KSB Amacan P 700 - 470 Installation instructions

Submersible Pump in Discharge Tube
Amacan P
(60Hz)
Amacan P 700 - 470
Amacan P 800/900 - 540
Amacan P 1000 - 700
Amacan P 1200 - 870
Amacan P 1500 - 1060
Installation/Operating Manual
Order number: 9972645218-200

Legal information/Copyright
Installation/Operating Manual Amacan P
Original operating manual
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
the manufacturer's express written consent.
Subject to technical modification without prior notice.
© 18.06.2014

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 .....................................................................................................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 these operating
instructions ........................................................................................................ 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 Unauthorized modes of operation .................................................................. 9
3 Transport/Temporary Storage/Disposal .............................................10
3.1 Transport ......................................................................................................... 10
3.2 Storage/preservation ...................................................................................... 13
3.3 Return to supplier ........................................................................................... 13
3.4 Disposal ...........................................................................................................14
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 .................................................................................................. 16
4.5 Type 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 in the discharge tube .............................................. 21
5.4 Electrical system .............................................................................................. 22
6 Commissioning/Start-up/Shutdown ...................................................27
Contents
Amacan P 3 of 68

6.1 Commissioning/start-up ................................................................................. 27
6.2 Operating limits .............................................................................................. 28
6.3 Shutdown/storage/preservation .................................................................... 29
6.4 Returning to service .......................................................................................30
7 Servicing/Maintenance .......................................................................31
7.1 Safety regulations ........................................................................................... 31
7.2 Servicing/inspection ........................................................................................ 31
7.3 Drainage/disposal ........................................................................................... 38
7.4 Dismantling the pump set .............................................................................. 38
7.5 Reassembling the pump set ........................................................................... 43
7.6 Tightening torques ......................................................................................... 52
7.7 Spare parts stock ............................................................................................. 53
8 Trouble-shooting ................................................................................54
9 Related Documents ............................................................................55
9.1 General assembly drawing ............................................................................. 55
9.2 Wiring diagrams ............................................................................................. 60
9.3 Outline drawing ............................................................................................. 62
9.4 Dimensions of the discharge tube ................................................................. 64
10 Certificate of Decontamination .........................................................65
Contents
4 of 68 Amacan P

Glossary
Certificate of decontamination
A certificate of decontamination is required to
return the pump to the manufacturer. In the
certificate of decontamination the customer
certifies that the pump (set) 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
ECB (ever clean blade) design
Self-cleaning vane profile
Submersible pump in discharge tube
A submersible motor pump which is completely
submerged and suspended in a discharge tube
Glossary
Amacan P 5 of 68

1 General
1.1 Principles
This operating manual is supplied as an integral part of the type series and variants
indicated on the front cover. 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, contact your nearest KSB service center immediately to
maintain the right to claim 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
of accessories and integrated machinery
components
Spare parts lists1) Description of spare parts
For accessories and/or integrated machinery components observe the product
literature of the corresponding manufacturer.
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.
2.
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
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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
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 responsible specialist
personnel/operators 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 which
are 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 P 7 of 68

▪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, mechanical seal damage, etc).
▪Observe the maximum flow rates indicated in the data sheet or product
literature (to prevent overheating, mechanical seal damage, 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 (pressure, temperature, etc.)
specified in the data sheet or product literature.
▪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 and
inspect the machinery this manual refers to.
The responsibilities, competence and supervision of all personnel involved in
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 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) Minimum permissible flow rate
3) Maximum permissible flow rate
2 Safety
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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 authorized 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 authorized, 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 29)
▪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 27)
2.9 Unauthorized 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 pump (set)
supplied is only valid if the equipment is used in accordance with its intended use.
2 Safety
Amacan P 9 of 68

3 Transport/Temporary Storage/Disposal
3.1 Transport
DANGER
Improper transport
Danger to life from falling parts!
Damage to the pump set!
▷Attach any lifting tackle to the attachment points (eyebolts) provided.
▷Never suspend the pump set by its power cable.
▷Never use the chains or lifting ropes included in KSB's scope of supply for lifting
loads other than the KSB product supplied.
▷Securely attach the lifting ropes or chains to the pump and crane.
3.1.1 Transporting the delivered pump set to the place of installation
Fig. 1: Transporting the pump set in its original packaging
▪The pump set is supplied in horizontal position in a suitable transport holder.
▪Use suitable lifting equipment to transport the pump set in its original packaging
to its place of installation.
Observe the marked centers of gravity and/or attachment points on the transport
boxes!
For the weight refer to the name plate or data sheet.
3.1.2 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.
CAUTION
Improper storage
Damage 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 of
installation.
3 Transport/Temporary Storage/Disposal
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WARNING
Incorrect positioning
Personal injury and damage to property!
▷Position the pump set vertically with the motor on top.
▷Use appropriate means to secure the pump set against overturning and tipping
over.
▷Refer to the weights given in the data sheet/on the name plate.
WARNING
Improper handling of the power cable when placing the pump set in vertical
position or transporting it
Personal injury and damage to property!
▷Secure power cables against falling down.
WARNING
Improper handling when placing the pump set in vertical/horizontal position
Personal injury and damage to property!
▷Use appropriate means to secure the pump set against overturning, tipping
over and rolling off.
▷Maintain sufficient safety distance when lifting the pump set (which may swing
when pulled upright).
▷Use additional supports for the transport holder to secure the pump set against
overturning.
Fig. 2: Placing the pump set in upright position
3 Transport/Temporary Storage/Disposal
Amacan P 11 of 68

✓Suitable hoisting tackle has been selected.
1. Attach a suitable lifting accessory to the eyebolts.
2. Attach the lifting accessory to the eye hook of the hoisting tackle.
3. Lift the pump set with the hoisting tackle (e.g. crane).
⇨Guiding the pump set over the edge of the bellmouth or pump casing is only
permissible on a wooden base!
⇨Protect the power cable against kinking!
4. Place the pump set on a clean and level surface, and protect it against
overturning, tipping over and rolling off.
3.1.3 Transporting the pump set
WARNING
Incorrect positioning
Personal injury and damage to property!
▷Position the pump set vertically with the motor on top.
▷Use appropriate means to secure the pump set against overturning and tipping
over.
▷Refer to the weights given in the data sheet/on the name plate.
WARNING
Improper handling of the power cable when placing the pump set in vertical
position or transporting it
Personal injury and damage to property!
▷Secure power cables against falling down.
Fig. 3: Transporting the pump set in vertical position
Use suitable lifting equipment to transport the pump set in the illustrated position.
3.1.4 Transport lock
Pump sets from size Amacan P 1000 - 700 are supplied with a transport lock (a metal
plate between impeller and bellmouth). Remove the transport lock prior to
commissioning.
3 Transport/Temporary Storage/Disposal
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3.2 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken:
Store the pump set as follows:
▪In its original packaging: in horizontal position
▪Without packaging: in vertical position with the motor on top
WARNING
Pump set tipping over
Risk of squashing hands and feet!
▷Suspend or support the pump set.
CAUTION
Improper storage
Damage 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 of
installation.
CAUTION
Damage during storage by humidity, dirt or vermin
Corrosion/contamination of the pump (set)!
▷For outdoor storage cover the pump (set) or the packaged pump (set) and
accessories with waterproof material.
CAUTION
Wet, contaminated or damaged openings and connections
Leakage or damage to the pump set!
▷Only remove caps/covers from the openings of the pump set at the time of
installation.
Table 4: Ambient conditions for storage
Ambient condition Value
Relative humidity 5 % to 85 %
(non-condensing)
Ambient temperature 4 °F to 158 °F (- 20 °C to + 70 °C)
▪Store the pump set under dry and vibration-free conditions, if possible in its
original packaging.
1. Rotate the impeller by hand once a month.
3.3 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 fluids handled by the pump (set) leave residues which might lead to
corrosion when coming into contact with atmospheric humidity, or which might
ignite when coming into contact with oxygen, the pump set must be
neutralized, and anhydrous inert gas must be blown through the pump for
drying purposes.
3 Transport/Temporary Storage/Disposal
Amacan P 13 of 68

3.4 Disposal
WARNING
Fluids posing a health hazard and/or hot fluids
Hazard to persons and the environment!
▷Collect and properly dispose of flushing liquid and any residues of the fluid
handled.
▷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
controlled manner.
3 Transport/Temporary Storage/Disposal
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4 Description of the Pump (Set)
4.1 General description
▪Submersible pump in discharge tube
Pump set for handling river and storm water, pre-screened domestic and industrial
waste water as well as activated sludge
4.2 Designation
Example: Amacan PA4 800- 540/ 80 6 UTG1
Table 5: Key to the designation
Code Description
Amacan Type series
P Impeller type, e.g. P = propeller
A Pressure class
4 Number of vanes
800 Nominal diameter of the discharge tube [mm]
540 Nominal impeller diameter [mm]
80 Motor size
6 Number of poles
UT Motor version,
UT = standard design
G1 Casing material, e.g. G1 = gray cast iron
4.3 Name plate
Fig. 4: Name plate: pump set (example)
1Designation 2 KSB order number
3 Flow rate 4 Maximum fluid and ambient temperature
5 Enclosure 6 Motor type
7 Rated power 8 Rated speed
9 Rated voltage 10 Rated current
11 Head 12 Year of construction
13 Total weight 14 Maximum submergence
15 Thermal class of winding insulation 16 Motor number
4 Description of the Pump (Set)
Amacan P 15 of 68

17 Power factor at design point 18 Rated frequency
19 Service factor 20 Starting current
4.4 Design details
Design
▪Fully floodable submersible pump in discharge tube (submersible motor pump)
▪Not self-priming
▪Close-coupled design
Impeller type
▪Axial propeller in ECB design
Shaft seal
▪Two bi-directional mechanical seals in tandem arrangement, with liquid reservoir
▪Leakage chamber
Bearings
▪Grease-packed rolling element bearings
Drive
▪Three-phase asynchronous squirrel-cage motor
4.5 Type of installation
Pump installation is horizontal.
Fig. 5: Type of installation
4 Description of the Pump (Set)
16 of 68 Amacan P

4.6 Configuration and function
Fig. 6: Amacan with axial propeller
The pump is designed with an axial fluid inlet and an axial outlet. The hydraulic
system sits on the extended motor shaft. The shaft runs in common bearings.
The fluid enters the pump axially via a suction nozzle (bellmouth) (1) and is
accelerated in a rotating flow by the rotating impeller (2). The required energy is
transmitted from the electric motor (4) to the impeller (2) via the shaft (5). In the
diffuser casing (3) the kinetic energy of the fluid is converted into pressure energy.
The rotational movement diverts the fluid flow into an axial flow. The shaft passage
through the casing is sealed towards the fluid with a shaft seal (10). The shaft (5) runs
in two rolling element bearings (6 and 8), which are supported by the bearing
housing (9) and the bearing bracket (7).
The pump is sealed by two bi-directional mechanical seals in tandem arrangement.
A lubricant chamber in-between the seals ensures cooling and lubrication of the
mechanical seals.
The pump sets are equipped with various sensors.
Standard
▪Temperature monitoring of the motor
▪Temperature monitoring at the lower bearing
▪Leakage monitoring of the mechanical seal system
▪Leakage sensors in the motor/connection space
Optional
▪Temperature monitoring at the upper bearing
4.7 Scope of supply
Depending on the model, the following items are included in the scope of supply:
▪Pump set complete with power cables
Design
Function
Sealing
Monitoring
equipment
4 Description of the Pump (Set)
Amacan P 17 of 68

▪Back-up name plate
Optional:
▪Discharge tube
NOTE
A separate name plate is included in KSB's scope of supply.
Attach this name plate 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 general arrangement drawing/outline
drawing or data sheet of the pump set.
4 Description of the Pump (Set)
18 of 68 Amacan P

5 Installation at Site
5.1 Safety regulations
DANGER
Persons in the intake area during pump operation
Electric shock! Risk of personal injury!
▷Never start up the pump set when there are persons in the intake area.
5.2 Checks to be carried out prior to installation
5.2.1 Checking the structural requirements
All structural work required must have been prepared in accordance with the
dimensions stated in the outline drawing/general arrangement drawing.
5.2.2 Checking the operating data
Before inserting the pump set into the discharge tube, verify the data on the name
plate against the data given in the purchase order and the system data.
KSB’s scope of supply includes a separate name plate attached to the end of the
pump cable which indicates the pump and motor data.
1. Attach this name plate in a clearly visible position outside the discharge tube,
e.g. at the control cabinet, pipeline or mounting bracket.
5.2.3 Checking the lubricant level
The lubricant reservoir is filled at the factory with an environmentally-friendly, non-
toxic lubricant.
Back-up name plate
5 Installation at Site
Amacan P 19 of 68

Fig. 7: Checking the lubricant level
FD
Always apply a liquid sealing agent (e.g. Hylomar SQ32M) to sealing
surfaces marked with this symbol.
1. Place the pump set in horizontal position and make sure it cannot roll off.
2. When placing it down, make sure that screw plug 903.03 is on top.
3. Remove screw plug 903.03.
4. Remove screw plug 903.01 and joint ring 411.01.
5. Shine a torch through the hole in the diffuser casing to inspect the opening of
the lubricant reservoir.
⇨If the lubricant level reaches the opening, topping up of the lubricant is not
required.
⇨If the lubricant level is below the opening, top up the lubricant.
6. Fit screw plug 903.01 and joint ring 411.01 as well as screw plug 903.03.
5.2.4 Checking the direction of rotation
CAUTION
Pump set running dry
Increased vibrations!
Damage to mechanical seals and bearings!
▷Never operate the pump set outside the fluid to be handled for more than 60
seconds.
5 Installation at Site
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