KSB 88980/02 Operating And Maintenance Instructions Manual Download Page 2

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I N D E X

Pump

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Amarex N Pumps Installation & Operating Instructions

Additional Data

•

Data Sheet

Drawing

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Certified G.A. Drawing No.UX02010

I.T.P.s

•

I.T.P.s

Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual

Q-Pulse Id VM381

Active 29/10/2013

Page 2 of 76

Summary of Contents for 88980/02

Page 1: ...TENANCE INSTRUCTIONS K S B A u s t r a l i a P t y L t d A B N 2 9 0 0 6 4 1 4 6 4 2 A Q u a l i t y E n d o r s e d C o m p a n y A S N Z I S O 9 0 0 1 2 0 0 8 Sales and Service Phone 07 3436 8600 Fa...

Page 2: ...Instructions 2 Additional Data Data Sheet 3 Drawing Certified G A Drawing No UX02010 4 I T P s I T P s Goodnal STP ST041 Biological Treatment KSB WAS PUMP 1 2 PU 0530 010 OM Instructions Vendor Manua...

Page 3: ...s DN 50 to DN 100 Motor sizes 2 pole 002 to 042 4 pole 004 to 044 Installation Operating Manual Goodnal STP ST041 Biological Treatment KSB WAS PUMP 1 2 PU 0530 010 OM Instructions Vendor Manual Q Puls...

Page 4: ...stributed copied reproduced processed for any other purpose nor otherwise transmitted to a third party without KSB s express written consent Subject to technical modification without prior notice KSB...

Page 5: ...es of operation 11 2 10 Explosion protection 11 3 Transport Temporary Storage Disposal 12 3 1 Transport 12 3 2 Storage and preservation 12 3 3 Return to supplier 13 3 4 Disposal 13 4 Description of th...

Page 6: ...ues 48 7 7 Spare parts stock 48 8 Trouble shooting 50 9 Related Documents 51 9 1 General assembly drawing with list of components 51 9 2 Wiring diagrams 57 9 3 Wiring diagrams overload protection 59 9...

Page 7: ...components in contact with the fluid handled Hydraulic system The part of the pump in which the kinetic energy is converted into pressure energy Monobloc pump set Motor housing and pump casing form a...

Page 8: ...d machinery To install partly completed machinery supplied by KSB refer to the sub sections under Servicing Maintenance 1 3 Target group This manual is aimed at the target group of trained and qualifi...

Page 9: ...structions Safety instructions Result of an action Cross references 1 2 Step by step instructions Note Recommendations and important information on how to handle the product 1 General Amarex N 7 of 66...

Page 10: ...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 oper...

Page 11: ...nly use impeller types designed for the fluid handled as described below Impeller with cutter impeller type S Suitable for the following fluids Faeces domestic sewage and waste water containing long f...

Page 12: ...nce 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 th...

Page 13: ...th its intended use 2 10 Explosion protection Always observe the information on explosion protection given in this section when operating an explosion proof pump set Sections of the manual marked by t...

Page 14: ...time after delivery we recommend that the following measures be taken for pump storage CAUTION Improper storage Damage to the power cables Support the power cables at the cable entry to prevent perma...

Page 15: ...so 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 Section 11 Page...

Page 16: ...00049 0 3 10 8 0 3 10 8 1 9 1 9 2835 2835 400 400 4 5 4 5 4 4 4 4 42 42 0 83 0 83 50 50 55 15 6 4 99 15 6 4 99 70165000 DKN 82 2 2U DKN 82 2 2U Amarex N F 50 170 012 YLG 120 Nicht unter Spannung ffnen...

Page 17: ...number of poles 50 172 002 012 022 50 222 032 042 Drive Three phase asynchronous squirrel cage motor Explosion proof pump sets comply with type of protection Ex d IIB 4 5 Types of installation Two des...

Page 18: ...shaft runs in rolling element bearings 9 and 10 which are supported by a bearing bracket 2 linked with the pump casing and or discharge cover The pump is sealed by two bi rotational mechanical seals...

Page 19: ...of installation e g at the control panel pipeline or mounting bracket 4 8 Dimensions and weights For dimensions and weights please refer to the general arrangement drawing outline drawing or data she...

Page 20: ...rotational frequency rotational noise must be prevented both in the foundation and in the connected piping as such frequencies may cause extreme vibrations 1 Check the structural requirements All str...

Page 21: ...903 with joint ring 411 Observe the tightening torques Section 7 6 Page 48 5 2 3 Checking the direction of rotation DANGER Pump set running dry Explosion hazard The direction of rotation of explosion...

Page 22: ...observe the general arrangement drawing outline drawing when installing the pump set 5 3 1 Stationary wet installation 5 3 1 1 Fastening the duckfoot bend Depending on the pump size the duckfoot bend...

Page 23: ...NOTE When the pump set is used for draining low level building areas install a swing check valve in the discharge line to avoid backwash from the sewer system CAUTION Critical speed Increased vibratio...

Page 24: ...t bend 72 1 and back again to suspension bracket 572 and insert it into clamping piece 571 3 Manually tension wire 59 24 01 and secure it by means of hexagon nuts 920 37 4 Pull the wire taut by tighte...

Page 25: ...ng brackets also serve as spacers between the two guide rails 1 Position adapter 82 5 on duckfoot bend 72 1 and fasten it with screws 914 2 discs 550 02 and nuts 920 02 2 Place rails 710 onto the coni...

Page 26: ...f guide hoop 571 into the grooves of duckfoot bend 72 1 2 Fasten the flanged duckfoot bend to the tank sump floor with 2 anchor bolts 90 3 38 Section 5 3 1 1 Page 20 5 3 1 6 Preparing the pump set Fas...

Page 27: ...4785 Attaching the lifting chain rope transportable wet installation Transportable wet installation 1 Attach the lifting chain or rope to the lug eyebolt bail at the pump set on the side of the discha...

Page 28: ...e installing the pump set fit the 3 pump feet and foot plate if applicable Fitting the pump feet 1 Undo screws 914 03 2 Push pump feet 182 into the opening in the suction cover 3 Tighten screws 914 03...

Page 29: ...n the name plate 5 4 1 2 Level control DANGER Pump set running dry Explosion hazard Never allow an explosion proof pump set to run dry CAUTION Fluid level below the specified minimum Damage to the pum...

Page 30: ...of the pump set itself Suitable analysing devices must be selected In this case we recommend to monitor the leakage sensor fitted inside the motor by means of a special relay available from KSB 5 4 1...

Page 31: ...20 and 21 max 250 V 2 A serve as temperature control devices which open when the winding temperature is too high Opening of the switch contacts must result in the pump set cutting out Automatic re sta...

Page 32: ...r bend or crush the power cables Never use the power cables to lift up the pump set CAUTION Motor overload Damage to the motor Protect the motor against overloading by a thermal time lag overload prot...

Page 33: ...read for a M8 x 20 socket head cap screw DANGER Touching the pump set during operation Electric shock Make sure that the pump set cannot be touched during operation DANGER Chemically corrosive fluids...

Page 34: ...with the fluid to be handled The direction of rotation has been checked The lubricant has been checked only for variants YL and WL After prolonged shutdown of the pump set the required activities have...

Page 35: ...y of starts CAUTION Excessive frequency of starts Damage to the motor Never exceed the specified frequency of starts To prevent high temperature increases in the motor do not exceed the following numb...

Page 36: ...he information on fluid density indicated in the data sheet Make sure the power reserve of the motor is sufficient 6 2 5 Supply voltage DANGER Non compliance with permissible supply voltage tolerances...

Page 37: ...zing remove the pump set from the fluid handled and clean preserve and store it Make sure sufficient fluid is available for the operation check run of the pump set 1 For prolonged shutdown periods sta...

Page 38: ...re install and or re activate any safety relevant and protective devices NOTE On pumps pump sets older than 5 years we recommend replacing all elastomer seals 6 Commissioning Start up Shutdown 36 of 6...

Page 39: ...d the environment Decontaminate pumps handling fluids posing a health hazard WARNING Hot surface Risk of personal injury Allow the pump set to cool down to ambient temperature NOTE Special regulations...

Page 40: ...d must be less than 1 2 Replace any damaged components by original spare parts DANGER Defective earth conductor Electric shock Never switch on a pump set with a defective earth conductor 7 2 1 3 Measu...

Page 41: ...leakage sensor in the motor Measurement between terminals Resistance 9 and earth conductor PE 1 Lower resistance values suggest water ingress into the motor In this case the motor must be opened and...

Page 42: ...nd 65 220 B Variant YL WL 2 Place a suitable container under the screwed plug WARNING Excess pressure in the lubricant reservoir Liquid spurting out when the lubricant reservoir is opened at operating...

Page 43: ...nical seal 433 02 along the shaft 3 Drain the oil 1 Fill 0 25 litres of oil through the opening between the stationary part of mechanical seal 433 02 and rotor 818 2 Thoroughly clean rotor 818 and the...

Page 44: ...e Risk of personal injury Allow the pump set to cool down to ambient temperature Observe the general safety instructions and information For dismantling and reassembly observe the general assembly dra...

Page 45: ...n which may affect explosion protection such as re winding and machining repairs must be inspected and approved by an approved expert or performed by the motor manufacturers No modifications must be m...

Page 46: ...mation Safety regulations CAUTION Improper reassembly Damage to the pump Reassemble the pump set in accordance with the general rules of sound engineering practice Use original spare parts only NOTE B...

Page 47: ...412 11 into discharge cover 163 and press them into bearing bracket 330 as far as they will go 3 Push pump end mechanical seal 433 02 onto shaft 210 For special mechanical seals with covered spring ti...

Page 48: ...x is the distance between the upper side of the suction cover and the mounting holes of the suction cover 8 Measure dimension y between pump casing and impeller vanes Dimension y is the distance betw...

Page 49: ...s scope of supply 13 Insert and tighten the impeller screw 7 5 3 Reassembling the motor section NOTE Before reassembling the motor section check that all joints relevant to explosion protection flamep...

Page 50: ...ing torques Table 21 Tightening torques Thread Torque Nm M 8 17 Impeller screw M8 40 Screwed plug 903 23 7 7 Spare parts stock NOTE For explosion proof pump sets only original spare parts or parts aut...

Page 51: ...3 02 Mechanical seal pump end 2 3 4 5 6 7 90 99 9 Set of seal elements 4 6 8 8 9 10 100 7 7 3 Sets of spare parts Table 23 Overview of spare parts sets Description Part No Rolling element bearing moto...

Page 52: ...pipes Replace seal elements X X X Impermissible air or gas content in the fluid handled Contact KSB X System induced vibrations Contact KSB X X X X Wrong direction of rotation Check the connection of...

Page 53: ...ooved pin 162 Suction cover 81 2 Connector 210 Shaft 81 59 Stator 230 Impeller 818 Rotor 321 01 02 Radial ball bearing 821 Rotor core pack 330 Bearing bracket 834 Cable gland 410 Profile joint 914 01...

Page 54: ...tion cover 81 2 Connector 210 Shaft 81 59 Stator 230 Impeller 818 Rotor 321 01 02 Radial ball bearing 821 Rotor core pack 330 Bearing bracket 834 Cable gland 355 Bearing bracket housing 903 Screwed pl...

Page 55: ...433 01 932 03 412 03 113 914 02 113 321 01 932 02 321 02 932 01 321 476 433 01 433 01 932 03 412 03 330 330 230 914 02 433 02 561 230 914 04 23 7 561 500 914 06 914 04 23 7 162 162 914 03 500 904 914...

Page 56: ...01 932 02 321 02 932 01 321 412 02 476 476 433 01 433 01 932 03 412 03 330 330 914 02 433 02 230 230 914 04 412 05 162 914 03 903 411 412 04 914 01 834 834 412 04 914 01 162 550 550 ULG Fig 31 Explode...

Page 57: ...476 476 433 01 932 03 433 01 412 03 330 914 02 330 433 02 230 914 04 550 230 162 914 03 904 162 914 04 904 410 932 04 411 903 834 834 914 01 412 04 412 04 914 01 100 100 410 411 903 ULG Fig 32 Explod...

Page 58: ...tor 330 Bearing bracket 821 Rotor core pack 355 Bearing bracket housing 834 Cable gland 410 Profile joint 99 9 Set of seal elements 411 Joint ring 903 Screwed plug 412 01 02 03 04 05 O ring 904 Grub s...

Page 59: ...WLG YLG Fig 33 Wiring diagram for variant WLG YLG 9 Related Documents Amarex N 57 of 66 Goodnal STP ST041 Biological Treatment KSB WAS PUMP 1 2 PU 0530 010 OM Instructions Vendor Manual Q Pulse Id VM3...

Page 60: ...g 34 Wiring diagram for variant ULG 9 Related Documents 58 of 66 Amarex N Goodnal STP ST041 Biological Treatment KSB WAS PUMP 1 2 PU 0530 010 OM Instructions Vendor Manual Q Pulse Id VM381 Active 29 1...

Page 61: ...LC1 D0910 RH Earth leakage protection relay with separate toroid e g Vigirex RH 328 A Merlin Gu rin Tore F Remote control H Auxiliary supply 12 43 44 A1 14 13 RH 230 240 V PE L3 L2 L1 KM KM Q Q M M R...

Page 62: ...nce ISO inside diameter F7 H8 H8 Tolerance ISO outside diameter g6 Tolerance in m inside diameter to DIN ISO 286 2 Maximum 41 63 39 Minimum 20 0 0 Tolerance in m outside diameter to DIN ISO 286 2 Maxi...

Page 63: ...meter F7 H8 H8 Tolerance ISO outside diameter g6 Tolerance in m inside diameter to DIN ISO 286 2 Maximum 41 63 39 Minimum 20 0 0 Tolerance in m outside diameter to DIN ISO 286 2 Maximum 14 Minimum 39...

Page 64: ...hanical seal bellows type mechanical seal 932 01 Circlip 433 01 Mechanical seal bellows type mechanical seal 433 Mechanical seal mechanical seal with covered springs HJ 9 Related Documents 62 of 66 Am...

Page 65: ...t the following harmonised international standards were applied ISO 12100 1 A1 ISO 12100 2 A1 ISO 14121 1 EN 809 A1 EN 60034 1 EN 60034 5 A1 Sequedin Lille 29 12 2009 Martial Smis Head of Product Deve...

Page 66: ...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 d...

Page 67: ...el control 27 Lubricant Intervals 38 Quality 39 M Maintenance work 38 Mechanical seal 62 Minimum fluid level 34 Misuse 9 O Operating voltage 34 Order number 6 Other applicable documents 6 Overload pro...

Page 68: ...T C 9241 71 1793 4 4 4 B P 95 h 59482 Haubourdin Cedex 128 rue Carnot h 59320 Sequedin Lille H9 I a T 3 20227000 h 9 T 3 20227099 h 333 563 81 11 10 Goodnal STP ST041 Biological Treatment KSB WAS PUM...

Page 69: ...ntry of manufacture REV IW GDSTP 4A ELE SPEC 6003 Technical Specification for Electrical Instrumentation IW IPSTP 0 MEC SPEC 0062 Technical Specification for Pumps Fluid temperature min 10 max 30 Oper...

Page 70: ...Maximum starts per hour Vendor to nominate 30 France Enclosure type Submersible kg 1 P2 2 3 The system duty flowrate per pump and operation configuration nominated are for the purpose of sizing the p...

Page 71: ...5 0 mm Free passage size 76 0 mm Direction of rotation from drive Clockwise Driver accessories Driver type Electric motor Model make KSB Motor const type KSB Sub motor Frequency invertor Yes Frequency...

Page 72: ...r Hydro primer water based Final coating 2 component epoxy resin Color Ultramarine blue RAL 5002 KSB blue Total film thickness approx 80 m Installation parts Scope of supply Pump with installation par...

Page 73: ...er Input Flow Curve data Speed of rotation 1406 rpm Fluid density 1011 kg m Viscosity 2 86 mm s Flow rate 15 094 l s Requested flow rate 15 100 l s Total developed head 9 92 m Requested developed head...

Page 74: ...not a guarantee point within the meaning of IEC 60034 Load 0 0 25 0 50 0 75 0 100 0 P2 0 00 kW 0 93 kW 1 85 kW 2 77 kW 3 70 kW n 1500 rpm 1465 rpm 1430 rpm 1395 rpm 1360 rpm P1 0 61 kW 1 51 kW 2 55 k...

Page 75: ...Goodnal STP ST041 Biological Treatment KSB WAS PUMP 1 2 PU 0530 010 OM Instructions Vendor Manual Q Pulse Id VM381 Active 29 10 2013 Page 75 of 76...

Page 76: ...Goodnal STP ST041 Biological Treatment KSB WAS PUMP 1 2 PU 0530 010 OM Instructions Vendor Manual Q Pulse Id VM381 Active 29 10 2013 Page 76 of 76...

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