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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual K S B A u s t r a l i a P t y L t d A B N 2 9 0 0 6 4 1 4 6 4 2...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual I N D E X Pump • Amarex N Pumps Installation & Operating Instructions Additional Data • Data Sheet Drawing • Certified G.A. Drawing No.UX02010 I.T.P.s...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual Submersible Motor Pump Amarex® N Pump sizes DN 50 to DN 100 Motor sizes: 2-pole: 002 to 042 4-pole: 004 to 044 Installation/Operating Manual...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual Copyright/Legal information Installation/Operating Manual Amarex® N Original operating manual KSB Aktiengesellschaft Pegnitz All rights reserved. Contents provided herein must neither be distributed, copied, reproduced, processed for any other purpose, nor otherwise transmitted to a third party without KSB´s express...
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual Glossary Glossary Certificate of decontamination Monobloc pump set A certificate of decontamination certifies that Motor housing and pump casing form a single the pump (set) has been properly drained to component.
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 1 General 1 General 1.1 Principles This manual is supplied as an integral part of the type series and variants indicated on the front cover (for details, please refer to the table below).
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 1 General 1.5 Symbols Table 3: Symbols used in this manual Symbol Description ✓ Conditions which need to be fulfilled before proceeding with the step-by-step instructions ⊳...
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 2 Safety 2 Safety All the information contained in this section refers to hazardous situations. DANGER 2.1 Key to safety symbols/markings Table 4: Definition of safety symbols/markings...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 2 Safety ▪ Only use the pump to handle the fluids described in the data sheet or product literature of the pump model. ▪ Never operate the system without the fluid to be handled.
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 2 Safety 2.4 Personnel qualification and training All personnel involved must be fully qualified to install, operate, maintain and inspect the machinery this manual refers to.
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 2 Safety 2.8 Safety information for maintenance, inspection and installation work ▪ Modifications or alterations of the pump are only permitted with the manufacturer's prior consent.
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 3 Transport/Temporary Storage/Disposal 3 Transport/Temporary Storage/Disposal 3.1 Transport DANGER Improper transport Danger to life from falling parts! Damage to the pump set! ▷ Use the attachment point (pump handle) provided for attaching lifting tackle.
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 4 Description of the Pump (Set) 4 Description of the Pump (Set) 4.1 General description Pump for handling untreated waste water containing long fibres and solid substances, fluids containing gas and air as well as raw, activated and digested sludge.
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 4 Description of the Pump (Set) 4.4 Design details D e s i g n ▪ Fully floodable submersible motor pump ▪ Not self-priming ▪...
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 4 Description of the Pump (Set) ▪ Foot pad or pump stool with mounting elements ▪ Lifting rope or chain NOTE A separate name plate is included in KSB's scope of supply.
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 5 Installation at Site 5 Installation at Site 5.1 Safety regulations DANGER Improper installation in potentially explosive atmospheres Explosion hazard! Damage to the pump set! ▷...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 5 Installation at Site 1. Check the structural requirements. All structural work required must have been prepared in accordance with the dimensions stated in the outline drawing/general arrangement drawing.
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 5 Installation at Site 2. Check the direction of rotation. Impeller rotation must be anti-clockwise, seen from the pump mouth. (The direction of rotation is marked by an arrow on the pump casing.) Fig.
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 5 Installation at Site Table 8: Anchor bolt dimensions Size Hex. Torque requ [mm] [mm] head [mm] [mm] [mm] instal [Nm] [mm] M 10x130...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 5 Installation at Site 5.3.1.3 Fitting the guide wire arrangement The pump set is guided into the sump or tank along two parallel, tightly stretched guide wires made of stainless steel.
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 5 Installation at Site NOTE The guide rails are not included in KSB's scope of supply. Select guide rail materials which are suitable for the fluid handled or as specified by the operator.
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 5 Installation at Site F i t t i n g t h e g u i d e r a i l s ( a r r a n g e m e n t w i t h 1 g u i d e r a i l ) 1.
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 5 Installation at Site F a s t e n i n g t h e c l a w f o r g u i d e r a i l a r r a n g e m e n t s w i t h 2 g u i d e r a i l s 1.
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 5 Installation at Site 5.3.1.7 Installing the pump set NOTE For pumping water containing sludge and suspended solids pump sets with impeller type S (cutter) are preferable. In such cases it is recommended to use an inclined claw.
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 5 Installation at Site 5.4 Electrical connection 5.4.1 Information for planning the control system For the electrical connection of the pump set observe the wiring diagrams contained in the Annex.
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 5 Installation at Site ▪ Data provided by the manufacturer ▪ Electrical data of the pump set, particularly the rated current ▪ Ensure short start ramps (max. 5 s) Start-up ▪...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 5 Installation at Site 5.4.1.5 Motor temperature DANGER Insufficient cooling Explosion hazard! Winding damage! ▷ Never operate an explosion-proof pump set without operational temperature monitoring.
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 5 Installation at Site Every time the relay trips the pump, the pump needs to be inspected and its insulation resistance measured. The electrode relay (K1) must meet the following requirements: ▪...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 5 Installation at Site CAUTION Flow-induced motion Damage to the power cable! ▷ Run the power cable upwards without slack. 1. Run the power cables upwards without slack and fasten them.
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 6 Commissioning/Start-up/Shutdown 6 Commissioning/Start-up/Shutdown 6.1 Commissioning/start-up 6.1.1 Preconditions for commissioning/startup DANGER Fluid level too low Explosion hazard! Damage to the pump set! ▷ Completely prime the pump set with the fluid to be handled to reliably prevent the formation of a potentially explosive atmosphere.
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 6 Commissioning/Start-up/Shutdown 6.2 Operating limits DANGER Non-compliance with operating limits Damage to the pump set! ▷ Comply with the operating data indicated in the data sheet.
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 6 Commissioning/Start-up/Shutdown The pump set is ready for operation when the fluid level has reached dimension "R3" as a minimum (see general arrangement drawing/outline drawing).
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 6 Commissioning/Start-up/Shutdown CAUTION Pumping solids-laden fluids at reduced speed Increased wear and clogging! ▷ Never operate the pump set with flow velocities below 0.7 m/s in horizontal pipes and 1.2 m/s in vertical pipes.
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 6 Commissioning/Start-up/Shutdown WARNING Failure to re-install or re-activate protective devices Risk of personal injury from moving parts or escaping fluid! ▷ As soon as the work is completed, re-install and/or re-activate any safety- relevant and protective devices.
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 7 Servicing/Maintenance 7 Servicing/Maintenance 7.1 Safety regulations The operator ensures that all maintenance, inspection and installation work is performed by authorised, qualified specialist personnel who are thoroughly familiar with the manual.
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 7 Servicing/Maintenance 7.2 Maintenance/Inspection Table 15: Overview of maintenance work Maintenance interval Maintenance work For details see ... Insulation resistance test (⇨ Section 7.2.1.3 Page 38)
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 7 Servicing/Maintenance NOTE If the insulation resistance for one of the power supply cables is less than 1 MΩ, the cable is defective and must be replaced.
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 7 Servicing/Maintenance WARNING Contamination of fluid handled by lubricant Hazardous to persons and the environment! ▷ Using machine oil is only permitted if the oil is disposed of properly.
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 7 Servicing/Maintenance 2563:109 Fig. 21: Topping up the lubricant a) Variants YL and WL; B) Variants YL, WL for pump sizes 50-170... and 65-220 2.
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 7 Servicing/Maintenance 7.3 Drainage/disposal WARNING Fluids posing a health hazard Hazardous to persons and the environment! ▷ Collect and properly dispose of flushing liquid and any fluid residues.
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 7 Servicing/Maintenance 7.4.3 Dismantling the pump section Dismantle the pump section in accordance with the relevant general assembly drawing. 1. Remove suction cover 162.
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 7 Servicing/Maintenance 11. Remove bearing bracket housing 355. 12. Pull out rotor 818. 13. Remove circlip 932.01. 14. Remove circlip 932.02. 15. Pull off the two rolling element bearings 321.
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 7 Servicing/Maintenance 7.5.2 Reassembling the pump section 7.5.2.1 Installing the mechanical seal Observe the following points to ensure trouble-free operation of the mechanical seal: ▪...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 7 Servicing/Maintenance CAUTION Incorrect installation Clearance gap inaccurate! ▷ Pull the rotor assembly right up to the suction cover until it will not go any further.
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 7 Servicing/Maintenance 2563:127 Fig. 28: Fitting impeller type D Slide impeller 230 onto the shaft end and fasten it with impeller screw 914.04. Then, remove the impeller screw again.
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 7 Servicing/Maintenance 2563:115 Fig. 29: Screwing in the testing device 1. Unscrew and remove the screwed plug and joint ring of the lubricant reservoir.
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 7 Servicing/Maintenance 7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296 Table 22: Quantity of spare parts for recommended spare parts stock Part No.
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 8 Trouble-shooting 8 Trouble-shooting Pump is running but does not deliver Pump delivers insufficient flow rate Excessive current/power consumption Insufficient discharge head Vibrations and noise during pump operation...
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 9 Related Documents 9 Related Documents 9.1 General assembly drawing with list of components 9.1.1 Amarex N — variant ULG Size of hydraulic system D 50 ...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 9 Related Documents 9.1.2 Amarex N — variant YLG/WLG Size of hydraulic system DN 50...100 Motor sizes 002...042 004...044 2563:121/2 General assembly drawing of explosion-proof pump set (YLG)/non-explosionproof pump...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 9 Related Documents 9.1.3 Exploded views A m a r e x N - S 5 0 YLG - - WLG 321.01 412.01 932.02 321.02...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 9 Related Documents A m a r e x N - F 5 0 - 1 0 0 YLG - - WLG 321.01 412.01 932.02...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 9 Related Documents A m a r e x N - D 8 0 - 1 0 0 YLG - - WLG 321.01 412.01 932.02...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 9 Related Documents Table 27: List of components Part No. Description Part No. Description Casing Ring Intermediate casing Disc Suction cover Grooved pin Feet...
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 9 Related Documents 9.4 Flamepaths on explosion-proof motors Table 29: Overview of flamepaths Motor sizes Pump set DKN 82 F 50-170 S 50-17... F 65-220...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 9 Related Documents Motor sizes Pump set DKN 92 F 50-220 S50-22... F65-170 F 80-220 D 80-220 F 100-220 D 100-220 Shaft Pump casing...
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 9 Related Documents 9.5 Installation drawings of the mechanical seal Table 30: Installation drawings of the mechanical seal Part No. Description Installation drawing 433.01...
Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual 11 Certificate of Decontamination 11 Certificate of Decontamination Type ..........................Order number/ ..........................Order item number Delivery date ..........................Field of application: ....................................................
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual KSB Document No: KSB-88980-028 VENDOR DOCUMENT NUMBER IW‐GDSTP‐24090‐DST‐0001 date DATA SHEET NO.: TAG NO.: P&ID DRAWING NO.: IW-GDSTP-4A-MEC-DSHT-1231 PU-0530-010, PU-0530-020 IW-GDSTP-4A-PRO-0500-5142 TITLE: TECHNICAL INFORMATION SHEET WAS PUMP 1 & 2...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual KSB Document No: KSB-88980-028 DESCRIPTION PURCHASER'S REQUIREMENTS VENDOR OFFER UNITS Motor Data Vendor to nominate Manufacturer's name Drive type Vendor to nominate France Country of manufacture...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual KSB Document No: KSB-88980-028 Data sheet Customer item no.: WAS (REV) Order dated: Goodna STP Number: Order no.: Item no.: 100 Quantity: 2 Date: 01/06/2011 Page: 1 / 5 Version no.: 1...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual KSB Document No: KSB-88980-028 Data sheet Customer item no.: Order dated: Number: Order no.: Item no.: 100 Quantity: Date: 01/06/2011 Page: 2 / 5 Version no.: 1...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual KSB Document No: KSB-88980-028 Performance curve Customer item no.: WAS (REV) Order dated: Goodna STP Number: Order no.: Item no.: 100 Quantity: 2 Date: 01/06/2011 Page: 3 / 5 Version no.: 1...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual KSB Document No: KSB-88980-028 Motor data sheet Customer item no.: Order dated: Number: Order no.: Item no.: 100 Quantity: Date: 01/06/2011 Page: 4 / 5 Version no.: 1...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual Page 75 of 76 Q-Pulse Id VM381 Active 29/10/2013...
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Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual Page 76 of 76 Q-Pulse Id VM381 Active 29/10/2013...
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