3400.87/4-10 G2 Pump units with motors >1 kV · PDF fileOperating instructions Pump units with...

Pump units with motors >1 kVOperating instructions3400.87/4-10 G2

Caution:These operating instructions contain fundamentalinformation and precautionary notes. Please read themanual thoroughly prior to installation of unit, connectionto the power supply and commissioning.It is imperative to comply with all other operatinginstructions referring to components of this unit.

Name plateBefore installing the unit, we recommend to copy the nameplate data into the space below or to stick in the name plate labelenclosed with the delivery.

Works No.:

Pump:

Qmin m3/h Hmax m

Qmax m3/h Hmin m

Q m3/h H m

3~ motor:

kW Hz 1)

V2) A cos ϕ

V2) A cos ϕ

Temperature Tmax = + oC rpm

Min. flow velocity past the motor vmin = m/s

VDE 0530 Part 1 IP 68

ZN 3823 - D 139 / D 881) Version for two electrical motor leads2) Possible supply voltages.

Quick-reference instructions (check list)Procedure for installation and commissioning:1. Unpack unit and support (3).2. Check installation conditions (4.3).3. Prepare support for vertical or horizontal installation (4.3).4. Have tools and equipment ready (5.1).5. Instructions for filling the motor (5.2)6. Connect extension cable to the motor lead by means of

cable connector (5.5).7. Install electric shock protection (5.6).8. Install or set up submersible unit and connect riser pipe or

discharge pipe (5.7).9. Attach cable to riser or discharge pipe continuously during

installation (5.8).10. Connect cable to control box (5.9).11. Start up the unit (6.1).

Submersible Borehole PumpsUPA 250, UPA 250C,

UPA 300, UPA 350,UPZ, BSX, BRY, BRZS, BRE, BSF

with submersible motorsT, V, X, Z, E

Supply voltage U1000 VFrequency 50 Hz or 60 Hz

Rotational speeds 2900 (1450) rpm; 3550 (1750) rpm

CertificationCertified quality management ISO 9001

Pump units with motors 1 kV

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1 General

1.1 ApplicationsSubmersible borehole pumps are used for handling clean orslightly contaminated water ...- in general water extraction / supply,- in irrigation and spray irrigation systems,- in pressure boosting systems,- in fire fighting systems,- in offshore applications and caverns,- in dewatering and gallery drainage in underground mines,- in emergency water supply systems,- for lowering and maintaining ground water levels.

Also used in mining, sprinkler installations, fountains etc.Particularly suitable for vertical installation in narrow deepwells.The pumps are not approved for handling explosive fluids, norfor installation in potentially explosive atmospheres. Specialpump models are available for handling such applications.

1.2 Product detailsThe name plate on the pump and / or motor specifies ...- the works number,- the type series / size,- the main operating data,- max. allow. fluid temperature Tmax in °C,- minimum flow velocity past the motor vmin in m/s.

Before installing the unit, we recommend to copy the nameplate data into the space provided on the cover sheet of theoperating manual or to stick in the name plate label enclosedwith the delivery.Overall length and weight of the pump units are indicated in theorder confirmation / shipping documents.Sound pressure level: 75 dBA!

1.3 Technical codesThe submersible borehole pumps meet the fundamental safetyrequirements as per EC directives Machinery 98/37/EC andElectromagnetic compatibility 89/336/EEC.Compliance with these directives is confirmed by the ECdeclaration of conformity provided with each delivery and theCE marking affixed to the product itself.If a pump is supplied without motor or a motor is suppliedwithout pump, compliance with EC directives is confirmed bythe EC manufacturers declaration.The EC declaration of conformity is issued and the CE markingaffixed by the party assembling the pump and the motor to forma complete pump unit.Other applicable regulations (e.g. VDE, DIN, IEC etc.) arereferred to in the individual chapters, where necessary.

1.4 Sales and service addressesThe addresses of our sales and service organization are listedin the enclosed Service Addresses booklet (ref. No. 0092.01).The address of the KSB factory responsible is printed on theback of this operating manual.

1.5 Designation (Example)UPA 250 C - 150 / 5 b

Pump type series

Minimum well dia. in mm(for ex.: 250 mm = 10 inches)

Design status

Flow rate Qopt in m3/h (l/s) (for 50 Hz)

Number of stages

Reduced impeller diameters

B R Z S 535 / 5

Pump type series

Design status

Code for min. well dia.Suction stage impeller

Hydraulics code

Number of stages

V B D FV 31 - 30 5Motor size in inchesT = 12 inchesV = 14 inchesX = 16 inchesZ = 19 inchesE = 24 inchesNumber of polesB = 2-poleM = 4-poleDesign statusLength of core packMaximum rated power / 10Voltage / 100(30 means UN = 3 kV)Frequency / 10(5 means f = 50 Hz)


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1.6 Scope of supplyCAUTION: The motor lead must be laid under water only! High-voltagemotors are equipped with electric cable type NTSWöu forvoltages 1000 V. If cables other than those available fromKSB are used, they must be approved for submergedoperation.The motors are supplied with one or two 4-core electric leads.The motor lead is designed for use in water. Please consult thefactory if the system configuration is such that the entire motorlead or part of it is operated in air.On request, pump units are available with:- motor lead and extension cable connected with cable

connector- single electric cable connected directly at the motor.

Further accessories can be enclosed with the delivery onrequest / when ordered:- Cable connector- Cable ties- Supporting and installation clamps- Supporting and installation flange- Cooling / suction shroud- Motor filling liquid (water / antifreeze mixture)- Control boxes- Supports for horizontal installation

Note: If the pump units are intended for horizontal installation,this installation type must be expressly specified in thepurchase order. In this case, the Horizontal installation kit(water storage tanks with installation drawing, if required) willbe enclosed with the delivery.

2 SafetyThese operating instructions contain fundamental informationwhich must be complied with during installation, operation andmaintenance. Therefore this operating manual must be readand understood both by the installing personnel and theresponsible trained personnel / operators prior to installationand commissioning, and it must always be kept close to thelocation of operation of the machine / unit for easy access. Not only the general safety instructions laid down in this chapteron Safety must be complied with, but also the safetyinstructions outlined under specific headings.

2.1 Marking of instructions in the manualThe safety instructions contained in this manual whosenon-observance might cause hazards to persons arespecially marked with the symbol:

when there is a general hazard (safety sign to DIN 4844-W9) and

where there is a risk of electric shocks (safety sign to DIN 4844-W8).

The word CAUTION is used to introduce safety instructionswhose non-observance may lead to damage to the machineand its functions.Instructions attached directly to the machine, e.g. Check motorfill (green sticker) etc., must always be complied with and bekept in perfectly legible condition at all times.

2.2 Personnel qualification and trainingAll personnel involved in the operation, maintenance,inspection and installation of the unit must be fully qualified tocarry out the work involved. In particular, the personnel must bequalified to handle operating voltages 1000 Volt.Personnel responsibilities, competence and supervision mustbe clearly defined by the operator. If the personnel in questionis not already in possession of the requisite know-how,appropriate training and instruction must be provided. If required, the operator may commission the manufacturer /supplier to take care of such training. In addition, the operatoris responsible for ensuring that the contents of the operatinginstructions are fully understood by the responsible personnel.

2.3 Non-compliance with safety instructionsNon-compliance with safety instructions can jeopardize thesafety of personnel, the environment and the machine / unititself. Non-compliance with these safety instructions will also lead toforfeiture of any and all rights to claims for damages. In particular, non-compliance can, for example, result in:- failure of important machine / unit functions,- failure of prescribed maintenance and servicing practices,- hazard to persons by electrical and mechanical effects.

2.4 Safety awarenessIt is imperative to comply with the safety instructions containedin this manual, the relevant national health and safetyregulations and the operators own internal work, operation andsafety regulations.

2.5 Safety instructions for the operator / userElectrical hazards must be eliminated. In this respect refer tothe relevant national (VDE for Germany) or European (IEC)safety regulations and to the regulations of the local energysupply company.

2.6 Safety instructions for maintenance,inspection and installation work

The operator is responsible for ensuring that all maintenance,inspection and installation work be performed by authorized,qualified specialist personnel who are thoroughly familiar withthe manual.Work on the machine / unit must be carried out only duringstandstill. The shutdown procedure described in the manual fortaking the unit out of service must be adhered to without fail.Immediately following completion of the work, allsafety-relevant and protective devices must be re-installed and/ or re-activated. Please observe all instructions set out in section 6.3.4Returning to service before returning the unit to service.

2.7 Unauthorized modification and manufactureof spare parts

Modifications or alterations of the equipment supplied are onlypermitted after consultation with the manufacturer. Originalspare parts and accessories authorized by the manufacturerensure safety. The use of other parts will invalidate any liabilityof the manufacturer for consequential damage.

2.8 Unauthorized modes of operationThe warranty relating to the operating reliability and safety ofthe unit supplied is only valid if the equipment is used inaccordance with section 1.1 Applications of the operatinginstructions. The limits stated on the name plate / orderconfirmation must be adhered to without fail.


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3 Transport and interim storageTake into account the unequal weight distributionbetween pump and motor!

Use suitable lifting tackle (e.g. straps)!

Always make sure that submersible boreholepumps cannot tip over!

CAUTION: Always protect electric cabling from mechanical damage!

CAUTION: Do not pull on the electric cable!

CAUTION: The pump units must be stored in vertical position!

Transport of a submersible borehole pump requires properpreparation and handling.Only approved transport equipment and lifting gear shall beused. The unit is supplied in packaging which largely preventssagging or other damage during transport and storage. Prior to and during unpacking, check whether the packaginghas been damaged.When opening the packaging or handling the unit make sure notto damage the power cable. Never pull on the electric cable!This could lead to initially undetected damage to the connectingelement in the motor or the cable itself.When using a fork-lift truck to transport the unit in horizontalposition, make sure to take into account the very unequalweight distribution between pump and motor. Normally, thecentre of gravity will be in the motor area. When transporting theunit in horizontal position with a crane, slings points shall bechosen to prevent excessive bending stresses on the unit, e.g.in the middle of the motor and at the upper end of the pump.Use suitable lifting tackle (e.g. straps). The use of chains orsteel wires is not recommended, as there is a risk of the chains/ wires slipping, resulting in personal injury and / or damage toproperty.Always make sure the unit is properly secured when standingvertically. Otherwise, the unit may tip over and cause personalinjury or damage to property.The free end of the electric cable is fitted with a protective capto prevent the ingress of moisture and dirt. This cap should notbe removed until immediately before connection to the exten-sion cable or control box.For special pump models (e.g. with cooling, suction or pressureshrouds) also follow the instructions given in the supplementarypages listed in section 11, if any.For interim storage, the instructions given in section 6.3Storage must be observed.

4 Description of the product,accessories and installation types

4.1 Technical specificationThe submersible borehole pumps consist of a centrifugal pumpand a rigidly coupled electric motor. They are designed inprinciple for vertical, stationary installation in water. With the restrictions described in section 5.7.2, they can alsobe installed horizontally. This is only possible if this installationtype was specified in the purchase order.The single- or multistage, single- or double entry centrifugalpump is in ring-section design, with or without outer casing.Radial or mixed flow hydraulics. The stage casings are held inplace by stud bolts or tie bolts. The suction casing, fittedbetween pump and motor, is equipped with a strainer to protectthe pump from coarse particles in the fluid. Pump with checkvalve or connection branch on option. Available with internalthread or flanged end on option.The unit is driven by a water-filled three-phase motor insquirrel-cage design. The windings are sealed with water-tightinsulation material.The liquid fill in the motor lubricates the bearings and cools themotor. The liquid fill is circulated by an internal pump(pump-driven circulation cooling). The shaft is sealed by ahigh-quality mechanical seal.At the lower end of the motor, a thrust bearing absorbs thepumps hydraulic axial thrust and the rotor weight of pump andmotor. Pressure differences between the motor andenvironment are equalized by a rubber expansion diaphragm.Also refer to the enclosed sectional drawing with list ofcomponents of pump and motor.

4.2 Special featuresThe submersible borehole pumps are supplied with a sealedsleeve coupling which protects the motor shaft from the fluidhandled. If motors are supplied without a pump, such protectionmust be provided for. This protection must be safeguardedwhenever the pump is serviced (dismantled) or replaced.Exception: The T series does not require a sealed sleevecoupling. The motor shaft end is made of CrNi steel.

4.3 Installation conditions

CAUTION:Minimum submergence > 0.5 m !A higher submergence may be required by both the NPSHvalue specified in the data sheet and the diagram in section4.3.1.

The submersible motor pumps are suitable for installation indeep wells, tanks, reservoirs or mine shafts. As they are onlyoperated when fully submerged, they have no specialrequirements on rooms or buildings.The submersible borehole pumps must be installed in such away that they neither sit on the base of the well nor touch thewell or tank walls. Fit centering devices on the riser pipe ordiaphragm housing of the motor, if necessary. The centeringdevices must not be fitted in the motor / pump shroud area,however.If several units are installed side by side, mutual interferencemust be prevented by ensuring a certain minimum installationdistance (see layout drawing supplied in such cases).Flow past the motor must be ensured as described in section4.3.2.


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The submergence X of the pump units shown in figs. 1 and 3must be 0.5m. However, the NPSH value and the diagram insection 4.3.1 may require a higher submergence. Vortexformation, which would result in air intake or dry-running of thetop pump bearing, must be prevented. The pump must neverbe allowed to run dry. Dry-running may be caused by low wellyields or other marked water level fluctuations. In such cases,dry-running protection must absolutely be provided (section5.10).The maximum submergence is 500 m.

a) Vertical installation(deep well, pump sump, etc.)

CAUTION: The construction of the well head must meet the relevantregulations of the competent authorities! The unit must neverbe installed with its suction strainer exactly at the level of thewell screen / filter!

Before installing the unit in narrow deep wells we recommend tocheck narrow boreholes for dimensional accuracy over theirentire length, e.g. by inserting a pipe of the length and biggestoutside diameter of the pump unit. Sharp bends or bottleneckscan make installation difficult or even impossible.The unit is supported on the well head by supporting clamps(low-weight units and low submergence) or a supporting flange.The construction of the well head must meet the relevantregulations of the competent authority.

3410:70/4

ÂÂ

ÄÄ

ÄÄ

ÄÄÄÄÄÄÄ

ÄÄÄÄÄÄÄÄÄÄÄ

ÄÄÄÄÄÄ

TB

TF

He

H t

H h

1

3

46

5

7

8

9

D

2

1 Submersible borehole pump2 Riser pipe3 Cable tie4 Supporting flange / Well head5 Pressure gauge6 Shut-off valve7 Power supply cable8 Control box9 Well screen / filter

D = Inside well diameterTB = Well depthTF = Well screen / filter depthHe = Installation depthHh = Static water levelHt = Dynamic water level (Pumping water level)

Fig. 1 Vertical installation (in deep well, pump sump, etc.)

X

The suspension arrangement of the pump unit must bedesigned and dimensioned so that all static and dynamic forcescan be absorbed and that the riser pipe cannot slip downwards.The supporting clamps or flanges must be fastened at the wellhead so that they cannot shift or lift off the well head.System- inducted vibrations must not be transmitted to thepump unit. The system must be designed in such a way thatvibrations are not amplified. Abrupt pressure equalization pro-cesses (pressure surges), in particular, present a hazard for thepump unit. Suitable precautions must be taken (e.g. expansionjoints, air vessels).The unit must never be installed with its suction strainer exactlyat the level of the well screen/filter where excessive flow entailsthe risk of large amounts of entrained sand clogging the wellscreen/filter and causing excessive wear in the pump.Pump units installed in a pump sump must generally beequipped with a cooling or suction shroud (fig. 2).

3400:50Fig. 2 Installation in a pump sump

Cooling / suction shroud

b) Horizontal installation(in reservoirs, mine shafts, etc.)

CAUTION: The instructions given in section 5.7.2 must be observed!For horizontal installation it is essential to observe theinstructions set forth in section 5.7.2.The instructions given in a) Vertical installation shall alsoapply by analogy to horizontal installation, when the pump unitis placed on mounts (pedestals / supporting frame, pressureshroud) supplied by us. If the pump and motor are suppliedready mounted on a supporting frame, on-site alignment ofpump and motor will not be necessary. If this is not the case, therelevant installation / assembly drawing must be ordered,giving the following details:- installation height (floor clearance),- spacing of supports,- submergence X (NPSH value and diagram see section

4.3.1)

The ground / foundation must be level and of sufficientload-bearing capacity to accept the weight of the unit withsupports.Air intake from an inlet arranged above the water level is notpermitted.


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3410:71/2

X

Fig. 3 Horizontal installation (in tanks, mine shafts etc.)

1 Submersible borehole pump2 Water storage tank3 Pedestal4 Expansion joint5 Check valve (only if pump unit does not have its own check

valve)6 Dismantling joint7 Shut-off valve8 Intake

c) Angled installation

The requirements described in a) and b) shall also apply byanalogy to angled installation. However, special design meas-ures must be taken in individual cases. Contact the KSB factory.

4.3.1 Minimum submergence X

Minimum submergence X (fig. 1 and fig. 3) refers to the upper edge of the suction strainer for horizontal installation, and to theupper edge of the check valve for vertical installation. Dimension X depends on the flow rate Q of the pump at duty point. For higherflow rates and units with UPZ pump please contact the KSB factory.

0,00,51,01,52,0

Xm

Minimum submergence X. See also figs. 1 and 3.

Q l/s0 100 20050 150

0 100 200 300 500 600 700 800Q m3/h

4.3.2 Flow velocity v past the motor (see section 8)

As standard and dependent on the fluid temperature, a forcedflow must pass along the motor. The max. permissibletemperature Tmax and the associated flow velocity vmin of thisforced flow are indicated on the name plate / in the orderconfirmation. The flow velocities v indicated there depend onthe outside diameter of the motor in question and on thefollowing installation conditions.

Standard: v 0.2 m/s ...This requirement is complied with if the units are installed asfollows:Vertical installationin deep wells:

The unit is installed above the well screen / filter. The pumpdraws water from below, which ensures a continuous waterflow past the motor,

- in reservoirs, etc.:The unit is freely suspended in the water and the water inletis below the motor.

In the following cases we recommend to use a special coolingshroud to ensure the required water flow past the motor:- in deep wells:

if the unit is installed below the well screen / filter,- in reservoirs, etc.:

if the unit is freely suspended in the water and the water inletis located above the motor, or if the unit is suspended in aseparate pump sump (see fig. 2).

For shroud dimensions please refer to section 8.

Horizontal installationDepending on the motor size, it will be necessary to install adevice guiding the flow along the motor (cooling shroud, flowinducer sleeve, etc.) in this case. Please refer to section 5.7.2and any information provided in the order documentation.

Variant: v 0.5 m/sThis requirement is complied with if the units are installed asfollows:Vertical installationIf the ratio of the outside motor diameter and the inside welldiameter DN meets certain conditions or if the unit is installedin a suitably sized (cooling) shroud. Please refer to section 8and any information provided in the order documentation.Horizontal installationIn this case special measures are required. Please observe anyinformation in the order documentation.

Variant: v 0 m/sNo forced flow is required here.Note: When the motor is running, a flow is generated aroundthe motor by the heat dissipated, irrespective of the installationsituation. The operator must ensure that this flow is notobstructed by installation conditions on site. (see also sections4.3 and 5.10.4)


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4.3.3 Water qualityThe submersible borehole pumps are suitable for operation inclean or slightly contaminated water of the following quality:

a) Temperature of the fluid pumpedThe max. permissible temperature Tmax and the requiredminimum flow velocity vmin are indicated on the name plate / inthe order confirmation.For higher temperatures please contact the factory.

b) Sand contentMaximum sand content: up to 50 g/m3.Higher sand contents may be permitted for more wear-resistantpump variants.Please refer to the information provided in the orderdocumentation.

c) AggressivenessThere are defined material variants available for the followingwater qualities:- standard variant for neutral or slightly aggressive water, or- special variant for more aggressive water.

Other water qualities (e.g. sea water) can be handled by otherspecial materials, as required.Please refer to the information provided in the orderconfirmation.

d) Ochre contentIf the unit is operated in water with a high ochre content, thesuction strainer may be clogged with ochre so that the unit mustbe prematurely removed from the well. In the case of otherwiseclean water and if the unit is installed well clear of the filter zone,we recommend to remove the suction strainer before the pumpis installed for the first time. Also, ochre deposits may form on the motor (in the stator area),which will affect motor cooling. In such cases, a temperaturemonitoring unit (Pt 100 resistance thermometer) is absolutelyrequired.

5 Installation at site

5.1 Installation tools and equipment

Use suitable lifting tackle (e.g. straps)!

Always make sure that submersible boreholepumps cannot tip over!

Installation and removal of submersible borehole pumpsrequires suitable lifting gear (e.g. mobile crane). Itsload-carrying capacity must be greater than the weight of pumpunit with motor fill (and shroud, if any), riser pipe with water fill(see table below), power supply cable, holders, etc. Usesuitable lifting tackle (e.g. straps). The use of chains or steelwires is not recommended, as there is a risk of the chains/wiresslipping, resulting in personal injury and/or damage to property.

Weight m of water fill per 1 m of riser pipe: DN (mm) 50 80 100 125 150 200 250 300 350 400

R (inch) 2 3 4 5 6 8 10 - - -

m (kg) 2 5 8 12 18 32 49 72 98 125

Further equipment / accessories may be needed, depending onthe installation type:a) vertical: 2 pairs of supporting and installation clamps,

1 mounting plate (flanged riser pipe),b) horizontal: support / supporting frame.

Because of their slim design the submersible borehole pumpsmust always be secured when placed vertically duringhandling. Otherwise, the unit may tip over and cause personalinjury or damage to property.

5.2 Motor fill

Quality of motor fillWhen filling the motors or topping up the motor fill use water incompliance with the European drinking water directive (normalclean drinking water) or a drinking water / antifreeze mixture(1,2 propylene glycol), depending on the motor type (green orred sticker). See also section 5.2.2, Protection againstfreezing.

5.2.1 Checking, topping up, replacing and filling in themotor filling liquid

Wear safety glasses and protective gloves whenhandling (topping up, checking and draining) themotor fill. The national health and safety regulationsshall be observed. The mixture must be disposed of incompliance with local applicable regulations.

CAUTION:The motor fill must be checked prior to installation.

CAUTION:Use clean drinking water for topping up the motor fill. On mo-tors with a green sticker a drinking water/ antifreeze mixtureidentical with the original filling liquid can also be used. If thequantity required for topping up is 0.5 l, a drinking water /antifreeze mixture must be used.

CAUTION:Only a filling liquid identical with the original filling liquidshall be used when the complete motor fill has to be renewedafter repair work or when the liquid fill has to be replaced.

CAUTION:Motors with a red sticker have to be filled immediately prior toinstallation. Use clean drinking water for filling these motors.If there is a risk of freezing, or at the operators wish, the motormust be filled with a drinking water / antifreeze mixture as de-scribed in section 5.2.2.

CAUTION:The first liquid fill of motors with additional coolers is addedvia the filler opening arranged between the motor and theadditional cooler.

The procedure for checking the filling level and topping up themotor fill differs depending on the motor concerned.A distinction is made between the following motors:- Submersible borehole motors, pre-filled at the factory, with

green sticker.- Submersible borehole motors, not pre-filled at the factory,

with red sticker.Motors pre-filled at the factory are filled with a water / antifreezemixture! These motors can be stored at ambient temperatures t = -15 °C.Motors filled with drinking water must be protected againstfreezing!The motors are equipped with two screwed plugs and a safetypressure relief valve at the adapter. At the bottom end of themotor, i.e. on the thrust bearing housing, a drain plug serves todrain the fluid handled. Motors with additional cooler areprovided with another screwed plug between the motor and theadditional cooler. Small amounts of liquid escaping whenstorage temperatures are high are no cause for alarm.


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For checking the filling level and filling, these motors mustalways be placed in vertical position, independent of theirultimate installation position.For units with suction or pressure shroud also follow theinstructions given in the relevant installation and assemblymanual provided.The water fill of the motors is roughly as follows:Type series Water fill

T 32 l

V 45 l

X 75 l

Z 115 l

E 170 l

Checking and topping up liquid fillSpecial tools required: filling funnel (supplied)Proceed as follows:1. Place the motor (pump unit) in vertical position and make

sure it cannot tip over.2. Unscrew both screwed plugs and remove together with the

sealing elements. resulting in a filler and vent opening.3. If the liquid level is visible in one of the two openings, the

motor fill is sufficient. If the liquid level is not visible, liquidmust be topped up.

4. To top up liquid, insert the filling funnel horizontally into oneof the two adapter openings. Top up filling liquid until acontinuous flow escapes from both openings. Wait at least30 minutes for the air to escape. Then check filling levelagain.

a

b

ab

Motor, type series T Motor, type series V, X, Z, E

a) Filler openingb) Vent opening

Fig. 4 Filling / Topping up

5. Screw the screwed plugs back in together with the sealingelements.

The motor (the pump unit) is now ready for vertical installation.Further preparations are required for horizontal installation.See section 5.7.2.

Replacing the filling liquidSpecial tools required: filling funnel (supplied)Proceed as follows:1. Place the motor in vertical position and make sure it cannot

tip over.2. Unscrew both screwed plugs and remove together with the

sealing elements, resulting in a filler and vent opening.3. Unscrew the drain plug in the thrust bearing housing and

remove together with the sealing elements. Make sure toplace a suitable vessel under the drain hole. The filling liquidwill drain from the opening in the thrust bearing housing.Allow motor fill to drain.

4. Re-insert the drain plug in the thrust bearing housing,together with the joint ring, and tighten.

5. To fill, insert the filling funnel horizontally into one of the twoadapter openings. Top up filling liquid until a continuous flowescapes from both openings. Wait approx. 12 hours for theair to escape. Move the motor suspended from the craneslightly to and fro, if possible. Top up slowly and wait another30 minutes.Then check filling level again.

Note: Fill slowly, with pauses, to allow air to escape. Check forleakage at the screwed plug at the bottom end of the motor. 6. Screw the screwed plugs back in together with the sealing

elements.


Filling the motors

CAUTION:Fill the motors approx. 12 hours before installation.Special tools required: filling funnel (supplied)Proceed as follows:1. Stand the motor vertically and make sure it cannot tip over

(irrespective of ultimate installation position).2. Unscrew both screwed plugs and remove together with the

sealing elements, resulting in a filler and vent opening.Motors with additional coolers must be pre- filled via the filleropening between the motor and the additional cooler, inanalogy with para. 3.

3. To fill, insert the filling funnel horizontally into one of the twoadapter openings. Add filling liquid until a continuous flowescapes from both openings. Wait approx. 12 hours for theair to escape. Move the motor suspended from the craneslightly to and fro, if possible.

4. Top up slowly and wait another 30 minutes. Then checkfilling level again.

5. Screw the screwed plugs back in together with the sealingelements. Check tightness of screw union.

Note: Fill slowly, with pauses, to allow air to escape. Check forleakage at the screwed plug at the bottom end of the motor.Note: Motors filled with drinking water must be protectedagainst freezing!



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5.2.2 Protection against freezing

When handling 1,2 propylene glycol antifreeze, we rec-ommend to wear safety goggles and protective gloves!

If there is a risk of freezing for the filled motor, we recommendto add 1,2 propylene glycol antifreeze to the water fill as follows,depending on the anticipated below-zero temperature:

Temperatures down to ...

Water(% by vol.)

1,2 propylene glycol(% by vol.)

- 10 oC- 15 oC 1)

- 20 oC- 25 oC- 30 oC

75 66 1)

625753

25 34 1)

384347

1) water-antifreeze mixture filled in at the factory

When handling 1,2 propylene glycol, we recommend to wearsafety goggles and protective gloves. The antifreeze must bedisposed of in compliance with local regulations. 1,2-propylene glycol is commercially available in the followingbrands:

Manufacturer Trade name

BASF BPChemische Werke HülsShell

Glythermin P 44 Thermofrost PILEXAN PGlyco-Shell S

The above order of producers is purely alphabetical and doesnot imply any quality ranking of individual products!

5.3 Models with suction, cooling or pressureshrouds

The submersible borehole pumps can be delivered withsuction, cooling or pressure shroud.In the case of models with vertical suction shrouds, the pumpunit and shroud are generally delivered separately. The pumpunit is then installed in the shroud on site.In the case of models with horizontal suction shrouds as well asvertical and horizontal pressure shrouds, the pump unit willgenerally be ready installed in the shroud upon delivery. Here,the motor fill must be checked and filling liquid added via specialfilling / vent lines.See supplementary instructions in the order documentation.

5.4 Check valve / Connection branch

CAUTION:Submersible borehole pumps are not designed for uncon-trolled backflow of the fluid through the pump. Suitable pre-cautions must be taken to prevent reverse rotation of thepump.

The submersible borehole pumps generally feature anintegrated check valve.Where pump sets without check valve are installed or in sys-tems where check valves have not been installed in the appro-priate places, emptying of the riser pipe may result in backflowof the fluid through the pump. The pump may reach inadmissi-ble rotational speeds which will eventually damage the pumpset.If the specific system configuration requires emptying of the riser pipe, suitable measures shall be taken to reduce theamount of backflow so that the pump rotor does not rotate.If the pump unit is ordered with connection branch the checkvalve will be replaced by a connection branch at the factory.

5.5 Connecting the electric extension cable at thecable connectorThe electric extension cable shall be connected bya trained electrician only!

CAUTION: The extension cable provided by us is designed for use freelyexposed to air and in contact with surfaces!

If required, an extension cable can be connected to the motorlead using a watertight cable connector available from KSB.These cable connectors are approved for supply voltages U 1000 Volt.The extension cable must be connected by a professionalelectrician only.The extension cable provided by us is designed for use freelyexposed to air and in contact with surfaces! For other cableinstallation methods, e.g. in cable ducts, etc., please observethe instructions set forth in VDE 0298.The cable connector shall be fitted as described in theassembly instructions enclosed with the cable connector. When connecting the extension cable, make sure that theconductor colours are properly matched and that the terminalidentifications of the motor lead are transferred to the ends ofthe extension cable (see Wiring principles). Example: The extension cable conductor connected to U inthe cable connector must be identified U at its free end (to beconnected to control box).

Wiring principles: Connecting the extension cable in thecable connector- Motors with 1 cable (d.o.l. starting)

1 = Motor2 = Motor lead3 = Conductor marking4 = Cable connector6 = Extension cablePE = Earth (green / yellow)

Fig 5: Connecting 1 extension cable

- Motors with 2 parallel cables (d.o.l. starting)

1 = Motor2 = Motor leads3 = Conductor marking4 = Cable connector6 = Extension cablePE = Earth (green / yellow)

Fig 6: Connecting 2 extension cables to 2 leads


10

5.6 Protection against electric shock

Protection against electric shock must be provided(earthing)!

Equipment connected to the electric power supply must havesome form of protection (earthing) to prevent electric shocks.This is a statutory requiremement stipulated by VDE 0100 /0101 (for Germany) or IEC 64. The submersible boreholepumps are always earthed. There are two variants available:

a) Internal earthing: The earth conductor has been connectedinternally to the stator at the factory. 1 (4-core) or 2 (4-core)leads with integrated earth conductor are brought out fromthe motor. It is the operators responsibility to ensure that theearth conductor is properly connected in the cable connectorand in the control box at the site.Application: generally all pump units.

b) External earthing: An earth conductor or additionalpotential equalizer can be connected to the outside of themotor adapter (earthing bolt) by the operators at their ownresponsibility.

5.7 Installation at site

Take suitable precautions to prevent anyone fromfalling into the well / reservoir / tank!

CAUTION:Protect electric cabling from mechanical damage! Protectopen cable ends against moisture and dirt.

During installation work, suitable precautions shall be taken toprotect anyone from falling into the open well / reservoir / tank.Suitably fence off the work area.During the entire installation procedure the electric cablingmust be adequately protected to prevent mechanical damage.Tools, equipment or accessories with sharp edges (e.g.sharp-edged pipe sockets) shall not be used during installation.

5.7.1 Vertical installation (in deep wells, etc.)

CAUTION: The first pipe section must not be longer than 2 m!

CAUTION: A pair of supporting clamps must always be attached to theriser pipe, to prevent the pump unit from dropping!

In order to prevent inadmissible sagging of the unit during lifting,the first pipe section must not be longer than 2 m.During the entire installation procedure a pair of supportingclamps shall always remain affixed to the riser pipe, to preventthe unit from dropping.In vertical installation, the pump unit is suspended in the wellhead. Threaded riser pipes are best supported with a socketand flanged riser pipes with a flange on the load-bearing el-ement (e.g. supporting clamp) at the well head, unless someother arrangement in the well head prevents the riser pipe fromslipping through.

Fig 7 Vertical installation with tripod

a) Installation with threaded riser pipe

CAUTION:Screw threaded pipes in tightly and secure against loosening!

Threaded pipes must be screwed in tightly and secured againstloosening. Bear in mind that whenever the pump is switched onand off the riser pipe is subjected to short-term twisting torques.Should the threaded pipes loosen during operation there is arisk of the pump falling down the well. When lowering the pumpunit into the well, take care not to damage the electric cable onthe well head or well wall. Use spacers or a centering device, ifnecessary.Installation procedure:1. Attach a pair of supporting clamps to the first pipe section

(max. 2 m long) just below the upper socket. Screw this pipeinto the pump using a thread-locking agent and secure withthe two locking screws. For this purpose, drill a shallow holeinto the threaded end of the pipe section, taking care not todrill through the threaded end.Insert the locking screws with thread-locking compound insuch a way that their tips rest lightly on the threaded pipeend. Allow time for the compound to cure. The connection isnow sufficiently secured against loosening.

2. Use cable ties to attach the power supply cables as well asthe control and measuring cables, if any, to the riser pipeapprox. 0.5 m above the socket.

3. Lift the unit by the first pair of supporting clamps with thelifting gear (e.g. tripod or mobile crane) and lower it into thewell until the pair of supporting clamp sits on the upper edgeof the well or well head.

4. Then assemble the second pipe section, using a second pairof supporting clamps.

5. Remove the supporting clamps from the first pipe sectionand lower the pump unit down the well until the second pairof supporting clamp sits on the the upper edge of the well orwell head.

6. Repeat these steps for every pipe section, lowering the unitinto the well until installation depth He is reached (see fig. 1).


11

b) Installation with flanged riser pipe

CAUTION:Use only pipes with recesses in the flanges!

Use pipes with flange recesses only (2 recesses as standard,offset by 90°). In these recesses, the power cable will beprotected against mechanical damage during pump installationand removal.These units are installed using a mounting plate in addition tothe supporting clamps in a).Installation procedure:1. Fasten the first pipe section (max. length: 2 m) to the pump.

Assemble the mounting plate to this pipe section, as well asthe first pair of supporting clamps, immediately below theupper flange.

Fig 8 Vertical installation with mobile crane and mounting plate

2. Use cable ties (see section 5.8) to attach the power supplycables as well as the control and measuring cables, if any, tothe riser pipe approx. 0.5 m above the flange.

3. Place two sturdy beams across the well opening. Beamsmust be sufficiently sized to carry all weights acting duringinstallation.

4. Attach the pump unit to the crane hook (e.g. mobile crane) bythe mounting plate and lower it into the well until the first pairof supporting clamps rests on the beams. The supportingclamps will hold the pump (fig. 9) so that the mounting platecan be removed and the second riser pipe can be fitted.

Fig 9 Supporting the riser pipe during installation

5. Fasten the mounting plate and the second pair of supportingclamps to the second riser pipe now. Attach the unit to thecrane again, remove the first pair of supporting clamps andlower the unit until the second pair of supporting clamps sitson the beams.

6. Repeat these steps for every pipe section, lowering the unitinto the well until installation depth He is reached (see fig. 1).

5.7.2 Horizontal installation (in reservoir, tank, etc.)

Fig. 10 Schematic for horizontal installation.

ÉÉÉÉÉ

ÉÉ ÉÉÉÇ

ÉÉÉÉÇÇ

ÇÇ

ÇÇÉÉ

PedestalSupporting frame

Water storage tank

a) Supporting frame

b) Pressure shroudPressure shroud

CAUTION: Check whether horizontal installation is permissible first!

CAUTION:The motors (pump units) must be expressly ordered for hori-zontal installation. (Vertical models are not provided with con-nections for the water storage tanks).

CAUTION:Non-flooded units with filled motor must always be protectedagainst direct sunlight by suitable covers! If there is a dangerof freezing, check that the motor fill is suitable for the below-zero temperatures anticipated.

CAUTION:Fastening elements (e.g. pedestals, centering device, etc.)must not be fitted in the area of the stator case. They can befastened on the casing flanges.

CAUTION: Before placing the unit in horizontal position, check the motorfill in acc. with section 5.2.1 and top up, if necessary.

CAUTION: For pump units with suction or pressure shrouds, the addi-tional notes in the enclosed installation instructions must beobserved.

First check whether horizontal installation is permissible (seeorder confirmation). If the pump unit was ordered for horizontalinstallation, the Horizontal installation accessories kit will beenclosed with the pump upon delivery.For standard cases the dimensions required for pedestal orsupporting frame arrangement can be derived from theenclosed layout drawing. For customized designs please referto the specific information provided in the order documentation.Horizontal non-flooded units with filled motors must always beprotected against direct sunlight by suitable covers (e.g. whenfountains are shut down for cleaning work), to preventoverheating of the motor. This situation as well as prolongedshutdown periods of non-flooded submersible units can reducethe fluid level in the motor (evaporation, etc.). Before floodingthe submersible units, the water fill of the motors must always


12

be checked in analogy with section 5.2.1 and topped up via thewater storage tanks, if required. If there is a danger of freezing, check that the motor fill issuitable for the below-zero temperatures anticipated. Ifnecessary, the unit must be removed or the motor must be filledwith a suitable water-antifreeze mixture.For horizontal installation, proceed as follows:1. Motors with green stickers have been filled at the factory.

Check the motor fill and top up as described in section 5.2.1with the pump in vertical position, if necessary.Motors with red stickers have not been filled at the factory.They must be filled and checked with the unit in verticalposition, as described in 5.2.1.

2. Undo the ties holding the cable guard and remove cableguard.

3. Fasten the supporting frame or pedestals to the unit, placethe unit on the foundation / floor and align.Make sure that the connections on the stator case of themotor point upwards.

4. Fasten the pump unit with supporting frame on thefoundation.

5. Remove the screwed plugs at the top and the bottom end ofthe stator, take out the joint rings, insert the water storagetanks supplied, incl. new joint rings, and screw in tightly. Note: The water storage tanks must line up with oneanother! The water storage tanks must not be mounted onthe adapter!

6. Top up the motor fill via the water storage tanks until theliquid overflows. Pre-filled motors (green sticker) shall onlybe topped up with water-antifreeze mixture (2:1). Motors notpre-filled (red sticker) can be topped up with drinking water.Close both water storage tanks with one pressure reliefvalve each.Note: Water storage tanks are generally supplied completewith a second pressure relief valve and, for topping uppre-filled motors, with a bottle containing 1,2 propyleneglycol for topping up the water-antifreeze mixture.

7. Run the cable through the foot of the supporting frame andfix it to the check valve housing or connection branch again,using a cable tie. On pumps with a higher number of stages,the cable should be attached with a cable tie a second timehalf way along the pump. Make sure the cable is securelyfastened to prevent it from fluttering in the water flow. Use aprotective tube, if necessary!

8. The pipe to be connected to the pump unit must then be laidin such a way that no piping forces (weights, torsional forces,vibrations, etc.) can act on the unit. To compensate suchforces, we therefore recommend to fit a flexible elementbetween the pump unit and the pipe, as required by thesystem.

5.7.3 Re-installing the pump unitBefore re-installing the pump unit (e.g. after on-site repair)check the free radial and axial movement of the rotor.Depending on the size and weight of the pump unit, this mustbe done separately for the motor and the pump. Also, rotorposition (pump and motor) and axial clearance have to bechecked. For large pump units, auxiliary equipment will berequired. This work should be performed by trained personnelonly.If the rotor cannot be turned or lifted, we recommend that youcontact our nearest service centre or the KSB factory in charge.In addition, the insulation resistance of the winding must bechecked, unless this has already been done during winding re-pair or when connecting the extension cable. The winding in-sulation resistance should be measured by a trained electricianonly.

Proceed as follows:- The filled motor has been submerged in water for at least 12 h,

incl. the power cable. (Do not submerge the cable ends -they must be protected against moisture!)

- Measuring voltage: 1000 V d.c.- Measure insulation resistance to earth.- Values required at an ambient temperature of 20°C and a

cable length of 5 m:Winding insulation J1: = 20 megohmWinding insulation J2: = 500 megohm

Other resistance values may be measured, depending onwater temperature, the length and quality of the power cableand the motors operating hours. If the resistance measured islower than the values specified above please contact the KSBfactory responsible.

5.8 Fixing the electric cable to the riser pipe (cable ties)

Tighten the ties firmly to ensure that the electriccable cannot slip downwards!

The cables shall be fixed to the riser pipe by a cable tie each onboth sides of the riser pipe flange or socket. 1 tie shall be usedper electric cable and every 3 metres of riser pipe. Tighten theties firmly to ensure that the electric cable cannot slipdownwards by its own weight! There is danger of the cablebeing subjected to excessive tensile stress. The type of cabletie used depends on the cable cross-section (or cable weight).

5.8.1 Cable tie size 1 (rubber)

This cable tie (rubber strap + plastic studs) can be used for thefollowing cables: round, 4-core up to 6 mm2 and for measuringcables.Procedure (see illustration):1. Cut the rubber strap to the following length, depending on

the diameter of the riser pipe (DN/R):

DN (mm) 80 100 125 150 200 250 300R (inch) 3 4 5 6 8 10 -

L (mm) 400 450 500 600 700 800 1000

The strap shall always be cut half way between two holes. 2. Place one plastic stud d into the third and fourth hole,

respectively, and then wrap the strap c around the riserpipe a in such a way that one end is beneath the cable b.

3. Wrap the other end around the riser pipe and cable and fix itto the stud. Tighten the rubber strap firmly to ensure that theelectric cable cannot slip downwards by its own weight!


13

Size 11:

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ

ÍÍ

ÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍ

ÉÉ

Sizes 2, 3, 3a, 3b, 4:

d

b

c

e

a

3400:38

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ

Í

Sizes 6-9:

b

a

d

c

Size 1:

a = riser pipeb = electric cablec = metal strapd = cable protectore = screw band with tension screw(reusable)

a = riser pipeb = electric cablec = rubber strapd = plastic stud

Fig. 11 Cable ties

5.8.2 Cable tie sizes 2 - 11 (metal)

This type of cable tie (metal + rubber cable protector) is usedfor cable cross-sections from 10 mm2 (round cables). Procedure (see illustration):1. Cut metal strap c to the required length L (L =

circumference of riser pipe + approx. 200 mm allowance)and bend both ends inwards by approx. 100 mm.

2. Extend the screw band e to its full length, if necessary, byloosening the tension screw and hook it into one end of themetal strap.

3. Place cable protector d around cable b and against riserpipe a, using the metal strap. Then hook the screw bandinto the other end of the metal strap.

4. Tighten the tension screw on the screw band with ascrewdriver so that the electric cable cannot slip downwardsby its own weight!

For larger cable cross-sections special cable ties must be used.In this case please refer to the information with assemblyinstructions provided in the order documentation, if applicable.

5.9 Connection to power supply (in control box)

Observe the applicable regulations!

The motor shall be connected by a professionalelectrician only!

Electrical installation must comply with national regulations(e.g. VDE 0100, 0101, 0113 for Germany) or IEC 64.The motor must be connected by a professional electricianonly.

5.9.1 GeneralWhen connecting the motors, the following instructions shall beobserved:- Check available mains voltage against the data on the motor

name plate.- Permissible voltage / frequency fluctuations from the values

specified on the name plate / in the order confirmation: + 5% as per VDE 530 T1 zone A.

- The motors are designed for short-time operation withshifted star point (t 1h). For prolonged operation and U0 0.2 x UN please contact the factory.

- The rating specified on the name plate and in the orderconfirmation applies to continuous operation S1 to VDE530T1 or IEC 34-1.

- A temperature-compensated overcurrent relay must beinstalled to protect the motor. If an earth leakage relay isused, it must be fitted in the motor power circuit.

- If the unit is to be operated with a frequency inverter, section6.1.5 of this manual shall be consulted prior tocommissioning.

5.9.2 Starting methodsThe submersible motors for supply voltages U 1000V arealways designed for d.o.l. starting. Maximum voltage drop atstart-up: 20 %.If higher voltage drops are expected, please consult the factory.We recommend to use surge arresters. Please refer to theorder confirmation or consult our factory to find out if otherstarting devices may be used. In view of the small moments ofinertia of submersible borehole pumps and the resultingextremely short run-up periods, make sure to chose aclosed-transition switchover method (Korndorfer connection) ifthe unit is operated with a starting transformer or resistor.

5.9.3 Terminal designationsDIN 42401 stipulates the following terminal designations forelectric motors, depending on the motor wiring type (see nameplate data).

Units with 1 cable (delta or star wiring):U V W

Units with 2 parallel cables (delta or star wiring):(as per DIN VDE 0530, Part 8)

U1 - 1 V1 - 1 W1- 1 U1 - 2 V1 - 2 W1- 2

These terminal designations are used throughout the wiringdiagrams shown in this operating manual.


14

5.9.4 Switchgear

National and international regulations must beobserved!

Switchgear shall always consist of contactors with integratedmotor protection (thermal overcurrent relay), to allow control bypressure switches, float switches, etc., if required.Switchgear must be in compliance with national regulations(e.g. VDE for Germany) or IEC regulations. In addition, theinstructions issued by the switchgear manufacturers must beobserved, unless they run contrary to VDE or IEC regulations.The overcurrent relay shall be set as follows:For d.o.l. starting to the operating current or, at most, to ratedcurrent IN. We recommend to fit an ammeter.

5.9.5 Connecting the motor cable in the control box

The motor cable shall be connected to the control boxby a trained electrician only.

The individual conductors have been marked to simplify theelectricians job of correctly connecting the cables to the controlbox.The motor cable must be connected to the control box by atrained electrician only. In 4-core cables the earth conductor (core colour:green-yellow) is integrated in the cable.The cables shall be connected in accordance with the wiringschematics shown below.

Motors with one cable for d.o.l. starting

1 = Motor2 = Motor cable3 = Conductor marking7 = Switchgear8 = Mains phasesPE = Earth

(green / yellow)

2

Fig. 12

Motors with 2 parallel cables for d.o.l. starting

Fig. 13

1 = Motor2 = Motor cable3 = Conductor marking7 = Switchgear8 = Mains phasesPE = Earth

(green / yellow)

5.10 Protective equipment

5.10.1 Dry runningWe strongly recommend installing dry-running protectionequipment if the pump is used in wells with marked water levelfluctuations or temporary low yield.There are semi-automatic and fully automatic systems. Forfurther details please refer to the accessories informationsupplied with the electrode relay.

5.10.2 Lightning / OvervoltageWe recommend to install lightning protection equipment.Although a lightning protection device cannot offer protectionagainst direct lightning strikes, it will protect the pump unit fromatmospheric overvoltage and any lightning strikes nearby.Such devices shall be fitted and connected to the power supplyas described in the instructions enclosed with the equipmentand in compliance with applicable regulations.

5.10.3 Phase failureTo prevent overloading of the remaining two phases should onephase fail, phase failure protection can be provided for. Allmotor contactors / control boxes supplied by us are providedwith phase failure protection.

5.10.4 Excessive temperature in the motorIf there is a risk that the motor could exceed the permissibletemperature as a result of system conditions, e.g. due todeposit build-up on the stator (precipitates out of water, etc.),installation in standing water, dirt / sand deposits in the statorarea, major unforeseeable temperature increases in the fluidhandled (in cooling circuits, etc.) as well as frequencycontrolled motors (risk of overheating during operation with lowfrequencies), our PT 100 temperature monitoring system mustbe installed.See also section 10: Pt100 temperature sensor.

5.10.5 Other protection parameters- Over- / undercurrent- Earth fault / short circuit- Current asymmetry- Over- / undervoltage- Vibrations


15

6 Commissioning, start-up / shutdown

6.1 Commissioning / Start-up

CAUTION:The pump units shall only be switched on when the motor isfilled and the unit is fully submerged or flooded!

CAUTION: As a rule, submersible borehole pumps shall be started upagainst a closed gate valve!

Due to the water-lubricated plain bearings in the pump andmotor, the pump units must only be switched on with filled motorand when fully submerged or flooded. Start-up outside thewater, even for short periods, is not permitted.To prevent pressure surges submersible borehole pumps, asa rule, must be started up against a closed gate valve asfollows:1st step: Close the discharge-side gate valve.2nd step: Switch on the pump unit and open the gate valve

slowly until the pump head and current intensity asshown on the name plate are reached.

Note: If the pump is started up against an empty riser pipe, thegate valve shall not be closed completely, to allow air to escapethrough the remaining gap into the riser pipe.It is not necessary to delay the start-up of a gate valve withelectric actuator, as the run-up time of the pump is shorter thanthe dead time of the gate valve.

6.1.1 Commissioning

a) Checking the direction of rotationCAUTION:Do not run the pump unit for more than 5 minutes in eachdirection when checking the direction of rotation!

On three-phase units the direction of rotation is checked byrunning the motor in both directions with the gate valve closed.The direction of rotation is changed by interchanging twophases of the power supply cable, resulting in two differentpressure gauge readings. The higher reading always indicatesthe correct direction of rotation. On pumps with free discharge,the correct direction of rotation is indicated by the greater watervolume produced, in fountains by the higher jet. To prevent damage to the motor, make sure that the pump unitdoes not run in the wrong direction of rotation against the closedgate valve for more than 5 minutes.

b) Commissioning instructions (sand content)Pumps started up in new boreholes for the first time shall onlybe operated for approx. 10 minutes with the gate valve onlyslightly open, also to prevent damage to the well. The waterpumped must be checked for any sand content first. If the watercontains relatively high amounts of sand, there is a risk for boththe pump and the well. The unit must then be operated with thegate valve only partially open (40% of well yield at the most)until the sand content has dropped. Only then shall the gatevalve be slowly opened further. If the sand content does not fall below 50 g/m3, please contactthe well building company or your nearest KSB service centre.

6.1.2 Start-up frequencyTo prevent inadmissible heat build-up in the motor, the followingmax. permissible number of start-ups or minimum standstillperiods must be complied with:

Motor type series

T V X Z E

Switching frequency

5/h 5/h 5/h 5/h 3/h

Standstill period 6 min 6 min 6 min 6 min 10 min

6.1.3 Pump operation with partially closed gate valveIf the pump is continuously operated against a throttled gatevalve, the flow rate must not fall below Qmin (see name plate).

6.1.4 Pump operation with closed gate valveThe pump units shall not be operated against a closed gatevalve for more than 5 minutes (max.), as the water inside thepump will heat up very quickly and the heat produced will betransferred to the motor, where it may damage the motorwinding. Also, bearing damage cannot be ruled out.

6.1.5 Pump operation with frequency inverter

CAUTION: Independently of the actual operating frequency, a minimumflow as specified in section 6.1.3 must always be ensured.

The submersible borehole pumps can also be run on afrequency inverter for variable speed operation. Since theelectrical losses in the motor are higher when a freqencyinverter is used, the pump motor shall have a 5 % powerreserve. It is therefore important to consult KSB beforeretrofitting frequency inverters on pump units already delivered.As submersible motors differ from conventional standardizedmotors in terms of bearings, moment of inertia, insulation,temperature increase, loss distribution and heat distribution,the following parameters must be observed:- maximum allowable acceleration time (start ramp)- maximum allowable deceleration time (stop ramp)- minimum frequency- maximum operating frequency- maximum permissible voltage increase velocity and peak

voltages- control principle of frequency inverter

Maximum allowable acceleration time (start ramp) anddeceleration time (stop ramp)Due to the plain bearings of the submersible motor, operationbelow the minimum frequency fmin is not permitted (operationin mixed lubrication range).For this reason, the acceleration period from standstill tominimum frequency fmin should not exceed 2s. The sameapplies to the deceleration period.

Minimum frequency

Vertical installation

2-pole motors: fmin = 20 Hz


Horizontal installation




16

Maximum operating frequencyFrequency inverter operation above the nominal frequency(50Hz / 60Hz) of the pump unit is not possible, to prevent motoroverload.

Maximum permissible voltage increase velocity andpeak voltagesExcessive voltage increase velocity and excessive peakvoltages will reduce the service life of the winding insulation.For this reason, the following limits must be adhered to:- Maximum voltage increase velocity:

du/dt 500 V/µs- Maximum peak voltages against earth:

High-voltage motors 3.3 kV: J2 insulation 2500 VHigh-voltage motors 3.3 kV: J2 insulation 5000 V

Note: Compliance with these limits can usually be assured bymeans of a sine filter or du/dt filter.

Control principle of frequency inverterThe control principle of the frequency converter mustcorrespond to linear U/f curve control. If other control principlesare employed, such as field-oriented inverters, inverters withDTC or NOF, the manufacturer of the frequency inverter mustensure that the special requirements of submersible motors(very small moment of inertia, electrical data) are taken intoaccount.

6.2 Operating limits

To ensure operational reliability and prevent cavitation,submersible borehole pumps in continuous operation shall onlybe operated up to the maximum flow rate (Qmax) indicated onthe name plate. In addition, the maximum permissible power orcurrent intensity must not be exceeded (see name plate). Ifnecessary, power or current intensity must be reduced to thepermissible limits by throttling the gate valve accordingly.For operation with throttled / closed gate valve sections 6.1.3and 6.1.4 must be observed.

6.3 Shutdown / Storage / Preservation / Returning toservice

6.3.1 ShutdownCAUTION:Only switch off the pump unit without preparations(emergency stop) if the system has been designed for theresulting pressure surges!

As a rule, the pump shall be switched off with the gate valveclosed.Proceed as follows:1st step: Close the discharge-side gate valve slowly.2nd step: Switch off the motor immediately after closing the

gate valve.

6.3.2 StorageThe submersible borehole pumps must be stored as follows:- vertically- dry- protected against direct sunlight and heat- protected against dirt and dust- protected against freezing.If the unit cannot be stored in vertical position, it must be storedin such a way that sagging is prevented. The cable must besupported at the point where it comes out of the cable guard andprotected against kinking. The cable ends must be protectedagainst the ingress of moisture and dirt.

In cases where motors have to be dismantled into components,the individual components shall be dried with warm air andpreserved with antifreeze as described in section 6.3.3.

a) Pump units with pre-filled motorsThe pump unit has not been in operation yet:The unit is stored with pre-filled motor. The antifreeze agent inthe factory-supplied motor fill protects the motor againstcorrosion and frost down to T = -15 °C.

The pump unit has already been in operation:The unit is stored with filled motor. The antifreeze agent in thefactory-supplied motor fill protects the motor against corrosionand frost.Antifreeze concentration gradually decreases. Therefore, theantifreeze level must be checked with a spindle. If theanticipated temperature is below the antifreeze value, eitherincrease the antifreeze concentration in the motor accordingly(section 5.2.2) or store the unit in a frost-free location.

b) Pump units with motors not pre-filled at the factory

The unit has not been in operation yet and the motor hasnot been filled:The unit can be stored in this condition.

The unit has already been in operation and is filled withwater / antifreeze mixture:Store as described in para. a).

The unit has already been in operation and is filled withdrinking water:If frost-free storage is possible, store the pump unit in thiscondition.If frost-free storage is not possible:- Drain the motor- Dry the motor with warm air (see para. c) below- Preserve motor in acc. with section 6.3.3The motor is now ready for storage.

c) Draining the motors- Undo the screwed plugs at the top and at the bottom end of

the motor- Allow the motor to drain- Flush the motor with water and allow flushing water to drain

from the motor- Dry the motor with warm air- Preserve the motor as described in section 6.3.3, if required- Close the motor again, fitting the screwed plugs and the

sealing washers.If the motor has been filled with a water / antifreeze mixture,make sure to follow the safety instructions. The mixture mustbe disposed of in compliance with local applicable regulations.See section 5.2.2.

6.3.3 Preserving the motorsCAUTION:To preserve the motors use only the preservatives specified insection 5.2.2!

If the motors have to be preserved, they must be filled withundiluted antifreeze as described in section 5.2.2. Thesesubstances also protect the motors against corrosion. Drain theantifreeze from the motor after apr. 1 hour. Allow to drip off,screw plugs / pressure relief valve back in. To prevent damageto the winding insulation, no other preservative shall be used.

6.3.4 Returning to service after storageChecks prior to re-installation see section 5.7.3.Proceed as described in 6.1.1 when returning the unit toservice. Also check if the pumping data still matches the nameplate data.


17

7 Servicing and maintenance

7.1 Servicing / inspectionThe submersible borehole pumps are generallymaintenance-free.In order to pin-point indications of potential damage at an earlystage, regular checks are required. Possible indications ofpotential damage:- temperature rise in the fluid pumped- increased sand content of the fluid pumped- change in current consumption- change in discharge head / flow rate- change in switching frequency- increase in noise and vibration levels

To make sure that the pump is always ready for instant start-up,the pump unit must be started up approximately every 2 weeksfor approx. 5 minutes during prolonged shutdown periods. Thiswill prevent the formation of deposits in the bearing and impellerclearances.The submersible borehole pumps need not be removed fromthe well/tank regularly for inspection.

7.2 Repair / Spare partsFor information concerning repair jobs and spare parts pleasecontact your nearest KSB service centre or the KSB factory incharge.For any queries and repeat orders, particularly when orderingspare parts, please specify the following information (see nameplate):- pump and motor type and size, - the operating data and- the works number.When ordering spare parts please also supply the followingdata (see enclosed sectional drawings with list of componentsof pump and motor): - the sectional drawing number,- the description and part number, - the quantity required and- the mode of dispatch.

8 Flow velocity past the motor v 0.2 or0.5 m/s

Depending on the flow rate, a flow is produced along the motorwith a certain velocity which depends on:- outside motor diameter- inside well or shroud diameter

The condition v 0.2 or 0.5 m/s is met if the actual value is lowerthan or equal to the value given for the inside well or shrouddiameter (see table below) at the nominal flow rate.

Q3

v MOTOR SERIESQ[m3/h] [m/s] T V X Z E

150 0.2 590 620 650 700 780

0.5 430 470 520 580 670

175 0.2 625 650 690 730 810

0.5 450 490 540 590 690

200 0.2 660 690 720 760 840

0.5 470 510 550 610 700

250 0.2 725 750 780 820 890

0.5 505 540 580 640 720

300 0.2 780 800 830 870 940

0.5 540 570 610 660 750

350 0.2 835 860 880 920 980

0.5 570 600 640 690 770

400 0.2 890 910 930 970 1030

0.5 605 630 670 710 790

500 0.2 985 1000 1020 1050 1110

0.5 660 690 720 760 840

600 0.2 1070 1090 1110 1140 1190

0.5 710 740 770 810 880

800 0.2 1225 1240 1260 1280 1330

0.5 805 830 850 890 960

1000 0.2 1360 1370 1390 1410 1460

0.5 890 910 930 970 1030

1200 0.2 1485 1500 1510 1530 1570

0.5 965 980 1010 1040 1090

1400 0.2 1600 1610 1620 1640 1680

0.5 1030 1050 1070 1100 1160

1600 0.2 1705 1720 1730 1750 1780

0.5 1100 1120 1140 1170 1220

1800 0.2 1805 1820 1830 1850 1880

0.5 1165 1180 1200 1230 1270

2000 0.2 1900 1910 1920 1940 1970

0.5 1225 1240 1260 1280 1330

Example:Pump unit with motor XBD...Design flow rate given on name plate 1000 m3/hFlow velocity given on name plate 0.5 m/sMaximum permissible inside well diameter or 930 mminside shroud diameter


18

9 Trouble-shooting

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Cause Remedy 1)

X Pump delivers against an excessivelyhigh discharge pressure.

Open the shut-off valve further to re-adjustto duty point.

X Pump delivers against an excessively lowdischarge pressure.

Close the shut-off valve further to re-adjustto duty point.

X X Deposits in the impellers Remove deposits. 2)

X X Wrong direction of rotation (3~) Interchange two of the phases of thepower supply cable.

X X Wear of internal components Replace worn components by new ones. 2)

X X Motor is running on two phases only. Replace the defective fuse, check theelectric cable connections.

X X Lack of voltage Check the electrical installation.Notify the energy supply company.

X X Pump clogged by sand Clean suction casing, impellers, stagecasings and check valve. 2)

X X X X Motor winding or electric cable aredefective.

2)

X X X Defective or clogged riser pipe (pipe andsealing elements).

Replace affected pipe sections;Fit new sealing elements.

X Water level lowered too much duringoperation.

2)

X X X Impermissible air or gas content in theliquid.

2)

X Mechanical defect on pump or motor 2)

X System-induced vibrations 2)

X X NPSH available (positive suction head) istoo low.

Submerge pump deeper.

X X Speed is too low. Check voltage and increase, if necessary. 2)

X Wrong fuse size Fit correct fuse size.

X X X Defective overcurrent relay Check and replace, if necessary.

X Motor winding not suitable for operatingvoltage available

Replace pump unit. 2)

1) System pressure must be released before attempting to remedy faults on parts which are subjected to pressure. 2) Contact KSB!


19

10 Pt 100 temperature sensor (optional)Temperature sensor optionally installed in the motor for measuring the temperature of the motors water fill.The sensor is equipped with a shielded 10-metre power cable S05BC4B - F 4 x 0.5 mm2 as a standard feature.

S = BLACK coreB = BROWN coreG = GREY or BLUE core

Only one PT100 temperature sensor is required for protecting the submersible motor.For analysing the measured signal, a separate analysing device (e.g. accessory display / control unit for temperature monitoring,ident. No. 90 064 446) is required.

ConnectionThe sensor can be connected by 2-, 3- or 4-wire system. (For 3-wire configuration, one of the two black cores must be cut off atthe cable end.)

2-wire system 3-wire system 4-wire system

The voltage at the PT100 measuring sensor must not exceed 6V. (Umax < 6V)

Checking

a) Core-to-core resistance (measure with d.c. voltage U < 6V)If the temperature sensor is intact, resistances between the individual cores shall be as follows:S to S and B to G: 0 Ω to 30 ΩS to B and S to G: 100 Ω to 130 Ω

b) Insulation resistance (measure with d.c. voltage U < 100V)Combine all core ends. Between the core ends and earth (e.g. motor housing), resistance must be higher than 6 MΩ.

FunctionTwo temperature limits are important for submersible motors.

a) Alert temperature TAlertIf the alert temperature limit TAlert is exceeded, there is a malfunction (e.g. inadmissible contamination / ochre content of motorhousing). Corrective action must be initiated.Setting:TAlert = TOperation + (TCutout - TOperation)/2TOperation = normal operating temperature after approx. 1.5 hours operation

b) Cutout temperature TCutoutIf the cutout temperature is reached, the motor must be tripped. It must not be re-started until the malfunction has beenremedied.Setting:Submersible motors with J1 winding (PVC) TCutout T = 55°CSubmersible motors with J2 winding (PE) TCutout T = 75°CSee UMA../.1 or UMA../.2 designation)Motor type 14D and motors with rated voltages higher than 900V are fitted with J2 winding.


20

11 Related documents

11.1 List of components with sectional drawing /Spare parts

The pertinent sectional drawings with list of components forpump and motor are always enclosed with the operatingmanual.

11.2 Models with suction or pressure shroudThe requisite assembly / installation instructions are enclosedwith this operating manual, as required.

11.3 Pt 100 temperature monitoring systemThe necessary details concerning function, operation andchecks are enclosed with this operating manual, as required.

11.4 Dry-running protectionThe necessary details concerning function and operation areenclosed with this operating manual, as required.

11.5 Service addressesThe Service addresses booklet (ref. No. 0092.01) is generallyenclosed.


21


22

Contents

1 General 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Applications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Product details 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Technical codes 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Sales and service addresses 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 Designation (Example) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 Scope of supply 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Marking of instructions in the manual 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Personnel qualification and training 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 Non-compliance with safety instructions 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 Safety awareness 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Safety instructions for the operator / user 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Safety instructions for maintenance, inspection and installation work 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Unauthorized modification and manufacture of spare parts 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 Unauthorized modes of operation 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Transport and interim storage 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Description of the product, accessories and installation types 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Technical specification 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Special features 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Installation conditions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.1 Minimum submergence X 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.2 Flow velocity v past the motor (see section 8) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.3 Water quality 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Installation at site 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Installation tools and equipment 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Motor fill 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1 Checking, topping up, replacing and filling in the motor filling liquid 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.2 Protection against freezing 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Models with suction, cooling or pressure shroud 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 Check valve / Connection branch 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Connecting the electric extension cable at the cable connector 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 Protection against electric shock 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 Installation at site 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.1 Vertical installation (in deep wells, etc.) 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.2 Horizontal installation (in reservoir, tank, etc.) 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.3 Re-installing the pump unit 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 Fixing the electric cable to the riser pipe (cable ties) 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8.1 Cable tie size 1 (rubber) 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8.2 Cable tie sizes 2 - 11 (metal) 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 Connection to power supply (in control box) 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.1 General 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.2 Starting methods 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.3 Terminal designations 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.4 Switchgear 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.5 Connecting the motor cable in the control box 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 Protective equipment 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.1 Dry running 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.2 Lightning / Overvoltage 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.3 Phase failure 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.4 Excessive temperature in the motor 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.5 Other protection parameters 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


23

6 Commissioning, start-up / shutdown 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 Commissioning / Start-up 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.1 Commissioning 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.2 Start-up frequency 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.3 Pump operation with partially closed gate valve 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.4 Pump operation with closed gate valve 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.5 Pump operation with frequency inverter 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Operating limits 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Shutdown / Storage / Preservation / Returning to service 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.1 Shutdown 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.2 Storage 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.3 Preserving the motors 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.4 Returning to service after storage 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Servicing and maintenance 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Servicing / inspection 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 Repair / Spare parts 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Flow velocity past the motor v 0.2 or 0.5 m/s 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Trouble-shooting 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Pt 100 temperature sensor (optional) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 Related documents 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 List of components with sectional drawing / Spare parts 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Models with suction or pressure shroud 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 Pt 100 temperature monitoring system 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4 Dry-running protection 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 Service addresses 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3400.87/4-10 G2 Pump units with motors >1 kV · PDF fileOperating instructions Pump units with...

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Transcript of 3400.87/4-10 G2 Pump units with motors >1 kV · PDF fileOperating instructions Pump units with...