Submersible motor pumps45).pdf · 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

Submersible motor pumps

S 100D; UPA 100C

Installation/OperatingManual

Legal information/Copyright Installation/Operating Manual S 100D; UPA 100COriginal operating manual KSB Aktiengesellschaft All rights reserved. Contents provided herein must neither be distributed, copied, reproduced, editedor processed for any other purpose, nor otherwise transmitted, published or made available to a thirdparty without KSB´s express written consent. Subject to technical modification without prior notice. © KSB Aktiengesellschaft Frankenthal 21.06.2010

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 operatinginstructions ...................................................................................................... 9

2.6 Safety awareness ............................................................................................. 9

2.7 Safety information for the operator/user .................................................... 10

2.8 Safety information for maintenance, inspection and installation work ... 10

2.9 Unauthorised modes of operation ............................................................... 10

3 Transport/Temporary Storage/Disposal ........................................... 11

3.1 As-delivered condition .................................................................................. 11

3.2 Transportation ............................................................................................... 11

3.3 Storage and preservation ............................................................................. 11

3.4 Return to supplier ......................................................................................... 11

3.5 Disposal .......................................................................................................... 12

4 Description of the Pump (Set) .......................................................... 13

4.1 General description ....................................................................................... 13

4.2 Designation ................................................................................................... 13

4.3 Name plate .................................................................................................... 13

4.4 Design ............................................................................................................ 13

4.5 Design and function ...................................................................................... 14

4.6 Scope of supply ............................................................................................. 14

4.7 Dimensions and weights ............................................................................... 15

5 Installation at Site ............................................................................. 16

5.1 Checks to be carried out prior to installation ............................................. 16

5.2 Installing the pump set in vertical position ................................................. 18

5.3 Installing the pump set in horizontal position ............................................ 20

5.4 Notes on electrical connection .................................................................... 21

5.5 Connection to power supply ........................................................................ 23

Contents

S 100D; UPA 100C 3 of 38

6 Commissioning/Start-up/Shutdown ................................................. 25

6.1 Commissioning/start-up ................................................................................ 25

6.2 Operating limits ............................................................................................ 26

6.3 Shutdown ...................................................................................................... 28

7 Servicing/Maintenance ...................................................................... 29

7.1 Servicing/inspection ...................................................................................... 29

8 Trouble-shooting ............................................................................... 30

9 Related Documents ........................................................................... 31

9.1 S 100D general assembly drawing ............................................................... 31

9.2 UPA 100C general assembly drawing ......................................................... 32

9.3 General assembly drawing DN 100 .............................................................. 33

10 EC Declaration of Conformity .......................................................... 34

11 Certificate of Decontamination ....................................................... 35

Index .................................................................................................. 36

Contents

4 of 38 S 100D; UPA 100C

Glossary

Certificate of decontaminationA certificate of decontamination certifies thatthe pump (set) has been properly drained to

eliminate any environmental and healthhazards arising from components in contactwith the fluid handled.

Glossary

S 100D; UPA 100C 5 of 38

1 General

1.1 Principles

This manual is supplied as an integral part of the type series indicated on the frontcover. It describes the proper and safe use of this equipment in all phases ofoperation.

The name plate indicates the type series, the main operating data, the order numberand the order item number. The order number and order item number clearlyidentify the pump and serve as identification for all further business processes.

In the event of damage, immediately contact your nearest KSB service centre tomaintain 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-sectionsunder Servicing/Maintenance.

1.3 Target group

This manual is aimed at the target group of trained and qualified specialist technicalpersonnel. (⇨ Section 2.4 Page 9)

1.4 Other applicable documents

Table 1: Overview of other applicable documents

Document ContentsData sheet Description of the technical data of the pump

(set)General arrangement drawing/Outline drawing

Description of mating and installation dimensionsfor the pump (set)

Drawing of auxiliary connections Description of auxiliary connectionsHydraulic characteristic curve Characteristic curves showing head, NPSH

required, efficiency and power inputGeneral assembly drawing1) Sectional drawing of the pump

Sub-supplier product literature1) Operating manuals and other product literatureof accessories and integrated machinerycomponents

Spare parts lists1) Description of spare parts

Piping layout1) Description of auxiliary piping

List of components1) Description of all pump components

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

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

1 General

6 of 38 S 100D; UPA 100C

Symbol Description1.

2.

Step-by-step instructions

NoteRecommendations and important information on how to handlethe product

1 General

S 100D; UPA 100C 7 of 38

2 SafetyAll 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 DANGERThis signal word indicates a high-risk hazard which, if not avoided,will result in death or serious injury.

! WARNING WARNINGThis signal word indicates a medium-risk hazard which, if notavoided, could result in death or serious injury.

CAUTION CAUTIONThis signal word indicates a hazard which, if not avoided, couldresult in damage to the machine and its functions.Explosion protectionThis symbol identifies information about avoiding explosions inpotentially explosive atmospheres in accordance with EC Directive94/9/EC (ATEX).General hazardIn conjunction with one of the signal words this symbol indicates ahazard which will or could result in death or serious injury.

Electrical hazardIn conjunction with one of the signal words this symbol indicates ahazard involving electrical voltage and identifies informationabout protection against electrical voltage.Machine damage In conjunction with the signal word CAUTION this symbol indicatesa hazard for the machine and its functions.

2.2 General

This manual contains general installation, operating and maintenance instructionsthat must be observed to ensure safe pump operation and prevent personal injuryand 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 responsible specialistpersonnel/operators prior to installation and commissioning.

The contents of this manual must be available to the specialist personnel at the siteat all times.

Information attached directly to the pump must always be complied with and bekept 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 whichare not taken into account in this manual.

2.3 Intended use

The pump (set) must only be operated within the operating limits which aredescribed in the other applicable documents.

▪ Only operate pumps/pump sets which are in perfect technical condition.

▪ Do not operate partially assembled pumps/pump sets.

! DANGER

2 Safety

8 of 38 S 100D; UPA 100C

▪ Only use the pump to handle the fluids specified in the data sheet or productliterature of the respective design variant.

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

▪ Observe the minimum flow rates indicated in the data sheet or product literature(to prevent overheating, bearing damage, etc).

▪ Observe the maximum flow rates indicated in the data sheet or productliterature (to prevent overheating, mechanical seal damage, cavitation damage,bearing damage, etc).

▪ Do not throttle the flow rate on the suction side of the pump (to preventcavitation damage).

▪ Consult the manufacturer about any use or mode of operation not described inthe data sheet or product literature.

Prevention of foreseeable misuse

▪ Never open discharge-side shut-off elements further than permitted.

– The maximum flow rate specified in the data sheet or product literaturewould be exceeded.

– Risk of cavitation damage

▪ Never exceed the permissible operating limits specified in the data sheet orproduct 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 install, operate, maintain andinspect the machinery this manual refers to.

The responsibilities, competence and supervision of all personnel involved ininstallation, operation, maintenance and inspection must be clearly defined by theoperator.

Deficits in knowledge must be rectified by sufficiently trained specialist personneltraining and instructing the personnel who will carry out the respective tasks. Ifrequired, the operator can commission the manufacturer/supplier to train thepersonnel.

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

2.5 Consequences and risks caused by non-compliance with these operatinginstructions

▪ Non-compliance with these operating instructions will lead to forfeiture ofwarranty 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 chemicaleffects 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

2 Safety

S 100D; UPA 100C 9 of 38

▪ Safety regulations for handling hazardous substances

▪ Applicable standards and laws

2.7 Safety information for the operator/user

▪ The operator shall fit contact guards for hot, cold or moving parts and check thatthe guards function properly.

▪ Do not remove any contact guards while the pump is running.

▪ Connect an earth conductor to the metal jacket if the fluid handled iselectrostatically charged.

▪ 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 nationalsafety regulations and/or regulations issued by the local energy supplycompanies.)

2.8 Safety information for maintenance, inspection and installation work

▪ Modifications or alterations of the pump are only permitted with themanufacturer's prior consent.

▪ Use only original spare parts or parts authorised by the manufacturer. The use ofother parts can invalidate any liability of the manufacturer for resulting damage.

▪ The operator ensures that all maintenance, inspection and installation work isperformed by authorised, qualified specialist personnel who are thoroughlyfamiliar with the manual.

▪ Carry out work on the pump (set) during standstill only.

▪ 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 proceduredescribed in the manual.

▪ Decontaminate pumps which handle fluids posing a health hazard.

▪ As soon as the work is completed, re-install and/or re-activate any safety-relevantand protective devices. Before returning the product to service, observe allinstructions on commissioning. (⇨ Section 6.1 Page 25)

2.9 Unauthorised modes of operation

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

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. (⇨Section 2.3 Page 8)

2 Safety

10 of 38 S 100D; UPA 100C

3 Transport/Temporary Storage/Disposal

3.1 As-delivered condition

NOTEThe pump set is supplied by the manufacturer/supplier in packaging which usuallyprevents sagging or other damage during transport and/or storage.We recommend inspecting the pump set for any in-transit damage. If there are anycomplaints or objections, the recipient and carrier must jointly draw up a damage report.

3.2 Transportation

CAUTIONPump set tipping over or slipping out of the suspension arrangementPersonal injury and damage to property!

▷ Always make sure pump sets in upright position cannot tip over.

NOTETake into account 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 and preservation

If commissioning is to take place some time after delivery, we recommend that thefollowing measures be taken for storage:

CAUTIONPump set tipping over or slipping out of the suspension arrangementPersonal injury and damage to property!

▷ Always make sure pump sets in upright position cannot tip over.

CAUTIONImproper storageDamage to the power cables!

▷ Support the power cables at the cable entry to prevent permanent deformation.

▷ Only remove the protective caps from the power cables at the time ofinstallation.

Store submersible borehole pumps as follows:

1. Horizontally if in its original packaging

2. Vertically if unpacked (motor below)

3. Dry

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.


S 100D; UPA 100C 11 of 38

2. Always flush and clean the pump, particularly if it has been used for handlingnoxious, explosive, hot or other hazardous fluids.

3. If the fluids handled by the pump leave residues which might lead to corrosiondamage when coming into contact with atmospheric humidity, or which mightignite when coming into contact with oxygen, the pump set must also beneutralised, and anhydrous inert gas must be blown through the pump fordrying purposes.

4. Always complete and enclose a certificate of decontamination when returningthe pump (set). (⇨ Section 11 Page 35)It is imperative to indicate any safety and decontamination measures taken.

NOTEIf required, a blank certificate of decontamination can be downloaded from the KSB website at: www.ksb.com/certificate_of_decontamination

Also see• Certificate of decontamination [⇨ 35]

3.5 Disposal

WARNINGFluids posing a health hazardHazardous to persons and the environment!

▷ Collect and properly dispose of flushing liquid 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 regulations or in another controlledmanner.


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http://www.ksb.com/GRAS-Cert

4 Description of the Pump (Set)

4.1 General description

Pump for handling clean or slightly contaminated water.

Composition of fluid see data sheet.

4.2 Designation

Submers ible borehole pumpExample: S 100D - 4 / 6

Table 4: Key to the designation

Code DescriptionS Type series100 Nominal pump size [mm]D Design status4 Flow rate at best efficiency point [m³/h]6 Number of stages

Submers ible borehole pumpExample: UPA 100C 4 - 6

Table 5: Key to the designation

Code DescriptionUPA Type series100 Nominal pump size [mm]C Design status4 Flow rate at best efficiency point [m³/h]6 Number of stages

4.3 Name plate

4.4 Design

Design

▪ Centrifugal pump

▪ Submersible motor in squirrel-cage design

▪ Rigid connection between pump and motor

▪ Outer casing or ring-section design

Impel ler type

▪ Radial or mixed-flow hydraulics

Bear ing in the motor

▪ Thrust bearing with tilting pads to absorb the pump's hydraulic thrust

Shaft seal in the motor

▪ Mechanical seal or shaft seal ring


S 100D; UPA 100C 13 of 38

4.5 Design and function

1

2

3

4

5

6

7

5

Fig. 1: Sectional drawing of example: UPA 100C

Pump and motor are connected by a sleeve coupling. The stage casings are supportedby a pump shroud, by straps or stud bolts. A suction strainer protects the pump fromcoarse particles in the fluid. The pipe is connected via a non-return valve orconnecting branch, with either internal thread or flanged ends.

The fluid runs parallel to the motor and enters the suction casing (2) via the suctionstrainer (1). The suction stage impeller (3) accelerates the flow outwards in acylindrical flow. The flow profile of the stage casing (4) converts the kinetic energy ofthe fluid into pressure energy. The fluid is pumped to the next impeller (5). Thisprocess is repeated for each stage until the fluid reaches the last impeller (5). It thenpasses the integrated non-return valve (6) and leaves the pump via the connectionbranch (7). The integrated non-return valve prevents uncontrolled backflow of thefluid.

4.6 Scope of supply

Depending on the model, the following items are included in the scope of supply:

▪ Pump set with motor lead

▪ Electric extension cableoptional: connected or supplied loosely

▪ Back-up name plate

Design

Function


14 of 38 S 100D; UPA 100C

▪ Accessories, such as:

– Cable connector

– Cable ties

– Cooling shroud

– Pedestals

– Electrical protection devices

– Automatic control units

NOTEA separate name plate is included in KSB's scope of supply.This name plate must be attached in a clearly visible position outside the place ofinstallation, e.g. at the control panel, pipeline or mounting bracket.

4.7 Dimensions and weights

For dimensions and weights please refer to the data sheet of the pump (set).


S 100D; UPA 100C 15 of 38

5 Installation at Site

5.1 Checks to be carried out prior to installation

5.1.1 Checking the motor fill

The pump set can be installed directly in vertical or horizontal 2) position without anyfurther preparations. The motors are filled at the factory with water and antifreezeagent. The loss of a few drops of liquid fill will not impair the motor function as themotor will self-prime with clean well water after it has been installed. If largerquantities of leakage are suspected, contact the manufacturer!

5.1.2 Checking the installation position

WARNINGImpermissible installation positionDamage to the machine! Damage to the bearings!

▷ For angled installation, always install the pump set with the discharge side at arising slope.

The pump set can be installed in vertical or, depending on the number of stages, alsoin angled or horizontal position.Never install the pump set with the pump positioned at the lowest point.

A

B

Fig. 2: Installation position

A Permissible B Impermissible

Notes on horizontal instal lat ion

Only install the pump set in horizontal position if the following criteria are met:

▪ Has the pump set been ordered for horizontal installation?

▪ Has a sufficiently dimensioned cooling jacket or shroud been provided?

Horizontal installation of pump sets which were originally designed for verticalinstallation is impermissible! Horizontal installation of pump sets without a cooling jacket is impermissible.

Horizontal installation is impermissible for pumps with the following number ofstages. See order documentation.

Table 6: Number of stages which are impermissible for horizontal installation

S 100D 1 / .. 2 / .. 4 / .. 7 / .. 12 / ..Number ofstages

25 27 24 23 1730 30 33 28 2135 33 40 33 2540 38 -- -- --

2) Only if equipped with a cooling jacket


16 of 38 S 100D; UPA 100C

S 100D 1 / .. 2 / .. 4 / .. 7 / .. 12 / ..50 44 -- -- ---- 50 -- -- --

5.1.3 Electric wiring

DANGERUnqualified personnel connecting cablesInstallation in a well - electric shock!

▷ The extension cable must be connected by a professional electrician only.

▷ The cable ends must be dry and clean.

If agreed with KSB, the extension lead can be supplied connected to the motor leadwith a watertight cable connector.

▪ Extension leads supplied by KSB are designed for:

– Being laid freely exposed to air

– A voltage drop along the lead of ᅀ U ≦3 %

For any other types of laying the lead, e.g. in cable ducts, etc. observe theinformation on the maximum current-carrying capacity as per the applicabledirectives.

▪ If the extension lead is to be connected at the site, observe the installationinstructions of the accessory "cable connector"!

▪ If the operator is responsible for connecting an extension lead, make sure theextension lead is selected and dimensioned for a maximum voltage drop of ≦3 %.The extension lead has to be approved for the applicable operating conditions.

▪ On shielded extension leads, the shield must be connected at both ends. At themotor lead, the shield must be connected to the earth conductor.

In 4-core cables, the earth conductor is integrated into the power cable. Whenconnecting such an extension lead, the earth conductor is also connected in the cableconnector. If additional earthing is required3) , connect the earth conductor to theoutside of the motor adapter (earthing bolt) in accordance with the applicabledirectives. The operator is responsible for connecting and laying the earth conductor.

5.1.4 Measuring the insulation resistance

It is recommended to measure the insulation resistance prior to installation andconnection to the power supply. Have the insulation resistance measured by atrained electrician with an insulation resistance measuring device of 1000 VDCmeasuring voltage. The contact points must be dry and clean.

Measurement duration: 1 minuteMinimum insulation resistance at 20 °C: > 2 MΩObserve the operating instructions provided by the manufacturer of the measuringdevice!

Extension lead

Earth conductor

3) Potential equalisation


S 100D; UPA 100C 17 of 38

V WU

Risol(MΩ)

M 3~

V1 W1U1

Risol(MΩ)

M 3~

V2 W2U2V1-1 W1-1U1-1

Risol(MΩ)

M 3~

V1-2 W1-2U1-2

1 cable 2 cables (for both star anddelta operation )

2 cables (parallel)

5.2 Installing the pump set in vertical position

WARNINGPersons could fall into unsecured wells/reservoirs/tanksRisk of personal injury!

▷ During installation work, take suitable precautions to protect anyone fromfalling into an open well/reservoir/tank.

▷ Suitably fence off the work area.

DANGERDamaged power cables in the wellElectric shock!

▷ Never bend power cables during installation or drag them over sharp edges.

▷ Use cable ties or other suitable fasteners to fasten the power cables as well asany measuring and control cables to the riser every three meters.

▷ Do not use any tools, equipment or accessories with sharp edges (e.g. sharp-edged pipe sockets) for the installation.

CAUTIONRisk of the pump set falling into the well/reservoir/tankDamage to the pump set!

▷ Secure the pump set during the entire installation procedure.

▷ Dimension any securing devices (supporting clamps, supports, etc.) so that theycan carry all weights during the installation.


18 of 38 S 100D; UPA 100C

1

2

3 4

5

6

Fig. 3: Example of vertical installation

1 Pump set 2 Power cable3 Mains connection 4 Control box5 Well head 6 Riser pipe

Instal lat ion instruct ions

▪ Install the pump set in such a way that it does not sit on the base of the well.

▪ Install the pump set in a way that prevents sand and sludge deposits in the motorarea.

▪ Install the pump set with the suction strainer above the filter.

▪ The use of hemp and hemp paste is recommended for the connection of pumpand piping.

▪ It is recommended to verify the well dimensions. This can be done, for example,by inserting a pipe of the same outer diameter as the pump set. Remove this pipebefore 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 andheld in position with two suitably thick, rust-proof wires attached to the body ofthe swing check valve.

Lowering the pump set into the wel l

✓ The extension lead has been connected to the power cable.

✓ Hoisting tackle designed for the weight of the pump set is on hand.

1. Observe the installation instructions of the pipe suppliers.

2. Lower the pump set into the well.

3. Fasten the electric cable as well as any measuring and control cables to the riserwith suitable fasteners (e.g. cable clips). Attach them every three metres.

1

2

3

4

Fig. 4: Cable clip


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1 Flat cable 2 Riser3 Plastic stud 4 Rubber strap

5.3 Installing the pump set in horizontal position

WARNINGPersons could fall into unsecured wells/reservoirs/tanksRisk of personal injury!

▷ During installation work, take suitable precautions to protect anyone fromfalling into an open well/reservoir/tank.

▷ Suitably fence off the work area.

WARNINGInstallation on foundations which are unsecured and cannot support the loadPersonal injury and damage to property!

▷ Make sure the foundation concrete is of sufficient strength (min. X0 toDIN 1045).

▷ Only place the pump set on a foundation whose concrete has set firmly.

▷ Only place the pump set on a horizontal and level surface.

▷ Refer to the weights given in the general arrangement drawing.

CAUTIONTemperature and pressure increase of the motor fillDamage to the motor!

▷ Always protect non-flooded pump sets against direct exposure to sun.

1 2 3

4 5 6

7

Fig. 5: Example of horizontal installation

1 Cooling jacket 2 Pump set3 Expansion joint 4 Check valve4)

5 Spacer 6 Shut-off valve7 Inlet nozzle

Instal lat ion instruct ions

▪ For horizontal installation, a device guiding the flow along the motor (coolingjacket, shroud, etc.) is required.

▪ For horizontal installation, install the pump set with the venting pointingupwards at an angle.

▪ Lay the pipe in such a way that no piping forces (weights, torsional forces,vibrations, etc.) can act on the pump set. To compensate such forces, we

4) Only for pump sets without check valve.


20 of 38 S 100D; UPA 100C

recommend fitting a tailored expansion joint between the pump set and thepipe.

Posit ioning the pump set

✓ The tank or well have been prepared in accordance with the instructions.

✓ The concrete floor is of sufficient strength.

✓ An extension cable of the specified length has been connected to the powercable.

1. Arrange the pedestals in accordance with the general arrangement drawing andfasten them to the foundation with the foundation bolts, anchor bolts, etc.provided by the operator.

2. Position and fasten the pump set (including cooling jacket) on the pedestals.

3. Fit the expansion joint, if any.

4. Install the piping in accordance with the piping layout. Observe the installationinstructions of the pipe supplier.

5. Fasten the electric cable as well as any measuring and control cables to the pipewith suitable fasteners (e.g. cable clips). Attach them every three metres.

1

2

3

4

Fig. 6: Cable clip

1 Flat cable 2 Riser3 Plastic stud 4 Rubber strap

5.4 Notes on electrical connection

KSB's submersible borehole pumps are generally designed for direct on line starting.

If this starting method is not permitted for the mains, starting devices can be used toreduce starting currents. For example: star-delta contactors (Y-Δ), autotransformersor starting resistors as well as soft starters.

Always observe the following rule:The starting devices must be set up for automatic operation, i.e. switchover from star(Y) to delta (Δ) or from partial to full voltage must be automatic.

General notes on the motor

Motor protectionProvide a temperature-compensated overcurrent relay of tripping class 10 or 10A toprotect the motor. If an earth leakage relay is used, it must be fitted in the motorpower circuit.

RatingThe rating specified on the name plate and in the order confirmation applies tocontinuous operation S1 to VDE 530T1 or IEC 34-1.

NOTEAny conspicuous noises or vibrations during run-up indicate that the soft starter has notbeen set correctly. This includes, for example, excessive ramp times, incorrect operatingmodes (control), activated special functions, etc.

5.4.1 Operation with star-delta contactor, starting transformer and resistor

Operation in the Y-phase or partial voltage period shall not exceed 4 second. Theswitchover interval from Y to Δ must not exceed 60 milisecond. Additional delays are


S 100D; UPA 100C 21 of 38

not permitted. To operate the pump set with a starting transformer or resistor,choose a closed-transition switchover method (Korndorfer connection).

5.4.2 Operation with soft starter

Soft starters electronically reduce the incoming line voltage and, hence, the initialstarting torque and starting current of electric motors. During run-up they gentlyramp up the applied voltage to the motor. Due to their extremely slim design andresulting small moments of inertia, submersible borehole pump motors have anumber of special features which differ considerably from the normal, standardisedasynchronous motor type.

Comply with the following settings:

Table 7: Settings for soft starters

Parameter/Function SettingsMinimum starting voltage 40% of the motor's rated voltageRamp time/acceleration (run-up) time tH < 4 seconds

Current limitation IA / IN approx. 3.5

Deceleration (run-down) time/stop ramp tA < 4 seconds

All special functions, e.g.

▪ Delayed starting

▪ Current control

▪ Speed control

▪ Kick-start/boost function

OFF

1. After the unit has run up to full speed, the soft starter must be bypassed by acontactor.

2. Always observe the manufacturer's instructions.

3. The operation of submersible borehole pumps with soft starters for two-phaseconnection is impermissible!

5.4.3 Pump operation with frequency inverter

If KSB's submersible borehole pumps are operated with a frequency inverter, thepumps' special design (low moment of inertia, high output, etc.) requires that thefollowing points be observed.

Power reserveIf supplied by KSB for operation with a frequency inverter, see data sheet, the motorcomes with a 5 % power reserve. If the submersible borehole pump is retrofittedwith a frequency inverter, an electrical loss of 5 % has to be taken into account. Tocheck whether a frequency inverter can be retrofitted, always contact the pumpmanufacturer!

Maximum permissible acceleration time (start ramp) and deceleration time (stopramp)The acceleration time from standstill to minimum frequency fmin must not exceed 2seconds. Likewise, the deceleration time must not exceed 2 seconds.

Minimum frequencyThe minimum frequency must not be below 30 Hz.

Maximum operating frequencyDo not exceed the maximum operating frequency of 50 Hz or 60 Hz (as applicable).

Maximum permissible rate of voltage rise and voltage peaksObserve the following limits:

▪ Maximum rate of voltage rise: du/dt ≤ 500 V/μs

▪ Maximum peak voltages against earth: J1 insulation ≤ 600 V


22 of 38 S 100D; UPA 100C

NOTECompliance with these limits can usually be assured by means of a sine filter or du/dt filter.

Control principle of the frequency inverterThe control principle of the frequency converter must correspond to linear U/f curvecontrol. If other control principles are employed, such as field-oriented inverters,inverters with DTC or NOF, the manufacturer of the frequency inverter must ensurethat the special requirements of submersible motors (very small moment of inertia,electrical data) are taken into account.

5.5 Connection to power supply

DANGERUnqualified personnel performing work on the pump setDanger of death from electric shock!

▷ Electrical connection must be effected by a trained electrician only.

▷ Observe the regulations stipulated in IEC 30364 (DIN VDE 0100).

WARNINGIncorrect connection to the mainsDamage to the mains network, short circuit!

▷ Observe the technical specifications of the local energy supply companies.

1. Check the available mains voltage against the data on the name plate.

2. Select an appropriate start-up method and observe the respective requirements.

NOTEConnect shielded motor leads with the exposed shield as short as possible and theshield ends having contact over a large area. Interruptions of the shield must becompliant with EMC5) . Observe the EMC instructions of the device manufacturers.

Connect ing s ingle-phase (1~) motors

For this motor type a starting device is required. The starting device is not included inthe scope of supply.

5) Electromagnetic compatibility


S 100D; UPA 100C 23 of 38

1

2

4

5

1~

L N

3

L N BK/SW BN/BRBU/BL

a bcPE

Circuit diagram: Single-phase (1~) motorswith one cable for d.o.l starting

Codes in the starting device

1 = Motor2 = Motor lead3 = Starting device4 = Control box5 = Fuse

L = Phase conductorN = Neutral conductorPE = Earth conductor; core marking:green/yellowa = Core marking: blackb = Core marking: brownc = Core marking: grey (blue)

Connect ing three-phase (3~) motors

The 3 current-carrying conductors are designated U, V, W; the earth conductor isdesignated PE.

L1 L2 L3

U V W PE

PE

1

2

3

4

5

U

V

W

3~

Fig. 7: Circuit diagram: Three-phase (3~) motors with one cable for d.o.l starting

1 Motor 2 Motor lead3 Core marking 4 Control box5 Phase conductor PE Earth conductor

Core marking:(green/yellow)


24 of 38 S 100D; UPA 100C

6 Commissioning/Start-up/Shutdown

6.1 Commissioning/start-up

6.1.1 Start-up

CAUTIONStarting up the pump set outside the fluidDamage to the motor!

▷ Only start up pump sets when the motor is filled and the unit is fully submergedor flooded!

CAUTIONOperation with closed shut-off valveDamage to motor and bearings!

▷ Never let the pump set run against a closed shut-off valve for more than fiveminutes.

CAUTIONContinuous operation against a throttled gate valve

▷ In continuous operation against a throttled gate valve, the flow rate must notfall short of Qmin (see name plate).

✓ The pump set has been assembled as specified in this manual.

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

✓ The power cables, including control and measuring cables, have been fastenedand connected in the control box.

✓ The control box and protective equipment have been installed and set properly.

✓ The pump set is completely submerged or flooded.

1. Close 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.

NOTEIf the pump set is started up against an empty riser, do not close the shut-off elementcompletely to allow air to escape into the riser through the remaining gap.

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

6.1.2 Checking the direction of rotation

CAUTIONWrong direction of rotationDamage to the motor!

▷ Do not run the pump set for more than two minutes when checking thedirection of rotation.


S 100D; UPA 100C 25 of 38

CAUTIONUncontrolled backflow of the fluid from the riserDamage 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 dischargeline.

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:

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

✓ The pump set has been installed completely and is sufficiently covered by thefluid to be handled. (⇨ Section 6.2.2 Page 26)

✓ The power supply cable and the measuring and control cables, if any, areconnected to the control cabinet.

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

1. Switch on the motor at the control cabinet. (⇨ Section 6.1.1 Page 25)

2. Read the pressure on the pressure gauge.

3. Switch off the motor and interchange two phases of the connection cable in thecontrol cabinet.

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

5. Switch off the motor.

⇨ The higher reading at the pressure gauge indicates the correct direction ofrotation.

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

6. Wire the motor for the correct result.

6.2 Operating limits

6.2.1 Switching frequency

To prevent inadmissible heat build-up in the motor, the following max. number ofstart-ups or minimum standstill periods must be complied with:

▪ 20 start-ups per hour

▪ Minimum standstill periods of three minutes

6.2.2 Minimum submergence

Observe the minimum submergence of 0.5 metres.

NOTEThe water level in the well is usually measured with a water level contact meter (welldipper).

Measurement for vertical installation:Upper pump edge to lowest (dynamic) water level. He - Ht ≥ 0.5 metres!

Verticalinstallation


26 of 38 S 100D; UPA 100C

D

T

He

Hh

Ht

Hg

eo

Fig. 8: Minimum submergence for vertical installation

T Well depth Hh Static water level

D Well diameter Ht Dynamic water level

He Installation depth of the pump set Hgeo Height of control box above thestatic water level in the well

Measurement for horizontal installation: Upper pump edge of suction strainer to lowest (dynamic) water level.

0,5

m

Fig. 9: Minimum submergence for horizontal installation

6.2.3 Sand content

Make sure the maximum sand content of 50 g/m³ is not exceeded.

6.2.4 Temperature of the fluid handled

Make sure the maximum water temperature T = + 30 °C is not exceeded.

NOTEThe minimum flow velocity in the motor area has to equal 0.08 m/s. For inner welldiameters >150 mm always install a cooling jacket.

Horizontalinstallation


S 100D; UPA 100C 27 of 38

6.2.5 Frequency inverter operation

Do not operate the pump set outside the permissible frequency range of 30 to 50Hz / 60 Hz.

6.2.6 Voltage limits

Observe the following limits:

▪ Maximum rate of voltage rise du/dt < 500 V/µs.

▪ Maximum voltage peaks - J1 insulation < 600 V.

6.2.7 Supply voltage

Observe the permissible voltage and frequency fluctuations for the values to DIN EN60034-1 section A as indicated on the name plate/in the order confirmation; UN ± 5%,fN ± 2%.

6.2.8 Shifted star point

The motors are designed for short-time operation with shifted star point (t < 1h). Forprolonged operation and U0 > 0.2 x UN, consult the manufacturer.

6.3 Shutdown

CAUTIONUncontrolled backflow of the fluid from the riserDamage 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 dischargeline.

1. Slowly close the shut-off valve in the discharge line.

2. Switch off the motor immediately after closing the shut-off valve.

To make sure that the pump set is always ready for instant start-up, start up thepump set approximately every 2 weeks for approximately 5 minutes duringprolonged shutdown periods.


28 of 38 S 100D; UPA 100C

7 Servicing/Maintenance

7.1 Servicing/inspection

The submersible borehole pumps are generally maintenance-free. In order to pin-point indications of potential damage at an early stage, regular checks are required.Such indications could be:

▪ Temperature rise in the fluid handled

▪ Increased sand content of the fluid handled

▪ Change in power consumption

▪ Change in discharge head/flow rate

▪ Change in frequency of starts

▪ Increase in noise and vibration levels

Regular inspection does not require the submersible borehole pump to be removedfrom the well/tank.

For any queries and repeat orders, particularly when ordering spare parts, pleasespecify the following date (see name plate):

▪ Pump and motor type and size

▪ Operating data

For information concerning repair jobs and spare parts please contact your nearestKSB service centre.

7 Servicing/Maintenance

S 100D; UPA 100C 29 of 38

8 Trouble-shootingPump is running but does not deliver

Pump delivers insufficient flow rate

Insufficient discharge head

Vibrations and noise during pump operation

Unit tripped by overcurrent relay

Fuses have blown

Pump set cannot be started up

Pump set cannot be switched off

Table 8: Trouble-shooting

A B C D E F G H Cause Remedy 6)

X Pump delivers against an excessivelyhigh discharge pressure.

Open the shut-off valve to re-adjust toduty point.

X Pump delivers against an excessivelylow discharge pressure.

Close the shut-off valve to re-adjust toduty point.

X X Deposits in the impellers Remove deposits. Contact KSB.

X X Wrong direction of rotation (in case ofthree-phase, 3 ~)

Interchange two of the phases of thepower supply cable.

X X Wear of internal components Replace worn components by new ones. Contact KSB.

X X Motor is running on two phases only. Replace the defective fuse. Check the electric cable connections.

X X No power supply Check electrical installation.Notify energy supply company.

X X Pump clogged by sand. Clean suction impellers, stage casings andnon-return valve.Contact KSB.

X X X X Motor winding or electric cable aredefective.

Contact KSB.

X X X Defective or clogged riser pipe (pipeand sealing elements).

Replace affected pipes.Replace sealing elements.

X Water level lowered too much duringoperation.

Contact KSB.

X X X Impermissible air or gas content in thefluid.

Contact KSB.

X Mechanical defect on pump or motor Contact KSB. X System-induced vibrations Contact KSB. X X NPSH available (positive suction head)

is too low.Submerge pump deeper.

X X Speed is too low. Check voltage and increase, if necessary. Contact KSB.

X Wrong fuse size Fit correct fuse size. X X X Defective overcurrent relay Check and replace, if necessary. X Motor winding not suitable for

operating voltage available.Replace pump set. Contact KSB.

A

B

C

D

E

F

G

H

6) Pump set pressure must be released before attempting to remedy faults on parts which are subjected to pressure.

8 Trouble-shooting

30 of 38 S 100D; UPA 100C

9 Related Documents

9.1 S 100D general assembly drawing

914.03

81-29

81-73

412

108.02

350

384

232.02

540.1

131

525

914.01

106

143

503

232.01

541

529.01

913

825

Fig. 10: Sectional drawing of an S 100D pump with radial impellers

Table 9: List of S 100D components

Part No. Description Part No. Description81-29 Cable clamp 412 O-ring81-73 Cable support 503 Impeller wear ring106 Suction casing 525 Spacer sleeve108.02 Stage casing 529.01 Bearing sleeve131 Inlet ring 540.1 Bushing143 Suction strainer 541 Interstage bush232.01 Clockwise impeller 825 Cable guard232.02 Impeller (last stage) 913 Vent plug350 Bearing housing 914.01 Screw - Round head384 Thrust collar 914.03 Screw - Cheese head

9 Related Documents

S 100D; UPA 100C 31 of 38

9.2 UPA 100C general assembly drawing

107

753

506752

171.03

525

545

230

512

301

917

920

59-18

920

554

106

143

525

211

825

840

171.02

171.01

Fig. 11: Sectional drawing of a UPA 100C pump with mixed flow impellers

Table 10: List of UPA 100C components

Part No. Description Part No. Description59-18 Hook 512 Wear ring106 Suction casing 525 Spacer sleeve107 Discharge casing 545 Bearing bush143 Suction strainer 554 Washer171.01 Bottom diffuser 752 Valve seat171.02 Diffuser 753 Valve disc171.03 Top diffuser 825 Cable guard211 Pump shaft 840 Coupling230 Impeller 917 Tie bolt301 Intermediate bearing 920 Nut506 Retaining ring

9 Related Documents

32 of 38 S 100D; UPA 100C

9.3 General assembly drawing DN 100

540

421

81-2

745

545

545

412

550.52

900

160.53

271

550.51

902

920

411.51

160.51

412

382.51

389

818

81-59

550.53

384

387

392.51

392.52

382.52

411.52

59-12

160.52

Fig. 12: Example of a DN 100 motor < 3.0 kW

Table 11: List of components DN 100

Part No. Description Part No. Description59-12 Diaphragm 412 O-ring81-2 Plug 421 Lip seal81-59 Stator 540 Bushing160.51/.52/.53

Cover 545 Bearing bush

271 Sand guard 550.51/.52./53

Disc

382.51/.52 Bearing carrier 745 Filter384 Thrust collar 818 Rotor387 Thrust bearing pad 900 Screw389 Counter thrust bearing ring 902 Stud392.51/.52 Pad carrier 920 Hexagon nut411.51/.52 Joint ring

9 Related Documents

S 100D; UPA 100C 33 of 38

10 EC Declaration of Conformity

Manufacturer: KSB AktiengesellschaftJohann-Klein-Straße 9

67227 Frankenthal (Germany)

The manufacturer herewith declares that the product:

S 100 D, UPA 100C▪ is in conformity with the provisions of the following directives as amended from time to time:

– EC Machinery Directive 2006/42/EC

The manufacturer also declares that

▪ the following harmonised international standards were applied:

– ISO 12100-1/A1, ISO 12100-2/A1,

– ISO 14121-1,

– EN 809/A1,

– EN 60034-1, EN 60034-5/A1

Frankenthal, 29 December 2009

...........................................................

Name

Function

Responsible for compiling the technical documentationKSB AktiengesellschaftJohann-Klein-Straße 9

67227 Frankenthal (Germany)

10 EC Declaration of Conformity

34 of 38 S 100D; UPA 100C

11 Certificate of Decontamination

Type ................................................................................................................................Order number/Order item number7) ................................................................................................................................ Delivery date ................................................................................................................................ Field of application: ................................................................................................................................ Fluid handled7) : ................................................................................................................................

Please tick where applicable7) :

⃞ ⃞ ⃞ ⃞radioactive explosive corrosive toxic

⃞ ⃞ ⃞ ⃞harmful bio-hazardous highly flammable safe

Reason for return7) : ................................................................................................................................ Comments: ................................................................................................................................ ................................................................................................................................ The pump/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/placingat your disposal.

On seal-less pumps, the rotor has been removed from the pump for cleaning.

⃞ No special safety precautions are required for further handling.⃞ The following safety precautions are required for flushing fluids, fluid residues and disposal:

............................................................................................................................................................... ............................................................................................................................................................... We confirm that the above data and information are correct and complete and that dispatch is effected in accordance withthe relevant legal provisions.

.................................................................... ....................................................... .......................................................Place, date and signature Address Company stamp

7) Required fields

11 Certificate of Decontamination

S 100D; UPA 100C 35 of 38

Index

CCertificate of decontamination 35

DDescription of the fluid handled 13Disposal 12

FFrequency inverter operation 28

IIntended use 8

MMisuse 9

OOperating limits 8Other applicable documents 6

PPartly completed machinery 6

RReturn to supplier 12

SSafety 8Safety awareness 9Scope of supply 14

Index

36 of 38 S 100D; UPA 100C

KSB Aktiengesellschaft67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Deutschland)Tel. +49 6233 86-0 • Fax +49 6233 86-3401www.ksb.de

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