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UPA 150C - URSAN Pompa

1. 5 9 4 Switchgear Observe the applicable regulations Switchgear shall always consist of contactors with integrated motor protection thermal overcurrent relay to allow control by pressure switches float switches etc if required Switchgear must be in compliance with national regulations e g VDE for Germany or IEC regulations In addition the instructions issued by the switchgear manufacturers must be observed The overcurrent relay shall be set as follows for d o l starting to the operating current at most to rated current N for star delta starting to the operating current at most to rated current x 0 58 We strongly recommend an integrated ammeter 5 9 5 Connecting the motor cable in the control box The motor cable shall be connected to the control box by a trained electrician only Observe the markings on the cables when connecting the cables The motor cable must be connected to the control box by a trained electrician only In 4 core cables the earth conductor core colour green yellow is integrated in the cable In the case of 3 core cables the earth conductor is separate or included in the 4 core cable On motors with individual cables the earth conductor is marked by green yellow adhesive tape at the end In both cases the earth conductor must be connected to the earthing terminal in the control box The length of exposed shield should be as short as possible and the shield ends sho
2. 6 1 6 1 1 6 1 2 6 1 3 6 1 4 6 1 5 6 2 6 3 6 3 1 6 3 2 6 3 3 6 3 4 7 1 7 2 10 11 12 12 1 12 2 12 3 12 4 12 5 13 Commissioning start up shut down 0 aaa 13 Gomtissioning Stari Up rs sA nan ns Md et YD THYN A DYD yd yi BE e mus 13 Gommissionifig a A IE CI Me A LEA RE Y GL A DW Y 13 SIarup freguencysaies i AA MR Dae yn A A A Aaa anlaml IG Fy YR EG 13 Pump operation with partially closed gate valve FFF n 13 Pump operation withclosedgatevalve tenn FEED YF uu 13 Operation with frequency inverter hes 13 Operating limits 1o Ar np dele ek FR e kl dob la care dd ay Yd eio EY 14 Shutdown Storage Preservation Returning to service eee 14 STitutdown a nala I TRIPS I NBN a DE A dU da RACE VERE ER li 14 OIOrage 5904 s hs fuo ed a a aA d et dd es AA a ue aed eae Mid ctt A ede ape NS 14 Preserving UMA rriotOIS nr erp Rm one bem e in ek bem ndaki e ri peg ero Rs 14 Returning 10 Service reo RL e AN uw A Y Rd cu A iB GAU nen A Bulk 14 Servicing and maintenance a a hh nnn sh 15 Servicitig inspection dc oun ner atte te dpt Beto et Sallad Tamamen da Toa uti wu dd EN 15 Repair Spare parts enn eee Sea ea se demi op Dy GU dU oi 15 Flow velocity past the motor v 20 20r0 5M s nr 15 Wiring principles 1 Connect
3. ilana 5 3 Transport and interim storage een 5 4 Description of the product accessories and installation types 4 1 2025 6 4 1 Techriical specifiCation iie eu ey atk oes y oe y YCW YR ee ar DR AD WE Yg Y ee Y yd fo RETE nk 6 4 2 Installation conditions 1552 yala i el az a we RERO ade a atte ead qr e Roe 6 4 2 1 Minimum submiergence eu yer YA DD a UR ed peed oe RO DL ek ili ani 6 4 2 2 Angled installation i am ke il epe Pee Y I a ace we e Du reet DA A puma lil 6 4 23 Flow velocity v pastthermotor a saa yin e 6 4 2 4 Nater guality eu Si kalp te ewe E Sm elele Mali kr Gale de aed er PETERE Nase Rs 6 5 Installation at Site 22 nu A a aa rn ama eda a Ca ea ea aa 7 5 1 Installationtoolsandeguipment aaa 7 5 2 Motor fill ueu ey ine A agi ee pak ei DI ae peni pl arian il ie Lad 7 5 2 1 Franklin DN 100 and UMA 150D motors aaa 7 5 2 2 Protection against freezing iu a ed A ed UE UMP da e ETE 8 5 3 Pump sets in suction cooling or pressureshroud FFF FFF EY uu 8 5 4 Check valve Connection branch RR I n 8 5 5 Connecting the electric extension cable cable connector 9 5 6 Protection against electric shock Gu er Y A De e ORI VEN IH ne nie Ran 9 5 7 nstallation at site ei ar ped Re Re RT ERR EE BLAID galan GA la
4. Maximum operating freguency Freguency inverter operation above the nominal freguency 50Hz 60Hz of the pump unit is not possible to prevent motor 13 Kse D Motors lt 1 kV overload Maximum permissible voltage increase velocity and peak voltages Excessive voltage increase velocities and excessive peak voltages 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 lt 500 V us Maximum peak voltages against earth Low voltage motors lt 1 kV J1 insulation lt 600 V J2 insulation lt 800 V For motors of pump sizes DN100 and DN150 the limits for J1 insulation apply Note Compliance with these limits can usually be assured by means of a sine filter or U filter Control principle of frequency inverter The control principle of the frequency converter must correspond to linear U f curve control If other control principles are employed such as field oriented inverters inverters with DTC or NOF the manufacturer of the frequency inverter must ensure that the special requirements of submersible motors very small moment of inertia electrical data are taken into account 6 2 Operating limits To ensure operational reliability and prevent cavitation submersible borehole pumps in continuous operation shall only be operated up to the maximum flow rate Omax indicated on the name plate In addition the m
5. Motors lt 1 kV 4 Description of the product accessories and installation types 4 1 Technical specification The submersible motor is an electric motor with is rigidly connected to the pump They are designed in principle for vertical stationary use in water With the restrictions described in section Operating instruction of the pump they can also be installed horizontally The liquid fill in the motor lubricates the bearings and cools the space inside the motor On UMA motors it also cools the windings sealed with water tight insulation material The shaft is sealed by a high quality mechanical seal At the lower end of the unit a thrust bearing absorbs the pump s hydraulic thrust and the rotor weight of pump and motor Pressure differences between the motor and environment are equalized by a rubber expansion diaphragm Also refer to the enclosed sectional drawings with list of components of pump and motor Note When added at the factory the motor fill meets food protection regulations 4 2 Installation conditions 4 2 1 Minimum submergence CAUTION The submersible motor must only be operated when fully submerged For specific installation conditions please refer to the operating instructions of the pump UPA 150C 4 2 2 Angled installation Contact the KSB factory 4 2 3 Flow velocity v past the motor see section 8 As standard and dependent on the fluid temperature a forced flow must pas
6. W9 and where there is a risk of electric shocks safety sign to DIN 4844 W8 The word CAUTION is used to introduce safety instructions whose non observance may lead to damage to the machine and its functions Instructions attached directly to the machine e g Check motor fill green sticker etc must always be complied with and be kept in perfectly legible condition at all times 2 2 Personnel gualification and training All personnel involved in the operation maintenance inspection and installation of the unit must be fully gualified to carry out the work involved Personnel responsibilities competence and supervision must be clearly defined by the operator If the personnel in question is not already in possession of the reguisite know how appropriate training and instruction must be provided If reguired the operator may commission the manufacturer supplier to take care of such training In addition the operator is responsible for ensuring that the contents of the operating instructions are fully understood by the responsible personnel KSE b Motors x 1 kV 2 3 Non compliance with safety instructions Non compliance with safety instructions can jeopardize the safety of personnel the environment and the machine unit itself Non compliance with these safety instructions will also lead to forfeiture of any and all rights to claims for damages In particular non compliance can for example result i
7. able Replace the pump unit Contact KSB Fuses have blown Motor winding or electric cable are defective Wrong fuse size Contact KSB Fit correct fuse size Unit cannot be switched on Lack of voltage Check the electrical instal lation Notify the energy supply company Motor winding or electric cable are defective Contact KSB Defective overcurrent relay Check and replace if nec essary Unit cannot be switched of Defective overcurrent relay Check and replace if nec essary 29 Kse b UPA 150C 13 Annexes 13 1 Parts list UPA 150C Pos nr Description 52 4 Locking sleeve 58 1 Protection plug 81 39 Clamp 106 Suction casing 108 01 Stage casing 108 02 Stage casing with holes 108 05 Upper stage casing 143 Suction strainer 145 Adapter 210 Shaft 230 Impeller 316 Thrust bearing 371 Counter thrust bearing 412 01 O ring 502 Casing wear ring 503 Impeller wear ring 545 Bearing bush 550 Disc 751 Valve body 752 Valve seat 756 Valve spring 759 Valve plate 825 Cable guard 849 Coupling 905 Tiebolt 914 01 Hexagon socket head screw 914 02 Hexagon socket head screw 914 03 Hexagon socket head screw 920 Nut 922 Impeller nut 20050452 1 Rigidly connected to shaft 210 30 UPA 150C KSB b Exploded view UPA 150C 16 13
8. 3 Conductor marking 5 Star point 1 7 Control box 8 Mains phases PE Earth 3400 126 3 green yellow Connecting a motor with delta star configuration and 2 cables for star delta starting 17 KSB b Motors lt 1 kV 11 Pt 100 temperature sensor optional Temperature sensor installed in the motor on option for measuring the temperature of the motor s water fill The sensor is equipped with a shielded 10 metre power cable SO5BC4B F 4 x 0 5 mm as a standard feature A1 BLACK core A2 BLACK or GREY core A3 BROWN core A4 BLUE core Only one Pt100 temperature sensor is reguired 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 reguired Connection The 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 at the cable end 2 wire system 3 wire system 4 wire system ome i ji n A1 A2 A3 A4 The voltage at the Pt 100 measuring sensor must not exceed 6V Umax lt 6V Checking 8 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 A1 to A2 and A3 to A4 0 Q to 30 Q A1 to A3 and A2 to A4 100 Q to 130 Q b Insulation resistance measure with d c voltage U 100V Combine all co
9. IS ATTENTION Before placing the pump unit in horizontal position check the motor fill according to the instructions given in the documentation of the motor concerned IS ATTENTION For exact procedures for horizontal installation of the pump and motor please follow the instructions in the documentation of the motor concerned and if applicable in the enclosed installation instructions provided with the horizontal installation kit 21 Kse b UPA 150C 8 9 Re installing the pump unit Before 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 must be done separately for the motor and the pump Also rotor position pump and motor and axial clearance have to be checked For large pump units auxiliary equipment will be required This work should be performed by trained personnel only If the rotor cannot be turned or lifted we recommend that you contact our nearest service centre In addition the winding insulation resistance must be checked unless this has already been done during winding repair or when connecting the extension cable The winding insulation resistance should be measured by a trained electrician only 22 Kse b UPA 150C 9 Commisioning start up shutdown 9 1 Commissioning Start up WARNING The pump unit shall only be switched on when the motor is filled and the p
10. before installation maintenance and repairs Secure this disconnection WARNING Surface of the pump can be hot after continuous operation WARNING Make sure that no one can be near rotating components when starting the pump WARNING Handle a pump with dangerous liguids with the utmost care Avoid danger for persons or the environment when repairing leakages draining liguids and venting It is strongly recommended to place a relief barge under the pump WARNING Immediately following completion of the work all safety relevant and protective devices must be re installed and or re activated gt PEP D WARNING N Please observe all instructions set out in the chapter on Commissioning Start up before returning the pump to service 4 5 Environmental aspects 4 5 1 General The pumps of KSB are designed to function in an environmentally friendly way during their entire life Therefore always use biodegradable lubricants for maintenance OY ENVIRONMENTAL INSTRUCTION we Always act according to the laws by laws regulations and instructions with respect to health safety and the environment 4 5 2 Dismantling Dismantle the pump and dispose of it in an environmentally friendly way The owner is responsible for this Oy ENVIRONMENTAL INSTRUCTION we Ask at the local government about the re use or the environmentally friendly processing of discarded materials KSB b UPA 150C 5 Pumpin
11. cooling water C2 cycles fire protection industrial applica tions 10 The liquid is sucked in through the pump inlet on the suction side under minimum pressure The pump increases the pressure The liquid leaves the pump through the pump outlet on the delivery side under increased pressure 20060274 Functional principle of the UPA 150C Kse b UPA 150C 5 7 Sound pressure levels 5 7 1 Sound pressure level of pumps The sound pressure level has been measured in accordance with the rules laid down in the EC machinery directive 98 37 EC and applies to pumps submerged in water without external regulating valve Pump type dB A UPA 150C 16 lt 70 UPA 150C 30 lt 70 UPA 150C 48 lt 70 UPA 150C 60 lt 70 5 7 2 Sound pressure level of motors The sound pressure level of the motor depends on the motor used in combination with the UPA 150C pump Consult the documentation of the motor concerned for the exact specifications 11 Kse b UPA 150C 6 Transport o 1 Transport WARNING Lift the pump if necessary using a hoist and suitable slings Attach the slings to the hoisting eyes on the packaging where present gualified personnel are allowed to hoist the pump WARNING Always make sure that the pump cannot tip over WARNING The pump must be hoisted according to the current hoist guidelines Only WARNING N Always protect electric cabling from mec
12. reliability and safety of the pump supplied is only valid if the pump is used in accordance with its designated use as described in the following sections of this manual The limits stated in the data sheet must not be exceeded under any circumstances The warranty becomes invalid if one or more of the points below occur The buyer makes modifications himself e The buyer carries out repairs himself or has these carried out by a third party The pump has been handled or maintained improperly e The pump has non original KSB spare parts fitted KSB remedies defects under warranty if the points below are observed s Defects are caused by flaws in the design the materials or the production e The defect has been reported within the warranty period Other terms of warranty have been included in the general terms of delivery which are available upon request Kse b UPA 150C 4 Safety and environment 4 1 General This KSB pump has been developed in accordance with state of the art technology itis manufactured with utmost care and subject to continuous quality control KSB does not accept any liability for damage and injury caused by not observing the directions and instructions in this manual This also applies in cases of carelessness during the installation procedure use and maintenance of the pump Non compliance with safety instructions can jeopardize the safety of personnel the environment and the pu
13. removal of the check valve the use of a tyre lever is not required 8 5 1 Changing the pipe connection When the pipe connection needs to be changed proceed as follows 1 Loosen and remove the hexagon socket head screws 914 01 at the discharge side of the pump 2 _ Take of the threaded or flanged adapter 145 Fit the required adapter to the pump 4 Place the removed hexagon socket head screws 914 01 and tighten them crosswise 8 5 2 Removal of the check valve When the check valve has to be accessed or removed proceed as follows 1 Loosen and remove the hexagon socket head screws 914 01 at the discharge side of the pump Take of the threaded or flanged adapter 145 Take out the valve spring 756 and valve plate 759 4 ln case of cleaning or replacement put back the valve plate 759 and valve spring 756 Co N 5 Put back the threaded or flanged adapter 145 6 Placethe removed hexagon socket head screws 914 01 and tighten them crosswise 8 6 Electrical connections IS ATTENTION For specific instructions about connecting the submersible motors carefully follow the instructions given in the documentation of the motor concerned WARNING Before starting work on the pump make sure that the electricity supply has been switched off and that it cannot be accidentally switched on WARNING AN The electrical connection should be carried out by an authorized electrician in
14. 2 945 752 108 05 316 922 52 4 230 503 108 02 756 759 412 905 58 1 108 01 210 108 01 502 550 143 106 G SlL60S00Z2 N ks NEA ego zx oj oi o PE S A MN N gt DCD 7 gt gt ls 920 31 KSB b UPA 150C 13 3 Exploded view UPA 150C 30 914 01 145 545 756 752 98 108 05 412 751 905 316 922 58 1 52 4 230 503 210 108 02 108 01 502 550 143 106 920 4 g E o amp 32 Operating Instructions 3400 881 10 Caution These operating instructions contain fundamental information and precautionary notes Please read the manual thoroughly prior to installation of unit connection to t
15. are installed using a mounting plate in addition to supporting clamps 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 as the first pair of supporting clamps immediately below the upper flange 2 _ Use cable ties to attach the power supply cables as well as the control and measuring cables if any to the riser pipe approx 0 5 m above the flange 3 Place two sturdy beams across the well opening 4 Attach the pump to the crane hook e g mobile crane by the mounting plate and lower it into the well until the first pair of supporting clamps rests Kse b UPA 150C on the beams The supporting clamps will hold the pump unit so that the mounting plate can be removed and the second riser pipe can be fitted 5 Fasten the mounting plate and the second pair of supporting clamps to the second riser pipe Attach the pump unit to the crane again remove the first pair of supporting clamps and lower the pump until the second pair of supporting clamps sits on the beams 6 Repeat these steps for every pipe section lowering the pump unit into the well until installation depth is reached 8 7 3 Fixing the electric cable to the riser pipe WARNING AN Tighten the ties firmly to ensure that the electric cable cannot slip downwards The cables shall be fixed to the riser pipe by a cable tie each on both sides of the riser pipe flange or soc
16. eed dak DDR 9 5 51 Re installing the pump unit 4 onere Ree si eent eler dp Ic sa din e elemi dm dp FU pik 9 5 8 Fixing the electric cable to the riser pipe cable ties 0 10 5 8 1 Cable tie size 1 rubber le ri Mae ale EG BIG RE RE RUN GEG IE Satis ERAN CR dg 10 5 8 2 Cablettie sizes 2 41 metal o oae o te d Lau a dg ali dle Lp tu de ood 10 5 9 Connection to power supply in control box 1 1 1111 10 DOM Genaral sairin neta haa P y YF A ea M d x akel gi e ya ae Gale 10 5 9 2 Starting methods ene alice nt et me sw e B R d devant Re ed alaka e aata Reyes fatten o pb alak 11 5 9 3 Terminal designations ale ad deme DWR Dd el des banda doped d epe da ela donee tez P Pe 12 5 9 4 Switchgear air ei ad PR AK lk RG a kel la eei E Fd 12 5 9 5 Connecting the motor cableinthecontrolbox 2 1 4000 12 5 10 Protective equipment esris il A NL e rb RR ED R peak 12 5 10 1 Dryrrunnintg seen xe A DIEM Du I TP UE QUUM e GRAU DG GY o 12 5 10 2 Lightning Overvoltage Y Y Lu 12 5 10 89 Phase tall 2 Leu a alla ah ve e RN ot qe ED Gn YO i aa A ns dede A Sd a Maca Res Man 12 5 10 4 Excessive temperature in the motor 1 12 5 10 5Otherprotectilonparameters EFE EFE EY EEF EEF FEE EE EY YY Y FY ug 12 KSB b Motors lt 1 kV
17. installed with its suction strainer exactly at the level of the well screen filter The maximum diameter of the UPA 150C pump is always 6 150mm It is recommended to check the borehole with an inside calliper to ensure unobstructed passage Check narrow boreholes for dimensional accuracy over their entire length e g by inserting a pipe of the length and biggest outside diameter of the pump or motor Sharp bends or bottlenecks can make installation difficult or even impossible The pump unit is supported on the well head by supporting clamps low weight units and low submergence or a supporting flange 14 or SS NN A M He IX gt 0 5 be pD 20060263 A Vertical installation deep well pump sump etc Borehole pump UPA 150C Riser pipe Cable tie Supporting flange well head Pressure gauge Power supply cable Well screen filter ADO BEN D Inside well diameter TB Well depth TF Well screen filter depth He Installation depth Hh Static water level Ht Dynamic water level pumping water level The suspension arrangement of the pump unit must be designed and dimensioned so that all static and dynamic forces can be absorbed and that the riser KSB b UPA 150C pipe cannot slip downwards The supporting clamps or flanges must be fastened at the well head so that they cannot shift
18. motor if necessary The centering devices must not be fitted in the motor pump casing area however If several pump units are installed side by side mutual interference must be prevented by ensuring a certain minimum installation distance see layout drawing supplied in such cases IS ATTENTION Vortex formation which would result in air intake or dry running of the top pump bearing must be prevented The pump must never be allowed to run dry Dry running may be caused by low well yields or other marked water level fluctuations In such cases dry running protection must absolutely be provided 7 2 Liguid temperatures cooling For the maximum liguid temperature and the minimum liguid velocity over the motor please consult the documentation of the motor concerned It is recommended to install the motor above the well screen in order to achieve proper motor cooling IS ATTENTION In cases where the stated liquid velocity cannot be achieved a flow sleeve must be installed If there is a risk of sediment build up such as sand around the motor a flow sleeve should be used in order to ensure proper cooling of the motor Out of consideration for the rubber parts in pump and motor the liquid temperature must not exceed 30 C The pump itself can also operate at liquid temperatures above 30 C Please contact your supplier for the exact possibilities or consult the technical documentation of the motor used in combinatio
19. of the eguipment supplied are only permitted after consultation with the manufacturer Original spare parts and accessories authorized by the manufacturer ensure safety The use of other parts will invalidate any liability of the manufacturer for conseguential damage 2 8 Unauthorized modes of operation The warranty relating to the operating reliability and safety of the unit supplied is only valid if the eguipment is used in accordance with section 1 1 Applications of the operating instructions The limits stated on the name plate order confirmation must be adhered to without fail 3 o Transport and interim storage Take into account the unegual weight distribution between pump and motor N Use suitable lifting tackle e g straps Always make sure that the motor resp submersible borehole pump 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 reguires proper preparation and handling Only approved transport eguipment and lifting gear shall be used The motor resp pump unit is supplied in packaging which largely prevents sagging or other damage during transport and storage Prior to and during unpacking check whether the packaging has been damaged When opening the packaging or handling the motor resp pump unit make sure not to dam
20. or lift off the well head System induced vibrations must not be transmitted to the pump The system must be designed in such a way that vibrations are not amplified Abrupt pressure egualization processes pressure surges in particular present a hazard for the pump Suitable precautions must be taken e g expansion joints air vessels The pump unit must never be installed with its suction strainer exactly at the level of the well screen filter where excessive flow entails the risk of large amounts of sand clogging the well screen filter and causing excessive wear in the pump IS ATTENTION Pump units installed in a pump sump must generally be equipped with a cooling or suction shroud Min X gt 05 M Cooling Suction Shroud 20060266 A Installation in a pump sump 7 5 Horizontal installation Depending on motor type and number of stages the pump can also be installed in horizontal position For detailed information about this possibility for the motor consult the documentation of the motor concerned or contact the motor supplier distributor IS ATTENTION If the pump is installed in a horizontal position the discharge port should never be positioned below the horizontal plane Allowed Not allowed 20060275 The instructions given in vertical installation shall also apply by analogy to horizontal installation whe
21. plugged with a filter plug or a plug with or without filter insert The filler valve allows trapped air to escape and serves to top up liquid Small amounts of liquid escaping when storage temperatures are high are no cause for alarm Tools and diaphragm distances A filling kit ident No 90 066 762 is required for topping up and checking the liquid fill The filling kit comprises filling syringe test pin and filter plugs Correlation of diaphragm distances and test pins with motor type Motor type series Variants Distance required A UMA 250D Standard special 64 mm 2mm UMA 200D Standard special 44 mm 2mm UMA 150D Standard special 44 mm 2 mm DN 150 59 mm 2 mm DN 100 Axial load 6500N 10mm 2 mm Fig 4 Diaphragm distance DN 100 DN 150 and UMA 150D Fig 4 Diaphragm distance UMA 200D and UMA 250D The description below refers to UMA 150D motors in standard material variant and applies by analogy to UMA 150D motors in special material variant UMA 200D UMA 250D as well as DN 150 and DN 100 motors with axial load 6500 N Kse D Motors lt 1 kV Proceed as follows Venting the motor 1 Place the motor pump unit carefully in horizontal position and support in such a way that the filler valve 2 is at the highest point 2 Take the filter plug 21 out of the filler valve in the upper bearing end plate 3 Carefully insert the test pi
22. starting torque and starting current of electric motors During run up they gently ramp up the applied voltage to the motor Due to their extremely slim design and resulting small moments of inertia submersible borehole pump motors have a number of special features which differ considerably from the normal standardized asynchronous motor type Soft starter settings Effects on submersible borehole pumps Starting current approx 4096 to 6596 of la required for d o l starting Running up time ty increased to approx 1s to 3s compared with approx 0 2s to 0 5s for d o l starting Starting torque MA roughly 1 4 of the direct starting torque No current or torque peaks la Ma as in start delta Switching arrangement Hydraulic pressure surges water hammer upon starting and stopping of the pump can be reduced but not fully eliminated Therefore soft starters are not suitable for solving water hammer problems This would require the use of hydraulic control equipment or a frequency inverter To prevent effects due to power failure additional measures are required Note Conspicuous noises during run up could well be an indication of incorrect settings on the soft starter such as excessive ramp times wrong operating mode control activated special functions etc Parameter Function Setting Notes Minimum starting voltage 4096 of the motor s rated voltage Ramp time acceleration 4s
23. the contents of the operating instructions are fully understood by the responsible personnel 4 3 Safety provisions The pump has been designed with the greatest possible care Original parts and accessories meet the safety regulations Modifications in the construction or the use of non original parts may lead to a safety risk IS ATTENTION Make sure that the pump operates within its working range Only then the pump performance is guaranteed 4 3 1 Labels on the pump The icons warnings and instructions applied to the pump are part of the safety provisions The labels may not be removed or covered Labels must remain legible during the entire life of the pump Replace immediately damaged labels Kse b UPA 150C 4 4 Safety precautions 4 4 1 During normal use e _ Contact the local electricity company for guestions about the power supply e Shield parts that can become hot in such a way that direct contact is impossible Always place undeformed coupling protection plates to protect the coupling before putting the pump into use Make sure that the coupling protection plates are never in contact with the running coupling e Always close the switch box 4 4 2 During installation maintenance and repair Only authorised personnel may install maintain and inspect the pump and repair electrical components Observe the local safety regulations WARNING Always disconnect the energy supply to the pump first
24. valve further to re adjust to duty point Deposits in the impellers Remove deposits Wrong direction of rota tion in case of 3 Interchange two of the phases of the power sup ply cable Wear of internal compo nents Defective or clogged riser pipe pipe and sealing ele ments Impermissible air or gas content in the liguid Replace worn components by new ones Contact KSB Replace affected fit new sealing elements Contact KSB Speed is too low Check voltage and increase if necessary Contact KSB Vibrations and noise dur ing pump operation 28 Deposits in the impellers Remove deposits Impermissible air or gas content in the liguid Contact KSB Mechanical defect on pump or motor System induced vibrations Contact KSB Contact KSB NPSH available positive suction head is too low Submerge pump deeper Kse b UPA 150C Problem Unit tripped by overcurrent relay Possible cause Motor is running on two phases only Possible solution Replace the defective fuse check the electric cable connections Checkpoints Pump clogged by sand Clean suction casing impellers stage casings and check valve Contact KSB Motor winding or electric cable are defective Contact KSB Defective overcurrent relay Check and replace if nec essary Motor winding not suitable for operating voltage avail
25. with pre filled motors Franklin DN 100 UMA 150D The pump unit has not been in operation yet The unit is stored with pre filled motor The antifreeze agent in the factory supplied motor fill protects the motor against corrosion 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 the factory supplied motor fill protects the motor against corrosion and frost Antifreeze concentration gradually decreases Therefore the antifreeze level must be checked with a spindle If the anticipated temperature is below the antifreeze value either increase the antifreeze concentration in the motor accordingly section 5 2 2 or store the unit in a frost free location b 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 the water to drain 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 must be disposed of in compliance with local applicable regulations See section 5 2 2 6 3 3 Preserving UMA motors CAUTION To preserve UMA motors use only the preservatives specified in section 5 2 2 If the motors hav
26. 71 37 22 4 51 5 2 1 Franklin DN 100 and UMA 150D motors CAUTION If these motor types have been stored or taken out of service for one year or longer the motor fill must be checked prior to installation CAUTION Use clean drinking water for topping up the liguid fill or even better use the original filling liguid CAUTION Only the original filling liquid shall be used when the complete motor fill has to be renewed after repair work or when the liquid fill has to be replaced Franklin DN 100 motors with axial loads of 1500 N 3000 N and 4000 N 1 Place motor vertically with diaphragm cover pointing upwards Make sure not to place it onto the shaft 2 Unscrew the three slotted screws at the diaphragm cover and take off the diaphragm cover Then take out the diaphragm 3 The motor fill should reach halfway up the diaphragm housing If not top up with clean water do not use distilled water Itis better to use the original filling liquid however as it will ensure sufficient protection against freezing Franklin DN 100 UMA 150D motors with axial load of 6500 N Standard material UMA 150D motors are provided with a filler valve to the left and a pressure relief valve to the right of the earthing bolt atthe upper bearing end plate UMA 150D motors in special material variant and DN 150 and DN 100 motors with an axial load of 6500 N are provided with a filler valve only Depending on the model the valve may be
27. For a supply voltage of 400 V the motor must be wired in delta configuration For 690 V it must be star wired 3 UVW PE 3 UVW PE 4 LLL 6 6 Bl s inp PANA 4 j T PE 4 i U qu tv EV HW rw i U14 A wa vdd hil 3 lt v Quel Motor svi L1 iz Wi E Motor cables W1 V2 ili qms 3 Conductor LL wo tT marking Ph H HPE L Mu 4 Cable pea m 2 connector 2 pre 5 Star point N 6 Extension 4 3 cable 1 3 PE Earth 3400 24 3 Delta configuration xi e Star configuration green yellow Wiring and connecting of 1 extension cable to 2 motor cables in the cable connector If the pump unit is ordered with extension cable the cable connector will be pre wired in this configuration at the factory In this case the following applies as per VDE 0530 Parts 1 8 the cable connector is a constituent part of the submersible unit the wiring type shown on the name plate corresponds to the wiring in the cable connector the terminal designations at the conductor ends of the extension cable correspond to the wiring type shown on the name plate Note The details on the name plate do not refer to the wiring in the cable connector if the cable connection has been made by the operator of the submersible unit 16 3 Motors with 2 parallel c
28. URSAN POMPA LTD STI Original Operating Instructions 3400 88 3 10 UPA 150C Caution These operating instructions contain fundamental information and precautionary notes Please read the manual thoroughly prior to installation of unit connection to the power supply and commissioning lt is imperative to comply with all other operating instructions referring to components of this unit Li y d H Lj 7 Submersible Motor Pump KSE b KSB b Motors lt 1 kV Installation and operating instructions U 0 C 3400 88 10 PA 1 5 Submersible Borehole Pumps iiu V i YT V ih E gt U KsB b Kse b UPA 150C Table of Contents 1 Manual introduction O 1 2 ICONS aNd symbols inei aste baba ini salk aaa il 2 Identification service and technical support 2 1 Obtainingdataandinformatin 22 Supplementarydocumentation 3 Warranty 321 ep z ag e ER air arap rea aa 4 Safety and environment 41 Generalki ei laaan lan saklap FOL ed 42 USOS cuide EN FT GC Cn y rt rrr 4 3 Safety PrOVISIONS vce se sase nter dence pe eya lm yanal nee Gla 44 Safety precaullOris crisderi tesisi ni ipi Ba lam FESSA REIR DO 45 Environmental aspecis 15 essei ea alanla ae seansa is 5 P
29. a FO NE DAL SW eke 22 9 Commisioning start up shutdown 10 11 12 13 9 1 Commissioning Start up nemen enne rennes enn rennen nnns innen nnns 23 9 2 Commissioning Start up sandconteni nennen nnns 23 9 3 MINIMUM MOW Tate ice ertet tr en a a hemme Mam sade A pt ERA EEan Ea EE ord cocks a PERI eMe S B es cer e 24 94 Operating MMS ce 24 95 UI e ER FFF M A 24 Operation 10 1 Operation ES MP E A SE A FN FEN e 25 Servicing and maintenance Ti Servicing INSPECIO ert id 26 11 2 Repair Spare PS iii ii aT di odin alanad same G ya pe Sl a ee 26 Failures PA A RE REF FFY PE EM REM Rp 26 Annexes 13 4 Parts lis UPA Olite sulak ani kame anadan aks eL Ee Hera Kline EE eda RE ED R 30 13 2 ExplodedviewUPA150C16 ee 31 13 3 ExplodedviewUPA150C30 00 32 13 4 CE declaratien f Conformlty 2521514140241 0014 a 33 Kse b UPA 150C 1 Manual introduction 1 1 Preface D ENVIRONMENTAL INSTRUCTION we Remarks with respect to the environment The manual contains important information for reliable proper and efficient operation Compliance with the operating instructions is of vital importance to ensure reliability and a long service life of the pump and to avoid any risks Chapters 1 and 2 contain inf
30. ables for d o l starting The motors are wired in delta or star as shown on the name plate and are fitted with 2 cables in parallel 3 HE U1 1J LU1 2 3 V1 1 pvi 2 W1 1 rW1 2 PE ri TE AAA a lli Mt Ut4 ni Vi 2 V a l 1 2 Uu vi tl EE Motor Motor cables p AE d gt Conductor marking Cable connector Extension cable Earth green yellow 4 1 gt 6 P T E Motor with 2 leads and 1 extension cable 3400 127 3 Motor with 2 leads and 2 extension cables Connecting 1 or 2 extension cables to 2 parallel motor cables 4 Motors with 2 cables for star delta starting The motors are wired for both delta and star operation as shown on the name plate Ui i U2 3 lt V1 V2 w1 H W2 PE 6 e el U1 34 V1 j W1 1 Motor 2 2 Motor cables 3 Conductor marking 4 Cable connector 1 6 Extension cables PE Earth 3400 129 3 green yellow Connecting 2 extension cables to 2 motor cables KsBb Motors lt 1 kV 10 Wiring principles 2 Connecting the motor cables in the control box The wiring principles shown are for motors with one 4 core cable and two 3 and 4 core cables The wiring principles shall also appl
31. accordance with local regulations WARNING AN The pump unit must be earthed and must be connected to an external mains switch 19 Kse b UPA 150C 8 7 Vertical installation at site WARNING During installation work suitable precautions shall be taken to protect anyone from falling into the open well reservoir tank Suitably fence off the work area prevent the pump unit from dropping ATTENTION The first pipe section must not be longer than 2 m WARNING N A pair of supporting clamps must always be attached to the riser pipe to In order to prevent inadmissible sagging of the pump unit during lifting the first pipe section must not be longer than 2 m During the entire installation procedure a pair of supporting clamps shall always remain affixed to the riser pipe to prevent the pump unit from dropping In vertical installation the pump unit is suspended in the well head Threaded riser pipes are best supported with a socket and flanged riser pipes with a flange on the load bearing element e g supporting clamp in the well head unless some other arrangement in the well head prevents the riser pipe from slipping through 8 7 1 Installation with threaded riser pipe 1 Attach a pair of supporting clamps to the first pipe section max 2 m long just below the upper socket and screw this pipe into the pump unit using a thread locking agent Secure with the two locking screws supplied if applicable For
32. age the power cable Never pull on the electric cable This could lead to initially undetected damage to the connecting element in the motor or the cable itself When using a fork lift truck to transport the motor resp pump unit in horizontal position make sure to take into account the very unegual weight distribution between pump and motor Normally the centre of gravity will be in the motor area When transporting the unit in horizontal position with a crane slings points shall be chosen to prevent excessive bending stresses on the unit e g in the middle of the motor and atthe upper end of the pump Use suitable lifting tackle e g straps The use of chains or steel wires is not recommended as there is a risk of the chains wires slipping resulting in personal injury and or damage to property Always make sure the motor resp pump unit is properly secured when standing vertically Otherwise the unit may tip over and cause personal injury or damage to property The free end of the electric cable is fitted with a protective cap to prevent the ingress of moisture and dirt This cap should not be removed until immediately before connection to the extension cable or control box For special pump models e g with pump shroud etc also follow the instructions given in the enclosed supplementary pages listed in section 12 if any For interim storage the instructions given in section 6 3 2 Storage must be observed Kse D
33. ainst the closed gate valve for more than 5 minutes 9 2 Commissioning Start up sand content Pump units started up in new boreholes for the first time shall only be operated for approx 10 minutes with the gate valve only slightly open also to prevent damage to the well The water pumped must be checked for any sand content first If the water contains relatively high amounts of sand there is a risk for both the pump unit and the well The pump unit must then be operated with the gate valve only partially open 40 of well yield at the most until the sand content has dropped Only then shall the gate valve be slowly opened further If the sand content does not fall below 50 g m please contact the well building company or your nearest KSB service centre 9 3 Minimum flow rate To ensure the necessary cooling of the motor the pump unit should never be set so low that the cooling reguirements specified in the technical documentation of the motor concerned cannot be met 24 9 3 1 Pump operation with partially closed gate valve If the pump unit is continuously operated against a partially closed gate valve the flow rate must not fall below Qmin see name plate 9 3 2 Pump operation with closed gate valve Pump operation with closed gate valve The pump units shall not be operated against a closed gate valve for more than 5 minutes max as the water inside the pump will heat up very guickly and the heat produced wil
34. anual as required 12 4 Dry Running Protection The necessary details concerning function and operation are enclosed with this operating manual as required 12 5 Service addresses The Service addresses booklet ref No 0092 01 is generally enclosed 19 kse O EC Declaration of Conformity Manufacturer KSB Aktiengesellschaft Johann Klein Stra e 9 67227 Frankenthal Germany The manufacturer herewith declares that the product UPA 150C UPA 350 DN100 DN150 UPA 150C UPA 350 UMA UPV UMA is in conformity with the provisions of the following directives as amended from time to time EC Machinery Directive 2006 42 EC The manufacturer also declares that the following harmonised international standards have been applied ISO 12100 1 A1 ISO 12100 2 A1 ISO 14121 1 EN 809 A1 EN 60034 1 EN 60034 5 A1 Frankenthal 29 December 2009 Name Function Responsible for compiling the technical documentation KSB Aktiengesellschaft Johann Klein StraBe 9 67227 Frankenthal Germany KSB b Motors lt 1 kV UPA 150C KsB b Ursan Pompa Armat r ve End striyel r nler San Tic Ltd Sti G zeller Mah Bagdat Cad No 601 A 41400 Gebze KOCAELI Tel 0 262 642 05 60 641 84 15 641 82 60 Fax 0 262 642 39 79 e mail kocaeli ksb com tr ursan ursanpompa com www ursanpompa com Subject to technical modification without prior notice 12 2010 3400 88 3 10
35. aximum permissible power or current intensity must not be exceeded see name plate If necessary power or current intensity must be reduced to the permissible limits by throttling the gate valve accordingly For operation with throttled closed gate valve sections 6 1 3 and 6 1 4 must be observed 6 3 Shutdown Storage Preservation Returning to service 6 3 1 Shutdown CAUTION Only switch off the pump unit without preparations emergency stop if the system has been designed to withstand the resulting pressure surges As a rule the pump shall be switched off with the gate valve closed 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 Storage The submersible borehole pumps must be stored as follows vertically dry protected against direct sunlight and heat protected against dirt and dust protected against freezing 14 If the unit cannot be stored in vertical position it must be stored in such a way that sagging is prevented The cable must be supported atthe point where it comes out of the cable guard and protected against kinking The cable ends must be protected against 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 and preserved with anti freeze as described in section 6 3 3 a Pump units
36. cerning repair jobs and spare parts please contact your nearest KSB service centre or the KSB factory in charge For any queries and repeat orders particularly when ordering spare parts please specify the following information see name plate pump and motor type and size the operating data and the works number When ordering spare parts please also supply the following data see enclosed sectional drawings with list of components of 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 gt 0 2 or 0 5 m s Depending on the flow rate a flow is produced along the motor with a certain velocity which depends on outside motor diameter inside well or shroud diameter The condition v gt 0 2 or 0 5 m s is met if the actual inside well or shroud diameter is lower than or egual to the value given for the inside well or shroud diameter see table below at the relevant design flow rate rh m s UMA 150D 15 20 2 lt 215 20 5 lt 175 25 20 2 lt 255 gt 0 5 lt 195 50 gt 0 2 lt 330 gt 0 5 lt 235 75 gt 0 2 lt 390 gt 0 5 lt 270 100 gt 0 2 lt 445 gt 0 5 lt 300 125 gt 0 2 lt 490 gt 0 5 lt 330 150 gt 0 2 lt 535 20 5 lt 355 175 gt 0 2 lt 575 gt 0 5 lt 380 200 20 2 lt 615 20 5
37. d y fv E Es N ym E Jn J C Di PE Ee PE pwe ui AL U22 3 Ly1 U2 v2 W1 V2 W2 2 3 i 3 3400 124 3 Delta configuration Star configuration Connecting a motor with delta star configuration and 2 cables for d o l starting 3 Motors with 2 parallel cables for d o l starting The motors are wired in delta or star as shown on the name plate and are fitted with 2 cables in parallel The 6 current carrying conductors of the two parallel cables are designated U1 1 V1 1 W1 1 and U1 2 V1 2 W1 2 the earth conductor is marked PE These motors shall be used for d o l starting only L1 L2 L3 8 rates de4 a HU uo T on u fv jw re PE U1 1 i m U1 2 V1 1 V1 2 gt W1 14 wa 2 1 Motor 2 Motor cables 3 Conductor marking 7 Control box 1 8 Mains phases PE Earth 3400 128 3 green yellow Connecting a motor with delta or star configuration and 2 parallel cables for d o l starting 4 Motors with 2 cables for star delta starting The motors are wired for both delta and star operation as shown on the name plate The 6 current carrying conductors of the two cables are designated U 1 V1 W1 and U 2 V 2 W 2 the earth conductor is marked PE 8 Li L2 L3 L1 i 7 i y L w2fu2 Ava PET PE 3 W2 U2 V2 1 Motor 2 2 Motor cables
38. ding the scope of this manual or in case of damage please contact KSB nearest customer service centre The name plate on the pump specifies Serial number Model size Omin Qmax for 50 Hz operation Hmax Hmin for 50 Hz operation Omin Qmax for 60 Hz operation Hmax Hmin for 60 Hz operation When the pump is already fitted with a motor the name plate on the pump also specifies Model size i Frequency Before installing the UPA 150C we recommend to copy the name plate data into the operating manual Please consult the seperate booklet Service addresses for service and technical support 2 2 Supplementary documentation Apart from this manual the documentation given below is also available Document Date version Code General terms of deliv June 2002 0074 01 22 ery 0071a 11 28 06 2005 See also www ksb com EE Service addresses 0092 01 31 Kse b UPA 150C 3 Warranty 3 1 Terms of warranty The warranty period is settled by terms of your contract or at least by the general terms and conditions of sales IS ATTENTION Modifications or alterations of the pump supplied are only permitted after consultation with the manufacturer Original spare parts and accessories authorized by the manufacturer ensure safety The use of other parts can invalidate any liability of the manufacturer for consequential damage IS ATTENTION The warranty relating to the operating
39. e chains wires slipping resulting in personal injury and or damage to property For details please refer to the operating instructions of the pump UPA 150C 5 2 Motor fill Quality of motor fill When filling the motors or topping up the motor fill use water in compliance with the European drinking water directive normal clean drinking water or a drinking water antifreeze mixture 1 2 propylene glycol depending on the motor type see information on green or red sticker See also section 5 2 2 Protection against freezing Wear safety glasses and protective gloves when handling topping up checking and draining the motor fill The national health and safety regulations shall be observed The mixture must be disposed of in compliance with local applicable regulations Checking the filling level of the motors The procedure for checking the filling level and topping up the motor fill differs depending on the motor concerned A distinction is made between the following motors Franklin DN 100 encapsulated motors pre filled at the factory UMA 150D rewindable motors pre filled at the factory Motors pre filled at the factory are filled with a water antifreeze mixture These motors can be stored at ambient temperatures t gt 15 C The water fill of the motors is roughly as follows UMA 150D 5 21 3 21 UMA 150D 18 21 3 91 7 21 3 31 22 21 4 01 9 21 3 41 26 21 4 21 13 21 3 61 30 21 4 31 15 21 3
40. e pump If the pump can pump more than yielded by the well it is recommended to fit a control unit or some other type of dry running protection If no water level electrodes or level switches are installed the water level may be drawn down to the suction interconnector of the pump and the pump will then draw in air Long time operation with water containing air may damage the pump and cause insufficient cooling of the motor 9 1 1 Checking of direction of rotation WARNING N Do notrun the pump unit for more than 5 minutes in either direction when checking the direction of rotation WARNING N Make sure that the suction strainer has been completely submerged in the liguid before starting the pump IS ATTENTION Seen from the connection side of the motor the correct direction of rotation should always be counterclockwise When the pump unit has been connected to the electricity supply determine the correct direction of rotation as follows 23 Kse b UPA 150C 1 Start the pump and check the quantity of water and head developed 2 Stop the pump and interchange two of the phase connections 3 Start the pump and check the quantity of water and head developed 4 Stop the pump 5 Compare the results taken The connection with the larger quantity of water and the higher head is the correct connection To prevent damage to the motor make sure that the pump unit does not run in the wrong direction of rotation ag
41. e to be preserved they must be filled with undiluted antifreeze as described in section 5 2 2 These substances also protect the motors against corrosion Drain the antifreeze from the motor after apr 1 hour To prevent damage to the winding insulation no other preservative shall be used 6 3 4 Returning to service Checks prior to re installation see section 5 7 1 Proceed as described in section 6 1 1 when returning the unit to service Also check if the pumping data still matches the name plate data KSE D Motors lt 1 kV 7 Servicing and maintenance 7 1 Servicing inspection The submersible borehole maintenance free In order to pin point indications of potential damage at an early stage regular checks are required Possible indications of potential 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 weeks for approx 5 minutes during prolonged shutdown periods This will prevent the formation of deposits in the bearing and impeller clearances The submersible borehole pumps need not be removed from the well tank regularly for inspection pumps are generally 7 2 Repair Spare parts For information con
42. er sand content will reduce the life of the pump and increase the risk of blocking The transport of liquids with a different viscosity or density than water is possible as well For this a motor with an adjusted power is used Ask KSB or your distributor for advice Any other or further use of the UPA 150C is not in conformity with its intended use KSB does not accept any liability for any damage or injury that results from this The UPA 150C is produced in accordance with the current standards and guidelines Use the UPA 150C only in a perfect technical state conform with the intended use described below The ntended use as laid down in EN 12100 1 is the use for which the technical product is intended according to the specifications of the manufacturer The use of the product has been described in the sales brochure and in the user manual Always observe the instructions given in the user manual When in doubt the product must be used as becomes evident from its construction version and function Kse b UPA 150C 5 4 Working range Working range of the pumps in this series can be summarised as follows Table 1 Specifications of the working range Pump type UPA 150C UPA 150C material exe material exe cution C1 cution C2 Main material Stainless steel High grade 5 5 Model key Table 3 Model key UPA 150C UPA 150 C 16 9 Type series Minimum well diameter mm Design statu
43. erature rise in the fluid pumped e Increased sand content of the fluid pumped a Change in current consumption e Change in discharge head flow rate e 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 weeks for approx 5 minutes during prolonged shutdown periods This will prevent the formation of deposits in the bearing and impeller clearances The borehole pumps need not be removed from the well tank regularly for inspection WARNING Ifa pump has been used for a liquid which is hazardous to health or toxic the pump will be classified as con taminated 11 2 Repair Spare parts For information concerning repair jobs and spare parts please contact your nearest KSB service centre For any queries and repeat orders particularly when ordering spare parts please specify the following information see name plate e Pump and motor type and size e The operating data 26 Kse b UPA 150C 12 Failures 12 1 Failure table WARNING AN Observe the general safety precautions for installation maintenance and repair WARNING N System pressure must be released before attempting to remedy faults on parts which are subjected to pressure Problem Pump is running but does not deliver Possible cause Lack of voltage Possible solution Check the electrical in
44. guency a minimum flow as specified in section 6 1 3 must always be ensured The submersible borehole pumps can also be run on a freguency inverter for variable speed operation Since the electrical losses in the motor are higher when a frequency inverter is used the pump motor shall have a 5 96 power reserve lt is therefore important to consult KSB before retrofitting freguency inverters on pump units already delivered As submersible motors differ from conventional standardized motors 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 freguency maximum operating freguency maximum permissible voltage increase velocity and peak voltages control principle of freguency inverter Maximum allowable acceleration time start ramp and deceleration time stop ramp Due to the plain bearings of the submersible motor operation below the minimum freguency min s not permitted operation in mixed lubrication range For this reason the acceleration period from standstill to minimum freguency min should not exceed 2s The same applies to the deceleration period Minimum freguency Minimum frequencies fmin Hz Vertical Horizontal Motor size installation installation DN 100 30 30 UMA 150D 20 30
45. hanical damage During unpacking and prior to installation care must be taken when handling the pump to ensure that misalignment does not occur due to bending Transport of a borehole pump reguires proper preparation and handling Only approved transport eguipment and lifting gear shall be used The pump is supplied in packaging which largely prevents sagging or other damage during transport and storage Prior to and during unpacking check whether the packaging has been damaged Transport the pump in the position as indicated on the pallet or packaging Make sure the pump is stable Observe the instructions on the packaging if present cc When using a fork lift truck to transport the pump unit in horizontal position make sure to take into account the possibly very unegual weight distribution between pump and motor Normally the centre of gravity will be in the motor area When transporting the pump 12 unit in horizontal position with a crane sling points shall be chosen to prevent excessive bending stresses on the pump unit e g in the middle of the motor and at the upper end of the pump unit The use of chains or steel wires is not recommended as there is a risk of the chains wires slipping resulting in personal injury and or damage to property Always make sure the pump is properly secured when standing vertically Otherwise the pump may tip over and cause personal injury or damage to property W
46. he power supply and commissioning lt is imperative to comply with all other operating instructions referring to componenis of this unit Caution Please observe the operating instructions of the pump UPA 150C Name plate Before installing the unit we recommend to copy the name plate data into the space below or to stick in the name plate label enclosed with the delivery Works No Pump Omin m3 h Hmax m Qmax m3 h Hmin m Q m3 h H m 3 motor m s VDE 0530 Part 1 IP 68 ZN3823 D139 D 88 Min flow velocity past the motor Vmin 1 Version for two electrical motor leads 2 Possible supply voltages Guick reference instructions check list Procedure for installation and commissioning Unpack unit and support 3 Check installation conditions 4 2 Prepare support for vertical or horizontal installation 4 2 Have tools and eguipment ready 5 1 Instructions for filling the motor 5 2 Connect extension cable to the motor lead by means of cable connector 5 5 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 SO PENP N Motors lt 1 kV Submersible Motors Franklin DN 100 UMA 150D for supply voltages up to U 1000 V Frequency 50 or 60 Hz Rotati
47. hen the pump part and motor are supplied as separate units fit the motor to the pump as described in Fitting the motor to the pump vertical installation on page 18 6 2 Storage The borehole pumps must be stored as follows e Vertically Dry Protected against direct sunlight and heat i Protected against dirt and dust Protected against freezing If the pump unit cannot be stored in vertical position it must be stored in such a way that sagging is prevented The cable must be supported at the point where it comes out of the cable guard and protected against kinking The cable ends must be protected against 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 and preserved with anti freeze Storage tambient C 20 60 Max rel humidity 80 at 20 C Kse b UPA 150C 7 Installation conditions 7 1 Installation conditions WARNING Minimum submersion gt 0 5 m A higher submergence may be reguired The borehole pumps are suitable for installation in deep wells tanks reservoirs or mine shafts As they are only operated when fully submerged they have no special reguirements on rooms or buildings The borehole pumps must be installed in such a way that they neither sit on the base of the well nor touch the well or tank walls Fit centering devices on the riser pipe or diaphragm housing of the
48. ing the extension cable in the cable connector 16 Wiring principles 2 Connecting the motor cables in the control box 17 Pt 100 temperature sensor optional e eau 18 Related documents Y Y LE uu 19 List of components with sectional drawing Spare parts VYFFFFFE EFE EE FEE EEF ua 19 Models with pump shroutd a Ae Ye e eke tae ae e y Fd e ae i need awe e erga re dw gl ER I ODD 19 Pt 100 temperature monitoring system Rh uu 19 Dry Running Protection 2 is kR I A ode da DALMA Y GU Yanl ank da OU a 19 S Irvice addresses eo case YR e b lama YR CP AAA nat YNG YG ve Kala DY Yd pus 19 Declaration by the manufacturer 0 YY nnn hh hn 20 Kse D Motors lt 1 kV 1 General 1 1 Applications The submersible motors DN 100 and UMA 150D serve to drive a submersible motor pump 1 2 Product details The name plate on the 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 name plate data into the space provided on the cover sheet of the operating manual or to stick in the name plate label enclosed with the delivery Overall length and weight of the pump units are indicated in the order c
49. ingle core leads are brought out from the motor Application Protective earthing for motors with 1 or 2 three core leads and for motors with single core leads or for additional potential equalization 5 7 Installation at site Take suitable precautions to prevent anyone from falling into the well reservoir tank CAUTION Protect electric cabling from mechanical damage Protect open cable ends against moisture and dirt During installation work suitable precautions shall be taken to protect anyone from falling into the open well reservoir tank Suitably fence off the work area During the entire installation procedure the electric cabling must 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 For special conditions please refer to the operating instructions of the pump UPA 150C 5 7 4 Re installing the pump unit Before 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 must be done separately for the motor and the pump Also rotor position pump and motor and axial clearance have to be checked For large pump units auxiliary equipment will be required This work should be performed by trained personnel only If the rotor cannot be turned or lifted we recommend that you contact our
50. ize 1 rubber This cable tie rubber strap plastic studs can be used for the following cables flat 3 and 4 core 1 5 mm to 6 mm and round 4 core 1 5 mm to 6 mm Procedure see also fig 14 1 Cut the rubber strap to the following length depending on the diameter of the riser pipe DN R DN mm 50 80 100 125 150 R inch 2 3 4 5 6 L mm 320 400 450 500 600 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 riser pipe 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 it to the stud Tighten the rubber strap firmly to ensure that the electric cable cannot slip downwards by its own weight 10 5 8 2 Cable tie sizes 2 11 metal This type of cable tie metal rubber cable protector is used for larger cables than those referred to in section 5 8 1 Procedure see also fig 14 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 by loosening the tension screw and hook it into one end of the metal strap 3 Place cable protector d around cable b and against riser pipe a using the metal strap Then hook the screw band into the othe
51. ket 1 tie shall be used per electric cable and every 3 metres of riser pipe Tighten the ties firmly to ensure that the electric cable cannot slip downwards by its own weight There is danger of the cables being subjected to excessive tensile stress The type of cable tie used depends on the cable cross section or cable weight 8 8 Horizontal installation at site IS ATTENTION Check whether horizontal installation is permissible first IS ATTENTION Non flooded pump units must always be protected against direct sunlight If there is a danger of freezing check that the motor fill is suitable for the below zero temperatures anticipated Horizontal non flooded pump units must always be protected against direct sunlight by suitable covers e g when fountains are shut down for cleaning work to prevent overheating of the motor Prolonged shut down periods of non flooded borehole pumps can reduce the fluid level in the motor evaporation etc Before flooding the pump units the water fill of the motors must always be checked and topped up if required If there is a danger of freezing check that the motor fill is suitable for the below zero temperatures anticipated If necessary the pump unit must be removed or the motor must be filled with a suitable water antifreeze mixture IS ATTENTION For pump units with suction or pressure shrouds the additional notes in the enclosed installation instructions must be observed
52. l be transferred to the motor where it may damage the motor winding Also bearing damage cannot be ruled out 9 4 Operating limits To ensure operational reliability and prevent cavitation borehole pumps in continuous operation shall only be operated up to the maximum flow rate Omax indicated on the name plate In addition the maximum permissible power or current intensity must not be exceeded see name plate If necessary power or current intensity must be reduced to the permissible limits by throttling the gate valve accordingly 9 5 Shutdown WARNING N Only switch off the pump unit without preparations emergency stop if the system has been designed to withstand the resulting pressure surges As arule the pump shall be switched off with the gate valve closed Proceed as follows e o Close the discharge side gate valve slowly e Switch off the motor immediately after closing the gate valve Kse b UPA 150C 10 Operation 10 1 Operation The pump is controlled externally and therefore does not need any operation guidance 25 Kse b UPA 150C 11 Servicing and maintenance 11 1 Servicing Inspection WARNING Observe the general safety precautions for installation maintenance and repair The borehole pumps are generally maintenance free In order to pin point indications of potential damage at an early stage regular checks are required Possible indications of potential damage Temp
53. lt 405 250 gt 0 2 lt 680 gt 0 5 lt 445 300 gt 0 2 lt 745 gt 0 5 lt 485 350 gt 0 2 gt 0 5 400 z0 2 gt 0 5 e 500 20 2 gt 0 5 600 gt 0 2 gt 0 5 Ee 800 z0 2 gt 0 5 e 1000 20 2 gt 0 5 Example Pump unit with UMA 150D motor Design flow rate given on name plate 15 m3 h Flow velocity given on name plate 0 5 m s Maximum permissible inside well or shroud diameter 175 mm 15 kse D Motors lt 1 kV 9 Wiring principles 1 Connecting the extension cable in the cable connector The wiring principles shown are for motors with one 4 core cable and two 3 and 4 core cables The wiring principles shall also apply by analogy to motors with the corresponding number of three core and or single core cables and externally connected earth conductor 1 Motors with 1 cable for d o l starting The motors are wired in delta or star as shown on the name plate U A PE 6 Fis ea 1 Motor 4 pe 2 Motor cable u 3 Conductor marking 3 Y Wifi 4 Cable connector W 6 Extension cable e E PE Earth green yellow 3400 32 3 Connecting one extension cable 2 Motors with 2 cables for d o l starting The motors are wired for both delta and star operation as shown on the name plate Depending on the supply voltage the motors must be wired in delta or star in the cable connector Example Name plate indicates 400 690 V
54. mp itself Non compliance with these safety instructions will also lead to forfeiture of any and all rights to claims for damages In particular non compliance can for example result in failure of important pump system functions failure of prescribed maintenance and servicing practices injury to persons by electrical mechanical and chemical effects hazard of the environment due to leakage of hazardous substances e explosions Depending on specific activities extra safety measures may be required Contact KSB if during use a potential danger arises IS ATTENTION The owner of the pump is responsible for compliance with the local safety regulations and internal company guidelines IS ATTENTION Not only must the general safety instructions laid down in this chapter on Safety be complied with but also the safety instructions outlined under specific headings 4 2 Users All personnel involved in the operation maintenance inspection and installation of the pump must be fully qualified to carry out the work involved Personnel responsibilities competence and supervision must be clearly defined by the operator If the personnel in question is not already in possession of the required 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 operator is responsible for ensuring that
55. n failure of important machine unit functions failure of prescribed maintenance and servicing practices hazard to persons by electrical and mechanical effects 2 4 Safety awareness It is imperative to comply with the safety instructions contained in this manual the relevant national health and safety regulations and the operator s own internal work operation and safety regulations 2 5 Safety instructions for the operator user Electrical hazards must be eliminated In this respect refer to the relevant national VDE for Germany or European IEC safety regulations and to the regulations of the local energy supply 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 gualified specialist personnel who are thoroughly familiar with the manual Work on the machine unit must be carried out only during standstill The shut down procedure described in the manual for taking the unit out of service must be adhered to without fail Immediately following completion of the work all safety relevant and protective devices must be re installed and or re activated Please observe all instructions set out in section 6 3 4 Returning to service before returning the unit to service 2 7 Unauthorized modification and manufacture of spare parts Modifications or alterations
56. n 1 into the filler valve and vent until liquid escapes Fig 5 Venting the motor Checking the motor fill 4 Insert the test pin carefully through the hole 3 in the diaphragm housing until resistance can be felt 5 Measure the distance between the diaphragm and the edge of the hole in the diaphragm housing and compare the result with the required distance A given in the table 6 If the diaphragm distance falls short of the required value the motor is overfilled Drain filling liquid through the filler valve see Venting the motor Ifthe required value is exceeded filling liquid must be topped up through the filler valve Fig 6 Checking the motor fill TPRI up motor fill Press the filling syringe 4 against the filler valve and top up motor fill until the diaphragm distance measured is below the reguired value A 8 Adjust diaphragm distance to reguired value A by draining see Venting the motor or topping up motor fill as required 9 Re insert the filter plug 21 in the filler valve Fig 7 Topping up the motor 5 2 2 Protection against freezing When handling 1 2 propylene glycol antifreeze we recommend to wear safety goggles and protective gloves If there is a risk of freezing for the filled motor 1 2 propylene giycol antifreeze must be added to the water fill as follows depending on the anticipated below zero temperature Temperatures Water 1 2 propylene glycol down to 9c b
57. n the pump unit is fitted on mounts pedestals supporting frame pump shroud WARNING N Ifthe pump unit is to be installed in an accessible position the coupling must be suitably isolated to prevent the possibility of human touch IS ATTENTION The ground foundation must be level and of sufficient load bearing capacity to accept the weight of the pump unit with supports 15 Kse b UPA 150C IS ATTENTION Air intake from an inlet arranged above the water level is not permitted 20060268 Horizontal installation Tanks mine shafts etc 7 6 Minimum submersion X Minimum submersion refers to the upper edge of the suction strainer for horizontal installation and to the upper edge of the check valve for vertical installation Dimension X in m depends on the flow rate Q of the pump at duty point 20 15 X 10 Mos 00 0 100 200 300 Qm 500 600 700 800 0 50 100 Ol 150 200 2797118052006 Minimum submersion X 16 Kse b UPA 150C 8 Installation at site 1 Installation tools and eguipment WARNING Lift the pump using a hoist and suitable slings Attach the slings to hoisting eyes when present WARNING The pump must be hoisted according to the current hoist guidelines Only gualified personnel are allowed to hoist the pump WARNING Always make sure that the borehole pump cannot tip over WARNING Tools eguipme
58. n with the UPA 150C IS ATTENTION If the pump is used for pumping hot liquids precautions should be taken to ensure that persons cannot come into contact with the pump and the installation 7 3 Liquid quality The borehole pumps are suitable for operation in clean or slightly contaminated water of the following quality 7 3 1 Sand content Maximum sand content up to 50 g m Higher sand contents may be permitted for more wear resistant pump variants 7 3 2 Aggressiveness There are defined material variants available for the following water qualities UPA 150C material execution C1 for neutral or slightly aggressive water UPA 150C material execution C2 for more aggressive liquids 13 KSB b UPA 150C 7 3 3 Ochre content If the pump is operated in water with a high ochre content the suction strainer may be clogged with ochre so that the pump must be prematurely removed from the well In the case of otherwise clean water and if the pump is installed well clear of the filter zone we recommend to remove the suction strainer before the pump is installed for the first time Also ochre deposits may form on the motor in the stator area which will affect the motor cooling In such cases a temperature monitoring device is absolutely reguired 7 4 Vertical installation WARNING The construction of the well head must meet the relevant regulations of the competent authorities The pump unit must never be
59. nearest service centre or the KSB factory in charge In addition the winding insulation resistance must be checked unless this has already been done during winding repair or when connecting the extension cable The winding insulation resistance should be measured by a trained electrician only Procedure Thefilled 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 megohm Winding insulation J2 500 megohm Other resistance values may be measured depending on water temperature the length and quality of the power cable and the motor s operating hours If the resistance measured is lower than the values specified above please contact the KSB factory responsible Kse D Motors lt 1 kV 5 8 Fixing the electric cable to the riser pipe cable ties b a Size 1 d a riser pipe b electric cable c rubber strap c d plastic stud ap aA XS Sizes 2 3 3a 3b 4 a riser pipe b electric cable c metal strap d cable protector e screw band with tension screw Sizes 6 9 Size 11 Fig 14 Cable ties Tighten the ties firmly to ensure that the electric cable cannot slip downwards 5 8 4 Cable tie s
60. nt or accessories with sharp edges e g sharp edged pipe sockets shall not be used during installation WARNING During the entire installation procedure the electric cabling must be adeguately protected to prevent mechanical damage gt PEP bib Installation and removal of borehole pumps reguires suitable lifting gear for example a tripod mobile crane etc Its load carrying capacity must be greater than the weight of pump riser pipe with water fill see table below power supply cable holders etc Use suitable lifting tackle The use of chains or steel wires is not recommended as there is a risk of the chains wires slipping resulting in personal injury and or damage to property Weight of water fill per 1m of riser pipe DN mm 50 80 100 125 150 200 7250 R inch 2 3 la s 6 s lo m kg 2 s se 12 18 32 49 Further eguipment accessories may be needed depending on the installation type 8 2 Motor fill WARNING The motor fill must always be checked prior to installation IS ATTENTION For specific instructions about filling up submersible motors carefully follow the instructions given in the documentation of the motor concerned WARNING N Wear safety glasses and protective gloves when handling topping up checking and draining the motor fill The local health and safety regulations shall be observed The mixture must be disposed of in compliance with l
61. ocal applicable regulations The procedure for checking the filling level and topping up the motor fill differs depending on the motor concerned Please refer to the instructions given in the documentation of the motortype used with the UPA 150C When filling the motors or topping up the motor fill use water in compliance with the European drinking water directive normal clean drinking water or a drinking water anti freeze mixture depending on motor type use and risk of freezing 17 KSB b UPA 150C 8 3 Check valve IS ATTENTION Borehole pumps are not designed for uncontrolled backflow of the fluid through the pump Suitable precautions must be taken to prevent reverse rotation of the pump The borehole pumps generally feature an integrated check valve Where pump units without check valve are installed or in systems where check valves have not been installed in the appropriate places emptying of the riser pipe upon pump shut down may result in backflow of the fluid through the pump The pump unit may reach inadmissible rotational speeds which will eventually damage the pump If the specific system configuration requires emptying of the riser pipe suitable measures shall be taken to reduce the amount of backflow so that the pump rotor does not rotate 8 4 Fitting the motor to the pump vertical installation WARNING AN Before starting work on the pump make sure that the electricity supply has been swi
62. on the name plate are reached Note If the pump is started up against an empty riser pipe the gate valve shall not be closed completely to allow air to escape through the remaining gap into the riser pipe It is not necessary to delay the start up of an gate valve with electric actuator as the run up time of the pump is shorter than the dead time of the gate valve 6 1 1 Commissioning a Checking the direction of rotation CAUTION Do not run the pump unit for more than 5 minutes in either direction when checking the direction of rotation On single phase a c units 1 the direction of rotation is set and cannot subseguently be changed On three phase units 3 the direction of rotation is checked by running the motor in both directions with the gate valve closed The direction of rotation is changed by interchanging two phases of the power supply cable resulting in two different pressure gauge readings The higher reading always indicates the correct direction of rotation On pumps with free discharge the correct direction of rotation is indicated by the greater water volume produced in fountains by the higher jet To prevent damage to the motor make sure that the pump unit does not run in the wrong direction of rotation against the closed gate valve for more than 5 minutes b Commissioning instructions sand content Pumps started up in new boreholes for the first time shall only be operated for approx 10 minutes wi
63. onal speeds 2900 1450 rpm 3550 1750 rpm Certification Quality management certified to ISO 9001 KsB b KSB b Motors lt 1 kV Contents 1 General eu EE 4 1 1 Applications az 3 oe toe ec e E RE EE el ar Ny a a a eet et E Gk E SES 4 1 2 Product details c eiii feres PES AA n BB ln GY NG ee 4 1 3 Technical codes iore ll tay Ke Sd kak CU A Sac dd RERO RM PER la kim AA 4 14 Salesand service addresses ve ea Eod e e hee Le dad Sa desde AA 4 1 5 Designation example m eter vied bea bie ow UR DUO le GIFT PE DR ead bende V ep re epus 4 1 6 Scope of Supply ae el wd DN dy p ege b y eh Gn de Ads Sk tow tu a LR e n eds 4 2 Safety 2 ooo ette yk I O O a Ad a m ai eRe ee 4 2 1 Marking of instructions in the manual aaa 4 2 2 Personnel gualificattonandtraining I e 4 2 3 Non compliance with safetyinstructions laaan 5 2 4 Safety awareness nr uu tates cee ane dada as LME KL e ING ECC Ay aya YL ki e ey ae ae LES 5 2 5 o Safetyinstructionsfortheoperator user EF FE FY Yad 5 2 6 o Safety instructions for maintenance inspection and installation work 5 2 7 Unauthorized modification and manufacture of spare parts 000000 5 2 8 Unauthorized modes of operation
64. onfirmation shipping documents Sound pressure level lt 75 dBA 1 3 Technical codes The submersible borehole pumps meet the fundamental safety requirements as per EC directives Machinery 98 37 EC Electromagnetic compatibility 89 336 EEC and the EC directive on low voltage equipment 73 23 EEC Compliance with these directives is confirmed by the EC declaration of conformity provided with each delivery and the CE marking affixed to the product itself If a pump is supplied without motor or a motor is supplied without pump compliance with EC directives is confirmed by the EC manufacturer s declaration The EC declaration of conformity is issued and the CE marking affixed by the party assembling the pump and the motor to form a complete pump unit Other applicable regulations e g VDE DIN IEC etc are referred to in the individual chapters where necessary 1 4 Sales and service addresses The addresses of our sales and service organization are listed in the enclosed Service Addresses booklet ref No 0092 01 The address of the KSB factory responsible is printed on the back of this operating manual 1 5 Designation example UMA 150 D 13 2 1 Motor type series EN Motor size in mm for ex 150 mm 6 inches Design status Max rated power Py in kW for 50 Hz Number of poles Winding insulation 1 6 Scope of supply CAUTION The motor lead must always be laid under
65. ormation about this manual and safety in general The following chapters provide information about normal use installation maintenance and repairs of the pump The annexes contain the technical data the parts drawings and the declaration s of conformity Make yourself familiar with the content e o Accurately follow the directions and instructions a Never change the seguence of the operations to be carried out e Keep this manual or a copy of it together with the logbook in fixed place near the pump which can be accessed by all personnel 1 2 Icons and symbols In this manual and in all accompanying documentation the following icons and symbols are used WARNING Danger of electric tension Safety sign according to IEC 417 5036 WARNING Operations or procedures if carried out without caution may cause personal injury or damage to the pump General hazard sign according to ISO 7000 0434 gt l gt ATTENTION Is used to introduce safety instructions whose non observance may lead to damage to the pump and its functions d Kse b UPA 150C 2 Identification service and technical support 2 1 Obtaining data and information The name plate indicates the type series size main operating data and identification number Please quote this information first two lines in all queries repeat orders and particularly when ordering spare parts If you need any additional information or instructions excee
66. r end of the metal strap 4 Tighten the tension screw on the screw band with a screwdriver so that the electric cable cannot slip downwards by its own weight 5 9 Connection to power supply in control box y Observe the applicable regulations y The motor shall be connected by a trained electrician only Electrical installation must comply with national regulations e g VDE 0100 0113 for Germany or IEC 64 The motor must be connected by a trained electrician only 5 9 1 General When connecting the motors the following instructions shall be observed 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 VDE 530 T1 zone A Un 5 fy 2 The motors are designed for short time operation with shifted star point t 1h For prolonged operation and Up gt 0 2 x Un please contact the factory The power rating specified on the name plate and in the order confirmation applies to continuous operation S1 to VDE 530T1 or IEC 34 1 Als Motorschutz ist ein temperaturkompensiertes Uberstromrelais der Ausl seklasse 10 oder 10A vorzusehen If an earth leakage relay is used it must be fitted in the motor power circuit Ifthe unitis to be operated with a soft starter or speed control eguipment e g with freguency inverter sections 5 9 2 and 6 1 5 of this manual shall be consul
67. re as a result of system conditions e g due to deposit build up on the stator precipitates out of water etc installation in standing water dirt sand deposits in the stator area major unforeseeable temperature increases in the fluid handled in cooling circuits etc as well as freguency controlled motors risk of overheating during operation with low freguencies our PT 100 temperature monitoring system must be installed See section 11 Pt 100 temperature sensor 5 10 5 Other protection parameters Over undercurrent Earth fault short circuit Current asymmetry Over undervoltage Vibrations KsBb Motors lt 1 kV 6 Commissioning start up shutdown 6 1 Commissioning Start up CAUTION The pump units shall only be switched on when the motor is filled and the unit is fully submerged or flooded CAUTION As a rule submersible borehole pumps shall be started up against a closed gate valve Due to the water lubricated plain bearings in the pump and motor the pump units must only be switched on with filled motor and when fully submerged or flooded Start up outside the water even for short periods is not permitted To prevent pressure surges submersible borehole pumps as a rule must be started up against a closed gate valve as follows 1ststep 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 as shown
68. re ends Between the core ends and earth e g motor housing resistance must be higher than 6 MQ Function Two temperature limits are important for submersible motors a Alert temperature tAleri If the alert temperature limit tajert is exceeded there is a malfunction e g inadmissible contamination ochre content of motor housing Corrective action must be initiated Setting talert toperation cutout tOperation 2 toperation normal operating temperature after approx 1 5 hours operation b Cutout temperature tcutout If the cutout temperature is reached the motor must be tripped It must not be re started until the malfunction has been remedied Setting Submersible motors with J1 winding PVC tCutout t 55 C Submersible motors with J2 winding PE tcutout t 75 C See UMA 1 or UMA 2 designation Motor type 14D and motors with rated voltages higher than 900V are fitted with J2 winding 18 KSE D Motors lt 1 kV 12 Related documents 12 1 List of components with sectional drawing Spare parts The pertinent sectional drawings with list of components for pump and motor are always enclosed with the operating manual 12 2 Models with pump shroud The requisite assembly installation instructions are enclosed with this operating manual as required 12 3 Pt 100 temperature monitoring system The necessary details concerning function operation and checks are enclosed with this operating m
69. run up time Ramp time is not identical with the motor s actual running up time Current limitation la IN preset to approx 3 5 Should only be altered with allowance for tu special pump function kick start boost function speed adjustment current control cos q economy function delayed starting lt 4s Deceleration run down time Deceleration time ta lt 4s Better without a ramp stop ramp Special functions e g Off Usually excluded as they tend to be troublesome particularly in submersible borehole applications The soft starter must remain bridged bypassed as long as the pump is in operation in order to avoid power losses in both the starter and the motor and to ensure correct continous operation 120 Run up l 100 o 80 S 60 9 40 20 0 gt ll 4s Operation Run down Time s 4s 11 Kse D Motors lt 1 kV 5 9 3 Terminal designations DIN 42401 stipulates the following terminal designations for electric motors depending on the motor starting method see name plate data Delta or star wiring with 1 cable U V W Delta star wiring with 2 cables U1 V1 W 1 U2 V2 W2 Delta or star wiring with 2 parallel cables as per DIN VDE 0530 Part 8 Bi at VE U1 2 These terminal designations are used throughout the wiring diagrams shown in this operating manual W1 1 v1 2 Wi 2
70. s AISI 304 stainless steel ASI 316 Capacity m3 h Liquid temperature C 0 to 607 Liquid temperature F 32 to 140 Number of stages Qmax 50 60 Hz m h 79 93 Qmax 50 60 Hz US gpm 348 410 Hmax 50 60 Hz m 3 31 130 5 6 Functional principle of the Hmax 50 60 Hz ft 1880 2400 Maximum working pres 5730 57 3 831 UPA 150C sure 50 Hz kPa bar psi Maximum working pres sure 60Hz kPa bar psi 7300 73 0 1060 Minimum supply pressure Not cavitating Viscosity liquid cSt 1 A higher viscosity may require more motor power Density liquid kg dm Ibs inch 1 0 0 036 A higher density may require more motor power Number of starts Related to the motor Minimum frequency Hz 10 Maximum frequency Hz 60 Max power kW HP 37150 1 Maximum liquid temperature for the pump only For maximum allowable liquid temperature of the motor please consult the technical documentation of the motor concerned Table 2 Specific applications Pump type Application area UPA 150C Domestic and general water supply irriga material tion systems groundwater lowering pres execution sure boosting fountains air conditioning C1 Systems cooling water cycles fire protec tion industrial applications UPA 150C Raw water supply irrigation systems material groundwater lowering pressure boosting execution air conditioning systems
71. s At the motor lead the shield must be connected to the earth conductor In the case of three core motor leads without earth conductor the motor must also be earthed externally This earth conductor core size corresponding to phase conductor min 4 mm must be connected to the shield Example The extension cable conductor connected to U1 in the cable connector must be identified U1 at its free end to be connected to control box See wiring principles sections 9 and 10 5 6 Protection against electric shock Protection against electric shock must be provided earthing Equipment connected to the electric power supply must have some form of protection earthing to prevent electric shocks This is a statutory requirement stipulated by VDE 0100 for Germany or IEC 64 The submersible borehole pumps are always earthed There are two variants available a Internal earthing The earth conductor has been connected internally to the stator at the factory One 4 core or two 3 and 4 core leads with integrated earth conductor is are brought out from the motor It is the operator s responsibility to ensure that the earth conductor is properly connected in the cable connector and in the control box at the site b External earthing The earth conductor is connected to the outside of the upper bearing carrier of the motor earthing bolt at site by the operator 1 or 2 leads with 3 cores each or the corresponding number of s
72. s along the motor The max permissible temperature Tmax and the associated flow velocity Vmin of this forced flow are indicated on the name plate in the order confirmation The flow velocities v indicated there depend on the outside diameter of the motor in guestion and on the following installation conditions Standard v gt 0 2 m s This reguirement is complied with if the units are installed as follows Vertical installation in deep wells The unit is installed above the well screen filter The pump draws water from below which ensures a continuous water flow past the motor in reservoirs etc The unit is freely suspended in the water and the water inlet is below the motor In the following cases we recommend to use a special cooling shroud to ensure the reguired water flow past the motor in deep wells if the unit is installed below the well screen filter in reservoirs etc ifthe unit is freely suspended in the water and the water inlet is located above the motor or if the unit is suspended in a separate pump sump see fig 2 For shroud dimensions please refer to section 8 Horizontal installation Depending on the motor size it will be necessary to install a device guiding the flow along the motor cooling shroud flow inducer sleeve etc in this case See operating instructions of the pump and specifications in the order documentation if applicable Variant v 2 0 5 m s This requirement i
73. s complied with if the units are installed as follows Vertical installation If the ratio of the outside motor diameter and the inside well diameter DN meets certain conditions or if the unit is installed in a suitably sized cooling shroud Please refer to section 8 and any information provided in the order documentation Horizontal installation Inthis case special measures are required Please observe any information in the order documentation Variant v 0 m s No forced flow is required here Note When the motor is running a flow is generated around the motor by the heat dissipated irrespective of the installation situation The operator must ensure that this flow is not obstructed by installation conditions on site see also section 5 10 4 4 2 4 Water quality The submersible motor pumps are suitable for operation in clean or slightly contaminated water of the following quality a Temperature of the fluid pumped The max permissible temperature Tmax and the required minimum flow velocity Vmin are indicated on the name plate in the order confirmation For higher temperatures please contact the factory b Sand content Maximum sand content up to 50 g m3 Higher sand contents may be permitted for more wear resistant pump variants Please refer to the information provided documentation in the order c Aggressiveness There are defined material variants available for the following water qualities s
74. stal lation Notify the energy supply company Checkpoints Pump is clogged by sand Clean suction casing impellers stage casings and check valve Motor winding or electric cable are defective Contact KSB Defective or clogged riser pipe pipe and sealing ele ments Replace affected fit new sealing elements Impermissible air or gas content in the liguid Contact KSB 27 Kse b UPA 150C Problem Pump delivers insufficient flow rate Possible cause Wrong direction of rota tion in case of 3 Possible solution Interchange two of the phases of the power sup ply cable Checkpoints Wear of internal compo nents Replace worn components by new ones Contact KSB Motor is running on two phases only Replace the defective fuse check the electric cable connections Defective or clogged riser pipe pipe and sealing ele ments Replace affected fit new sealing elements Water level lowered too much during operation Contact KSB NPSH available positive suction head is too low Speed is too low Submerge pump deeper Check voltage and increase if necessary Contact KSB Pump delivers against an excessively high dis charge pressure Open the shut off valve further to re adjust to duty point Insufficient discharge head Pump delivers against an excessively low discharge pressure Close the shut off
75. tandard 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 other special materials as required Please refer to the information provided in the order confirmation d Ochre content If the unit is operated in water with a high ochre content the suction strainer may be clogged with ochre so that the unit must be prematurely removed from the well In the case of otherwise clean water and if the unit is installed well clear of the filter zone we recommend to remove the suction strainer before the pump is 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 temperature monitoring device Pt 100 resistance thermometer is absolutely required ksB b Motors x 1 kV 5 Installation at site 5 1 Installation tools and equipment IN Use suitable lifting tackle e g straps Always make sure that submersible borehole pumps cannot tip over Installation and removal of submersible borehole pumps requires suitable lifting gear e g tripod mobile crane etc Its load carrying capacity must be greater than the weight of pump unit riser pipe with water fill see table below and table in 5 2 power supply cable holders etc Use suitable lifting tackle e g straps The use of chains or steel wires is not recommended as there is a risk of th
76. tched off and that it cannot be accidentally switched on When the UPA 150C borehole pumps are supplied without motor fit the motor to the pump as follows 1 _ Use pipe clamps when handling the motor 2 Place the motor in vertical position at the well head 18 SHA H lt A ZA lt 20050915 A 3 Liftthe pump part by means of pipe clamps fitted to the extention pipe 20060278 4 Place the pump part on top of the motor Kse b UPA 150C 5 Fit and tighten the nuts see the following table Make sure that the coupling between the pump and motor engages properly When fitting the motor to the pump part the nuts must be tightened diagonally to the torgues as stated in the following table Pump motor stud diame ter Torgue Nm M8 18 M12 70 M16 150 M20 280 IS ATTENTION Make sure that the pump chambers are aligned when assembly has been completed 8 5 Changing the pipe connection removal of the check valve The UPA 150C is fitted with an unique interchangeable adapter which makes it possible to change the pipe connection whenever this is necessary e g When the pump is re installed in a well with a flanged riser pipe in stead of a threaded riser pipe Also because of the interchangeable adapter the check valve is easily accessible or when reguired removable IS ATTENTION For changing the pipe connection
77. ted prior to commissioning ksB b Motors x 1 kV 5 9 2 Starting methods As arule submersible borehole pumps from KSB are designed for d o l starting If this starting method is not permitted in the mains starting devices must be used to reduce starting currents except for DN 100 motors Suitable methods are star delta contactors Y A autotransformers or starting resistors as well as soft starters Please refer to the order confirmation to check if the starting device chosen is acceptable The starting devices must be set up for automatic operation i e switchover from Y to A or from partial to full voltage must be automatic Due to the small moments of inertia of submersible borehole pumps and the resulting extremely short run up period compliance with the following instructions is important a Star delta contactor autotransformer and starting resistor The Y phase or partial voltage period shall not exceed 4 s The switchover interval from Y to A must not be longer than 60 ms additional delays are not permitted If the unit is operated with a starting transformer or resistor a closed transition switchover method shall be chosen Korndorfer connection b Soft starter CAUTION Incorrect parameter settings present a hazard to the motor Conspicuous noises or vibrations may well be an indication of incorrect settings Soft starters electronically reduce the incoming line voltage and hence the initial
78. th the gate valve only slightly open also to prevent damage to the well The water pumped must be checked for any sand contentfirst If the water contains relatively high amounts of sand there is a risk for both the pump and the well The unit must then be operated with the gate valve only partially open 4096 of well yield at the most until the sand content has dropped Only then shall the gate valve be slowly opened further If the sand content does not fall below 50 g m3 please contact the well building company or your nearest KSB service centre 6 1 2 Start up freguency To prevent inadmissible heat build up in the motor the following max number of start ups or minimum standstill periods mustbe complied with Motor si Max start ups Min standstill Ee per h period in minutes DN 100 20 1 UMA 150D 15 2 6 1 3 Pump operation with partially closed gate valve If the pump is continuously operated against a partially closed gate valve the flow rate must not fall below Qmin see name plate 6 1 4 Pump operation with closed gate valve The pump units shall not be operated against a closed gate valve for more than 5 minutes max as the water inside the pump will heat up very guickly and the heat produced will be transferred to the motor where it may damage the motor winding Also bearing damage cannot be ruled out 6 1 5 Operation with freguency inverter CAUTION Independently of the actual operating fre
79. this purpose drill a shallow hole into the threaded end of the pipe section taking care not to drill through the threaded end Insert the locking screws with thread locking compound in such a way that their tips rest lightly but do not 20 press on the threaded pipe end Allow time for the compound to cure The connection is now sufficiently secured against loosening 2 Use cable ties to attach the power supply cables as well as the control and measuring cables if any to the riser pipe approx 0 5 m above the socket 3 Lift the pump unit by the first pair of supporting clamps with the lifting gear e g tripod or mobile crane and lower it into the well until the pair of supporting clamps sits on the upper flange of the well or well head 4 Then assemble the second pipe section using a second pair of supporting clamps 5 Remove the supporting clamps from the first pipe section and lower the pump unit down the well until the second pair of supporting clamps sits on the the upper edge of the well or well head 6 Repeat these steps for every pipe section lowering the unit into the well until the installation depth is reached 8 7 2 Installation with flanged riser pipe IS ATTENTION Only use pipes with recesses in the flanges Use pipes with flange recesses only 2 recesses as standard offset by 909 In these recesses the power cable will be protected against mechanical damage during pump installation and removal These units
80. troduction 5 1 General NX CELEI 20051344 B Borehole pump UPA 150C The single or multistage borehole pumps UPA 150C are produced by KSB Alphen aan den Rijn Holland 5 2 Description of the product The UPA 150C borehole pumps are designed for well diameters of 150 mm 6 inches and larger They are particularly suitable for vertical installation in narrow deep wells The UPA 150C consist of a single or multistage single entry centrifugal pump and a rigidly coupled electric motor when applicable fitted to the pump afterwards The pump is initialy designed for vertical stationary use in water With the restrictions as described in this documentation it can also be installed horizontally The suction casing located between pump and motor is equipped with a suction strainer to protect the pump from coarse particles in the fluid The UPA 150C borehole pumps are equipped with a check valve and are available with internal thread or flanged end 5 3 Intended use The UPA 150C material execution C1 are suitable for applications with clean thin non aggressive liquids without solid parti cles or fibres The UPA 150C material execution C2 versions are made of a higher grade of stainless steel and are available for applications involving more aggressive liquids The maximum permissible sand content in the fluid is 50 g m A larg
81. uld have contact over a large area Interruptions of the shield must be EMC compliant Observe the EMC instructions given by the equipment manufacturers For wiring diagrams please refer to Wiring principles 2 in section10 12 5 10 Protective eguipment 5 10 1 Dry running Dry running protection equipment must be installed if the pump is used in wells with excessive water level fluctuations or temporary low yield There are semi automatic and fully automatic systems For further details please refer to the accessories information supplied with the electrode relay The control box UPA Control supplied by KSB features integrated dry running protection 5 10 2 Lightning Overvoltage We recommend to install lightning protection eguipment Although a lightning protection device cannot offer protection against direct lightning strikes it will protect the pump unit from atmospheric overvoltage and any lightning strikes nearby Such devices shall be fitted and connected to the power supply as described in the instructions enclosed with the eguipment and in compliance with applicable regulations 5 10 3 Phase failure To prevent overloading of the remaining two phases should one phase fail phase failure protection must be provided for All motor contactors control boxes supplied by us have phase failure protection 5 10 4 Excessive temperature in the motor If there is a risk that the motor could exceed the permissible temperatu
82. ump introduction 5 1 CO ciar a asama lale 5 2 Description of the prodUCt oocooccccnnnnccccnnnniccccncnnnnnncnncnnnnancnnnnnnnn m 6 3 Intended US m 54 Working range ssssssssssssssesseseeeenee ennt ne ner nnne retinet enn anisini CMM bcME 5 6 Functional principle of the UPA 150C b Sound pressure levels iii ue iie etie nen tr etd e 6 Transport Mile PDT DAMES Lo S T Installation conditions 7 1 Installatonconditions 7 2 liguidtemperatures cooling 139 Liquid quality iiie RE O FA Vertical installation sc cnn ciere ein tede DN cake ed ede 7 55 Horizontal installation 7 6 Minimum submersion XX Kse b UPA 150C 8 Installation at site 8 1 Installation tools and equipment arice caes 17 9 2 Motor fll voca nit ii a A A 17 AO PS 18 8 4 Fittingthemotortothepump verticalinstallation 18 8 5 Changingthepipeconnection removalofthecheckvalve 19 8 6 Electrical CONNECTIONS v2 ici A a tte 19 8 6 VerticalinstallatiOn at SIl amp ii eiri rin ihmali gel alani YDD DRA y A Edn iaaa a Aa aiaa aaeain 19 9 7 Horizontal installation at Site iii a EO RR Rap as 20 8 9 Reinstalling the PUMP Unit ien uci ren ne GONE RO bam o
83. ump is fully submerged or flooded WARNING N As a rule borehole pumps shall be started up against a closed gate valve Due to the water lubricated plain bearings in the pump and motor the pump units must only be switched on with filled motor and when fully submerged or flooded Start up outside the water even for short periods is not permitted To prevent pressure surges in the borehole pumps as a rule must be started up against a closed gate valve as follows e Close the discharge side gate valve Switch on the pump unit and open the gate valve slowly until the pump head and current intensity as shown on the name plate are reached IS ATTENTION If the pump is started up against an empty riser pipe the gate valve shall not be closed completely to allow air to escape through the remaining gap into the riser pipe It is not necessary to delay the start up of a gate valve with electric actuator as the run up time of the pump is shorter than the dead time of the gate valve If there are impurities in the water the valve should be opened gradually as the water becomes clearer The pump should not be stopped until the water is completely clean otherwise the pump parts and the non return valve may be blocked As the valve is being opened the draw down of the water level should be checked to ensure that the pump always remains submerged The dynamic water level should always be above the suction in terconnector of th
84. utions must be taken to prevent reverse rotation of the pump The pump may reach inadmissible rotational speeds which will eventually damage the motor KSE D Motors lt 1 kV 5 5 Connecting the electric extension cable cable connector The electric cable shall be connected by a trained electrician only CAUTION The extension cable provided by us is designed for use freely exposed to air and in contact with surfaces If required an extension cable can be connected to the motor lead using a watertight cable connector available from KSB These cable connectors are approved for supply voltages up to U 1000 V low voltage The extension cable must be connected by a trained electrician only The extension cable included in our scope of supply is designed for use freely exposed to air and in contact with surfaces and for a voltage drop along the cable of AU lt 3 incl motor lead For other cable installation methods e g in cable ducts etc please observe the instructions set forth in VDE 0298 The cable connector shall be fitted as described in the assembly instructions enclosed with the cable connector When connecting the extension cable make sure that the terminal identifications of the motor lead are transferred to the extension cable and that the conductor colours are properly matched Also refer to section 5 9 3 Terminal designation On shielded extension cables the shield must be connected at both end
85. water only The submersible borehole pumps are delivered with Franklin DN 100 UMA 150D motors pre filled at the factory The motors are supplied with 1 or 2 electric motor leads or in the case of motors with high power rating with 7 individual cables The motor lead is designed for use in water Please contact KSB if the system configuration is such that the entire motor lead or part of it is operated in air On request pump units are available with motor lead and extension cable connected with cable connector or complete electric cable connected in the motor 2 Safety These operating instructions contain fundamental information which must be complied with during installation operation and maintenance Therefore this operating manual must be read and understood both by the installing personnel and the responsible trained personnel operators prior to installation and commissioning and it must always be kept close to the location of operation of the machine unit for easy access Not only the general safety instructions laid down in this chapter on Safety must be complied with but also any specific safety instructions outlined in other sections of this manual e g for private use 2 1 Marking of instructions in the manual The safety instructions contained in this manual whose non observance might cause hazards to persons are specially marked with the symbol when there is a general hazard safety sign to DIN 4844
86. y by analogy to motors with the corresponding number of three core and or single core cables and externally connected earth conductor 1 Motors with 1 cable for d o l starting The motors are wired in delta or star as shown on the name plate The 3 current carrying conductors are designated U V W the earth conductor is marked PE These motors shall be used for d o l starting only Note For motors with 2 leads and 1 extension cable the information given on page 20 para 2 Motors with 2 cables for d o l starting must be observed 8 L1 12 13 poser Ae 1 L1 L2 L3 ei 7 E il Aa H 3 V PE 2 1 Motor 2 Motor cable 3 Conductor marking 7 Control box 1 8 Mains phases PE Earth 3400 30 3 green yellow Connecting a motor with delta or star configuration and 1 cable for d o l starting 2 Motors with 2 cables for d o l starting The motors are wired for both delta and star operation as shown on the name plate Depending on the supply voltage the motors must be wired in delta or star in the control box Example Name plate indicates 400 690 V For a supply voltage of 400 V the motor must be wired in delta configuration For 690 V it must be star wired The 6 current carrying conductors of the two cables are designated U 1 V1 W1 and U 2 V 2 W 2 the earth conductor is marked PE L1 Le L3 8 L1 L2 L3 NT 12 3 y ENT ui La me e L7
87. y vol by vol 10 9C 75 25 15 C 1 66 34 1 20 C 62 38 25 C 57 43 30 C 53 47 1 water antifreeze mixture filled in at the factory When handling 1 2 propylene glycol wear safety goggles and protective gloves The antifreeze must be disposed of in compliance with local applicable regulations 1 2 propylene glycol is commercially available in the following brands Manufacturer Trade name BASF Glythermin P 44 BP Thermofrost P Chemische Werke Hils ILEXAN P The above order of producers is purely alphabetical and does not imply any quality ranking of individual products 5 3 Pump sets in suction cooling or pressure shrouds The submersible borehole pumps can also be equipped with suction cooling or pressure shrouds For pump models with vertical suction shroud the pump set and the shroud are generally delivered as separate items The pump set is then installed into the shroud on site Pump sets with horizontal suction shroud as well as vertical and horizontal pressure shrouds are generally delivered with the pump set already installed in the shroud In this case special filling and vent lines are provided for checking and adding the motor fill Also refer to any additional instructions given in the order documentation 5 4 Check valve Connection branch CAUTION Submersible borehole pumps are not designed for uncontrolled backflow of the fluid through the pump Suitable preca

UPA 150C - URSAN Pompa

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