KSB Amacan S Series User manual

Submersible Pump in Discharge Tube
Amacan S
Amacan S 650 - 364
Amacan S 650 - 365
Amacan S 650 - 404
Amacan S 650 - 405
Amacan S 800 - 505
Installation/Operating Manual
Mat. No.: 01350210

Legal information/Copyright
Installation/Operating Manual Amacan S
Original operating manual
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 20.05.2014

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 ....................................................... 9
2.8 Safety information for maintenance, inspection and installation work ....... 9
2.9 Unauthorised modes of operation .................................................................. 9
3 Transport/Temporary Storage/Disposal .............................................10
3.1 Checking the condition upon delivery .......................................................... 10
3.2 Transport ......................................................................................................... 10
3.3 Storage/preservation ...................................................................................... 14
3.4 Return to supplier ........................................................................................... 14
3.5 Disposal ...........................................................................................................15
4 Description of the Pump (Set) ............................................................16
4.1 General description ........................................................................................ 16
4.2 Designation ..................................................................................................... 16
4.3 Name plate ...................................................................................................... 16
4.4 Design details .................................................................................................. 17
4.5 Installation types ............................................................................................17
4.6 Configuration and function ........................................................................... 19
4.7 Scope of supply ............................................................................................... 20
4.8 Dimensions and weights ................................................................................20
5 Installation at Site ...............................................................................21
5.1 Safety regulations ........................................................................................... 21
5.2 Checks to be carried out prior to installation ............................................... 21
5.3 Lowering the pump set into the discharge tube .......................................... 23
5.4 Electrical system .............................................................................................. 29
6 Commissioning/Start-up/Shutdown ...................................................35
6.1 Commissioning/start-up ................................................................................. 35
Contents
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6.2 Operating limits .............................................................................................. 36
6.3 Shutdown/storage/preservation .................................................................... 37
6.4 Returning to service .......................................................................................38
7 Servicing/Maintenance .......................................................................40
7.1 Safety regulations ........................................................................................... 40
7.2 Maintenance/inspection ................................................................................. 40
7.3 Removing the pump set ................................................................................. 43
7.4 Lubrication and lubricant change ................................................................. 46
7.5 Dismantling the pump set .............................................................................. 51
7.6 Reassembling the pump set ........................................................................... 56
7.7 Checking the electrical connection and motor ............................................. 65
7.8 Tightening torques ......................................................................................... 65
7.9 Spare parts stock ............................................................................................. 66
8 Trouble-shooting ................................................................................67
9 Related Documents ............................................................................68
9.1 General assembly drawing of pump sets with UAG motors (DKA motor) .. 68
9.2 Cable guide ..................................................................................................... 71
9.3 Wiring diagrams ............................................................................................. 72
9.4 Dimensions ...................................................................................................... 75
9.5 General arrangement drawings .................................................................... 77
10 EC Declaration of Conformity ............................................................97
11 Certificate of Decontamination .........................................................98
Index ....................................................................................................99
Contents
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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
environmental and health hazards arising from
components in contact with the fluid handled.
Close-coupled design
Motor directly fitted to the pump via a flange
or a drive lantern
Submersible pump in discharge tube
A submersible motor pump which is completely
submerged and suspended in a discharge tube
Glossary
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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
phases of operation.
The name plate indicates the type series and size, the main operating data, the order
number and the order item number. The order number and order item number
uniquely identify the pump (set) and serve as identification for all further business
processes.
In the event of damage, contact your nearest KSB service centre immediately to
maintain the right to claim under warranty.
1.2 Installation of partly completed machinery
To install partly completed machinery supplied by KSB, refer to the sub-sections
under Servicing/Maintenance.
1.3 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. (⇨ Section 2.4 Page 8)
1.4 Other applicable documents
Table 1: Overview of other applicable documents
Document Contents
Data sheet Description of the technical data of the pump (set)
Hydraulic characteristic curve Characteristic curves showing head, NPSH
required, efficiency and power input
General assembly drawing1) Sectional drawing of the pump set
Sub-supplier product literature1) Operating manuals and other product literature
describing accessories and integrated machinery
components
Spare parts lists1) Description of spare parts
For accessories and/or integrated machinery components observe the relevant
manufacturer's product literature.
1.5 Symbols
Table 2: Symbols used in this manual
Symbol Description
✓Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳Safety instructions
⇨Result of an action
⇨Cross-references
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 specialist personnel/
operators responsible prior to installation and commissioning.
The contents of this manual must be available to the specialist personnel at the site
at all times.
Information attached directly to the pump must always be complied with and be
kept in a perfectly legible condition at all times. This applies to, for example:
▪Arrow indicating the direction of rotation
▪Markings for connections
▪Name plate
The operator is responsible for ensuring compliance with all local regulations not
taken into account in this manual.
2.3 Intended use
The pump (set) must only be operated within the operating limits described in the
other applicable documents.
▪Only operate pumps/pump sets which are in perfect technical condition.
▪Do not operate partially assembled pumps/pump sets.
▪Only use the pump to handle the fluids specified in the data sheet or product
literature of the respective design variant.
▪Never operate the pump without the fluid to be handled.
!DANGER
2 Safety
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▪Observe the limits for continuous operation specified in the data sheet or
product literature (Qmin2) and Qmax3)) (to prevent damage such as shaft fracture,
bearing failure, damaged mechanical seal, etc).
▪Observe the information on the maximum flow rates provided in the data sheet
or product literature (to prevent overheating, cavitation damage, bearing
damage, etc).
▪Consult the manufacturer about any use or mode of operation not described in
the data sheet or product literature.
Prevention of foreseeable misuse
▪Observe the minimum flow velocities required to fully open the swing check
valves to prevent the reduction of pressure and risk of clogging.
(Contact the manufacturer for the required minimum flow velocities/loss
coefficients.)
▪Never exceed the permissible operating limits specified in the data sheet and in
the product literature regarding pressure, temperature, etc.
▪Observe all safety information and instructions in this manual.
2.4 Personnel qualification and training
All personnel involved must be fully qualified to transport, install, operate, maintain
and inspect the machinery this manual refers to.
The responsibilities, competence and supervision of all personnel involved in
transport, installation, operation, maintenance and inspection must be clearly
defined by the operator.
Deficits in knowledge must be rectified by means of training and instruction
provided by sufficiently trained specialist personnel. If required, the operator can
commission the manufacturer/supplier to train the personnel.
Training on the pump (set) must always be supervised by technical specialist
personnel.
2.5 Consequences and risks caused by non-compliance with this manual
▪Non-compliance with this operating manual will lead to forfeiture of warranty
cover and of any and all rights to claims for damages.
▪Non-compliance can, for example, have the following consequences:
–Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to leakage of hazardous substances
2.6 Safety awareness
In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪Accident prevention, health and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards and laws
2) Minimum permissible flow rate
3) Maximum permissible flow rate
2 Safety
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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 authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for resulting damage.
▪The operator ensures that all maintenance, inspection and installation work is
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.
▪Only carry out work on the pump (set) during standstill of the pump.
▪The pump casing must have cooled down to ambient temperature.
▪Pump pressure must have been released and the pump must have been drained.
▪When taking the pump set out of service always adhere to the procedure
described in the manual. (⇨ Section 6.3 Page 37)
▪Decontaminate pumps which handle fluids posing a health hazard.
▪As soon as the work has been completed, re-install and/or re-activate any safety-
relevant and protective devices. Before returning the product to service, observe
all instructions on commissioning. (⇨ Section 6.1 Page 35)
2.9 Unauthorised modes of operation
Never operate the pump (set) outside the limits stated in the data sheet and in this
manual.
The warranty relating to the operating reliability and safety of the supplied pump
(set) is only valid if the equipment is used in accordance with its intended use.
2 Safety
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3 Transport/Temporary Storage/Disposal
3.1 Checking the condition upon delivery
1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer (as applicable) and the insurer about the
damage in writing immediately.
3.2 Transport
DANGER
Improper transport
Danger to life from falling parts!
Damage to the pump set!
▷Use the attachment point provided (eyebolt, lifting lug or bail) for attaching
lifting accessories.
▷Never suspend the pump set by its power cable.
▷Never use the lifting ropes included in KSB's scope of supply for lifting loads
other than the KSB product supplied.
▷Securely attach the lifting ropes to the pump and crane.
3.2.1 Transporting the delivered pump set to the place of installation
Fig. 1: Transporting the delivered pump set to the place of installation
▪The pump set is supplied in horizontal position in a suitable saddle-shaped
holder.
▪Use suitable hoisting tackle to transport the pump set in its original packaging to
its place of installation.
Note the marked centres of gravity and/or attachment points on the transport
boxes!
For the weight refer to the name plate or data sheet.
3.2.2 Placing the pump set in vertical or horizontal position
WARNING
Pump set tipping over
Risk of squashing hands and feet!
▷Suspend or support the pump set.
3 Transport/Temporary Storage/Disposal
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