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

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.

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

UPA, UPZ, BSX 3 of 64

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

4 of 64 UPA, UPZ, BSX

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

UPA, UPZ, BSX 5 of 64

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

6 of 64 UPA, UPZ, BSX

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

Step-by-step instructions

Note

Recommendations and important information on how to handle

the product

1 General

UPA, UPZ, BSX 7 of 64

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

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

8 of 64 UPA, UPZ, BSX

▪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

UPA, UPZ, BSX 9 of 64

▪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

10 of 64 UPA, UPZ, BSX

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