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KSB UPAchrom CC, Installation & Operating Manual

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KSB UPAchrom CC Installation & Operating Manual Download Page 30

6 Commissioning/Start-up/Shutdown

30 of 44

UPAchrom

NOTE

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

ü

The pump set has been assembled as described in this manual.

ü

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

ü

The power cables, control cables and measuring cables have been fastened and
connected in the switchgear.

ü

The switchgear and protective equipment have been installed and set properly.

ü

The pump set is completely submerged or flooded.

1.

Slightly open 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.

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.

▷

Control

 the fluid backflow, e.g. by throttling the gate valve in the discharge

line.

For 

single-phase a.c. units

 the direction of rotation is fixed and cannot be changed.

For 

three-phase units

, check the direction of rotation as described below:

ü

The back-up name plate is attached at the place of installation of the
submersible borehole pump.

ü

The pump set has been installed completely and is sufficiently covered by the
fluid to be handled.

 (

ð

 Section 6.2.6.1, Page 31)

ü

The power supply cable and the measuring and control cables, if any, are
connected to the control cabinet.

ü

The shut-off valve in the discharge line has been closed.

1.

Switch on the motor at the control cabinet.

2.

Read the pressure on the pressure gauge.

3.

Switch off the motor and interchange two phases of the power cable in the
control cabinet.

4.

Start up the motor and read the pressure at the pressure gauge.

5.

Switch off the motor.

ð

The higher reading at the pressure gauge indicates the correct direction of
rotation.

ð

On pumps with free discharge, the correct direction of rotation is indicated
by the greater water volume produced, in fountains by the higher jet.

6.

Wire the motor for the correct result.

Summary of Contents for UPAchrom CC

Page 1: ...Submersible Borehole Pump UPAchrom Installation Operating Manual ...

Page 2: ...ents 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 01 2018 ...

Page 3: ...as per Regulation No 547 2012 for 4 and 6 water pumps implementing Ecodesign Directive 2009 125 EC 14 4 3 Designation 14 4 4 Name plate 15 4 5 Design details 15 4 6 Configuration and function 16 4 7 Scope of supply 16 4 8 Dimensions and weights 17 5 Installation at Site 18 5 1 Checks to be carried out prior to installation 18 5 1 1 Checking the motor fill 18 5 1 2 Checking the installation positio...

Page 4: ... content 32 6 2 6 3 Temperature of the fluid handled 32 6 3 Shutdown 33 7 Servicing inspection 34 7 1 Servicing inspection 34 8 Trouble shooting 35 9 Related Documents 37 9 1 General assembly drawing of UPAchrom CC 37 9 2 General assembly drawing of UPAchrom CN 38 9 3 General assembly drawing of motor DN 100 39 10 EU Declaration of Conformity 40 11 Certificate of Decontamination 41 Index 42 ...

Page 5: ... 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 ...

Page 6: ...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 Drawing of auxiliary connections Description of auxiliary connections Hydraulic characteristic curve Characteristic curves showing head NPSH required efficiency and power i...

Page 7: ...1 General 7 of 44 UPAchrom Symbol Description 1 2 Step by step instructions Note Recommendations and important information on how to handle the product ...

Page 8: ...hine damage In conjunction with the signal word CAUTION this symbol indicates a hazard for the machine and its functions 2 2 General This operating manual contains general installation operating and maintenance instructions that must be observed to ensure safe operation of the system and prevent personal injury and damage to property The safety information in all sections of this manual must be co...

Page 9: ...nstall 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 oper...

Page 10: ...can invalidate any liability of the manufacturer for resulting damage The operator ensures that maintenance inspection and installation is performed by authorised qualified specialist personnel who are thoroughly familiar with the manual Only carry out work on the pump set during standstill of the pump The pump casing must have cooled down to ambient temperature The maximum length of the riser is ...

Page 11: ...count the unequal weight distribution between pump and motor Select hoisting tackles suitable for the weight of the pump set Take care not to bend or damage the power supply cable during transport 3 3 Storage handling preservation If commissioning is to take place some time after delivery we recommend that the following measures be taken WARNING Pump set tilting or rolling off Risk of personal inj...

Page 12: ...y environment 4 Protected against direct sunlight and heat 5 Protected against dirt and dust 6 Protected against freezing 7 Protected against vermin 3 4 Return to supplier 1 Drain the pump as per operating instructions 2 Always flush and clean the pump particularly if it has been used for handling noxious explosive hot or other hazardous fluids 3 If the pump set has handled fluids whose residues c...

Page 13: ...luid 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 1 Dismantle the pump set Collect greases and other lubricants during dismantling 2 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 r...

Page 14: ...ciency of a pump with a trimmed impeller is usually lower than that of a pump with full impeller diameter Trimming of the impeller will adapt the pump to a fixed duty point leading to reduced energy consumption The minimum efficiency index MEI is based on the full impeller diameter Operation of this water pump with variable duty points may be more efficient and economic when controlled for example...

Page 15: ... Order number 2 Minimum efficiency index 3 Pump designation 4 Efficiency see data sheet 5 Minimum flow rate 6 Maximum flow rate 7 Flow rate at duty point 8 Motor designation 9 Rated power 10 Electrical voltage 11 Frequency 12 Weight 13 Maximum fluid temperature 14 Minimum available flow velocity past the motor 15 Year of construction 16 Material number 17 Maximum head 18 Minimum head 19 Head at du...

Page 16: ... 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 lift check valve 6 to the connection branch 7 where it leaves the pump The integrated lift che...

Page 17: ...luded 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 4 8 Dimensions and weights For dimensions and weights please refer to the data sheet of the pump set ...

Page 18: ...ischarge side The pump set can be installed in a vertical or depending on the number of stages also in an angled or horizontal position The pump set must not be installed with the pump as the lowest point A B Fig 3 Installation position A Permitted B Not permitted Particularities of horizontal installation Check the following criteria before installing the pump set in a horizontal position Has the...

Page 19: ...ed 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 freely exposed to air and in contact with surfa...

Page 20: ... W1 1 U1 2 V1 2 W1 2 5 1 4 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 ...

Page 21: ...es 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 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 CAUTIO...

Page 22: ...ions This can be done for example by inserting a pipe of the same outer diameter as the pump set Remove this pipe before starting with the installation Always observe the instructions of the pipe supplier If the pump is to be installed with plastic risers the pump set can be lowered and held in position with two suitably thick rust proof wires attached to the body of the lift check valve Lowering ...

Page 23: ...en well reservoir tank Suitably fence off the work area 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 indi...

Page 24: ... pipe Positioning the pump set ü The tank or well have been prepared in accordance with the instructions ü The concrete floor is of sufficient strength ü An extension cable of the specified length has been connected to the power cable 1 Arrange the pedestals in accordance with the general arrangement drawing and fasten them to the foundation with the foundation bolts anchor bolts etc provided by t...

Page 25: ...star delta contactor autotransformer and starting resistors Star delta contactor The Y phase or partial voltage period shall not exceed 4 s The switchover interval from Y to Δ must not be longer than 60 ms Additional delays are not permitted Starting devices Set up the starting devices for automatic operation i e switchover from partial to full voltage must be automatic The partial voltage period ...

Page 26: ...plied by KSB for operation on a frequency inverter see data sheet the motor comes with a 5 power reserve If the submersible borehole pump is retrofitted with a frequency inverter an electrical loss of 5 has to be taken into account To check whether a frequency inverter can be retrofitted always contact the pump manufacturer Maximum permissible run up and run down time The run up time from standsti...

Page 27: ...eld as short as possible and the shield ends having contact over a large area Interruptions of the shield must be compliant with EMC8 Observe the EMC instructions given by the equipment manufacturers Connecting single phase 1 motors For this motor type a starting device is required The starting device is included in the scope of supply 1 2 4 5 1 L N 3 L N BK SW BN BR BU BL a b c PE Circuit diagram...

Page 28: ...PAchrom L1 L2 L3 U V W PE PE 1 2 3 4 5 U V W 3 Fig 8 Circuit diagram three phase 3 motors with one cable for DOL starting 1 Motor 2 Motor cable 3 Core marking 4 Switchgear 5 Phase conductor PE Earth conductor Core marking green yellow ...

Page 29: ... start up make sure that any air contained can escape to the atmosphere CAUTION Starting up the pump set outside the fluid Pump damage and motor damage Only start up the pump set when its motor is filled and the pump set is fully submerged or flooded CAUTION Operation with closed shut off valve Damage to motor and bearings Never let the pump set run against a closed shut off valve for more than fi...

Page 30: ...rolled backflow of the fluid handled with suitable means Control the fluid backflow e g by throttling the gate valve in the discharge line For single phase a c units the direction of rotation is fixed and cannot be changed For three phase units check the direction of rotation as described below ü The back up name plate is attached at the place of installation of the submersible borehole pump ü The...

Page 31: ...d must be limited to one operating hour 6 2 3 Voltage limits Observe the following limits Maximum rate of voltage rise du dt 500 V µs Maximum voltage peaks J1 insulation 600 V 6 2 4 Operation on a frequency inverter Do not operate the pump set outside the permissible frequency range of 30 to 50 Hz 60 Hz 6 2 5 Star point displacement The motors are designed for short time operation with displaced s...

Page 32: ...rizontal installation Measurement for horizontal installation Upper pump edge of suction strainer to lowest dynamic water level 0 5 m Fig 10 Minimum submergence for horizontal installation 6 2 6 2 Sand content Make sure the maximum sand content of 50 g m is not exceeded 6 2 6 3 Temperature of the fluid handled Make sure the maximum water temperature T 30 C is not exceeded NOTE The minimum flow vel...

Page 33: ... Slowly close the shut off element on the discharge side 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 Control the fluid backflow e g by throttling the gate valve in the discharge line 1 Slowly close the shut off element on the discharge side 2 Switch off the motor immediately after closin...

Page 34: ...e fluid handled Change in current consumption Change in head flow rate Change in frequency of starts Increase in noise and vibration levels The submersible borehole pump need not be removed from the well tank regularly for inspection For any queries and repeat orders particularly when ordering spare parts specify the following information given on the name plate Pump and or motor type series and s...

Page 35: ...ut off element accordingly Deposits in the impellers Remove deposits Contact the manufacturer Wrong direction of rotation three phase units Interchange two of the phases of the power cable Wear of internal components Replace worn components by new ones Contact the manufacturer Two phase operation Replace defective fuse Check cable connections No power supply Check electrical installation Inform el...

Page 36: ... too low Check electrical voltage and increase if necessary Contact the manufacturer 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 the manufacturer ...

Page 37: ...ble 8 List of components of UPAchrom CC Part No Description Part No Description 106 Suction casing 52 4 Locking sleeve 107 Discharge casing 545 Bearing bush 108 Stage casing 550 Disc 143 Suction strainer 825 Cable guard 171 Diffuser 840 Coupling 211 Pump shaft 917 Metal strap 230 Impeller 920 Nut 317 Counter thrust bearing 922 Impeller nut 512 Wear ring ...

Page 38: ... 9 List of components of UPAchrom CN Part No Description Part No Description 10 6 Pump shroud 382 Bearing carrier 106 Suction casing 412 O ring 107 Discharge casing 529 Bearing sleeve 108 Stage casing 545 Bearing bush 143 Suction strainer 752 Valve seat 171 Diffuser 759 Valve disc 211 Pump shaft with coupling 825 Cable guard 230 Impeller ...

Page 39: ...le of a DN 100 motor 3 0 kW Table 10 List of components DN 100 Part No Description Part No Description 59 12 Diaphragm 412 O ring 81 2 Plug 421 Lip seal 81 59 Stator 540 Bush 160 51 52 53 Cover 545 Bearing bush 271 Sand guard 550 51 52 53 Disc 382 51 52 Bearing carrier 745 Filter 384 Thrust collar 818 Rotor 387 Thrust bearing segment 900 Screw 389 Counter thrust bearing ring 902 Stud 392 51 52 Bea...

Page 40: ...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 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 EU Declaration of Conformity was issued in on Place date 10 Name Func...

Page 41: ...in 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 space has been examined for f...

Page 42: ...ion 14 Disposal 13 F Faults Causes and remedies 35 I Impeller type 15 Intended use 8 M Misuse 9 O Operation on a frequency inverter 31 Order number 6 Other applicable documents 6 P Partly completed machinery 6 Product description 14 R Return to supplier 12 S Safety 8 Safety awareness 9 Scope of supply 16 Shaft seal 15 ...

Page 43: ......

Page 44: ...KSB SE Co KGaA Johann Klein Straße 9 67227 Frankenthal Germany Tel 49 6233 86 0 www ksb com 3412 81 02 EN ...

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