KSB UPAchrom CC Installation instructions

Submersible Borehole Pump
UPAchrom
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual UPAchrom
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 SE & Co. KGaA, Frankenthal 30/01/2018

Contents
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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...................................................................................................................................................... 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 this manual .........................................................9
2.6 Safety awareness ..............................................................................................................................................9
2.7 Safety information for the operator/user.....................................................................................................10
2.8 Safety information for maintenance, inspection and installation ..............................................................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/handling/preservation......................................................................................................................11
3.4 Return to supplier...........................................................................................................................................12
3.5 Disposal ...........................................................................................................................................................13
4 Description of the Pump (Set)............................................................................................................. 14
4.1 General description ........................................................................................................................................14
4.2 Product information as per Regulation No. 547/2012 (for 4" and 6" water pumps) implementing
"Ecodesign" Directive 2009/125/EC ...............................................................................................................14
4.3 Designation.....................................................................................................................................................14
4.4 Name plate......................................................................................................................................................15
4.5 Design details..................................................................................................................................................15
4.6 Configuration and function...........................................................................................................................16
4.7 Scope of supply...............................................................................................................................................16
4.8 Dimensions and weights ................................................................................................................................17
5 Installation at Site................................................................................................................................ 18
5.1 Checks to be carried out prior to installation...............................................................................................18
5.1.1 Checking the motor fill......................................................................................................................18
5.1.2 Checking the installation position ....................................................................................................18
5.1.3 Connecting the cables .......................................................................................................................18
5.1.4 Measuring the insulation resistance .................................................................................................20
5.2 Installing the pump set in a vertical position ...............................................................................................21
5.3 Installing the pump set in a horizontal position ..........................................................................................23
5.4 Information on electrical connection............................................................................................................25
5.4.1 Operation with star-delta contactor, autotransformer and starting resistors...............................25
5.4.2 Operation with soft starter ...............................................................................................................25
5.4.3 Operation on a frequency inverter...................................................................................................26
5.5 Electrical connection ......................................................................................................................................27
6 Commissioning/Start-up/Shutdown................................................................................................... 29
6.1 Commissioning/Start-up.................................................................................................................................29
6.1.1 Start-up...............................................................................................................................................29
6.1.2 Checking the direction of rotation ...................................................................................................30
6.2 Operating limits..............................................................................................................................................31
6.2.1 Frequency of starts.............................................................................................................................31
6.2.2 Supply voltage....................................................................................................................................31

Contents
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6.2.3 Voltage limits .....................................................................................................................................31
6.2.4 Operation on a frequency inverter...................................................................................................31
6.2.5 Star point displacement.....................................................................................................................31
6.2.6 Fluid handled .....................................................................................................................................31
6.2.6.1 Minimum submergence ................................................................................................................31
6.2.6.2 Sand content..................................................................................................................................32
6.2.6.3 Temperature of the fluid handled ...............................................................................................32
6.3 Shutdown........................................................................................................................................................33
7 Servicing/inspection............................................................................................................................. 34
7.1 Servicing/inspection........................................................................................................................................34
8 Trouble-shooting.................................................................................................................................. 35
9 Related Documents.............................................................................................................................. 37
9.1 General assembly drawing of UPAchrom CC................................................................................................37
9.2 General assembly drawing of UPAchrom CN................................................................................................38
9.3 General assembly drawing of motor, DN 100...............................................................................................39
10 EU Declaration of Conformity............................................................................................................. 40
11 Certificate of Decontamination........................................................................................................... 41
Index ..................................................................................................................................................... 42

Glossary
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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.

1 General
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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
clearly 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 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. (ðSection2.4,Page9)
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)
General arrangement drawing/
outline drawing
Description of mating and installation dimensions
for the pump (set), weights
Drawing of auxiliary connections Description of auxiliary connections
Hydraulic characteristic curve Characteristic curves showing head, NPSH
required, efficiency and power input
General assembly drawing1) Sectional drawing of the pump
Sub-supplier product literature1) Operating manuals and other product literature
describing accessories and integrated machinery
components
Spare parts lists1) Description of spare parts
Piping layout1) Description of auxiliary piping
List of components1) Description of all pump components
Drawing for assembly1) Sectional drawing of the installed shaft seal
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) If agreed upon in scope of supply

1 General
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Symbol Description
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product

2 Safety
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2 Safety
!DANGER
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 Directive
2014/34/EU (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 operating manual contains general installation, operating and maintenance
instructions that must be observed to ensure safe operation of the system and
prevent personal injury and damage to property.
The safety information in all sections of this manual must be complied with.
The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
The contents of this operating manual must be available to the specialist personnel
at the site at all times.
Information attached directly to the product must always be complied with and 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 operating manual.
2.3 Intended use
▪The pump (set) must only be operated within the operating limits described in
the other applicable documents. (ðSection1.4,Page6)
▪Only operate pumps/pump sets which are in perfect technical condition.
▪Do not operate the pump (set) in partially assembled condition.

2 Safety
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▪Only use the pump to handle the fluids described in the data sheet or product
literature of the pump model or variant.
▪Never operate the pump without the fluid to be handled.
▪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).
▪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 the discharge-side shut-off elements further than permitted.
–The maximum flow rates specified in the product literature or data sheet
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 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, directives and laws

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
▪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 maintenance, inspection and installation 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.
▪The maximum length of the riser is 2metres so as not to exceed the max.
permissible bending moment.
▪Additionally secure the riser against loosening.
▪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 has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning. (ðSection6.1,Page29)
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.
(ðSection2.3,Page8)

3 Transport/Temporary Storage/Disposal
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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 and the insurer about the damage in writing
immediately.
NOTE
The pump set is supplied by the manufacturer/supplier in packaging which largely
prevents sagging or other damage during transport and/or storage.
3.2 Transport
CAUTION
Pump set tipping over or slipping out of the suspension arrangement
Personal injury and damage to property!
▷Always make sure pump sets in upright position cannot tip over.
NOTE
Take into account the unequal weight distribution between pump and motor.
Select hoisting tackles suitable for the weight of the pump set.
Take care not to bend or damage the power supply cable during transport.
3.3 Storage/handling/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken:
WARNING
Pump set tilting or rolling off
Risk of personal injury!
▷Always secure vertically positioned pump sets against tipping over.
▷Always secure horizontally positioned pump sets against rolling off.
WARNING
Laying cables at temperatures below zero degrees
Damage to the cables!
▷Observe the minimum permissible temperature at the cable surface of -25 °C for
moving cables.
▷Observe the minimum permissible temperature at the cable surface of -40 °C for
stationary cables.
CAUTION
Pump stored at wrong temperature
Damage to the pump!
▷The pump must be stored at a temperature range of -20°C to +60°C.

3 Transport/Temporary Storage/Disposal
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CAUTION
Ambient temperature below the specified minimum
Danger of frost!
▷Never subject the pump set to ambient temperatures which are lower than
those permitted for the drinking water/antifreeze mixture provided (see section
on drinking water/antifreeze mixture / order documentation).
CAUTION
Improper storage
Damage to the power cables!
▷Support the power cables at the cable entries to prevent permanent
deformation. Observe the minimum bending radius2) of the cables.
▷Only remove the protective caps from the power cables at the time of
installation.
For temporary storage, store the submersible borehole pumps as follows:
1. In the original packaging: in a horizontal position
2. Without packaging: in a vertical position (with the motor below)
3. In a dry environment
4. Protected against direct sunlight and heat
5. Protected against dirt and dust
6. Protected against freezing
7. Protected against vermin
3.4 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 pump set has handled fluids whose residues could lead to corrosion
damage in the presence of atmospheric humidity or could ignite upon contact
with oxygen, the pump set must also be neutralised, and anhydrous inert gas
must be blown through the pump to ensure drying.
4. Always complete and enclose a certificate of decontamination when returning
the pump (set).
Always indicate any safety and decontamination measures taken.
(ðSection11,Page41)
NOTE
If required, a blank certificate of decontamination can be downloaded from the
following web site: www.ksb.com/certificate_of_decontamination
2) See cable manufacturer's documentation or DIN VDE 0298-3.

3 Transport/Temporary Storage/Disposal
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3.5 Disposal
WARNING
Fluids handled, 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 fluid residues.
▷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.

4 Description of the Pump (Set)
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4 Description of the Pump (Set)
4.1 General description
Pump for handling clean or slightly contaminated water.
Verify the fluid composition against the data sheet.
Not approved for handling explosive fluids or for forming part of an explosion-proof
system!
4.2 Product information as per Regulation No. 547/2012 (for 4" and 6" water
pumps) implementing "Ecodesign" Directive 2009/125/EC
▪Minimum efficiency index: see name plate, key to name plate
▪The benchmark for the most efficient water pumps is MEI ≥ 0.70.
▪Year of construction: see name plate, key to name plate
▪Manufacturer’s name or trade mark, commercial registration number and place
of manufacture: see data sheet or order documentation
▪Product’s type and size identificator: see name plate, key to name plate
▪Hydraulic pump efficiency (%) with trimmed impeller: see data sheet
▪Pump performance curves, including efficiency characteristics: see documented
characteristic curve
▪The efficiency of a pump with a trimmed impeller is usually lower than that of a
pump with full impeller diameter. Trimming of the impeller will adapt the pump
to a fixed duty point, leading to reduced energy consumption. The minimum
efficiency index (MEI) is based on the full impeller diameter.
▪Operation of this water pump with variable duty points may be more efficient
and economic when controlled, for example, by the use of a variable speed drive
that matches the pump duty to the system.
▪Information on dismantling, recycling and disposal after decommissioning:
(ðSection3.5,Page13)
▪Information on benchmark efficiency or benchmark efficiency graph for
MEI=0.70(0.40) for the pump based on the model shown in the Figure are
available at: http://www.europump.org/efficiencycharts
4.3 Designation
Example: UPAchrom 100-12/8 CC - DN100-3,0, 1~230V, 50Hz
Table4: Designation key
Code Description
UPAchrom Pump type series DN 100
100 Well diameter [mm]
12 Flow rate at best efficiency point [m³/h]
8 Number of stages
C Casing material AISI 304
C C Impeller material AISI 304
N Impeller material Noryl
DN100 4-inch motor, water-filled
3,0 3.0kW
1~230V Electrical voltage
50Hz Mains frequency

4 Description of the Pump (Set)
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4.4 Name plate
Serialnr. 99720202635-000100-01
1
2
3
5
6
7
18
19
20
Pumpe UPAchrom CC - 1/9
Qmin
Qmax
Q
Motor
0,37 KW
400 V
Temp.
Strömung am Motor min. C = 0,2 m/s
EN 60034-1 IP 68
Mat-No.: 01 000 854 ZN 3823 - D 88
0,16 M3/H
2,5 M3/H
1,69 M3/H
Hmax
Hmin
H
43,00 M
16,00 M
29,71 M
3~ DN 100 0,37
50 HZ
1,1 A 0,74 COS
max. 20 °C 2.870 1/MIN
8
9
13
14
11
22
21
23
24
MEI ≥ 0,4 η --,- % Mat.-Nr. __________
2012
Gewicht 12 kg
10
12
4
15
16
17
Johann-Klein-Straße 9
Deutschland
67227 Frankenthal
KSB SE & Co. KGaA
Fig.1: Name plate
1 Order number 2 Minimum efficiency index
3 Pump designation 4 Efficiency (see data sheet)
5 Minimum flow rate 6 Maximum flow rate
7 Flow rate at duty point 8 Motor designation
9 Rated power 10 Electrical voltage
11 Frequency 12 Weight
13 Maximum fluid temperature 14 Minimum available flow velocity
past the motor
15 Year of construction 16 Material number
17 Maximum head 18 Minimum head
19 Head at duty point 20 Power factor
21 Amperage 22 Speed
23 EN standard 24 Motor enclosure
4.5 Design details
Design
▪Centrifugal pump
▪Submersible motor in squirrel-cage design
▪Rigid connection between pump and motor
▪Shroud design
Impeller type
▪Radial or mixed flow versions
Bearings
▪Radial and thrust bearings lubricated by the motor fill
Shaft seal
▪In the motor

4 Description of the Pump (Set)
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4.6 Configuration and function
Fig.2: Sectional drawing, example of an UPAchrom
Design Pump and motor are connected by a rigid coupling. The stage casings are supported
by a pump shroud, by straps or studs. A suction strainer at the suction casing protects
the pump from coarse particles in the fluid. The pipe is connected via a lift check
valve or connection branch, with either internal thread or flanged end.
Function The fluid flows along the motor and enters the suction casing (2) through the suction
strainer (1). It is accelerated outward by the suction impeller (3). In the flow passage
of the stage casing (4) the kinetic energy of the fluid is converted into pressure
energy, and the fluid is routed to the next impeller (5). This process is repeated in all
stages until the fluid has passed the last impeller (5). It is then guided through the
integrated lift check valve (6) to the connection branch (7), where it leaves the pump.
The integrated lift check valve prevents uncontrolled backflow of the fluid.
4.7 Scope of supply
Depending on the model, the following items are included in the scope of supply:
▪Pump set with motor lead
▪Extension cable
optional: connected or supplied but not fitted
▪Back-up name plate
Optional accessories:
▪Cable connector
▪Cable clips
▪Cooling shroud
▪Pedestals
▪Electrical protection equipment
▪Automatic control units

4 Description of the Pump (Set)
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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 please refer to the data sheet of the pump (set).

5 Installation at Site
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5 Installation at Site
5.1 Checks to be carried out prior to installation
5.1.1 Checking the motor fill
The pump set can be installed directly in a vertical or horizontal 3) position without
any further preparations. The motors are filled at the factory with water and
antifreeze agent. The loss of a few drops of liquid fill will not impair the motor
function as the motor will self-prime with clean well water after it has been installed.
If larger quantities of leakage are suspected, contact the manufacturer!
5.1.2 Checking the installation position
WARNING
Impermissible installation position
Damage to the machine! Damage to the bearings!
▷For angled installation, always install the pump set with a rising slope towards
the discharge side.
The pump set can be installed in a vertical or, depending on the number of stages,
also in an angled or horizontal position.
The pump set must not be installed with the pump as the lowest point.
A
B
Fig.3: Installation position
A Permitted B Not permitted
Particularities of horizontal installation
Check the following criteria before installing the pump set in a horizontal position:
▪Has the pump set been ordered for horizontal installation?
▪Has a sufficiently dimensioned cooling shroud or cooling hood been provided?
Pump sets originally selected for vertical installation must not be installed
horizontally.
Only pump sets equipped with cooling shrouds may be installed horizontally.
5.1.3 Connecting the cables
DANGER
Unqualified personnel connecting extension cables
Installation in a well - electric shock!
▷The extension cable must be connected by a professional electrician only.
▷The cable ends must be dry and clean.
3) Only if equipped with a cooling shroud

5 Installation at Site
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DANGER
Earth conductor not properly connected
Danger of death from electric shock!
▷Never operate the motor without earth conductor.
▷The earth conductor must be connected by a professional electrician only.
NOTE
The motor lead is selected for submerged operation and must be completely
submerged, including the cable connector.
See order documentation for any other use!
For pump sets installed in VdS-approved sprinkler installations always refer to and
observe the applicable requirements stipulated by VdS (German association of
property insurance companies). In accordance with VdS 2025, the cable must be laid
in such a way that it is protected against short circuit and earth fault.
NOTE
Before fitting the submersible cable to the motor verify that the cable entry is clean
and dry. Apply a non-conductive silicone paste to the rubber elements of the cable
connector to facilitate assembly.
Submersible motors are supplied fitted with a motor lead. The motor lead has been
extended with a suitably sized extension cable to meet the length required for the
specific installation. Unless otherwise indicated, the motor lead is designed for
submerged operation only. To meet this condition the cable connector also has to be
completely submerged.
Extension cables connected by KSB
If agreed with KSB, the extension cable can be supplied connected to the motor lead
with a watertight cable connector.
▪Unless otherwise specified in the order documentation, KSB's extension cables
are designed for:
–Being laid freely exposed to air and in contact with surfaces
–A voltage drop along the cable of ᅀV≦3%
For any other ways of laying the cable, e.g. in cable ducts, etc. observe the
information on the maximum current-carrying capacity as per the applicable
directives.
Extension cables connected by the operator
If the supplied extension cable is to be connected at the site, observe the following:
1. Observe the installation instructions of the cable connector to be used.
2. If the operator is responsible for connecting an extension cable, make sure the
extension cable is selected and dimensioned for a maximum voltage drop of
≦3%. The extension cable has to be approved for the applicable operating
conditions.
3. In 4-core cables the earth conductor is part of the power cable and must also be
connected in the cable connector when connecting an extension cable.
4. 3-core motor leads do not include an earth conductor. A separate earth
conductor is connected on the outside of the motor. The earth conductor has to
be extended and connected separately.

5 Installation at Site
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If no earth conductor is provided, the operator shall be responsible for earthing
the motor externally. (Core cross-section corresponding to phase conductor, min.
4 mm2)
5. Connect the shield of shielded extension cables to the earth conductor. 3-core
motor leads as described in paragraph 4 must be earthed externally; connect the
shield of the extension cable to the earth conductor.
6. Transfer the core identification of the motor lead to the cores of the extension
cable. Make sure the colour codes match when connecting the cores.
The core codes depend on the wiring type of the motor:
Table5: Core codes
Motors for DOL starting with 1 cable
U V W
Motors for star/delta starting with 2 cables
U 1 V 1 W 1 U 2 V 2 W 2
Motors for DOL starting with 2 parallel cables
U1 - 1 V1 - 1 W1 - 1 U1 - 2 V1 - 2 W1 - 2
5.1.4 Measuring the insulation resistance
DANGER
Hazardous voltage during and after measurement
Danger of death from electric shock!
▷Do not touch the contact points during and immediately after measurement.
▷Insulation resistance measurement must be effected by a trained electrician
only.
Measure the insulation resistance prior to installation and prior to connection to the
power supply.
Insulation resistance measurement must be effected by a trained electrician only.
Prior to the measurement, ensure compliance with the operating instructions of the
insulation resistance measuring device.
üAn insulation resistance measuring device with a measuring voltage of 1000 V DC
is available.
üThe contact points are clean and dry.
1. Measurement period: 1 minute4)
2. Recommendation: insulation value at 20°C - 30°C: > 200MOhm 5)
4) The measured value must be steady; a longer measurement period might be needed for larger cable cross-sections.
5) The insulation resistance depends on the cable type and length.