KSB Ixo-Pro Operating Manual
Submersible Borehole Pump with
Integrated Pressure Switch
Ixo-Pro
Installation/Operating Manual
Legal information/Copyright
Installation/Operating Manual Ixo-Pro
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.
© KSB SE & Co. KGaA, Frankenthal 09/02/2018
Contents
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Contents
Glossary .................................................................................................................................................. 4
1 General.................................................................................................................................................... 5
1.1 Principles ...........................................................................................................................................................5
1.2 Target group.....................................................................................................................................................5
1.3 Symbols .............................................................................................................................................................5
2 Safety...................................................................................................................................................... 6
2.1 Key to safety symbols/markings.......................................................................................................................6
2.2 General..............................................................................................................................................................6
2.3 Intended use .....................................................................................................................................................7
2.4 Personnel qualification and training...............................................................................................................7
2.5 Consequences and risks caused by non-compliance with this manual .........................................................7
2.6 Safety awareness ..............................................................................................................................................7
2.7 Safety information for the operator/user.......................................................................................................8
2.8 Safety information for maintenance, inspection and installation ................................................................8
2.9 Unauthorised modes of operation..................................................................................................................8
3 Transport/Temporary Storage/Disposal............................................................................................... 9
3.1 Checking the condition upon delivery............................................................................................................9
3.2 Transport...........................................................................................................................................................9
3.3 Storage/preservation........................................................................................................................................9
3.4 Return to supplier...........................................................................................................................................10
3.5 Disposal ...........................................................................................................................................................10
4 Description............................................................................................................................................ 11
4.1 General description ........................................................................................................................................11
4.2 Designation.....................................................................................................................................................11
4.3 Name plate......................................................................................................................................................11
4.4 Design details..................................................................................................................................................11
4.5 Configuration and function...........................................................................................................................13
4.6 Scope of supply...............................................................................................................................................13
4.7 Dimensions......................................................................................................................................................14
5 Installation at Site................................................................................................................................ 15
5.1 Installing the pump set ..................................................................................................................................15
5.2 Connecting the piping ...................................................................................................................................16
5.3 Electrical connection ......................................................................................................................................17
6 Commissioning/Start-up/Shutdown................................................................................................... 18
6.1 Commissioning/Start-up.................................................................................................................................18
6.1.1 Starting up and stopping ..................................................................................................................18
6.2 Operating data ...............................................................................................................................................18
6.3 Operating limits..............................................................................................................................................19
6.4 Taking the pump set out of service...............................................................................................................19
7 Servicing/Maintenance........................................................................................................................ 20
7.1 Maintenance/inspection.................................................................................................................................20
8 Trouble-shooting.................................................................................................................................. 21
9 Related Documents.............................................................................................................................. 22
9.1 General assembly drawing.............................................................................................................................22
9.2 Exploded view.................................................................................................................................................23
10 EC Declaration of Conformity ............................................................................................................. 25
11 Certificate of Decontamination........................................................................................................... 26
Index ..................................................................................................................................................... 27
Glossary
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Glossary
Certificate of decontamination
A certificate of decontamination is enclosed by the
customer when returning the product to the
manufacturer to certify that the product has been
properly drained to eliminate any environmental
and health hazards arising from components in
contact with the fluid handled.
Close-coupled design
Motor directly fitted to the pump via a flange or a
drive lantern
Pump
Machine without drive, additional components or
accessories
Pump set
Complete pump set consisting of pump, drive,
additional components and accessories
1 General
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1 General
1.1 Principles
This operating manual is supplied as an integral part of the type series and variants
indicated on the front cover. The manual describes the proper and safe use of this
equipment in all phases of operation.
The name plate indicates the type series / size and the main operating data.
In the event of damage, immediately contact your nearest KSB service centre to
maintain the right to claim under warranty.
1.2 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. (ðSection2.4,Page7)
1.3 Symbols
Table1: 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
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
2 Safety
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2 Safety
!
DANGER
All the information contained in this section refers to hazardous situations.
In addition to the present general safety information the action-related safety
information given in the other sections must be observed.
2.1 Key to safety symbols/markings
Table2: Definition of safety symbols/markings
Symbol Description
!
DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
!
WARNING
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
Explosion protection
This symbol identifies information about avoiding explosions in
potentially explosive atmospheres in accordance with EU Directive
2014/34/EU (ATEX).
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.
2.2 General
This 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 Safety
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2.3 Intended use
▪ The pump (set) must only be operated in the fields of application and within the
use limits specified in the other applicable documents.
▪ Only operate pumps/pump sets which are in perfect technical condition.
▪ Do not operate the pump (set) in partially assembled condition.
▪ Only use the pump to handle the fluids described in the data sheet or product
literature of the pump model or variant.
▪ Never operate the pump without the fluid to be handled.
▪ Observe the minimum flow rates indicated in the data sheet or product literature
(to prevent overheating, bearing damage, etc).
▪ Observe the minimum flow rate and maximum flow rate indicated in the data
sheet or product literature (to prevent overheating, mechanical seal damage,
cavitation damage, bearing damage, etc).
▪ Do not throttle the flow rate on the suction side of the pump (to prevent
cavitation damage).
▪ Consult the manufacturer about any use or mode of operation not described in
the data sheet or product literature.
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, directives and laws
2 Safety
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2.7 Safety information for the operator/user
▪ Fit protective equipment (e.g. contact guards) supplied by the operator for hot,
cold or moving parts, and check that the equipment functions properly.
▪ Do not remove any protective equipment (e.g. contact guards) during operation.
▪ Provide the personnel with protective equipment and make sure it is used.
▪ Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g.
explosive, toxic, hot) so as to avoid any danger to persons and the environment.
Adhere to all relevant laws.
▪ Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
▪ If shutting down the pump does not increase potential risk, fit an emergency-
stop control device in the immediate vicinity of the pump (set) during pump set
installation.
2.8 Safety information for maintenance, inspection and installation
▪ Modifications or alterations of the pump (set) are only permitted with the
manufacturer's prior consent.
▪ Use only original spare parts or parts/components authorised by the
manufacturer. The use of other parts/components can invalidate any liability of
the manufacturer for resulting damage.
▪ The operator ensures that maintenance, inspection and installation is performed
by authorised, qualified specialist personnel who are thoroughly familiar with
the manual.
▪ Only carry out work on the pump (set) during standstill of the pump.
▪ Only perform work on the pump set when it has been disconnected from the
power supply (de-energised).
▪ The pump (set) must have cooled down to ambient temperature.
▪ Pump pressure must have been released and the pump must have been drained.
▪ When taking the pump set out of service always adhere to the procedure
described in the manual.
▪ Decontaminate pumps which handle fluids posing a health hazard.
▪ As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning. (ðSection6.1,Page18)
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.
(ðSection2.3,Page7)
3 Transport/Temporary Storage/Disposal
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3 Transport/Temporary Storage/Disposal
3.1 Checking the condition upon delivery
1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer and the insurer about the damage in writing
immediately.
NOTE
The pump set is supplied by the manufacturer/supplier in packaging which largely
prevents sagging or other damage during transport and/or storage.
3.2 Transport
CAUTION
Improper pump transport
Damage to the pump!
▷ Always transport the pump/pump set in the specified position.
▷ Never suspend the pump (set) from the power cable.
▷ Prevent the pump (set) from getting knocked or dropped.
▷ Always secure a pump set in upright position against tipping over.
▷ Wear personal protective equipment.
Use lifting equipment which is suitable for the weight of the pump set.
Make sure that the power cable is not kinked or damaged during transport.
3.3 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken:
WARNING
Pump set tilting or rolling off
Risk of personal injury!
▷ Always secure vertically positioned pump sets against tipping over.
▷ Always secure horizontally positioned pump sets against rolling off.
CAUTION
Damage during storage by frost, humidity, dirt, UV radiation or vermin
Corrosion/contamination of the pump!
▷ Store the pump (set) in a dry, dark, frost-proof room not exposed to sunlight
where the atmospheric humidity is as constant as possible.
Store the pump as follows:
▪ In a dry environment
▪ Protected against direct sunlight and heat
▪ Protected against dirt and dust
▪ Protected against freezing
▪ Protected against vermin
Further information on storing the pump set after it has been in use
(ðSection6.4,Page19) .
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