimensions for installation types BU, CU, DU

Table 45: Dimensions in [mm]

Size h

Design without

suction umbrella d

(e1)

28)

Design with

umbrella d

suction

Design without

suction umbrella d

Design with

suction

umbrella d

650 - 364 150 10 20 60 420 540 835 955 650 - 365 150 10 20 60 420 540 835 955 650 -404 150 10 20 60 420 540 835 955 650 - 405 190 10 20 70 420 540 875 1050 800 - 505 190 10 20 70 500 620 1050 1150

Dimensions for installation types BG, CG, DG Table 46: Dimensions in [mm]

Size h

650 - 364 150 10 20 60 650 - 365 150 10 20 60 650 - 404 150 10 20 60 650 - 405 190 10 20 70 800 - 505 190 10 20 70

Length IR of the flow-straightening vane must be adjusted to the 45° angle of the inlet chamber.

28)

See installation examples for types BU, CU and DU

96 of 100

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10 EC Declaration of Conformity

Manufacturer: KSB Aktiengesellschaft

Johann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the product:

KSB order number: ...................................................................................................

▪ is in conformity with the provisions of the following Directives as amended from time to time:

–

Pump (set): Machinery Directive 2006/42/EC

The manufacturer also declares that

▪ the following harmonised international standards have been applied:

–

ISO 12100 – EN 809 – EN 60034-1, EN 60034-5/A1

Person authorised to compile the technical file:

Name Function Address (company) Address (Street, No.) Address (post or ZIP code, city) (country)

The EC Declaration of Conformity was issued in/on:

Place, date

..............................

29)

.............................

Name

Function

Company

Address

Amacan K, Amacan P, Amacan S

29)

A signed, legally binding declaration of conformity is supplied with the product.

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11 Certificate of Decontamination

Type: ................................................................................................................................

Order number/ Order item number

Delivery date: ................................................................................................................................

Field of application: ................................................................................................................................

Fluid handled

Please tick where applicable

Radioactive Explosive Corrosive Toxic

Reason for return

Comments: ................................................................................................................................

The product/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/ placing at your disposal.

We herewith declare that this product is free from hazardous chemicals, biological and radioactive substances.

On seal-less pumps, the rotor has been removed from the pump for cleaning.

 No special safety precautions are required for further handling.  The following safety precautions are required for flushing fluids, fluid residues and disposal:

We confirm that the above data and information are correct and complete and that dispatch is effected in accordance with the relevant legal provisions.

.................................................................... ....................................................... .......................................................

Place, date and signature Address Company stamp

30)

   

Harmful Bio-hazardous Highly flammable Safe

................................................................................................................................

30)

...............................................................................................................................................................

................................................................................................................................

30)

Required fields

98 of 100

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Index

Abrasive fluids 37

Bearing temperature monitoring 32

Certificate of decontamination 98 Commissioning/start-up 35

Dismantling 52 Disposal 15

Electrical connection 33 Electromagnetic compatibility 29 Explosion protection 36

Fluid handled

Density 36

Frequency inverter operation 29, 36

Grease lubrication

Grease quality 50

Installation 21 Installation at site 21 Intended use 7 Interference immunity 29

Level control 29 Lubricant 46

Maintenance 40 Mechanical seal leakage 32 Misuse 8

Operating limits 7 Order number 6 Other applicable documents 6 Overload protection device 29

Partly completed machinery 6 Preservation 14

Reassembly 52 Return to supplier 14 Returning to service 38

Safety 7 Safety awareness 8 Scope of supply 20 Sensors 30 Shutdown 38 Spare parts stock 66 Start-up 35 Storage 14, 38 Supply voltage 36

Tightening torques 65

Leakage monitoring 32

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KSB Aktiengesellschaft

P.O. Box 200743 • 06008 Halle (Saale) • Turmstraße 92 • 06110 Halle (Germany) Tel. +49 345 4826-0 • Fax +49 345 4826-4699 www.ksb.com

1589.82/02-EN (01350210)

KSB Amacan S, Amacan S 650-365, Amacan S 650-364, Amacan S 800-505, Amacan S 650-404 Installation And Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Glossary

1 General

2 Safety

3 Transport/Temporary Storage/Disposal

3.2.1 Transporting the delivered pump set to the place of installation

3.2.2 Placing the pump set in vertical or horizontal position

3.2.3 Transporting the pump set

4 Description of the Pump (Set)

5 Installation at Site

5.2.4 Checking the direction of rotation

5.3.2 Installing the pump set without support rope

5.3.4 Installing the pump set with a support rope and support spacer

5.4.1 Information for planning the control system

5.4.1.1 Overload protection

5.4.1.2 Level control

5.4.1.4 Sensors

5.4.2 Electrical connection

6 Commissioning/Start-up/Shutdown

6.1.1 Prerequisites for commissioning/start-up

6.1.2 Start-up

6.2.2 Frequency of starts

6.2.4 Fluid handled

6.2.4.3 Minimum level of fluid handled

6.3.1 Shutdown

6.3.2 Measures to be taken for shutdown

7 Servicing/Maintenance

7.2.1 Inspection work

7.2.1.1 Checking the earth conductor

7.2.1.3 Checking the sensors

7.3.1 Removing the pump set

7.3.2 Drainage/cleaning

7.3.4 Checking the mechanical seal leakage

Pump size Lubricant quantity

7.4.1.4 Changing the lubricant

7.4.2.2 Grease quality

Size Grease type Grease quantity

7.5.1 General information/Safety regulations

7.5.2 Preparing the pump set

7.5.3 Removing the bellmouth

7.5.4 Removing the impeller

7.5.5 Removing the mechanical seal

7.5.5.1 Removing the impeller-end mechanical seal

7.5.5.2 Removing the drive-end mechanical seal

7.5.6.1 Removing the motor housing cover

7.5.6.2 Dismantling the cable gland and power cable

7.6.1 General information/Safety regulations

7.6.2 Installing the replacement cable gland

7.6.3 Fitting the motor housing cover

7.6.4.1 Installing the drive-end mechanical seal

7.6.4.2 Installing the impeller-end mechanical seal

7.6.5 Fitting the impeller

7.6.6 Fitting the bellmouth

7.6.7 Adjusting the clearance

7.6.8 Leak testing

7.6.8.1 Checking the lubricant reservoir for leakage

7.6.8.2 Testing the motor for leakage

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

8 Trouble-shooting

9 Related Documents

9.3.1 Wiring diagram

9.3.2 Wiring diagrams for the sensors

9.5.1 Example of installation type BU

9.5.2 Example of installation type BG

9.5.3 Example of installation type CU

9.5.4 Example of installation type CG

9.5.5 Example of installation type DU

9.5.6 Example of installation type DG

Index