Submersible Motor Pump Ama-Porter Installation/Operating Manual Legal information/Copyright Installation/Operating Manual Ama-Porter Original operating manual KSB Aktiengesellschaft All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited or processed for any other purpose, nor otherwise transmitted, published or made available to a third party without KSB's express written consent. Subject to technical modification without prior notice. © KSB Aktiengesellschaft Frankenthal 12.02.2013 Contents Contents Glossary .................................................................................................5 1 General..................................................................................................6 1.1 Principles ...........................................................................................................6 1.2 Installation of partly completed machinery....................................................6 1.3 Target group.....................................................................................................6 1.4 Other applicable documents............................................................................6 1.5 Symbols .............................................................................................................6 2 Safety.....................................................................................................8 2.1 Key to safety symbols/markings.......................................................................8 2.2 General..............................................................................................................8 2.3 Intended use .....................................................................................................8 2.4 Personnel qualification and training...............................................................9 2.5 Consequences and risks caused by non-compliance with these operating instructions......................................................................................................10 2.6 Safety awareness ............................................................................................10 2.7 Safety information for the user/operator.....................................................10 2.8 Safety information for maintenance, inspection and installation work.....10 2.9 Unauthorised modes of operation ................................................................11 3 Transport/Temporary Storage/Disposal.............................................12 3.1 Checking the condition upon delivery..........................................................12 3.2 Transport.........................................................................................................12 3.3 Storage/preservation......................................................................................12 3.4 Return to supplier...........................................................................................13 3.5 Disposal ...........................................................................................................13 4 Description of the Pump (Set)............................................................15 4.1 General description ........................................................................................15 4.2 Designation.....................................................................................................15 4.3 Name plate......................................................................................................15 4.4 Design details..................................................................................................15 4.5 Types of installation .......................................................................................16 4.6 Configuration and function...........................................................................17 4.7 Scope of supply...............................................................................................17 4.8 Dimensions and weights ................................................................................18 5 Installation at Site...............................................................................19 5.1 Safety regulations...........................................................................................19 5.2 Checks to be carried out prior to installation...............................................19 5.3 Installing the pump set ..................................................................................20 5.4 Electrical system..............................................................................................26 Ama-Porter 3 of 54 Contents 6 Commissioning/Start-up/Shutdown ...................................................30 6.1 Commissioning/start-up .................................................................................30 6.2 Operating limits..............................................................................................31 6.3 Shutdown/storage/preservation ....................................................................32 6.4 Returning to service .......................................................................................32 7 Servicing/Maintenance .......................................................................34 7.1 Safety regulations...........................................................................................34 7.2 Servicing/inspection........................................................................................35 7.3 Drainage/cleaning ..........................................................................................38 7.4 Dismantling the pump set..............................................................................38 7.5 Reassembling the pump set...........................................................................40 7.6 Bolt tightening torques..................................................................................42 7.7 Spare parts stock.............................................................................................42 8 Trouble-shooting................................................................................44 9 Related Documents ............................................................................45 9.1 General assembly drawings with lists of components .................................45 9.2 Exploded views ...............................................................................................47 9.3 Wiring diagram...............................................................................................49 10 EC Declaration of Conformity ............................................................51 11 Certificate of Decontamination.........................................................52 Index....................................................................................................53 4 of 54 Ama-Porter Glossary Glossary Certificate of decontamination has been properly drained to eliminate any environmental and health hazards arising from A certificate of decontamination is enclosed by components in contact with the fluid handled. the customer when returning the product to the manufacturer to certify that the product Hydraulic system The part of the pump in which the kinetic energy is converted into pressure energy Ama-Porter 5 of 54 1 General 1 General 1.1 Principles This manual is supplied as an integral part of the type series and variants indicated on the front cover (for details, please refer to the tables below). Table 1: Variants covered by this manual Sizes Impeller type Material variant G 5__ F G S545 S G 6__ F G The manual describes the proper and safe use of this equipment in all phases of operation. The name plate indicates the type series and size, the main operating data, the order number and the order item number. The order number and order item number uniquely identify the pump (set) and serve as identification for all further business processes. In the event of damage, immediately contact your nearest KSB service centre to maintain the right to claim under warranty. 1.2 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 manual is aimed at the target group of trained and qualified specialist technical personnel.(⇨ Section 2.4 Page 9) 1.4 Other applicable documents Table 2: Overview of other applicable documents Document Contents Data sheet Description of the technical data of the pump (set) General arrangement drawing/ Description of mating and installation dimensions outline drawing for the pump (set), weights Hydraulic characteristic curve Characteristic curves showing head, flow rate, efficiency and power input General assembly drawing1) Sectional drawing of the pump Spare parts lists1) Description of spare parts Supplementary operating e.g. for installation parts for stationary wet manuals1) installation For accessories and/or integrated machinery components observe the relevant manufacturer's product literature. 1.5 Symbols Table 3: Symbols used in this manual Symbol Description ✓ Conditions which need to be fulfilled before proceeding with the step-by-step instructions ⊳ Safety instructions 1) If agreed to be included in the scope of supply 6 of 54 Ama-Porter 1 General Symbol Description ⇨ Result of an action ⇨ Cross-references 1. Step-by-step instructions 2. Note Recommendations and important information on how to handle the product Ama-Porter 7 of 54 2 Safety 2 Safety All the information contained in this section refers to hazardous situations. DANGER ! 2.1 Key to safety symbols/markings Table 4: Definition of safety symbols/markings Symbol Description DANGER ! DANGER This signal word indicates a high-risk hazard which, if not avoided, will result in death or serious injury. WARNING ! WARNING This signal word indicates a medium-risk hazard which, if not avoided, could result in death or serious injury. CAUTION CAUTION This signal word indicates a hazard which, if not avoided, could result in damage to the machine and its functions. General hazard In conjunction with one of the signal words this symbol indicates a hazard which will or could result in death or serious injury. Electrical hazard In conjunction with one of the signal words this symbol indicates a hazard involving electrical voltage and identifies information about protection against electrical voltage. Machine damage In conjunction with the signal word CAUTION this symbol indicates a hazard for the machine and its functions. 2.2 General This manual contains general installation, operating and maintenance instructions that must be observed to ensure safe pump operation and prevent personal injury and damage to property. The safety information in all sections of this manual must be complied with. This manual must be read and completely understood by the specialist personnel/ operators responsible prior to installation and commissioning. The contents of this manual must be available to the specialist personnel at the site at all times. Information attached directly to the pump must always be complied with and be kept in a perfectly legible condition at all times. This applies to, for example: ▪ Arrow indicating the direction of rotation ▪ Markings for connections ▪ Name plate The operator is responsible for ensuring compliance with all local regulations not taken into account in this manual. 2.3 Intended use The pump (set) must only be operated within the operating limits described in the other applicable documents. ▪ Only operate pump sets which are in perfect technical condition. ▪ Do not operate partially assembled pump sets. ▪ Only use the pump set to handle the fluids described in the data sheet or product literature of the pump model. ▪ Never operate the pump set without the fluid to be handled. 8 of 54 Ama-Porter 2 Safety ▪ Observe the limits for continuous operation specified in the data sheet or product literature (Q 2) and Q 3)) (to prevent damage such as shaft fracture, min max bearing failure, mechanical seal damage, etc). ▪ When untreated waste water is handled the duty points in continuous operation lie within 0.7 to 1.2 x Q 4) to minimise the risk of clogging/hardening. opt ▪ Avoid duty points for continuous operation at very low speeds and small flow rates (<0.7 x Q 4)). opt ▪ Observe the maximum flow rates indicated in the data sheet or product literature (to prevent overheating, mechanical seal damage, cavitation damage, bearing damage, etc). ▪ Do not throttle the flow rate on the suction side of the pump set (to prevent cavitation damage). ▪ Consult the manufacturer about any use or mode of operation not described in the data sheet or product literature. ▪ The pump set must only be used in the following applications: Impeller with cutter Ama-Porter S545 (three- phase) Impeller with cutter Ama-Porter SB545 (single-phase) Impeller type F Suitable for intermittent operation handling the following fluids: rainwater, surface water (car parks, wash water), drainage, drainage of pump sumps. Waste water containing solid particles and long fibres as well as fluids containing air or gas. Prevention of foreseeable misuse ▪ Observe the minimum flow velocities required to fully open the swing check valves to prevent the reduction of pressure and risk of clogging. (Contact the manufacturer for the required minimum flow velocities/loss coefficients.) ▪ Never exceed the permissible operating limits specified in the data sheet and in the product literature regarding pressure, temperature, etc. ▪ Observe all safety information and instructions in this manual. 2.4 Personnel qualification and training All personnel involved must be fully qualified to transport, install, operate, maintain and inspect the machinery this manual refers to. The responsibilities, competence and supervision of all personnel involved in transport, installation, operation, maintenance and inspection must be clearly defined by the operator. Deficits in knowledge must be rectified by means of training and instruction provided by sufficiently trained specialist personnel. If required, the operator can commission the manufacturer/supplier to train the personnel. 2) Minimum permissible flow rate 3) Maximum permissible flow rate 4) Best efficiency point Ama-Porter 9 of 54 2 Safety Training on the pump (set) must always be supervised by technical specialist personnel. 2.5 Consequences and risks caused by non-compliance with these operating instructions ▪ Non-compliance with these operating instructions will lead to forfeiture of warranty cover and of any and all rights to claims for damages. ▪ Non-compliance can, for example, have the following consequences: – Hazards to persons due to electrical, thermal, mechanical and chemical effects and explosions – Failure of important product functions – Failure of prescribed maintenance and servicing practices – Hazard to the environment due to leakage of hazardous substances 2.6 Safety awareness In addition to the safety information contained in this manual and the intended use, the following safety regulations shall be complied with: ▪ Accident prevention, health and safety regulations ▪ Explosion protection regulations ▪ Safety regulations for handling hazardous substances ▪ Applicable standards and laws 2.7 Safety information for the user/operator ▪ Provide the personnel with protective equipment and make sure it is used. ▪ Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g. explosive, toxic, hot) so as to avoid any danger to persons and the environment. Adhere to all relevant laws. ▪ Eliminate all electrical hazards. (In this respect refer to the applicable national safety regulations and/or regulations issued by the local energy supply companies.) ▪ If shutting down the pump does not increase potential risk, fit an emergency- stop control device in the immediate vicinity of the pump (set) during pump set installation. 2.8 Safety information for maintenance, inspection and installation work ▪ Modifications or alterations of the pump are only permitted with the manufacturer's prior consent. ▪ Use only original spare parts or parts authorised by the manufacturer. The use of other parts can invalidate any liability of the manufacturer for resulting damage. ▪ The operator ensures that all maintenance, inspection and installation work is performed by authorised, qualified specialist personnel who are thoroughly familiar with the manual. ▪ Only carry out work on the pump (set) during standstill of the pump. ▪ The pump casing must have cooled down to ambient temperature. ▪ Pump pressure must have been released and the pump must have been drained. ▪ When taking the pump set out of service always adhere to the procedure described in the manual.(⇨ Section 6.3 Page 32) ▪ Decontaminate pumps which handle fluids posing a health hazard. ▪ As soon as the work is completed, re-install and/or re-activate any safety-relevant and protective devices. Before returning the product to service, observe all instructions on commissioning.(⇨ Section 6.1 Page 30) 10 of 54 Ama-Porter