KSB 88980/48, Operating And Maintenance Instructions Manual

Page 1: ...ND MAINTENANCE INSTRUCTIONS K S B A u s t r a l i a P t y L t d A B N 2 9 0 0 6 4 1 4 6 4 2 A Q u a l i t y E n d o r s e d C o m p a n y A S N Z I S O 9 0 0 1 2 0 0 8 Sales and Service Phone 07 3436...

Page 2: ...mp Station IOM Fibreglass Wetwell Instructions Package Pump Station Product Literature 2 Drawings Certified G A Drawing No KSB 88980 076 Goodnal STP ST041 Pre Treatment KSB Amenities Pump Station OM M...

Page 3: ...mp sizes DN 50 to DN 100 Motor sizes 2 pole 002 to 042 4 pole 004 to 044 Installation Operating Manual Goodnal STP ST041 Pre Treatment KSB Amenities Pump Station OM Manual Vendor Manual Q Pulse Id VM3...

Page 4: ...r be distributed copied reproduced processed for any other purpose nor otherwise transmitted to a third party without KSB s express written consent Subject to technical modification without prior noti...

Page 5: ...ised modes of operation 11 2 10 Explosion protection 11 3 Transport Temporary Storage Disposal 12 3 1 Transport 12 3 2 Storage and preservation 12 3 3 Return to supplier 13 3 4 Disposal 13 4 Descripti...

Page 6: ...ing torques 48 7 7 Spare parts stock 48 8 Trouble shooting 50 9 Related Documents 51 9 1 General assembly drawing with list of components 51 9 2 Wiring diagrams 57 9 3 Wiring diagrams overload protect...

Page 7: ...ng from components in contact with the fluid handled Hydraulic system The part of the pump in which the kinetic energy is converted into pressure energy Monobloc pump set Motor housing and pump casing...

Page 8: ...completed machinery To install partly completed machinery supplied by KSB refer to the sub sections under Servicing Maintenance 1 3 Target group This manual is aimed at the target group of trained and...

Page 9: ...step instructions Safety instructions Result of an action Cross references 1 2 Step by step instructions Note Recommendations and important information on how to handle the product 1 General Amarex N...

Page 10: ...ON this symbol indicates a hazard for the machine and its functions 2 2 General This manual contains general installation operating and maintenance instructions that must be observed to ensure safe pu...

Page 11: ...turer Only use impeller types designed for the fluid handled as described below Impeller with cutter impeller type S Suitable for the following fluids Faeces domestic sewage and waste water containing...

Page 12: ...maintenance and servicing practices Hazard to the environment due to leakage of hazardous substances 2 6 Safety awareness In addition to the safety information contained in this manual and the intende...

Page 13: ...dance with its intended use 2 10 Explosion protection Always observe the information on explosion protection given in this section when operating an explosion proof pump set Sections of the manual mar...

Page 14: ...ace some time after delivery we recommend that the following measures be taken for pump storage CAUTION Improper storage Damage to the power cables Support the power cables at the cable entry to preve...

Page 15: ...must also be neutralised and anhydrous inert gas must be blown through the pump for drying purposes 4 Always complete and enclose a certificate of decontamination when returning the pump set Section...

Page 16: ...0049 39100049 0 3 10 8 0 3 10 8 1 9 1 9 2835 2835 400 400 4 5 4 5 4 4 4 4 42 42 0 83 0 83 50 50 55 15 6 4 99 15 6 4 99 70165000 DKN 82 2 2U DKN 82 2 2U Amarex N F 50 170 012 YLG 120 Nicht unter Spannu...

Page 17: ...ize and number of poles 50 172 002 012 022 50 222 032 042 Drive Three phase asynchronous squirrel cage motor Explosion proof pump sets comply with type of protection Ex d IIB 4 5 Types of installation...

Page 18: ...al 8 The shaft runs in rolling element bearings 9 and 10 which are supported by a bearing bracket 2 linked with the pump casing and or discharge cover The pump is sealed by two bi rotational mechanica...

Page 19: ...e place of installation e g at the control panel pipeline or mounting bracket 4 8 Dimensions and weights For dimensions and weights please refer to the general arrangement drawing outline drawing or d...

Page 20: ...and 2 x rotational frequency rotational noise must be prevented both in the foundation and in the connected piping as such frequencies may cause extreme vibrations 1 Check the structural requirements...

Page 21: ...d plug 903 with joint ring 411 Observe the tightening torques Section 7 6 Page 48 5 2 3 Checking the direction of rotation DANGER Pump set running dry Explosion hazard The direction of rotation of exp...

Page 22: ...t Always observe the general arrangement drawing outline drawing when installing the pump set 5 3 1 Stationary wet installation 5 3 1 1 Fastening the duckfoot bend Depending on the pump size the duckf...

Page 23: ...piping NOTE When the pump set is used for draining low level building areas install a swing check valve in the discharge line to avoid backwash from the sewer system CAUTION Critical speed Increased...

Page 24: ...duckfoot bend 72 1 and back again to suspension bracket 572 and insert it into clamping piece 571 3 Manually tension wire 59 24 01 and secure it by means of hexagon nuts 920 37 4 Pull the wire taut by...

Page 25: ...e mounting brackets also serve as spacers between the two guide rails 1 Position adapter 82 5 on duckfoot bend 72 1 and fasten it with screws 914 2 discs 550 02 and nuts 920 02 2 Place rails 710 onto...

Page 26: ...ends of guide hoop 571 into the grooves of duckfoot bend 72 1 2 Fasten the flanged duckfoot bend to the tank sump floor with 2 anchor bolts 90 3 38 Section 5 3 1 1 Page 20 5 3 1 6 Preparing the pump...

Page 27: ...d UG1274785 Attaching the lifting chain rope transportable wet installation Transportable wet installation 1 Attach the lifting chain or rope to the lug eyebolt bail at the pump set on the side of the...

Page 28: ...n Before installing the pump set fit the 3 pump feet and foot plate if applicable Fitting the pump feet 1 Undo screws 914 03 2 Push pump feet 182 into the opening in the suction cover 3 Tighten screws...

Page 29: ...cified on the name plate 5 4 1 2 Level control DANGER Pump set running dry Explosion hazard Never allow an explosion proof pump set to run dry CAUTION Fluid level below the specified minimum Damage to...

Page 30: ...cable of the pump set itself Suitable analysing devices must be selected In this case we recommend to monitor the leakage sensor fitted inside the motor by means of a special relay available from KSB...

Page 31: ...minals 20 and 21 max 250 V 2 A serve as temperature control devices which open when the winding temperature is too high Opening of the switch contacts must result in the pump set cutting out Automatic...

Page 32: ...5 C Never bend or crush the power cables Never use the power cables to lift up the pump set CAUTION Motor overload Damage to the motor Protect the motor against overloading by a thermal time lag overl...

Page 33: ...inner thread for a M8 x 20 socket head cap screw DANGER Touching the pump set during operation Electric shock Make sure that the pump set cannot be touched during operation DANGER Chemically corrosive...

Page 34: ...primed with the fluid to be handled The direction of rotation has been checked The lubricant has been checked only for variants YL and WL After prolonged shutdown of the pump set the required activit...

Page 35: ...Frequency of starts CAUTION Excessive frequency of starts Damage to the motor Never exceed the specified frequency of starts To prevent high temperature increases in the motor do not exceed the follow...

Page 36: ...serve the information on fluid density indicated in the data sheet Make sure the power reserve of the motor is sufficient 6 2 5 Supply voltage DANGER Non compliance with permissible supply voltage tol...

Page 37: ...st freezing remove the pump set from the fluid handled and clean preserve and store it Make sure sufficient fluid is available for the operation check run of the pump set 1 For prolonged shutdown peri...

Page 38: ...pleted re install and or re activate any safety relevant and protective devices NOTE On pumps pump sets older than 5 years we recommend replacing all elastomer seals 6 Commissioning Start up Shutdown...

Page 39: ...rsons and the environment Decontaminate pumps handling fluids posing a health hazard WARNING Hot surface Risk of personal injury Allow the pump set to cool down to ambient temperature NOTE Special reg...

Page 40: ...measured must be less than 1 2 Replace any damaged components by original spare parts DANGER Defective earth conductor Electric shock Never switch on a pump set with a defective earth conductor 7 2 1...

Page 41: ...e of the leakage sensor in the motor Measurement between terminals Resistance 9 and earth conductor PE 1 Lower resistance values suggest water ingress into the motor In this case the motor must be ope...

Page 42: ...50 170 and 65 220 B Variant YL WL 2 Place a suitable container under the screwed plug WARNING Excess pressure in the lubricant reservoir Liquid spurting out when the lubricant reservoir is opened at o...

Page 43: ...e mechanical seal 433 02 along the shaft 3 Drain the oil 1 Fill 0 25 litres of oil through the opening between the stationary part of mechanical seal 433 02 and rotor 818 2 Thoroughly clean rotor 818...

Page 44: ...t surface Risk of personal injury Allow the pump set to cool down to ambient temperature Observe the general safety instructions and information For dismantling and reassembly observe the general asse...

Page 45: ...section which may affect explosion protection such as re winding and machining repairs must be inspected and approved by an approved expert or performed by the motor manufacturers No modifications mu...

Page 46: ...al information Safety regulations CAUTION Improper reassembly Damage to the pump Reassemble the pump set in accordance with the general rules of sound engineering practice Use original spare parts onl...

Page 47: ...412 15 412 11 into discharge cover 163 and press them into bearing bracket 330 as far as they will go 3 Push pump end mechanical seal 433 02 onto shaft 210 For special mechanical seals with covered sp...

Page 48: ...imension x is the distance between the upper side of the suction cover and the mounting holes of the suction cover 8 Measure dimension y between pump casing and impeller vanes Dimension y is the dista...

Page 49: ...in KSB s scope of supply 13 Insert and tighten the impeller screw 7 5 3 Reassembling the motor section NOTE Before reassembling the motor section check that all joints relevant to explosion protection...

Page 50: ...Tightening torques Table 21 Tightening torques Thread Torque Nm M 8 17 Impeller screw M8 40 Screwed plug 903 23 7 7 Spare parts stock NOTE For explosion proof pump sets only original spare parts or pa...

Page 51: ...7 90 433 02 Mechanical seal pump end 2 3 4 5 6 7 90 99 9 Set of seal elements 4 6 8 8 9 10 100 7 7 3 Sets of spare parts Table 23 Overview of spare parts sets Description Part No Rolling element bear...

Page 52: ...e riser pipes Replace seal elements X X X Impermissible air or gas content in the fluid handled Contact KSB X System induced vibrations Contact KSB X X X X Wrong direction of rotation Check the connec...

Page 53: ...1 02 Grooved pin 162 Suction cover 81 2 Connector 210 Shaft 81 59 Stator 230 Impeller 818 Rotor 321 01 02 Radial ball bearing 821 Rotor core pack 330 Bearing bracket 834 Cable gland 410 Profile joint...

Page 54: ...162 Suction cover 81 2 Connector 210 Shaft 81 59 Stator 230 Impeller 818 Rotor 321 01 02 Radial ball bearing 821 Rotor core pack 330 Bearing bracket 834 Cable gland 355 Bearing bracket housing 903 Scr...

Page 55: ...476 476 433 01 932 03 412 03 113 914 02 113 321 01 932 02 321 02 932 01 321 476 433 01 433 01 932 03 412 03 330 330 230 914 02 433 02 561 230 914 04 23 7 561 500 914 06 914 04 23 7 162 162 914 03 500...

Page 56: ...13 321 01 932 02 321 02 932 01 321 412 02 476 476 433 01 433 01 932 03 412 03 330 330 914 02 433 02 230 230 914 04 412 05 162 914 03 903 411 412 04 914 01 834 834 412 04 914 01 162 550 550 ULG Fig 31...

Page 57: ...412 02 476 476 433 01 932 03 433 01 412 03 330 914 02 330 433 02 230 914 04 550 230 162 914 03 904 162 914 04 904 410 932 04 411 903 834 834 914 01 412 04 412 04 914 01 100 100 410 411 903 ULG Fig 32...

Page 58: ...g 818 Rotor 330 Bearing bracket 821 Rotor core pack 355 Bearing bracket housing 834 Cable gland 410 Profile joint 99 9 Set of seal elements 411 Joint ring 903 Screwed plug 412 01 02 03 04 05 O ring 90...

Page 59: ...ariant WLG YLG Fig 33 Wiring diagram for variant WLG YLG 9 Related Documents Amarex N 57 of 66 Goodnal STP ST041 Pre Treatment KSB Amenities Pump Station OM Manual Vendor Manual Q Pulse Id VM372 Activ...

Page 60: ...ULG Fig 34 Wiring diagram for variant ULG 9 Related Documents 58 of 66 Amarex N Goodnal STP ST041 Pre Treatment KSB Amenities Pump Station OM Manual Vendor Manual Q Pulse Id VM372 Active 29 10 2013 P...

Page 61: ...canique LC1 D0910 RH Earth leakage protection relay with separate toroid e g Vigirex RH 328 A Merlin Gu rin Tore F Remote control H Auxiliary supply 12 43 44 A1 14 13 RH 230 240 V PE L3 L2 L1 KM KM Q...

Page 62: ...2 Tolerance ISO inside diameter F7 H8 H8 Tolerance ISO outside diameter g6 Tolerance in m inside diameter to DIN ISO 286 2 Maximum 41 63 39 Minimum 20 0 0 Tolerance in m outside diameter to DIN ISO 28...

Page 63: ...ide diameter F7 H8 H8 Tolerance ISO outside diameter g6 Tolerance in m inside diameter to DIN ISO 286 2 Maximum 41 63 39 Minimum 20 0 0 Tolerance in m outside diameter to DIN ISO 286 2 Maximum 14 Mini...

Page 64: ...3 01 Mechanical seal bellows type mechanical seal 932 01 Circlip 433 01 Mechanical seal bellows type mechanical seal 433 Mechanical seal mechanical seal with covered springs HJ 9 Related Documents 62...

Page 65: ...ares that the following harmonised international standards were applied ISO 12100 1 A1 ISO 12100 2 A1 ISO 14121 1 EN 809 A1 EN 60034 1 EN 60034 5 A1 Sequedin Lille 29 12 2009 Martial Smis Head of Prod...

Page 66: ...ps the rotor has been removed from the pump for cleaning No special safety precautions are required for further handling The following safety precautions are required for flushing fluids fluid residue...

Page 67: ...29 Level control 27 Lubricant Intervals 38 Quality 39 M Maintenance work 38 Mechanical seal 62 Minimum fluid level 34 Misuse 9 O Operating voltage 34 Order number 6 Other applicable documents 6 Overl...

Page 68: ...71 h 9 T C 9241 71 1793 4 4 4 B P 95 h 59482 Haubourdin Cedex 128 rue Carnot h 59320 Sequedin Lille H9 I a T 3 20227000 h 9 T 3 20227099 h 333 563 81 11 10 Goodnal STP ST041 Pre Treatment KSB Ameniti...

Page 69: ...ION www gebelaquasafe com au Publication No MAN 200 Effective Date May 2010 FIBREGLASS WETWELL Installation Instructions Including Lift Stations Vertical Pump Vaults and Basins Goodnal STP ST041 Pre T...

Page 70: ...not avoided may result in property damage IMPORTANT INFORMATION Proper installation of each wetwell is essential To ensure the safety of all the individuals involved in the installation To prevent wet...

Page 71: ...ing room around the wetwell Minimum anti floatation ring and ballast dimensions are speci fied in Table 1 page 7 Anti floatation ring and ballast designs in Table 1 page 7 meet Australian Standard Cod...

Page 72: ...ment travel and in some cases foot traffic Letter and Definition Second Letter and Definition G Gravel S Sand M Silt C Clay O Organic P Poorly Graded uniform particle sizes W Well Graded diversified p...

Page 73: ...ngineer The invert may be at any angle and may project up the wetwell any distance H TOP PAD The wetwell is designed to support the dead weight of an 200mm thick square pad 600mm larger than the diam...

Page 74: ...bar Reinforcement per Engineer of Record Design 250mm Max Base Use 300 Soil Cement Mix with Compressive Strength of 1mpa Subbase Use 300mm Minimum Low PI Select Fill Approved by a certified Engineer C...

Page 75: ...550 200 400 600 2200 1 2600mm Dia N12 1 3000mm Dia FN12 700 200 500 700 2470 1 2900mm Dia N16 1 3300mm Dia N16 800 250 500 800 3000 1 3400mm Dia N16 1 3800mm Dia N16 900 300 700 1000 FIGURE 1 BACKFIL...

Page 76: ...l Rights Reserved May 2010 Pub No MAN 200 FIBREGLASS WETWELL INSTALLATION Fast Installation time Saves Time Goodnal STP ST041 Pre Treatment KSB Amenities Pump Station OM Manual Vendor Manual Q Pulse I...

Page 77: ...thod used for Bottom Slab _________ _________ Closed Fibreglass Bottom with external structural anchors Section D3 Cast in place slab 3 Bottom Slab design according to select only one As per drawing C...

Page 78: ...le solution Fibre Reinforced Plastic FRP Packaged Pump Stations GebelFRP 16pp 1110 26 11 10 2 51 PM Page 1 Goodnal STP ST041 Pre Treatment KSB Amenities Pump Station OM Manual Vendor Manual Q Pulse Id...

Page 79: ...ons have allowed us to design engineer and manufacture our range of high quality Pump Stations Our modern plant equipment and quality assurance procedures ensure both quality and competitive pricing 2...

Page 80: ...gital read out system the resin rich layer and main laminate resins are kept within specification parameters thus minimising human error Each pump station has a smooth molded resin rich corrosion barr...

Page 81: ...n reduces Labour cost and down time Corrosion The problem of corrosion due to sewer gases in concrete wells is entirely eliminated giving long life with minimum maintenance GEBEL AQUASAFE PUMP WELLS a...

Page 82: ...igh performance externally applied Isophthalic NPG Flowcoat for external finish Minimum Standards of Design and Construction shall be BS4994 1987 Design Construction of vessels tanks in reinforced pla...

Page 83: ...S Series FRP Pumping Station GebelFRP 16pp 1110 26 11 10 2 51 PM Page 6 Goodnal STP ST041 Pre Treatment KSB Amenities Pump Station OM Manual Vendor Manual Q Pulse Id VM372 Active 29 10 2013 Page 83 of...

Page 84: ...850 4839 10216 15593 20969 2000 5656 11940 18224 24508 2200 6843 14447 22051 29654 2470 8626 18211 27795 37380 3000 12725 26864 41003 55142 4000 22622 47758 72894 98030 Pumping station available sizes...

Page 85: ...Series FRP Pumping Station w GebelFRP 16pp 1110 26 11 10 2 51 PM Page 8 Goodnal STP ST041 Pre Treatment KSB Amenities Pump Station OM Manual Vendor Manual Q Pulse Id VM372 Active 29 10 2013 Page 85 o...

Page 86: ...900 900 900 600 x 900 SQ VP999 99 900 900 900 900 x 900 SQ VP1212 912 1200 1200 1200 1200 x1200 SQ VP1212 1212 1200 1200 1200 1200 x 1200 SQ with Valve Pit Valve Pit available sizes GebelFRP 16pp 111...

Page 87: ...Series FRP Pumping Station wit GebelFRP 16pp 1110 26 11 10 2 51 PM Page 10 Goodnal STP ST041 Pre Treatment KSB Amenities Pump Station OM Manual Vendor Manual Q Pulse Id VM372 Active 29 10 2013 Page 87...

Page 88: ...30000 2470 7500 2 35000 2470 9000 2 Series 500 40000 3000 6000 2 45000 3000 7000 2 50000 3000 8000 2 with Valve Pit Emergency Storage Emergency Storage available sizes GebelFRP 16pp 1110 26 11 10 2 51...

Page 89: ...SQ 600mm diameter 900mm diameter 1200mm diameter Custom sizes available upon request Available sizes GebelFRP 16pp 1110 26 11 10 2 51 PM Page 12 Goodnal STP ST041 Pre Treatment KSB Amenities Pump Stat...

Page 90: ...ia 900mm Dia 1200mm Dia Light Duty Aluminum 600mm x 600mm Square 600mm x 900mm Square 900mm x 900mm Square 900mm x 1200mm Square 1200mm x 1200mm Square Custom sizes available upon request Available si...

Page 91: ...le 20mm stainless steel dual 20mm stainless steel triplex 32mm stainless steel single 32mm stainless steel dual 32mm stainless steel triplex 50mm stainless steel single 50mm stainless steel dual 50mm...

Page 92: ...iron valves Polyethylene 2 complete with cast iron valves 3 complete with cast iron valves 4 complete with cast iron valves 2 complete with bronze valves 3 complete with bronze valves 4 complete with...

Page 93: ...waste water industries Tel 02 4722 9696 Fax 02 4722 9506 www gebelaquasafe com au 26 Coombes Drive Penrith NSW 2750 PO Box 7051 Penrith South LPO NSW 2750 GebelFRP 16pp 1110 26 11 10 2 52 PM Page 16 G...

Page 94: ...M VIC 3012 KSB DOC No KSB 88980 076 Client Doc No IW GDSTP 4A VEN 0200 2001_P2 CUSTOMER Thiess Goodna STP Stage 4A Goodnal STP ST041 Pre Treatment KSB Amenities Pump Station OM Manual Vendor Manual Q...