KSB UPA Installation instructions

Submersible Borehole Pumps
UPA, UPZ, BSX
with motors of 1000 V operating voltage and above
50 Hz, 60 Hz
Installation/Operating
Manual
Mat.No.: 01463374

Legal information/Copyright
Installation/Operating Manual UPA, UPZ, BSX
Original operating manual
KSB Aktiengesellschaft
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
KSB's express written consent.
Subject to technical modification without prior notice.
© KSB Aktiengesellschaft Frankenthal 16.11.2012

Contents
Glossary .................................................................................................5
1 General ..................................................................................................6
1.1 Principles ...........................................................................................................6
1.2 Target group ..................................................................................................... 6
1.3 Other applicable documents ............................................................................ 6
1.4 Symbols .............................................................................................................7
2 Safety .....................................................................................................8
2.1 Key to safety symbols/markings ....................................................................... 8
2.2 General .............................................................................................................. 8
2.3 Intended use .....................................................................................................8
2.4 Personnel qualification and training ............................................................... 9
2.5 Consequences and risks caused by non-compliance with these operating
instructions ........................................................................................................ 9
2.6 Safety awareness ..............................................................................................9
2.7 Safety information for the operator/user ..................................................... 10
2.8 Safety information for maintenance, inspection and installation work ..... 10
2.9 Unauthorised modes of operation ................................................................10
3 Transport/Temporary Storage/Disposal .............................................11
3.1 Checking the condition upon delivery .......................................................... 11
3.2 Transport ......................................................................................................... 11
3.3 Storage and preservation ............................................................................... 13
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 ...................................................................................................... 17
4.4 Design details .................................................................................................. 17
4.5 Configuration and function ........................................................................... 18
4.6 Scope of supply ............................................................................................... 18
4.7 Dimensions and weights ................................................................................19
5 Installation at Site ...............................................................................20
5.1 General information/Safety regulations .......................................................20
5.2 Preparing the installation .............................................................................. 21
5.3 Installing the pump set in vertical position ..................................................27
5.4 Installing the pump set in a horizontal position ..........................................30
5.5 Installing the pump set in an angled position .............................................. 32
5.6 Notes on electrical connection ...................................................................... 32
5.7 Electrical connection ...................................................................................... 34
Contents
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6 Commissioning/Start-up/Shutdown ...................................................39
6.1 Commissioning/start-up ................................................................................. 39
6.2 Operating limits .............................................................................................. 41
6.3 Shutdown ........................................................................................................ 44
7 Servicing/Maintenance .......................................................................45
7.1 Servicing/inspection ........................................................................................ 45
7.2 Removing the pump set ................................................................................. 45
7.3 Separating pump and motor ......................................................................... 46
7.4 Motor fill ......................................................................................................... 47
7.5 Storage and preservation ............................................................................... 49
7.6 Reassembling the pump set ........................................................................... 50
8 Trouble-shooting ................................................................................53
9 Related Documents ............................................................................54
9.1 General assembly drawing with list of components .................................... 54
9.2 Mating dimensions for motors V, X, Z, E ......................................................58
9.3 Mating dimensions for motor T ..................................................................... 59
10 EC Declaration of Conformity ............................................................60
11 Certificate of Decontamination .........................................................61
Index ....................................................................................................62
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.
Pump set
Complete pump set consisting of pump, drive,
additional components and accessories
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 (see details listed below).
▪UPA 250C
▪UPA 300
▪UPA 350
▪UPZ
▪BSX
▪BRY
▪BRZS
▪BRE
▪BSF
▪T
▪V
▪X
▪Z
▪E
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, immediately contact your nearest KSB service centre to
maintain the right to claim under warranty.
1.2 Target group
This manual is aimed at the target group of trained and qualified specialist technical
personnel.(⇨ Section 2.4 Page 9)
1.3 Other applicable documents
Table 1: Overview of other applicable documents
Document Contents
Data sheet Description of the technical data of the pump (set)
General arrangement drawing/
outline drawing
Description of mating and installation dimensions
for the pump (set), weights
Hydraulic characteristic curve Characteristic curves showing head, NPSH
required, efficiency and power input
General assembly drawing1) Sectional drawing of the pump
Sectional drawing of the motor
Sub-supplier product literature1) Operating manuals and other product literature
describing accessories and integrated machinery
components
Spare parts lists1) Description of spare parts
Operating manual for
accessories1)
Description of accessories, e.g. cable connector
Pump sizes
Motor sizes
1) If agreed to be included in the scope of supply
1 General
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For accessories and/or integrated machinery components observe the relevant
manufacturer's product literature.
1.4 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 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.
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/motor 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 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.
!DANGER
2 Safety
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▪Never operate the pump without the fluid handled.
▪Never operate the motor without fill liquid.
▪Observe the minimum flow rates indicated in the data sheet or product literature
(to prevent overheating, bearing damage, etc).
▪Observe the maximum flow rates indicated in the data sheet or product
literature (to prevent overheating, mechanical seal damage, cavitation damage,
bearing damage, etc).
▪Do not throttle the flow rate on the suction side of the pump (to prevent
cavitation damage).
▪Do not let the motor run in the wrong direction of rotation for more than two
minutes.
▪Consult the manufacturer about any use or mode of operation not described in
the data sheet or product literature.
Prevention of foreseeable misuse
▪Never open discharge-side shut-off elements further than permitted.
–The maximum flow rate specified in the data sheet or product literature
would be exceeded.
– Risk of cavitation damage
▪Never exceed the permissible operating limits specified in the data sheet or
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 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
2 Safety
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▪Applicable standards 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.
▪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.
▪Prior to any dismantling work, disconnect the motor from the mains.
▪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.
▪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.
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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