KSB UQD 112 User manual

Submersible Motor pumps
Operating Instructions
3300.8115 / 04 - 85 G3
Submersible Motor Pumps (50 Hz)
150 mm + 150 mm
175 mm + 150 mm
200 mm + 150 mm

Submersible Motor Pumps (150 mm and above)
Sr. no. Description Page no.
1General 1
2Safety of Pumpset 1
2.1 Safety checks of Pumpset 1
2.2 Labeled instruction on pumpset 1
2.3 Unauthorized spare parts and modifications 1
2.4 Unauthorized mode of operation 1
2.5 Unauthorized site condition 1
2.6 Water characteristics 1
3.0 Preparation for Installation 1
3.1 Installation and operational accessories 1
3.2 Auxiliary equipment required for installation
and dismantling 1
3.3 Motor preparations for installation 2
3.3.1 Motor filling 2
3.3.2 Insulation resistance (IR) 2
3.3.3 Selection of Extended Cable 2
3.3.4 Extended Cable connection 2
3.4 Preparation of Pump set for installation 3
4Vertical installation 3
5Horizontal Installation 4
6Cable connection to the Switchgear 5
6.1 Motor with 1 cable 5
6.2 Motor with two cables 5
6.2.1 Submersible motor with open circuit 5
6.2.2 Motor with two cables in parallel 5
7Commissioning and start up 6
7.1 Verification of power supply 6
7.2 Trip circuit for over current 6
7.3 Protection against electric shock 6
7.4 Installation of water level guard 6
7.5 Checking the direction of rotation 6
7.6 Discharge valve position during initial start-up 6
7.7 Operation against a closed discharge valve 6
7.8 Operation against a throttled discharge valve 6
7.9 Operating limits of pump 6
7.10 Start-up frequency 6
7.11 Interruptions / Shutdown periods 6
Contents
Sr. no. Description Page no.
8Maintenance & Service 6
8.1 Supervision of Operation 6
8.2 Storage of used pumset 6
8.3 Services 7
9Dismantling 7
9.1 Pumpset 7
9.2 Pump U type (UQD) 7
9.3 Pump B type (BPD, BPI & BPHA) 7
9.4 Motors 7
10 Reassembly 7
11 Trouble shooting 8
11.1 Motor 8
11.2 Pump 9
12 Recommended spare parts for 2 years
of operation 10
12.1 Pump 10
12.2 Motor 10
13 Pump Construction (Schematic) 11
13.1 Radial flow pump (150mm) - UQD 112, 152, 182
& 212 11
13.2 Mixed flow pump (150/175/200mm) -
BPD 242, 273, 301 BPI 333 & BPHA 333, 384 12
14 Motor Constructions (Schematic) 13
14.1 UMA I 150 (Up to 15 HP) 13
14.2 UMA G 150 (Above 15 HP) 14
Annexure I - Environment Protection -
Product Disposal after useful life 15

Submersible Motor Pumps (150 mm and above)
1
1. General
KSB’s submersible Pump-motors, generally referred as
“pumpsets” in this manual are developed in accordance with
state- oftheart of design and manufacturing technology, with
extreme care and rigid quality control. This manual contains
important information for reliable operation of the pumpset.
The special feature of this submersible pumpset are installation
in narrow deep wells to pump the clean water for various
applications like water supply systems, irrigation & sprinkling
systems, ground water pumping, pressure boosting, fountains
etc.
For any additional information or instructions, please contact
KSB’s nearest office.
2. Safety of Pumpset
This operating manual contains fundamental installation,
operation and maintenance instructions. Hence this must be
clearly understood by concerned people, prior to the installation,
operation & maintenance. The booklet must always be located
for easy access at site.
2.1 Safety checks of Pumpset
•After the receipt of pumpset in a packed condition, check it
for any damages during transit and if observed, inform to the
concern KSB’s Dealer.
•Avoid lifting & dragging of motor through cable.
This operating manual does not take into account any safety
regulations those may apply specifically to the site. It’s a pump
operator’s responsibility that any such regulations are adhered
to.
2.2 Labeled instruction on pumpset
Follow the instructions given on the motor / pump e.g.
-Various plugs for water connections viz. filling, venting,
draining etc. on motor.
-Arrow indicating the direction of rotation.
2.3 Unauthorized spare parts and modifications
Modifications or alterations of the pumpset are strictly not
permitted. Original spare parts from KSB and accessories
authorized by the KSB only ensure safety of the pumpsets.
The use of spurious parts invalidates any warranty liability of
the manufacturer.
2.4 Unauthorized mode of operation
The warranty related to the operation reliability and safety of
the pumpset supplied is valid only if the equipment is operated
as per the designated parameters that have been mutually
agreed upon. The operating limits should not exceed from the
limits of Flow “Q” & Head “H” specified on the pump nameplate
and Voltage & Current in Amp specified on the motor nameplate.
2.5 Unauthorized site condition
The warranty of the pumpset will be in accordance with our
terms of Warranty Certificate. Our warranty will not apply if;
•The pump is used for handling the liquids other than those
specified / mutually agreed.
•The damages to the pumpset arise due to corrosion & erosion
or due to incorrect electrical supply connections or due to
reason not attributable to KSB.
2.6 Water characteristics
Submersible pumps are designed for handling the clean water,
within the following main characteristics: (As per IS 8034: 2002)
a) Turbidity : 50 ppm*, Max (Silica scale)
b) Chlorides : 500 ppm*, Max
c) Total Solids : 3000 ppm*, Max
d) pH value : 6.5 to 8.5
e) Temperature : 33oC, Max
f) Specific gravity : 1.004
g) Hardness : 300, Max (Drinking water)
* ppm - parts per million
3.0 Preparation for Installation
3.1 Installation and operational accessories
The following accessories are necessary for installation and
commissioning of the pumpset :
•Extended cable (to be calculated as per 3.3.3) with
vulcanizing Rubber compound / Cushion compound and
electric insulation PVC tapes.
•Control panels with protection devices, Discharge Valve,
Pressure Gauge, Discharge pipes.
•Overload Trip unit, Water Level Guard,
•2 Pairs of supporting or installation clamps for vertical
installation (for Horizontal installation supporting arrangement
as shown in Fig. 7)
(The motor is supplied with 3 core waterproof cable in standard
length of 3.25 meter).
3.2 Auxiliary equipment required for installation
and dismantling
For installing and removing the pumpset, reliable lifting device
(e.g. crane, chain pulley block) is required to handle the total
weight of the pumpset, riser pipe and an extended cable weight.
Please refer Table no 1 & 2 for the weight of pump and motor
respectively.Weight of pumpset for respective stages needs to
be calculated from Table no. 1.
Pump Type Approx. Wt. of Per stage
one stage pump Approx. Wt. (kg.)
UQD 112 20 1
UQD 152 20 1
UQD 182 20 1
UQD 212 25 1.5
BPD 242 30 3
BPD 273 30 3
BPD 302 30 3
BPI 322 40 5
BPHA 333 40 7
BPHA 384 40 7
Table No. 1 : Per Stage weight of the pump

Submersible Motor Pumps (150 mm and above)
2
Bore of pipe Wt. of water Bore of pipe Wt. of water
column column
inch mm lb/ft. kg/m inch mm lb/ft. kg/m
1.5 40 0.9 1.3 5 125 8 12
2 50 1.3 2 6 150 12 18
2.5 65 2.2 3.3 8 200 21.5 32
3 80 3.4 5 10 250 33 49
4100 5.4 8
Table No. 3 : Weight of water column
Cross - section area Resistance in Ohm / m
(mm2)At 30oC
1.5 0.0124
2.5 0.0075
4.0 0.0047
6.0 0.0031
10 0.0019
16 0.0012
25 0.00073
35 0.00054
50 0.00040
Motor Type Weight
(Kg.)
UMA I 100 1.5/22 17
2.2/22 22
3/22 38
4/22 40
UMA I 150 6/22 45
8/22 48
9/22 58
13/22 66
16/21 79
UMA G 21/21 90
24/21 98
Table No. 2 : Weight of Motor
In addition to the above, the weigtht of the water column present
in the riser pipe also needs to be considered. Refer Table No. 3
for weight of water column.
3.3 Motor preparations for installation
3.3.1 Motor filling
Before installation in the well, the motor must be filled with clean
potable water. The following procedure may be adopted for filling:
•Place the motor vertically up.
•Remove the two plugs provided at the top of the motor (One
plug is for air ventilation and another is for water filling).
•Fill the motor completely with clear potable water (Do not
use distilled / acidic water).
•Let the motor stand for 30 minutes, rotate motor rotor by
hand or rock the top end of the motor slightly for natural
venting.
•Top up the water to fill the loss of volume caused by the
escaped air.
•Plug the motor.
•Check the motor for any water leakage.
Now motor is ready to couple to the pump.
3.3.2 Insulation resistance (IR)
The insulation resistance value (with 500 V DC megger) should
not less than 20 Mega Ohms for the new motor & 2 mega ohms
for old motor. If observed, please contact KSB or Authorized
Dealer before switching the motor ON.
3.3.3 Selection of Extended Cable :
Proper selection of cables ensures smooth and safe operation
of the pumpset. For the selection of extended cable, voltage
drop needs to be calculated. Voltage drop for extended cable
should not be more than 3 % of rated voltage i.e.Permissible
voltage drop = Avaiable voltage at site x 0.03
For three phase motor :
Voltage drop = Cable Length in meters x Resistance / meter
for particular cable size (as per Table No 4 below) x motor rated
current (mentioned on the name plate)
Permissible voltage drop is up to 12.5 volts (Considering
available voltage at site is 415 volts).
e.g. A 3 ph motor with cable length of 100 mtr, the cross-
sectional area 2.5mm2and rated current 4 A,
The Voltage drop = 100 x 0.0075 x 4
=3 volts (which is less than permissible
voltage drop)
Table No 4 : Resistance / meter for different cable sizes
3.3.4 Extended Cable connection
Only the proper cable connection ensures a perfect watertight
joint and provides a protection against mechanical damage to
the cable jointing and offers good electrical connection. Thus,
while connecting extra cable beyond standard cable length
(supplied with motor), it is necessary to have a watertight cable
joint for the cable connection.For which the following procedure
will help -
•Cut and strip the cable leads.
•Join it in staggered fashion as shown in the Fig.1.
(Ensure that the same color leads joined to each other as
per the Fig.1)
•Wrap vulcanizing rubber compound to each cable joint and
then wrap it with insulation tape.
•Once again wrap vulcanizing rubber compound and
insulation tape on each joint to ensure proper insulation.
•Finally wound the total cable joint with electric insulation tape.
(Oil or grease should not come in contact with electric
insulation tape)
•Complete the taping over core insulation at each side.
Note : Please see that each turn of the tape should have 50%
overlap over the previous turn. The tape should be wound to
the thickness at least equal to that of core insulation.

Submersible Motor Pumps (150 mm and above)
3
Fig. 2 : Coupled pump & motor
Fig. 3 : Supporting the submersible pumpset during installation
Fig. 1: Extended Cable connection
R = Red colour lead
Y = Yellow colour lead
B = Blue colour lead
3.4 Preparation of Pump set for installation
In order to avoid transit damage, motor and pump are supplied
in uncoupled condition. They are to be coupled at site, as
describe below
•Keep the motor, duly filled with water as per 3.3.1, vertically
on the ground.
•Couple the pump & motor shaft by a coupling. (use strong
crane / chain pulley block / hoist or any other similar lifting
device to lift the pump).
•Lock the coupling on the motor shaft with the help of grub
screw provided along with the coupling. (for 4" motor + 6"
pump combination, this is not required).
•Couple the pump and motor with the help of four studs and
nut provided on the top face of motor.
•Check free rotation of coupling / rotor.
•Fit the strainer on Suction casing.
•Pass the cable through cable protection pipe.
The pump set is now ready for installation.
4.0 Vertical installation
Before installing the pumpset in the bore well, it is recommended
to check the trueness of the borewell throughout its depth by
pattern. (Pattern: A piece of pipe of overall length and diameter
equal to the max diameter of the pumpset). A slight inclination
of the well is immaterial so long as the clearance is sufficient
for the pumpset to lower easily into the bore, but any twist or
bend can make installation difficult or even impossible.

Submersible Motor Pumps (150 mm and above)
4
Fig. 4 : Installed Pumpset
5.0 Horizontal Installation
Fig .3 shows the installation and suspension of the pumpset.
The first section of the pipe, to which a pair of mounting clamps
is to be fixed at a suitable height, is connected to the pumpset.
The pumpset is hanged by means of pulley block. It is then
lowered until the second mounting clamps rest on the edge of
the well. Successive lengths of the pipes are added in the same
way to reach the necessary installation depth. (The threaded
pipe section must be firmly tight and if necessary locking device
fitted so that the pumpset will not fall into the well)
Installation depth to be selected in such a way that the motor
should never run dry even when the water level reaches to its
lowest level. (i.e. draw down of bore well capacity). The
minimum water level should be 0.5 m above the top of the non-
return valve.
During installation the cable must not be subjected to any of
distortion or strain. The power supply cable should be fixed to
the riser pipe by means of Rubber Band at a distance of approx.
3 meter. The Rubber Band must grip the cable firmly enough to
prevent its slipping down under its own weight. Also the opening
should be provided in the in the pipe flange for cable entry to
avoid the cable rubbing against the wall of borewel. Also refer
Fig. 4 for installation.
1. Discharge valve
2. Supporting clamp
3. Riser pipe
4. Submersible motor-pump set
5. Power supply cable
6. Starter
7. Slotted Casing pipe
(Length up to soft rock level)
8. Pressure Gauge
9. Cable clamp
10. Non return valve
Fig. 5 : Horizontal installed pumpset (in tank or pit)
1. Control Valve
2. Support
3. Riser Pipe
4. Submersible Pumpset
5. Water reservoir for Motor
6. Expansion Joint
7. Ventilation
8. Pressure gauge
Note : The horizontal installation of submersible pumpset
is required to be equipped with two storage tanks to maintain
water level in the motor. Contact Authorized Dealer / nearest
KSB Office for such installation.
•For horizontal installation, support system & intallation to be
made as shown in the fig. 5.
•To align pump-motor, provide sufficient metallic packing in
the foundation itself. To attain precise alignment, minor shims
up to 2 mm thick (M. S.) sheet can be used.
•Such installed pumpset shall be either perfectly horizontal
or maximum 5 degree inclination with motor down and pump
side lifted up from the ground. Precise tightening of foundation
bolts has to be done at the final stage.
•Refer Table No. 5 for limits of Horizontal Installation.
Pump Motors Max. stages allowed for
horizontal execution
50 Hz 60 Hz
UQD 112 UMA I 150 10 10
UQD 152 UMA I / G 150 10 10
UMA I 100
UQD 182 10 10
UQD 212 10 10
BPD 242 UMA I / G 150 8 8
BPD 273 7 7
BPD 302 7 7
Table No. : 5 Horizontal execution limits for submersible
pumpset
Note : On no account, the pumpset should rest on the bottom
of the bore well. The pumpset should be installed in such a way
that no silting or sanding can occur in the region of the motor,
as this would seriously impair the heat dissipation from the
motor.
D = Well diameter
TB= Well depth
He= Installation depth
Hh= Stationary water level
Ht = Operation water level
Hgeo = Geostatic head
Ht - Hh = Drawdown

Submersible Motor Pumps (150 mm and above)
5
Fig. 7 : DOL starting
6. Cable connection to the Switchgear
To facilitate the connection of cable to the Switchgear (Panel),
the individual cores to be labeled as U or U1 or U2 (Red colour
lead), V or V1 or V2 (Yellow colour lead) & W or W1 or W2
(Blue colour lead ) as shown in the Fig. 6, 7, 8 & 9.
Protective conductor (if provided) is colored yellow-green and
to be led separately to connect to the earth terminal of
Switchgear.
6.1 Motor with 1 cable
Motor with one cable is suitable for direct online (DOL) starting.
The individual cores U, V & W to be connected to the Switchgear
as shown in the Fig. 6. The inside connection of the motor is
Star or Delta.
Fig. 6 : Motor with 1 cable for DOL starting
1. Submersible motor
2. Cable
3. Switchgear panel
4. Cable leads
5. Incoming supply
6.2 Motor with two cables
Distinguish initially between the motor with open circuit and the
motor with two cables parallel, by following way.
1. If there is continuity between any two of U1–V1-W1-U-V-W
the motors are connected like two cables in parallel.
2. If there is only continuity between U1-U,or V1-V or W1-W
then the motor are connected in open ckt.
6.2.1 Submersible motor with open circuit
Motors with open circuit have the provision of either to connect
to DOL panel with autotransformer or star-delta panel,
depending on the feasibility/ availability.
Fig. 8 : Submersible motor with open circuit
1. Submersible motor
2. Cable
3. Switchgear panel
4. Cable leads
5. Incoming supply
6.2.2 Motor with two cables in parallel
In case of two cables in parallel, only direct on line (DOL) or
autotransformer starting (ATS) is possible. Connection to be
made as shown in the Fig. 9.

Submersible Motor Pumps (150 mm and above)
6
1. Submersible motor
2. Cable
3. Switchgear panel
4. Cable leads
5. Incoming supply
Fig. 9 : Two cable in parallel motor connection
7.0 Commissioning and start up
7.1 Verification of power supply
Verify the voltage and frequency of main supply with the data
specified on the motor nameplate. If it is not matching then
consult with concerned electrical authority.
7.2 Trip circuit for over current
A temperature compensated over current relay to be provided
in the control panel. For the Relay setting, please refer the value
of rated current specified on the nameplate.
7.3 Protection against electric shock
The earth conductor to be connected to the earthing Lug,
provided at upper part of the motor. The operator / user shall be
responsible for proper connection of the earthed conductor and
of control unit at site.
7.4 Installation of water level guard
Install a water level guard for dry running protection to avoid
the damage of pumpset in case of fluctuation in water level.
7.5 Checking the direction of rotation
To determine the correct direction of rotation of the pumpset,
•Close the discharge valve and let pumpset run in both the
directions (Direction can be changed by reversing the two
phases in the supply connection) for a short. In both cases
check the flow by opening the discharge valve.(Higher flow
rate corresponds to the correct direction of rotation.) OR
•Check the discharge pressure in both the directions of
rotations (by using pressure gauge). The higher value of
pressure corresponds to the correct direction of rotation.
7.6 Discharge valve position during initial start-
up
During initial startup, the pumpset should run for 10 minutes
approximately with discharge valve slightly open (approx.1/3
of full opening) and examined for the sand contains. If the sand
contain is more than 50 mg / liter then it is recommended to run
the pumpset till sand contain fall to the unnoticeable
level.Otherwise sand will block the pump internals resulting in
damage.
7.7 Operation against a closed discharge valve
Pumpset should not be allowed to run against a closed discharge
valve for more than 5 minutes. This is because the water trapped
in the pump will heat up very quickly and this heat will transfer
to the motor, where it will cause the winding damage.
7.8 Operation against a throttled discharge
valve
If the pump set operated against throttled discharge valve for a
prolonged period of time, the flow must not fall below Qmin. OR
be at least 10% of the flow at best efficiency point* (BEP). This
needs to be ensured in order to reduce noisy operation and the
overheating of the pump set.
*For best efficiency point (BEP) of the characteristic curve
consult KSB / Dealer.
7.9 Operating limits of pump
Operational safety requirements stipulate that pump should only
be operated continuously within the flow rate and pump head
limits, specified on the nameplate. Otherwise ±10% of best
efficiency flow rate should be the pump operation range,
provided that motor is not overloaded. (To ensure this, check
the motor current which should not exceed as specified on
nameplate).
7.10 Start-up frequency
In order to prevent the overheating of motor winding, startup
frequency is restricted up to 15 per hour. (Ensure minimum 3
min. down time between switch OFF & switch ON again).
7.11 Interruptions / Shutdown periods
For prolonged service, the pump should not be allowed to remain
idle / stationary in water for more than 8 to 10 days, otherwise
fine deposits like lime, iron and other substances will settle in
the bearings and impeller gaps. This might block the pump rotor.
If operating conditions require the pump to remain not in use for
a long period, it is recommended to run the pump atleast 10 to
15 minutes in a week. This will enable the pump to resume
instant service at any time.
8.0 Maintenance & Service
8.1 Supervision of Operation
Basically submersible pumpset require no supervision or
maintenance during operation. However the current absorbed
by the motor should be checked from time to time on the
ammeter, also the total head on the pressure gauge in order to
confirm that these instruments indicate the same values as at
the start of operation and do not exceed those indicated on the
nameplate.
8.2 Storage of used pumpset
Always store the motor in upright position and away from the
direct sunlight, heat, dust and frost.For prolonged storage (more
than 1 year), pump should be dismntaled, cleaned and
reassembled. Before reassembly, all the rubbing and sliding
surfaces (except rubber bearings) should be well coated with
graphite base lubricant. On no account, use any grease
containing acid for this purpose.

Submersible Motor Pumps (150 mm and above)
7
Before reinstallation, check the free rotation of both shafts by
hand and water level.
8.3 Services
Do not attempt to open the motor / pump for repair that will render
our warranty null & void. Please take up with Authorized
Service Center or to the concerned dealer.
Unauthorized repair are not permitted since it will cause poor
performance and impair / shorten life of the pumpset.
9.0 Dismantling
Note : Numbers in bracket are the Part Nos.
9.1 Pump set
1. Dismantle Cable protection pipe (825) & suction strainer
(143).
2. Unscrew coupling screw (904).
3. Unscrew nuts on suction casing (106).
4. Now, disconnect pump from motor.
9.2 Pump U type (UQD)
1) Unscrew Hex nuts (920) on non-return valve (751).
2) Dismantle non-return valve (751).
3) Remove the cover (580).
4) Remove the discharge bearing body (355).
5) Unscrew lock nut (921).
6) Remove the bearing sleeve (529) & retaining ring (506).
7) Remove the stage casing (108) & Impeller (232) one by
one.
8) Unscrew the diffuser (171) and other remaining parts.
9.3 Pump B type (BPD, BPI & BPHA)
1) Unscrew Hex nuts (920) on non-return valve (75-9).
2) Dismantle non-return valve (75-9).
3) Remove the cover (580).
4) Remove stage bowl (112).
5) Unscrew bolt (901.1), washer 931.1 & bearing sleeve (521).
6) Remove one by one stage bowl (112) & impeller (232).
7) Remove the wear ring (502).
9.4 Motors
1. Unscrew drain plug (903) and drain the filled water.
2. Lay the motor down & unscrew hex head cap nut (920).
3. Remove the cover (160), diaphragm (823).
4. Dismantle thrust bearing housing (354) together with the
bearing segment carrier (392) & segment (387).
5. Remove the circlip (932) and pull out thrust bearing plate
(384).
(Caution : Take care not to damage the rubbing face).
6. Dismantle bottom bearing body (382)/Interpart lower (use
a lead hammer /pipe wrench for this purpose).
7. Remove sand guard (271) from top bearing body (382).
8. Pull out rotor (818).
(Caution : Take care to avoid damage to the winding).
9. Remove the adaptor (145) in case of UMA I 150 motor .
10. Remove cable compression ring (829) and cable rubber
ring (828).
11. Remove the Bearing Body upper (382) & Interpart Upper
(132).
Note : UMA I 150 Motor is with Hook bolt design & UMA G is
with Threaded part (open it by rotating in clockwise direction
for interpart upper & anticlockwise in interpart lower.)
10.0 Reassembly
The pump should be reassembled according to the rules of sound
engineering practice. The fits of the individual components
should be coated with Graphite base lubricant before assembly,
and this also applies to the screw threads of screwed
connections. O-rings and radial seal should be examined for
signs of damage and if necessary, replace by new one. Flat
gasket should be replaced by new one. (Make sure that the
thickness of new gasket is exactly the same as that of the old
one.)
Caution: Do not coat “O” rings with graphite base lubricant or
similar media. Use water-soluble grease for this purpose.
For re-assembly, proceed in reverse sequence to that of
dismantling.

Submersible Motor Pumps (150 mm and above)
8
11. Trouble shooting
11.1 Motor
Motor could not start Motor fails, fuses blown or motor tripped Overload protection actuate after long operation time Repeated starting of the motor Motor is not cut off (automatic control is not in function) Applicable only to pressure booster pumps.
Possible causes Remedies
•Too low voltage / no voltage. Retighten loose connections,
Contact electrical supply authority.
• • Motor winding or supply cable damaged. Repair / replace motor, cable.
• • Fuses or automatic switches are not suitable Replace fuse or switch
•Supply voltage is either too high or too low Change either supply or Check the motor
than rated. connections.
• • Failure of a phase (single phasing in 3 phase Rectify loose connections. Replace fuses.
motor). Consult electrical authority.
•Switchgear positioned in too warm place. Protect switchgear from heat.
•Control switch is not in function Repair / replace the control device.
(level switch / level guard).
• • Leakage in the unit / faulty pressure gauge. Trace leakage and seal it.
•Contaminated filter, excessive wear in Dismantle pump, clean & repair.
pumping unit.
•Incorrect co-ordination of pump & pressure Correct the co-ordination.
tank (applied to the booster pump).
Pump should be repaired to prevent such
•Pump components are clogged. incidents. The pumpset should not be idle for
a long time & should be operated at least
once in a week.

Submersible Motor Pumps (150 mm and above)
9
11.2 Pump
Pump fails to deliver the water Pump delivers insufficient flow of water Pump does not develop required head / pressure Pump has vibrations and noise
Possible causes Remedies
•Unavailability of power. Check the line.
•Defective motor winding, cable and starters. Repair / replace the defective parts.
•Coupling / motor shaft worn out. Take out pump-set for repairing of the damaged
Motor runs while pump remains stationary. parts.
•Pump is silted up. Clean the suction casing, Impeller, Stage casing
and non return valve - (1).
•Pump set broken away from the riser pipe as a Consult Installer.
result of corrosion.
• • Rotational speed is too low. Check supply frequency and increase the voltage
up to tolerance limit as shown on name plate.
•Pump delivers against an excessive discharge Open discharge valve to attain desired flow.
pressure. Reduce no. of bends, increase the pipe size.
•The pump delivers higher flow of water against low Regulate discharge valve till the duty flow is
discharge pressure. attained.
•Leakage in pipes. Change the pipe.
• • • Excessive wear of pump internal. Replace the worn-out components - (1).
••• Closed riser pipe. Replace defective length of riser pipe with new
gasket.
•Discharge pipe coated with depositions. Clean the pipe and remove the deposition or
Replace the pipe.
•Incorrect installation. Consult Installer.
•Loose assembled parts Tighten the fasteners.
Ensure the operating parameters with respect to
•Positive suction head is too low specified duty parameters and the correctness of
submergence as specified.
(1) Consult KSB

Submersible Motor Pumps (150 mm and above)
10
12. Recommended spare parts for 2 years of operation
12.1 Pump
No. of pumps including standby pumps
Part No. Description 1 2 4 5 6 8 10 & above
Quantity of spare parts
143 Suction strainer 1 1 1 2 2 2 3
502 Wearing ring (set) 1 1 2 2 2 2 3
521 Stage sleeve (set) 1 1 1 1 2 2 3
524 Shaft protection sleeve - Oil seal 1 1 1 2 2 2 3
529 Bearing sleeve (set) 1 1 1 1 2 2 3
545 Bearing bush - Rubber 1 1 2 2 2 2 3
545.01 Bearing bush (LTB4) 1 1 2 2 2 2 3
752 Valve seat with O-ring 1 1 1 1 2 2 3
---- Set of gasket & O-ring 1 1 2 2 2 3 3
12.2 Motor
No. of pumps including standby motors
Part No. Description 1 2 3 4 5 6 8 10 & above
Quantity of spare parts
271 Sand guard 1 1 1 1 2 2 3 4
412 O rings 1 1 1 2 2 2 3 4
421 Oil seal 1 1 1 2 2 2 3 4
829 Cable packing ring 1 1 1 1 2 2 3 3
829 Cable gland ring 1 1 1 1 2 2 3 3
903 Drain plug 1 1 1 1 2 2 3 3
932 Circlip 1 1 1 1 2 2 3 3
411 Gasket (set) 1 1 1 2 2 3 3 4
550 Washer (set) 1 1 1 2 2 3 3 4
384 Thrust bearing plate 1 1 1 1 2 2 2 3
387 Thrust bearing segment (set) 1 1 1 1 2 2 3 4
59.12 Diaphragm 1 1 1 2 2 3 3 4

Submersible Motor Pumps (150 mm and above)
11
Part No. Description
106 Suction casing
108 Stage casing with
integral diffuser
134 Profile disc
143 Suction strainer
211 Shaft
230.01 Impeller
230.02 Impeller at 21st stage
355 Discharge brg. body with
brg. bush (545.01)
506 Retainig ring
529.01 Bearing sleeve (Last)
580 Cap
751 Valve body
752 Valve seat
756 Valve spring
759 Valve dish
849 Sleeve coupling
904 Threaded pin
914 Screw
917 Hook bolt
920 Nut
921 Shaft nut
931 Washer
13 Pump Construction (Schematic)
13.1 Radial flow pump (150mm) - UQD 112, 152, 182 & 212

Submersible Motor Pumps (150 mm and above)
12
Note : This is a representative drawing.
The construction of pump with motor
combination will be different.
Please refer KSB for the drawing of specific
pump and motor combination.
Part No. Description
106 Suction casing
112 Stage bowl
112.02 Stage bowl last stage
143 Suction strainer
211 Pump shaft
232 Clockwise impeller
412 O-ring
502 Wearing ring
521 Stage sleeve
525 Spacer sleeve
529 Bearing sleeve
545.01 Bearing bush
545.02 Bearing bush
550 Washer
580 Cap
751 Valve body
752 Valve seat
756 Valve spring
759 Valve dish
849 Coupling sleeve
900 Round head screw
901 Hex. bolt
902 Studs
904 Threaded pin
914 Grub screw
920 Hex. nut
931 Washer
940.01 Key
940.02 Key
13.2 Mixed flow pump (150/175/200mm) - BPD 242, 273, 302, BPI 333 & BPHA 333, 384

Submersible Motor Pumps (150 mm and above)
13
14 Motor Construction (Schematic)
14.1 UMAI 150 (Up to 15 HP)
* Recommended spare parts
Part No. Description
59-12 Diaphragm
59-33 Storage tank
81-18 Cable shoe
81-59 Stator with press ring (815)
Finger presser disc (81.34)
145 Adapter
160 Cover
271* Sand guard
354 Thrust bearing housing
382.51 Bearing body (Lower)
with Bearing bush (Lower - 545.01)
382.52 Bearing body (Upper)
with Bearing bush (Upper - 545.02)
384 Thrust plate assembly with disc (550)
387 Thrust bearing segment
389 Counter thrust bearing
392 Bearing segment carrier
411.51,52,53* Gasket
412* ‘O’ ring
421* Oil seal
550.01,02,03,04 Washer
554 Cable press washer
580 Cap
720 Double nipple
818 Rotor with balancing ring (81-77)
828* Cable packing ring
903.51 Threaded plug (Allen head)
903.52 Threaded plug (Hex.)
903.53 Threaded plug (Allen head)
904 Threaded pin
914.01 Screw (Allen head)
914.02 Screw (Hex. head)
917.01 Hook bolt (Lower)
917.02 Hook bolt (Upper)
920.51 Nut (Hex.)
920.52 Nut (Cap)
931 Lock washer
932* Circlip
940.01,02 Key

Submersible Motor Pumps (150 mm and above)
14
14.2 UMAG 150 / UMAH 150 (Above 15HP)
* Recommended spare parts
Part No. Description
59-12 Diaphragm
68-2 Cover plate
81-34 Finger presser disc
81-59 Stator with winding
81-6 Winding protection cover
81-60 Thrust insert
132.51 Intermediate part (Lower)
132.52 Intermediate part (Upper)
160 Cover
271* Sand guard
382.51 Bearing body (Lower)
382.52 Bearing body (Upper)
384 Thrust bearing plate
387 Thrust bearing segment
389 Counter thrust bearing ring
392 Bearing segment carrier
411.51* Gasket
411.52* Gasket
421* Oil seal
545.51 Bearing bush (Lower)
545.52 Bearing bush (Upper)
550 Disc
550.51 Washer (Machined)
550.52 Washer (Punched)
580 Cap
818 Rotor
828* Cable packing ring
829.51 Cable gland ring
829.52 Cable pressure washer
902.51 Stud
902.52 Stud
903.51 Allen head plug
904 Threaded pin
920.51 Nut (Cap)
920.52 Nut (Hex)
932* Circlip
940.51 Key
940.52 Key

Submersible Motor Pumps (150 mm and above)
15
Annexure I - Environment Protection - Product Disposal after useful life
Products manufactured by KSB Pumps are designed with utmost care for environmental protection. Innovative designs and wide
product range takes care of specific customer requirements reducing material and electrical energy consumption. Product materials
are recyclable. Our customers are educated with environment friendly methods of disposing product ingredients at the end of their
useful life. Please find herewith methods of disposing used pump ingredients.
Environment Protection measures during product disposal
Sr. Product Ingredients Disposal Methods
1. Pumps Paint : Pump body, Base frame Sludge to be disposed through authorised re processor
Non ferrous parts :
a) Impellers, Diffusers
b) Bushes
c) Stage sleeves
d) Thrust plate To be disposed through authorized re-processor
e) Wearing ring
f) Coupling Guard
g) Brg. Guard
Rubber / Plastic Parts :
a) Cover for NRV
b) Plastic cap To be disposed through authorized re-processor
c) Nozzle blanking
d) Cooling Fan
2. Motor Paint : Motor body, Rotor Sludge to be disposed through authorised re-processor
Non ferrous parts :
a) Support bushes
b) Copper sticks and stampings To be disposed through authorized re-processor
c) Balancing rings
d) Winding wire with varnish
Rubber / Plastic Parts :
a) Oil seal
b) Sand guard To be disposed through authorized re-processor
c) Notch keys, slot insulators
d) Overhang protection pipe

Submersible Motor Pumps (150 mm and above)
NOTES

Submersible Motor Pumps (150 mm and above)
NOTES

Submersible Motor pumps (150 mm and above)
Operating Instructions
Mktg. Serv./11-15/20,000