KSB Ama-Drainer 4 Series Installation & Operating Manual
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KSB Ama-Drainer 4 Series Installation & Operating Manual

KSB Ama-Drainer 4 Series Installation & Operating Manual

Submersible waste water pump
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Submersible Waste Water Pump
Ama-Drainer 4../5..
Installation/Operating Manual

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Summary of Contents for KSB Ama-Drainer 4 Series

  • Page 1 Submersible Waste Water Pump Ama-Drainer 4../5.. Installation/Operating Manual...
  • Page 2 All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited or processed for any other purpose, nor otherwise transmitted, published or made available to a third party without the manufacturer's express written consent. Subject to technical modification without prior notice. © KSB SE & Co. KGaA, Frankenthal 12/03/2019...

  • Page 3: Table Of Contents

    Contents Contents Glossary .............................. 5 General.............................. 6 Principles ................................ 6 Installation of partly completed machinery.................... 6 Target group.............................. 6 Other applicable documents.......................... 6 Symbols ................................ 6 Key to safety symbols/markings........................ 7 Safety .............................. 8 General................................ 8 Intended use .............................. 8 2.2.1 Prevention of foreseeable misuse....................... 8 Personnel qualification and training....................... 8 Consequences and risks caused by non-compliance with this manual ............ 9 Safety awareness .............................. 9 Safety information for the operator/user ....................... 9...
  • Page 4 Contents Operating limits.............................. 26 6.2.1 Frequency of starts.......................... 26 6.2.2 Operation on the power supply network .................. 26 6.2.3 Fluid handled ............................. 27 Shutdown/storage/preservation ........................ 29 6.3.1 Measures to be taken for shutdown .................... 29 Returning to service ............................ 29 Servicing/Maintenance ........................ 30 Safety regulations............................ 30 Servicing/inspection............................ 30 Drainage/disposal ............................ 30 Dismantling the pump set.......................... 31 Reassembling the pump set ........................... 33 Tightening torques............................ 34...

  • Page 5: Glossary

    Glossary Glossary Backflow submerged. They may be operated outside the fluid for short periods of time, until the minimum Waste water flowing back from the sewer into the fluid level has been reached. connected drainage piping Waste water Certificate of decontamination Water consisting of a combination of water A certificate of decontamination is enclosed by the discharged from households, industrial and other...

  • Page 6: General

    The serial number uniquely describes the product and is used as identification in all further business processes. In the event of damage, immediately contact your nearest KSB Service centre to maintain the right to claim under warranty. 1.2 Installation of partly completed machinery To install partly completed machinery supplied by KSB refer to the sub-sections under Servicing/Maintenance.

  • Page 7: Key To Safety Symbols/Markings

    1 General 1.6 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.

  • Page 8: Safety

    2 Safety 2 Safety All the information contained in this section refers to hazardous situations. DANGER In addition to the present general safety information the action-related safety information given in the other sections must be observed. 2.1 General ▪ This operating manual contains general installation, operating and maintenance instructions that must be observed to ensure safe operation of the system and prevent personal injury and damage to property.

  • Page 9: Consequences And Risks Caused By Non-Compliance With This Manual

    2 Safety 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.

  • Page 10: Unauthorised Modes Of Operation

    2 Safety ▪ 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. (ð Section 6.3, Page 29) ▪ Decontaminate pumps which handle fluids posing a health hazard. ▪...

  • Page 11: Transport/Temporary Storage/Disposal

    1. On transfer of goods, check each packaging unit for damage. 2. In the event of in-transit damage, assess the exact damage, document it and notify KSB or the supplying dealer and the insurer about the damage in writing immediately.

  • Page 12: Disposal

    3 Transport/Temporary Storage/Disposal 3.5 Disposal WARNING Fluids, consumables and supplies posing a health hazard Hazard to persons and the environment! ▷ Collect and dispose of any preservatives, flushing liquids and fluid residues. ▷ Wear safety clothing and a protective mask, if required. ▷...

  • Page 13: Description Of The Pump (Set)

    4 Description of the Pump (Set) 4 Description of the Pump (Set) 4.1 General description ▪ Submersible waste water pump (see submersible motor pump) Variant A (standard design) ▪ Chemically neutral waste water ▪ Slightly contaminated waste water (up to 40 °C max.) ▪...

  • Page 14: Designation

    4 Description of the Pump (Set) 4.2 Designation Example: Ama-Drainer A 4 22 S D / 10 K Table 4: Designation key Code Description Ama-Drainer Type series Material variant Standard variant Variant for aggressive water Variant for water containing oil / oil emulsions Nominal discharge nozzle diameter ~ 40 mm (G 1  ~ 50 mm (G 2) Motor rating [kW x 10] 0.55 kW...

  • Page 15: Name Plate

    4 Description of the Pump (Set) 4.3 Name plate KSB SE & Co. KGaA Johann-Klein-Straße 9 67227 Frankenthal Deutschland AMA-DRAINER A 507 SE/10K 220-240 V ~ 50 Hz T40°C 0,75 kW 5,5 A classe F 2-25 m³/h 11,6-3,2 m IP 68 7m...
  • Page 16 4 Description of the Pump (Set) Ama-Drainer NE/SE 10/35: ▪ AC motor ▪ Integrated temperature switch ▪ 10-metre power cable ▪ Shockproof plug Ama-Drainer SD 10/11/35: ▪ Three-phase motor ▪ Integrated temperature switch ▪ 10-metre power cable ▪ CEE plug (3L+PE+N) with motor contactor and phase inverter Ama-Drainer ND 10/11/35: ▪...

  • Page 17: Configuration And Function

    4 Description of the Pump (Set) 4.5 Configuration and function Fig. 2: Sectional drawing Bearing, motor end Shaft Bearing, pump end Shaft seal Discharge nozzle Impeller Foot Pump casing Float switch Volute casing Suction nozzle Design The pump is designed with a vertical fluid inlet and a vertical outlet. The hydraulic system sits on the extended motor shaft.

  • Page 18: Scope Of Supply

    4 Description of the Pump (Set) 4.6 Scope of supply Depending on the model, the following items are included in the scope of supply: ▪ Pump set ▪ Connection socket or discharge elbow with internal thread ▪ 10-metre power cable For ...

  • Page 19: Installation At Site

    5 Installation at Site 5 Installation at Site 5.1 Safety regulations DANGER Unsuitable electrical installation Danger to life! ▷ Make sure the electrical installation meets the VDE 0100 installation rules (i.e. sockets with earthing terminals). ▷ Make sure the electric mains is equipped with a residual current device of maximum 30 mA.

  • Page 20: Installing The Pump Set

    5 Installation at Site 5.3 Installing the pump set l x b Fig. 3: Dimensions for installation Table 6: Recommended installation dimensions Type series l × b [mm] [mm] Ama-Drainer 4..SE/10 500 × 500 Ama-Drainer 5..SD/10 K Ama-Drainer 4..SD/35 Ama-Drainer 522/11 1. For transporting and lifting the pump observe the following notes. (ð Section 3.2, Page 11) 2.

  • Page 21: Electrical System

    5 Installation at Site NOTE The highest point of the discharge line must be above the flood level (usually street level) to prevent any backflow from the sewage system. Transportable models 1. Connect the discharge nozzle to a hose with a suitable adapter (e.g. Storz coupling).

  • Page 22: Setting The Overload Protection Device

    5 Installation at Site 5.5.2 Setting the overload protection device 1. Protect the pump set against overloading by a thermal time-lag overload protection device in accordance with IEC 60947 and local regulations. 2. Set the overload protection device to the rated current specified on the name plate.

  • Page 23: Connection To Power Supply

    5 Installation at Site 5.5.4 Connection to power supply DANGER Electrical connection work by unqualified personnel Danger of death from electric shock! ▷ Always have the electrical connections installed by a trained and qualified electrician. ▷ Observe regulations IEC 60364. DANGER Operating a pump set that has not been fully connected Explosion hazard! Damage to the pump set!
  • Page 24 5 Installation at Site Ama-Drainer SD and ND WARNING Hands inside the pump casing Risk of injuries, damage to the pump! ▷ Always disconnect the pump set from the power supply and secure it against unintentional start-up before inserting your hands or other objects into the pump.

  • Page 25: Commissioning/Start-Up/Shutdown

    6 Commissioning/Start-up/Shutdown 6 Commissioning/Start-up/Shutdown 6.1 Commissioning/Start-up 6.1.1 Prerequisites for commissioning/start-up Before commissioning/starting up the pump set, make sure that the following conditions are met: ▪ The operating data has been verified. ▪ The pump (set) has been installed and connected as described in this manual. ▪...

  • Page 26: Operating Limits

    6 Commissioning/Start-up/Shutdown Fig. 5: Vent hole 6.2 Operating limits 6.2.1 Frequency of starts CAUTION Excessive frequency of starts Risk of damage to the motor! ▷ Never exceed the specified frequency of starts. To prevent high temperature increases in the motor and excessive loads on the motor, seal elements and bearings, the frequency of starts shall not exceed 30 starts per hour.

  • Page 27: Fluid Handled

    6 Commissioning/Start-up/Shutdown 6.2.3 Fluid handled 6.2.3.1 Permissible fluids to be handled WARNING Pumping of impermissible fluids Hazardous to persons and the environment! ▷ Only discharge permissible fluids into the public sewer system. ▷ Check the suitability of pump/system materials. CAUTION Unsuitable fluids Damage to the pump! ▷...
  • Page 28 6 Commissioning/Start-up/Shutdown 6.2.3.2 Minimum/maximum fluid level Minimum level of fluid handled CAUTION Fluid level below the specified minimum Damage to the pump set by cavitation! ▷ Never allow the fluid level to drop below the specified minimum. The pump set is operational when the minimum fluid level is not lower than dimension W .

  • Page 29: Shutdown/Storage/Preservation

    6 Commissioning/Start-up/Shutdown Table 8: Particle size for slightly contaminated waste water Type series Max. particle size [mm] Ama-Drainer /10 Ama-Drainer /11 Ama-Drainer /35 6.3 Shutdown/storage/preservation 6.3.1 Measures to be taken for shutdown WARNING Unintentional starting of the pump set Risk of injury by moving components and shock currents! ▷...

  • Page 30: Servicing/Maintenance

    7 Servicing/Maintenance 7 Servicing/Maintenance 7.1 Safety regulations DANGER Power supply not disconnected Danger to life! ▷ Pull the mains plug and secure the pump against unintentional start-up. DANGER Work on the pump set by unqualified personnel Danger of death from electric shock! ▷...

  • Page 31: Dismantling The Pump Set

    7 Servicing/Maintenance 7.4 Dismantling the pump set WARNING Hot surface Risk of injury! ▷ Allow the pump set to cool down to ambient temperature. 1. Remove the cover from the clamp tie bar. 2. Undo screw 914.03 at the clamp tie bar. 3.
  • Page 32 7 Servicing/Maintenance 4. Pull out the volute casing. 5. Clean all dismantled parts and check them for signs of wear. Ama-Drainer 4../5.. 32 of 60...

  • Page 33: Reassembling The Pump Set

    7 Servicing/Maintenance 7.5 Reassembling the pump set ü All parts have been cleaned and checked for wear. ü Any damaged or worn parts have been replaced by original spare parts. 1. Fit the volute casing. 2. Fit the clamp tie bar. Ama-Drainer 4../5..

  • Page 34: Tightening Torques

    7 Servicing/Maintenance 3. Insert and tighten screw 914.03 at the clamp tie bar. 4. Fit the cover on the clamp tie bar. 7.6 Tightening torques Table 9: Tightening torques [Nm] Part No. Description Tightening torque [Nm] 914.03 Hexagon socket head cap screw 7.7 Recommended spare parts stock It is not necessary to keep spare parts on stock.

  • Page 35: Trouble-Shooting

    Replace the defective fuse. Check the electrical cable connections. - Motor winding or electric cable are defective. Contact KSB's pump service. ✘ The pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
  • Page 36 8 Trouble-shooting A B C D E Possible cause Remedy - ✘ - ✘ Defective radial bearing in the motor Contact the manufacturer. - ✘ ✘ - Pump clogged by sand, dirt in the pump Clean the intake, strainer, pump components and sump, insufficient inflow check valve;...

  • Page 37: Related Documents

    9 Related Documents 9 Related Documents 9.1 General assembly drawing with list of components 9.1.1 General assembly drawing of Ama-Drainer .../10, .../10K, .../35 (576) (920.03) (550.07) (81-29.02) (550.06) (81-29.05) (412.04) 99-9.02 (81-17.01) (412.02) (81-17.02) 1~99-20.01 (732) (824) (689) 1~99-20.02 (837) (99-7.02) (900) (99-20.02)
  • Page 38 9 Related Documents Part No. Description Comprises: Pump casing, complete Pump casing [101] Joint ring 411 O-ring 412.01 Hexagon socket head cap screw 914.01 Volute casing Volute casing 102 O-ring 412.05 Intermediate ring 509 13-16 Protective casing Protective casing 13-16 Suction cover Suction cover 162 Intermediate ring 509...
  • Page 39 9 Related Documents Part No. Description Comprises: Capacitor (single-phase units only) Installation kit for hood 99-7.02 99-7.01 Impeller installation kit Adjusting washer 550.02 Disc 550.04 Nut 920.01 99-7.02 Installation kit for hood O-ring 412.02/.04 Disc 550.06 99-11 Bearing Deep groove ball bearing 321.01/.02 O-ring 412.01 Shaft seal ring 421 Disc 550.05...

  • Page 40: General Assembly Drawing Ama-Drainer 522/11

    9 Related Documents 9.1.2 General assembly drawing Ama-Drainer 522/11 (824) (571) (689) (901.10) (81-29.02) (920.10) 99-20.02 (81-17.01) (81-17.02) (412.02) (826) (920.05) 826 (900) 99-9.02 (412.04) (930) (550.06) (550.09) (576) (920.03) (550.07) (321.01) (321.02) 99-11 (421) (412.01) (81-59) (99-15) 81-59 (81-78) (550.05) (433) 13-16...
  • Page 41 9 Related Documents Part No. Description Comprises: 199-3 Flange adapter Flange adapter (DN 50) 182.5 Profile seal 410.02 Disc 550.12 Stud 902.01 Impeller, complete Impeller 230 Impeller installation kit 99-7.01 Mechanical seal, complete Mechanical seal 433 Spacer disc 551 (for variant C only) Circlip 932 Bracket, complete Bracket 571...

  • Page 42: Dimensions And Connections

    9 Related Documents 9.2 Dimensions and connections 9.2.1 Single pumps 9.2.1.1 Ama-Drainer 4..SE/10 min 500 x 500 Fig. 8: Outline drawing Ama-Drainer 4..SE/10 without cooling jacket Start-up level Stop level P 10 Swing check valve Gate valve Residual water level Ama-Drainer 4../5.. 42 of 60...
  • Page 43 9 Related Documents 9.2.1.2 Ama-Drainer 5..SD/10 K min 500 x 500 Fig. 9: Outline drawing Ama-Drainer 5..SD/10 K with cooling jacket Start-up level Stop level P 10 Swing check valve Gate valve Residual water level 9.2.1.3 Ama-Drainer 4..SD/35 min 500 x 500 Fig. 10: Outline drawing Ama-Drainer 4..SD/35 without cooling jacket Start-up level Stop level...
  • Page 44 9 Related Documents Gate valve Residual water level 9.2.1.4 Ama-Drainer 522/11 min 500 x 500 Fig. 11: Outline drawing Ama-Drainer 522/11 without cooling jacket Start-up level Stop level P 10 Swing check valve P 11 Gate valve Residual water level Ama-Drainer 4../5.. 44 of 60...

  • Page 45: Examples Of Transportable Models

    9 Related Documents 9.2.2 Examples of transportable models 9.2.2.1 Ama-Drainer 4..NE/10 Fig. 12: Outline drawing Ama-Drainer 4..NE/10 without cooling jacket P 24 Storz rigid coupling P 28 Plastic hose P 32 Pipe extension 9.2.2.2 Ama-Drainer 5..NE/10 K Fig. 13: Outline drawing Ama-Drainer 5..NE/10 K with cooling jacket P 24 Storz rigid coupling P 28...
  • Page 46 9 Related Documents 9.2.2.3 Ama-Drainer 522 ND/11 Fig. 14: Outline drawing Ama-Drainer 522 ND/11 without cooling jacket P 24 Storz rigid coupling P 28 Plastic hose Ama-Drainer 4../5.. 46 of 60...

  • Page 47: Examples Of Stationary Installation

    9 Related Documents 9.2.3 Examples of stationary installation 9.2.3.1 Ama-Drainer 522 ND/11 with guide hoop 167* DN 50 PN 16 ANSI 2“ P 29 Ø 10 436** Fig. 15: Outline drawing Ama-Drainer 522 ND/11 with guide hoop When using flange adapter P 5: 217 mm When using flange adapter P 5: 486 mm Table 13: Overview of connections Connection...
  • Page 48 9 Related Documents 9.2.3.2 Ama-Drainer 522 ND/11 with guide wire 85 85 167* DN 50 PN 16 ANSI 2“ P 29 Ø 10 436** Fig. 16: Outline drawing Ama-Drainer 522 ND/11 with guide wire When using flange adapter P 5: 217 mm When using flange adapter P 5: 486 mm Table 14: Overview of connections Connection...

  • Page 49: Installation Example Of A Dual-Pump Station

    9 Related Documents 9.2.4 Installation example of a dual-pump station E 70 E 30/31 P 13 P 29 P 11 P 10 P 18 P 18 E 60.3 E 60.2 E 60 Fig. 17: Position of float switches in a dual-pump station P 10 Swing check valve P 11...

  • Page 50: Wiring Diagrams

    9 Related Documents 9.3 Wiring diagrams 9.3.1 Ama-Drainer SE gn/ye Fig. 18: Wiring diagram Ama-Drainer SE Bimetal switch Motor Float switch blue brown white gn/ye green/yellow green Ama-Drainer 4../5.. 50 of 60...

  • Page 51: Ama-Drainer Ne

    9 Related Documents 9.3.2 Ama-Drainer NE bn bu Fig. 19: Wiring diagram Ama-Drainer NE Bimetal switch Motor blue brown white gn/ye green/yellow green Ama-Drainer 4../5.. 51 of 60...

  • Page 52: Ama-Drainer Sd

    9 Related Documents 9.3.3 Ama-Drainer SD N PE PE PE Fig. 20: Wiring diagram Ama-Drainer SD Contactor Manual-0-automatic selector switch Terminal strip Motor Float switch blue brown Ama-Drainer 4../5.. 52 of 60...

  • Page 53: Ama-Drainer Nd

    9 Related Documents 9.3.4 Ama-Drainer ND 21 22 PE F6, F7: 21 22 Fig. 21: Wiring diagram Ama-Drainer ND F6/F7 Bimetal switch Motor black green gn/ye green/yellow Ama-Drainer 4../5.. 53 of 60...

  • Page 54: Eu Declaration Of Conformity

    10 EU Declaration of Conformity 10 EU Declaration of Conformity Manufacturer: KSB SE & Co. KGaA Johann-Klein-Straße 9 67227 Frankenthal (Germany) The manufacturer herewith declares that the product: Ama-Drainer 405 _E/10, 407 _E/10, 411 _E/10, 415 _E/10, 422 _E/10 Ama-Drainer 505 _E/10 K, 507 _E/10 K, 511 _E/10 K, 515 _E/10 K,...

  • Page 55: Eu Declaration Of Conformity

    11 EU Declaration of Conformity 11 EU Declaration of Conformity Manufacturer: KSB SE & Co. KGaA Johann-Klein-Straße 9 67227 Frankenthal (Germany) The manufacturer herewith declares that the product: Ama-Drainer 405 _D/10, 407 _D/10, 411 _D/10, 415 _D/10, 422 _D/10 Ama-Drainer 505 _D/10 K, 507 _D/10 K, 511 _D/10 K, 515 _D/10...

  • Page 56: Certificate Of Decontamination

    12 Certificate of Decontamination 12 Certificate of Decontamination Type: ..........................Order number/ Order item number ..........................Delivery date: ..........................Applications: ..........................Fluid handled ..........................Please tick where applicable ⃞ ⃞ ⃞ ⃞ ⃞ Corrosive Oxidising Flammable Explosive Hazardous to health ⃞...

  • Page 57: Index

    Index Index Bearings 16 Safety 8 Safety awareness 9 Scope of supply 18 Certificate of Decontamination 56 Shaft seal 16 Commissioning 25 Shutdown 29 Commissioning/start-up 25 Start-up 25 Switch-off 25 Design 15 Designation 14 Tightening torques 34 Disposal 12 Transport 11 Drive 15 Warnings 7 Electrical connection 23 Warranty claims 6 Event of damage 6 Explosion protection 23 Faults Causes and remedies 35 Fields of application 8 Fluid handled Density 28...
  • Page 60 KSB SE & Co. KGaA Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com...

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