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KSB Amacan S 1000-600, Installation & Operating Manual

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KSB Amacan S 1000-600 Installation & Operating Manual Download Page 92

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92 of 126

Amacan S

1589.837/01-EN

733.05

A - A

720

59-24

719.05

d

c

Fig. 51: 

Section A - A, position of power cable, control cable and support rope

c

Power cable

d

Control cable

Table 39: 

List of spare parts of the cable bundle

Part No.

Description

Part No.

Description

59-7

Support

59-47

Lifting lug

59-8

Turnbuckle

719.05

Flexible tube

59-17.01/.02

Shackle

720

Fitting

59-24

Rope / support rope

733.05

Hose clip

Summary of Contents for Amacan S 1000-600

Page 1: ...Submersible Pump in Discharge Tube Amacan S 50 Hz Amacan S 535 Amacan S 550 Amacan S 600 Amacan S 615 Amacan S 620 Amacan S 655 Amacan S 820 Installation Operating Manual Mat No 05152100 ...

Page 2: ...nts 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 30 June 2022 ...

Page 3: ...rt lock 15 3 3 Storage preservation 15 3 4 Return to supplier 16 3 5 Disposal 17 4 Description of the Pump Set 18 4 1 General description 18 4 2 Product information as per Regulation No 1907 2006 REACH 18 4 3 Designation 18 4 4 Name plate 19 4 5 Design details 19 4 6 Installation types 20 4 7 Configuration and function 21 4 8 Scope of supply 22 4 9 Dimensions and weights 22 5 Installation at Site ...

Page 4: ...element bearings 61 7 5 Dismantling the pump set 62 7 5 1 General information Safety regulations 62 7 5 2 Preparing the pump set 63 7 5 3 Removing the bellmouth 64 7 5 4 Removing the impeller 64 7 5 5 Removing the mechanical seal 65 7 5 6 Dismantling the motor section 66 7 6 Reassembling the pump set 68 7 6 1 General information Safety regulations 68 7 6 2 Installing the replacement cable gland 70...

Page 5: ...ion type BG 104 9 5 3 Installation type CU 107 9 5 4 Installation type CG 110 9 5 5 Installation type DU 113 9 5 6 Installation type DG 116 9 5 7 Dimensions of the flow straightening vane 119 10 UK Declaration of Conformity 122 11 Certificate of Decontamination 123 Index 124 ...

Page 6: ...ufacturer to certify that the product has been properly drained to eliminate any environmental and health hazards arising from components in contact with the fluid handled Close coupled design Motor directly fitted to the pump via a flange or a drive lantern Submersible pump in discharge tube A submersible motor pump which is completely submerged and suspended in a discharge tube ...

Page 7: ... 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 Data sheet Description of the technical data of the pump set Hydraulic characteristic curve Characteristic curves showing head NPSH required efficiency and power input General assembly drawing1 Sectional drawing of the pump se...

Page 8: ...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 and i...

Page 9: ...ithin the use limits specified in the other applicable documents Only operate pumps pump sets which are in perfect technical condition Do not operate the pump set in partially assembled condition Only use the pump to handle the fluids described in the data sheet or product literature of the pump model or variant Never operate the pump without the fluid to be handled Observe the limits for continuo...

Page 10: ... 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 sup...

Page 11: ...ll and re activate any safety relevant devices and protective devices Before returning the product to service observe all instructions on commissioning ð Section 6 1 Page 44 2 8 Unauthorised modes of operation Never operate the pump set outside the limits stated in the data sheet and in this operating manual The warranty relating to the operating reliability and safety of the pump set supplied is ...

Page 12: ...pproved lifting accessories only Observe the regional transport regulations Observe the documentation of the lifting accessory manufacturer The load carrying capacity of the lifting accessory must be higher than the weight indicated on the name plate of the pump set to be lifted Take into account any additional system components to be lifted 3 2 1 Transporting the delivered pump set to the place o...

Page 13: ...t a safe distance to the electric cables WARNING Improper handling when placing the pump set in a vertical horizontal position Personal injury and damage to property Use one or two pieces of lifting equipment depending on the pump set size Use appropriate means to secure the pump set against tilting tipping over or rolling off Maintain a safe distance during lifting operations load may swing when ...

Page 14: ...e second crane hook 2 Lift the pump set with the lifting equipment ð Guiding the pump set over the edge of the bellmouth or pump casing is only permissible on a wooden base ð Protect the power cable against kinking 3 Place the pump set on a level clean surface and protect it against tilting tipping over or rolling off 3 2 3 Transporting the pump set WARNING Incorrect positioning placing down Perso...

Page 15: ...t keep at a safe distance to the electric cables WARNING Improper lifting moving of heavy assemblies or components Personal injury and damage to property Use suitable transport devices lifting equipment and lifting tackle to move heavy assemblies or components Fig 3 Transporting the pump set Use suitable lifting equipment to transport the pump set in the illustrated position 3 2 4 Transport lock P...

Page 16: ...Value Relative humidity 5 to 85 non condensing Ambient temperature 20 C to 70 C Store the pump set under dry and vibration free conditions if possible in its original packaging 1 Rotate the impeller by hand once every three months 3 4 Return to supplier 1 Drain the pump as per operating instructions ð Section 7 3 2 Page 55 2 Flush and clean the pump particularly if it has been used for handling no...

Page 17: ...he 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 service li...

Page 18: ...rmation as per chemicals Regulation EC No 1907 2006 REACH see https www ksb com ksb en About KSB Corporate responsibility reach 4 3 Designation Example Amacan S 1000 655 250 8 UTG2 Table 5 Designation key Code Description Amacan Type series S Impeller type S Mixed flow impeller 1000 Nominal diameter of the discharge tube mm 655 Nominal impeller diameter mm 250 Motor size 8 Number of motor poles UT...

Page 19: ...r 3 Flow rate 4 Maximum fluid temperature and ambient temperature 5 Enclosure 6 Motor type 7 Rated power 8 Rated speed 9 Rated voltage 10 Rated current 11 Head 12 Year of construction 13 Total weight 14 Maximum immersion depth 15 Thermal class of winding insulation 16 Motor number 17 Power factor at rated operating point 18 Rated frequency 19 Duty type 20 Starting current ratio 4 5 Design details ...

Page 20: ... floor discharge nozzle for installation in open intake chamber BG discharge tube Overflow design for installation in covered intake chamber with low suction side water levels CG discharge tube Design with underfloor discharge for installation in covered intake chamber with low suction side water levels DG discharge tube Design with above floor discharge nozzle for installation in covered intake c...

Page 21: ...tted from the electric motor 4 to the impeller 2 via the shaft 5 In the pump casing 3 the kinetic energy of the fluid is converted into pressure energy The rotational movement diverts the fluid flow into a mixed flow The shaft passage through the casing is sealed towards the fluid with a shaft seal 10 The shaft 5 runs in two rolling element bearings 7 and 8 which are supported by the bearing housi...

Page 22: ...Back up name plate Optional accessories Support rope Accessories for installing the cable guide Fitting Turnbuckle Support Shackle Cable clamps Cable support sleeves Discharge tube Flow straightening vane to prevent floor vortices NOTE A separate name plate is included in the scope of supply This name plate must be attached in a clearly visible position outside the place of installation e g at the...

Page 23: ...l structural work required must have been prepared in accordance with the dimensions stated in the outline drawing general arrangement drawing 5 2 2 Checking the operating data Before inserting the pump set into the discharge tube verify the data on the name plate against the data given in the purchase order and the system data Back up name plate KSB s scope of supply includes a separate name plat...

Page 24: ...on of rotation WARNING Hands and or foreign objects in the pump casing Risk of injuries damage to the pump Never insert your hands or any other objects into the pump Check that the inside of the pump is free from any foreign objects Verify that the transport lock has been removed Take suitable precautions e g wear safety goggles WARNING Improper handling when placing the pump set in a vertical hor...

Page 25: ...k which core ends match which of the terminals in the control cabinet 6 Disconnect the pump set from the power supply and secure it against unintentional start up WARNING Unintentional starting of the pump set Risk of injury by moving components and shock currents Ensure that the pump set cannot be started unintentionally Always make sure the electrical connections are disconnected before carrying...

Page 26: ...ow straightening vane is indispensable for the inlet conditions of the pump set It prevents the development of a submerged vortex floor vortex which could cause a drop in performance for example To provide optimum inlet conditions observe the following information 1 Observe the structural requirements Install the flow straightening vane concentrically below the discharge tube see general arrangeme...

Page 27: ...r to and comply with the general arrangement drawing outline drawing when installing the pump set 1 If O ring 412 05 is supplied but not fitted insert it into pump casing 101 2 Attach the crane hook the bail of the pump set 3 Centre the pump set above the discharge tube Slowly lower the pump set into the discharge tube until it is seated in the recommended position ð Section 5 3 1 Page 26 4 Pull t...

Page 28: ...fy that the pump set is correctly seated in the discharge tube WARNING Pump set drops during the installation or removal process Personal injury and damage to property Never use the turnbuckle shackle or discharge tube cover to lift the pump set Always use lifting lug 59 47 NOTE Prior to fitting the turnbuckle check that the corresponding split pin has not been cracked or chipped If damaged always...

Page 29: ...set 5 Partially unwind the support rope and electric cables 6 Lower the pump set into the discharge tube until the bail is in an accessible position protruding from the discharge tube 7 Securely cover the discharge tube except for a gap which allows work to continue 8 Attach the first lifting lug of the support rope 5 to the hoisting rope 1 to securely position the pump set above the discharge tub...

Page 30: ...the cable bundle with evenly spaced sheathed cable clamps 17 Fit a heat shrink tube on any protruding sharp edged rope ends e g at the ferrule to prevent any damage to the power cable and control cable Fig 16 Lowering the pump set 18 Finally attach the support rope with shackle and turnbuckle to a suspension loop provided in the discharge tube or structure Secure the turnbuckle with a split pin Af...

Page 31: ...rrectly seated in the discharge tube WARNING Pump set drops during the installation or removal process Personal injury and damage to property Never use the turnbuckle shackle or discharge tube cover to lift the pump set Always use lifting lug 59 47 NOTE Prior to fitting the turnbuckle check that the corresponding split pin has not been cracked or chipped If damaged always use a new split pin ü Sui...

Page 32: ...ible position protruding from the discharge tube 6 Securely cover the discharge tube except for a gap which allows work to continue 7 Attach the first lifting lug of the support rope 5 to the lifting rope 1 to securely position the pump set above the discharge tube 8 Unclip the hook of the lifting equipment from the lifting lug of the support rope and run the lifting equipment to a higher level 8 ...

Page 33: ...be on any protruding sharp edged rope ends e g at the ferrule to prevent any damage to the power and control cables 17 Trim the spacer a to suit the position of support 59 7 at the support rope f and the type of installation Insert the support rope and control cable c 18 Insert the power cables b into the hollows of the spacer a and firmly clamp the power cables with cable clamps d 59 7 X X 733 05...

Page 34: ...ure it with Loctite 243 ð Section 9 2 Page 91 NOTE The support must be firmly clamped to the support rope and the GFRP rod must be firmly clamped to the support If necessary pad out clamps 81 39 23 Trim the spacer to fill the space between the two ferrules and accommodate the support 24 Guide the power cables and control cable along the support to the next cable clamp Pull them taut and secure the...

Page 35: ...with shackle and turnbuckle to a suspension loop provided in the discharge tube or structure Secure the turnbuckle with a split pin After inserting the split pin bend over its two legs 27 Tighten the turnbuckle until the cables are tight but do not lift the pump off its seat 28 Unclip the hook of the lifting equipment from the lifting lug free the electric cables from the manila rope and route the...

Page 36: ...macan S 1589 837 01 EN 29 Attach the top loose lifting lug to the cables to prevent noise and wear caused by chafing 30 Remove the safety cover from the discharge tube and mount the discharge tube cover 31 Seal the cable entries if any ...

Page 37: ...gulations 2 Set the overload protection device to the rated current specified on the name plate ð Section 4 4 Page 19 5 4 1 2 Level control DANGER Pump set running dry Explosion hazard Never allow a pump set to run dry CAUTION Fluid level below the specified minimum Damage to the pump set by cavitation Never allow the fluid level to drop below the specified minimum Automatic operation of the pump ...

Page 38: ...vel varies depending on the inverter used type interference suppression make To prevent the drive system consisting of a submersible motor and a frequency inverter from exceeding any given limits always observe the EMC information provided by the inverter manufacturer If the inverter manufacturer recommends a shielded power cable make sure to use a submersible motor pump with shielded power cables...

Page 39: ...akage inside the motor connection and winding space 2 Bearing temperature upper bearing assembly 3 Bearing temperature lower bearing assembly 4 Mechanical seal leakage 5 Vibration sensor 6 Motor temperature PTC 7 Motor temperature Pt100 5 4 1 4 1 Motor temperature CAUTION Insufficient cooling Damage to the pump set Never operate a pump set without operational temperature monitoring Three series co...

Page 40: ...be connected to an electrode relay Tripping of the electrode relay must result in the pump set cutting out The electrode relay K1 must trip the motor at a tripping resistance between 3 and 60 kΩ Pump sets with vibration sensors A different wiring system is used for the electrodes of pump sets with vibration sensors 5 4 1 4 3 Mechanical seal leakage Fig 25 Float switch The chamber for mechanical se...

Page 41: ...tems or process control systems Table 9 Technical data of the sensor Characteristic Value Measuring range 4 20 mA at 0 20 mm s Measurement error 5 Long term stability 1 in 10 years Maximum shock load 500 g Frequency range 2 Hz 1000 Hz Resonant frequency 18 kHz Output impedance 200 Ω max Voltage supply 18 30 V smoothed Working resistance 50 100 Ω Connecting the vibration sensor 41 42 mA 18 30V DC F...

Page 42: ... cables Adjust the length of the electric cables to the site requirements CAUTION Motor overload Damage to the motor Protect the motor by a thermal time lag overload protection device in accordance with IEC 60947 and local regulations For the electrical connection observe the circuit diagrams ð Section 9 3 Page 93 in the Annex and the information for planning the control system ð Section 5 4 1 Pag...

Page 43: ...from the power cables immediately before connecting the cables 3 If necessary adjust the length of the power cables to the site requirements 4 After shortening the cable correctly re affix the markings on the individual cores at the cable ends Potential equalisation The pump set is not fitted with an external potential equalisation connection risk of corrosion DANGER Touching the pump set during o...

Page 44: ...WARNING People falling into the unsecured discharge tube Risk of personal injury Take suitable precautions during the entire installation removal process to protect people from falling into the open discharge tube Fence off the work area appropriately Before commissioning starting up the pump set make sure that the following conditions are met The lubricant has been checked The direction of rotati...

Page 45: ...ndstill Never start up the pump set while the pump is running in reverse ü The fluid level is sufficiently high CAUTION Start up against a closed shut off element Damage to the pump set Never operate the pump set against a closed shut off element 1 Fully open the discharge line shut off element if any 2 Start up the pump set 6 2 Operating limits DANGER Non compliance with operating limits Damage t...

Page 46: ... start up the pump set while the pump is running in reverse 6 2 3 Operation on a frequency inverter Frequency inverter operation of the pump set is permitted in the frequency range from 25 to 50 Hz 6 2 4 Fluid handled 6 2 4 1 Fluid temperature The pump set is designed for transporting liquids The pump set is not operational under freezing conditions CAUTION Danger of freezing Damage to the pump se...

Page 47: ...t When the pump handles fluids containing abrasive substances increased wear of the hydraulic system and shaft seal are to be expected In this case reduce the commonly recommended inspection intervals 6 3 Shutdown storage preservation 6 3 1 Shutdown CAUTION Uncontrolled backflow of the fluid from the riser Damage to the pump set Prevent any uncontrolled backflow of the fluid handled with suitable ...

Page 48: ... sufficient fluid is available for the functional check run of the pump set 1 For prolonged shutdown periods start up the pump set regularly once every three months Let it run for about one minute This will prevent the formation of deposits within the pump and the pump intake area The pump set is removed from the pipe and stored ü All safety regulations are observed 1 Clean the pump set 2 Spray co...

Page 49: ...6 Commissioning Start up Shutdown 49 of 126 Amacan S 1589 837 01 EN NOTE On pumps pump sets older than 5 years we recommend replacing all elastomer seals ...

Page 50: ...nd qualified electrician Observe the IEC 61557 regulations as well as any regional regulations 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 posing a health hazard WARNING Unintentional ...

Page 51: ... to the enclosed Addresses booklet or visit www ksb com contact on the Internet Never use force when dismantling and reassembling the pump set 7 2 Maintenance inspection KSB recommends the following regular maintenance schedule Table 10 Overview of maintenance work Maintenance interval Maintenance work For details see Every 4000 hours at least once a year Measure the insulation resistance ð Sectio...

Page 52: ...he motor for this purpose NOTE If the insulation resistance of the power cable is lower than 1 MΩ the power cable is defective and must be replaced NOTE If the insulation resistances measured on the motor are too low the winding insulation is defective The pump set must not be returned to service in this case 7 2 1 2 Checking the sensors CAUTION Excessive test voltage Damage to the sensors Use a c...

Page 53: ...emperature sensor Table 14 Resistance measurement of the bearing temperature sensor Measurement between terminals Resistance Ω 15 and 16 100 to 120 16 and 175 100 to 120 Vibration sensor Table 15 Current measurement at vibration sensor Measurement between terminals Current value 41 and 426 Constant 4 mA during standstill Functional test Connect the vibration sensor Measure the current in the measu...

Page 54: ... to continue ü Suitable lifting equipment is provided 1 Attach the lifting chain or lifting rope to the trolley 2 Free the uppermost lifting lug from the cables attach it to the crane hook and run the lifting equipment to a higher level 3 Open and disconnect the turnbuckle NOTE Prevent any loose parts from falling into the pump sump 4 Pull the pump set up until it reaches the second lifting lug of...

Page 55: ...ve mask if required Observe all legal regulations on the disposal of fluids posing a health hazard 1 Always flush the pump if it has been used for handling noxious explosive hot or other hazardous fluids 2 Always flush and clean the pump before transporting it to the workshop Provide a certificate of decontamination for the pump set ð Section 11 Page 123 7 3 3 Checking the cable bundle When removi...

Page 56: ... and any fluid residues Wear safety clothing and a protective mask if required Observe all legal regulations on the disposal of fluids posing a health hazard WARNING Excess pressure inside the pump set Risk of injury when opening the pump set Take care when opening the inner chambers Equalise the pressure NOTE Slight wear of the mechanical seal is unavoidable This will be aggravated by abrasive su...

Page 57: ...ularly check the condition of the lubricant in the lubricant reservoir of the mechanical seal Top it up if required The mechanical seal is supplied with lubricating liquid from the lubricant reservoir 7 4 1 1 Intervals Replace the lubricant every 8000 operating hours but at least every 3 years 7 4 1 2 Lubricant quality The lubricant reservoir is filled at the factory with an environmentally friend...

Page 58: ...pressure inside the pump set Risk of injury when opening the pump set Take care when opening the inner chambers Equalise the pressure WARNING Improper handling when placing the pump set in a vertical horizontal position Personal injury and damage to property Select suitable lifting equipment for the size of the pump Use appropriate means to secure the pump set against tilting tipping over or rolli...

Page 59: ...ver ü A suitable container for collecting the lubricant is on hand 1 Undo nuts 920 01 2 Attach the crane hook to the bail and lift the pump set off the bellmouth with the casing wear ring 3 Place the pump set in a horizontal position on wooden supports Secure it against rolling off 914 07 922 210 940 02 230 Fig 31 Removing the impeller 4 Undo socket head cap screws 914 07 and impeller nut 922 5 Pu...

Page 60: ...he mechanical seal 6 Properly dispose of the lubricant 7 Remove the tube Fit screw plug 903 02 oil drain and a new joint ring with liquid sealant Version with 2 screw plugs 1 Move the screw plug 903 02 and joint ring 411 02 which are the furthest from the shaft oil drain into upper position and remove them 2 Screw in a sufficiently long tube b with G 1 2 thread 3 Carefully rotate the pump set unti...

Page 61: ...against rolling off ü Screw plug 903 02 and joint ring 411 02 have been removed from the filler opening ü The drain opening is closed with screw plug 903 02 and joint ring 411 02 1 Screw a sufficiently long tube with G 1 2 thread into the filler opening 2 Fill the lubricant in through the tube until it overflows 3 Remove the tube Fit screw plug 903 02 and a new joint ring 411 02 with liquid sealan...

Page 62: ...by the manufacturer Type A Klüberquiet BQH 72 102 made by Klüber Lubrication KG München ð Section 7 4 2 1 Page 61 7 4 2 3 Grease quantity Table 21 Grease quantity Size Grease type Grease quantity cm3 Drive end Pump end 800 850 535 Type A 30 800 850 550 Type A 30 800 900 600 615 620 Type A 30 800 1000 600 615 620 Type A 50 1850 1000 655 Type A 30 800 1850 1300 820 Type A 50 800 1850 7 5 Dismantling...

Page 63: ...k of cutting or shearing injuries Always use appropriate caution for installation and dismantling work Wear work gloves WARNING Pump set tilting or rolling off Risk of personal injury Make sure the pump set is secured against tilting during the entire dismantling process For dismantling the pump set in a horizontal position secure it against rolling off Observe the general safety instructions and ...

Page 64: ...ane hook to the bail and lift the pump set off bellmouth 138 Casing wear ring 502 remains in bellmouth 138 3 Place the pump set in a horizontal position on wooden supports and make sure it cannot roll off 7 5 4 Removing the impeller 914 07 922 210 940 02 230 Fig 35 Removing the impeller ü The pump has been placed in a horizontal position on wooden supports and is protected against rolling off ü Th...

Page 65: ... set has been securely placed in a horizontal position on wooden supports ü The impeller has been removed ü The lubricant has been drained ð Section 7 4 1 4 1 Page 58 1 Remove circlip 932 44 and disc 550 44 2 Pull mechanical seal 433 02 off the shaft NOTE To protect the mechanical seal against damage when pulling it off the shaft placing a foil no thicker than 0 3 mm around the free shaft stub is ...

Page 66: ...01 down 2 Undo hexagon socket head cap screws 914 02 3 Attach the lifting tackle to bail 571 and lift the pump set out of pump casing 101 4 Place motor unit 80 1 including rotor 818 with bearing and bearing housing 350 on a wooden support and protect it against rolling off ð Section 3 2 Page 12 5 Remove circlip 932 03 and disc 550 03 6 Carefully slide mechanical seal 433 01 and its mating ring off...

Page 67: ...yebolt 900 04 or bail 571 2 Undo hexagon socket head cap screws 914 01 3 Carefully lift off motor housing cover 812 If the motor housing cover cannot be lifted off use the extraction threads located underneath caps 903 51 4 Remove the cable ties 5 Lift motor housing cover 812 up further until the power cables and control cable can be disconnected 6 Disconnect plug 81 2 of the control cable from th...

Page 68: ... 914 04 at cable gland 834 01 4 Pull cable gland 834 01 out of the centring seat in motor housing cover 812 Removing the control cable ü The motor housing cover has been removed placed down and protected against rolling off 1 Disconnect the cores of the control cable from plug 81 2 2 Undo screws 914 05 at cable gland 834 02 3 Pull cable gland 834 02 out of the centring seat in motor housing cover ...

Page 69: ...l spare parts only NOTE Apply liquid sealant to all screw plugs Apply liquid sealant to all wetted clearances e g Hylomar SQ 32M Sequence Always re assemble the pump set in accordance with the corresponding general assembly drawing and or exploded view Sealing elements Check O rings for any damage and replace by new O rings if required Never use O rings that have been made by cutting an O ring cor...

Page 70: ...ymbol Description L 243 Always secure screwed connections marked with this symbol with Loctite 243 Installing the power cable version without plug 1 Adjust the lengths of the cable cores to the original cable gland 2 Attach the core identification to match the original cable gland 3 Slide O ring 412 07 onto the core ends of the power cable and into the groove of the centring seat 4 Use a connector...

Page 71: ...nnect the plug of the control cable with the plug of the pump set 3 Insert cable gland 834 02 with the control cable and O ring 412 08 into the opening provided 4 Fasten cable gland 834 02 with clamping element 81 51 and hexagon socket head cap screws 914 05 and secure the screwed connection with Loctite 243 Fastening the cover plate to the bail 1 Insert the power cable and control cable with cabl...

Page 72: ...or housing cover 812 and motor housing 811 The alignment grooves must be properly aligned 6 Fasten motor housing cover 812 to motor housing 811 or motor unit 80 1 with socket head cap screws 914 01 Secure with Loctite 243 Observe the tightening torque ð Section 7 8 Page 80 7 Cover the extraction threads with caps 903 51 8 Perform a leak test on the motor ð Section 7 6 8 2 Page 78 7 6 4 Installing ...

Page 73: ... Guide disc 550 03 and circlip 932 03 onto the shaft Press the circlip in with an assembly sleeve until it is axially fastened in the shaft groove 4 Screw the testing device into the leakage drain hole X of bearing housing 350 and perform a leak test 5 Attach the crane hook to the bail and pull upright motor unit 80 1 including rotor 818 with bearing and bearing housing 350 6 Place the pump set on...

Page 74: ... an assembly sleeve of a suitable diameter to press the mating ring of mechanical seal 433 02 together with the O ring into the drilled recess in the pump casing 2 Carefully guide on the bellows part of the mechanical seal until it rests against the mating ring 3 Guide disc 550 44 and circlip 932 44 onto the shaft Press the circlip in with an assembly sleeve until it is axially fastened to the sha...

Page 75: ...o the keyway 2 Coat all sides of the shaft seat and shaft thread with an assembly paste which prevents seizure of the chrome steel parts 3 Guide impeller 230 onto shaft 210 until it abuts against the shaft collar ð This is as far as the impeller can move along the shaft This position results in the maximum possible clearance between bellmouth with casing wear ring and impeller vanes 4 Screw impell...

Page 76: ... pump set has been completely pre assembled ü Casing wear ring 502 has been fitted in bellmouth 138 1 Attach lifting equipment to bail 571 and carefully pull the pump set upright 2 Centre the pump set above bellmouth 138 NOTE Make sure that the pin of bail 571 for attaching the lifting tackle and the baffles in bellmouth 138 are aligned in the same direction 3 Slowly lower the pump set While lower...

Page 77: ...crew the impeller nut on further by dimension B to move the impeller along the shaft until the specified clearance A is established 5 Use a feeler gauge to measure and verify the adjusted clearance between the impeller vanes and casing wear ring 502 Perform this measurement at several points spaced around the circumference 6 Align two tapped holes in the impeller hub with two holes in the impeller...

Page 78: ...nutes P 1 0 bar Fig 47 Screwing in the testing device ü The impeller end mechanical seal has been installed 1 Screw the testing device tightly into the G 1 2 lubricant filler opening 2 Carry out the leak test with the values specified above The pressure must not drop during the test period If the pressure does drop check the seals and screwed connections 3 Repeat the leak test if required 4 If the...

Page 79: ...cified above ð The pressure must not drop during the test period ð If the pressure does drop check the sealing elements and screwed connections 4 Repeat the leak test if required 5 Remove the testing device DANGER Screw plug leaking or missing Damage to the motor Never start up a pump set without screw plug 903 31 Apply a thread locking agent Loctite 243 to screw plug 903 31 6 Apply a thread locki...

Page 80: ... 338 375 287 319 M24 704 782 231 257 495 550 583 648 495 550 M27 1025 1139 36 374 721 801 849 944 721 801 M30 1403 1559 460 511 986 1096 1162 1291 986 1096 M33 1888 2098 619 688 1327 1475 1563 1737 1327 1475 M36 2445 2717 802 891 1719 1910 2025 2250 1719 1910 M42 3904 4338 1281 1423 2745 3050 3233 3592 2745 3050 M48 5880 6534 1929 2144 4135 4594 4870 5411 4135 4594 NOTE If using an adjustable torq...

Page 81: ... 1 2 2 3 30 320 321 Rolling element bearing pump end 1 1 2 2 3 4 50 322 Rolling element bearing drive end 1 1 2 2 3 4 50 412 05 412 60 O ring for discharge tube cover 2 3 4 5 6 8 100 433 01 Mechanical seal drive end 2 3 4 5 6 7 90 433 02 Mechanical seal pump end 2 3 4 5 6 7 90 502 Casing wear ring 2 2 2 3 3 4 50 80 1 Motor unit 1 2 30 818 Rotor 1 2 30 834 Cable gland 1 1 2 2 2 3 40 99 9 Set of sea...

Page 82: ...sible or unsuccessful please contact KSB Unfavourable flow to the pump inlet Improve the flow to the intake chamber contact KSB Pump running in off design conditions part load overload Check the pump s operating data Pump clogged by deposits Clean intake and pump components Wear Replace worn parts Impermissible air or gas content in the fluid handled Contact KSB System induced vibrations Contact K...

Page 83: ...EN A B C D E Possible causes Remedy7 Bearing temperature monitor has tripped Have cause determined and eliminated by qualified and trained personnel In case of star delta configuration motor running in star configuration only Check star delta contactor ...

Page 84: ... 812 412 01 330 80 1 818 412 06 914 03 914 02 350 101 412 03 412 05 230 138 940 02 914 07 922 GP QNB50 L 243 L 243 L 243 FD 571 901 20 932 20 81 18 03 914 06 L 243 82 5 360 412 02 320 321 421 02 500 02 932 02 433 01 550 03 932 03 502 433 02 550 44 932 44 FD FD FD 81 29 03 Fig 49 General assembly drawing ...

Page 85: ...05 834 02 412 08 903 31 411 31 82 11 903 51 901 26 L 243 L 243 L 243 L 243 L 243 Motor sizes 415 6 350 8 320 10 420 10 81 97 02 571 81 97 01 68 3 02 914 01 901 26 903 31 411 31 901 25 920 25 550 25 914 04 834 01 412 07 Bearing drive end Motor sizes 120 6 340 6 85 8 290 8 200 10 250 10 421 01 932 01 500 01 322 932 13 500 04 932 05 500 29 932 29 Motor sizes 415 6 350 8 320 10 420 10 421 01 500 01 93...

Page 86: ...y drawing Bearing pump end Motor sizes 120 6 415 6 85 8 350 8 200 10 420 10 421 02 412 57 484 02 561 02 483 02 950 02 932 02 500 02 321 504 02 320 On specific sizes only Bearing bracket fastening Motor sizes 120 6 205 6 85 8 120 8 932 37 330 Motor sizes 250 6 415 6 205 8 350 8 200 10 420 10 330 914 48 ...

Page 87: ...23 920 23 920 24 932 23 914 19 932 19 99 4 01 99 17 01 900 30 914 48 H L 243 L 243 Only for variants with vibration sensor 69 8 50 Only on specific sizes H alignment groove Bearing bracket sensors and terminals 81 45 411 26 Y X Y X 970 04 970 03 970 05 970 01 970 02 970 01 company name plate 970 02 name plate 970 03 oil drain 970 04 oil filler plug 970 05 leakage drain Float switch Labels plates ...

Page 88: ... Pump end bearing temperature sensor Screwed connection bellmouth pump casing 69 6 01 520 01 903 02 411 02 903 02 411 02 970 03 970 04 903 01 411 01 970 05 970 03 oil drain 970 04 oil filler plug 970 05 leakage drain Drive end bearing temperature sensor Lubricant and leakage chamber Table 34 List of components Part No Description Part No Description 110 Pump casing 80 1 Motor unit 138 Bellmouth 81...

Page 89: ...asing 99 17 Desiccant 484 02 Spring plate 900 06 26 30 Screw 500 01 02 04 29 Ring 901 02 05 20 25 Hexagon head bolt 502 Casing wear ring 902 01 Stud 504 02 Spacer ring 903 01 02 31 Screw plug 520 01 02 Sleeve 914 01 02 03 04 05 06 07 19 48 51 Socket head cap screw 550 01 03 05 23 25 44 50 Disc 920 01 23 24 25 Nut 561 02 Grooved pin 922 Impeller nut 571 Bail 932 01 02 03 05 06 13 20 23 25 26 29 44 ...

Page 90: ...th adapter 110 914 02 82 5 412 06 80 1 914 06 L 243 L 243 Part No Description Part No Description 110 Pump casing 82 5 Adapter 412 06 O ring 914 02 06 Hexagon socket head cap screw 80 1 Motor unit Table 37 Key to the symbols and codes Symbol Description L 243 Always secure screwed connections marked with this symbol with Loctite 243 ...

Page 91: ...59 47 720 59 8 59 17 02 59 47 733 05 719 05 720 59 24 59 17 01 59 7 59 47 A A 1 2 3 M M M M M M M M M M A A A A L 243 L 243 L 243 Fig 50 Cable bundle 1 Basic design 2 Design with lifting lug 3 Design with support Only required for galvanised version NOTE Distance M 50 mm Table 38 Symbols key Symbol Description L 243 Always secure screwed connections marked with this symbol with Loctite 243 ...

Page 92: ...tion of power cable control cable and support rope c Power cable d Control cable Table 39 List of spare parts of the cable bundle Part No Description Part No Description 59 7 Support 59 47 Lifting lug 59 8 Turnbuckle 719 05 Flexible tube 59 17 01 02 Shackle 720 Fitting 59 24 Rope support rope 733 05 Hose clip ...

Page 93: ...lated Documents 93 of 126 Amacan S 1589 837 01 EN 9 3 Wiring diagrams 9 3 1 Wiring diagram for power cable Fig 52 Wiring diagram for power cable Shielded cable option 1 Up to 3 parallel cable pairs possible ...

Page 94: ...s for the sensors Standard pump sets Fig 53 Wiring diagram for sensors of standard pump sets Shielded cables optional Ⓐ Motor temperature PTC Ⓑ Mechanical seal leakage Ⓒ Bearing temperature lower bearings Ⓓ Bearing temperature upper bearing optional Ⓕ Leakage inside the motor ...

Page 95: ... by vibration sensor Fig 54 Wiring diagram for sensors of pump sets with additional monitoring by vibration sensor Ⓐ Motor temperature PTC Ⓑ Mechanical seal leakage Ⓒ Bearing temperature lower bearings Ⓓ Bearing temperature upper bearing optional Ⓕ Leakage inside the motor Ⓖ Vibration sensor ...

Page 96: ...ature monitoring Fig 55 Wiring diagram for sensors of pump sets with additional motor temperature monitoring Pt100 Ⓐ Motor temperature PTC Ⓑ Mechanical seal leakage Ⓒ Bearing temperature lower bearings Ⓓ Bearing temperature upper bearing optional Ⓕ Leakage inside the motor Ⓗ Motor temperature Pt100 ...

Page 97: ... sensor Fig 56 Wiring diagram for sensors of pump sets with additional Pt100 motor temperature monitoring and vibration sensor Ⓐ Motor temperature PTC Ⓑ Mechanical seal leakage Ⓒ Bearing temperature lower bearings Ⓓ Bearing temperature upper bearing optional Ⓕ Leakage inside the motor Ⓖ Vibration sensor Ⓗ Motor temperature Pt100 ...

Page 98: ...350 2050 775 670 700 475 40 885 80 1840 850 535 250 6 3150 3090 350 2550 775 670 700 555 50 885 90 2440 850 550 155 6 2780 2740 415 2090 826 720 700 475 40 865 80 1735 850 550 180 6 2780 2740 415 2090 826 720 700 475 40 865 80 1830 850 550 205 6 2780 2740 415 2090 826 720 700 475 40 865 80 1885 850 550 250 6 3190 3130 415 2590 826 720 700 555 50 865 90 2480 850 550 290 6 3190 3130 415 2590 826 720...

Page 99: ...20 90 2775 1000 655 250 8 3235 3175 550 2635 975 855 900 555 50 1220 90 2905 1000 655 290 8 3235 3175 550 2635 975 855 900 555 50 1220 90 3070 1000 655 350 8 3685 3610 550 2985 975 855 900 650 60 1220 90 3770 1300 820 200 10 3280 3220 600 2680 1200 970 1050 555 50 1195 90 3720 1300 820 250 10 3280 3220 600 2680 1200 970 1050 555 50 1195 90 3970 1300 820 310 10 3580 3505 600 2880 1200 970 1050 650 ...

Page 100: ...615 290 6 914 780 1300 420 10 900 615 340 6 914 780 1300 420 10 900 620 250 6 914 770 1300 365 10 900 620 290 6 914 770 1300 365 10 900 620 340 6 914 770 1300 365 10 1000 600 415 6 1016 800 1300 415 10 1000 615 415 6 1016 780 1300 420 10 1000 620 415 6 1016 770 1300 365 10 1000 655 205 8 1016 920 1500 515 10 1000 655 250 8 1016 920 1500 515 10 1000 655 290 8 1016 920 1500 515 10 1000 655 350 8 101...

Page 101: ...tube Drawing without pump 45 d7 h 7 Detailed view Y seating ring Minimum water level values see diagram on the next page Approach flow Flow straightening vane ð Section 9 5 7 Page 119 Table 42 Dimensions mm Size D b b1 b2 d7 d8 d9 d12 Suction umbrella Suction umbrella d8 d9 d8 d9 800 535 813 1500 300 300 720 810 1300 850 850 535 868 1500 300 300 720 865 1300 920 850 550 868 1500 300 300 740 865 13...

Page 102: ...50 535 525 750 325 975 980 1050 790 380 3210 850 550 525 750 375 975 980 1050 790 380 3250 900 600 550 750 415 950 1050 1120 860 380 3200 900 615 550 750 420 1250 1050 1120 860 440 3200 900 620 550 620 365 700 1050 1120 860 320 3200 1000 600 600 750 415 900 1150 1220 960 380 3650 1000 615 600 750 420 1200 1150 1220 960 440 3650 1000 620 600 620 365 650 1150 1220 960 320 3650 1000 655 600 850 515 1...

Page 103: ...las H Hgeo Hv Hv Overflow head hü see diagram Loss in the riser pipe friction Outlet loss v2 2 g v refers to DA Overflow head hü depends on Q and the discharge diameter DA The characteristic curve values only apply to unimpeded outlet in all directions otherwise they are approximate values only Minimum water level diagram Open chamber 4000 3000 1600 1200 1000 500 400 2000 t1 mm 0 1 0 2 0 5 1 1 5 2...

Page 104: ...ter level values see diagram on the next page Approach flow Flow straightening vane ð Section 9 5 7 Page 119 Table 44 Dimensions mm Size D b b1 b2 d7 d8 d10 d12 e1 13 800 535 813 1500 300 600 720 840 885 850 450 850 535 868 1500 300 600 720 840 885 920 450 850 550 868 1500 300 600 740 840 885 920 450 900 600 914 1500 300 600 800 820 860 970 450 900 615 914 1800 360 720 780 910 955 970 520 900 620 ...

Page 105: ...0 1800 1150 1220 960 440 3650 660 1000 620 625 365 1250 1150 1220 960 320 3650 470 1000 655 900 515 1800 1150 1220 960 440 3750 660 1300 820 1150 545 2300 1460 1520 1260 560 3900 850 Permissible tolerances Tolerances in building construction to DIN 18202 Part 4 Group B Welded construction B F to DIN EN ISO 13920 Tolerances for conical seat detail Y ISO 2768 mH Loss diagram D DA h ü 7 Overflow head...

Page 106: ...106 of 126 Amacan S 1589 837 01 EN Minimum water level diagram Covered chamber 4000 3000 2500 1600 1200 1000 900 800 700 600 500 400 0 1 0 2 0 3 0 4 0 5 0 6 0 8 1 1 5 2 5 3 4 5 6 7 8 2 2000 t1 mm Q m3 s Minimum water level ...

Page 107: ...m1 n Detailed view X support plate of the discharge tube Drawing without pump 45 d7 h 7 Detailed view Y seating ring Vent line Minimum water level values see diagram on the next page Approach flow Flow straightening vane ð Section 9 5 7 Page 119 Connect the discharge line to the discharge tube without transmitting any stresses or strains 15 All dimensions for foundation recesses apply to discharge...

Page 108: ...380 2800 835 850 535 865 1300 525 750 325 975 1325 530 1375 1075 1175 380 3250 835 850 550 865 1300 525 750 375 975 1325 530 1375 1075 1175 380 3250 835 900 600 910 1300 550 750 415 950 1380 560 1480 1180 1280 380 3200 925 900 615 910 1300 550 750 420 1250 1380 560 1480 1180 1280 440 3200 925 900 620 910 1050 550 620 365 700 1380 560 1480 1180 1280 320 3200 925 1000 600 1015 1300 600 750 415 900 1...

Page 109: ...800 mm DN2 900 mm DN2 1000 mm DN2 1100 mm DN2 1200 mm DN2 1300 mm DN2 1400 mm DN2 1500 mm DN2 1600 mm Calculation formulas H Hgeo Hv Hv Loss in the riser pipe friction Hv ges see diagram HV ges comprises Elbow Discharge pipe length 5 x DN2 Swing check valve Outlet losses v2 2g Minimum water level diagram Open chamber 4000 3000 1600 1200 1000 500 400 2000 t1 mm 0 1 0 2 0 5 1 1 5 2 3 4 5 6 8 Q m3 s ...

Page 110: ... m1 n Detailed view X support plate of the discharge tube Drawing without pump 45 d7 h 7 d8 10 Detailed view Y seating ring Vent line Minimum water level values see diagram on the next page Approach flow Flow straightening vane ð Section 9 5 7 Page 119 Connect the discharge line to the discharge tube without transmitting any stresses or strains 19 All dimensions for foundation recesses apply to di...

Page 111: ...m m1 n p1 p2 t3 20 t4 min21 t5 min22 t9 800 535 450 750 325 1500 1270 505 1375 1075 1175 380 2800 835 570 850 535 450 750 325 1500 1325 530 1375 1075 1175 380 3250 835 570 850 550 450 750 375 1500 1325 530 1375 1075 1175 380 3250 835 570 900 600 450 750 415 1500 1380 560 1480 1180 1280 380 3200 925 570 900 615 520 900 420 1800 1380 560 1480 1180 1280 440 3200 925 660 900 620 415 625 365 1250 1380 ...

Page 112: ...mm DN2 700 mm DN2 800 mm DN2 900 mm DN2 1000 mm DN2 1100 mm DN2 1200 mm DN2 1300 mm DN2 1400 mm DN2 1500 mm DN2 1600 mm Calculation formulas H Hgeo Hv Hv Loss in the riser pipe friction Hv ges see diagram HV ges comprises Elbow Discharge pipe length 5 x DN2 Swing check valve Outlet losses v2 2g Minimum water level diagram Covered chamber 4000 3000 2500 1600 1200 1000 900 800 700 600 500 400 0 1 0 ...

Page 113: ...ew X support plate of the discharge tube Drawing without pump 45 d7 h 7 Detailed view Y seating ring Vent line Minimum water level values see diagram on the next page Approach flow Flow straightening vane ð Section 9 5 7 Page 119 Not pressure proof Connect the discharge line to the discharge tube without transmitting any stresses or strains 23 All dimensions for foundation recesses apply to discha...

Page 114: ...030 1260 960 1060 380 2800 850 535 865 1300 525 750 325 975 1080 1310 1010 1110 380 3250 850 550 865 1300 525 750 375 975 1080 1310 1010 1110 380 3250 900 600 910 1300 550 750 415 950 1130 1360 1060 1160 380 3200 900 615 910 1300 550 750 420 1250 1130 1360 1060 1160 440 3200 900 620 910 1050 550 620 365 700 1130 1360 1060 1160 320 3200 1000 600 1015 1300 600 750 415 900 1240 1500 1160 1260 380 365...

Page 115: ... DN2 800 mm DN2 900 mm DN2 1000 mm DN2 1100 mm DN2 1200 mm DN2 1300 mm DN2 1400 mm DN2 1500 mm DN2 1600 mm Calculation formulas H Hgeo Hv Hv Loss in the elbow hV Kr see diagram Loss in the riser pipe friction HV System valves etc HV System must be determined for the specific system Minimum water level diagram Open chamber 4000 3000 1600 1200 1000 500 400 2000 t1 mm 0 1 0 2 0 5 1 1 5 2 3 4 5 6 8 Q ...

Page 116: ... seating ring Vent line Minimum water level values see diagram on the next page Approach flow Flow straightening vane ð Section 9 5 7 Page 119 Not pressure proof Connect the discharge line to the discharge tube without transmitting any stresses or strains Table 52 Dimensions mm Size D DN2 min DN2 max a a1 a2 b b1 b2 d7 d8 d10 800 535 813 500 800 700 960 710 1500 300 600 720 840 885 850 535 868 500...

Page 117: ... 450 750 325 1500 1030 1260 960 1060 380 2800 570 850 535 450 750 325 1500 1080 1310 1010 1110 380 3250 570 850 550 450 750 375 1500 1080 1310 1010 1110 380 3250 570 900 600 450 750 415 1500 1130 1360 1060 1160 380 3200 570 900 615 520 900 420 1800 1130 1360 1060 1160 440 3200 660 900 620 415 625 365 1250 1130 1360 1060 1160 320 3200 470 1000 600 450 750 415 1500 1240 1500 1160 1260 380 3650 570 1...

Page 118: ... 600 mm DN2 700 mm DN2 800 mm DN2 900 mm DN2 1000 mm DN2 1100 mm DN2 1200 mm DN2 1300 mm DN2 1400 mm DN2 1500 mm DN2 1600 mm Calculation formulas H Hgeo Hv Hv Loss in the elbow hV Kr see diagram Loss in the riser pipe friction HV System valves etc HV System must be determined for the specific system Minimum water level diagram Covered chamber 4000 3000 2500 1600 1200 1000 900 800 700 600 500 400 0...

Page 119: ... of the intake chamber should be designed as a rough concrete surface Rough surfaces minimise the separation of boundary layers that may cause wall and floor vortices Flow straightening vane and intake chamber The anti swirl baffles in the bellmouth must be aligned with the flow straightening vane The bail of the pump is oriented in the same direction as the anti swirl baffles in the bellmouth 1 2...

Page 120: ...525 750 1100 1350 850 550 230 10 25 90 525 750 1100 1350 900 600 230 10 25 90 550 750 1200 1500 900 615 265 12 25 100 550 750 1300 1500 900 620 190 10 20 70 550 620 1050 1150 1000 600 230 10 25 90 600 750 1200 1500 1000 615 265 12 25 100 600 750 1300 1500 1000 620 190 10 20 70 600 620 1150 1150 1000 655 265 12 25 100 600 850 1300 1500 1300 820 335 12 30 120 750 1000 1625 1875 Installation types BG...

Page 121: ...Size hR sR s1 s2 800 535 230 10 25 90 850 535 230 10 25 90 850 550 230 10 25 90 900 600 230 10 25 90 900 615 265 12 25 100 900 620 190 10 20 70 1000 600 230 10 25 90 1000 615 265 12 25 100 1000 620 190 10 20 70 1000 655 265 12 25 100 1300 820 335 12 30 120 ...

Page 122: ...ations 2012 The manufacturer also declares that the following harmonised international standards32 have been applied ISO 12100 EN 809 EN 60034 1 EN 60034 5 A1 Person authorised to compile the technical file Name Function Address company Address street No Address post or ZIP code city country The UK Declaration of Conformity was issued in on Place date 33 Name Function Company Address 31 Where appl...

Page 123: ...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 stator...

Page 124: ...llation at site 23 Intended use 9 Interference immunity 38 K Key to safety symbols markings 8 L Leakage monitoring 40 Level control system 37 Lubricant Quantity 58 Lubricating liquid 57 M Maintenance 51 Mechanical seal leakage 40 O Operation on a frequency inverter 38 46 Order number 7 Other applicable documents 7 Overload protection 37 P Partly completed machinery 7 Preservation 15 Product descri...

Page 125: ......

Page 126: ...KSB SE Co KGaA Johann Klein Straße 9 67227 Frankenthal Germany Tel 49 6233 86 0 www ksb com 1589 837 01 EN 05152100 ...

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