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
Amacan S 3 of 100

6.2 Operating limits .............................................................................................. 36
6.3 Shutdown/storage/preservation .................................................................... 37
6.4 Returning to service .......................................................................................38
7 Servicing/Maintenance .......................................................................40
7.1 Safety regulations ........................................................................................... 40
7.2 Maintenance/inspection ................................................................................. 40
7.3 Removing the pump set ................................................................................. 43
7.4 Lubrication and lubricant change ................................................................. 46
7.5 Dismantling the pump set .............................................................................. 51
7.6 Reassembling the pump set ........................................................................... 56
7.7 Checking the electrical connection and motor ............................................. 65
7.8 Tightening torques ......................................................................................... 65
7.9 Spare parts stock ............................................................................................. 66
8 Trouble-shooting ................................................................................67
9 Related Documents ............................................................................68
9.1 General assembly drawing of pump sets with UAG motors (DKA motor) .. 68
9.2 Cable guide ..................................................................................................... 71
9.3 Wiring diagrams ............................................................................................. 72
9.4 Dimensions ...................................................................................................... 75
9.5 General arrangement drawings .................................................................... 77
10 EC Declaration of Conformity ............................................................97
11 Certificate of Decontamination .........................................................98
Index ....................................................................................................99
Contents
4 of 100 Amacan S

Glossary
Certificate of decontamination
A certificate of decontamination is enclosed by
the customer when returning the product to
the manufacturer to certify that the product
has been properly drained to eliminate any
environmental and health hazards arising from
components in contact with the fluid handled.
Close-coupled design
Motor directly fitted to the pump via a flange
or a drive lantern
Submersible pump in discharge tube
A submersible motor pump which is completely
submerged and suspended in a discharge tube
Glossary
Amacan S 5 of 100

1 General
1.1 Principles
This manual is supplied as an integral part of the type series and variants indicated
on the front cover. It describes the proper and safe use of this equipment in all
phases of operation.
The name plate indicates the type series and size, the main operating data, the order
number and the order item number. The order number and order item number
uniquely identify the pump (set) and serve as identification for all further business
processes.
In the event of damage, contact your nearest KSB service centre immediately to
maintain the right to claim under warranty.
1.2 Installation of partly completed machinery
To install partly completed machinery supplied by KSB, refer to the sub-sections
under Servicing/Maintenance.
1.3 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. (⇨ Section 2.4 Page 8)
1.4 Other applicable documents
Table 1: Overview of other applicable documents
Document Contents
Data sheet Description of the technical data of the pump (set)
Hydraulic characteristic curve Characteristic curves showing head, NPSH
required, efficiency and power input
General assembly drawing1) Sectional drawing of the pump set
Sub-supplier product literature1) Operating manuals and other product literature
describing accessories and integrated machinery
components
Spare parts lists1) Description of spare parts
For accessories and/or integrated machinery components observe the relevant
manufacturer's product literature.
1.5 Symbols
Table 2: Symbols used in this manual
Symbol Description
✓Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳Safety instructions
⇨Result of an action
⇨Cross-references
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
6 of 100 Amacan S

2 Safety
All the information contained in this section refers to hazardous situations.
2.1 Key to safety symbols/markings
Table 3: Definition of safety symbols/markings
Symbol Description
!DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
!WARNING
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.
2.2 General
This manual contains general installation, operating and maintenance instructions
that must be observed to ensure safe pump operation and prevent personal injury
and damage to property.
The safety information in all sections of this manual must be complied with.
This manual must be read and completely understood by the specialist personnel/
operators responsible prior to installation and commissioning.
The contents of this manual must be available to the specialist personnel at the site
at all times.
Information attached directly to the pump must always be complied with and be
kept in a perfectly legible condition at all times. This applies to, for example:
▪Arrow indicating the direction of rotation
▪Markings for connections
▪Name plate
The operator is responsible for ensuring compliance with all local regulations not
taken into account in this manual.
2.3 Intended use
The pump (set) must only be operated within the operating limits described in the
other applicable documents.
▪Only operate pumps/pump sets which are in perfect technical condition.
▪Do not operate partially assembled pumps/pump sets.
▪Only use the pump to handle the fluids specified in the data sheet or product
literature of the respective design variant.
▪Never operate the pump without the fluid to be handled.
!DANGER
2 Safety
Amacan S 7 of 100

▪Observe the limits for continuous operation specified in the data sheet or
product literature (Qmin2) and Qmax3)) (to prevent damage such as shaft fracture,
bearing failure, damaged mechanical seal, etc).
▪Observe the information on the maximum flow rates provided in the data sheet
or product literature (to prevent overheating, cavitation damage, bearing
damage, etc).
▪Consult the manufacturer about any use or mode of operation not described in
the data sheet or product literature.
Prevention of foreseeable misuse
▪Observe the minimum flow velocities required to fully open the swing check
valves to prevent the reduction of pressure and risk of clogging.
(Contact the manufacturer for the required minimum flow velocities/loss
coefficients.)
▪Never exceed the permissible operating limits specified in the data sheet and in
the product literature regarding pressure, temperature, etc.
▪Observe all safety information and instructions in this manual.
2.4 Personnel qualification and training
All personnel involved must be fully qualified to transport, install, operate, maintain
and inspect the machinery this manual refers to.
The responsibilities, competence and supervision of all personnel involved in
transport, installation, operation, maintenance and inspection must be clearly
defined by the operator.
Deficits in knowledge must be rectified by means of training and instruction
provided by sufficiently trained specialist personnel. If required, the operator can
commission the manufacturer/supplier to train the personnel.
Training on the pump (set) must always be supervised by technical specialist
personnel.
2.5 Consequences and risks caused by non-compliance with this manual
▪Non-compliance with this operating manual will lead to forfeiture of warranty
cover and of any and all rights to claims for damages.
▪Non-compliance can, for example, have the following consequences:
–Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to leakage of hazardous substances
2.6 Safety awareness
In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪Accident prevention, health and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards and laws
2) Minimum permissible flow rate
3) Maximum permissible flow rate
2 Safety
8 of 100 Amacan S

2.7 Safety information for the operator/user
▪The operator shall fit contact guards for hot, cold and moving parts and check
that the guards function properly.
▪Do not remove any contact guards during operation.
▪Provide the personnel with protective equipment and make sure it is used.
▪Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g.
explosive, toxic, hot) so as to avoid any danger to persons and the environment.
Adhere to all relevant laws.
▪Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
▪If shutting down the pump does not increase potential risk, fit an emergency-
stop control device in the immediate vicinity of the pump (set) during pump set
installation.
2.8 Safety information for maintenance, inspection and installation work
▪Modifications or alterations of the pump are only permitted with the
manufacturer's prior consent.
▪Use only original spare parts or parts authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for resulting damage.
▪The operator ensures that all maintenance, inspection and installation work is
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.
▪Only carry out work on the pump (set) during standstill of the pump.
▪The pump casing must have cooled down to ambient temperature.
▪Pump pressure must have been released and the pump must have been drained.
▪When taking the pump set out of service always adhere to the procedure
described in the manual. (⇨ Section 6.3 Page 37)
▪Decontaminate pumps which handle fluids posing a health hazard.
▪As soon as the work has been completed, re-install and/or re-activate any safety-
relevant and protective devices. Before returning the product to service, observe
all instructions on commissioning. (⇨ Section 6.1 Page 35)
2.9 Unauthorised modes of operation
Never operate the pump (set) outside the limits stated in the data sheet and in this
manual.
The warranty relating to the operating reliability and safety of the supplied pump
(set) is only valid if the equipment is used in accordance with its intended use.
2 Safety
Amacan S 9 of 100

3 Transport/Temporary Storage/Disposal
3.1 Checking the condition upon delivery
1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer (as applicable) and the insurer about the
damage in writing immediately.
3.2 Transport
DANGER
Improper transport
Danger to life from falling parts!
Damage to the pump set!
▷Use the attachment point provided (eyebolt, lifting lug or bail) for attaching
lifting accessories.
▷Never suspend the pump set by its power cable.
▷Never use the lifting ropes included in KSB's scope of supply for lifting loads
other than the KSB product supplied.
▷Securely attach the lifting ropes to the pump and crane.
3.2.1 Transporting the delivered pump set to the place of installation
Fig. 1: Transporting the delivered pump set to the place of installation
▪The pump set is supplied in horizontal position in a suitable saddle-shaped
holder.
▪Use suitable hoisting tackle to transport the pump set in its original packaging to
its place of installation.
Note the marked centres of gravity and/or attachment points on the transport
boxes!
For the weight refer to the name plate or data sheet.
3.2.2 Placing the pump set in vertical or horizontal position
WARNING
Pump set tipping over
Risk of squashing hands and feet!
▷Suspend or support the pump set.
3 Transport/Temporary Storage/Disposal
10 of 100 Amacan S

WARNING
Setting the pump set down on unsecured and uneven surfaces
Personal injury and damage to property!
▷Always set down the pump set on a solid and level surface with the pump set in
a vertical position and the motor on top.
▷Only place the pump set on a surface of sufficient load-carrying capacity.
▷Use appropriate means to secure the pump set against overturning or 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 a 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 a vertical/horizontal position
Personal injury and damage to property!
▷Depending on the size of the pump (set) use either one or two pieces of lifting
equipment.
▷Use appropriate means to secure the pump set against overturning, tipping
over or rolling off.
▷Maintain adequate safety distance during lifting operations (load may swing
when being lifted).
▷Use additional supports for the transport holder to secure the pump set against
overturning.
WARNING
Improper lifting/moving of heavy assemblies or components
Personal injury and damage to property!
▷Use suitable transport devices, lifting equipment and lifting tackle to move
heavy assemblies or components.
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
Amacan S 11 of 100

Fig. 2: Placing the pump set in a vertical or horizontal position
✓Suitable lifting equipment has been selected (e.g. crane).
1. a) For one piece of lifting equipment: Attach the eyehook to the bail of the
pump set.
b) For two pieces of lifting equipment: Attach one eyehook to the bail of the
pump set. Then suitably loop a rope around the pump set and attach this loop
to the second eye hook.
2. Lift the pump set with the lifting equipment.
⇨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!
3. Place the pump set on a level, clean surface and protect it against tipping over,
overturning or rolling off.
3.2.3 Transporting the pump set
WARNING
Incorrect positioning
Personal injury and damage to property!
▷Set the pump set down in a vertical position 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.
3 Transport/Temporary Storage/Disposal
12 of 100 Amacan S

WARNING
Improper handling when placing the pump set in a vertical/horizontal position
Personal injury and damage to property!
▷Depending on the size of the pump (set) use either one or two pieces of lifting
equipment.
▷Use appropriate means to secure the pump set against overturning, tipping
over or rolling off.
▷Maintain adequate safety distance during lifting operations (load may swing
when being lifted).
▷Use additional supports for the transport holder to secure the pump set against
overturning.
WARNING
Improper handling of the power cable when placing the pump set in a vertical
position or transporting it
Personal injury and damage to property!
▷Secure power cables against falling down.
WARNING
Improper lifting/moving of heavy assemblies or components
Personal injury and damage to property!
▷Use suitable transport devices, lifting equipment and lifting tackle to move
heavy assemblies or components.
Fig. 3: Transporting the pump set
Use suitable lifting equipment to transport the pump set in the illustrated position.
3 Transport/Temporary Storage/Disposal
Amacan S 13 of 100

3.3 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 a horizontal position
▪Without packaging: in a 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 packed or unpacked 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 conditions Value
Relative humidity 5 % to 85 %
(non-condensing)
Ambient temperature - 20 ℃ 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 every three months.
3.4 Return to supplier
1. Drain the pump as per operating instructions. (⇨ Section 7.3.2 Page 44)
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 damage when coming into contact with atmospheric humidity, or
which might ignite when coming into contact with oxygen, the pump set must
also be neutralised, and anhydrous inert gas must be blown through the pump
for drying purposes.
3 Transport/Temporary Storage/Disposal
14 of 100 Amacan S

4. Always complete and enclose a certificate of decontamination when returning
the pump (set).
Always indicate any safety and decontamination measures taken. (⇨ Section 11
Page 98)
NOTE
If required, a blank certificate of decontamination can be downloaded from the
KSB web site at: www.ksb.com/certificate_of_decontamination
3.5 Disposal
WARNING
Fluids, consumables and supplies which are hot and/or pose a health hazard
Hazard to persons and the environment!
▷Collect and properly dispose of flushing fluid 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
Amacan S 15 of 100

4 Description of the Pump (Set)
4.1 General description
Pump set for handling clean water, pre-screened river water and stormwater, waste
water without any long fibres or large solid particles, and activated sludge
4.2 Designation
Example: Amacan S 650-365 / 80 4 UAG2
Table 5: Key to the designation
Code Description
Amacan Type series
SImpeller type, e.g. S = mixed flow impeller
650 Nominal diameter of the discharge tube [mm]
365 Nominal impeller diameter [mm]
80 Motor size
4 Number of motor poles
4 4-pole
6 6-pole
UA Motor version
UA Non-explosionproof
G2 Material variant
G2 Grey cast iron, standard material variant
G3 Grey cast iron with Zn anodes, shaft made of 1.4057
stainless steel
4.3 Name plate
Mat. No. 01097374 ZN 3826 - M 24
TYPE
No.
Q
TEMP. MAX.
H
WARNING - DO NOT OPEN WHEN ENERGIZED
AVERTISSEMENT - NE PAS OUVRIR SOUS TENSION
MOTOR IP 68 SUBM. MAX. 30 m CLASS H
3 ~ M.-No.
Hz cosφ 0,82
IA/IN 5,3
P2
67227 Frankenthal
KSB Aktiengesellschaft
WARNUNG - NICHT UNTER SPANNUNG ÖFFNEN
EN
DE
FR
S1
1
2
3
4
11
12
13
6
5
7
8
9
10
15
16
17
14
18
19
20
Amacan S 650 - 365 / 80 4 UAG2
99719100010/000100
1700 m³/h 12 m
40 °C 1070 kg
2011
DKA 225.4-80
75 kW
1470 min-1 145 A
400 V 50
123456
Fig. 4: Name plate: standard pump set (example)
1 Designation 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
17 Power factor at design point 18 Rated frequency
19 Mode of operation 20 Starting current ratio
4 Description of the Pump (Set)
16 of 100 Amacan S

4.4 Design details
Design
▪Fully floodable submersible pump in discharge tube (submersible motor pump)
▪Not self-priming
▪Close-coupled design
▪Single-stage
▪Vertical installation
Impeller type
▪Open mixed flow impeller
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 Installation types
Six design variants4) are available for the following installation types:
4) For information on the various designs (foundation measurements, intake chamber, etc.) refer to the general arrangement
drawings.
4 Description of the Pump (Set)
Amacan S 17 of 100

Table 6: Installation types
BU discharge tube
Overflow design with open intake chamber
BG discharge tube
Overflow design for installation in covered intake chamber with low suction-side
water levels
CU discharge tube
Underfloor discharge with open intake chamber CG discharge tube
Design with underfloor discharge for installation in covered intake chamber with low
suction-side water levels
DU discharge tube
Above-floor discharge nozzle with open intake chamber
DG discharge tube
Design with above-floor discharge nozzle for installation in covered intake chamber
with low suction-side water levels
4 Description of the Pump (Set)
18 of 100 Amacan S

4.6 Configuration and function
1
2
3
4
57
6
8
9
10
Fig. 5: Amacan with mixed flow impeller
1 Suction nozzle (bellmouth) 2 Impeller
3 Pump casing 4 Electric motor
5 Shaft 6 Bearing housing, drive end
7 Bearing, drive end 8 Bearing, pump end
9 Bearing housing, pump end 10 Shaft seal
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 outward 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 pump casing (3) the kinetic energy of the fluid is converted into pressure
energy. The rotational movement diverts the fluid flow into a mixed 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 (7 and 8), which are supported by the
lower bearing housing (9) and the upper bearing housing (6).
The pump is sealed by two bi-directional mechanical seals in tandem arrangement.
A lubricant reservoir in-between the seals ensures cooling and lubrication of the
mechanical seals.
The pump sets are equipped with various sensors.
▪Temperature monitoring of the motor
▪Temperature monitoring at the lower bearing
▪Temperature monitoring at the upper bearing
▪Leakage monitoring of the mechanical seal system
Design
Function
Sealing
Monitoring
equipment
4 Description of the Pump (Set)
Amacan S 19 of 100

▪Leakage sensors in the motor space
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
▪O-ring
▪Back-up name plate
Optional:
▪Support rope
▪Accessories for mounting the cable guide
- Spacer
- Turnbuckle
- Support
- Shackle
- Clamps
▪Cable support sleeves
▪Flow-straightening vane to prevent floor vortices
▪Discharge tube
NOTE
A 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 of
installation, e.g. at the control panel, pipeline or mounting bracket.
4.8 Dimensions and weights
For dimensions and weights refer to the name plate or data sheet of the pump set.
4 Description of the Pump (Set)
20 of 100 Amacan S