KSB UPA, BSX, UPZ, UPA 300, UPA 350 Operating Manual

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Page 1

Submersible Borehole Pumps

UPA, UPZ, BSX

with motors of 1000 V operating voltage and above 50 Hz, 60 Hz

Installation/Operating Manual

Mat.No.: 01463374

Page 2

Legal information/Copyright

Installation/Operating Manual UPA, UPZ, BSX

Original operating manual

KSB Aktiengesellschaft

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 KSB's express written consent.

Subject to technical modification without prior notice.

Page 3

Contents

Glossary .................................................................................................5

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

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

1.2 Target group ..................................................................................................... 6

1.3 Other applicable documents ............................................................................ 6

1.4 Symbols .............................................................................................................7

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

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

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

2.3 Intended use .....................................................................................................8

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

2.5 Consequences and risks caused by non-compliance with these operating instructions

........................................................................................................ 9

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

2.7 Safety information for the operator/user ..................................................... 10

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

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

3 Transport/Temporary Storage/Disposal .............................................11

3.1 Checking the condition upon delivery .......................................................... 11

3.2 Transport ......................................................................................................... 11

3.3 Storage and preservation ............................................................................... 13

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 ...................................................................................................... 17

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

4.5 Configuration and function ........................................................................... 18

4.6 Scope of supply ............................................................................................... 18

4.7 Dimensions and weights ................................................................................19

5 Installation at Site ...............................................................................20

5.1 General information/Safety regulations .......................................................20

5.2 Preparing the installation .............................................................................. 21

5.3 Installing the pump set in vertical position ..................................................27

5.4 Installing the pump set in a horizontal position ..........................................30

5.5 Installing the pump set in an angled position .............................................. 32

5.6 Notes on electrical connection ...................................................................... 32

5.7 Electrical connection ...................................................................................... 34

Contents

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6 Commissioning/Start-up/Shutdown ...................................................39

6.1 Commissioning/start-up ................................................................................. 39

6.2 Operating limits .............................................................................................. 41

6.3 Shutdown ........................................................................................................ 44

7 Servicing/Maintenance .......................................................................45

7.1 Servicing/inspection ........................................................................................ 45

7.2 Removing the pump set ................................................................................. 45

7.3 Separating pump and motor ......................................................................... 46

7.4 Motor fill ......................................................................................................... 47

7.5 Storage and preservation ............................................................................... 49

7.6 Reassembling the pump set ........................................................................... 50

8 Trouble-shooting ................................................................................53

9 Related Documents ............................................................................54

9.1 General assembly drawing with list of components .................................... 54

9.2 Mating dimensions for motors V, X, Z, E ......................................................58

9.3 Mating dimensions for motor T ..................................................................... 59

10 EC Declaration of Conformity ............................................................60

11 Certificate of Decontamination .........................................................61

Index ....................................................................................................62

Contents

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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.

Pump set

Complete pump set consisting of pump, drive, additional components and accessories

Glossary

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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 (see details listed below).

▪ UPA 250C

▪ UPA 300

▪ UPA 350

▪ UPZ

▪ BSX

▪ BRY

▪ BRZS

▪ BRE

▪ BSF

▪ T

▪ V

▪ X

▪ Z

▪ E

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

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

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

1.2 Target group

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

1.3 Other applicable documents

Table 1: Overview of other applicable documents

Document Contents

Data sheet Description of the technical data of the pump (set) General arrangement drawing/ outline drawing

Description of mating and installation dimensions for the pump (set), weights

Hydraulic characteristic curve Characteristic curves showing head, NPSH

required, efficiency and power input

General assembly drawing

Sectional drawing of the pump Sectional drawing of the motor

Sub-supplier product literature

Operating manuals and other product literature describing accessories and integrated machinery components

Spare parts lists

Description of spare parts Operating manual for accessories

Description of accessories, e.g. cable connector

Pump sizes

Motor sizes

If agreed to be included in the scope of supply

1 General

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

1.4 Symbols

Table 2: Symbols used in this manual

Symbol Description

✓ Conditions which need to be fulfilled before proceeding with the

step-by-step instructions

⊳ Safety instructions ⇨ Result of an action ⇨ Cross-references

Step-by-step instructions

Note Recommendations and important information on how to handle the product

1 General

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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

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 EC Directive 94/9/EC (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/motor 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 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.

DANGER

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▪ Never operate the pump without the fluid handled.

▪ Never operate the motor without fill liquid.

▪ Observe the minimum flow rates indicated in the data sheet or product literature

(to prevent overheating, bearing damage, etc).

▪ Observe the maximum flow rates 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).

▪ Do not let the motor run in the wrong direction of rotation for more than two

minutes.

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

the data sheet or product literature.

Prevention of foreseeable misuse

▪ Never open discharge-side shut-off elements further than permitted.

–

The maximum flow rate specified in the data sheet or product literature

would be exceeded.

– Risk of cavitation damage

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

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 these operating instructions

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

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

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

–

Hazards to persons due to electrical, thermal, mechanical and chemical effects and explosions

– Failure of important product functions

– Failure of prescribed maintenance and servicing practices

– Hazard to the environment due to leakage of hazardous substances

2.6 Safety awareness

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

▪ Accident prevention, health and safety regulations

▪ Explosion protection regulations

▪ Safety regulations for handling hazardous substances

2 Safety

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▪ Applicable standards and laws

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.

▪ Prior to any dismantling work, disconnect the motor from the mains.

▪ 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.

▪ Decontaminate pumps which handle fluids posing a health hazard.

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

and protective devices. Before returning the product to service, observe all instructions on commissioning.

2.9 Unauthorised modes of operation

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

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

2 Safety

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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.

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

WARNING

Improper transport Risk of squashing hands and feet! Damage to the pump set!

▷ Always transport the pump set in horizontal position.

▷ Do not use electrical cables for transport.

▷ Gently set down the pump set.

▷ Observe the centre of gravity of the pump set and the weights indicated.

WARNING

Pump set tipping over 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.

WARNING

Ambient temperature below the specified minimum Danger of frost!

▷ Never subject the pump set to ambient temperatures which are lower than

those permitted for the drinking water/antifreeze mixture provided (see section on drinking water/antifreeze mixture / order documentation).

NOTE

Take into account the unequal weight distribution between pump and motor.

Transporting the transport boxes

Submersible borehole pumps are supplied in appropriate packaging, e.g. transport boxes, containing either the pump set or the pump and/or motor as individual components (depending on the design). Use suitable lifting equipment to transport the transport box to the place of installation or storage. Observe the marking on the long side of the transport box! This marking indicates the centre of gravity.

Transport boxes

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Unpacking the pump set/pump/motor

WARNING

Unsecured cable drum Risk of personal injury!

▷ Always secure the cable drum against tipping over.

▷ Always secure the cable drum against rolling off.

WARNING

Laying cables at temperatures below zero degrees Damage to the cables!

▷ Observe the minimum permissible temperature at the cable surface of -25 °C for

moving cables.

▷ Observe the minimum permissible temperature at the cable surface of -40 °C for

stationary cables.

CAUTION

Excessive bending stress on the pump set Damage to the pump set!

▷ Choose sling points which prevent excessive bending stress on the pump set.

Use suitable lifting equipment for lifting the pump set out of the packaging and transporting it(⇨ Section 4.7 Page 19

) Use suitable lifting tackle for lifting the pump

set out of the packaging and transporting it, e. g. lifting straps. Sling points: in the middle of the motor and at the upper end of the pump.

Fig. 1: Transporting the pump set by crane

✓ Suitable lifting equipment and lifting tackle are available.

✓ The surface on which the pump set is to be positioned is solid and level.

✓ Securing means, e.g. timber wedges are on hand.

Gently set down the transport box.

2. Open the transport box.

3. Take out the power cable and put it down.

4. Position the lifting tackle allowing for balanced lifting. Normally, the centre of gravity of the pump set will be in the motor area. Watch any add-on parts, such as piping and cables!

5. Use the lifting equipment to lift the pump set out and position it on a solid and level surface.

6. Use appropriate means to secure the pump set against rolling off.

Unpacking

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3.2.1 Pulling the pump/motor/pump set upright

WARNING

Incorrect positioning Personal injury and damage to property!

▷ Position the pump set vertically with the motor below.

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

over.

▷ Refer to the weights given in the data sheet.

WARNING

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

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

over and 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 vertical position or transporting it Personal injury and damage to property!

▷ Secure power cables against falling down.

CAUTION

Improper storage Damage to the power cables!

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

deformation. Observe the minimum bending radius2) of the cables.

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

installation.

CAUTION

Excessive bending stress on the pump set Damage to the pump set!

▷ Choose sling points which prevent excessive bending stress on the pump set.

✓ Suitable lifting equipment for the total weight has been selected and is on hand.

Fasten to a suitable lifting accessory, e.g. mounting plate.

2. Attach the lifting equipment, pull the pump/motor/pump set upright, and secure it against tipping over.

3.3 Storage and preservation

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

See cable manufacturer's documentation or DIN VDE 0298-3.

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WARNING

Pump set tipping over 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.

WARNING

Ambient temperature below the specified minimum Danger of frost!

▷ Never subject the pump set to ambient temperatures which are lower than

those permitted for the drinking water/antifreeze mixture provided (see section on drinking water/antifreeze mixture / order documentation).

WARNING

Laying cables at temperatures below zero degrees Damage to the cables!

▷ Observe the minimum permissible temperature at the cable surface of -25 °C for

moving cables.

▷ Observe the minimum permissible temperature at the cable surface of -40 °C for

stationary cables.

CAUTION

Improper storage Damage to the power cables!

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

deformation. Observe the minimum bending radius3) of the cables.

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

installation.

Store the submersible borehole pumps as follows:

In its original packaging: horizontally

2. Without packaging: vertically (with the motor below)

3. In a dry environment

4. Protected against direct sunlight and heat

5. Protected against dirt and dust

6. Protected against freezing

7. Protected against vermin

Further information on storing the pump set after use (⇨ Section 7.5 Page 49).

3.4 Return to supplier

WARNING

Ambient temperature below the specified minimum Danger of frost!

▷ Never subject the pump set to ambient temperatures which are lower than

those permitted for the drinking water/antifreeze mixture provided (see section on drinking water/antifreeze mixture / order documentation).

1. Clean the pump set properly from the outside.

See cable manufacturer's documentation or DIN VDE 0298-3.

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

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.

4. Always complete and enclose a certificate of decontamination when returning the pump (set). Always indicate any safety and decontamination measures taken.

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 handled posing a health hazard Hazard to persons and the environment!

▷ Collect and properly dispose of flushing liquid and any liquid residues.

▷ Wear safety clothing and a protective mask, if required.

▷ Observe all legal regulations on the disposal of fluids posing a health hazard.

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

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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4 Description of the Pump (Set)

4.1 General description

Pump for handling clean or slightly contaminated water.

Verify the fluid composition against the data sheet.

Not approved for handling explosive fluids or for forming part of an explosion-proof system!

4.2 Designation

Submersible borehole pump Example: UPA 250C - 150 / 5b

Table 4: Key to the designation

Code Description

UPA Pump type 250 Nominal size [mm] C Design status 150 Flow rate at best efficiency point [m³/h] 5 Number of stages b Reduced impeller diameters

Submersible borehole pump Example: BRZS 535 / 5

Table 5: Key to the designation

Code Description

B R Pump type Z Nominal size S Design with suction impeller 535 Hydraulic code 5 Number of stages

Submersible motor Example: VBD FV 31 - 30 5

Table 6: Key to the designation

Code Description

V Motor size, e.g. V = 14 inch B Number of poles, e.g. B = 2 poles D Design status FV Length of core pack 31 Maximum rated power 30 Voltage, e.g. 30 = 3 kV 5 Frequency, e.g. 5 = 50 Hz

4 Description of the Pump (Set)

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4.3 Name plate

Serial No. 9971276748-000100

5 6

Pump RE 555/3 Qmin Qmax

Q Motor

340 KW 3300 V

Temp. Min. flow velocity past the motor = 0.2 m/s

EN 60034-1

IP 68

Mat. No.: 01 000 854 ZN 3823 - D 88

300 L/MIN

1170 L/MIN

879.6 L/MIN

Hmax Hmin H

108 M

69 M

92.7 M

3~ XMD HQ 37-335

50 Hz

86 A 0.77 COS

20 °C max. 1467 rpm

7 8

11 12

17 18

Fig. 2: Name plate (example)

1 Order number 2 Pump designation 3 Minimum flow rate 4 Maximum flow rate 5 Flow rate at duty point 6 Motor designation 7 Rated power 8 Voltage 9 Frequency 10 Amperage 11 Maximum fluid temperature 12 Minimum available flow along the

motor 13 Maximum head 14 Minimum head 15 Head at duty point 16 Power factor 17 Speed 18 VDE Standard 19 Motor enclosure

4.4 Design details

Pump design

▪ Centrifugal pump

▪ Single-stage or multi-stage

▪ Radial or mixed flow versions

▪ Single-entry or double-entry

▪ Shroud or ring-section design

▪ With non-return valve or connection branch

▪ Pump connection with threaded or flanged end

▪ Rigid connection between pump and motor

Motor design

▪ Submersible motor in squirrel-cage design

▪

Motor shaft4) protected by sealed sleeve coupling

▪ Rubber expansion diaphragm for pressure equalisation

▪ Thrust bearing with tilting pads to absorb the pump's hydraulic thrust

▪ Single mechanical seal

For motor sizes V, X, Z and E

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4.5 Configuration and function

6/7

Fig. 3: Sectional drawing, example of a UPA

Pump and motor are connected by a rigid coupling. The stage casings are supported by straps or stud bolts. A suction strainer at the suction casing protects the pump from coarse particles in the fluid. The pump set is connected to the piping via a nonreturn valve or connection branch with either internal thread or flanged end (optional).

The fluid flows along the motor and enters the suction casing (2) through the suction strainer (1). It is accelerated outward by the suction impeller (3). In the flow passage of the stage casing (4) the kinetic energy of the fluid is converted into pressure energy, and the fluid is routed to the next impeller (5). This process is repeated in all stages until the fluid has passed the last impeller (5). It is then guided through the integrated non-return valve to the connection branch (7), where it leaves the pump. The integrated non-return valve prevents uncontrolled backflow of the fluid.

4.6 Scope of supply

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

▪

Pump set with motor lead

Optional: pump and/or motor as individual units

Design

Function

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▪ Electric cable

Optional: connected or supplied loosely

▪ Tools for filling the motor

▪

Separate name plate

▪ Accessories, such as:

–

Cable connector

– Cable ties

– Cooling, suction or pressure shroud

– Bearing pedestals

– Electrical protection devices

– Automatic control units

4.7 Dimensions and weights

For dimensions and weights please refer to the data sheet of the pump (set).

To be attached outside the place of installation, e.g. control panel, pipeline or mounting bracket.

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5 Installation at Site

5.1 General information/Safety regulations

DANGER

Using damaged cables in a well Electric shock!

▷

Do not kink cables (observe the minimum bending radius 6) of the cable) or drag the cables over sharp edges.

▷ Use cable ties or other suitable fasteners to fasten the power cables as well as

any measuring and control cables to the riser or piping every three meters.

▷ Do not use any tools, equipment or accessories with sharp edges (e.g. sharp-

edged pipe sockets) during installation.

WARNING

Pump set falling into the well Personal injury or persons being dragged down by uncontrolled cable movements! Damage to the pump set and the well!

▷ Securely store the cable with extension lead. Keep at a safe distance during

installation.

▷ Secure the pump set during the entire installation procedure.

▷ Dimension any securing devices (supporting clamps, supports, etc.) so that they

can carry all weights during the installation.

WARNING

Persons could fall into unsecured wells/reservoirs/tanks Risk of personal injury!

▷ During installation work, take suitable precautions to protect anyone from

falling into an open well/reservoir/tank.

▷ Suitably fence off the work area.

WARNING

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

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

over and 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 vertical position or transporting it Personal injury and damage to property!

▷ Secure power cables against falling down.

See cable manufacturer's documentation or DIN VDE 0298-3.

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WARNING

Laying cables at temperatures below zero degrees Damage to the cables!

▷ Observe the minimum permissible temperature at the cable surface of -25 °C for

moving cables.

▷ Observe the minimum permissible temperature at the cable surface of -40 °C for

stationary cables.

NOTE

Do not expose power cables to direct sunlight.

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.

NOTE

The motor lead is selected for submerged operation and must be completely submerged, including the cable connector. See order documentation for any other use!

5.2 Preparing the installation

5.2.1 Checking the installation conditions

Prior to starting with the installation, check compliance with the particular framework conditions required for a trouble-free operation of the submersible borehole pump. To do so, verify the order data and/or delivery data against the constructional plans, the operating conditions and the operating limits of the pump set.

Has this pump set been ordered for the required installation position?(⇨ Section

5.2.2 Page 22)

2. Does the material variant of the pump set match the installation conditions?

3. Can the required flow velocity past the motor be guaranteed?

4. Is the required minimum submergence met during operation? (⇨ Section 6.2.3.1

Page 41)

5. Is the sand content of the fluid to be handled below the specified maximum?(⇨ Section 6.2.3.2 Page 42)

6. Is the temperature of the fluid to be handled below the specified maximum?

7. If fluids liable to form deposits are handled, is temperature monitoring provided?

8. Will the motor lead and the cable connector be completely submerged?

General information on the system design

Select a pump set suspension arrangement whose design and dimensions allow for all static and dynamic forces to be absorbed. Tightly fasten the supporting clamps or flanges to the well head so that they cannot move or lift off the well head.

System-induced vibrations must not be transmitted to the pump set. The system must be designed in such a way that vibrations are not amplified. Abrupt pressure equalisation processes (pressure surges), in particular, present a hazard for the pump set. Take suitable precautions (e.g. fit expansion joints, air vessels).

Well head

Vibrations

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Do not install the pump set with the suction strainer exactly at the level of the well screen/filter. Excessive flow in the area of the well screen/filter entails the risk of large amounts of sand being transported, which will cause excessive wear in the pump.

Verify the well dimensions.

Pumps which are to be installed in a pump sump are always designed with a suction or cooling shroud. The pump set must not sit on the base of the well! The pump set must not touch the well and tank walls! Use a centring device, if required! Prevent adjacent pump sets from influencing each other. Provide an even approach flow in the suction area and do not obstruct it with any structural components or installations. Air intake from an inlet arranged above the water level is not permitted.

5.2.2 Checking the installation position

WARNING

Impermissible installation position Damage to the machine! Damage to the bearings!

▷ For angled installation, always install the pump set with a rising slope towards

the discharge side.

The submersible borehole pump can be installed in a vertical or, depending on the number of stages, also in an angled or horizontal position.

Never install horizontally a pump set which has been selected for vertical installation!

2. Never install the pump set with the pump at the lowest point.

Fig. 4: Checking the installation position

A1, A2 Permissible installation position

B Permissible installation position, if approved in the order documentation C Impermissible installation position

Sand deposits

Narrowing

Installation conditions

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5.2.3 Checking the motor fill

DANGER

Unfilled or insufficiently filled motor Damage to the motor winding!

▷ Never install and run the motor without sufficient motor fill.

▷ Observe the information sticker on the motors and top up the motor fill as

instructed.

DANGER

Unfilled or insufficiently filled motor Winding damage! Corrosion damage!

▷ Observe the information sticker on the motor and top up the motor fill as

instructed.

WARNING

Drinking water/antifreeze mixture could escape Hazardous to persons and the environment!

▷ Wear safety glasses and protective gloves when topping up, checking and

draining the motor fill.

▷ Observe the national health and safety regulations.

▷ Observe all legal regulations on the disposal.

CAUTION

Freezing of motor fill Motor damage!

▷ Match the mixing ratio of drinking water / antifreeze agent to the expected

temperatures.

▷ Always protect water-filled motors against frost.

▷ Provide frost-proof storage.

NOTE

The loss of a few drops of liquid fill will not impair the motor function. If any larger amounts of leakage are suspected, the motor fill must be checked.

Information sticker / motor fill

Submersible motors are filled with a liquid based on drinking water. A distinction is made between filled and unfilled motors, marked by colour-coded information stickers attached to the motor, depending on the motor type series. Motors which are supplied filled with a mixture of drinking water / antifreeze agent must not be filled with pure drinking water at a later stage. Pure drinking water can only be filled into motors which have not been filled before.

Table 7: Type of motor fill

Sticker colour Supplied condition Motor fill

Green Filled Drinking water / antifreeze mixture (1,2 propylene glycol) Red Unfilled Drinking water

or drinking water / antifreeze mixture (1,2 propylene glycol)

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5.2.3.1 Checking the fill level

WARNING

Drinking water/antifreeze mixture could escape Hazardous to persons and the environment!

▷ Wear safety glasses and protective gloves when topping up, checking and

draining the motor fill.

▷ Observe the national health and safety regulations.

▷ Observe all legal regulations on the disposal.

WARNING

Screw plugs subjected to pressure When opening screw plugs, liquid might spurt out!

▷ Wear safety goggles and protective clothing, if required.

▷ Open the screw plug slowly.

For motor type series T For motor type series V, X, Z, E a) Filler opening b) Vent opening c) Filling funnel

a) Filler opening b) Vent opening c) Filling funnel

1. Set down the motor or pump set in a vertical position. Secure it against tipping over.

Undo the two screw plugs (a and b) and remove them together with the seal elements.

⇨ If the liquid level is visible in one of the two openings, the motor fill is

sufficient.

⇨ If the fill level is not visible, fill the motor sufficiently. (⇨ Section 7.4.1 Page

48)

3. Screw the screw plugs (a and b) back in together with the sealing elements.

Check the screw plugs for tightness. Make sure that the contact faces are clean and that the joint ring is inserted and free from damage.

1. Suspend the motor or pump set from a crane. Fasten the motor or pump set to

the floor and secure it against slipping.

Carefully lower the crane to slightly tilt the motor or pump set.

3. Monitor the screw plugs for escaping fluid.

4. If required, fit new sealing elements.

5.2.4 Installing water storage tanks

If the pump set is intended for horizontal installation, the motor has to be fitted with water storage tanks.

Checking the screw plugs

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✓ The motor has been set down in a horizontal position on a level and solid

surface. It has been secured against rolling off.

✓ Position the motor with the connections for the water storage tanks at the

highest point.

✓ The water storage tanks are on hand.

✓ The motor fill has been checked with the motor in vertical position.

✓ Suitable liquid for topping up the motor fill has been prepared.

Remove the screw plugs from the top and bottom of the stator case. Remove the joint rings.

2. Insert the water storage tanks (59-33) with new joint rings (411.51) into the

stator and screw them in tightly.

3. Fill the water storage tanks with the specified liquid fill until they overflow.

4. Close both water storage tanks with a screw plug with integrated vent valve

(741) and joint ring (411.51).

5.2.5 Preventing backflow

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.

▷ Make sure that backflow of the fluid handled is slow and controlled, so that the

pump rotor does not start to rotate, e.g. by throttling the discharge-side gate valve accordingly.

The submersible borehole pumps are generally fitted with an integrated non-return valve. On pump sets without non-return valve the operator must prevent any uncontrolled backflow of the fluid, e.g. by structural means. Otherwise the pump could be operated in the wrong direction of rotation and critical speeds could be exceeded.

5.2.6 Calculating the total weight

Suitable lifting equipment (e.g. tripod, crane, etc.) is required for installing and removing submersible borehole pumps. The load-carrying capacity of the lifting equipment must be larger than the weight of the pump set + the riser7) + the water column 8) in the riser + the power cable + the cable ties. For the weights refer to the order documentation, the product literature of the sub-suppliers and the following table.

Table 8: Weight of the water column per 1 metre of the riser

Pipe diameter [mm] Pipe diameter [inch]

50 2"

803"1004"1255"1506"2008"250

10"

300--350--400

Weigh t [kg]

2 5 8 12 18 32 49 72 98 125

741

411.51

903.53

59-33

411.51

Fig. 5: Installing water storage tanks

See product literature of the riser used.

Applies to pumps with non-return valve if no other measures to drain the riser have been taken

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5.2.7 Electric wiring

DANGER

Unqualified personnel connecting extension leads Installation in a well - electric shock!

▷ The extension lead must be connected by a professional electrician only.

▷ The cable ends must be dry and clean.

DANGER

Earth conductor not properly connected Danger of death from electric shock!

▷ Never operate the motor without earth conductor.

▷ The earth conductor must be connected by a professional electrician only.

NOTE

The motor lead is selected for submerged operation and must be completely submerged, including the cable connector. See order documentation for any other use!

Submersible motors are supplied fitted with a motor lead. The motor lead has been extended with a suitably sized extension cable to meet the length required for the specific installation. Unless otherwise indicated, the motor lead is designed for submerged operation only. To meet this condition the cable connector also has to be completely submerged.

Extension cables connected by KSB

If agreed with KSB, the extension cable can be supplied connected to the motor lead with a watertight cable connector.

▪ Unless otherwise specified in the order documentation, KSB's extension cables

are designed for:

–

Being laid in free air

– A voltage drop along the lead of ᅀ U ≦3 %

For any other ways of laying cables, e.g. in cable ducts, etc. observe the information on the maximum current-carrying capacity as per the applicable directives.

Extension cables connected by the operator

If the supplied extension cable is to be connected at the site, observe the following points:

1. Observe the installation instructions of the cable connector to be used.

2. If the operator is responsible for connecting an extension cable, make sure the

extension cable is selected and dimensioned for a maximum voltage drop of ≦3 %. The extension cable has to be approved for the applicable operating conditions.

3. In 4-core leads the earth conductor is part of the power cable and must also be connected in the cable connector when connecting an extension cable.

4. 3-core motor leads do not include an earth conductor. A separate earth conductor is connected on the outside of the motor. The earth conductor has to be extended separately. If no earth conductor is provided, the operator shall be responsible for earthing the motor externally. (Core size corresponding to phase conductor, min. 4 mm2)

5. Connect the shield of shielded extension cables to the earth conductor. 3-core motor leads as described in paragraph 4 must be earthed externally; connect the shield of the extension cable to the earth conductor.

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6. Transfer the core identification of the motor lead to the cores of the extension cable. Make sure the colour codes match when connecting the cores.

The core codes depend on the wiring type of the motor:

Table 9: Core codes

Motors for DOL starting with 1 lead

U V W

. Motors for DOL starting with 2 parallel leads

U1 - 1 V1 - 1 W1 - 1 U1 - 2 V1 - 2 W1 - 2

5.2.8 Measuring the insulation resistance

DANGER

Hazardous voltage during and after measurement Danger of death from electric shock!

▷ Do not touch the contact points during and immediately after measurement.

▷ Insulation resistance measurement must be effected by a trained electrician

only.

Measure the insulation resistance prior to installation and prior to connection to the power supply.

Insulation resistance measurement must be effected by a trained electrician only.

Prior to the measurement, ensure compliance with the operating instructions of the device for measuring the insulation resistance.

✓ An insulation resistance measuring device with a measuring voltage of 1000 V DC

to 2500 VD C max. is available.

✓ The contact points are clean and dry.

Measurement period: 1 minute

Minimum insulation resistance at 20 °C - 30 °C: > 200 MOhm

V WU

Risol (MΩ)

M 3~

V1-1 W1-1U1-1

Risol (MΩ)

M 3~

V1-2 W1-2U1-2

1 lead 2 leads (parallel)

5.3 Installing the pump set in vertical position

NOTE

Observe all safety instructions contained in this manual for the following installation instructions. (⇨ Section 5.1 Page 20

)

The measured value must be steady; a longer measurement period might be needed for larger cable cross-sections.

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Suspend the submersible borehole pump from the riser to transport it to its actual place of installation/operation. The riser can differ in design and material. Consequentially, the installation and application options also differ. Always observe the installation instructions of the respective riser when installing a submersible borehole pump! The riser always has to be designed for the maximum forces, torques and pressures in the system.

General information of lowering the pump set into the well

▪ It is recommended to fit a centring device to prevent the pump set and the walls

of the well from any damage during installation.

▪ Fit cable ties every three metres to protect the power cable against any damage.

Cable ties are suitable for metal risers and/or thick-walled plastic risers. On all other riser types, the power cable also has to be secured every three metres.

▪ Tighten the cable ties firmly to prevent the power cable from slipping

downwards by its own weight! Otherwise, the cable could be affected by impermissibly high tensile stress.

WARNING

Installing pipe sections of extensive length Impermissible bending of the pump set when pulling it upright!

▷ The length of the first pipe section must not exceed two metres.

Installation example with a metal riser (pipes)

✓ Suitable lifting equipment for the total weight has been selected and is on hand.

(⇨ Section 5.2.6 Page 25)

✓ The motor fill has been checked and topped up, if required.

✓ Any extension cables have been properly connected to the power cable as well as

to the measuring and control cables.

✓ The pump set has been placed in horizontal position in a level assembly area and

is protected against rolling off.

✓ Cable ties to securely fasten the power cable and any measuring and control

cables are on hand.

✓ A sealing agent is available.

✓ A mounting plate, pairs of supporting clamps and beams have been selected for

the total weight(⇨ Section 5.2.6 Page 25)and are on hand.

✓

Risers with recesses in the flanges

10)

are on hand.

1. For flanged risers: Bolt the first pipe section (max. length 2 m) to the connection branch. Fasten the mounting plate to this pipe section.

Fasten the first pair of supporting clamps below the upper flange.

NOTE

On threaded risers fit an anti-rotation device to prevent the pump set from unscrewing itself from the threaded riser during start-up.

1. For threaded risers: Apply a sealing agent and screw the first pipe section (max. length 2 m) into the connection branch. Secure the connection with the two supplied securing screws. For this purpose, drill a shallow hole into the threaded end of the pipe section, taking care not to drill through the threaded end. Insert the locking screws with thread-locking compound in such a way that their tips rest lightly but do not press on the threaded pipe end! Allow time for the sealing agent to cure. The connection is now sufficiently secured against loosening.

10)

Applies to flanged risers only

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2. Use cable ties to attach the power supply cable as well as any control and measuring cables to the riser approximately 0.5 m above the lower flange.

Place two sturdy beams across the well opening.

4. Pull the pump set into upright position with the lifting equipment.

5. Attach the pump set to the crane hook (e.g. mobile crane) by the mounting plate and lower it into the well until the first pair of supporting clamps rests on the beams.

6. Remove the mounting plate and fasten it to the second riser.

7. Fasten a second pair of supporting clamps to the second riser.

8. Use the lifting equipment to lower the second riser onto the first riser, and install it.

9. Undo the first pair of supporting clamps and lower the pump set until the second pair of supporting clamps rests on the beams.

10. Repeat these steps for every pipe section, lowering the pump set into the well until the installation depth He is reached.

5.3.1 Attaching the cable ties

The cables shall be fixed to the riser pipe by a cable tie each on both sides of the riser pipe flange or socket. Attach a cable tie every 3 metres. Implement this arrangement over the entire length of the riser.

Sizes 2, 3, 3a, 3b, 4 1 = turnbuckle (reusable)

2 = cable guard 3 = power cable 4 = metal strap 5 = riser

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1. Cut metal strap (4) to the required length L (L = circumference of riser pipe + approx. 200 mm allowance) and bend both ends inwards by approx. 100 mm.

Fully open the turnbuckle (1) and attach it to one end of the metal strap.

3. Place the cable guard (2) around the power cable (3). Guide it around the riser (5) together with the metal strap (4). Then attach the other end of the turnbuckle (1) to the metal strap (4).

4. Tighten the turnbuckle (1) with a screwdriver so that the power cable (3) cannot slip downwards by its own weight!

5.4 Installing the pump set in a horizontal position

NOTE

Observe all safety instructions contained in this manual for the following installation instructions.(⇨ Section 5.1 Page 20)

WARNING

Installation on mounting surface which is unsecured and cannot support the load Personal injury and damage to property!

▷ Use a concrete of compressive strength class C12/15 which meets the

requirements of exposure class XC1 to EN 206-1.

▷ The mounting surface must have set and must be completely horizontal and

even.

▷ Observe the weights indicated.

CAUTION

Temperature and pressure increase of the motor fill Damage to the motor!

▷ Always protect non-flooded pump sets against direct exposure to sun.

NOTE

Only install pump sets in horizontal position if they have been approved for this type of installation.

Submersible borehole pumps can be installed in a horizontal position, provided the pump set has been approved for this type of installation. (See data sheet.) The required accessories depend on the weight and the overall length of the pump set. If agreed with KSB, the pump set is supplied with the accessories for the required installation type already fitted. For assembly at the site: It is imperative to use original accessories (bearing pedestals, supporting frames, pressure shroud).

5.4.1 Installing the pump set on supporting frame and bearing pedestal

NOTE

Fasten the power cable as well as any measuring and control cables to the piping at least every three metres as well as upstream and downstream of any pipe bends by means of cable ties or other suitable fasteners. Prevent any fluttering of the cables caused by the water flow. This applies especially to any other types of cable guide; use a protecting tube, if required.

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Fig. 6: Installation example with supporting frame and bearing pedestal

1 Motor 2 Pump 3 Supporting frame 4 Pedestal

Observe the following positions of the supporting frame and bearing pedestal: Supporting frame for the motor: Mounting clamps at the casing flanges Bearing pedestal for the pump: Last stage or non-return valve / connection branch.

✓ The structural dimensions have been verified.

✓ The water storage tanks have been installed.

✓ The motor fill has been checked and topped up, if required.

✓ Any extension cables have been connected to the power cable as well as to the

measuring and control cables.

Undo the ties holding the cable guard. Remove the cable guard.

2. Fasten the supporting frame and bearing pedestals to the pump set. Position and align the assembly on the foundation/floor.

3. Mark and drill the holes for the fixing bolts on the foundation and fasten the pump set with the supporting frame/pedestals on the foundation.

4. Run the power cable through the foot of the pump bearing pedestal and fasten it to the pump (approximately in the middle of the pump's overall length) and the non-return valve / connection branch with cable ties. Make sure the cable is securely fastened to prevent it from fluttering in the water flow. Use a protective tube, if necessary!

NOTE

Fit an expansion joint between the piping and the pump set to prevent any piping forces and vibrations from affecting the pump set.

5. Install the piping.

Securely fasten the power cable as well as any measuring and control cable to the piping with cable ties or use other suitable cable guides.

5.4.2 Installing the pump set in a suction, pressure or cooling shroud

For special operating conditions, submersible borehole pumps can be equipped with a suction, pressure or cooling shroud; see order documentation or data sheet. In such cases, always refer to the additional documentation supplied with the delivery. See the operating instructions of the accessory "Suction, pressure or cooling shroud".

1 3 2

Fig. 7: Example: pressure shroud

1 Motor 2 Pump 3 Pressure shroud

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5.5 Installing the pump set in an angled position

NOTE

Observe all safety instructions contained in this manual for the following installation instructions.(⇨ Section 5.1 Page 20

)

The pump sets are suitable for angled installation, provided they have been selected for this type of installation. See order documentation or data sheet. Angled installation of a submersible borehole pump always requires structural adjustments. For angled installation, always refer to the additional documentation supplied with the delivery.

Permissible installation positions:

Fig. 8: Installation position

Table 10: Selection table

A1 Permissible up to

maximum 3°

Installation see section: Installing the pump set in a vertical position (⇨ Section 5.3 Page 27

)

A2 Permissible up to

maximum 3°

Installation see section: Installing the pump set in

a horizontal position B Permissible installation position, if approved in the order documentation C Impermissible The pump set must not be installed in this

position.

5.6 Notes on electrical connection

KSB's submersible borehole pumps > 1000 V are wired for DOL starting. During startup and run-up the voltage must not fall below the value specified in the order documentation.

If this starting method is not permitted by the power supply utility, starting devices to reduce starting currents must be provided (e.g. autotransformers, starting resistors or soft starters ).

General information on the motor

Motor protection Provide a temperature-compensated overcurrent relay of tripping class 10 or 10 A as motor protection. If an earth leakage relay is used, it must be fitted in the motor power circuit.

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Rating The rating specified on the name plate and in the order confirmation applies to continuous operation S1 to DIN EN 60034-1.

5.6.1 Operation with autotransformers and starting resistors

Set up the starting devices for automatic operation, i.e. switchover from partial to full voltage must be automatic. The partial voltage period shall not exceed 4 s. To operate the pump set with a starting transformer or starting resistor, choose a closed-transition switchover method (Korndorfer connection).

5.6.2 Operation with soft starter

Submersible motors differ from ordinary standardised asynchronous motors in their slim design (low moments of inertia), their output, mechanical seal design and winding type.

The following reference values, based on our experience, ensure safe operation of submersible borehole pumps. The operator is responsible for checking with the manufacturer of the soft starter that the particular features of submersible borehole pumps have been taken into account. Depending on the make the indicated reference values may be exceeded.

Table 11: Reference values for soft starters

Parameter/function Settings

Minimum starting voltage 40 % of the motor's rated voltage Ramp time / acceleration (run-up) time tH < 4 seconds

Current limitation IA / IN approx. 3.5 Deceleration (run-down) time / stop ramp tA < 4 seconds All special functions, e.g.

▪ Delayed starting

▪ Current control

▪ Speed control

▪ Kick-start / boost function

OFF

1. After run-up, the soft starter must be bypassed by a contactor.

Always observe the manufacturer's operating instructions.

3. Soft starters for two-phase connection are only permitted if the starter's control algorithm eliminates the physically caused d.c. components.

4. If the soft starter fulfils motor protection functions, such as an over-current trip (tripping class 10 or 10A), phase failure, etc., these functions must be ensured when the soft starter is bypassed by a contactor.

NOTE

Conspicuous noises or vibrations during run-up and run-down could indicate incorrect parameter settings on the soft starter, such as excessive ramp times, incorrect operating mode (control) or enabled special functions.

5.6.3 Operation with frequency inverter

The motors of submersible borehole pumps differ from ordinary standardised asynchronous motors due to their slim design (low moments of inertia), their output, mechanical seal design and winding type. For this reason, submersible borehole pumps > 1000 V must only be operated with a frequency inverter, if frequency inverter operation has been approved for the pump set (see data sheet, order documentation). In accordance with DIN EN 61800-4 the drive system supplier is responsible for clarifying the details of and reaching an agreement on the interface between motor and frequency inverter.

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Maximum permissible run-up and run-down times The run-up process from standstill to the minimum frequency f

min

must not exceed 2

seconds. The run-down process must also take no more than 2 seconds.

Minimum frequency Observe the following minimum frequencies.

Table 12: Minimum frequencies

Motor size Minimum frequency f

min

(Hz)

for vertical installation for horizontal installation

2-pole motors 20 30 4-pole motors 30 35

Maximum operating frequency Do not exceed the maximum operating frequency of 50 Hz/60 Hz.

Winding load Observe the following limits:

Maximum rate of voltage rise: du/dt ≤ 500 V/μs Maximum voltage peaks against earth: 0.9 • U

NOTE

An output filter must be fitted to observe the limits.

Control principle of the frequency inverter The control principle has to correspond with a linear U/f characteristic. If other control principles are employed, such as field-oriented inverters, inverters with DTC or NOF, the manufacturer of the frequency inverter must ensure that the special features of submersible motors (very small moment of inertia, electrical data) are taken into account.

5.7 Electrical connection

DANGER

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

▷ Have cables terminated by qualified personnel only.

▷ Observe regulations IEC 30364 (DIN VDE 0100) and HD 637 S1 (DIN VDE 0101).

DANGER

Earth conductor not properly connected Danger of death from electric shock!

▷ Never operate the motor without earth conductor.

▷ The earth conductor must be connected by a professional electrician only.

WARNING

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

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

1. Check the available mains voltage against the data on the name plate.

Terminate the cable ends properly with suitable cable terminations. If cable terminations are included in KSB's scope of supply, observe the separate installation instructions.

3. Check the starting method in the data sheet and select the corresponding circuit diagram.

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NOTE

Connect shielded motor leads with the exposed shield as short as possible and the shield ends having contact over a large area. Interruptions of the shield must be compliant with EMC

11)

. Observe the EMC instructions given by the equipment

manufacturers.

Three-phase (3~) motors with one cable for DOL starting

The 3 current-carrying conductors are designated U, V, W; the designation of the earth conductor is PE. (See circuit diagram.)

L2 L3

Fig. 9: Circuit diagram: three-phase (3~) motors with one cable for DOL starting

1 Motor 2 Motor lead 3 Conductor marking 4 Control unit 5 Mains phases PE Earth conductor (green/yellow)

Three-phase (3~) motors with two parallel cables for DOL starting

The 6 current-carrying conductors of the two parallel power cables are designated U1-1, V1-1, W1-1 and U1-2, V1-2, W1-2; the earth conductor is marked PE. (See circuit diagram.)

The motors are wired in star (Y), and are fitted with two parallel cables.

11)

Electromagnetic compatibility

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V W PE

U1-1 V1-1

W1-1

V1-2

W1-2

U1-2

Fig. 10: Circuit diagram: motors with two parallel cables for DOL starting

1 Motor 2 Motor lead 3 Conductor marking 4 Control unit 5 Mains phases PE Earth conductor (green/yellow)

DANGER

Earth conductor not properly connected Danger of death from electric shock!

▷ Never operate the motor without earth conductor.

▷ The earth conductor must be connected by a professional electrician only.

5.7.1 Recommended monitoring and protective equipment

The following monitoring and protective equipment is recommended to ensure proper operation of the pump set:

Table 13: Monitoring options

To be monitored If there is any risk of: Monitoring options, e.g.:

Dry running ▪ Highly fluctuating water levels

▪ Wells with temporary low yields

▪ Semi-automatic or fully

automatic dry running protection equipment (e.g. integrated in KSB's control unit UPA Control)

Lightning/overvoltage Although a lightning protection device cannot offer

protection against direct lightning strikes, it will protect the pump unit from atmospheric overvoltage and any lightning strikes nearby.

▪ Lightning protection

with earthing terminal (available from KSB)

Phase failure ▪ Failure of one phase resulting in overloading of

the remaining two phases Excessive temperature in the motor

▪ Permissible motor temperature exceeded by

system conditions, e.g.:

–

Deposits on the stator

– Installation in standing water

– Dirt/sand deposits in the stator area

– Major temperature rise in the fluid handled

– Frequency controlled motors

▪ Pt 100 temperature

sensor and the corresponding analysing device

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Also:

▪ Overcurrent/undercurrent

▪ Earth fault / short circuit

▪ Current asymmetry

▪ Overvoltage/undervoltage

▪ Vibrations

5.7.2 Connecting the temperature monitoring equipment

Submersible motors can be fitted with a temperature sensor for the motor fill temperature. This is necessary whenever the operating limits of the motor can be exceeded because of reduced cooling (e.g. ochre build up, increased temperature of the fluid pumped, etc).

Submersible motors > 1 kV can be fitted with either of the following two options: a temperature sensor which is inserted into the motor or a temperature sensor which is fastened directly to the end windings. The option of retrofitting depends on the motor make and has to be checked. As a standard (order-related deviations are possible), the sensor has a shielded connection cable of 0.5 mm2 with 4 cores or of 1.5 mm2 with 3 cores. Maximum cable length:

▪ for a cross-section of 0.5 mm2 = 280 m

▪ for a cross-section of 1.5 mm2 = 1400 m

For analysing the temperature sensor, a separate analysing device is required.

Table 14: Number of cores and corresponding colour codes

4 cores 3 cores

Pt 100

A1 A2 A3 A4

Pt 100

A1 A3 A4

A1 = black core

A2 = grey core A3 = blue core

A4 = brown core

Connection to the analysing device

The sensor can be connected by 2-, 3- or 4-wire system.

Pt 100

A1 A2 A3 A4

2-wire system

Pt 100

A1 A2 A3 A4

3-wire system For 4-core cables do not connect core A2.

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Pt 100

A1 A2 A3 A4

4-wire system For 4-core cables only.

1. Core-to-core resistance (measure with d.c. voltage U < 6 V) If the temperature sensor is intact, resistances between the individual cores shall be as follows:

– Resistance between A1 and A2 / between A3 and A4: 0 Ω to 30 Ω

– Resistance between A1 and A3 / between A2 and A4: 100 Ω to 130 Ω

2. Insulation resistance (measure with d.c. voltage U < 100 V). Combine all core ends.

– The resistance between the core ends and earth (e.g. motor housing) must be

higher than 6 MΩ.

Two temperature limits are important for submersible motors.

1. Alert temperature t

Alert

If the alert temperature t

Alert

is exceeded, a malfunction has occurred (e.g.

inadmissible contamination / ochre build up on the motor housing). Corrective action must be initiated.

Setting: t

Alert

= t

Operating

+ (t

Cut-out

- t

Operating

) / 2

Operating

= normal operating temperature after approximately 1.5 operating hours

2. Cut-out temperature t

Cut-out

If the cut-out temperature t

Cut-out

is reached, the motor must be tripped. It must

not be re-started until the malfunction has been remedied.

Setting: Submersible motors with J2 winding (PE): t

Cut-out

= 75 °C

Testing:

Function

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6 Commissioning/Start-up/Shutdown

6.1 Commissioning/start-up

6.1.1 Start-up

DANGER

Start-up with defective earth conductor Personal injury from electric shock!

▷ Never switch on a pump set without an earth conductor or with a defective

earth conductor.

CAUTION

Starting up the pump set outside the fluid Damage to the motor!

▷ Only start up pump sets when the motor is filled and the unit is fully submerged

or flooded!

CAUTION

Operation with closed shut-off element Damage to motor and bearings!

▷ Never let the pump set run against a closed shut-off element for more than two

minutes.

CAUTION

Continuous operation against a throttled shut-off element Damage to pump and motor!

▷ In continuous operation against a throttled shut-off element, the flow rate

must not fall short of Q

min

(see name plate).

✓ The pump set has been assembled as specified in this manual.

✓ The pump set has been installed as described in this manual.

✓ The power cables, including control and measuring cables, have been fastened

and connected in the control box.

✓ The control box and protective equipment have been installed and set properly.

✓ The pump set is completely submerged or flooded.

Close the shut-off element on the discharge side.

2. Start up the pump set.

3. Slowly open the shut-off element until the duty point is reached.

NOTE

When starting against an empty pipe, make sure that the air contained in the pipe can escape to the atmosphere.

NOTE

It is not necessary to delay the start-up of a shut-off element with electric actuator, as the running-up time of the pump is shorter than the dead time of the shut-off element.

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6.1.1.1 Information on commissioning

CAUTION

Excessive sand content in the water Damage to the pump set!

▷ If the sand content equals 50 g/m3 or more, switch off the pump set.

▷ Inform the well building company.

1. When commissioning pump sets in new boreholes, initially only operate the pump set for approximately 10 minutes with the shut-off element slightly open.

Check escaping water for any sand content.

⇨ If the sand content equals 50 g/m3 or more, switch off the pump set and

inform the well building company.

⇨ If the sand content decreases, slowly open the shut-off element until the

duty point is reached.

6.1.2 Checking the direction of rotation

CAUTION

Wrong direction of rotation Damage to the motor!

▷ Do not run the pump set for more than two minutes when checking the

direction of rotation.

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.

▷ Make sure that backflow of the fluid handled is slow and controlled, so that the

pump rotor does not start to rotate, e.g. by throttling the discharge-side gate valve accordingly.

✓ The back-up name plate has been attached at the place of installation of the

submersible borehole pump.(⇨ Section 4.6 Page 18)

✓ The pump set has been installed completely.

✓ The power cable and the measuring and control cables, if any, have been

connected in the control cabinet.

✓ The shut-off element in the discharge line is slightly open.

Switch on the motor at the control cabinet.

2. As soon as the system has reached a steady state, read off the pressure and/or flow rate from the pressure gauges.

3. Verify the read data against the data on the back-up name plate.

⇨ If the values are almost identical, the direction of rotation is correct.

⇨ If the read values are too low, the direction of rotation is incorrect.

4. If the direction of rotation is incorrect, switch the motor off at the control cabinet.

5. Have the phase sequence (U, V, W) corrected on the motor connection side in the control cabinet by a trained electrician.

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6.2 Operating limits

DANGER

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

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

6.2.1 Frequency of starts

Observe the following values:

Table 15: Frequency of starts and standstill periods

Motor type series Maximum No. of starts

per [h]

Minimum standstill

period [min]

T < 5 6 V < 5 6 X < 5 6 Z < 5 6 E < 3 10

6.2.2 Supply voltage

Observe the permissible voltage and frequency fluctuations to DIN EN 60034-1 section A; UN ± 5 %, fN ± 2 %. The limits may differ if specified in the order, see order

confirmation.

Star point displacement

Operation with displaced start point must not exceed the value U0 > 0.2 x UN and must be limited to one operating hour.

6.2.3 Fluid handled

6.2.3.1 Minimum submergence

The submergence X of the pump sets must be ≥ 0.5 m for the following examples of vertical and horizontal installation. A higher submergence may be required by the NPSH value specified in the order documentation or the value indicated in the following diagram.

0,0

0,5

1,0

1,5

2,0

X m

Q l/s

100

200

150

100

200

Q m3/h

600300 500 800700

Fig. 11: Minimum submergence depending on the flow rate

The values in the above mentioned diagram apply to submersible borehole pumps up to size UPA 350. For larger pump sets refer to the value X in the order documentation or the data sheet. Contact the manufacturer, if required.

NOTE

The water level in the well is usually measured with a water level contact meter (well dipper).

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Measurement for vertical installation: upper edge of the pump to lowest (dynamic) water level X = He - H

geo

Fig. 12: Minimum submergence for vertical installation

T Well depth HhStatic water level D Well diameter HtDynamic water level HeInstallation depth of the pump set H

geo

Height of control box above the static water level in the well

X Minimum submergence

Measurement for horizontal installation: upper edge of the suction strainer to lowest (dynamic) water level

Fig. 13: Minimum submergence for horizontal installation

X Minimum submergence

6.2.3.2 Sand content

Make sure the maximum sand content of 50 g/m³ is not exceeded.

Vertical

installation

Horizontal

installation

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6.2.3.3 Fluid flow along the motor

To provide sufficient cooling of the motor, enforce the required flow velocity of the fluid flowing along the motor. For the maximum permissible temperature T

max

and the required flow velocity v

min

refer to the name plate. Provide suitable installation arrangements to comply with these values.

The required flow velocity is achieved by perfect dimensioning of the outer pump diameter and the inner well diameter.

Table 16: Maximum permissible inside diameter of the well or shroud

Flow rate Flow

velocity

Inside diameter of the well or shroud [mm]

Q [m³/h] v [m/s] for

motor T

for

motor V

for

motor X

for

motor Z

for

motor E

150 ≥ 0.2 ≤ 590 ≤ 620 ≤ 650 ≤ 700 ≤ 780

≥ 0.5 ≤ 430 ≤ 470 ≤ 520 ≤ 580 ≤ 670

175 ≥ 0.2 ≤ 625 ≤ 650 ≤ 690 ≤ 730 ≤ 810

≥ 0.5 ≤ 450 ≤ 490 ≤ 540 ≤ 590 ≤ 690

200 ≥ 0.2 ≤ 660 ≤ 690 ≤ 720 ≤ 760 ≤ 840

≥ 0.5 ≤ 470 ≤ 510 ≤ 550 ≤ 610 ≤ 700

250 ≥ 0.2 ≤ 725 ≤ 750 ≤ 780 ≤ 820 ≤ 890

≥ 0.5 ≤ 505 ≤ 540 ≤ 580 ≤ 640 ≤ 720

300 ≥ 0.2 ≤ 780 ≤ 800 ≤ 830 ≤ 870 ≤ 940

≥ 0.5 ≤ 540 ≤ 570 ≤ 610 ≤ 660 ≤ 750

350 ≥ 0.2 ≤ 835 ≤ 860 ≤ 880 ≤ 920 ≤ 980

≥ 0.5 ≤ 570 ≤ 600 ≤ 640 ≤ 690 ≤ 770

400 ≥ 0.2 ≤ 890 ≤ 910 ≤ 930 ≤ 970 ≤ 1030

≥ 0.5 ≤ 605 ≤ 630 ≤ 670 ≤ 710 ≤ 790

500 ≥ 0.2 ≤ 985 ≤ 1000 ≤ 1020 ≤ 1050 ≤ 1110

≥ 0.5 ≤ 660 ≤ 690 ≤ 720 ≤ 760 ≤ 840

600 ≥ 0.2 ≤ 1070 ≤ 1090 ≤ 1110 ≤ 1140 ≤ 1190

≥ 0.5 ≤ 710 ≤ 740 ≤ 770 ≤ 810 ≤ 880

800 ≥ 0.2 ≤ 1225 ≤ 1240 ≤ 1260 ≤ 1280 ≤ 1330

≥ 0.5 ≤ 805 ≤ 830 ≤ 850 ≤ 890 ≤ 960

1000 ≥ 0.2 ≤ 1360 ≤ 1370 ≤ 1390 ≤ 1410 ≤ 1460

≥ 0.5 ≤ 890 ≤ 910 ≤ 930 ≤ 970 ≤ 1030

1200 ≥ 0.2 ≤ 1485 ≤ 1500 ≤ 1510 ≤ 1530 ≤ 1570

≥ 0.5 ≤ 965 ≤ 980 ≤ 1010 ≤ 1040 ≤ 1090

1400 ≥ 0.2 ≤ 1600 ≤ 1610 ≤ 160 ≤ 1640 ≤ 1680

≥ 0.5 ≤ 1030 ≤ 1050 ≤ 1070 ≤ 1100 ≤ 1160

1600 ≥ 0.2 ≤ 1705 ≤ 1720 ≤ 1730 ≤ 1750 ≤ 1780

≥ 0.5 ≤ 1100 ≤ 1120 ≤ 1140 ≤ 1170 ≤ 1220

1800 ≥ 0.2 ≤ 1805 ≤ 1820 ≤ 1830 ≤ 1850 ≤ 1880

≥ 0.5 ≤ 1165 ≤ 1180 ≤ 1200 ≤ 1230 ≤ 1270

2000 ≥ 0.2 ≤ 1900 ≤ 1910 ≤ 1920 ≤ 1940 ≤ 1970

≥ 0.5 ≤ 1225 ≤ 1240 ≤ 1260 ≤ 1280 ≤ 1330

The following installation arrangements contribute to the best possible flow along the motor:

▪ Installation in deep wells

Install the pump set above the well screen/filter. The pump draws water from below, which ensures a continuous water flow along the motor.

▪ Installation in a tank/reservoir

The pump set is freely suspended in the water and the water inlet is below the motor.

▪ Installation in suction, pressure or cooling shroud

Installing the suction, pressure or cooling shroud leads to the required flow along the motor.

Perfect dimensioning

Installation arrangements

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6.3 Shutdown

1. Slowly close the shut-off element on the discharge side.

Switch off the motor immediately after closing the shut-off element.

NOTE

To make sure that the pump set is always ready for instant start-up, start up the pump set approximately every 2 weeks for approximately 5 minutes during prolonged shutdown periods.

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7 Servicing/Maintenance

7.1 Servicing/inspection

The submersible borehole pumps are generally maintenance-free. In order to pinpoint indications of potential damage at an early stage, regular checks are required. Such indications could be:

▪ Temperature rise in the fluid handled

▪ Increased sand content of the fluid handled

▪ Change in power consumption

▪ Change in discharge head/flow rate

▪ Change in frequency of starts

▪ Increase in noise and vibration levels

Regular inspection does not require the submersible borehole pump to be removed from the well/tank.

For any queries and repeat orders, particularly when ordering spare parts, specify the following information (see name plate(⇨ Section 4.3 Page 17)):

▪ Pump and/or motor type series and size

▪ Operating data

▪ Order number

For information concerning repair jobs and spare parts please contact your nearest KSB service centre.

7.2 Removing the pump set

DANGER

Electrical connection work 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 (DIN VDE 0100) and HD 637 S1 (DIN VDE 0101).

WARNING

Persons could fall into unsecured wells/reservoirs/tanks Risk of personal injury!

▷ During installation work, take suitable precautions to protect anyone from

falling into an open well/reservoir/tank.

▷ Suitably fence off the work area.

WARNING

Uncontrolled lifting of the pump (set) or drive Risk of injury!

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

when being lifted).

WARNING

Pump set tipping over Risk of squashing hands and feet!

▷ Suspend or support the pump set.

✓ Suitable lifting equipment for the total weight has been selected and is on hand.

(⇨ Section 5.2.6 Page 25)

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✓ Suitable removing equipment, e.g. lifting clamps or mounting plate, is on hand.

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

2. For removing the pump set refer to the assembly/dismantling instructions of the corresponding riser.

WARNING

Setting down pump sets with pipe sections of extensive length Impermissible bending of the pump set when setting it down in a horizontal position!

▷ The length of the last pipe section flanged to the pump set must not exceed

two metres.

3. Set the pump set down in a horizontal position on a solid and level surface. Secure it against rolling off.

7.3 Separating pump and motor

WARNING

Pump set tipping over 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.

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

against unintentional start-up.

✓ The pump set has been pulled out of the well or removed from the tank.

✓ The pump set has been disconnected from the piping.

✓ Lifting equipment of sufficient load-carrying capacity is on hand.

Attach the pump set to suitable lifting equipment.

2. Pull the pump set upright and make sure it cannot tip over.

Remove the cable guard. Observe the minimum bending radius for the cable

12)

4. Remove the suction strainer.

Remove the grub screw and the additional securing pin/bolt

13)

from the sleeve

coupling at the motor end.

6. Undo the assembly studs between pump and motor.

7. Use the lifting equipment to lift the pump off the motor in a vertical position. Then place it on a clean and level surface and secure it against rolling off.

8. Secure the key in the shaft stub, e.g. with adhesive tape.

9. Place the motor on a clean and level surface. Secure it against tipping over and rolling off.

12)

See cable manufacturer's documentation or DIN VDE 0298-3.

13)

If any

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7.4 Motor fill

DANGER

Unfilled or insufficiently filled motor Damage to the motor winding!

▷ Never install and run the motor without sufficient motor fill.

▷ Observe the information sticker on the motors and top up the motor fill as

instructed.

DANGER

Unfilled or insufficiently filled motor Winding damage! Corrosion damage!

▷ Observe the information sticker on the motor and top up the motor fill as

instructed.

WARNING

Drinking water/antifreeze mixture could escape Hazardous to persons and the environment!

▷ Wear safety glasses and protective gloves when topping up, checking and

draining the motor fill.

▷ Observe the national health and safety regulations.

▷ Observe all legal regulations on the disposal.

CAUTION

Freezing of motor fill Motor damage!

▷ Match the mixing ratio of drinking water / antifreeze agent to the expected

temperatures.

▷ Always protect water-filled motors against frost.

▷ Provide frost-proof storage.

Information sticker / motor fill

Table 17: Type of motor fill

Sticker colour Supplied condition Motor fill

Green Filled Drinking water / antifreeze mixture (1,2 propylene glycol) Red Unfilled Drinking water

or drinking water / antifreeze mixture (1,2 propylene glycol)

Mixing ratio / purpose

▪ The motors must only be filled with an antifreeze agent on a 1,2 propylene

glycol basis which has been approved by KSB.

▪ The drinking water / antifreeze mixture supplied by the factory is intended for

operation as well as storage/transport/preservation. It protects the motor up to temperatures of -15 °C. For any deviations refer to the order documentation / data sheet.

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▪ The percentage of antifreeze agent must always be selected for the expected

temperatures below 0 °C at the place of installation/transport/storage.

▪ The motor fill must be prepared with clean drinking water. The mixing ratios and

total quantity must be observed.

Table 18: Mixing ratios

Temperatures down to

Percentage of drinking water

Percentage of antifreeze agent

Purpose

Operation Storage Transport Preservation

-10 °C 75 % 25 % ✘ ✘ ✘ ✘

-15 °C

14)

66 %

14)

34 %

14)

✘ ✘ ✘ ✘

-20 °C 62 % 38 %

15)

✘ ✘ ✘

- 25 °C 57 % 43 %

15)

✘ ✘ ✘

-30 °C 53 % 47 %

15)

✘ ✘ ✘

Below - 30 °C Contact KSB.

Quantity of motor fill

Refer to the following table for the quantity of motor fill.

Table 19: Quantity of motor fill [litre]

Motor type series Quantity of motor fill

T approx. 32 V approx. 45 X approx. 80 Z approx. 140 E approx. 230

7.4.1 Filling/topping up the motor

WARNING

Drinking water/antifreeze mixture could escape Hazardous to persons and the environment!

▷ Wear safety glasses and protective gloves when topping up, checking and

draining the motor fill.

▷ Observe the national health and safety regulations.

▷ Observe all legal regulations on the disposal.

WARNING

Screw plugs subjected to pressure When opening screw plugs, liquid might spurt out!

▷ Wear safety goggles and protective clothing, if required.

▷ Open the screw plug slowly.

WARNING

Pump set tipping over 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.

✓ The information sticker has been checked.

14)

Drinking water/antifreeze mixture filled in at the factory

15)

Operation only if explicitly approved in the order confirmation.

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✓ A sufficient quantity of liquid of the specified concentration for the motor fill is

available.

✓ A drain pan for any escaping fill is on hand.

✓ The motor or pump set is positioned vertically and secured against tipping over.

Undo the two screw plugs (a and b) and remove them together with the seal elements. This results in a filler and a vent opening.

2. To fill the motor, insert the filling funnel (c) horizontally into one of the two adapter openings. Depending on the sticker colour, fill in or top up fill liquid until a continuous flow escapes from both openings.

3. For motors which have been supplied "unfilled", wait at least 12 hours to allow the air to escape. During this period, move the motor or pump set suspended from the crane slightly to and fro, if possible. Then continue filling it slowly. Wait another 30 minutes.

4. Check the fill level again.

5. Screw the screw plugs (a and b) back in together with the sealing elements. Check the screw plugs for tightness. Make sure that the contact faces are clean and that the joint ring is inserted and free from damage.

NOTE

Fill in the fill liquid slowly. Fill in with pauses to allow air to escape. Check the drain plugs at the bottom of the motor for tightness.

1. Suspend the motor or pump set from a crane. Fasten the motor or pump set to the floor and secure it against slipping.

Carefully lower the crane to slightly tilt the motor or pump set.

3. Monitor the screw plugs for escaping fluid.

4. If required, fit new sealing elements.

7.5 Storage and preservation

WARNING

Pump set tipping over 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

Improper storage Damage to the power cables!

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

deformation. Observe the minimum bending radius

16)

of the cables.

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

installation.

7.5.1 Storing new submersible borehole pumps

To store for a prolonged period pump sets / motors which have not been used yet ensure the following conditions are met:

Pump set / motor removed from packaging

2. Vertical (with the motor below)

Checking the

screw plugs.

16)

See cable manufacturer's documentation or DIN VDE 0298-3.

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3. In a dry environment

Protected against direct sunlight and heat

5. Protected against dirt and dust

6. Protected against freezing

7. Protected against vermin

If the motors have been supplied filled with a drinking water/antifreeze mixture, store them in this filled condition. Store unfilled motors in unfilled condition. If previously unfilled motors have been filled for functional testing, for example, the motor fill for storage must be equivalent to the drinking water/antifreeze mixture used by KSB to provide protection up to -15 °C.

NOTE

As the antifreeze concentration gradually decreases over time the remaining antifreeze level must be checked with a spindle. If the anticipated temperature is below the antifreeze value, either increase the antifreeze concentration in the motor accordingly or store the pump set in a frost-free location.

7.5.2 Storing submersible borehole pumps which have been removed from a system

Pump sets / motors which have been operated must generally be overhauled by qualified specialist personnel, for example a service workshop authorised by KSB. After the pump set / motor has been overhauled, fill the motor with drinking water / antifreeze mixture providing protection up to -15 °C, and store it. Motors must only be stored in unfilled condition if, in addition to the above, the inside of the motor has been preserved against corrosion. Store the pump set / motor as described in this manual.(⇨ Section 7.5.1 Page 49

)

7.6 Reassembling the pump set

7.6.1 Mounting the motor

CAUTION

Pump set tipping over or slipping out of the suspension arrangement Personal injury and damage to property!

▷ Always make sure pump sets in upright position cannot tip over.

NOTE

The submersible borehole pumps are supplied with a sealed sleeve coupling which protects the motor shaft from contact with the fluid handled. If motors are supplied without a pump, a sealed sleeve coupling must be used for mounting the pump on the motor. Make sure this protection is ensured also when the pump is serviced (dismantled) or replaced. Exception: No sealed sleeve coupling is required for type series T. The motor shaft end is made of CrNi steel.

✓ Lifting equipment of sufficient load-carrying capacity is available.(⇨ Section 5.2.6

Page 25)

✓ A mounting flange or mounting guide hoop and lifting straps are provided.

✓ Loctite 242 has been prepared.

✓ The cleaning agent (e.g. Aceton made by Rhinix or similar) has been prepared.

✓ Grease (e.g. BIO-Chem Tech) is available.

✓ A torque wrench is on hand.

✓ Common assembly tools are on hand.

✓ The general assembly drawings are on hand.

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1. If already assembled, remove the suction strainer and cable guard from the pump.

Clean all locating surfaces, contact surfaces and threads with a cleaning agent. Thoroughly remove any residues of the preservative.

3. Grease the shaft stub of the motor and the sleeve coupling of the pump.

4. Apply a thin layer of grease to the locating surfaces and contact surfaces.

5. On new motors, remove the transport lock from the shaft. To do so, remove screw (1) and strap (2).

6. Position the motor horizontally and secure it against tipping over.

Suspend the pump from the crane and align it so that the cable recess, coupling sleeve and screws/bolts are in the correct position.

8. Centre the pump, fit the sleeve coupling around the shaft stub, and lower the pump.

9. Fit nuts and assembly studs. Apply Loctite 242 and tighten the nuts by hand.

10. Insert the grub screw into the coupling sleeve and secure it with the corresponding securing pin/bolt, if any, to prevent the pump from lifting off the motor. Insert the securing screw into the coupling sleeve. Apply Loctite 242. Gently screw in the screw until flush, then turn it back by 1/8 of a turn.

NOTE

Make sure the fitted grub screw does not touch the rotor.

11. Use a torque wrench to tighten the assembly studs; alternate sides after each stud. Observe the tightening torque!(⇨ Section 7.6.2 Page 51)

12.

Re-check the tightening torques!

13. Fasten the power cables to the pump set together with the suction strainer and the cable guard.

7.6.2 Tightening torques

Table 20: Maximum permissible tightening torques for the screws/bolts

Material/Property class

5.6 8.8 C3 - 80 A4 - 50 A4 - 70 A4 - 80 1.4462 CuAl10Ni CuNi1,5S i

Rp 0.2 [N/mm²] 300 640 640 210 450 600 450 270 540 Metric thread

Coarse-

pitch

thread

Fine-pitch

thread

Tightening torque MA [Nm]

1.45 3.1 3.1 1.0 2.15 2.9 2.15 -- 2.6

2.85 6.1 6.1 2.0 4.25 5.7 4.25 -- 5.1

4.9 10.4 10.4 3.4 7.3 9.75 7.3 -- 8.75

11.8 25.2 25.2 8.3 17.7 23.7 17.7 -- 21.3

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Material/Property class

5.6 8.8 C3 - 80 A4 - 50 A4 - 70 A4 - 80 1.4462 CuAl10Ni CuNi1,5S i

M8x1 12.7 27.2 27.2 8.9 19.1 25.5 19.1 -- 22.9

M10

23.2 49.5 49.5 16.2 34.8 46.4 34.8 -- 41.8

M10x1.5 24.6 52.5 52.5 17.3 36.9 49.2 36.9 -- 44.3

M12 39.9 85.2 85.2 28.0 59.9 79.8 59.9 -- 71.9

M12x1.5 42.0 89.5 89.5 29.4 62.9 83.9 62.9 -- 75.5

M12x1.25 44.0 93.9 93.9 30.8 66.0 88.0 66.0 -- 79.2

M16

98.9 211.0 211.0 69.2 148.0 197.0 148.0 89.0 178.0

M16x1.5 106.0 226.0 226.0 74.3 159.0 211.0 159.0 95.5 191.0

M20

193.0 412.0 412.0 135.0 290.0 386.0 290.0 174.0 348.0

M20x1.5 216.0 461.0 461.0 151.0 324.0 432.0 324.0 194.0 389.0

M24

333.0 710.0 710.0 233.0 278.0 665.0 500.0 300.0 600.0

M24x2 365.0 780.0 780.0 256.0 305.0 731.0 548.0 329.0 658.0

M27

490.0 1050 1050 343.0 409.0 984.0 736.0 441.0 883.0

M27x2 532.0 1130 1130 372.0 443.0 1060 797.0 478.0 957.0

M30

665.0 1420 1420 466.0 554.0 1330 1000 599.0 1200

M30x2 741.0 1580 1580 519.0 618.0 1480 1110 667.0 1330

M33

908.0 1940 1940 636.0 -- 1820 1360 817.0 1630

M33x2 1000 2130 2130 700.0 -- 2000 1500 900.0 1800

M36

1160 2480 2480 812.0 -- 2325 1740 1040 2090

M36x3 1230 2630 2630 863.0 -- 2465 1850 1110 2220

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8 Trouble-shooting

Pump is running but does not deliver

Pump delivers insufficient flow rate

Insufficient discharge head

Vibrations and noise during pump operation

Unit tripped by overcurrent relay

Fuses have blown

Pump set cannot be started up

Pump set cannot be switched off

Table 21: Trouble-shooting

A B C D E F G H Cause

Remedy

17)

✘

Pump delivers against an excessively high discharge pressure.

Open the shut-off valve to re-adjust to duty point.

✘

Pump delivers against an excessively low discharge pressure.

Close the shut-off valve to re-adjust to duty point.

✘ ✘

Deposits in the impellers Remove deposits.

Contact KSB.

✘ ✘

Wrong direction of rotation (in case of 3 ~)

Interchange two of the phases of the power supply cable.

✘ ✘

Wear of internal components Replace worn parts by new ones.

Contact KSB.

✘

Motor is running on two phases only. Replace defective fuse.

Check cable connections.

✘

No power supply Check electrical installation,

contact electric utility company.

✘

Pump clogged by sand Clean suction casing, impellers, stage

casings and check valve. Contact KSB.

✘

✘ ✘ ✘

Motor winding or electric cable are defective.

Contact KSB.

✘ ✘ ✘

Defective or clogged riser (pipe and sealing elements).

Replace affected pipes. Replace sealing elements.

✘

Water level lowered too much during operation.

Contact KSB.

✘

✘ ✘

Impermissible air or gas content in the fluid handled

Contact KSB.

✘

Mechanical defect on pump or motor Contact KSB.

✘

System-induced vibrations Contact KSB.

✘

NPSH available (positive suction head) is too low.

Submerge pump deeper.

✘ ✘

Speed is too low. Check voltage and increase, if necessary.

Contact KSB.

✘

Wrong fuse size Fit correct fuse size.

✘

✘ ✘ Defective overcurrent relay Check and replace, if necessary.

✘

Motor winding not suitable for operating voltage available

Replace the pump set. Contact KSB.

17)

Pump set pressure must be released before attempting to remedy faults on parts which are subjected to pressure.

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9 Related Documents

9.1 General assembly drawing with list of components

The general assembly drawings are examples only. Refer to the documentation supplied with the delivery for the general assembly drawings with lists of components applicable for this order.

9.1.1 General assembly drawing: UPA 250C submersible borehole pump

550.11

901.11

756

759

58-- 1

81-- 39

931

550.01

108

412.01

940.01

520

540

825

529.01

270

545.01

502.01

211

106

940.05

904.03

914.11

753

751

75-- 6

752.12

752.11

902.11

920.11

901.01

545.02

232

940.03

502.02

940.04

940.02

525.01

529.02

503

902.01

920.01

849

143

900.01

901.02

920.02

Fig. 14: General assembly drawing: UPA 250C submersible borehole pump

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Table 22: List of components

Part No. Description Part No. Description

106 Suction casing 75-6 Plate guide 108 Stage casing 751 Valve housing 143 Suction strainer 752.11/.12 Valve seat 211 Pump shaft 753 Valve disc 232 Clockwise impeller 756 Valve spring 270 Deflector 759 Valve plate

412.01 O-ring 81-39 Clamp 58-1 Protecting plug 825 Cable guard

502.01/.02 Casing wear ring 849 Sleeve coupling 503 Impeller wear ring 900.01 Screw 520 Sleeve 901.01/.02/.11 Hexagon head bolt

525.01 Spacer sleeve 902.01/.02/.11 Stud

529.01/.02 Bearing sleeve 904.03 Grub screw 540 Bush 914.11 Hexagon socket head cap screw

545.01/.02 Bearing bush 920.01/.11 Nut

550.01/.11 Disc 931 Lockwasher

940.01/.02/.03/. 04/.05

Key

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9.1.2 General assembly drawing: submersible motor V, X

412.60

900.54 551

914.52

411.51

903.51

145

940.53

412.57

433.51

81-74

412.55

828 829

824.51

81-39

901.52

529

818

529

902.52

940.51

389 384

550.52

387

412.53

32-2 211

171

412.51 710

920.52

901.51

550.51

920.51

902.51

68-3

742

412.59

412.58

412.63

412.62

901.54

920.53

412.54

902.53

412.52

382.52

545

814

81-57

545

382.51

412.52

900.52 59-6

392 553

160.51

59-12

160.52

900.51

116.51

411.51

903.51

160.53

412.52

550.55

354

932.51 232

108

81-11*

Fig. 15: General assembly drawing: submersible motor V, X

81-11* earthing offset by 90°, 932.52, 550.54, 901.53

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Table 23: Detailed view

Description Details

Temperature sensor

824.52

69-6

914.51*

914.51* = shown offset

Table 24: List of components

Part No. Description Part No. Description

108 Stage casing 553 Thrust insert

116.51 Cooling casing 68-3 Cover plate 145 Adapter 69-6 Temperature sensor

160.51/.52/.53 Cover 710 Pipe 171 Diffuser 742 Non-return valve 211 Pump shaft 81-11 Earth conductor 232 Clockwise impeller 81-39 Clamp 32-2 Ball cage 81-57 Stator without winding 354 Thrust bearing housing 81-74 Pressure screw

382.51/.52 Bearing carrier 814 Winding 384 Thrust collar 818 Rotor 387 Thrust bearing pad 824.51/.52 Cable 389 Counter thrust bearing

ring

828 Cable grommet

392 Bearing segment carrier 829 Cable gland ring

411.51 Joint ring 900.51/.52/.54 Bolt

412.51/.52/.53/.54/.55/.57/.58/.59/.60/.62/.63O-ring 901.51/.52/.53/.54 Hexagon head bolt

433.51 Mechanical seal 902.51/.52/.53 Stud 59-6 Ball 903.51 Screw plug 59-12 Membrane 914.51/.52 Hexagon socket head cap

screw 529 Bearing sleeve 920.51/.52/.53 Nut 545 Bearing bush 932.51/.52 Circlip

550.51/.52/.54/.55 Disc 940.51/.53 Key 551 Spacer disc

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9.2 Mating dimensions for motors V, X, Z, E

Fig. 16: Mating dimensions for motors V, X, Z, E

Observe the following dimensions:

Table 25: Mating dimensions

Motor type series Axial clearance

A [mm]

Adjusting dimension

B [mm]

VBD ... 1.2 to 1.5 72 ± 0.1

VMD ... 1.2 to 1.5 72 ± 0.1

XBD ... 1.2 to 1.5 114 ± 0.1

XMD ... 1.2 to 1.5 114 ± 0.1

ZBD ... 1.2 to 1.5 114 ± 0.1 ZMD ... 1.2 to 1.5 114 ± 0.1 EMD ... 1.2 to 1.5 114 ± 0.1

EBD ... 1.2 to 1.5 114 ± 0.1

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9.3 Mating dimensions for motor T

Fig. 17: Mating dimensions for motor T

Observe the following dimensions:

Table 26: Mating dimensions

Motor type series Axial clearance

A [mm]

Adjusting dimension

B [mm]

TCD 1.2 to 1.5 4.5 ± 0.1

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10 EC Declaration of Conformity

Manufacturer: KSB Service GmbH (Frankenthal)

Neue Industriestraße 8

66424 Homburg (Germany)

The manufacturer herewith declares that the product:

UPA+TCD, VBD....EMD

UPZ, BSX... BSF+TCD, VBD....EMD

▪ 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/A1,

– 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

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

18)

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

Name

Function

Company

Address

18)

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

10 EC Declaration of Conformity

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11 Certificate of Decontamination

Type ................................................................................................................................

Order number/ Order item number

19)

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

Delivery date ................................................................................................................................

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

Fluid pumped

19)

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

Please tick where applicable

19)

   

Radioactive Explosive Corrosive Toxic

   

Harmful Bio-hazardous Highly flammable Safe

Reason for return

19)

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

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

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

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

We hereby declare that this product is free from hazardous chemicals, biological or 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

19)

Required fields

11 Certificate of Decontamination

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Index

Certificate of decontamination 61

Description of the fluid handled 16 Designation 16 Disposal 15

Intended use 8

Misuse 9

Operating limits 8 Order number 6 Other applicable documents 6

Return to supplier 15

Safety 8 Safety awareness 9 Scope of supply 18

Index

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3400.87/06-EN (01463374)

KSB Aktiengesellschaft

67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 • Fax +49 6233 86-3401 www.ksb.com

KSB UPA, BSX, UPZ, UPA 300, UPA 350 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual