Installing the pump set in a vertical position .................... 34 5.3.1 Attaching the cable ties........................ 36 Installing the pump set in a horizontal position .................. 38 5.4.1 Mounting the pump set on pedestals .................... 39 5.4.2 Installing the pump set on support frame and pedestal.............. 39 UPA / UPA S 3 of 98...
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Tightening torques .......................... 77 Trouble-shooting.......................... 79 Related Documents .......................... 81 General arrangement drawings with list of components................ 81 9.1.1 UPA S 250, standard design....................... 81 9.1.2 UMA 150 submersible motor ...................... 86 Mating dimensions for the motors........................ 89 9.2.1 UMA 150, UMA-S 150 mating dimensions .................. 89 9.2.2...
The order number and order item number clearly identify the pump set and serve as identification for all further business processes. In the event of damage, immediately contact your nearest KSB service facility to maintain the right to claim under warranty. 1.2 Target group This operating manual is aimed at the target group of trained and qualified specialist technical personnel.
Conditions which need to be fulfilled before proceeding with the step-by-step instructions ⊳ Safety instructions ⇨ Result of an action Cross-references ⇨ Step-by-step instructions Note Recommendations and important information on how to handle the product If included in agreed scope of supply UPA / UPA S 7 of 98...
Warning for persons with pacemaker In conjunction with one of the signal words this symbol indicates a hazard involving magnetic fields and identifies special information for persons with a pacemaker. UPA / UPA S 8 of 98...
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. UPA / UPA S 9 of 98...
▪ Decontaminate pumps which handle fluids posing a health hazard. ▪ As soon as the work has been completed, re-install and re-activate any safety- relevant devices and protective devices. Before returning the product to service, observe all instructions on commissioning. (ð Section 6.1, Page 54) UPA / UPA S 10 of 98...
In installed condition the magnetic field is fully shielded so that an assembled motor / pump set does not pose a hazard as a result of magnetic fields (even to persons with pacemaker), neither during standstill nor during operation. UPA / UPA S 11 of 98...
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.
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ü Securing means, e.g. timber wedges, are on hand. 1. Gently place down the transport box. 2. Open the transport box. 3. Take out the electric cables (if any) and place them down. UPA / UPA S 13 of 98...
▷ Observe the minimum bending radius of the electric cables. ▷ Only remove the protective caps from the electric cables at the time of installation. Observe the cable manufacturer's documentation, DIN VDE 0298-3 and/or the general arrangement drawing. UPA / UPA S 14 of 98...
In the original packaging: in a horizontal position Without packaging: in a vertical position with the motor below In a dry environment Protected against direct sunlight and heat Observe the cable manufacturer's documentation, DIN VDE 0298-3 and/or the general arrangement drawing. UPA / UPA S 15 of 98...
For this purpose, a “synchronous motor” warning sticker is supplied with the delivery, which must be attached to the motor if it is to be returned to the supplier. UPA / UPA S 16 of 98...
ZN 3822-162 Fig. 2: Warning sticker to be attached to the motor if it is to be returned to the supplier. If the sticker is no longer available, contact your nearest KSB service centre for a replacement. NOTE If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination...
▪ Information on dismantling, recycling and disposal after decommissioning: (ð Section 3.6, Page 17) ▪ Information on benchmark efficiency or benchmark efficiency graph for MEI = 0.70 (0.40) for the pump based on the model shown in the Figure are available at: http://www.europump.org/efficiencycharts UPA / UPA S 18 of 98...
4 Description of the Pump (Set) 4.3 Designation Submersible borehole pump Example: UPA S 200 - 135 / 04 CC Table 4: Designation key Code Description UPA S Pump type series, investment cast variant Nominal size [mm] Flow rate at best efficiency point [m³/h]...
4 Description of the Pump (Set) 4.3.1 Designation used for pump sets with VdS certification Submersible borehole pump Example: UPA 250C - 150 / 1a Table 8: Designation key Code Description Type series Minimum well diameter [mm] Design status Flow rate at best efficiency point [m...
67227 Frankenthal Deutschland Serialnr. 9974xxxx635-000100-01 2021 MEI ≥ 0,70 η --,- % Mat.-Nr. __________ Pumpe UPA C 150 - 16 / 16 EE 6,92 m 171,00 m 21,77 m 103,00 m 18,5 m 125,25 m Motor UMA-S 150 - 37 / 42 C...
▪ Axial thrust is balanced by a tilting-pad thrust bearing in the motor (lower end) 4.7 Configuration and function Fig. 5: Sectional drawing, example of a UPA 200 Design Pump and motor are connected by a rigid coupling. The stage casings are connected by means of studs.
4.9 Dimensions and weights For dimensions and weights refer to the data sheet of the pump (set). Only for UMA 300, 14D submersible motors Only for UMA-S 150, UMA-S 200, UMA-S 250 submersible motors UPA / UPA S 24 of 98...
▷ Use additional supports for the transport holder to secure it against tilting. WARNING Incorrect handling of the power cable Personal injury and damage to property! ▷ Secure the power cable against falling down. Observe the cable manufacturer's documentation, DIN VDE 0298-3 and/or the general arrangement drawing. UPA / UPA S 25 of 98...
Is the temperature of the fluid to be handled below the specified maximum? (ð Section 6.2.4.5, Page 60) If fluids liable to form deposits are handled, is temperature monitoring provided? (ð Section 5.7.2, Page 52) Will the motor lead and the cable connector be completely immersed in the fluid to be handled? (ð Section 5.2.7, Page 31) UPA / UPA S 26 of 98...
Never install horizontally a pump set which has been selected for vertical installation. Never install the pump set with the pump at the lowest point. UPA / UPA S 27 of 98...
Motor fill check required See Section series condition DN 100 Filled Not required (ð Section 7.4.1, Page 68) UMA 150 Filled Required if the motor has been (ð Section 7.4.2, Page 68) stored or out of service for more than 1 year UPA / UPA S 28 of 98...
3. Fill the water storage tanks with the specified liquid fill until they overflow. 4. Close both water storage tanks with a screw plug with integrated vent valve (741) and joint ring (411.51). UPA / UPA S 29 of 98...
For the weights see the other applicable documentation and the following table. See product literature of the riser used. Applies to pumps with lift check valve if no other measures to drain the riser have been taken. UPA / UPA S 30 of 98...
To meet this condition the cable connector must be completely submerged. Extension cables connected by KSB If agreed with KSB, the extension cable is supplied connected to the motor lead with a water-proof cable connector. ▪ Unless otherwise specified in the order documentation, KSB's extension cables are designed for: –...
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Motors for star-delta starting with 2 electric cables Motors for DOL starting with 2 parallel electric cables U1 - 1 V1 - 1 W1 - 1 U1 - 2 V1 - 2 W1 - 2 UPA / UPA S 32 of 98...
Fig. 9: Insulation resistance measurement, 2 power cables (open) The measured value must be steady. A longer measurement period might be needed for larger cable cross- sections. The insulation resistance depends on the cable type and cable length. UPA / UPA S 33 of 98...
Installing pipe sections of extensive length Risk of injury by falling components! Impermissible bending of the pump set when pulling it upright! ▷ The length of the first pipe section must not exceed 2 m. UPA / UPA S 34 of 98...
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10. Repeat these steps for every pipe section, lowering the pump set into the well until the installation depth H is reached. Applies to flanged risers only UPA / UPA S 35 of 98...
If there are 2 groups, offset them by 90° or 180°. ▪ Group 1: U1-1, V1-1, W1-1 or U1, V1, W1 ▪ Group 2: U1-2, V1-2, W1-2 or U2, V2, W2 UPA / UPA S 36 of 98...
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Table 15: Length of the rubber strap DN (mm) R (inch) L (mm) 5.3.1.2 Cable tie sizes 2 to 11 (metal) This type of cable tie (metal + rubber cable guard) is used for cables of large cross- section. UPA / UPA S 37 of 98...
The required accessories depend on the weight and the overall length of the pump set. ▪ If agreed with KSB, the pump set is supplied with the accessories for the required installation type already fitted. ▪ Using original accessories (pedestal, supporting frame, pressure shroud) is imperative for assembly at the site.
This prevents any fluttering of the electric cables in the water flow. Use a cable conduit if necessary. 5.4.2 Installing the pump set on support frame and pedestal Applicable to pump sets with the following motors: UMA 300, 14D UPA / UPA S 39 of 98...
5.4.3 Installing the pump set in a suction, pressure or cooling shroud For special operating conditions submersible borehole pumps can be fitted with a pressure, suction or cooling shroud. See order documentation. For these applications always observe the separate order documentation. UPA / UPA S 40 of 98...
5.6 Information on electrical connection Asynchronous motor Pump sets with asynchronous motors by KSB must only be used for DOL starting. During start-up and run-up the voltage must not fall below the value specified in the order documentation. If this starting method is not permitted for the power supply network used, starting devices to reduce starting currents must be provided (e.g.
For pump sets with a UMA-S 150, UMA-S 200 or UMA-S 250 submersible motor that are fitted with a PumpDrive R frequency inverter, also observe the operating manuals of the frequency inverter and output filter. UPA / UPA S 42 of 98...
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Power reserve of the submersible motor If supplied by KSB for operation on a frequency inverter (see data sheet), the motor comes with a 5 % power reserve. To check whether a frequency inverter can be retrofitted, contact the pump manufacturer.
▷ Take suitable precautions to prevent any inadvertent motor rotation caused by uncontrolled backflow of the fluid handled. ▷ As an option, provide electrical protection devices between the motor and the frequency inverter, such as fuses or circuit breakers. UPA / UPA S 44 of 98...
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For this motor type a starting device is required. The starting device is included in the scope of supply. 1. Check the terminal assignment diagram. Wire the starting device in accordance with the illustration and the manufacturer’s product literature. Electromagnetic compatibility UPA / UPA S 45 of 98...
Page 46
Three-phase (3~) motors with one power cable for DOL starting or operation on a frequency inverter (VFD) The three current-carrying conductors are designated U, V and W; the earth conductor is marked PE. UPA / UPA S 46 of 98...
Page 47
Fig. 20: Circuit diagram: three-phase (3~) motors with one power cable for DOL starting or operation on a frequency inverter (VFD) Motor Motor power cable Core marking Control unit Line conductor Earth conductor; core marking: green/yellow UPA / UPA S 47 of 98...
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ð For a supply voltage of 690 V, connect the motor in star (Y) configuration. Fig. 21: Circuit diagram: motors with two power cables for DOL starting; a) star, b) delta Motor Motor power cable Core marking Control unit Line conductor Star point Earth conductor; core marking: green/yellow UPA / UPA S 48 of 98...
Page 49
Fig. 22: Circuit diagram: motors with two parallel power cables for DOL starting or operation on a frequency inverter (VFD) Motor Motor power cable Core marking Control unit Line conductor Earth conductor; core marking: green/yellow UPA / UPA S 49 of 98...
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▪ For DOL starting to the operating current or, at most, to nominal current I ▪ For star-delta starting to the operating current or, at most, to the nominal current x 0.58. NOTE Fitting an ammeter is recommended. UPA / UPA S 50 of 98...
▪ Semi-automatic or fully automatic dry running ▪ Wells with temporary low yields protection equipment (e.g. integrated in KSB's control unit UPA Control) Lightning/overvoltage A lightning protection device cannot offer ▪ Lightning protection with protection against direct lightning strikes, however,...
The sensor can be connected by a 2, 3 or 4-wire system. A1 A2 A3 A4 Pt 100 2-wire system Pt 100 3-wire system For 4-core power cables, do not connect core A2. Order-specific adjustments are possible. UPA / UPA S 52 of 98...
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Submersible motors with J2 winding (VPE): t = 75 °C Cut-out NOTE For the winding type, refer to the motor designation. (ð Section 4.3, Page 19) UMA-S 150, UMA 200, UMA-S 200, UMA 300 and 14D submersible motors are fitted with a J2 winding. UPA / UPA S 53 of 98...
Continuous operation against a throttled shut-off element Damage to pump and motor! ▷ In continuous operation against a throttled shut-off element, the flow rate must not fall short of Q (see name plate). UPA / UPA S 54 of 98...
▷ Make sure the motor cannot be rotated inadvertently. ▷ Observe the safety regulations that apply to work involving electrical hazards. Verify that the equipment is de-energised. UPA / UPA S 55 of 98...
▷ Never operate the pump set outside the limits specified below. 6.2.1 Frequency of starts CAUTION Excessive frequency of starts Risk of damage to the motor! ▷ Never exceed the specified frequency of starts. UPA / UPA S 56 of 98...
1.2 times the maximum flow rate Q indicated permissible on the name plate of the sprinkler. 6.2.4.2 Minimum submergence NOTE Special conditions apply to pump sets in VdS-approved sprinkler installations. (ð Section 6.2.4.3, Page 59) UPA / UPA S 57 of 98...
Page 58
Installation depth of the pump set Height of switchgear above the static water level in the well Minimum submergence Horizontal Measurement for horizontal installation: installation upper edge of the suction strainer to lowest (dynamic) fluid level UPA / UPA S 58 of 98...
Page 59
Horizontal installation L = L + 1000 mm without suction hood Fig. 27: Illustration without suction hood Table 22: Dimensions, installation without suction hood Size UPA 250C - 150 1,00 See diagram. UPA 300 - 65 1,00 UPA 300 - 94 1,50...
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6 Commissioning/Start-up/Shutdown Horizontal installation with L = L + 1000 mm suction hood Fig. 29: Illustration with suction hood Table 23: Dimensions, installation with suction hood Size UPA 250C - 150 1,00 0,60 0,50 0,45 diagram. UPA 300 - 65 1,00 0,60...
1. Slowly close the shut-off element on the discharge side. 2. Switch off the motor immediately after closing the shut-off element. 3. Start up the pump set every 48 hours for approximately 5 minutes during prolonged shutdown periods. (ð Section 6.1, Page 54) UPA / UPA S 62 of 98...
▷ Make sure the motor cannot be rotated inadvertently. ▷ Observe the safety regulations that apply to work involving electrical hazards. Verify that the equipment is de-energised. UPA / UPA S 63 of 98...
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▷ The length of the last pipe section flanged to the pump set must not exceed 2 metres. 3. Place the pump set in a horizontal position on a solid and level surface and secure it against rolling off. UPA / UPA S 64 of 98...
Incorrect motor fill Winding damage! Corrosion damage! ▷ Observe the information sticker on the motor and top up the motor fill as instructed. See cable manufacturer's documentation or DIN VDE 0298-3. If any UPA / UPA S 65 of 98...
Page 66
Mixing ratio / purpose ▪ The motors must only be filled with an antifreeze agent on a 1,2 propylene glycol basis which has been approved by KSB. ▪ The drinking water / antifreeze mixture supplied by the factory is intended for operation as well as storage, transport and preservation.
Page 67
230 / 42 20,2 250 / 42 20,2 UMA 300 ... / ../ .. Drinking water / antifreeze mixture filled in at the factory Operation only if explicitly approved in the order confirmation. UPA / UPA S 67 of 98...
G, C, D 44 mm +/- 2 mm UMA-S 200 G, C, D 44 mm +/- 2 mm UMA 250 G, C, D 64 mm +/- 2 mm UMA-S 250 G, C, D 64 mm +/- 2 mm Fill check kit UPA / UPA S 68 of 98...
Page 69
The motors are fitted with valves (inlet valve and outlet valve) for controlling the pressure. They vary as follows: The hole in the diaphragm housing of UMA 200, UMA-S 200, UMA 250 and UMA-S 250 submersible motors is off centre. UPA / UPA S 69 of 98...
Page 70
Fig. 36: Sizes UMA 150, UMA-S 150 in material variants C, D Inlet valve Earthing bolt Fig. 37: Sizes UMA 200, UMA-S 200, UMA 250, UMA-S 250 in material variant G Inlet valve with filter plug Outlet valve with filter plug Earthing bolt UPA / UPA S 70 of 98...
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5. Adjust the diaphragm distance to the required distance A by draining (venting) or topping up the motor fill as required. 6. Insert the filter plug or screw plug into the inlet valve. On UMA 150 submersible motor in material variants C, D. UPA / UPA S 71 of 98...
▷ Wear protective clothing. WARNING Pump set tilting or rolling off Risk of personal injury! ▷ Always secure vertically positioned pump sets against tipping over. ▷ Always secure horizontally positioned pump sets against rolling off. UPA / UPA S 72 of 98...
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2. Carefully lower the crane to slightly tilt the motor or pump set. 3. Monitor the screw plugs for any escaping liquid. 4. Replace the sealing elements if required. UPA / UPA S 73 of 98...
▷ Observe the minimum bending radius of the electric cables. ▷ Only remove the protective caps from the electric cables at the time of installation. Observe the cable manufacturer's documentation, DIN VDE 0298-3 and/or the general arrangement drawing. UPA / UPA S 74 of 98...
Pump sets / motors which have been operated must be overhauled. This must be performed by qualified specialist personnel, for example from a service workshop authorised by KSB. After the pump set / motor has been overhauled, fill the motor with drinking water/antifreeze mixture providing protection down to -15 °C, and store it.
Page 76
8. Centre the pump, fit the sleeve coupling around the shaft end, and lower the pump. 9. Fit nuts on pump/motor assembly studs. Apply Loctite 242 and tighten the nuts by hand. UPA / UPA S 76 of 98...
- System-induced vibrations Contact KSB. ✘ ✘ ✘ - NPSHavailable (positive suction head) is Submerge pump deeper. too low. Release pump set pressure before attempting to remedy faults on parts which are subjected to pressure. UPA / UPA S 79 of 98...
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- Wrong fuse size Fit correct fuse size. ✘ ✘ ✘ Defective overcurrent relay Check and replace if necessary. - Motor winding not suitable for operating Replace the pump set. ✘ voltage available Contact KSB. UPA / UPA S 80 of 98...
9.1.1 UPA S 250, standard design 901.01 75-6 58-1 752.12 752.11 81-39 900.02 108.01 920.01 52-4 108.02 412.01 900.01 904.01 901.03 920.03 Fig. 46: UPA S 250 with connection for UMA 250 or UMA-S 250 motor UPA / UPA S 81 of 98...
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9 Related Documents 900.01 904.01 412.02 Fig. 47: UPA S 250 with connection for UMA 150 or UMA-S 150 motor 904.02 900.01 904.01 901.03 412.02 920.03 Fig. 48: UPA S 250 with connection for UMA 200 or UMA-S 200 motor UPA / UPA S...
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9 Related Documents 900.01 904.01 Fig. 49: UPA S 250 with connection for UMA 300 motor UPA / UPA S 83 of 98...
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Description Always secure screwed connections marked with this symbol with Loctite 242 . Always secure screwed connections marked with this symbol with Loctite 648 . Table 32: List of components for UPA S, standard design Quantity Part No. Designation Motor size...
Page 85
1 per stage × 4 Hexagon socket head cap ✔ ✔ ✔ ✔ - screw (1 per stage +1) × 12 920.01 ✔ ✔ ✔ ✔ - 920.03 ✔ ✔ ✔ ✔ ✔ - UPA / UPA S 85 of 98...
412.51 Sectional view of the motor shaft, UMA 150 < 26 kW 412.52 50-3 81--74 382.51 411.52 69--6 900.51 59-12 81-60 General assembly drawing, example UMA 150 > 30 kW Temperature sensor Sectional view of thrust bearing, UMA 150 UPA / UPA S 86 of 98...
Page 87
Screw plug With integrated joint ring 411.51 903.52 Screw plug Kit 5 Only in material variants C and D Grub screw Kit 1a and 1b Plug Kit 5 Only in material variant E UPA / UPA S 87 of 98...
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Kit 4a (E, C), 4b (D) 932.51 Circlip Kit 4a (E, C), 4b (D) Only in material variants E and C 932.52 Circlip Kit 4a (E, C), 4b (D) Kit 1a and 1b Spring UPA / UPA S 88 of 98...
▷ The pump shaft must rest on the motor shaft. Observe the following dimensions: 72.9 ± 0.1 ∅ 5.8 +0,1 4 x M12 +0,35 Fig. 51: UMA 150, UMA-S 150 mating dimensions in [mm] UPA / UPA S 89 of 98...
▷ The pump shaft must rest on the motor shaft. Observe the following dimensions: +0.7 Axial tolerance: 1.0 -0.6 Dimension to be set: 101.5 ± 0.1 mm 101,5 ±0,1 Fig. 53: UMA 250, UMA-S 250 mating dimensions in [mm] UPA / UPA S 90 of 98...
Incorrect pump connection Damage to the pump set! ▷ The pump shaft must rest on the motor shaft. Observe the following dimensions: Axial tolerance: 1.5 mm -0.3 Dimension to be set: 4.5 ± 0.1 mm UPA / UPA S 91 of 98...
▷ The pump shaft must rest on the motor shaft. Observe the following dimensions: Axial tolerance: A = 1.2 to 1.5 mm Dimension to be set: B = 72 ± 0.1 mm -0.3 Fig. 56: Mating dimensions 14D, dimensions in [mm] UPA / UPA S 92 of 98...
67227 Frankenthal (Germany) The manufacturer herewith declares that the product: UPA + UMA, UMA-S UPA S + UMA, UMA-S ▪ is in conformity with the provisions of the following directives / regulations as amended from time to time: – 2006/42/EC: Machinery Directive –...
We confirm that the above data and information are correct and complete and that dispatch is effected in accordance with the relevant legal provisions....................................Place, date and signature Address Company stamp Required field UPA / UPA S 94 of 98...
Page 95
Disposal 17 Drive 22 Event of damage 6 Faults Causes and remedies 79 Frequency of starts 57 Impeller type 22 Intended use 9 Key to safety symbols/markings 8 Magnetic field 11 Order number 6 Other applicable documents 7 Preservation 15 Product description 18 Return to supplier 16 UPA / UPA S 95 of 98...
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