KSB Ama-Drainer 4 Series, Installation & Operating Manual

Page 1: ...Submersible Waste Water Pump Ama Drainer 4 5 Installation Operating Manual ...

Page 2: ...ontents provided herein must neither be distributed copied reproduced edited or processed for any other purpose nor otherwise transmitted published or made available to a third party without the manufacturer s express written consent Subject to technical modification without prior notice KSB SE Co KGaA Frankenthal 12 03 2019 ...

Page 3: ... 11 3 4 Return to supplier 11 3 5 Disposal 12 4 Description of the Pump Set 13 4 1 General description 13 4 2 Designation 14 4 3 Name plate 15 4 4 Design details 15 4 5 Configuration and function 17 4 6 Scope of supply 18 4 7 Noise characteristics 18 4 8 Dimensions and weights 18 5 Installation at Site 19 5 1 Safety regulations 19 5 2 Checks to be carried out prior to installation 19 5 2 1 Checkin...

Page 4: ...mended spare parts stock 34 8 Trouble shooting 35 9 Related Documents 37 9 1 General assembly drawing with list of components 37 9 1 1 General assembly drawing of Ama Drainer 10 10K 35 37 9 1 2 General assembly drawing Ama Drainer 522 11 40 9 2 Dimensions and connections 42 9 2 1 Single pumps 42 9 2 2 Examples of transportable models 45 9 2 3 Examples of stationary installation 47 9 2 4 Installati...

Page 5: ...ndard for waste water lifting units which are used to dispose of faeces free waste water occurring below the flood level of buildings and sites It defines general requirements as well as principles of construction and testing Flood level Maximum backflow level of waste water in a drainage system Hydraulic system The part of the pump in which the kinetic energy is converted into pressure energy Pum...

Page 6: ...KSB refer to the sub sections under Servicing Maintenance 1 3 Target group This operating manual is aimed at the target group of trained and qualified specialist technical personnel ð Section 2 3 Page 8 1 4 Other applicable documents Table 1 Overview of other applicable documents Document Contents Sub supplier product literature Operating manuals and other product literature describing accessories...

Page 7: ...ION CAUTION This signal word indicates a hazard which if not avoided could result in damage to the machine and its functions General hazard In conjunction with one of the signal words this symbol indicates a hazard which will or could result in death or serious injury Electrical hazard In conjunction with one of the signal words this symbol indicates a hazard involving electrical voltage and ident...

Page 8: ... use limits specified in the other applicable documents Only operate pumps pump sets which are in perfect technical condition Do not operate the pump set in partially assembled condition Only use the pump to handle the fluids described in the data sheet or product literature of the pump model or variant Never operate the pump without the fluid to be handled Observe the minimum flow rates indicated...

Page 9: ...cold or moving parts and check that the equipment functions properly Do not remove any protective equipment e g contact guards during operation Provide the personnel with protective equipment and make sure it is used Contain leakages e g at the shaft seal of hazardous fluids handled e g explosive toxic hot so as to avoid any danger to persons and the environment Adhere to all relevant laws Elimina...

Page 10: ...s the work has been completed re install and re activate any safety relevant devices and protective devices Before returning the product to service observe all instructions on commissioning ð Section 6 1 Page 25 2 8 Unauthorised modes of operation Never operate the pump set outside the limits stated in the data sheet and in this manual The warranty relating to the operating reliability and safety ...

Page 11: ...om not exposed to sunlight where the atmospheric humidity is as constant as possible Store the pump set vertically in a dry dark frost proof room not exposed to sunlight Under these conditions it does not need additional preservation 3 4 Return to supplier 1 Drain the pump as per operating instructions 2 Always flush and clean the pump particularly if it has been used for handling noxious hot or o...

Page 12: ... the product Collect greases and other lubricants during dismantling 2 Separate and sort the materials e g by Metals Plastics Electronic waste Greases and other lubricants 3 Dispose of materials in accordance with local regulations or in another controlled manner Electrical or electronic equipment marked with the adjacent symbol must not be disposed of in household waste at the end of its service ...

Page 13: ...m Free passage 35 mm Waste water containing long fibres and stringy material Solid particles with a particle size of up to 35 mm Variant C for aggressive fluids In addition to standard variant Swimming pool water1 Brackish water Seawater Water containing salt Aggressive fluids Condensate from heat recovery applications Variant R for water containing oil oil emulsions In addition to standard varian...

Page 14: ...e water R Variant for water containing oil oil emulsions 4 Nominal discharge nozzle diameter 4 40 mm G 1 1 2 5 50 mm G 2 22 Motor rating kW x 10 05 0 55 kW 07 0 75 kW 11 1 1 kW 15 1 5 kW 22 2 2 kW S Float switch S With float switch N Without float switch D Motor D Three phase motor E Single phase alternating current 10 Free passage mm 10 10 mm 11 11 mm 35 35 mm K Cooling jacket K With cooling jack...

Page 15: ...Maximum immersion depth 5 Head Hmin Hmax 13 Enclosure 6 Principles of construction and testing 14 Total weight 7 Cable version e g E single phase 15 Year of production serial number 8 Rated frequency Table 5 Key to the serial number Code Description 2016 Calendar year 16 Calendar week 4 4 Design details Design Fully floodable submersible motor pump Close coupled design Single stage To EN 12050 2 V...

Page 16: ... PE N with motor contactor and phase inverter Ama Drainer ND 10 11 35 Three phase motor Integrated temperature switch 10 metre power cable with free cable end and protective cap Shaft seal Pump end 1 bi directional mechanical seal Drive end 1 shaft seal ring Liquid reservoir between the seals for cooling and lubrication Impeller type Open multi vane impeller Free flow impeller Bearings Maintenance...

Page 17: ...the extended motor shaft The shaft runs in common bearings Function The fluid enters the pump axially via the suction nozzle 11 and is accelerated outward by the rotating impeller 6 In the flow passage of the volute casing 10 the kinetic energy of the fluid is converted into pressure energy The fluid is pumped to the discharge nozzle 5 where it leaves the pump At the rear side of the impeller the ...

Page 18: ...t Connection socket or discharge elbow with internal thread 10 metre power cable For SE SD Float switch Accessories Control units for proper operation of the pump sets 4 7 Noise characteristics Sound pressure level 70 dB A 4 8 Dimensions and weights For dimensions and weights refer to the general arrangement drawing outline drawing or data sheet of the pump set ...

Page 19: ... or similar Danger of death from electric shock Make sure that nobody is in the water while the pump is in operation Only use the pump for draining swimming pools garden ponds etc It is impermissible to use this pump as a recirculation pump for example 5 2 Checks to be carried out prior to installation Before beginning with the installation check the following The pump set can be operated on the p...

Page 20: ... move freely 5 4 Piping 5 4 1 Connecting the piping DANGER Impermissible loads acting on the pump nozzles Danger to life from escaping hot toxic corrosive or flammable fluids Do not use the pump as an anchorage point for the piping Anchor the pipes in close proximity to the pump and connect them properly without transmitting any stresses or strains Observe the permissible forces and moments at the...

Page 21: ...ontrol system and the pump set s connection point verify that the number of cores is sufficient for the sensors A minimum cross section of 1 5 mm is required For the electrical connection of the pump set observe the wiring diagrams ð Section 9 3 Page 50 The pump set is supplied with power cables it is wired for DOL starting The motors can be connected to low voltage grids with nominal voltages and...

Page 22: ... switch Set the switching level on site Conditions to be met when setting the switching levels Observe the minimum fluid level ð Section 6 2 3 2 Page 28 The pump set stops before the water level falls to the level of the pump foot s suction openings The pump set starts up before the water level reaches the upper edge of the tank The float switch must neither come to rest at the bottom nor hit agai...

Page 23: ...ng of power cable Damage to the power cables Never move the power cables at temperatures below 25 Never kink or crush the power cables Never lift the pump set by the power cables Adjust the length of the power cables to the site requirements For the electrical connection observe the circuit diagrams ð Section 9 3 Page 50 in the Annex and the information for planning the control system The pump set...

Page 24: ... Wrong direction of rotation Damage to the pump Follow the step by step instructions given for checking the direction of rotation The power cable CEE plug has been connected in the factory so that the pump will have the correct direction of rotation provided that the mains phase sequence building supply mains is correct 1 Start up the pump ð If the direction of rotation is correct the pump should ...

Page 25: ...hutdown Type SE SD A B Fig 4 Start up switch off level A Start up level B Switch off level The pump set has been properly connected to the electric power supply The pump s automatic control system will start up when level A is reached and switched off when level B is reached Type NE ND The pump set does not need to be started up or switched off It is operational as soon as it has been properly con...

Page 26: ...prevent high temperature increases in the motor and excessive loads on the motor seal elements and bearings the frequency of starts shall not exceed 30 starts per hour 6 2 2 Operation on the power supply network CAUTION Wrong supply voltage Damage to the pump set The maximum permissible deviation in supply voltage is 10 of the rated voltage indicated on the name plate The maximum permissible volta...

Page 27: ...ste water Slightly contaminated waste water up to 40 C max Wash water up to 90 C max for short periods t 3 minutes Free passage 10 11 mm Solid particles with a particle size of up to 10 or 11 mm Free passage 35 mm Waste water containing long fibres and stringy material Solid particles with a particle size of up to 35 mm Variant C for aggressive fluids In addition to standard variant Swimming pool ...

Page 28: ...uid handled CAUTION Incorrect temperature of the fluid handled Damage to the pump set Do not operate the pump set outside the specified temperature limits Never operate the pump at temperatures exceeding the ones stated below Pump set in submerged condition Maximum 40 For a short time up to 3 minutes maximum 90 C Pump set outside the fluid handled For limited time up to 10 minutes maximum 40 For a...

Page 29: ...lth hazard Risk of injury Observe all relevant laws When draining the fluid take appropriate measures to protect persons and the environment Decontaminate pumps which handle fluids posing a health hazard 1 Disconnect the pump from the power supply and protect it against start up 2 Wait until the pump has cooled down 10 minutes then remove it 3 Properly flush the pump Point the water jet on the pum...

Page 30: ...ior to any maintenance and installation work Make sure persons cannot come into contact with the fluid handled 7 2 Servicing inspection The pump is practically maintenance free It will suffice to clean the pump once a year and carry out visual inspections of the condition of the pump and supply line 7 3 Drainage disposal WARNING Fluids consumables and supplies which are hot or pose a health hazard...

Page 31: ...ma Drainer 4 5 7 4 Dismantling the pump set WARNING Hot surface Risk of injury Allow the pump set to cool down to ambient temperature 1 Remove the cover from the clamp tie bar 2 Undo screw 914 03 at the clamp tie bar 3 Remove the clamp ...

Page 32: ...7 Servicing Maintenance 32 of 60 Ama Drainer 4 5 4 Pull out the volute casing 5 Clean all dismantled parts and check them for signs of wear ...

Page 33: ... 33 of 60 Ama Drainer 4 5 7 5 Reassembling the pump set ü All parts have been cleaned and checked for wear ü Any damaged or worn parts have been replaced by original spare parts 1 Fit the volute casing 2 Fit the clamp tie bar ...

Page 34: ...14 03 at the clamp tie bar 4 Fit the cover on the clamp tie bar 7 6 Tightening torques Table 9 Tightening torques Nm Part No Description Tightening torque Nm 914 03 Hexagon socket head cap screw 6 7 7 Recommended spare parts stock It is not necessary to keep spare parts on stock ...

Page 35: ...ting data Pump or piping are not completely vented Clean vent hole 5 B in pump casing 101 Pump intake clogged by deposits Clean the intake pump components and lift check valve Supply line or impeller clogged Remove deposits in the pump and or piping Dirt fibres in the clearance between the casing wall and impeller sluggish rotor Check whether the impeller can be easily rotated clean the hydraulic ...

Page 36: ...r Pump clogged by sand dirt in the pump sump insufficient inflow Clean the intake strainer pump components and check valve drain and clean the pump sump Temperature control device monitoring the winding has tripped the pump as a result of excessive winding temperatures The motor will restart automatically once the pump set has cooled down ...

Page 37: ... 920 08 550 08 509 914 03 82 10 572 576 920 03 550 07 576 550 06 412 04 412 02 99 9 02 732 837 99 20 01 837 66 2 412 03 412 06 66 2 321 01 550 05 321 02 99 9 02 421 99 15 412 01 230 99 7 01 230 550 02 550 04 920 01 433 932 433 826 05 920 02 826 82 14 99 7 02 99 20 01 82 14 826 05 920 02 826 824 99 7 02 99 20 02 824 81 45 826 81 45 826 06 920 06 81 45 99 7 02 99 20 01 C1 C3 C4 Fig 6 General assembl...

Page 38: ...e complete Handle 576 Disc 550 07 Nut 920 03 Plate 970 66 2 Cooling jacket set of accessories Cooling jacket 66 2 O ring 412 03 06 683 Hood Hood 683 81 45 Float switch single phase units Float switch 6 A 0 5 m 81 45 Float switch 10 A 0 5 m 81 45 Repair kit for cable single phase 99 20 01 Installation kit for hood 99 7 02 81 45 Float switch three phase units Float switch 6 A 10 m 81 45 81 59 Stator...

Page 39: ...kit for hood O ring 412 02 04 Disc 550 06 99 11 Bearing Deep groove ball bearing 321 01 02 O ring 412 01 Shaft seal ring 421 Disc 550 05 Lubricating oil 99 15 99 20 01 0 2 Cable repair kit Insulation tube 689 Disc 550 09 End connector 81 17 01 02 Terminal 81 29 02 Screw 900 Serrated lock washer 930 99 20 03 Hydraulic system repair kit O ring 412 05 Intermediate ring 509 Disc 550 08 Cover strip 82 ...

Page 40: ... 550 05 576 920 03 550 07 99 11 576 826 571 901 10 920 10 920 05 826 571 199 3 Fig 7 General assembly drawing of Ama Drainer 522 11 A Ama Drainer A R B Ama Drainer C Table 12 List of components Part No Description Comprises 100 Casing complete Casing 100 Profile seal 410 O ring 412 01 Hexagon socket head cap screw 914 01 144 Discharge elbow complete Discharge elbow 144 Disc 550 10 Hexagon head bol...

Page 41: ... Stator case 81 78 818 Pump rotor Pump rotor 818 824 Cable three phase units Cable 6 1mm2 length 10 m 824 Installation kit for hood 99 7 02 Repair kit 99 20 02 826 Cable gland Cable gland 826 Nut M20 1 5 920 05 99 7 01 Impeller installation kit Adjusting washer 550 02 Disc 550 04 Nut 920 01 99 7 02 Installation kit for hood O ring 412 02 04 Disc 550 06 99 11 Bearing Deep groove ball bearing 321 01...

Page 42: ...nections 9 2 1 Single pumps 9 2 1 1 Ama Drainer 4 SE 10 P11 P10 X1 300 440 min 500 x 500 60 max 400 min 500 A B Fig 8 Outline drawing Ama Drainer 4 SE 10 without cooling jacket A Start up level B Stop level P 10 Swing check valve P11 Gate valve X1 Residual water level ...

Page 43: ... drawing Ama Drainer 5 SD 10 K with cooling jacket A Start up level B Stop level P 10 Swing check valve P11 Gate valve X1 Residual water level 9 2 1 3 Ama Drainer 4 SD 35 P11 P10 X1 300 500 min 500 x 500 120 max 400 min 550 A B Fig 10 Outline drawing Ama Drainer 4 SD 35 without cooling jacket A Start up level B Stop level P 10 Swing check valve ...

Page 44: ... Residual water level 9 2 1 4 Ama Drainer 522 11 P11 P10 X1 340 480 min 500 x 500 120 max 400 min 550 A B Fig 11 Outline drawing Ama Drainer 522 11 without cooling jacket A Start up level B Stop level P 10 Swing check valve P 11 Gate valve X1 Residual water level ...

Page 45: ... P32 300 440 Fig 12 Outline drawing Ama Drainer 4 NE 10 without cooling jacket P 24 Storz rigid coupling P 28 Plastic hose P 32 Pipe extension 9 2 2 2 Ama Drainer 5 NE 10 K P28 P24 P32 300 440 Fig 13 Outline drawing Ama Drainer 5 NE 10 K with cooling jacket P 24 Storz rigid coupling P 28 Plastic hose P 32 Pipe extension ...

Page 46: ...9 Related Documents 46 of 60 Ama Drainer 4 5 9 2 2 3 Ama Drainer 522 ND 11 P28 P24 340 480 Fig 14 Outline drawing Ama Drainer 522 ND 11 without cooling jacket P 24 Storz rigid coupling P 28 Plastic hose ...

Page 47: ... B B A A DN 50 PN 16 ANSI 2 P 5 436 167 1200 1500 1800 Fig 15 Outline drawing Ama Drainer 522 ND 11 with guide hoop When using flange adapter P 5 217 mm When using flange adapter P 5 486 mm Table 13 Overview of connections Connection Description 1 Lowest stop level for automatic operation P 2 Guide hoop arrangement P 58 Flange adapter for stabilising the pump position during start up P 29 Threaded...

Page 48: ...2 A 85 85 13 70 Ø 10 125 P 5 436 167 Fig 16 Outline drawing Ama Drainer 522 ND 11 with guide wire When using flange adapter P 5 217 mm When using flange adapter P 5 486 mm Table 14 Overview of connections Connection Description 1 Lowest stop level for automatic operation P 4 Guide wire arrangement P 59 Flange adapter for stabilising the pump position during start up P 29 Threaded flange 9 Not show...

Page 49: ...P 18 Cover plate P 29 Threaded flange E 5 AS 5 alarm switchgear E 5 2 Horn E 12 E13 Control unit E 14 Float switch normal water level E 14 2 Float switch high water level E 14 3 Alarm contactor R Flood level Table 15 Dimensions and weights Size A B C D1 D2 E kg mm mm mm mm mm mm Ama Drainer 4 10 275 190 130 1060 x 500 500 55 16 Ama Drainer 4 35 275 190 130 1060 x 500 500 60 17 Ama Drainer 5 10 K 3...

Page 50: ...ms 9 3 1 Ama Drainer SE L1 N PE bn bn bu gn ye PE gn ye bn gn ye bn bu bu bu S2 U1 Z1 U2 wh gn rd U1 U2 Z1 Z2 M 1 3 21 22 F6 Fig 18 Wiring diagram Ama Drainer SE F6 Bimetal switch M Motor S2 Float switch bu blue bn brown rd red wh white gn ye green yellow gn green ...

Page 51: ...ainer 4 5 9 3 2 Ama Drainer NE L1 N PE bn bu gn ye bn gn ye bn bu bu U1 Z1 U2 wh gn rd U1 U2 Z1 Z2 M 1 3 21 22 F6 Fig 19 Wiring diagram Ama Drainer NE F6 Bimetal switch M Motor bu blue bn brown rd red wh white gn ye green yellow gn green ...

Page 52: ...ainer SD M1 L1 K1 1 2 1 M 3 L2 3 4 2 L3 5 6 3 N PE K1 A1 A2 5 4 S1 X1 PE H 0 A PE PE 1a br S2 BN BU 1 1b bl 4 S Fig 20 Wiring diagram Ama Drainer SD K1 Contactor S1 Manual 0 automatic selector switch X1 Terminal strip M1 Motor S2 Float switch bu blue bn brown ...

Page 53: ... 5 9 3 4 Ama Drainer ND 21 22 PE 5 1 gn ye bk gn rd M 3 6 F6 W1 V1 U1 2 3 4 F7 21 22 W1 V1 U1 bk gn rd W2 V2 U2 F6 F7 5 1 gn ye 2 3 4 Fig 21 Wiring diagram Ama Drainer ND F6 F7 Bimetal switch M Motor bk black gn green rd red gn ye green yellow ...

Page 54: ...ith the provisions of the following Directives as amended from time to time Pump set EC Machinery Directive 2006 42 EC Pump set Electromagnetic Compatibility Directive 2014 30 EU The manufacturer also declares that the following harmonised international standards have been applied ISO 12100 EN 809 EN 60034 1 EN 60034 5 A1 EN 60335 1 A1 EN 60335 2 41 Person authorised to compile the technical file ...

Page 55: ...n conformity with the provisions of the following Directives as amended from time to time Pump set EC Machinery Directive 2006 42 EC Pump set Electromagnetic Compatibility Directive 2014 30 EU The manufacturer also declares that the following harmonised international standards have been applied ISO 12100 EN 809 EN 60034 1 EN 60034 5 A1 Person authorised to compile the technical file Hugues Roland ...

Page 56: ... carrier plain bearing inner rotor has been removed from the pump and cleaned In cases of containment shroud leakage the outer rotor bearing bracket lantern leakage barrier and bearing bracket or intermediate piece have also been cleaned For canned motor pumps the rotor and plain bearing have been removed from the pump for cleaning In cases of leakage at the stator can the stator space has been ex...

Page 57: ... remedies 35 Fields of application 8 Fluid handled Density 28 I Impeller type 16 Installation 15 Intended use 8 K Key to safety symbols markings 7 L Level control 22 O Other applicable documents 6 Overload protection 22 P Partly completed machinery 6 R Return to supplier 11 Returning to service 29 S Safety 8 Safety awareness 9 Scope of supply 18 Shaft seal 16 Shutdown 29 Start up 25 Switch off 25 ...

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Page 60: ...KSB SE Co KGaA Johann Klein Straße 9 67227 Frankenthal Germany Tel 49 6233 86 0 www ksb com 2331 826 10 EN 01442616 ...