KSB Amacan S Series Bedienungsanleitung

Submersible Pump in Discharge Tube

Amacan S

Amacan S 650 - 364

Amacan S 650 - 365

Amacan S 650 - 404

Amacan S 650 - 405

Amacan S 800 - 505

Installation/Operating Manual

Mat. No.: 01350210

Legal information/Copyright

Installation/Operating Manual Amacan S

Original operating manual

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.

Contents

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 .....................................................................................................7

2.1 Key to safety symbols/markings ....................................................................... 7

2.2 General .............................................................................................................. 7

2.3 Intended use .....................................................................................................7

2.4 Personnel qualification and training ............................................................... 8

2.5 Consequences and risks caused by non-compliance with this manual ......... 8

2.6 Safety awareness ..............................................................................................8

2.7 Safety information for the operator/user ....................................................... 9

2.8 Safety information for maintenance, inspection and installation work ....... 9

2.9 Unauthorised modes of operation .................................................................. 9

3 Transport/Temporary Storage/Disposal .............................................10

3.1 Checking the condition upon delivery .......................................................... 10

3.2 Transport ......................................................................................................... 10

3.3 Storage/preservation ...................................................................................... 14

3.4 Return to supplier ........................................................................................... 14

3.5 Disposal ...........................................................................................................15

4 Description of the Pump (Set) ............................................................16

4.1 General description ........................................................................................ 16

4.2 Designation ..................................................................................................... 16

4.3 Name plate ...................................................................................................... 16

4.4 Design details .................................................................................................. 17

4.5 Installation types ............................................................................................17

4.6 Configuration and function ........................................................................... 19

4.7 Scope of supply ............................................................................................... 20

4.8 Dimensions and weights ................................................................................20

5 Installation at Site ...............................................................................21

5.1 Safety regulations ........................................................................................... 21

5.2 Checks to be carried out prior to installation ............................................... 21

5.3 Lowering the pump set into the discharge tube .......................................... 23

5.4 Electrical system .............................................................................................. 29

6 Commissioning/Start-up/Shutdown ...................................................35

6.1 Commissioning/start-up ................................................................................. 35

Contents

Amacan S 3 of 100

6.2 Operating limits .............................................................................................. 36

6.3 Shutdown/storage/preservation .................................................................... 37

6.4 Returning to service .......................................................................................38

7 Servicing/Maintenance .......................................................................40

7.1 Safety regulations ........................................................................................... 40

7.2 Maintenance/inspection ................................................................................. 40

7.3 Removing the pump set ................................................................................. 43

7.4 Lubrication and lubricant change ................................................................. 46

7.5 Dismantling the pump set .............................................................................. 51

7.6 Reassembling the pump set ........................................................................... 56

7.7 Checking the electrical connection and motor ............................................. 65

7.8 Tightening torques ......................................................................................... 65

7.9 Spare parts stock ............................................................................................. 66

8 Trouble-shooting ................................................................................67

9 Related Documents ............................................................................68

9.1 General assembly drawing of pump sets with UAG motors (DKA motor) .. 68

9.2 Cable guide ..................................................................................................... 71

9.3 Wiring diagrams ............................................................................................. 72

9.4 Dimensions ...................................................................................................... 75

9.5 General arrangement drawings .................................................................... 77

10 EC Declaration of Conformity ............................................................97

11 Certificate of Decontamination .........................................................98

Index ....................................................................................................99

Contents

4 of 100 Amacan S

Glossary

Certificate of decontamination

A 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.

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

Glossary

Amacan S 5 of 100

1 General

1.1 Principles

This manual is supplied as an integral part of the type series and variants indicated

on the front cover. It 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, contact your nearest KSB service centre immediately 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 2.4 Page 8)

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 set

Sub-supplier product literature1) Operating manuals and other product literature

describing accessories and integrated machinery

components

Spare parts lists1) Description of spare parts

For accessories and/or integrated machinery components observe the relevant

manufacturer's product literature.

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

1) If agreed to be included in the scope of supply

1 General

6 of 100 Amacan S

2 Safety

All the information contained in this section refers to hazardous situations.

2.1 Key to safety symbols/markings

Table 3: 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

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 pumps/pump sets which are in perfect technical condition.

▪Do not operate partially assembled pumps/pump sets.

▪Only use the pump to handle the fluids specified in the data sheet or product

literature of the respective design variant.

▪Never operate the pump without the fluid to be handled.

!DANGER

2 Safety

Amacan S 7 of 100

▪Observe the limits for continuous operation specified in the data sheet or

product literature (Qmin2) and Qmax3)) (to prevent damage such as shaft fracture,

bearing failure, damaged mechanical seal, etc).

▪Observe the information on the maximum flow rates provided in the data sheet

or product literature (to prevent overheating, cavitation damage, bearing

damage, etc).

▪Consult the manufacturer about any use or mode of operation not described in

the data sheet or product literature.

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.

Training on the pump (set) must always be supervised by technical specialist

personnel.

2.5 Consequences and risks caused by non-compliance with this manual

▪Non-compliance with this operating manual 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) Minimum permissible flow rate

3) Maximum permissible flow rate

2 Safety

8 of 100 Amacan S

2.7 Safety information for the operator/user

▪The operator shall fit contact guards for hot, cold and moving parts and check

that the guards function properly.

▪Do not remove any contact guards during operation.

▪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 37)

▪Decontaminate pumps which handle fluids posing a health hazard.

▪As soon as the work has been 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 35)

2.9 Unauthorised modes of operation

Never operate the pump (set) outside the limits stated in the data sheet and in this

manual.

The warranty relating to the operating reliability and safety of the supplied pump

(set) is only valid if the equipment is used in accordance with its intended use.

2 Safety

Amacan S 9 of 100

3 Transport/Temporary Storage/Disposal

3.1 Checking the condition upon delivery

1. On transfer of goods, check each packaging unit for damage.

2. In the event of in-transit damage, assess the exact damage, document it and

notify KSB or the supplying dealer (as applicable) and the insurer about the

damage in writing immediately.

3.2 Transport

DANGER

Improper transport

Danger to life from falling parts!

Damage to the pump set!

▷Use the attachment point provided (eyebolt, lifting lug or bail) for attaching

lifting accessories.

▷Never suspend the pump set by its power cable.

▷Never use the lifting ropes included in KSB's scope of supply for lifting loads

other than the KSB product supplied.

▷Securely attach the lifting ropes to the pump and crane.

3.2.1 Transporting the delivered pump set to the place of installation

Fig. 1: Transporting the delivered pump set to the place of installation

▪The pump set is supplied in horizontal position in a suitable saddle-shaped

holder.

▪Use suitable hoisting tackle to transport the pump set in its original packaging to

its place of installation.

Note the marked centres of gravity and/or attachment points on the transport

boxes!

For the weight refer to the name plate or data sheet.

3.2.2 Placing the pump set in vertical or horizontal position

WARNING

Pump set tipping over

Risk of squashing hands and feet!

▷Suspend or support the pump set.

3 Transport/Temporary Storage/Disposal

10 of 100 Amacan S

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