KSB Amacan P Installation instructions

Submersible Pump in Discharge Tube
Amacan P
50 Hz
Amacan P 700 - 470
Amacan P 800/900 - 540
Amacan P 1000 - 700
Amacan P 1200 - 870
Amacan P 1500/1600 - 1060
Installation/Operating Manual
Mat. No.: 01137299

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.
© KSB Aktiengesellschaft, Frankenthal 10.11.2014

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 ....................................................... 8
2.8 Safety information for maintenance, inspection and installation work ....... 9
2.9 Unauthorised modes of operation .................................................................. 9
2.10 Explosion protection ........................................................................................ 9
3 Transport/Temporary Storage/Disposal .............................................11
3.1 Checking the condition upon delivery .......................................................... 11
3.2 Transport ......................................................................................................... 11
3.3 Storage/preservation ...................................................................................... 14
3.4 Return to supplier ........................................................................................... 15
3.5 Disposal ........................................................................................................... 16
4 Description of the Pump (Set) ............................................................17
4.1 General description ........................................................................................ 17
4.2 Designation ..................................................................................................... 17
4.3 Name plate ...................................................................................................... 17
4.4 Design details .................................................................................................. 18
4.5 Installation types ............................................................................................ 18
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 .......................................... 24
5.4 Electrical system .............................................................................................. 34
6 Commissioning/Start-up/Shutdown ...................................................42
Contents
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6.1 Commissioning/start-up ................................................................................. 42
6.2 Operating limits .............................................................................................. 43
6.3 Shutdown/storage/preservation .................................................................... 45
6.4 Returning to service ....................................................................................... 46
7 Servicing/Maintenance .......................................................................47
7.1 Safety regulations ........................................................................................... 47
7.2 Maintenance/inspection ................................................................................. 48
7.3 Removing the pump set ................................................................................. 50
7.4 Lubrication and lubricant change ................................................................. 53
7.5 Dismantling the pump set .............................................................................. 57
7.6 Reassembling the pump set ........................................................................... 63
7.7 Checking the electrical connection and motor ............................................. 76
7.8 Tightening torques ........................................................................................ 76
7.9 Spare parts stock ............................................................................................. 76
8 Trouble-shooting ................................................................................78
9 Related Documents ............................................................................79
9.1 General assembly drawing ............................................................................. 79
9.2 Cable bundle ................................................................................................... 89
9.3 Wiring diagrams ............................................................................................. 91
9.4 Flamepaths on explosion-proof motors ........................................................ 96
9.5 Dimensions ...................................................................................................... 97
9.6 Wiring diagrams ........................................................................................... 101
10 EC Declaration of Conformity ..........................................................120
11 Certificate of Decontamination .......................................................121
Index ..................................................................................................122
Contents
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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 en-
vironmental 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
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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 pha-
ses 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 re-
quired, 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 manu-
facturer'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
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 avoi-
ded, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could re-
sult in damage to the machine and its functions.
Explosion protection
This symbol identifies information about avoiding explosions in
potentially explosive atmospheres in accordance with EC Directive
94/9/EC (ATEX).
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 tak-
en 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 the pump (set) in partially assembled condition.
▪Only use the pump to handle the fluids described in the data sheet or product
literature of the pump model or variant.
!DANGER
2 Safety
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▪Never operate the pump without the fluid to be handled.
▪Observe the limits for continuous operation specified in the data sheet or prod-
uct literature (Qmin and Qmax) (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 litera-
ture (to prevent overheating, mechanical seal damage, cavitation damage, bear-
ing 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 coeffi-
cients.)
▪Never exceed the permissible operating limits specified in the data sheet or prod-
uct 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 trans-
port, installation, operation, maintenance and inspection must be clearly defined by
the operator.
Deficits in knowledge must be rectified by means of training and instruction provi-
ded by sufficiently trained specialist personnel. If required, the operator can commis-
sion the manufacturer/supplier to train the personnel.
Training on the pump (set) must always be supervised by technical specialist person-
nel.
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 ef-
fects 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, directives and laws
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.
2 Safety
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▪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. explo-
sive, toxic, hot) so as to avoid any danger to persons and the environment. Ad-
here 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 compa-
nies.)
▪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 manufac-
turer'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 fa-
miliar 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 descri-
bed in the manual. (⇨ Section 6.3 Page 45)
▪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 42)
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.
2.10 Explosion protection
Always observe the information on explosion protection given in this section when
operating an explosion-proof pump set.
Sections of the manual marked by the Ex symbol apply to explosion-proof pump sets
also when temporarily operated outside potentially explosive atmospheres.
Only pumps/pump sets marked as explosion-proof and identified as such in the data
sheet must be used in potentially explosive atmospheres.
Special conditions apply to the operation of explosion-proof pump sets in accordance
with EC Directive 94/9/EC (ATEX).
Especially adhere to the sections in this manual marked with the Ex symbol.
The explosion-proof status of the pump set is only assured if the pump set is used in
accordance with its intended use.
Never operate the pump (set) outside the limits stated in the data sheet and on the
name plate.
Prevent impermissible modes of operation at all times.
!DANGER
2 Safety
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2.10.1 Repair
Special regulations apply to repair work on explosion-proof pumps. Modifications or
alterations of the pump set can affect explosion protection and are only permitted
after consultation with the manufacturer.
Repair work at the flameproof joints must only be performed in accordance with the
manufacturer's instructions. Repair to the values in tables 1 and 2 of EN 60079-1 is
not permitted.
2 Safety
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