Related Manuals for KSB AmaPorter SB 545 SE
Summary of Contents for KSB AmaPorter SB 545 SE
- Page 1 Submersible Motor Pump AmaPorter DN 50 to DN 80 Single-phase AC motor or three-phase asynchronous motor 50Hz - 60Hz 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 2023-06-01...
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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 ................................ 7 Key to safety symbols/markings........................ 7 Safety .............................. 8 General................................ 8 Intended use .............................. 8 Personnel qualification and training....................... 9 Consequences and risks caused by non-compliance with this manual ............ 9 Safety awareness .............................. 9 Safety information for the user/operator ....................... 9 Safety information for maintenance, inspection and installation .............. 10... - Page 4 Contents Shutdown/storage/preservation ........................ 33 6.3.1 Measures to be taken for shutdown.................... 33 Returning to service ............................ 34 Servicing/inspection.......................... 36 Safety regulations............................ 36 Servicing/inspection............................ 37 7.2.1 Inspection work.......................... 37 7.2.2 Lubrication and lubricant change .................... 39 Drainage/cleaning ............................ 41 Dismantling the pump set.......................... 41 7.4.1 General information/Safety regulations.................. 41 7.4.2 Preparing the pump set ........................
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Page 5: Glossary
Glossary Glossary Certificate of decontamination A certificate of decontamination is enclosed by the customer when returning the product to the manufacturer to certify that the product has been properly drained to eliminate any environmental and health hazards arising from components in contact with the fluid handled. -
Page 6: General
In the event of damage, immediately contact your nearest KSB service facility 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: Symbols
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 ⊳ Safety instructions ⇨ Result of an action Cross-references ⇨ Step-by-step instructions Note Recommendations and important information on how to handle the product 1.6 Key to safety symbols/markings Table 4: Definition of safety symbols/markings... -
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: Personnel Qualification And Training
2 Safety Vortex impeller Suitable for the following fluids: (impeller type F) fluids containing solids and stringy material as well as fluids with entrapped air or entrapped gas Impeller with cutter Suitable for the following fluids: (impeller type S) faeces, domestic sewage and waste water containing long fibres 2.3 Personnel qualification and training All personnel involved must be fully qualified to transport, install, operate, maintain and inspect the machinery this manual refers to. -
Page 10: Safety Information For Maintenance, Inspection And Installation
2 Safety 2.7 Safety information for maintenance, inspection and installation ▪ Modifications or alterations of the pump (set) are only permitted with the manufacturer's prior consent. ▪ Use only original spare parts or parts/components authorised by the manufacturer. The use of other parts/components can invalidate any liability of the manufacturer for resulting damage. -
Page 11: Transport/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: Storage/Preservation
3 Transport/Storage/Disposal 3.3 Storage/preservation If commissioning is to take place some time after delivery, we recommend that the following measures be taken: CAUTION Improper storage Damage to the power cable! ▷ Support the power cables at the cable entry to prevent permanent deformation. -
Page 13: Disposal
3 Transport/Storage/Disposal NOTE If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination 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. -
Page 14: Description Of The Pump (Set)
4.2 Product information as per Regulation No. 1907/2006 (REACH) For information as per European chemicals regulation (EC) No. 1907/2006 (REACH) see https://www.ksb.com/en-global/company/corporate-responsibility/reach. 4.3 Designation Example: AmaPorter SB 545 SE Table 6: Designation key Code Description AmaPorter... -
Page 15: Name Plate
4 Description of the Pump (Set) 4.4 Name plate AmaPorter SB 545 SE 39018468-B202322-00485 0.3-2.3 l/s 19.7-10.0 m S2322 2023 DKN 71.2M-1U 2720 0.97 Fig. 1: Name plate (example) Designation KSB order number Flow rate (Q Maximum fluid temperature and min. -
Page 16: Installation Types
Short-term operation with the motor outside the fluid handled is possible if the fluid level is above the level R specified by KSB (see outline drawings in type series booklet). 4.7 Configuration and function Fig. 2: Sectional drawing (example: AmaPorter S 545 ND) -
Page 17: Scope Of Supply
4 Description of the Pump (Set) (7). The shaft runs in rolling element bearings (8 and 9), which are supported by a bearing bracket (2). The bearing bracket is linked with the pump casing and/or casing cover on the drive end. Sealing Sealing the pump: ▪... -
Page 18: Installation At Site
5 Installation at Site 5 Installation at Site 5.1 Safety regulations DANGER Persons in the tank during pump operation Electric shock! Risk of injury! Danger of death from drowning! ▷ Never start up the pump set when there are persons in the tank. DANGER Risk of falling when working at a great height Danger to life by falling from a great height! -
Page 19: Checking The Direction Of Rotation
5 Installation at Site Resonances Any resonances at the usual excitation frequencies (1 x and 2 x rotational frequency, vane passing frequency) must be prevented both in the foundation and in the connected piping, as such frequencies may cause extreme vibrations. 1. -
Page 20: Installing The Pump Set
5 Installation at Site UG2056679 Fig. 3: Checking the direction of rotation 2. Start up the pump for a short period (5 seconds max.). 3. Check the direction of rotation. The direction of rotation is marked by an arrow on the pump casing. Anti-clockwise direction of rotation of the impeller can be determined via the suction-side pump opening (a) or the discharge side pump opening (b). - Page 21 5 Installation at Site Fig. 5: Dimensions Table 7: Chemical anchor dimensions Size [mm] [mm] [mm] [mm] [mm] [Nm] × l M10 × 130 M16 × 190 Table 8: Curing times of resin capsule Floor temperature Minimum curing time Dry concrete Wet concrete [°C] [min] ≥ +35 ≥ +30 ≥...
- Page 22 5 Installation at Site CAUTION Critical speed of reverse rotation Increased vibrations! Damage to mechanical seals and bearings! ▷ If long risers are used, fit a swing check valve to prevent excessive rotational speed of the pump running in reverse after it has been stopped. Watch the venting function when arranging the swing check valve.
- Page 23 5 Installation at Site Fitting the mounting bracket UG2052845 Fig. 7: Fitting the mounting bracket 1. Fasten mounting bracket 894.37 to the edge of the sump opening with anchor bolts 90-3.37 and tighten the anchor bolts to a tightening torque of 10 Nm. 2.
- Page 24 5 Installation at Site Table 10: Guide wire tension Pump size Tightening torque Guide wire tension [Nm] P [N] DN 50 6000 DN 65 6000 DN 80 6000 5.3.1.4 Fitting the guide rail arrangement (1 or 2 guide rails) The pump set is guided into the sump or tank along one or two vertical guide rails. It attaches itself automatically to the flanged bend which has been fitted to the floor.
- Page 25 5 Installation at Site NOTE For installation depths > 6 m, the scope of supply may include brackets as a middle support for the guide rails. The mounting brackets also serve as spacers between the two guide rails. 1. Position adapter 82-5.70 on flanged bend 72-1 and fasten it with screws 914.70 (DN 50/65)/901.70 (DN 80), discs 550.70 (DN 80) and nuts 920.70.
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Page 26: Stationary Wet Installation
5 Installation at Site 5.3.1.6 Preparing the pump set Fastening the claw for guide wire, single guide rail and guide hoop arrangement 1. Fasten claw 732.35 with screw 914.35 and disc 550.35 to the discharge flange (see illustration opposite). Tighten the screw to a torque of 17 Nm. Fastening the claw for twin guide rail arrangement UG2057913 Fig. 13: Fastening the claw... -
Page 27: Transportable Wet-Installed Model
5 Installation at Site shackle 59-17 and hook 59-18.01 – stationary wet installation Transportable wet-installed model Attach the lifting chain or rope to the lug/eyebolt/bail at the pump set on the side of the discharge nozzle. UG2057913 Attaching the lifting chain/rope – transportable wet- installed model 5.3.1.7 Installing the pump set... -
Page 28: Electrical System
5 Installation at Site Attaching the lifting chain / lifting rope 1. Attach the lifting chain or rope to the shackle on the discharge nozzle side of the pump set (see drawing and table "Types of attachment"). Connecting the piping The DIN connection can be connected to rigid or flexible pipes. -
Page 29: Information For Planning The Control System
The sensors are designed to prevent hazards and damage to the pump set. Measuring transducers are required for analysing the sensor signals supplied. Suitable devices for 230 V AC can be supplied by KSB. NOTE Reliable and safe operation of the pump within the scope of our warranty is only possible if the sensor signals are properly analysed as stipulated in this manual. - Page 30 5 Installation at Site The pump set is supplied with a power cable. Always connect all marked cores. DANGER Operating an incompletely connected pump set Damage to the pump set! ▷ Never start up a pump set with incompletely connected cables or non- operational monitoring devices.
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Page 31: 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 CAUTION Fluid level too low Damage to the pump set! ▷ Always operate the pump set in such a way that air cannot ingress into the pump casing. ▷ Never allow the fluid level to drop below the specified minimum (R3). ▷... -
Page 32: Operating Limits
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 specified in the data sheet. ▷ Never operate the pump set at ambient or fluid temperatures exceeding those specified in the data sheet or on the name plate. ▷... -
Page 33: Shutdown/Storage/Preservation
6 Commissioning/Start-up/Shutdown The pump set is ready for operation (S1) as soon as the motor is fully submerged and the minimum level of fluid handled is not lower than the specified minimum (R3 or R4). For exact dimensions see general arrangement drawing / outline drawing. The pump can be operated at a lower fluid level for short periods. -
Page 34: Returning To Service
6 Commissioning/Start-up/Shutdown WARNING Unintentional starting of the pump set Risk of injury by moving components and shock currents! ▷ Ensure that the pump set cannot be started unintentionally. ▷ Always make sure the electrical connections are disconnected before carrying out work on the pump set. WARNING Fluids handled, consumables and supplies which are hot and/or pose a health hazard... - Page 35 6 Commissioning/Start-up/Shutdown NOTE On pumps/pump sets older than 5 years we recommend replacing all elastomer seals. AmaPorter 35 of 62...
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Page 36: Servicing/Inspection
7 Servicing/inspection 7 Servicing/inspection 7.1 Safety regulations The operator ensures that maintenance, inspection and installation are performed by authorised, qualified specialist personnel who are thoroughly familiar with the manual. DANGER Risk of falling when working at a great height Danger to life by falling from a great height! ▷... -
Page 37: Inspection Work
NOTE All maintenance work, service work and installation work can be carried out by KSB Service or authorised workshops. Find your contact in the attached Addresses booklet or visit https://www.ksb.com/en-global/contact. - Page 38 7 Servicing/inspection 7.2.1.3 Measuring the insulation resistance Measure the insulation resistance of the motor winding during annual maintenance work. ü The pump set has been disconnected (e.g. in the control cabinet). ü Use an insulation resistance measuring device. ü The recommended measuring voltage is 500 V (maximum permissible voltage: 1000 V).
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Page 39: Lubrication And Lubricant Change
7 Servicing/inspection 7.2.2 Lubrication and lubricant change 7.2.2.1 Lubricating the mechanical seal DANGER Excessive temperatures at the shaft seal Explosion hazard! Damage to the pump set! ▷ Regularly check the condition of the lubricant in the lubricant reservoir of the mechanical seal. - Page 40 7 Servicing/inspection 7.2.2.1.4 Changing the lubricant WARNING Lubricants posing a health hazard and/or hot lubricants Hazard to persons and the environment! ▷ When draining the lubricant take appropriate measures to protect persons and the environment. ▷ Wear safety clothing and a protective mask if required. ▷...
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Page 41: Drainage/Cleaning
Observe the safety instructions and information. For dismantling and reassembly, observe the exploded view (ð Section 9.1, Page 49) . In the event of damage, you can always contact the KSB Service. DANGER Insufficient preparation of work on the pump (set) Risk of injury! ▷... -
Page 42: Removing The Mechanical Seal And Motor Section
Fig. 20: Forcing screw NOTE The forcing screw is not included in the scope of supply. It can be ordered separately from KSB. 7.4.4 Removing the mechanical seal and motor section Pumps with impeller F AmaPorter F 50_/60_ Proceed as below to remove the rotor unit parts in the following sequence: ü... -
Page 43: Reassembling The Pump Set
7 Servicing/inspection Pumps with impeller S AmaPorter S_ 545 ü The oil has been drained. (ð Section 7.2.2.1.4, Page 40) 1. Undo and remove screws 914.74 at bearing bracket 330. 2. Remove rotor unit from pump casing 100. 3. Remove rotor unit from pump casing 100 and dismantle in the following sequence: 4. - Page 44 7 Servicing/inspection AmaPorter F 50_ /60_ / S_ 545 ü Rolling element bearings 321.01/02 have been properly fitted on shaft 210 with circlip 932.02 if required. 1. Slide lip seal 421 onto shaft 210 up to rolling element bearing 321.02. 2.
- Page 45 7 Servicing/inspection Fig. 21: Pulling the rotor assembly up to the suction cover 6. Pull the rotor assembly right up to the suction cover until it will not go any further. UG2050036 Fig. 22: Adjusting impeller type S Distance between suction cover and pump casing Clearance gap between suction cover and impeller vanes Distance between the upper side of the suction cover and the mounting holes of the suction cover...
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Page 46: Reassembling The Motor Section
7 Servicing/inspection AmaPorter F 51_ /52_ /61_ /62_ /82_ Screw impeller 230 with screws 914.10 and discs 550.23 onto shaft 210. 7.5.3 Reassembling the motor section CAUTION Wrong screws/bolts Damage to the pump set! ▷ Always use the original bolts/screws for assembling a pump set. ▷... - Page 47 7 Servicing/inspection Table 19: Quantity of spare parts for recommended spare parts stock for 5 years’ continuous operation Part No. Description Number of pumps (including stand-by pumps) 6 and 7 8 and 9 10 and more 99-19 Spare parts set 50 % 05-230 Impeller 30 %...
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Page 48: Trouble-Shooting
- Motor is not running because of lack of Check the electrical installation. voltage. Contact the energy supplier. - Motor winding or power cable defective Replace by new original KSB parts or contact ✘ ✘ the manufacturer. ✘ Defective rolling element bearing Contact the manufacturer. -
Page 49: Related Documents
9 Related Documents 9 Related Documents 9.1 Exploded views with lists of components 9.1.1 AmaPorter F UG2049672 Fig. 23: Exploded view of AmaPorter F AmaPorter F 50_ /60_ AmaPorter F 51_ /52_ /61_ /62_ /82_ For AmaPorter F 50_ /60_ with single-phase motor, the capacitor is connected to the stator and placed on the bearing bracket. - Page 50 9 Related Documents Table 22: List of components Part No. Description Part No. Description Casing Mating ring carrier Suction cover 550.23 Disc Impeller Rivet 321.01/.02 Radial ball bearing 81-59 Stator Bearing bracket Rotor 410.01 Profile seal Cable gland 412.07/.15/.16/.63 O-ring 914.04/.10/.16/.74 Hexagon socket head cap screw Lip seal 932.02/.03/.04...
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Page 51: Amaporter S
Fig. 24: Exploded view of AmaPorter S AmaPorter SB 545 SE/ NE AmaPorter SB 545 ND For AmaPorter SB 545 SE/ NE: Start capacitors are delivered with the pump and connected directly (via the cable gland). Use an installation casing which is connected to the mains. -
Page 52: Wiring Diagram
9 Related Documents Table 23: List of components Part No. Description Part No. Description Casing Fitting piece Suction cover 561.03 Half round head / grooved pin 23-7 Impeller body Rivet Impeller 81-59 Stator 321.01/.02 Radial ball bearing Rotor Bearing bracket Cable gland 410.01 Profile seal Capacitor... - Page 53 9 Related Documents 9.2.1.2 Version without float switch (AmaPorter _______ NE) UG2058473 Fig. 26: Single-phase AC version without float switch Core colours White Yellow/green Blue Brown Black 9.2.1.3 Version with capacitor (AmaPorter SB ________ ) 2539:105 2539:105 Fig. 27: Single-phase AC versions with start capacitor Resistor 56 kΩ...
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Page 54: Pumps With Three-Phase Motors
9 Related Documents 9.2.2 Pumps with three-phase motors 9.2.2.1 Version without temperature sensors 7)8) 7) 8) AmaPorter F 50_ / 60_ / S 545 UG2058473 Fig. 28: Three-phase version without temperature sensors Core colours: U (phase) Black V (phase) Brown W (phase) Grey or blue PE (earth Green/yellow... - Page 55 9 Related Documents 9.2.2.2 Version with temperature sensors AmaPorter F 51_ /52_ /61_ /62_ /82_ UG2057916 Fig. 29: Three-phase version with temperature sensors U (phase) V (phase) W (phase) Bimetal switch Bimetal switch AmaPorter 55 of 62...
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Page 56: Eu Declaration Of Conformity
128, rue Carnot, 59320 Sequedin (France) The EU Declaration of Conformity was issued in/on: Frankenthal, 1 May 2023 Thomas Heng Head of Product Development Series & Heavy Duty Pumps KSB SE & Co. KGaA Johann-Klein-Straße 9 67227 Frankenthal (Germany) AmaPorter 56 of 62... -
Page 57: Eu Declaration Of Conformity
128, rue Carnot, 59320 Sequedin (France) The EU Declaration of Conformity was issued in/on: Frankenthal, 1 May 2023 Thomas Heng Head of Product Development Series & Heavy Duty Pumps KSB SE & Co. KGaA Johann-Klein-Straße 9 67227 Frankenthal (Germany) AmaPorter 57 of 62... -
Page 58: Eu Declaration Of Conformity
128, rue Carnot, 59320 Sequedin (France) The EU Declaration of Conformity was issued in/on: Frankenthal, 1 May 2023 Thomas Heng Head of Product Development Series & Heavy Duty Pumps KSB SE & Co. KGaA Johann-Klein-Straße 9 67227 Frankenthal (Germany) AmaPorter 58 of 62... -
Page 59: Certificate Of Decontamination
13 Certificate of Decontamination 13 Certificate of Decontamination Type: ..........................Order number / Order item number ..........................Delivery date: ..........................Application: ..........................Fluid handled ..........................Please tick where applicable ⃞ ⃞ ⃞ ⃞ ⃞ Corrosive Oxidising Flammable Explosive Hazardous to health ⃞... -
Page 60: Index
Index Index Oil lubrication Applications 8 Oil quality 39 Order number 6 Other applicable documents 6 Bearings 16 Overload protection 28 Certificate of Decontamination 59 Partly completed machinery 6 Commissioning 31 Permissible flange loads 22 Piping 22 Place of installation 18 Design 15 Preservation 12 Designation 14 Direction of rotation 20 Dismantling 41 Reassembly 41 Disposal 13 Return to supplier 12 Drive 15 Returning to service 34 Electrical connection 29... - Page 62 KSB SE & Co. KGaA Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com...
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