KSB Ama-Drainer 80 Installation & Operating Manual Download Page 6

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1 General

6 of 56

Ama-Drainer 80/100

2331.823/07-EN

1 General

1.1 Principles

This operating manual is valid for the type series and variants indicated on the front
cover.

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

The name plate indicates the type series, the main operating data and the serial
number. The serial number uniquely describes the product and is used as
identification in all further business processes.

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

1.2 Installation of partly completed machinery

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

1.3 Target group

This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. (

Section 2.3, Page 9)

1.4 Other applicable documents

Table 1:

Overview of other applicable documents

Document

Contents

Sub-supplier product literature

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

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

1.5 Symbols

Table 2:

Symbols used in this manual

Symbol

Description

✓

Conditions which need to be fulfilled before proceeding with the
step-by-step instructions

⊳

Safety instructions

⇨

Result of an action

⇨

Cross-references

Step-by-step instructions

Note
Recommendations and important information on how to handle
the product

Summary of Contents for Ama-Drainer 80

Page 1: ...Submersible Waste Water Pump Ama Drainer 80 100 Installation Operating Manual ...

Page 2: ... contents provided herein must neither be distributed copied reproduced edited or processed for any other purpose nor otherwise transmitted published or made available to a third party without the manufacturer s express written consent Subject to technical modification without prior notice KSB SE Co KGaA Frankenthal 08 01 2020 ...

Page 3: ... 12 4 Description of the Pump Set 13 4 1 General description 13 4 2 Product information as per Regulation No 1907 2006 REACH 13 4 3 Designation 13 4 4 Name plate 14 4 5 Design details 14 4 6 Configuration and function 15 4 7 Noise characteristics 17 4 8 Scope of supply 17 4 9 Dimensions and weights 17 4 10 Accessories 17 5 Installation at Site 18 5 1 Safety regulations 18 5 2 Checks to be carried ...

Page 4: ...oving the ball bearings 36 8 5 Reassembling the pump set 36 8 5 1 General information Safety regulations 36 8 5 2 Installing the ball bearings 37 8 5 3 Installing the mechanical seal 37 8 5 4 Fitting casing insert 13 6 variant B BH only 37 8 5 5 Installing the pump section 38 8 6 Recommended spare parts stock 38 9 Trouble shooting 39 10 Related Documents 41 10 1 Exploded view and list of component...

Page 5: ... to dispose of faeces free waste water occurring below the flood level of buildings and sites It defines general requirements as well as principles of construction and testing Flood level Maximum backflow level of waste water in a drainage system Hydraulic system The part of the pump in which the kinetic energy is converted into pressure energy Pump Machine without drive additional components or a...

Page 6: ...pplied by KSB refer to the sub sections under Servicing Maintenance 1 3 Target group This operating manual is aimed at the target group of trained and qualified specialist technical personnel ð Section 2 3 Page 9 1 4 Other applicable documents Table 1 Overview of other applicable documents Document Contents Sub supplier product literature Operating manuals and other product literature describing a...

Page 7: ...jury CAUTION CAUTION This signal word indicates a hazard which if not avoided could result in damage to the machine and its functions General hazard In conjunction with one of the signal words this symbol indicates a hazard which will or could result in death or serious injury Electrical hazard In conjunction with one of the signal words this symbol indicates a hazard involving electrical voltage ...

Page 8: ...imes 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 2 2 Intended use The pump set must only be operated in the fields of application and within the use limits specified in the other applicable documents Only operate pumps pump sets which ...

Page 9: ... practices Hazard to the environment due to leakage of hazardous substances 2 5 Safety awareness In addition to the safety information contained in this operating manual and the intended use the following safety regulations shall be complied with Accident prevention health regulations and safety regulations Explosion protection regulations Safety regulations for handling hazardous substances Appli...

Page 10: ... it has been disconnected from the power supply de energised The pump set must have cooled down to ambient temperature Pump pressure must have been released and the pump must have been drained When taking the pump set out of service always adhere to the procedure described in the manual ð Section 6 3 Page 29 Decontaminate pumps which handle fluids posing a health hazard As soon as the work has bee...

Page 11: ...ost humidity dirt UV radiation or vermin Corrosion contamination of the pump Store the pump set in a dry dark frost proof room not exposed to sunlight where the atmospheric humidity is as constant as possible Store the pump set vertically in a dry dark frost proof room not exposed to sunlight Under these conditions it does not need additional preservation 3 4 Return to supplier 1 Drain the pump as...

Page 12: ...smantle the product Collect greases and other lubricants during dismantling 2 Separate and sort the 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 Electrical or electronic equipment marked with the adjacent symbol must not be disposed of in household waste at the end of its s...

Page 13: ...aining sand 4 2 Product information as per Regulation No 1907 2006 REACH For information as per chemicals Regulation EC No 1907 2006 REACH see http www ksb com reach 4 3 Designation Example Ama Drainer B 80 40 S Table 4 Designation key Code Description Ama Drainer Type series B Design B Wear resistant variant BH Wear resistant variant with impeller made of Norihard white cast iron 1 Variant for wa...

Page 14: ...Hmin Hmax 13 Enclosure 6 Principles of construction and testing 14 Total weight 7 Power cable version e g E single phase 15 Serial number year of production week of production 8 Rated frequency 4 5 Design details Design Fully floodable submersible motor pump Close coupled design Single stage To EN 12050 2 Vertical discharge nozzle With or without level control Wetted parts made of materials coated...

Page 15: ...lement bearings sealed for life Electrical connection Ama Drainer 80 Ready to be plugged in Power cable and CEE plug with phase inverter Phase sequence indicator Over current trip Ama Drainer 100 Power cable with free cable ends Control unit available as an accessory Standard design 10 metre power cable Variants B BH 20 m power cable 4 6 Configuration and function 1 2 3 4 5 6 7 8 9 10 Fig 2 Sectio...

Page 16: ...d outward In the flow passage of the volute casing 8 the kinetic energy of the fluid handled is converted into pressure energy and the fluid handled is pumped to the discharge nozzle 5 The fluid handled leaves the pump via the discharge nozzle At the rear side of the impeller the shaft 2 enters the hydraulic system via the volute casing 8 The shaft passage through the volute casing is sealed to at...

Page 17: ...loat switch 4 9 Dimensions and weights For dimensions and weights refer to the general arrangement drawing outline drawing or data sheet of the pump set 4 10 Accessories Control unit Pipe connection Table 5 Pipe connection Pipe connection Size Ama Drainer B 80 100 Special connection elbow made of grey cast iron Rp 2 1 2 Flange3 DN 65 DN 80 DN 100 Internal thread to DIN 2999 14 Rp 4 Further require...

Page 18: ...ections to any moisture DANGER Faulty power cable Danger of death from electric shock Have the power cable replaced by a trained electrician DANGER Continuous pump operation in swimming pools garden ponds or similar Danger of death from electric shock Make sure that nobody is in the water while the pump is in operation Only use the pump for draining swimming pools garden ponds etc It is impermissi...

Page 19: ...cked or dropped l x b h Fig 3 Installing the pump set Table 6 Recommended installation dimensions l b5 h5 mm mm 800 800 800 ü Transport equipment lifting equipment suitable for the corresponding weight has been selected and is available ð Section 4 9 Page 17 ü The place of installation is solid and level ü The piping hose has been properly connected ð Section 5 4 Page 20 1 If the place of installa...

Page 20: ...highest point of the discharge line must be above the flood level usually street level to prevent any backflow from the sewage system Stationary installation 1 Connection as per installation examples ð Section 10 3 Page 45 Transportable model 1 Connect the special connection elbow to the hose with an adapter e g Storz coupling 5 5 Electrical connection DANGER Operating a pump set that has not been...

Page 21: ...s 10 of the rated voltage indicated on the name plate The maximum permissible voltage difference between the individual phases is 1 For the electrical connection observe the circuit diagrams ð Section 10 4 Page 47 in the Annex and the information for planning the control system The pump set is supplied complete with power cables Always use all cables provided and connect all marked cores of the co...

Page 22: ...rrent Refer to the name plate for the setting value ð Section 4 4 Page 14 Overload protection for Ama Drainer 80 If the thermal circuit breakers in the motor have tripped the pump the red lamp at the multi functional plug will be lit until the drive has cooled down The drive re starts automatically The multi functional plug comprises a motor protection relay that protects the motor against overcur...

Page 23: ...ttom or bump against anything at the top ü The minimum level of fluid handled is observed ð Section 6 2 2 4 Page 28 1 Choose an appropriate height for attaching the float switch cable 2 Fasten the float switch cable to the discharge line or another suitable point The distance between fastening point A and antikink bush B must be 100 mm as a minimum Level control system for two pump sets with contr...

Page 24: ... the pump Always disconnect the pump set from the power supply and secure it against unintentional start up before inserting your hands or other objects into the pump CAUTION Pump set running dry Increased vibrations Damage to mechanical seals and bearings Never operate the pump set for more than 60 seconds without the fluid handled CAUTION Wrong direction of rotation Damage to the pump Follow the...

Page 25: ... CEE plug with an appropriate screwdriver and turn it by 180 3 If the pump set is connected via a control unit interchange wires 1 and 2 of the 7 wire cable Ama Drainer B 100 Electrical connection is effected via a switchgear YΔ starting If the direction of rotation is incorrect interchange wires L1 and L2 of the power cable 1 Start up the pump ð If the direction of rotation is correct the pump sh...

Page 26: ...set has been installed and connected as described in this manual The pump set has been properly connected to the power supply and is equipped with all protection devices ð Section 5 5 Page 20 The direction of rotation has been checked ð Section 5 6 Page 24 6 1 2 Start up Ama Drainer N without float switch The pump set starts up automatically via the control unit Ama Drainer S with float switch A A...

Page 27: ... be handled WARNING Pumping of impermissible fluids Hazardous to persons and the environment Only discharge permissible fluids into the public sewer system Check the suitability of pump system materials CAUTION Unsuitable fluids Damage to the pump Never use the pump to handle corrosive combustible or explosive fluids Never use the pump to transport waste water from toilets and urinal systems Do no...

Page 28: ...sity data against the order data Make sure the motor has sufficient power reserves The power input of the pump set will change in proportion to the density of the fluid handled The pump set is suitable for fluids not containing coarse substances or faeces Maximum particle size 12 mm 6 2 2 4 Minimum fluid level maximum fluid level Minimum level of fluid handled CAUTION Fluid level below the specifi...

Page 29: ... cannot be started unintentionally Always make sure the electrical connections are disconnected before carrying out work on the pump set WARNING Fluids handled consumables and supplies which are hot and or pose a health hazard Risk of injury Observe all relevant laws When draining the fluid take appropriate measures to protect persons and the environment Decontaminate pumps which handle fluids pos...

Page 30: ...r than 5 years we recommend replacing all elastomer seals For returning the equipment to service observe the sections on commissioning start up ð Section 6 1 Page 26 and the operating limits ð Section 6 2 Page 27 In addition carry out all servicing maintenance operations before returning the pump set to service ð Section 8 Page 32 ...

Page 31: ... all electric cables prior to commissioning start up 7 1 Controlling an Ama Drainer 80 Variant N Switch position Pump ON the green equipment on lamp is lit Switch position 0 Pump OFF Switch position No function Variant S Switch position Pump manually ON The green equipment on lamp is lit Switch position 0 Pump OFF Switch position Pump automatically ON OFF via float switch The green equipment on la...

Page 32: ...e environment Decontaminate pumps which handle fluids posing a health hazard WARNING Improper lifting moving of heavy assemblies or components Personal injury and damage to property Use suitable transport devices lifting equipment and lifting tackle to move heavy assemblies or components 8 2 Maintenance inspection The pump set is practically maintenance free Slight wear of the mechanical seal is u...

Page 33: ...can be disposed of properly 8 2 1 2 Lubricant quantity Table 10 Lubricant quantity Size Lubricant quantity l 80 40 0 8 100 75 1 0 8 2 1 3 Changing the lubricant WARNING Lubricants posing a health hazard and or hot lubricants Hazard to persons and the environment When draining the lubricant take appropriate measures to protect persons and the environment Wear safety clothing and a protective mask i...

Page 34: ...trated 903 1 Fig 8 Filling in the lubricant 2 Fill the lubricant through the lubricant filler opening into the lubricant reservoir 3 Replace joint ring 411 1 if required 4 Insert and tighten screw plug 903 1 8 3 Drainage disposal WARNING Fluids consumables and supplies which are hot or pose a health hazard Hazard to persons and the environment Collect and properly dispose of flushing fluid and any...

Page 35: ...g the pump section Dismantle the pump section in accordance with the relevant exploded view 1 Undo socket head cap screws 914 22 and remove duckfoot bend P3 2 Undo socket head cap screws 914 21 3 Remove discs 550 3 4 Remove foot 182 5 Undo socket head cap screw 914 6 6 Remove suction cover 162 for size 100 suction cover with inlet ring 131 profile joint 410 2 and bush 540 1 7 Pull plug 916 2 out o...

Page 36: ... 12 5 Pull off ball bearing 321 2 and shaft sleeve 523 6 Remove circlip 932 31 or 932 32 7 Pull ball bearing 321 1 and bearing sleeve 529 off the shaft 8 Remove circlip 932 2 9 Press the ball bearing out of the bearing sleeve 8 5 Reassembling the pump set 8 5 1 General information Safety regulations WARNING Improper lifting moving of heavy assemblies or components Personal injury and damage to pro...

Page 37: ...earing 321 1 and bearing sleeve 529 onto the shaft 5 Insert tolerance ring 500 21 into the shaft To protect the shaft surface use the special KSB assembly sleeve 6 Fit ball bearing 321 2 on shaft sleeve 523 and insert circlip 932 31 or 932 32 7 Fit circlip 932 12 8 Insert the complete rotor assembly Make sure grooved pin 561 2 anti rotation device is fitted properly 9 Fit bearing cover 360 with O ...

Page 38: ...er hub cap 260 6 Insert profile joint 410 2 as well as bushes 540 1 for Ama Drainer B BH only insert bushes 540 1 7 Fit suction cover 162 for size 100 with inlet ring 131 8 Screw in socket head cap screw 914 6 9 Fit foot 182 10 Insert discs 550 3 11 Screw in socket head cap screws 914 21 12 Insert duckfoot bend P3 13 Screw in socket head cap screws 914 22 8 6 Recommended spare parts stock It is no...

Page 39: ...letely vented Clean vent bore E in duckfoot bend P3 Pump intake clogged by deposits Clean the intake pump components and lift check valve Supply line or impeller clogged Remove deposits in the pump and or piping Dirt fibres in the clearance between the casing wall and impeller of a sluggish rotor Check whether the impeller can be easily rotated clean the hydraulic system if required Wear of intern...

Page 40: ...he pump sump insufficient inflow Clean the intake sand trap pump components and check valve Drain and clean the pump sump Temperature control device monitoring the winding has tripped the pump as a result of excessive winding temperatures The motor will restart automatically once the unit has cooled down Investigate the cause ...

Page 41: ...S 100 AD B BH 13 6 81 45 AD S AD B BH 916 1 AD B BH 900 AD B BH 506 824 1 81 21 AD 80 230 932 4 433 2 131 AD 100 162 914 6 182 550 3 914 21 914 6 AD 80 914 24 AD 100 914 42 81 22 412 2 AD 80 914 25 AD 100 914 43 576 AD 80 S 100 81 47 930 914 10 930 81 44 260 914 41 916 2 AD 80 S 81 17 412 1 838 813 811 833 412 4 932 2 321 1 412 5 529 412 5 932 13 500 22 818 940 474 11 411 11 834 1 474 12 81 74 1 8...

Page 42: ... 833 Terminal box 474 11 12 Thrust ring 834 1 2 Cable gland 474 22 23 Thrust ring 836 Terminal strip 500 21 22 Tolerance ring 838 Temperature switch 506 Retaining ring 894 Mounting bracket 523 Shaft sleeve 900 Countersunk head screw 525 Spacer sleeve 903 1 44 Screw plug 529 Bearing sleeve 914 1 5 6 7 98 10 11 21 22 23 24 25 Hexagon socket head cap screw 540 1 Bush 914 41 42 Hexagon socket head cap...

Page 43: ... E B Ø 309 B Ø 356 A A C 80 80 min R autom manual Fig 10 Outline drawing Ama Drainer 80 A Start up level B Switch off level E Vent hole R Residual water level Type series A B C D Weight mm kg Ama Drainer 80 Duckfoot bend with internal thread Rp 2 1 2 223 445 Rp 21 2 314 68 Ama Drainer 80 Duckfoot bend with flange DN 80 233 511 80 312 70 ...

Page 44: ...800 Ø 416 autom manual min 500 80 80 R Fig 11 Outline drawing Ama Drainer 100 A Start up level B Switch off level E Vent hole R Residual water level Type series A B C D Weight mm kg Ama Drainer 100 Duckfoot bend with internal thread Rp 4 275 546 Rp 4 383 110 Ama Drainer 100 Duckfoot bend with flange DN 100 260 578 100 340 119 ...

Page 45: ...rz coupling Suggested connection 2 Connection via flanged pipes for stationary use Suggested connection 3 Hose connection for stationary use quick connection with Storz coupling P 10 P 9 P 8 P 3 P 5 P 12 P 3 P 6 P 9 P 12 P 9 P 8 P 10 P 3 P 5 P 3 Connection elbow P 5 Storz rigid coupling with external thread P 6 Storz rigid coupling with flange P 8 Storz hose coupling P 9 Hose clip P 10 Plastic hos...

Page 46: ... in dual pump station P 3 Connection elbow P 11 Gate valve P 12 Swing check valve P 14 Y pipe P 15 Threaded flange E 5 Control unit E 6 Float switch normal water base load E 6 2 Float switch normal water peak load E 6 3 Float switch high water level E 10 AS 5 alarm switchgear E 10 2 Horn R Flood level Size A B C D1 D2 mm Ama Drainer 80 350 260 260 1690 x 800 1000 Ama Drainer 100 325 295 300 1690 x...

Page 47: ...o 1 1a 1b 1 3 5 2 4 6 S1 F1 1 5 95 96 S br bl PE 4 PE M1 S2 F 1 M 3 2 3 5 4 U1 V1 W1 PE PE 22 21 br bl Fig 13 Wiring diagram Ama Drainer 80 1 Direction of rotation 2 Operation 3 Fault K1 Contactor S1 Manual 0 automatic selector switch F1 Motor protection relay X1 Terminal strip M1 Motor F Thermal circuit breaker S2 Float switch for Ama Drainer S only PE Green yellow br Brown bl Blue ...

Page 48: ...80 100 2331 823 07 EN 10 4 2 Ama Drainer 100 A B U1 PE 1 2 V1 W1 W2 U2 V2 PE Z X Y 1 2 3 4 5 I II III IV M 3 F Fig 14 Wiring diagram Ama Drainer 100 A Cable 1 B Cable 2 M Motor F Thermal circuit breaker I Black II Brown III Grey IV Green yellow ...

Page 49: ... 2331 823 07 EN 10 4 2 1 Overload protection for Ama Drainer 100 N with LevelControl Basic 2 A Fig 15 Printed circuit board in the control cabinet Overload protection for Ama Drainer 100 N with LevelControl Basic 2 A Thermistor motor protection relay ...

Page 50: ... 65 EU Restriction of the use of certain hazardous substances in electrical and electronic equipment RoHS 2014 30 EU Electromagnetic Compatibility EMC The manufacturer also declares that the following harmonised international standards have been applied ISO 12100 EN 809 EN 60034 1 EN 60034 5 A1 Person authorised to compile the technical file Hugues Roland Head of Design Engineering KSB S A S 128 r...

Page 51: ...g cover bearing ring carrier plain bearing inner rotor has been removed from the pump and cleaned In cases of containment shroud leakage the outer rotor bearing bracket lantern leakage barrier and bearing bracket or intermediate piece have also been cleaned For canned motor pumps the rotor and plain bearing have been removed from the pump for cleaning In cases of leakage at the stator can the stat...

Page 52: ...es and remedies 39 Fields of application 8 Fluid handled Density 28 G General assembly drawing 41 I Impeller type 15 Installation 14 Installation at site 18 Intended use 8 K Key to safety symbols markings 7 N Name plate 14 O Other applicable documents 6 P Partly completed machinery 6 R Return to supplier 11 Returning to service 30 S Safety 8 Safety awareness 9 Scope of supply 17 Shaft seal 15 Shut...

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Page 56: ...KSB SE Co KGaA Johann Klein Straße 9 67227 Frankenthal Germany Tel 49 6233 86 0 www ksb com 2331 823 07 EN ...

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